Power source cooling apparatus, method, and configuration

A cooling component suitable for cooling an electrical component disposed in a power source of a welding or cutting system includes a heat transfer surface, an inlet, an outlet, and a closed flow area. The heat transfer surface transfers heat away from the electrical component. The inlet receives process gas from a gas source and the outlet directs the process gas downstream towards a torch assembly. The closed flow area extends between the inlet and the outlet and is in thermal communication with the heat transfer surface so that the process gas enhances cooling of the electrical component as the process gas travels through the closed flow area, from the inlet to the outlet.

TECHNICAL FIELD

The present disclosure is directed toward power sources for welding and/or cutting systems and, in particular, to an apparatus, method, and/or configuration for cooling one or more components disposed within a power source for a welding and/or cutting system.

BACKGROUND

Welding and cutting systems, such as plasma cutting systems, typically include multiple interconnected components. For example, a plasma cutting system may include a power source that interconnects a gas supply, a torch assembly, and a clamp. Then, during welding or cutting operations, electrical components (e.g., resistors, capacitors, integrated circuits, computing components (e.g., microprocessors), etc.) in the power source can be manipulated/controlled (e.g., in response to trigger signals, inputs at a control panel, etc.) to control a supply of gas and a supply of electricity to the torch assembly. However, these electrical components must be cooled properly in order to operate effectively, insofar as the term “cooled” or variations thereof, as well as the terms “heat,” “heat transfer,” and variations thereof, are used herein to indicate a transmission of power. For example, the phrase “electrical components must be cooled properly” may indicate that power must be transferred away from electrical components via a media (e.g., air, water, etc.) in order to maintain the electrical components at a suitable operational temperature.

Often, these electrical components are cooled by a subsonic flow of ambient air that is forced through the power source with a fan. For example, a fan may propel ambient air into contact with a heat sink that is in thermal communication with the electrical components disposed in a power source to transfer of heat away from the electrical components. Unfortunately, typically, cooling technologies that use forced subsonic flows (e.g., fan-propelled ambient air) have limited convection coefficients in the range of approximately 25-250 Watts per square meter for a temperature difference of one degree Kelvin (W/m2K). Moreover, cooling electrical components with ambient air may introduce contaminants into the power source and, thus, the electrical components may need to be partitioned from a flow of ambient air. However, this partitioning may increase the weight of a power source, which is undesirable for at least power sources that are intended to be portable. In fact, a fan that forces ambient air into a power source may also increase the weight and/or cost of manufacturing of a power source and, unfortunately, it is difficult to reduce the weight and/or cost of a power source's fan may often without creating an undesirable decrease in the amount of cooling airflow that is introduced into the power source.

In some cases, force ambient airflows are replaced or enhanced with forced liquid cooling or phase change setups to increase the amount of cooling provided within a power source. Liquid cooling setups typically have convection coefficients in the range of approximately 100-20000 W/m2K and phase change setups typically have convection coefficients in the range of approximately 2500-100000 W/m2K. Unfortunately, these technologies require yet additional components to be included in the power source and are much more expensive and complicated to implement as compared to forced subsonic flows. Thus, power source cooling configurations and/or apparatuses, as well as methods of cooling a power source, that improve cooling for the electrical components included in a power source while also minimizing or eliminating the weight and cost of manufacturing a power source are desired.

SUMMARY

The present disclosure is directed towards an apparatus and configuration for cooling a power source, as well as a method of cooling a power source.

According to one embodiment, the present disclosure is directed towards a cooling component suitable for cooling an electrical component disposed in a power source of a welding or cutting system. The cooling component includes a heat transfer surface, an inlet, an outlet, and a closed flow area. The heat transfer surface transfers heat away from the electrical component. The inlet receives process gas from a gas source and the outlet directs the process gas downstream towards a torch assembly. The closed flow area extends between the inlet and the outlet and is in thermal communication with the heat transfer surface so that the process gas enhances cooling of the electrical component as the process gas travels through the closed flow area, from the inlet to the outlet. Advantageously, this cooling component may cool electrical components to suitable temperatures without requiring cooling-specific components (e.g., components dedicated to cooling and not involved in operational undertakings of the power source, such as transferring power or process gas). Thus, power sources including the cooling component may be lighter and/or cheaper than power sources with cooling-specific components, such as fans or liquid flow paths. Alternatively, the cooling component may enhance the cooling provided by cooling-specific components without substantially increasing the weight and/or cost of a power source.

In some of these embodiments, the process gas is plasma gas, the torch assembly is a plasma arc torch assembly, and when the plasma gas reaches the plasma arc torch assembly, the plasma gas is ionized to create a plasma stream. Additionally or alternatively, the process gas may be the only media (e.g., gas, liquid, etc.) flowing through the closed flow area. Moreover, in some of these embodiments, the cooling component also includes one or more fins disposed in the closed flow area so that the process gas travels over the one or more fins when flowing from the inlet to the outlet to enhance the cooling of the electrical component.

In some embodiments, the cooling component comprises a heat sink including a base and heat sink fins that extend away from the base. In some of these heat sink embodiments, the closed flow area is formed in the base of the heat sink. For example, the closed flow area may be formed as the heat sink is manufactured or formed after the heat sink is manufactured (e.g., a heat sink may be, in essence, retrofitted to include the closed flow area). As a more specific example, in some instances, the closed flow area is formed in a cavity defined by the base, and the cooling component further comprises a cover that seals the cavity to define the closed flow area. Alternatively, in some of these heat sink embodiments, the closed flow area is formed by a cover that defines an internal volume with an outer surface of the base. For example, the cover and the base may enclose at least one of the heat sink fins within the internal volume. If the closed flow area is formed in the base, the inlet and the outlet may also be formed in the base of the heat sink. Meanwhile, if the closed flow area is formed with a cover, the inlet and the outlet may be formed in the cover. Thus, the closed flow area may be included on a variety of heat sinks, of varying shapes and sizes. Notably, if heat sink fins are enclosed within the closed flow area, these fins may serve to enhance cooling in the same manner as the one or more fins mentioned above.

According to another embodiment, the present disclosure is directed towards a power source for a welding or cutting system including an external housing, electrical components disposed within the external housing, and a cooling component positioned within the external housing in a position that receives heat generated by at least one of the electrical components. The cooling component includes an inlet for receiving process gas from a gas source, an outlet that directs the process gas downstream towards a torch assembly, and a closed flow area. The closed flow area directs the process gas from the inlet to the outlet so that the process gas enhances cooling of the at least one electrical component as the process gas travels through the closed flow area, from the inlet to the outlet.

In some of these embodiments, the external housing includes a housing outlet configured to receive the process gas from the outlet of the cooling component and deliver the process gas to the torch assembly. Additionally or alternatively, the gas source may be external to the power source and the external housing may include a housing inlet configured to receive the process gas from the gas source and deliver the process gas to the inlet of the cooling component.

According to another embodiment, the present disclosure is directed towards a method of cooling components in a power source for a welding or cutting system. The method includes forming a gas flow passage in thermal connection with heated components in the power source and directing process gas through the flow passage as the process gas flows towards a torch assembly. In at least some embodiments, the directing occurs during welding or cutting operations of the welding or cutting system. This eliminates risks associated with detecting a rise in temperature and also conserves energy because electrical components do not experience a relatively extreme rise in temperature between cooling cycles. Instead, when the electrical components are generating heat (e.g., during operation of the power source), cooling is provided.

Like numerals identify like components throughout the figures.

DETAILED DESCRIPTION

An apparatus, configuration, and method for cooling components of a power source are presented herein. The apparatus, configuration, and method direct process gas (i.e., operational gas), such as plasma gas, over and/or through heat transfer surfaces/objects in a power source to cool electrical components (e.g., resistors, capacitors, integrated circuits, computing components (e.g., microprocessors), etc.) included in the power source. That is, power source components typically used to deliver process gas to a torch assembly are modified/replaced so that the process gas travels over and/or through heat transfer surfaces in the power source as it moves from the power source's gas inlet port to the power source's gas outlet port. Consequently, the apparatus and configuration provide cooling without adding cooling-specific components to a power source. Moreover, the cooling provided by the process gas provides efficient cooling and, thus, can replace or enhance cooling provided by ambient airflow, liquid, and/or phase change configurations. In fact, in at least some embodiments, cooling-specific components, such as fans, can be removed from a power source and/or replaced with smaller and/or cheaper components. For example, a power source incorporating the cooling apparatus/configuration presented herein may not need a fan to force a flow of ambient air through the power source. Consequently, the cooling apparatus/configuration presented herein may reduce the cost, weight, and/or electrical consumption of a power source while still providing any electrical components included in the power source with sufficient cooling.

Since the apparatus and configuration presented herein utilize process gas for cooling, the power source may not need to include components dedicated solely to cooling the power source (e.g., liquid flow paths, heat pipes, bonding agents, fans, etc.). That is, the power source need not add cooling-specific components to a power source and may utilize components that exists in nearly all power sources (e.g., heat sink and pipes for process gas) to generate effective cooling. Moreover, a power source including the cooling configuration presented herein need not pass a second media (e.g., gas, liquid, etc.) through the power source to provide cooling.

By comparison, liquid cooling and phase change cooling can only be implemented by adding (e.g., installing/including) cooling-specific components to a power source, insofar as cooling-specific components are dedicated to cooling and not directly involved in operational undertakings of the power source (e.g., transferring gas and electricity to a torch assembly). For example, liquid cooling requires a power source to include or define closed flow paths dedicated to passing a flow of liquid (e.g., water) through the power source. Meanwhile, a power source utilizing phase change cooling may require one or more heat pipes with an internal fluid that evaporates at a low temperature (to pull energy away from a heat sink/electrical component) to be bonded to a heat sink or heat transfer surface with a specific gap filler or bonding agent (e.g., a bonding agent that increases the resistance of the thermal bonded joint and slows the conduction of heat from the heat sink/heat transfer surface to the heat pipe).

FIG. 1illustrates an example embodiment of cutting system150including a power source200with a process gas cooling configuration201(seeFIGS. 2 and 3) formed in accordance with an embodiment of the present disclosure. At a high-level, the power source200supplies power to a torch assembly170while also controlling the flow of gas from a gas supply180to the torch assembly170(however, in other embodiments, the power source200might supply the gas itself). The gas supply180is connected to the power source200via cable hose182and the power source200is connected to the torch assembly170via cable hose172. The cutting system150also includes a working lead192with a grounding clamp190. As is illustrated, cable hose172, cable hose182, and/or cable hose192may each be any length. In order to connect the aforementioned components, the opposing ends of cable hose172, cable hose182, and/or cable hose192may each be coupled to the power source200, torch assembly170, gas supply180, or clamp190in any manner now known or developed hereafter (e.g., a releasable connection).

Still referring toFIG. 1, but now together withFIGS. 2 and 3, generally, in the depicted embodiment, the process gas cooling configuration201utilizes compressed process gas from the gas supply180to cool various electrical components in the power source200as the compressed process gas flows through the power source200, from the gas supply180to the torch assembly170. More specifically, first, the compressed process gas flows from the gas supply180to the power source200via cable hose182. Then, the compressed gas flows through a closed flow path280that extends from a gas inlet port214included on a back wall210of the power source200to an outlet port222included on a front wall220of the power source200while passing through/over heat sinks250included in the power source200(the flow rate may be controlled at the inlet214by a flow controller270, such as a solenoid valve assembly). When the compressed process gas reaches the port222included on the front wall220, the compressed process gas is directed to the torch assembly170via cable hose172. Notably, for the purposes of this description, port222is largely described with respect to gas transfer of a single gas; however, it is to be understood that port222may also allow the power source200to transfer additional gasses and/or electricity to the torch assembly170via cable hose172. By comparison, the front220also includes a port224for the cable hose192that connects the working clamp190to the power source200and, typically, port224only provides an electrical connection and is unrelated to gas flow.

In the depicted embodiment, the compressed process gas is plasma gas and, thus, once the compressed process gas reaches the torch assembly170, the compressed process gas is directed through an arc in the torch assembly170to generate a stream of plasma. However, in other embodiments, the cooling configuration201presented herein might also be used in welding systems, automated cutting systems, and/or any other system in which electrical components require cooling and operational gas is flowing from a power source to a torch. That is, the cooling apparatus and configuration presented herein may be useful in power sources suitable for various types of welding or cutting. In these other embodiments, the process gas might be any gas utilized during welding or cutting operations and need not necessarily be compressed gas. For example, in some embodiments, the process gas might be shielding gas. That being said, using compressed process gas will also take advantage of the throttling effect of compressed gasses expanding and cooling. This will create a larger temperature differential between the cooler compressed gas and the higher temperature of heated surfaces which will drive higher convection cooling. However, regardless of the type of process gas used, the process gas is the only media that travels through the cooling configuration201; no water, other liquids, or other gasses pass therethrough.

Still referring toFIGS. 1-3, in the depicted embodiment, the power source200includes a fan244(seeFIGS. 2 and 3) and the process gas cooling configuration201enhances cooling provided by forced subsonic airflow created by the fan244. To facilitate airflow for the fan244, a cover202that defines at least a portion of an exterior housing of the power source200includes vents204(the top vents204may serve as an inlet and the bottom vents204may serve as an outlet). However, in other embodiments, the process gas cooling configuration201may replace a forced subsonic airflow system and, in these embodiments, the power source200might not include vents204in its exterior housing.

InFIGS. 2 and 3, the power source200is illustrated with the cover202removed. As can be seen, in the depicted embodiment, the cover202defines sides and a top of the power source200so that the cover202, the back210, and the front220can cooperate with a bottom228to form an exterior housing that defines an interior cavity230. The interior cavity230houses various electrical components and the process gas cooling configuration201(at a minimum). More specifically, in the depicted embodiment, the interior cavity230houses a printed circuit board (PCB)242that extends perpendicularly upwards from the bottom236(e.g., parallel to the sides of the power source200defined by the cover204) and various electrical components260are mounted, either directly or indirectly, to the PCB242. That is, the power source200may include electrical components262(e.g., capacitors) mounted directly to the PCB242and/or electrical components264mounted to heat sinks250(e.g., with a thermal interface) and, despite these different mountings, electrical components262and264may each be operatively coupled to the PCB242and may be operative to control the supply of electricity and/or gas to a torch assembly (e.g., torch assembly170) based on commands/signals received by the power source200(e.g., commands received at a control panel226included on the power source200).

In the depicted embodiment, the closed flow path280defined by the process gas cooling configuration201extends through each of the heat sinks250included in power source200in series. More specifically, in the depicted embodiment, the power source200includes four heat sinks250: a first heat sink250A; a second heat sink250B; a third heat sink250C; and a fourth heat sink250D. Each of the heat sinks250are arranged so that fins (e.g., extruded/machined surfaces) are disposed in or adjacent the flow path of the subsonic airflow generated by the fan224. That is, the fins of heat sinks250A and250B extend towards the front220(and towards the electrical components262) while the fins of heat sinks250C and250D extend towards the back210(and towards the electrical components262). Meanwhile, electrical components264are mounted on the bases of the heat sinks250(e.g., the sides of the heat sinks250from which the fins extend away, so that the electrical components264are disposed on a back of the heat sinks250). The bases of the heat sinks250may serve as heat transfer surfaces for heat generated by electrical components264. As is explained in further detail below, each of the heat sinks250includes or defines a closed flow area (e.g., a closed pathway) that allows compressed process gas to flow through or over each of the heat sinks250. These closed flow areas (e.g., pathways) are connected by segments of pipe and, cooperate with the pipes to define the closed flow path280.

More specifically, in the depicted embodiment, the closed flow path280includes five pipe segments that extend between the heat sinks250, the gas inlet214, and the gas outlet222. A first pipe segment250A extends from the gas inlet214to the first heat sink250A and allows gas received from the gas supply180to flow into a passageway in the first heat sink250A (the passageway is described in further detail below). When the gas exits the first heat sink205A, it flows through a second pipe segment280B and into the second heat sink250B. The gas then flow through a third segment280C, a third heat sink250C, a fourth pipe segment280C, and a fourth heat sink250D, in that order. Upon exiting the fourth heat sink250D, the gas flows through a fifth and final segment280D (also referred to as exit segment280D) to the gas outlet222, where the gas may be directed towards torch assembly170via cable hose172. Since the gas flows through the heat sinks sequentially (e.g., one after another), the heat sinks250may be referred to as being arranged in series. However, in other embodiments, the heats sinks250may be arranged in parallel (e.g., a pipe segment may split and deliver gas to two or more heat sinks simultaneously), series, or some combination thereof.

Now turning toFIGS. 4-8, generally, these figures illustrate heat sinks that are suitable for the cooling configuration presented herein. That is, the heat sinks illustrated inFIGS. 4-8define closed flow areas that allow a process gas to flow over and/or through the heat sink. As is described in further detail below, in the embodiment depicted inFIGS. 4, 5A, and 5Bthe closed flow area is formed within the heat sink while in the embodiment depicted inFIGS. 6-8the closed flow area is formed on/over a portion of the heat sink. However, heat sinks are not the only component through/over which a process gas may be directed to enhance cooling of electrical components in a power source in accordance with the present disclosure. For example, a heat plate or any other component that can transfer heat away from an electrical component (e.g., any component with a heat transfer surface for transferring heat away from the electrical component) may include the closed flow area described herein that allow a process gas to flow over and/or through. That being said, each of the embodiments depicted inFIGS. 4-8is described in turn below.

First,FIGS. 4, 5A, and 5billustrate a first embodiment of a heat sink250suitable for the cooling configuration illustrated inFIGS. 2 and 3. The heat sink250includes a base310, a set of fins340that extend away from the base, and a flow area320(also referred to as a gas flow passage320) that is formed in the base310. More specifically, the base310extends from a front312to a back314and between a first side316and a second side318. The base310also includes a bottom317and a top319that are separated by a height “H.” The fins340, which may be extruded or machined surface, extend from the bottom317of the base310and are each parallel to the sides316,318of the base310. Meanwhile, the flow area320is formed within the base310(e.g., in a space between, but inclusive of: (1) the front312and back314; (2) the top319and the bottom317; and (3) the first side316and the second side318).

In the depicted embodiment, the flow area320extends from the top319of the base310towards the bottom317of the base310, but does not extend through the bottom317. Instead, the base310defines a bottom326of the internal flow area320, as can be seen inFIG. 5B. That is, in the depicted embodiment, the internal flow area320extends from the top319of the base310and has a depth “D2” that is less than the height “H” of the base310. The base310also defines sidewalls328of the internal flow area320, but in the depicted embodiment, does not define a top of the flow area320. Instead, a cover350is secured to the top319of the base310, over the flow area320in order to enclose the flow area320. For example, in some embodiments, the flow area may be formed by removing (e.g., via milling or other such machining techniques) portions of the base310to form the flow area320and, then, a cover350may be secured over the flow area320with fasteners (e.g., screws) or a fastening agent (e.g. epoxy, glue, etc.).

However, in other embodiments, the flow area320may be formed within the base310in any desirable manner. For example, in some embodiments, the heat sink250might be formed with additive manufacturing techniques and, thus, the flow area320might be formed within the base310as the base310is formed. In these embodiments, the base310might also cover the flow area320, rendering the cover350unnecessary. Moreover, in some embodiments, the flow area320may be formed within the base310adjacent any side or portion of the heat sink250(e.g., portions of side316, side318, bottom317, front312, back314, corners or edges extending therebetween, etc.), by removing material or in any other manner. Still further, in embodiments including relatively large fins340, the flow area320could also be formed within one of the fins, whether by removing material or in any other manner.

Regardless of how the flow area320is formed within the heat sink250, the flow area320is closed or sealed, except for an inlet321that is disposed adjacent one of the front330or back332of the flow area320and an outlet323that is disposed adjacent the other of the front330or back332of the flow area320. For example, in the depicted embodiment, inlet321extends through the side316of the base310adjacent the front330to provide a conduit into the flow area320and outlet323extends through the side316of the base310adjacent the back332to provide a conduit out of the flow area320. Fittings322and324can be mounted in the inlet321and outlet323, respectively, to securely connect pipe segments280to the inlet321and outlet323so that process gas flowing through the closed flow path280in a power source200can flow into and out of a heat sink250without any leaks.

In some embodiments, the flow area320may also include cooling enhancement features, such as extruded fins334(referred to herein as flow area fins334simply to provide clarity with respect to the fins340of the heat sink250, to which fins334are similar); however, in other embodiments, the flow area320need not include any cooling enhancement features and may simply be an unobstructed conduit of any shape or size. That is, the flow area might simply be a channel or conduit with a square, circular, irregular, etc. cross-sectional shape. In the depicted embodiment, the flow area320includes rectangular flow area fins334that define cooling channels336within the flow area320. To enhance side-to-side flow between the cooling channels336, the flow area fins334may have a height “D1” that is less than the height D2of the flow area320so that a space338spanning the width of the flow area320is provided at the top of the flow area320, insofar as the width is the dimension spanning the two sidewalls328of the flow area320(notably, only one sidewall328is shown in the detail view ofFIG. 5B). Additionally or alternatively, the flow area fins334may include one or more crossflow openings337and/or the flow area fins334might not span the entire length of the flow area320, insofar as the length is the dimension spanning from the front330to the back332of the flow area332. For example, the fins334might include gaps or breaks adjacent the front330, the back332, and/or any areas there between.

Still referring toFIGS. 4, 5A, and 5B, in the depicted embodiment, electrical component264is mounted atop of top319of the base310, but out of alignment with the flow area320(and the cover350). Thus, the top319serves as a heat transfer surface of the heat sink250and draws heat away from the electrical component264. However, in other embodiments, the electrical component264might be mounted to any surface of the heat sink and that surface may serve as the heat transfer surface of the heat sink component. For example, in some embodiments, the electrical component264may be mounted to the heat sink250atop the cover350so that the electrical component264is mounted directly above the flow area320. In some instances (e.g., depending on the amount of thermal conduction between the cover350and the remainder of the heat sink250), aligning the electrical component264atop the cover350may increase the amount of cooling provided to the electrical component264. In fact, it may be particularly desirable to mount the electrical component264atop the flow area320if the flow area320is formed within the base310without creating an opening in the top319(e.g., if the flow area is formed with additive manufacturing) at least because a portion of the top319may have increased thermal conduction with the remainder of the heat sink250as compared to a cover350. On the other hand, if the flow area320is formed in a heat sink250after the electrical component264is mounted to the heat sink250(e.g., if the cooling configuration is retrofitted onto a power source with an existing cooling configuration), the flow area320may be offset from the electrical component264to avoid removing and remounting the electrical component264. Regardless of where the electrical component264is mounted to the heat sink250, the electrical component264may be mounted to the heat sink250(e.g., to the top319) with a thermal interface to ensure heat dissipates from the electrical component264to the heat sink250efficiently.

Now turning toFIGS. 6 and 7, these figures illustrate a second embodiment of a heat sink250′ suitable for a cooling configuration that can be implemented with or in place of the cooling configuration illustrated inFIGS. 2 and 3. In fact, inFIGS. 6 and 7, the heat sink250′ is shown mounted on a back side of the PCB242fromFIGS. 2 and 3, insofar as the back side of the PCB242is the side of the PCB opposite to the side on which electrical components262are mounted. Thus, in some embodiments, heat sink250′ could be used in place of heat sinks250and the flow path280could run solely along the back side of the PCB242(and through the heat sink250′), but in other embodiments, the heat sink205′ could be installed in the power source200in addition to the heat sinks250. In the latter scenario, the flow path280splits so that some process gas is directed through heat sinks250and the remainder (e.g., approximately half) of the process gas is directed through heat sink250′. That is, heat sink250′ might be installed in parallel to the heat sinks250.

Regardless of how the heat sink250′ is implemented, the heat sink250′ is similar to the heat sink250illustrated inFIGS. 4, 5A, and 5Binsofar as heat sink250′ includes a base310, a set of fins340that extend away from the base310, and a flow area320. However, in contrast with heat sink250, the flow area320of heat sink250′ is formed over a portion of the fins340, instead of within the base310. More specifically, the fins340include a first set of fins342and a second set of fins344. The fins in the first set342have a height “H1” and the fins in the second set344have a height “H2” that is smaller than H1. That is, the first set of fins342extend further from the base310of the heat sink250′ than the second set of fins344. Consequently, open space is provided above and around the second set of fins344and this space can be used to form the gas flow area320and to mount any associated parts (e.g., fittings, gas flow controllers, etc.). In the depicted embodiment, this space provides room for a cover360to be secured over at least a portion of the second set of fins344(in any manner now know or developed hereafter) and form the gas flow area320over, around, and/or between the second set of fins344.

The cover360includes sides364and a top362that extend between a front366and a back368. The sides364, front366, and back368extend downwards, perpendicularly away from the top362and, in the depicted embodiment, enclose all of the fins in the second set of fins344between the cover360and the base310. However, in other embodiments, any portion of the second set of fins344might be enclosed between the cover360and the base310. More specifically, inFIGS. 6 and 7, the front366of the cover360defines a front330of the flow area320, the back368of the cover360defines a back332of the flow area320, and the sides364of the cover360define sidewalls328of the flow area320. That is, the cover360and base310form a closed flow area320substantially similar to the flow area320illustrated inFIGS. 5A, and 5Band, thus, any description of the flow area320ofFIGS. 4, 5A, and 5Bincluded above should be understood to apply to the flow area320depicted inFIGS. 6 and 7. For example, although the second set of fins344serve as flow area fins334(i.e., fins that enhance cooling in the flow area320) in the embodiment depicted inFIGS. 6 and 7, fins344may be substantially similar to the flow area fins334that are formed in the flow area320ofFIGS. 4, 5A, and 5B.

One difference between the flow area shown inFIGS. 4, 5A, and 5Band the flow area320depicted inFIGS. 6 and 7is that the inlet321and outlet323are disposed atop the flow area320, instead of through a side328of the flow area320. Consequently, the flow area320may not need features that enhance side-to-side flow within the flow area320, such as holes337or a cross-flow area338. Nevertheless, if desired, the fins334and/or the cover360shown inFIGS. 6 and 7may define features that enhance side-to-side flow, such as holes337or a cross-flow area338(despiteFIGS. 6 and 7not illustrating these features). One other difference between the embodiment ofFIGS. 4, 5A, and 5Band the embodiment of inFIGS. 6 and 7is that, the heat sink250′ depicted inFIGS. 6 and 7includes a flow controller270′ (e.g., a solenoid valve assembly) mounted adjacent its inlet321. As is described in further detail below, flow controller270′ may be configured to control the amount of gas flowing through flow area320(as opposed to the amount of gas flowing through an entire closed flow pathway280).

Now turning toFIG. 8, this Figure illustrates a third embodiment of a heat sink250″ that is substantially similar to heat sink250′, except that heat sink250″ does not include two sets of fins. Instead, the base310extends beyond its fins340or, from another perspective, the heat sink250″ includes fins340that only span a portion of the base310. Either way, a portion of the bottom326of the base310is exposed (when viewed from the bottom) and provides an area on which cover360can be mounted to form a flow area320extending across the heat sink250. Thus, in the embodiment depicted inFIG. 8, the flow area320does not include any internal flow area fins334. Otherwise, the embodiment depicted inFIG. 8may be substantially similar to the embodiment depicted inFIGS. 6-7and any description of the embodiment ofFIGS. 6-7should be understood to apply to the embodiment depicted inFIG. 8. However, it should be noted that the embodiment depicted inFIG. 8is merely one example of a flow area320formed without any cooling enhancement features (e.g., fins) and in various embodiments, similar unimpeded flow areas might formed on any surface (flat, rounded, or irregular) of a cooling component.

Referring generally toFIGS. 1-8, in some embodiments, a heat sink, such as heat sink250′ may include a flow controller dedicated to that heat sink to control the amount of gas flowing into the inlet321of the flow area320. For example, in the embodiments depicted inFIGS. 6-8, a flow controller270′ is mounted to cover360adjacent fitting322and controls an amount of gas flowing through the fitting322into the inlet321. This flow controller270′ may be included in addition to or in lieu of the flow controller270shown inFIGS. 2 and 3(which controls gas flow entering the closed flow path280at the inlet214of the power source200).

For example, in embodiments that include a plurality of heat sinks250installed on a first side of a PCB242and another heat sink250′ installed on an opposite side of the PCB242, flow controller270may control the flow of gas into closed flow path280(from the gas supply180) and flow controller270′ may determine what portion or percentage of that flow of gas is diverted to the heat sink250′ (as compared to heat sinks250). That is, the entry segment280A of the closed flow path280may have a split or fork and the flow controller270′ may control an amount of gas that flows down a first pathway of the split (and into/onto heat sink250′) and gas not flowing down the first pathway may flow down a second pathway. The gas flowing along the second pathway may flow through the heat sinks250. For example, in the depicted embodiments, the gas flowing along the second pathway flows sequentially through the heat sinks250, which are aligned in series. Additionally or alternatively, in some embodiments, any component with a closed flow area320may include a dedicated flow controller270′ so that the flow of process gas through that component can be controlled, for example, to provide additional or decreased cooling to one particular electrical component as compared to other electrical components.

Now turning toFIG. 9, this Figure is a diagram400illustrating temperatures of three electronic devices included in a power source when cooled with ambient air and when cooled with ambient air and the cooling configuration of the present disclosure. Initially, at stage410, the temperature of each of each of the three electronic devices (each device is illustrated with a different line) rises due to natural convection during welding or cutting operations that require the three electrical devices to generate heat. Then, after approximately 1000 seconds of natural convection (e.g., when the electronic devices are all at or above approximately 60 degrees Celsius (° C.)), a fan is turned on to cool the three electronic devices with a forced subsonic flow of ambient air to begin a stage420of subsonic airflow cooling. The temperature of three electronic devices drops into a more suitable operational range (e.g., approximately 35-40° C.) over the span of approximately 1700-1900 seconds during stage420. At stage430, the cooling techniques presented herein are used together with the forced subsonic flow of ambient air and the temperature of three electronic devices drops further (e.g., to approximately 30-35° C.) over the span of about 700-900 seconds.

FIG. 10is a diagram500illustrating temperatures of two electronic devices included in a power source when cooled, during convection, with only the cooling configuration of the present disclosure. Notably, over the course of approximately 2000 seconds of convection and cooling with only the cooling techniques presented herein (e.g., process gas passing over/through heat transfer surfaces for the two electronic devices), both electronic devices remain at temperatures within a suitable operational range for electronic components (e.g., approximately 35-40° C.). More specifically, device520beings to settle into temperatures in the range of approximately 33-35° C. and device510beings to settle into temperatures in the range of approximately 36-38° C. Thus, when used alone, the cooling techniques presented herein may provide effective cooling that is at least as effective as the cooling provided with the forced subsonic flow of ambient air utilized in stage420ofFIG. 9.

Moreover, notably, inFIG. 9, the electrical components experienced an initial stage without cooling and, then, a cooling stage was initiated to effectuate a drastic change in temperature (almost a 50% reduction in temperature). This method of cooling may create a number of unwanted issues. For example, to initiate a cooling stage, accurate temperature readings must be constantly monitored. If there is a failure in any portion of the temperature feedback process, the failure may delay or prevent initiation of a cooling stage and cause damage or unwanted wear for the electrical components. Moreover, cooling in stages allows the temperature to become relatively high before cooling begins and, thus, the cooling may require more time and more energy. By comparison, since the techniques presented herein utilize welding/cutting resources that are being supplied to a torch assembly to effectuate welding/cutting operations to provide cooling, the techniques presented herein will initiate when welding or cutting processes initiates Thus, the cooling provided by the techniques presented herein does not need to be activated by a feedback loop (thereby avoiding one pitfall typically associated with cooling). Additionally, the cooling provided by the techniques presented herein will prevent electrical components from rising to relatively high temperatures during an initial convection stage because there is no convection stage without cooling. Put simply, the techniques presented herein direct process gas through the closed gas flow path280during welding or cutting operations of the welding or cutting system.

FIG. 11is a high-level flow chart depicting a method600for cooling a power source in accordance with the techniques presented herein. Initially, at610, a gas flow passage is formed in thermal connection with heated components in the power source. For example, a gas flow passage (i.e., a gas flow area) may be formed in the base of a heat sink, over the fins of a heat sink, or on a surface of a heat sink (e.g., on the top of the base of a heat sink). In some embodiments, such as the embodiment shown inFIGS. 4, 5A, and 5B, the gas flow passage is formed by forming (e.g., machining) a cavity in a portion of a component (e.g., a heat sink) in thermal connection with heated components (e.g., electrical components). However, in other embodiments, such as the embodiment shown inFIGS. 6-8, the gas flow passage is formed by securing a cover to a portion of a component (e.g., a heat sink) in thermal connection with heated components (e.g., electrical components). The cover may or may not enclose heat transfer features (e.g., fins) of the component.

At420, process gas is directed through the flow passage as the process gas flows towards a torch assembly. This may cause the process gas to transfer heat away from the component (e.g., a heat sink) in thermal connection with heated components (e.g., electrical components) which, in turn, may cool the heated components. Moreover, the transfer of heat may cause the process gas to rise in temperature as the process gas travels through the power source. For example, in one embodiment, process gas may enter the power source at approximately 23° C. and exit the power source at approximately 48° C. This change in temperature may provide significant cooling to electrical components in a power source and cool electrical components at least as effectively as typical forced subsonic airflows (as is demonstrated inFIGS. 9 and 10) and, thus the cooling configuration presented herein may provide a cooling solution that can replace typical forced subsonic airflow cooling solutions to create a lighter and/or cheaper power source. Moreover, this rise in temperature will typically not effect cutting or welding operations in which the process gas is involved. For example, process gas used as plasma gas may be heated to temperatures at or in excess of approximately 2000° C. to generate a stream of plasma, so altering the temperature of process gas delivered to the torch from approximately 23° C. to approximately 48° C. will have little impact on the generation of a stream of plasma.

To summarize, in one form a cooling component suitable for cooling an electrical component disposed in a power source of a welding or cutting system is presented herein, the cooling component comprising: a heat transfer surface for transferring heat away from the electrical component; an inlet for receiving process gas from a gas source; an outlet that directs the process gas downstream towards a torch assembly; a closed flow area extending between the inlet and the outlet, wherein the closed flow area is in thermal communication with the heat transfer surface so that the process gas enhances cooling of the electrical component as the process gas travels through the closed flow area, from the inlet to the outlet.

In another form, a power source for a welding or cutting system is presented herein, the power source comprising: an external housing; electrical components disposed within the external housing; and a cooling component positioned within the external housing in a position that receives heat generated by at least one of the electrical components, the cooling component comprising: an inlet for receiving process gas from a gas source; an outlet that directs the process gas downstream towards a torch assembly; and a closed flow area that direct the process gas from the inlet to the outlet so that the process gas enhances cooling of the at least one electrical component as the process gas travels through the closed flow area, from the inlet to the outlet.

In yet another form, a method of cooling components in a power source for a welding or cutting system is presented herein, the method comprising: forming a gas flow passage in thermal connection with heated components in the power source; and directing process gas through the flow passage as the process gas flows towards a torch assembly.

Although the techniques are illustrated and described herein as embodied in one or more specific examples, the specific details of the examples are not intended to limit the scope of the techniques presented herein, since various modifications and structural changes may be made within the scope and range of the invention. For example, a power source including a cooling configuration formed in accordance with the techniques presented herein may include any number of closed flow paths extending from a gas inlet to a gas outlet of a power source. As another example, a flow path may include any number of branches so that any number of components are incorporated into the flow path in series or in parallel. In addition, various features from one of the examples discussed herein may be incorporated into any other examples. Accordingly, the appended claims should be construed broadly and in a manner consistent with the scope of the disclosure.