Welding wire container and method of making the same

Abstract

A container for packaging and unwinding a welding wire having a natural cast that is essentially a straight line. The container including a box with vertical side walls each having an inner wall surface and vertically extending corners between the side walls, a closed bottom, a top opening for removing the welding wire. The container further including a first vertically extending cylindrical liner with a first radial outwardly facing surface and a first radial inwardly facing surface wherein the first inward surface has a diameter A and is coaxial with a vertically extending container axis such the first liner is supported by the side walls. The container further includes a second cylindrical liner having a second radial outwardly facing surface and a second radial inwardly facing surface. The second outward surface having a diameter B that is less than diameter A and is coaxial with the axis. The second outward surface defining a radial inward extent of an annular wire cavity and the first inward surface defines a radial outward extent of the annular wire cavity. The container also including a wire coil made up of a plurality of convolutions of the wire. Each of the convolutions having a similar effective convolution diameter that is greater than fifty percent of diameter A but less than diameter A. The natural cast producing a radially outward force in the each convolution that is supported by the first liner and the coil extending radially between the first and second liners.

1 . A container for packaging and unwinding a welding wire having a natural cast that is essentially a straight line, said container comprising: a square box with four vertical side walls each having an inner wall surface and four vertically extending corners between said side walls, a closed bottom, a top opening for removing said welding wire; a first vertically extending cylindrical liner with a first radial outwardly facing surface and a first radial inwardly facing surface, said first inward surface having a diameter A and being coaxial with a vertically extending container axis such that said first liner is supported radially by said side walls; a second cylindrical liner having a second radial outwardly facing surface and a second radial inwardly facing surface, said second outward surface having a diameter B that is less than said diameter A and is coaxial with said axis such that said second outward surface defines a radial inward extent of an annular wire cavity and said first inward surface defines a radial outward extent of said annular wire cavity; and a wire coil made up of a plurality of convolutions of said wire, each said convolution having a similar effective convolution diameter that is greater than fifty percent of said diameter A but less than said diameter A, said natural cast producing a radially outward force in said each convolution that is supported by said first liner, said coil extending radially between said first and second liners.  
   
   
       2 . The container as defined in  claim 1 , further including four vertically extending corner supports, each said corner support being adjacent one of said four vertically extending corners and extending between said first liner and said box.  
   
   
       3 . The container as defined in  claim 2 , wherein said four vertically extending corner supports include a cylindrical outer corner support surface, said corner support surface engaging said first outward surface and two of said four inner wall surfaces.  
   
   
       4 . The container as defined in  claim 3 , further including a braking ring for controlling the unwinding of said wire from said wire coil, said ring resting on a coil top and descending within said cavity during the unwinding of said wire from said container.  
   
   
       5 . The container as defined in  claim 4 , wherein said braking ring is annular having an inner periphery, an outer periphery, a bottom surface extending between said inner and outer peripheries and a top, said bottom surface resting on said coil top, said inner periphery including an upwardly curved surface extending from said bottom surface to an inner edge of said ring for guiding said wire from said coil toward said top opening, said ring being sized to allow freely descending movement of said ring within said cavity during the unwinding of said wire from said container.  
   
   
       6 . The container as defined in  claim 4 , wherein said braking ring includes a generally flat radial outer portion with an outer periphery, an inner diameter and a radial distance therebetween, said braking ring containing a number of projecting lobe portions, each said lobe portion generally disposed in said flat outer portion whereby said radial distance from said inner diameter to said outer periphery varies within each said lobe portion and an inner upwardly curved portion defining an innermost wire extraction opening between said braking ring and said second liner, said curved portion curving upward from said inner diameter of said flat portion to said wire extraction opening, said wire extraction opening having a diameter smaller than said inner diameter of said flat portion.  
   
   
       7 . The container as defined in  claim 1 , further including a braking ring for controlling the unwinding of said wire from said wire coil, said ring resting on a coil top and descending within said cavity during the unwinding of said wire from said container.  
   
   
       8 . The container as defined in  claim 7 , wherein said braking ring is annular having an inner periphery, an outer periphery, a bottom surface extending between said inner and outer peripheries and a top, said bottom surface resting on said coil top, said inner periphery including an upwardly curved surface extending from said bottom surface to an inner edge of said ring for guiding said wire from said coil toward said top opening, said ring being sized to allow freely descending movement of said ring within said cavity during the unwinding of said wire from said container.  
   
   
       9 . The container as defined in  claim 7 , wherein said braking ring includes a generally flat radial outer portion with an outer periphery, an inner diameter and a radial distance therebetween, said braking ring containing a number of projecting lobe portions, each said lobe portion generally disposed in said flat outer portion whereby said radial distance from said inner diameter to said outer periphery varies within each said lobe portion and an inner upwardly curved portion defining an innermost wire extraction opening between said braking ring and said second liner, said curved portion curving upward from said inner diameter of said flat portion to said wire extraction opening, said wire extraction opening having a diameter smaller than said inner diameter of said flat portion.  
   
   
       10 . The container as defined in  claim 1 , wherein said wire coil includes a coil top and said container further including a plurality of resistance elements on said coil top, said resistance elements substantially covering said coil top and descending within said cavity during the unwinding of said wire from said container, said first and second liners maintaining said plurality of resistance elements on said coil top.  
   
   
       11 . The container as defined in  claim 10 , wherein said plurality of resistance elements includes spherical resistance elements.  
   
   
       12 . The container as defined in  claim 10 , wherein said plurality of resistance elements includes elongated resistance elements.  
   
   
       13 . The container as defined in  claim 10 , wherein said plurality of resistance elements includes cylindrical resistance elements.  
   
   
       14 . The container as defined in  claim 10 , wherein said plurality of resistance elements includes disc-shaped resistance elements.  
   
   
       15 . The container as defined in  claim 10 , wherein said plurality of resistance elements includes resistance elements shaped like nickels.  
   
   
       16 . The container as defined in  claim 10 , wherein said plurality of resistance elements includes nickels.  
   
   
       17 . The container as defined in  claim 2 , wherein said wire coil includes a coil top and said container further including a plurality of resistance elements on said coil top, said resistance elements substantially covering said coil top and descending within said cavity during the unwinding of said wire from said container, said first and second liners maintaining said plurality of resistance elements on said coil top.  
   
   
       18 . The container as defined in  claim 17 , wherein said plurality of resistance elements includes spherical resistance elements.  
   
   
       19 . The container as defined in  claim 17 , wherein said plurality of resistance elements includes elongated resistance elements.  
   
   
       20 . The container as defined in  claim 17 , wherein said plurality of resistance elements includes cylindrical resistance elements.  
   
   
       21 . The container as defined in  claim 17 , wherein said plurality of resistance elements includes disc-shaped resistance elements.  
   
   
       22 . The container as defined in  claim 17 , wherein said plurality of resistance elements includes resistance elements shaped like nickels.  
   
   
       23 . The container as defined in  claim 17 , wherein said plurality of resistance elements includes nickels.  
   
   
       24 . The container as defined in  claim 17 , wherein said four vertically extending corner supports include a cylindrical outer corner support surface, said corner support surface engaging said first outward surface and two of said four inner wall surfaces.  
   
   
       25 . The container as defined in  claim 24 , wherein said first liner is a planar sheet having a top edge, a bottom edge, a first side edge and a second side edge, said first liner wrapped into said box such that said op edge is near said top opening, said bottom edge is near said closed bottom and said first and second side edges facing one another.  
   
   
       26 . The container as defined in  claim 24 , wherein said first liner is a molded article.  
   
   
       27 . The container as defined in  claim 24 , wherein said box is a cardboard box.  
   
   
       28 . The container as defined in  claim 1 , wherein said box is a cardboard box.  
   
   
       29 . The container as defined in  claim 2 , wherein said box is a cardboard box.  
   
   
       30 . The container as defined in  claim 5 , wherein said box is a cardboard box.  
   
   
       31 . The container as defined in  claim 10 , wherein said box is a cardboard box.  
   
   
       32 . The container as defined in  claim 1 , wherein said effective convolution diameter that is greater than seventy percent of said diameter A.  
   
   
       33 . The container as defined in  claim 2 , wherein said effective convolution diameter that is greater than seventy percent of said diameter A.  
   
   
       34 . The container as defined in  claim 5 , wherein said effective convolution diameter that is greater than seventy percent of said diameter A.  
   
   
       35 . The container as defined in  claim 10 , wherein said effective convolution diameter that is greater than seventy percent of said diameter A.  
   
   
       36 . The container as defined in  claim 1 , wherein said effective convolution diameter that is greater than eighty percent of said diameter A.  
   
   
       37 . The container as defined in  claim 2 , wherein said effective convolution diameter that is greater than eighty percent of said diameter A.  
   
   
       38 . The container as defined in  claim 5 , wherein said effective convolution diameter that is greater than eighty percent of said diameter A.  
   
   
       39 . The container as defined in  claim 10 , wherein said effective convolution diameter that is greater than eighty percent of said diameter A.  
   
   
       40 . The container as defined in  claim 1 , wherein said first radial outwardly facing surface is spaced from said inner wall surfaces.  
   
   
       41 . The container as defined in  claim 1 , wherein said first radial outwardly facing surface engages said inner wall surfaces.  
   
   
       42 . A container for packaging and unwinding a welding wire having a natural cast that is essentially a straight line, said container comprising: a square box with four vertical side walls each having an inner wall surface and four vertically extending corners between said side walls, a closed bottom, a top opening for removing said welding wire; a first vertically extending cylindrical liner with a first radial outwardly facing surface and a first radial inwardly facing surface, said first inward surface having a diameter A and being coaxial with a vertically extending container axis such that said first outward surface engages each said inner wall surface; a second cylindrical liner having a second radial outwardly facing surface and a second radial inwardly facing surface, said second outward surface having a diameter B that is less than said diameter A and is coaxial with said axis such that said second outward surface defines a radial inward extent of an annular wire cavity and said first inward surface defines a radial outward extent of said annular wire cavity; a wire coil made up of a plurality of convolutions of said wire having a coil bottom supported by said closed bottom and an oppositely facing coil top, each said convolution having a similar effective convolution diameter that is greater than fifty percent of said diameter A but less than said diameter A, said natural cast producing a radially outward force in said each convolution that is supported by said first liner, said coil extending radially between said first and second liners; and a plurality of nickel-shaped resistance elements substantially covering said coil top.  
   
   
       43 . A container for packaging and unwinding a welding wire having a natural cast that is essentially a straight line, said container comprising: an outer box having a plurality of flat vertical side walls each having an inner wall surface and a corresponding plurality of vertically extending corners between said side walls, a closed bottom, a top opening for removing said welding wire; a first vertically extending cylindrical liner with a first radial outwardly facing surface and a first radial inwardly facing surface, said first inward surface having a diameter A and being coaxial with a vertically extending container axis, said first liner being supported radially by said side walls; a second cylindrical liner having a second radial outwardly facing surface and a second radial inwardly facing surface, said second outward surface having a diameter B that is less than said diameter A and is coaxial with said axis such that said second outward surface defines a radial inward extent of an annular wire cavity and said first inward surface defines a radial outward extent of said annular wire cavity; a wire coil made up of a plurality of convolutions of said wire having a coil bottom supported by said closed bottom and an oppositely facing coil top, each said convolution having a similar effective convolution diameter that is greater than fifty percent of said diameter A but less than said diameter A, said natural cast producing a radially outward force in said each convolution that is supported by said first liner, said coil extending radially between said first and second liners; and a means for controlling the outflow of said wire from said coil during the unwinding of said welding wire.  
   
   
       44 . The container as defined in  claim 43 , wherein said control means includes a plurality of resistance elements positioned on said coil top.  
   
   
       45 . The container as defined in  claim 44 , wherein said resistance elements include nickel-shaped resistance elements.  
   
   
       46 . The container as defined in  claim 43 , wherein said control means includes a braking ring, said ring resting on said coil top and descending within said cavity during the unwinding of said wire from said container.  
   
   
       47 . The container as defined in  claim 46 , wherein said braking ring is annular having an inner periphery, an outer periphery, a bottom surface extending between said inner and outer peripheries and a top, said bottom surface resting said coil top, said inner periphery including an upwardly curved surface extending from said bottom surface for guiding said wire from said coil toward said top opening, said ring being sized to allow freely descending movement of said ring within said cavity during the unwinding of said wire from said container.  
   
   
       48 . The container as defined in  claim 43 , wherein said effective convolution diameter that is greater than seventy percent of said diameter A.  
   
   
       49 . A method of transforming a polygonal container into a drum-like container for packaging and unwinding a coil of welding wire having a natural cast that is essentially a straight line, said method including the steps of: 
 providing a polygonal container having a plurality of outer planar side walls coaxial with a vertically extending container axis, each of said plurality of planar side walls having a top edge, a bottom edge and an inner wall surface, the spacing between said top and bottom edges defining a container height; a corresponding plurality of vertically extending corners between said each side walls; a closed bottom;    and a top opening for removing said welding wire;    providing a first liner that is cylindrical, said first liner having a bottom edge and an oppositely facing top edge, said first liner having a height between said bottom edge and said top edge that is approximately equal to said container height, said first liner further including a first radial outwardly facing surface and a first radial inwardly facing surface, said first inward surface having a diameter A and defining a radial outward extent of a wire cavity;    positioning said first liner into said polygonal container such that said first liner is coaxial with said vertical container axis, said bottom edge is adjacent to said closed bottom of said polygonal container, said top edge is near said top opening, and said first radial outward surface engages said inner wall surfaces;    winding a plurality of convolutions of said wire into said wire cavity, said plurality of convolutions forming a wire coil having a coil bottom supported by said closed bottom and an oppositely facing coil top, each said convolution having a similar effective convolution diameter that is greater than fifty percent of said diameter A but less than said diameter A, said natural cast producing a radially outward force in said each convolution that is supported by said first liner, said coil extending radially between said first liner and a central coil opening coaxial with said axis;    providing a second cylindrical liner having a second radial outwardly facing surface and a second radial inwardly facing surface, said second outward surface having a diameter B that is less than said diameter A of said first liner; and,    positioning said second liner into said polygonal container and said central coil opening such that said second outward surface is coaxial with said vertical container axis, said second outward surface defines a radial inward extent of the wire cavity.    
   
   
       50 . The method as defined in  claim 49 , further including the steps of providing a plurality of resistance elements and substantially covering said coil top with said elements.  
   
   
       51 . The container as defined in  claim 50 , wherein said plurality of resistance elements includes spherical resistance elements.  
   
   
       52 . The container as defined in  claim 50 , wherein said plurality of resistance elements includes elongated resistance elements.  
   
   
       53 . The container as defined in  claim 50 , wherein said plurality of resistance elements includes cylindrical resistance elements.  
   
   
       54 . The container as defined in  claim 50 , wherein said plurality of resistance elements includes disc-shaped resistance elements.  
   
   
       55 . The container as defined in  claim 50 , wherein said plurality of resistance elements includes resistance elements shaped like nickels.  
   
   
       56 . The container as defined in  claim 50 , wherein said plurality of resistance elements includes nickels.  
   
   
       57 . The method as defined in  claim 49 , further including the steps of providing a plurality of vertically extending corner supports having a cylindrical outer corner support surface and positioning said corner supports in said polygonal container such that said corner support surface of each support engages said outer liner surface and two of said plurality of inner wall surfaces.  
   
   
       58 . The method as defined in  claim 57 , wherein said positioning step for said plurality of vertically extending corner supports is before said positioning step for said first liner.  
   
   
       59 . The method as defined in  claim 49 , wherein said polygonal container is a square box.