Endless wire container and method of using the same

Abstract

A container for packaging and unwinding a coil of welding wire to allow an uninterrupted flow of the welding wire from one the container to another the container. The coil of welding wire including a coiled portion having a top and a bottom, a first extension of the wire extending from the coil near the coil top to a feeding end and a second extension of the wire extending from the coil near the bottom to a transfer end. The transfer end of the one container being joinable to the feeding end of the another container. The container including an outer packaging with at least one vertically extending side wall, a closed bottom, a top opening for removing the welding wire and a wire coil receiving cavity within the outer packaging for receiving the wire coil. The feeding end and the transfer end being positionable near the top opening; the container further including a transfer sleeve having a first end, a second end and a wire passage extending along a sleeve axis longitudinally between the first and second ends, the wire passage being sized to allow the welding wire to travel axially through the passage. The sleeve further including a separable release slot extending between the first and second ends and the slot having a substantially closed position to maintain the welding wire in the passage. The slot also including a separated position to allow a length of the wire in the passage to pass transversely through the slot.

1 . A container for packaging and unwinding a coil of welding wire to allow an uninterrupted flow of said welding wire from one said container to another said container, said coil of welding wire including a coiled portion having a top and a bottom, a first extension of said wire extending from said coil near said coil top to a feeding end and a second extension of said wire extending from said coil near said bottom to a transfer end, said transfer end of said one container being joinable to said feeding end of said another container, said container comprising: an outer packaging including at least one vertically extending side wall, a closed bottom, a top opening for removing said welding wire and a wire coil receiving cavity within said outer packaging for receiving said wire coil, said feeding end and said transfer end being positionable near said top opening; said container further including a transfer sleeve having a first end, a second end and a wire passage extending along a sleeve axis longitudinally between said first and second ends, said wire passage being sized to allow said welding wire to travel axially through said passage, said sleeve further including a separable release slot extending between said first and second ends, said slot having a substantially closed position to maintain said welding wire in said passage and a separated position to allow a length of said wire in said passage to pass transversely through said slot.  
   
   
       2 . The container as defined in  claim 1 , wherein said sleeve is substantially tubular.  
   
   
       3 . The container as defined in  claim 2 , wherein said sleeve is formed from a planar sheet extending about said sleeve axis.  
   
   
       4 . The container as defined in  claim 1 , wherein said sleeve is formed from a planar sheet extending about said sleeve axis.  
   
   
       5 . 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 said coil top and descending within said cavity during the unwinding of said wire from said container, said ring being 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 having a diameter, said sleeve having a length between said first and second ends that is greater than said diameter.  
   
   
       6 . 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 said coil top and descending within said cavity during the unwinding of said wire from said container, said ring being 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 having a diameter, said sleeve having a length between said first and second ends that is greater than said diameter.  
   
   
       7 . The container as defined in  claim 6 , wherein said sleeve axis and said sleeve are arcuate.  
   
   
       8 . The container as defined in  claim 5 , wherein said sleeve axis and said sleeve are arcuate.  
   
   
       9 . The container as defined in  claim 1 , wherein said sleeve axis and said sleeve are arcuate.  
   
   
       10 . The container as defined in  claim 9 , wherein said sleeve axis and said sleeve are radiused.  
   
   
       11 . The container as defined in  claim 1 , wherein said separable release slot is parallel to said axis.  
   
   
       12 . The container as defined in  claim 11 , wherein said separable release slot has a width transverse to said sleeve axis and said width is less than the diameter of said wire.  
   
   
       13 . The container as defined in  claim 1 , wherein said separable release slot has a width transverse to said sleeve axis and said width is less than the diameter of said wire.  
   
   
       14 . The container as defined in  claim 1 , wherein said separable release slot is curvilinear.  
   
   
       15 . The container as defined in  claim 14 , wherein said curvilinear slot is general shaped like a sine wave.  
   
   
       16 . The container as defined in  claim 1 , wherein said separable release slot is spiraled about said axis between said first and second ends.  
   
   
       17 . The container as defined in  claim 1 , wherein said separable release slot includes a flap extending parallel to said axis.  
   
   
       18 . The container as defined in  claim 1 , wherein said sleeve is formed from a planar sheet extending about said sleeve axis from a first longitudinal edge to a second longitudinal edge, said first and second longitudinal edges being circumferentially spaced from one another.  
   
   
       19 . The container as defined in  claim 18 , wherein said sleeve extends circumferentially about said sleeve axis greater than 360 degrees.  
   
   
       20 . The container as defined in  claim 18 , wherein said sleeve extends circumferentially about said sleeve axis greater than 375 degrees.  
   
   
       21 . The container as defined in  claim 7 , wherein said sleeve is formed from a planar sheet extending about said sleeve axis from a first longitudinal edge to a second longitudinal edge, said first and second longitudinal edges being circumferentially spaced from one another.  
   
   
       22 . The container as defined in  claim 21 , wherein said sleeve extends circumferentially about said sleeve axis greater than 360 degrees.  
   
   
       23 . The container as defined in  claim 21 , wherein said sleeve extends circumferentially about said sleeve axis greater than 375 degrees.  
   
   
       24 . The container as defined in  claim 1 , wherein said sleeve further includes welding wire grippers, said gripper frictionally engaging at least a portion of said length of said wire in said passage.  
   
   
       25 . The container as defined in  claim 24 , wherein said grippers includes the surface friction between said passage and said wire.  
   
   
       26 . The container as defined in  claim 25 , wherein said sleeve axis and said sleeve are arcuate, said arcuate configuration producing said frictional engagement.  
   
   
       27 . The container as defined in  claim 26 , wherein said sleeve axis and said sleeve are radiused.  
   
   
       28 . The container as defined in  claim 25 , wherein said sleeve has a weight and said grippers produce a gripping force between said wire and said sleeve, said gripping force being greater than said weight.  
   
   
       29 . The container as defined in  claim 28 , wherein said sleeve axis and said sleeve are arcuate, said arcuate configuration producing said frictional engagement.  
   
   
       30 . The container as defined in  claim 1 , wherein said sleeve further includes finger engaging projectiles.  
   
   
       31 . The container as defined in  claim 30 , wherein said finger engaging projectiles includes at least one outwardly facing tab.  
   
   
       32 . The container as defined in  claim 31 , wherein said at least one outwardly facing tab includes at least one outwardly facing tab on either side of said separable release slot.  
   
   
       33 . The container as defined in  claim 31 , wherein said at least one outwardly facing tab includes at least one outwardly facing circumferentially opposite of said separable release slot.  
   
   
       34 . The container as defined in  claim 1 , wherein said sleeve includes a unidirectional contour in said passage.  
   
   
       35 . The container as defined in  claim 34 , wherein said a unidirectional contour includes inwardly extending barbs.  
   
   
       36 . A container for packaging and unwinding a coil of welding wire to allow an uninterrupted flow of said welding wire from one said container to another said container, said coil of welding wire including a coiled portion having a top and a bottom, a first extension of said wire extending from said coil near said coil top to a feeding end and a second extension of said wire extending from said coil near said bottom to a transfer end, said transfer end of said one container being joinable to said feeding end of said another container, said container comprising: an outer packaging including at least one vertically extending side wall a closed bottom, a top opening for removing said welding wire and a wire coil receiving cavity within said outer packaging for receiving said wire coil, said feeding end and said transfer end being positionable near said top opening; a braking ring for controlling the unwinding of said wire from said wire coil, said ring resting on said coil top and descending within said cavity during the unwinding of said wire from said container, said ring including an inner periphery opening having a diameter; and a transfer sleeve having a first end, a second end and a wire passage extending along a sleeve axis longitudinally between said first and second ends, said wire passage being sized to allow said welding wire to travel axially through said passage, said sleeve having a length between said first and second ends that is greater than said diameter.  
   
   
       37 . The container as defined in  claim 36 , wherein said sleeve axis and said sleeve are arcuate.  
   
   
       38 . The container as defined in  claim 36 , wherein said sleeve further includes welding wire grippers, said gripper frictionally engaging at least a portion of said length of said wire in said passage.  
   
   
       39 . The container as defined in  claim 38 , wherein said grippers includes the surface friction between said passage and said wire.  
   
   
       40 . The container as defined in  claim 36 , wherein said sleeve further including a separable release slot extending between said first and second ends, said slot having a substantially closed position to maintain said welding wire in said passage and a separated position to allow a length of said wire in said passage to pass transversely through said slot.  
   
   
       41 . The container as defined in  claim 36 , wherein said sleeve is substantially tubular.  
   
   
       42 . A container for packaging and unwinding a coil of welding wire to allow an uninterrupted flow of said welding wire from one said container to another said container, said coil of welding wire including a coiled portion having a top and a bottom, a first extension of said wire extending from said coil near said coil top to a feeding end and a second extension of said wire extending from said coil near said bottom to a transfer end, said transfer end of said one container being joinable to said feeding end of said another container, said container comprising: an outer packaging including at least one vertically extending side wall a closed bottom, a top opening for removing said welding wire and a wire coil receiving cavity within said outer packaging for receiving said wire coil, said feeding end and said transfer end being positionable near said top opening; a braking ring for controlling the unwinding of said wire from said wire coil, said ring resting on said coil top and descending within said cavity during the unwinding of said wire from said container, said ring including an inner periphery opening having a diameter; and a transfer sleeve having a first end, a second end and a wire passage extending along a sleeve axis longitudinally between said first and second ends, said wire passage being sized to allow said welding wire to travel axially through said passage, said sleeve axis and said sleeve being arcuate.  
   
   
       43 . A sleeve for a container for packaging and unwinding a coil of welding wire to allow an uninterrupted flow of said welding wire from one said container to another said container, said coil of welding wire including a coiled portion having a top and a bottom, a first extension of said wire extending from said coil near said coil top to a feeding end and a second extension of said wire extending from said coil near said bottom to a transfer end, said transfer end of said one container being joinable to said feeding end of said another container, said sleeve comprising: a first end, a second end and a wire passage extending along a sleeve axis longitudinally between said first and second ends, said sleeve axis and said sleeve being arcuate and said wire passage being sized to allow said welding wire to travel axially through said passage, said sleeve further including a separable-release slot extending between said first and second ends, said slot having a substantially closed position to maintain said welding wire in said passage and a separated position to allow a length of said wire in said passage to pass transversely through said slot.  
   
   
       44 . The sleeve as defined in  claim 43 , wherein said sleeve includes a unidirectional contour in said passage.  
   
   
       45 . The sleeve as defined in  claim 44 , wherein said a unidirectional contour includes inwardly extending barbs.  
   
   
       46 . The sleeve as defined in  claim 43 , wherein said separable release slot has a width transverse to said sleeve axis and said width is less than the diameter of said welding wire.  
   
   
       47 . The sleeve as defined in  claim 43 , wherein said separable release slot is curvilinear.  
   
   
       48 . The sleeve as defined in  claim 47 , wherein said curvilinear slot is general shaped like a sine wave.  
   
   
       49 . The sleeve as defined in  claim 43 , wherein said separable release slot is spiraled about said axis between said first and second ends.  
   
   
       50 . The sleeve as defined in  claim 43 , wherein said separable release slot includes a flap extending parallel to said axis.  
   
   
       51 . The sleeve as defined in  claim 43 , wherein said sleeve is formed from a planar sheet extending about said sleeve axis from a first longitudinal edge to a second longitudinal edge, said first and second longitudinal edges being circumferentially spaced from one another.  
   
   
       52 . The sleeve as defined in  claim 51 , wherein said sleeve extends circumferentially about said sleeve axis greater than 430 degrees.  
   
   
       53 . The sleeve as defined in  claim 51 , wherein said sleeve extends circumferentially about said sleeve axis greater than 375 degrees.  
   
   
       54 . The sleeve as defined in  claim 43 , wherein said sleeve further includes welding wire grippers, said gripper frictionally engaging at least a portion of said length of said wire in said passage.  
   
   
       55 . The sleeve as defined in  claim 54 , wherein said grippers includes the surface friction between said passage and said wire.  
   
   
       56 . The sleeve as defined in  claim 55 , wherein said sleeve axis and said sleeve are arcuate, said arcuate configuration producing said frictional engagement.  
   
   
       57 . The sleeve as defined in  claim 55 , wherein said sleeve has a weight and said grippers produce a gripping force between said wire and said sleeve, said gripping force being greater than said weight.  
   
   
       58 . The sleeve as defined in  claim 57 , wherein said sleeve axis and said sleeve are arcuate, said arcuate configuration producing said frictional engagement.  
   
   
       59 . The sleeve as defined in  claim 43 , wherein said sleeve further includes finger engaging projectiles.  
   
   
       60 . The sleeve as defined in  claim 59 , wherein said finger engaging projectiles includes at least one outwardly facing tab.  
   
   
       61 . The sleeve as defined in  claim 60 , wherein said at least one outwardly facing tab includes at least one outwardly facing tab on either side of said separable release slot.  
   
   
       62 . The sleeve as defined in  claim 60 , wherein said at least one outwardly facing tab includes at least one outwardly facing circumferentially opposite of said separable release slot.  
   
   
       63 . A method of joining a container for packaging and unwinding a coil of welding wire with another said container of welding wire to allow an uninterrupted flow of said welding wire from said one container to said another container, said method including the steps of: 
 providing said container comprising said coil of welding wire including a coiled portion having a top and a bottom, a first extension of said wire extending from said coil near said coil top to a feeding end and a second extension of said wire extending from said coil near said bottom to a transfer end; an outer packaging having a top opening and a wire coil receiving cavity within said outer packaging for receiving said wire coil, said feeding end and said transfer end being positionable near said top opening; said container further including a transfer sleeve having a first end, a second end and a wire passage extending along a sleeve axis longitudinally between said first and second ends, said wire passage being sized to allow said welding wire to travel axially through said passage, said sleeve further including a separable release slot extending between said first and second ends, said slot having a substantially closed position to maintain said welding wire in said passage and a separated position to allow a length of said wire in said passage to pass transversely through said slot;    providing said another container comprising another said coil of welding wire including a coiled portion having a top and a bottom, a first extension of said wire extending from said coil near said coil top to a feeding end and a second extension of said wire extending from said another coil near said bottom to a transfer end; another outer packaging having a top opening and a wire coil receiving cavity within said another outer packaging for receiving said another wire coil, said feeding end and said transfer end being positionable near said top opening; and,    joining said feeding end of said another container to said transfer end of said container to form a continuous wire extension between said coil in said container and said another coil in said another container, said continuous wire extension extending through said sleeve.    
   
   
       64 . The method as defined in  claim 63 , wherein said another container further includes another said transfer sleeve having a first end, a second end and a wire passage extending along a sleeve axis longitudinally between said first and-second ends, said wire passage being sized to allow said welding wire to travel axially through said passage, said another sleeve further including a separable release slot extending between said first and second ends, said slot having a substantially closed position to maintain said welding wire in said passage and a separated position to allow a length of said wire in said passage to pass transversely through said slot.  
   
   
       65 . The method as defined in  claim 63 , further including the step of feeding said wire through a wire feeder for supplying said wire to a welding operation.  
   
   
       66 . The method as defined in  claim 63 , wherein said sleeve includes a unidirectional contour in said passage.  
   
   
       67 . The method as defined in  claim 66 , wherein said a unidirectional contour includes inwardly extending barbs.  
   
   
       68 . The method as defined in  claim 63 , wherein said separable release slot has a width transverse to said sleeve axis and said width is less than the diameter of said welding wire.  
   
   
       69 . The method as defined in  claim 63 , wherein said separable release slot is curvilinear.  
   
   
       70 . The method as defined in  claim 69 , wherein said curvilinear slot is general shaped like a sine wave.  
   
   
       71 . The method as defined in  claim 63 , wherein said separable release slot is spiraled about said axis between said first and second ends.  
   
   
       72 . The method as defined in  claim 63 , wherein said sleeve further includes welding wire grippers, said gripper frictionally engaging at least a portion of said length of said wire in said passage.  
   
   
       73 . The method as defined in  claim 72 , wherein said grippers includes the surface friction between said passage and said wire.  
   
   
       74 . The method as defined in  claim 73 , wherein said sleeve axis and said sleeve are arcuate, said arcuate configuration producing said frictional engagement.  
   
   
       75 . The method as defined in  claim 72 , wherein said sleeve has a weight and said grippers produce a gripping force between said wire and said sleeve, said gripping force being greater than said weight.  
   
   
       76 . The method as defined in  claim 75 , wherein said sleeve axis and said sleeve are arcuate, said arcuate configuration producing said frictional engagement.  
   
   
       77 . The method as defined in  claim 63 , wherein said sleeve further includes finger engaging projectiles.  
   
   
       78 . The method as defined in  claim 77 , wherein said finger engaging projectiles includes at least one outwardly facing tab.  
   
   
       79 . The method as defined in  claim 78 , wherein said at least one outwardly facing tab includes at least one outwardly facing tab on either side of said separable release slot.  
   
   
       80 . The method as defined in  claim 78 , wherein said at least one outwardly facing tab includes at least one outwardly facing circumferentially opposite of said separable release slot.  
   
   
       81 . The method as defined in  claim 63 , wherein at least one of said container and said another container includes a braking ring for controlling the unwinding of said wire from said wire coil, said ring resting on said coil top and descending within said cavity during the unwinding of said wire, said ring being annular having an inner periphery, an outer periphery, a bottom surface extending between said inner and outer peripheries and a top, said inner periphery having a diameter, said sleeve having a length between said first and second ends that is greater than said diameter, said sleeve being maintained above said ring.  
   
   
       82 . The method as defined in  claim 83 , wherein said sleeve axis and said sleeve are arcuate.  
   
   
       83 . The method as defined in  claim 64 , wherein said sleeve axis and said sleeve are radiused.