An inline thermal treatment system for thermally treating a continuous product includes a gas supply system configured to supply a first gas flow and a power source configured to supply power. The system includes a plasma torch configured to receive the first gas flow from the gas supply system and power from the power source to form a plasma arc, wherein the plasma arc heats a portion of the continuous product disposed near the plasma arc.

An inductively coupled plasma (ICP) torch is described that facilitates laminar flow of a cooling gas introduced by a plurality of input ports between an outer tube and an inner tube configured to surround an injector for introduction of an aerosolized sample to a plasma. A system embodiment includes, but is not limited to, an inner tube; and an outer tube surrounding at least a portion of the inner tube to form an annular space, the outer tube defining a plurality of inlet ports for introduction of a cooling gas into the annular space as a laminar flow via each inlet port of the plurality of inlet ports.

An inductively coupled plasma (ICP) torch is described that facilitates laminar flow of a cooling gas introduced by a plurality of input ports between an outer tube and an inner tube configured to surround an injector for introduction of an aerosolized sample to a plasma. A system embodiment includes, but is not limited to, an inner tube; and an outer tube surrounding at least a portion of the inner tube to form an annular space, the outer tube defining a plurality of inlet ports for introduction of a cooling gas into the annular space as a laminar flow via each inlet port of the plurality of inlet ports.

In some aspects, power supplies for liquid cooled plasma cutting systems configured to support plasma arc generation by a torch head connected to the power supply can include: a set of electrical components for plasma arc generation; and a power supply housing containing the set of electrical components, the power supply housing having a front panel and at least two side panels and defining: a set of inlets for allowing a cooling gas to enter the power supply housing to thermally regulate the set of electrical components, at least one inlet of the set of inlets being positioned at a corner of the housing and oriented at a non-zero angle relative to the front panel and to at least one of the two side panels; and a set of vents for allowing at least a portion of the cooling gas to exit the power supply housing.

A nozzle for a plasma arc torch is provided with a distal region sidewall formed by rotation of a variably curved element about a nozzle axis. The distal region sidewall has an inclination to the nozzle axis that increases at an increasing rate as it approached a nozzle terminal plane that terminates an orifice of the nozzle. The distal region sidewall is substantially tangent to the nozzle terminal plane where it intersect the same. The desired curvature can be formed by rotation of a portion of an ellipse or parabola. The curvature of the distal region sidewall appears to draw a portion of the shield gas along the nozzle to provide improved cooling and greater stability to the plasma arc, which can improve the quality of cuts made by the arc and can increase nozzle life.

A nozzle for a plasma arc torch is provided with a distal region sidewall formed by rotation of a variably curved element about a nozzle axis. The distal region sidewall has an inclination to the nozzle axis that increases at an increasing rate as it approached a nozzle terminal plane that terminates an orifice of the nozzle. The distal region sidewall is substantially tangent to the nozzle terminal plane where it intersect the same. The desired curvature can be formed by rotation of a portion of an ellipse or parabola. The curvature of the distal region sidewall appears to draw a portion of the shield gas along the nozzle to provide improved cooling and greater stability to the plasma arc, which can improve the quality of cuts made by the arc and can increase nozzle life.

The invention features an inner cap for a liquid-cooled plasma arc torch. The inner cap includes a body having a longitudinal axis, a first end, and a second end. The first end includes an annular portion disposed proximate a torch tip. A liquid passage is formed within the body, is shaped to convey a liquid therethrough, and has a first set of ports formed in the annular portion. A gas passage is formed within the body, is shaped to convey a gas therethrough, and includes a second set of ports formed in the annular portion. The annular portion is configured such that subsets of ports in the first set of ports direct the liquid in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of ports.

The invention features an inner cap for a liquid-cooled plasma arc torch. The inner cap includes a body having a longitudinal axis, a first end, and a second end. The first end includes an annular portion disposed proximate a torch tip. A liquid passage is formed within the body, is shaped to convey a liquid therethrough, and has a first set of ports formed in the annular portion. A gas passage is formed within the body, is shaped to convey a gas therethrough, and includes a second set of ports formed in the annular portion. The annular portion is configured such that subsets of ports in the first set of ports direct the liquid in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of ports.

A plasma cutting system is provided. The system includes a torch tip having a proximal end and a distal end defining a longitudinal axis extending therethrough. The torch tip includes a plasma plenum and a plasma arc exit orifice located at the distal end of the torch tip. The system includes a lead having a distal end configured for connection to the proximal end of the torch tip. The system also includes an atmospheric vent port disposed between the plasma arc exit orifice and the distal end of the lead. The system further includes a conduit fluidly connecting the plasma plenum and the atmospheric vent port.

The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.