Patent Publication Number: US-2021178505-A1

Title: Consumable Cartridge For A Plasma Arc Cutting System

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. Ser. No. 15/971,703, filed May 4, 2018 entitled “Consumable Cartridge for a Plasma Arc Cutting System,” which is a continuation in part of U.S. Ser. No. 14/708,972, filed May 11, 2015 and issued as U.S. Pat. No. 10,456,855 on Oct. 29, 2019, entitled “Consumable Cartridge for a Plasma Arc Cutting System.” application Ser. No. 15/971,703 is also a continuation in part of U.S. Ser. No. 14/824,946, filed Aug. 12, 2015 and issued as U.S. Pat. No. 10,582,605 on Mar. 3, 2020, entitled “Cost Effective Cartridge for a Plasma Arc Torch. application Ser. No. 15/971,703 is also a continuation of U.S. Ser. No. 14/708,957, filed May 11, 2015 and issued as U.S. Pat. No. 9,981,335 on May 29, 2018, which is a continuation-in-part of U.S. Ser. No. 14/079,163, filed Nov. 13, 2013 and entitled “Automated Cartridge Detection for a Plasma Arc Cutting System.” application Ser. No. 14/708,957 claims the benefit of U.S. Ser. No. 61/991,114, filed May 9, 2014 and entitled “Cartridge Type Consumable Assembly for a Plasma Arc Cutting System.” application Ser. No. 14/708,957 also claims the benefit of U.S. Ser. No. 62/036,393, filed Aug. 12, 2014 and entitled “Cost Effective Cartridge for a Plasma Arc Torch.” application Ser. No. 14/708,957 is also a continuation-in-part of International Patent Application No. PCT/US14/56546, filed Sep. 19, 2014 and entitled “Thread Connection for a Torch System.” The contents of all of these applications are hereby incorporated herein by reference in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to the field of plasma arc cutting systems and processes. More specifically, the invention relates to methods and apparatuses for simplifying, optimizing and decreasing the time and cost of cutting through the use of improved consumable cartridges. 
     BACKGROUND 
     Plasma arc torches are widely used in the cutting and marking of materials. A plasma torch generally includes an arc emitter (e.g., an electrode), an arc constrictor or constricting member (e.g., a nozzle) having a central exit orifice mounted within a torch body, electrical connections, passages for cooling, and passages for arc control fluids (e.g., plasma gas). The torch produces a constricted ionized jet of a gas with high temperature and high momentum. Gases used in the torch can be non-reactive (e.g., argon or nitrogen) or reactive (e.g., oxygen or air). During operation, a pilot arc is first generated between the arc emitter (cathode) and the arc constrictor (anode). Generation of the pilot arc can be by means of a high frequency, high voltage signal coupled to a DC power supply and the torch or by means of any of a variety of contact starting methods. 
     Known consumables suffer from a host of drawbacks both before and during a cutting operation. Before a cutting operation, selecting and installing the correct set of consumables for a particular cutting task can be burdensome and time-consuming. During operation, current consumables encounter performance issues such as failing to effectively dissipate and conduct heat away from the torch and failing to maintain proper consumable alignment and spacing. Furthermore, current consumables include substantial amounts of expensive materials, such as Copper and/or Vespel™, which leads to significant manufacturing costs and inhibits their widespread commercialization, production and adoption. What is needed is a new and improved consumable platform that decreases manufacturing costs, increases system performance (e.g., heat conduction, component alignment, cut quality, consumable life, variability/versatility, etc.) and eases installation and use of consumables by end users. 
     SUMMARY OF THE INVENTION 
     The present invention provides one or more cost effective cartridge designs that reduce manufacturing costs, facilitate cartridge commercialization and production, improve installation and ease of use by end users, and increase system performance. In some embodiments, numerous traditional consumable components (e.g., swirl ring, nozzle, shield, retaining cap, and electrode components) are redesigned. In some embodiments new components (e.g., an electrode sleeve, a lock ring, and/or an interfacing insulator) are created. In some embodiments, a conventional swirl ring is replaced with a different feature within the torch body that imparts a swirl to a gas flow within the torch body (e.g., a swirl feature having flow holes built directly into a body of the nozzle). In some embodiments, a nozzle shield is electrically isolated from the nozzle (e.g., by using anodized aluminum and/or plastic). 
     In some embodiments, each cartridge comprises one or more of the following consumable components: a frame or body having one or more sections; an arc emitter (e.g., an electrode); an arc constrictor or arc constricting member (e.g., a nozzle); a feature to impart a swirl to a gas within the plasma torch (e.g., a swirl feature built into the nozzle, a swirl ring, or another swirl feature); a shield (e.g., a nozzle shield that is electrically isolated by the use of aluminum, anodized aluminum and/or a plastic material); an emitting element (e.g., a hafnium emitter); and/or an end cap. In some embodiments, a cartridge includes a substantially copper portion (e.g., a copper inner core) and a substantially non-copper portion (e.g., a non-copper portion external to the inner core). In some embodiments, a cartridge can be used on a handheld plasma cutting system and/or a mechanized plasma cutting system. 
     In some embodiments, a cartridge has a resilient element, such as a spring electrode or a spring start mechanism affixed to an electrode, integrated directly into the cartridge and designed not to be separable or disassemblable from the cartridge. The resilient element can be in physical communication with the frame and/or can be configured to pass a pilot current from the frame to the arc emitter. The resilient element can bias the arc emitter in a direction along an axis of the resilient element, e.g., by imparting a separating force. In some embodiments, the separating force has a magnitude that is less than a magnitude of a coupling force holding the cartridge together. 
     In some embodiments, the cartridge has enhanced cooling and insulative capabilities, reduced manufacturing and material costs, and/or improved recyclability, durability and performance. In some embodiments, the cartridge provides consumable components in one integrated piece. In some embodiments, the cartridge enables a significantly reduced torch installation time (e.g., by a factor of 5-10); ensures that mating parts are always chosen correctly for a given cutting task; improves heat dissipation and/or conduction capabilities; enables easier recognition of appropriate consumable components for a given cutting task; enhances consumable alignment and/or spacing; and/or reduces operator error. In some embodiments, heat is moved substantially away from the torch, but not so far as to heat or melt plastic components. In some embodiments, using a metal besides copper (e.g., in a region outside an inner core of copper components) helps move heat away from the torch. In some embodiments, the cartridge allows specific combinations of consumables to be pre-chosen for specific cutting tasks. 
     In some embodiments, the cartridge frame includes a strongly thermally conductive material, e.g., aluminum, copper, or another highly conductive metal. In some embodiments, the cartridge frame is formed by molding. In some embodiments, at least one of the first end of the cartridge frame or the second end of the frame includes a threaded region shaped to engage a complementary component. In some embodiments, the shield, the arc constrictor and the frame are thermally coupled. In some embodiments, an external surface of the frame is shaped to connect to a retaining cap. In some embodiments, the cartridge includes a shield insulator connected to the frame. In some embodiments, the shield insulator is press fit to the frame. 
     In some embodiments, a cartridge cap defines an aperture of the arc emitter and includes a fluid sealing surface disposed about a circumference of the arc emitter aperture. In some embodiments, the electrode comprises a spring. In some embodiments, the cartridge cap extends within a base region of the arc constricting member to a location near the set of swirl holes. In some embodiments, a base of the arc constricting member is formed by molding. In some embodiments, a retaining cap is connected to the cartridge body. In some embodiments, the retaining cap comprises a plastic. In some embodiments, the arc constricting member and the electrode are connected to the retaining cap via a base of the arc constricting member. 
     In some embodiments, a cartridge includes a shield connected to the cartridge body. In some embodiments, the shield is connected to the cartridge body via a shield insulator. In some embodiments, the shield insulator is press fit to at least one of the shield or a base of the arc constricting member. In some embodiments, the shield insulator is electrically insulative. In some embodiments, the shield insulator is thermally conductive. In some embodiments, the shield insulator includes anodized aluminum. In some embodiments, a sleeve is disposed about a portion of the electrode. In some embodiments, the sleeve includes an anodized layer formed to electrically isolate the electrode from a base of the arc constricting member. In some embodiments, the sleeve includes a set of flow surfaces configured to facilitate fluid flow within the plasma torch, e.g., to improve cooling. 
     In some embodiments, a cartridge (or consumable assembly) includes a seal disposed within the cap insert. In some embodiments, a cartridge includes a retaining cap directly connected to the gas flow diverter. In some embodiments, the retaining cap is formed of a plastic. In some embodiments, the arc constrictor and the emissive member are connected to the retaining cap via a swirl ring. In some embodiments, the shield insulator is press fit to at least one of the shield and the gas flow diverter. In some embodiments, the shield insulator is electrically insulative. In some embodiments, the shield insulator is thermally conductive. In some embodiments, the shield insulator includes anodized aluminum. In some embodiments, the shield has a heat capacity to current ratio of about 2 to about 4 W/m-° K-A. In some embodiments, the cartridge or consumable assembly includes a sleeve disposed about a portion of the emissive member. In some embodiments, the sleeve includes an anodized layer formed to electrically isolate the emissive member from a base of the arc constrictor. In some embodiments, the sleeve includes a set of flow surfaces. 
     In some embodiments, the cartridge is replaced as a unit. In some embodiments, a length of the emitting element can be adjusted to match the life of the nozzle, such that the cartridge parts reach the end of their useful lives at approximately the same time. In some embodiments, cut quality can be similar to that achieved using current consumables. In some embodiments, a cartridge type consumable assembly including a spring electrode disposed within a nozzle body and a sealing device disposed within a lock ring. The sealing device can be configured to connect to a plasma arc torch. The spring electrode can include a thumbtack or contact element that extends within the electrode body and is connected to a spring disposed between the contact element and the electrode body. In some embodiments, the electrode sleeves can have shaped (e.g., scooped) front ends to direct gas flow within the cartridge. 
     In one aspect, the invention features a replaceable cartridge for a plasma arc torch. The replaceable cartridge includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section. The cartridge also includes an electrode included within the substantially hollow chamber. The cartridge also includes a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force hasg a magnitude that is less than a magnitude of the coupling force. 
     In some embodiments, a gas input moves the electrode and overcomes the separating force. In some embodiments, at least a portion of the electrode and the contact start spring element are irremovably disposed within the substantially hollow chamber. In some embodiments, a base of the arc constricting member is anodized. In some embodiments, the cartridge has a region with a thermal conductivity of between about 200-400 Watts per meter per degree Kelvin. In some embodiments, the shield has a heat capacity to current ratio of 2-4 W/m-° K-A. In some embodiments, the cartridge includes a cap insert connected to the second section of the cartridge body, the cap insert substantially orienting the electrode and retaining the electrode within the cartridge body. 
     In another aspect, the invention features a sealed cartridge unit for a plasma arc torch. The cartridge unit includes a substantially hollow frame including a first substantially hollow portion defining a first end and a second substantially hollow portion defining a second end. The cartridge unit includes an arc emitter located within the frame. The arc emitter is translatable relative to the frame. The cartridge includes an arc constrictor attached to the second end of the frame. The cartridge includes a resilient element in physical communication with the frame. The resilient element biases the arc emitter toward one of the first end or the second end to facilitate ignition at or near the arc emitter. 
     In some embodiments, a gas input moves the electrode and overcomes the separating force. In some embodiments, the frame includes an electrical insulator. In some embodiments, the frame includes at least one of a metal or a strongly thermally conductive material. In some embodiments, the frame is anodized. In some embodiments, the cartridge includes at least one set of flow holes, each flow hole in the set of flow holes radially offset from the other flow holes. In some embodiments, the flow holes have a total cross-sectional area of about one square inch. In some embodiments, the first end is configured to connect to a shield via a shield insulator, and the shield, the arc constrictor and the frame are thermally coupled. In some embodiments, the cartridge unit has a region with a thermal conductivity of between about 200-400 Watts per meter per degree Kelvin. In some embodiments, the cartridge includes a cartridge cap disposed in the second end of the frame, the cartridge cap shaped to contact the arc emitter and to retain the arc emitter within the frame. 
     In another aspect, the invention features a replaceable, unitary consumable assembly for a plasma arc torch. The consumable assembly includes a gas flow diverter, an arc constrictor in physical communication with the gas flow diverter, an emissive member disposed substantially within the gas flow diverter and the arc constrictor, and a resilient arc initiator disposed between the emissive member and at least one of the gas flow diverter or the arc constrictor. At least a portion of each of the gas flow diverter, the arc constrictor, the emissive member and the arc initiator are irremovably integrated within the consumable assembly. 
     In some embodiments, the emissive member includes an electrode and the arc starter includes a spring. In some embodiments, the gas flow diverter is anodized. In some embodiments, the gas flow diverter includes a cap insert located substantially opposite the arc constrictor, the cap insert substantially orienting the emissive member and retaining the emissive member within the gas flow diverter. In some embodiments, a seal is disposed within the cap insert. In some embodiments, the consumable assembly includes a shield connected to the gas flow diverter. In some embodiments, the shield is connected to the gas flow diverter via a shield insulator. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing discussion will be understood more readily from the following detailed description of the invention when taken in conjunction with the accompanying drawings. 
         FIG. 1  is a cross-sectional schematic illustration of a cartridge for a plasma arc cutting system, according to an illustrative embodiment of the invention. 
         FIG. 2A  is an isometric illustration of a unitary cartridge for a plasma arc cutting system, according to an illustrative embodiment of the invention. 
         FIG. 2B  is a cross-sectional illustration of a unitary cartridge for a plasma arc cutting system, according to an illustrative embodiment of the invention. 
         FIG. 2C  is a cross-sectional illustration of a unitary cartridge for a plasma arc cutting system, according to an illustrative embodiment of the invention. 
         FIG. 3A  is an isometric illustration of an inner cartridge assembly for a plasma arc torch, according to an illustrative embodiment of the invention. 
         FIG. 3B  is a cross-sectional illustration of an inner cartridge assembly for a plasma arc torch, according to an illustrative embodiment of the invention. 
         FIGS. 4A-4B  are cross-sectional illustrations of consumable cartridges for a plasma arc cutting system, each cartridge having a nozzle, an electrode, a swirl ring, a resilient element and an end cap, according to illustrative embodiments of the invention. 
         FIG. 5  is a cross-sectional illustration of a consumable cartridge for a plasma arc cutting system having a nozzle, an electrode, a swirl ring, a resilient element and an end cap, according to illustrative embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a cross-sectional schematic illustration of a cartridge  100  for a plasma arc cutting system, according to an illustrative embodiment of the invention. The cartridge  100  has a first end  104 , a second end  108 , and a substantially hollow frame  112  having a first section  112 A toward the first end  104  and a second section  112 B toward the second end  108 . The cartridge  100  also includes an arc emitter  120 , an arc constrictor  124 , and a resilient element  128 . The arc emitter  120  is located within the frame  112  and is translatable relative to the frame  112 . As shown, the arc constrictor  124  forms a part of the frame  112  (e.g., at the second end  108 , but in some embodiments can be attached to the frame  112 ). The resilient element  128  is in physical communication with the frame  112 , e.g., is in direct physical communication with the first section  112 A. In some embodiments, the resilient member  128  is a contact start spring element affixed to the arc emitter  120 . The resilient element  128  can be configured to pass a pilot current from the frame  112  to the arc emitter  120 . The resilient element  128  can bias the arc emitter  120  toward one of the first end  104  or the second end  108  to facilitate ignition at or near the arc emitter  120 . The arc emitter  120  can be an electrode and can include a highly emissive element  122  such as a hafnium insert. 
     The first section  112 A and second section  112 B are joined at an interface  132  to form a substantially hollow chamber. The interface  132  provides a coupling force (F coupling ) that secures the first section  112 A and the second section  112 B together. The resilient member  128  can impart a separating force (F separating ) that biases the arc emitter  120  toward at least one of the first section  112 A or the second section  112 B. The separating force can have a magnitude that is less than a magnitude of the coupling force. In some embodiments, the coupling force is provided at the interface  132  by at least one of a static frictional force, an adhesive force, or a normal force (e.g., a force countering a downward gravitational force) provided at a notch  136  of the interface  132 . In some embodiments, the coupling force is stronger than is possible for a person to overcome by hand, either intentionally or inadvertently. 
     In some embodiments, the frame  112  includes at least one of a metal (e.g., aluminum) or other thermally conductive material. In some embodiments, the frame  112  is formed by molding. In some embodiments, the frame  112  is anodized (e.g., includes anodized aluminum, as set forth more fully below). In some embodiments, the frame  112  includes an electrical insulator, for example anodized aluminum and/or thermoplastics (e.g., PEEK, Torlon, Vespel, etc.). In some embodiments, at least one of the first end  104  or the second end  108  of the frame  112  includes a threaded region shaped to engage a complementary component. In some embodiments, the electrode  120  includes the resilient element  128  such as a spring. 
     In some embodiments, an external surface of the cartridge  100  is shaped to connect to, or mate with, a retaining cap or a cartridge cap (not shown). In some embodiments, the retaining cap is replaceable, threaded, and/or snap-on. The cartridge cap can be disposed about (e.g., can surround) the second end  108  of the frame  112 . The cartridge cap can be shaped to contact the arc emitter  120  and to retain the arc emitter  120  within the frame  112 . The cartridge cap can define an aperture of the arc emitter  120 . The cartridge cap can include a fluid sealing surface disposed about a circumference of the aperture of the arc emitter  120 . In some embodiments, the cartridge cap substantially orients the electrode  120  and retains the electrode  120  within the cartridge  100 . In some embodiments, the cartridge cap includes a seal. 
     The cartridge  100  can be a “consumable” cartridge or assembly of consumable components, e.g., the cartridge  100  can be replaced as a unit after it reaches the end of its useful life. The cartridge  100  can be a sealed unit that is not intended to have individual component parts replaced. In some embodiments, individual components are irremovably disposed within or integrated into the cartridge  100 . For example, at least a portion of the electrode  120  and the contact start spring element  128  can be irremovably disposed within the frame  112 , e.g., sealed within the frame  112  and/or not intended to be removed or replaced by an operator. In some embodiments, the cartridge  100  is a consumable component. In some embodiments, the components (e.g., frame  112  and arc constrictor  124 ) may be connected via press fits or other like means with tight tolerances and will degrade, fracture, or fail if separated. 
       FIG. 2A  is an isometric illustration of a unitary cartridge  200  for a plasma arc cutting system, according to an illustrative embodiment of the invention. Visible from the exterior are a plastic exterior section  204 , a metallic exterior section  208 , and a copper exterior section  212  (e.g., a nozzle shield). The plastic exterior section  204  and the metallic exterior section  208  are joined at a junction  206 . In some embodiments, the junction  206  is included in or near a tapered region. In some embodiments, the plastic exterior section  204  is a retaining cap. In some embodiments, the metallic exterior section  208  is a shield insulator. In some embodiments, the metallic exterior section  208  is formed substantially of a material other than copper. In some embodiments, the copper exterior section  212  is formed of a pure or substantially pure copper or copper alloy. The components of the cartridge  200  are seen in more detail in  FIG. 2B , described below. 
       FIG. 2B  is a cross-sectional illustration of a unitary cartridge  200  for a plasma arc cutting system, according to an illustrative embodiment of the invention. In this view, additional elements of the cartridge  200  are visible, including a nozzle body  216 , a nozzle orifice  218 , an electrode  220  having an emitting element  222 , an insulator sleeve  224  having an elongated portion  224 A, a resilient element  226 , and an electrode contact button  236  (e.g., made of brass). In the present invention, one or more of these elements can be redesigned to achieve one or more of the objectives set forth above. 
     For example, the nozzle body  216  can be formed from a conductive material (e.g., a highly conductive material such as aluminum) and can be attached to (e.g., can be in direct physical contact with) other parts of the cartridge  200 . In some embodiments, the nozzle body  216  is in thermal communication with certain parts of the cartridge  200  (e.g., via thermal conduction) but electrically isolated from other parts. For example, the nozzle body  216  can function as a heat sink for the nozzle orifice  218  while remaining electrically isolated from the nozzle shield  212 . Such a configuration can enhance cooling performance (for example, of the nozzle and the electrode) and reduce manufacturing costs by comparison to previously used materials (e.g., as Vespel™). In some embodiments, the cartridge has a region with a thermal conductivity of between about 200-400 Watts per meter per degree Kelvin (for example, aluminum may have a thermal conductivity of between 200-250 W/m-° K, while copper may have a thermal conductivity of between 350-400 W/m-° K). In some embodiments, the consumable cartridge has a heat capacity to current ratio of 2-4 W/m-° K-A. 
     In addition, the nozzle body  216  includes a set of inlet swirl holes  228  (e.g., swirl holes  228 A and  228 B). In some embodiments, the set of inlet swirl holes  228  includes five swirl holes, or optionally between three and ten swirl holes. The swirl holes  228  can be radially offset to impart a swirl flow (e.g., radial and tangential velocity components) to gases flowing therethrough (e.g., a shield gas, plasma gas, and/or a plenum gas). In this configuration, the nozzle body  216  provides the swirl function previously provided by a swirl ring, thus eliminating the need for a traditional swirl ring. In addition, in some embodiments the nozzle body  216  is formed via a molding process, thus eliminating the need for expensive and time-consuming drilling procedures to create the swirl holes. In some embodiments, the nozzle shield  212  includes an angle  232  that helps redirects fluid flow away from the plasma arc during operation. 
       FIG. 2C  is a cross-sectional illustration of a unitary cartridge  240  for a plasma arc cutting system, according to an illustrative embodiment of the invention. The unitary cartridge  240  can be similar in many respects to the cartridge  200  shown in  FIG. 2B  but can differ in certain other respects. For example, the cartridge  240  utilizes a stamped torch interface  250  (e.g., a stamped pieces of copper) having a cross-sectional “T”-shape. The interface  250  can allow the electrode to slide more freely than in the  FIG. 2B  configuration, which uses an electrode with a nipple feature that forms a mating surface with the spring. In  FIG. 2C , the cap and the nozzle body have been opened to ease manufacture and allow the electrode to slide freely into the nozzle body during cartridge assembly. The spring can then rest on the electrode, and the stamped torch interface  250  can use a small tab feature  252  to snap readily into the nozzle body, securing the electrode therein. Such a configuration avoids the need to press fit multiple pieces together (and, in turn, avoids the need to have to achieve tight tolerances between pieces) and/or the need to assemble different pieces of the torch from different directions. Using the cartridge  240 , a manufacturer can simply slide the electrode into place in one step. 
     In addition, the cartridge  240  uses a molded, slotted swirl feature  266  to achieve the swirling function instead of using holes drilled in the nozzle body. In this configuration, during operation gas flows out of the slots  266  and into the plasma chamber to form the swirl gas about the plasma arc. During operation, gas may also flow through molded gas shield channel  254 , further cooling the nozzle body. Slots  266  form a set of swirl holes once the nozzle body, nozzle orifice, and/or nozzle liner are connected. Gas delivered to the slots is conveyed from the torch through a chamber defined by an internal surface of the nozzle body and an external surface of the nozzle liner (which, in combination, form the swirl holes). Such a configuration eliminates post-process machining steps and the associated expenses. In addition, the cartridge  240  includes a radial swage connection  258  between the nozzle orifice and the nozzle body. The radial swage connection  258  provides a robust connection interface to allow contact to be maintained between the nozzle orifice and the nozzle body, but also exposes significant surface area for heat to be conducted from the nozzle orifice to the nozzle body. Finally, in this embodiment, the electrode sleeve is removed and replaced with a more traditional heat exchanger. 
       FIG. 3A  is an isometric illustration of an inner cartridge assembly  300  for a plasma arc torch, according to an illustrative embodiment of the invention. Visible from the exterior are a shield  304  having vent holes  306  (e.g., holes  306 A-D as shown), a nozzle body  308  having flow holes or inlet swirl holes  312  (e.g., holes  312 A,  312 B as shown in  FIG. 3A ), a front insulator (or shield insulator)  314 , and a rear insulator (or lock ring)  316 . These and additional elements are described more fully in conjunction with the cross-sectional view shown in  FIG. 3B  below. 
       FIG. 3B  is a cross-sectional illustration of the inner cartridge assembly  300  of  FIG. 3A , according to an illustrative embodiment of the invention. In this view, several additional components of the inner cartridge assembly  300  are visible, including an electrode  320  having an emitting element  322 , an arc constrictor or nozzle orifice  324 , shield flow holes  328  (e.g., flow holes  328 A-B as shown) directed toward the nozzle orifice  324 , an insulator sleeve  332 , and a cooling gas flow channel  336 . In this embodiment, the nozzle body  308  functions as the cartridge frame to which other parts attach. 
     A number of features of the inner cartridge assembly  300  can enhance its cooling capabilities. First, the nozzle body  308  can be made of aluminum, which can enhance heat conduction over previous materials and configurations as described above. Second, the nozzle orifice  324  can be made of copper and can be pressed onto the nozzle body  308 . In such embodiments, the nozzle body  308  can serve as a heat sink for the copper nozzle orifice  324 . Third, improved gas flow surfaces, can assist in cooling, e.g., with shield gas flowing forward through holes  328 A,  328 B just outside of the press area. A press fit arrangement can also provide improved thermal conduction paths between torch parts as a result of tight tolerances between the surfaces of the parts. In some embodiments, the press fit arrangement includes an interference fit and/or a tabbed or interlocking fit having one or more step-like features. In addition, the small size of the press fit design has the additional advantages of reducing manufacturing and/or material costs and simplifying manufacture and assembly of the components (e.g., by having fewer parts). 
     The nozzle shield  304  can also be made of copper and can be pressed onto an anodized aluminum insulator  314  at a surface  305 A. This assembly can then be pressed onto the nozzle body  308  at a press fit surface  305 B. In such embodiments, the shield insulator  314  connects the nozzle body  308  to the shield  304 . In some embodiments, the shield insulator  314  is press fit to the nozzle body  308 . In some embodiments, the shield insulator  314  is an electrically insulative ring and/or includes a set of press-fit surfaces  305 A,  305 B that connect the shield  304  and the nozzle body  308 . The shield insulator  314  can connect the nozzle body  308  to the shield  304  such that the nozzle body  308  and the shield  304  are electrically insulated from one another while still transferring thermal energy to one another. In some embodiments, using a two-piece shield insulator can increase (e.g., double) electrical insulation abilities as a result of increasing contact surfaces. 
     The nozzle shield  304  can be considerably smaller than previous shields, allowing for efficient manufacture and assembly of components, improved durability, and greater assurances of proper orientation of cartridge parts relative to one another. By way of example, for a  45 - amp  system, a prior art stock shield might have a diameter of about one inch and a mass of about 0.04 pounds, whereas a cartridge shield in accordance with the current invention can have a diameter of about 0.5 inches with a mass of less than 0.01 pounds (e.g., about 0.007 pounds). For a  105 - amp  system, a prior art stock shield might have a diameter of about one inch with a mass of about 0.05 pounds, whereas a cartridge shield in accordance with the current invention can have a diameter of about a half inch with a mass of about 0.01 pounds (e.g., 0.013 pounds). 
     The smaller size configuration can carry significant advantages. First, components having a reduced mass have a reduced heat capacity, which allows the components to be rapidly cooled during post-flow and/or allows more heat to be transferred to the cooling gas during operation. Second, a smaller shield can attain comparatively higher temperatures during operation and can transfer more heat to the cooling gas. In some embodiments, the nozzle shield  304  is exposed to a cold gas entering the shield area, e.g., via shield flow holes  328 , which can further reduce the temperature. The flow holes  328  can each have a total cross sectional area of at least about one square inch. 
     In some embodiments, the electrode  320  includes a base made of copper. In some embodiments, the electrode  320  base has a small diameter with a pressed-on insulator sleeve  332  made of anodized aluminum and/or plastic used for electrical isolation. In some embodiments, a cooling gas flow channel or gap  336  exists between the insulator sleeve  332  and the nozzle body  308 . In some embodiments, a cool gas flows in the gap  336 . In some embodiments, a “dumbbell” configuration  340  defined by two end contacts  340 A,  340 B is used, which can reduce or minimize contact area between the nozzle body  308  and the insulator sleeve  332 . Such a configuration can reduce friction between parts. 
     In some embodiments, the sleeve  332  contacts the electrode  320 , which can be part of a separate current path from the nozzle body  308  and/or a different portion of the current path from the nozzle body  308 . In some embodiments, the electrode  320  and the nozzle body  308  can be electrically separated by a gap to create the arc and/or to ensure proper orientation of the parts in the torch. In such embodiments, the nozzle  308  and the electrode  320  can be in physical contact between the sleeve  332  and the nozzle body  308 . In such embodiments, insulative layers are needed in this region so that current is able to pass through the emitting element  322 . 
     In some embodiments, a wall of the nozzle body  342  near which the electrode  320  moves can stay comparatively cool during operation as gas flow passes both on the inside of the nozzle body  308  and directly across an exterior surface  344  of the nozzle  324 . The material choice (e.g., aluminum or another metal) for the nozzle body  342  design provides for a better conduction path and heat sink ability as compared with previous materials such as Vespel™ Such factors assist in cooling the electrode isolation piece and allow the electrode to function even after a deep pit is formed in the emitting element from electrode use. 
     In some embodiments, a lock ring  316  (or isolation ring) forms an interface  346  between the cartridge  300  and the torch. In some embodiments, the lock ring  316  can be made of anodized aluminum. The lock ring  316  can be pressed into the nozzle body to “trap” the moveable electrode  320 . The lock ring  316  can contain the components within the cartridge  300  and electrically isolate the torch. In some embodiments, the lock ring  316  is replaced by heat shrinking or gluing. In some embodiments, the lock ring  316  is shaped to orient the cartridge  300  (e.g., axially), to optimize gas flow, to enable electrical connection to the cathode, and/or to provide electrical isolation. 
     In various embodiments described herein, the cartridges or consumable assemblies are about 3.5 inches in length and 1.1 inches in diameter. In some embodiments, the retaining cap is considered part of the torch, e.g., not a consumable component. In such configurations, machining steps can be minimized, with no machining necessary after assembly (as compared to some torch assemblies that require a final machining step to achieve functional axiality of the cartridge). In some embodiments, the reduction in swirl holes can minimize drilling operations compared to prior art swirl rings. In some embodiments, replacing Vespel™ with aluminum can significantly reduce manufacturing costs of the cartridge. In some embodiments, copper is used only in certain locations in the electrode, nozzle, and/or orifice, which can reduce manufacturing costs by reducing the use of this expensive material. For example, copper can be concentrated primarily in an inner core or region. While copper can be desirable for its thermal and electrical properties, it is also more expensive than other materials, and so designs that minimize its usage are sought. 
       FIGS. 4A-4B and 5  are cross-sectional illustrations of consumable cartridges for a plasma arc cutting system, each cartridge having a nozzle, an electrode, a swirl ring, a resilient element and an end cap, according to illustrative embodiments of the invention.  FIG. 4A  shows an exemplary cartridge design  400 . As shown, the cartridge  400  includes a swirl ring  402 , an end cap  406 , a nozzle  408  and an electrode  404 . The electrode  404  can be a spring-forward electrode for a contact start plasma arc torch, where a resilient element  412  (e.g., a spring) exerts a separating force on the distal end of the electrode  404  to bias the electrode  404  away from the end cap  406  and toward the nozzle  408 . The resilient element  412  can also be a part of the cartridge  400 . The cartridge  400  can include a starting mechanism for contact starting a plasma arc torch upon assembly into the torch. 
     The swirl ring  402  can extend substantially over the length of the electrode  404  along a longitudinal axis  410  of the electrode  404 . In some embodiments, the swirl ring  402  is manufactured through injection molding of high-temperature thermoplastics (e.g., PAI, PEI, PTFE, PEEK, PEKPEKK, etc). Use of thermoplastics to manufacture swirl rings can reduce cartridge cost in comparison to Vespel™, which is a material that has been used to manufacture swirl rings, but is comparatively more expensive. It is known that thermoplastics have operating temperatures that are lower than Vespel™ (a thermoset), which can impact the integrity of swirl rings and electrode life. However, the cartridge designs of the present technology, which can incorporate swirl rings made from thermoplastics resins having various fortifying additives that provide the desired thermal resistance and/or thermal conductivity (e.g., glass fibers, minerals, boron nitride (BN), and/or Cubic BN), have resolved the high temperature performance issues, thus enabling the effective use of thermoplastics in these cartridges. This is achieved since (1) thermoplastics have a sufficently high-temperature resistance and (2) a cartridge design that properly incorporates thermoplastics can avoid exposure of the thermoplastics to excessive temperatures during operation. In addition, when an electrode experiences an end-of-life event, which is also the end of life of the cartridge, the simultaneous melting of the plastic material is not problematic. 
     The end cap  406  can be made of a conductive material, such as copper. The end cap  406  can be inexpensively formed via stamping from a material blank and can be irremoveably inserted, press fit or over molded onto the cartridge  400 . The end cap  406  is configured to contain the resilient element  412  within the cartridge  400  and compress the resilient element  412  against the distal end of the electrode  404  such that the resilient element  412  exerts a separating force on the distal end of the electrode  404  to bias the electrode  404  toward the nozzle  408 . In some embodiments, end cap  406  may be shaped to matingly engage a patterned torch head and/or may include a set of fluid flow holes formed therethrough. 
     In some embodiments, an unreleasable snap-fit interface  414  is formed between the swirl ring  402  and the nozzle  408  to join the two consumable components together as a part of the cartridge  400 . In addition, a second snap-fit interface  416  can be formed between the swirl ring  402  and the end cap  406  to join the two consumable components together as a part of the cartridge  400 . Other manufacturing and assembly options are available and viable. For example, the swirl ring  402  can be over-molded onto the end cap  406 . The end cap  406  can also be capsulated by the swirl ring  402  and the resilient element  412  (e.g., a spring), where the end cap  406  can move within the cartridge  400 . 
       FIG. 4B  shows another exemplary cartridge design  450 . As shown, the cartridge  450  includes a swirl ring  452 , an end cap  456 , a nozzle  458  and an electrode  454 . In some embodiments, the cartridge  450  also includes a resilient element  462  that functions similarly as the resilient element  412  of  FIG. 4A . The cartridges of  FIGS. 4A and 4B  have different electrodes (e.g., different sizes of heat exchanger flanges, circumferential flange for uniform flow), different nozzles (e.g., different swirl ring attachment), and different swirl rings (e.g., different swirl holes and attachment). In the cartridge design  450  of  FIG. 4B , an interface  464  is formed as the swirl ring  452  is inserted into position in relation to the nozzle  458 . Another interface  466  can be formed between the swirl ring  452  and the end cap  456 . 
       FIG. 5  shows another exemplary cartridge design  500 . As shown, the cartridge  500  includes a swirl ring  502 , a sleeve  514 , an end cap  506 , a nozzle  508  and an electrode  504 . In some embodiments, the cartridge  500  also includes a resilient element  512  that functions similarly as the resilient element  512  of  FIG. 4A . The sleeve  514  and/or end cap  506  can be made from a conductive material (e.g., copper) using a stamping method. The sleeve  514  can be press fit or over molded onto the cartridge  500 . The end cap  506  can be a part of the sleeve  514 . Therefore, the sleeve  514  and the end cap  506  can be constructed as a single component piece. 
     As shown, the swirl ring  502  can be relatively short in comparison to the swirl ring  402  such that the swirl ring  502  only extends along a portion of the length of the electrode  504  in the longitudinal axis  510 . Similar to the swirl ring  402 , the swirl ring  502  can be manufactured through injection molding of high-temperature thermoplastics (e.g., Torlon™). A snap-fit interface  520  can be formed between the swirl ring  502  and the nozzle  508  to join the two consumable components together as a part of the cartridge  500 . Another snap-fit interface  518  can be formed between the swirl ring  502  and the sleeve  514  to join the two consumable components together as a part of the cartridge  500 . Alternatively, the swirl ring  502  can be over-molded onto the sleeve  514 . 
     There are many benefits associated with using a cartridge in a plasma arc torch. First, such a design promotes ease of use through quick change capabilities, short setup time and ease of consumable selection for an end user. It also provides consistent cut performance because a suite of consumables are changed at once when the cartridge is changed. In contrast, variation in performance is introduced when components are changed individually at different times. For example, long term re-use of the same swirl ring can cause dimensional alteration after each blow-out, thereby altering the performance quality even if all other components are changed regularly. In addition, since the manufacturing and/or installation cost of a cartridge is lower than the combined cost of a set of consumables, there is a lower cost associated with per cartridge change than per change of a set of consumables. Furthermore, different cartridges can be designed to optimize torch operation with respect to different applications, such as marking, cutting, maintaining long life, etc. 
     While the invention has been particularly shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the following claims.