Abstract:
In certain embodiments, a welding wire and container assembly includes a container having an interior volume; a coil of welding wire disposed in the interior volume; and a wire container cover. The wire container cover may include a top surface having an opening therethrough to enable welding wire to pass through the wire container cover when the wire container cover is disposed on the container. The assembly also may include a skirt askew to the top surface, wherein the skirt is adapted to produce friction between the skirt and a side of the container when the wire container cover is disposed on the container housing and wherein the skirt is non-locking with respect to the container.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 10/195,743, filed on Jul. 15, 2002, now U.S. Pat. No. 7,152,735, which is hereby incorporated by reference, and which is a continuation-in-part of U.S. patent application Ser. No. 10/119,463, filed on Apr. 10, 2002, now U.S. Pat. No. 7,017,742, which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     Recyclable containers, such as fiber drums are used to store a variety of products and materials. For example, fiber drums may be used to store wire for use in an arc welding system. In some arc welding systems, such as MIG (Metal Inert Gas) welding systems, metal wire is used as an electrode to produce an arc. The welding wire also acts as filler material and is consumed during the welding process. Typically, the welding wire is fed from a wire feeder to a hand-held welding gun. A welding wire supplier may provide the welding wire to a customer in a fiber drum. A typical fiber drum used for storing welding wire is hollow and formed of a cellulosic material, such as paper or cardboard. In addition, a typical fiber drum has a metal band around the top to enable the fiber drum to be lifted by a device coupled to the metal band. In addition, special straps may be needed to move the fiber drum onto a pallet or to remove the fiber drum from the pallet. The weight of the fiber drums may make movement of the fiber drums difficult. Thus, the fiber drum is placed on a pallet when being moved. A forklift, or other lifting device may then move the pallet. 
     Once in position, the cover for the fiber drum is removed from the fiber drum. The cover for the fiber drum may be composed of metal or a cellulose material secured to the fiber drum by a metal ring. A conical payoff typically is placed atop the fiber drum after the cover is removed. The payoff serves as a funnel to guide the wire from the fiber drum to a conduit system. The conduit system, in turn, guides the wire to a welding machine. However, the payoffs are limited in their application to fiber drums having a corresponding size and shape. For example, a conical payoff may be used with a fiber drum having a round top, but may not be used on a fiber drum having an octagonal shape. In addition, the diameter of the payoff would have to correspond to the diameter of the fiber drum. A payoff could not be used with a given fiber drum if the diameter of the payoff was less than the diameter of the fiber drum. Furthermore, each payoff does has a certain cost that is associated with the payoff. This cost could be avoided if the payoff were not needed. 
     Fiber drums typically are discarded after the wire, or other material housed therein, is consumed because the fiber drums cannot easily be recycled. Recycling is difficult because the cellulosic portion of the drum must be separated from the metal portion of the drum to recycle either the fibrous portion or the metal portion. That operation can be complex and time consuming. Thus, a typical fiber drum owner ultimately pays to dispose of the empty fiber drum as refuse, rather than regaining some of the cost of the fiber drum by recycling. 
     BRIEF DESCRIPTION 
     In certain embodiments, a welding wire and container assembly includes a container having an interior volume; a coil of welding wire disposed in the interior volume; and a wire container cover. The wire container cover may include a top surface having an opening therethrough to enable welding wire to pass through the wire container cover when the wire container cover is disposed on the container. The assembly also may include a skirt askew to the top surface, wherein the skirt is adapted to produce friction between the skirt and a side of the container when the wire container cover is disposed on the container housing and wherein the skirt is non-locking with respect to the container. 
    
    
     
       DRAWINGS 
       The foregoing and other advantages and features of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which: 
         FIG. 1  is a diagrammatical view of a wire welding system, according to an exemplary embodiment of the present technique; 
         FIG. 2  is an elevational view illustrating the lifting of a fiber drum by a forklift, according to an exemplary embodiment of the present technique; 
         FIG. 3  is a cross-sectional view of a fiber drum adapted for shipping; 
         FIG. 3A  is a detailed view of an alternative embodiment of the cover, as taken generally along line A-A of  FIG. 3 ; 
         FIG. 3B  is a detailed view of a second alternative embodiment of the cover, as taken generally along line A-A of  FIG. 3 ; 
         FIG. 4  is an elevational view of a false bottom for a fiber drum, according to an exemplary embodiment of the present technique; 
         FIG. 5  is a top view of the false bottom of  FIG. 4 , according to an exemplary embodiment of the present technique; 
         FIG. 6  is a top view of an alternative embodiment of a fiber drum, according to an exemplary embodiment of the present technique; 
         FIG. 7  is a top view of a second alternative embodiment of a fiber drum, according to an exemplary embodiment of the present technique; 
         FIG. 8  is a top view of the fiber drum of  FIG. 7  and an alternative embodiment of a false bottom, illustrating the insertion of forks into the fiber drum from a first direction, according to an exemplary embodiment of the present technique; 
         FIG. 9  is a top view of the fiber drum of  FIG. 7  and an alternative embodiment of a false bottom, illustrating the insertion of forks into the fiber drum from a second direction, according to an exemplary embodiment of the present technique; 
         FIG. 10  is a cross-sectional view of the fiber drum of  FIG. 1 , taken generally along line  10 - 10  of  FIG. 1 ; and 
         FIG. 10A  is an exploded view of the fiber drum and adapter assembly, according to an exemplary embodiment of the present technique. 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to  FIG. 1 , a wire-welding system  12 , such as a MIG welding system, is featured. In the illustrated embodiment, wire-welding system  12  comprises a wire feeder  13 , a power source  14 , a gas cylinder  16  and a recyclable container  18  containing welding wire  20 . Preferably, the recyclable container  18  is comprised of a fibrous material, such as cellulosic paper, paperboard, or cardboard. 
     The power source  14  provides electricity to the wire feeder  13 ; the gas cylinder  16  provides inert gas to the wire feeder  13 ; and the container  18  provides welding wire  20  to the wire feeder  13  via a conduit system  21 . In the illustrated embodiment, the wire feeder  13  provides electricity, welding wire  20 , and inert gas to a welding torch  22 . The wire, gas, and electricity are coupled to the torch  22  by a welding cable  24 . In addition, a work clamp  26  is coupled to the wire feeder  13  by a ground cable  28 . The work clamp  26  is secured to a workpiece  30  to electrically couple the workpiece  30  to the wire feeder  13 . The torch  22  controls the operation of the system  12 . When the torch  22  is activated, welding wire  20  is fed through the torch  22  by the wire feeder  13 . When the welding wire  20  contacts the workpiece  30 , an electrical circuit between the workpiece  30  and the wire feeder  13  is completed and an electric arc is produced. The electric arc melts the workpiece  30  and welding wire  20  at the point of contact. The inert gas shields the molten area from contaminants. A power cable  32  conducts electricity from the power source  14  to the wire feeder  13 . A hose  34  channels gas from the gas cylinder  16  to the wire feeder  13 . 
     In the illustrated embodiment, the container  18  is a hollow, generally cylindrical fiber drum. However, the container  18  may have a shape other than a cylindrical shape. For example, the container  18  may be square, hexagonal, octagonal, etc. A spool of welding wire is disposed within the hollow interior of the fiber drum  18 . 
     In the illustrated embodiment, the fiber drum  18  has at least one, and as illustrated, a plurality of holes, or recesses,  40  located on a bottom portion of the fiber drum  18 . As best illustrated in  FIG. 2 , the fiber drum  18  is adapted to enable the forks  42  of a forklift  44 , or other member of a lifting device, to enter one or more of the plurality of holes, or recesses,  40  and be positioned below the welding wire  20  to lift the fiber drum  18 . In the illustrated embodiment, two holes  40  are used, one for each fork  42  of the forklift  44 . However, the fiber drum  18  also may be adapted with a single hole, or recess, that enables two forks  42 , or a single lifting member to enter the fiber drum  18 . In addition, exit holes may be provided to enable the forks  42  to extend through the fiber drum  18 . Furthermore, a lifting device other than a forklift  44  may be used to lift the fiber drum  18  via one or more of the holes  40 , or other (i.e. open) recesses. For example, lifting straps could be passed through the openings to enable an overhead crane to lift the container  18 . Other lifting devices may also be used. 
     Referring generally to  FIG. 3 , an exemplary embodiment of a fiber drum  18  adapted for shipping is illustrated. In the illustrated embodiment, the fiber drum  18  has a cylindrical portion  46 , a bottom  48 , a lid  50 , and a false bottom  52 . The false bottom  52  is placed within the cylindrical portion  46  and the welding wire  20  is then placed atop the false bottom  52 . A removable ring  54  is floated atop the spool of wire  20  to guide the wire  20  as it is unwound from the spool. Preferably, the removable ring  54  is made of metal. An elastic strap  56  and metal rod  58  are used to drive the metal ring  54  downward to secure the welding wire  20  within the cylindrical housing  46  during transport. The rod  58  may be removed from the fiber drum  18  when the drum is placed in service. The elastic strap  56  also may be removed at this time. The ring  54  is removed when the wire  20  has been consumed. 
     In the illustrated embodiment, the cylindrical portion  46 , bottom  48 , cover  50 , and false bottom  52  are composed of a fibrous material, such as cellulosic paper, paperboard, or cardboard. In the illustrated embodiment, the cover  50  has a top portion  59  and a skirt portion  60 . The top portion has an opening  61  therethrough to enable welding wire  20  to pass through the cover  50 . The opening  61  may be a hole, as shown in  FIG. 3 , or a notch located on the periphery of the cover  50 . As illustrated in  FIG. 3A , the cover  50  may be adapted with a punch-out  63  to enable a customer to form the opening  61  by punching the punch-out  63  through the top portion  59  of the cover  50 . The punch-out  63  may be formed in a number of ways. For example, a press may be used to press a circular pattern into the top portion of the cover  50 . The circular pattern of the cover  50  is weaker than the cover  50 , causing the cover  50  to tear at the circular pattern when a sufficient force is applied to the center of the circular pattern. Alternatively, as illustrated in  FIG. 3B , a plug  65  or insert may be placed over the hole  61  during shipment to prevent debris or other objects from entering the container. 
     In the illustrated embodiment, the cover  50  is held in position on the housing  46  by friction between the skirt portion  60  of the cover and the cylindrical portion of the fiber drum  18 . However, a strap or other device may be used to further secure the cover  50  to the housing  46 . In addition, in this embodiment, the cylindrical housing  46 , bottom  48 , cover  50 , and false bottom  52  are adapted to be free of metal so that they may be more readily recycled once the welding wire has been consumed. The metal ring  54  and metal rod  58  may be recycled as metal once they are removed from the fiber drum  18 . 
     Referring generally to  FIGS. 4 and 5 , a plurality of supports  62  are secured to the false bottom  52 . The plurality of supports  62  and false bottom  52  are adapted to support the welding wire  20  above the bottom to provide clearance for the forks  42  of the forklift  44  to enter the fiber drum  18  below the wire  20 . In the illustrated embodiment, the supports  62  also are adapted from cellulosic cylinders, such as cardboard tubing. However, the supports  62  may be comprised of another suitable material. In this embodiment, there are circular supports  63  and semi-circular supports  64 . The semi-circular supports  64  may be adapted from the circular supports  63 , for example, by cutting them in half lengthwise. Preferably, the supports  62  are secured, such as by glue, to the bottom  48  and the false bottom  52 . The false bottom  52  also may be secured to the cylindrical portion  46  of the fiber drum  18 . Furthermore, rather than using a false bottom  52  and the plurality of holes  40 , the fiber drum  18  may be adapted with the supports  62  secured to the bottom  48  of the fiber drum  18  from below, rather than from above, to create a space for the forks  42 , or another lifting member, to be positioned below the bottom  48  of the fiber drum  18 . 
     In the illustrated embodiment, the false bottom  52  has a hole  66  to enable the elastic strap  56  to pass through the false bottom  52 . Furthermore, the cylindrical housing  46 , bottom  48 , false bottom  52 , and supports  62  are adapted to be free of metal so that they may be more readily recycled as a fibrous material once the welding wire has been consumed. The metal ring  54  and metal rod  58  may be recycled as metal once they are removed from the fiber drum  18 . 
     Referring generally to  FIG. 6 , an alternative embodiment of a fiber drum  68  is illustrated. In the embodiment illustrated, a second plurality of holes  40  are provided opposite the first plurality of holes  40  to enable the forks to extend through the fiber drum  18  and to enable the forks to enter the fiber drum from a second orientation. 
     Referring generally to  FIG. 7 , a second alternative embodiment of a fiber drum  70  is illustrated. In the illustrated embodiment, there are four pairs of holes disposed in fiber drum  70 , one pair in each quadrant. The plurality of holes  40  enable the forks  42  to enter the fiber drum  70  from four directions. 
     Referring generally to  FIGS. 8 and 9 , an alternative embodiment of a false bottom  72  disposed within the fiber drum  70  is featured. The false bottom  72  is adapted to be aligned with the plurality of holes  40  to provide clearance for the forks  42  to enter the fiber drum  70  from each of four directions around the fiber drum  70 . 
     The illustrated embodiments of fiber drums described above enable the metal portions of the fiber drums to be easily separated from the non-metal portions of the fiber drums, thus enabling the fiber drums to be recycled easily. In addition, the fiber drums described above are easily moved by standard lifting devices, such as forklifts, without the need of special lifting straps or pallets. 
     Referring generally to  FIG. 10 , a cross-sectional view of the fiber drum of  FIG. 1  is illustrated. A conduit adapter assembly  74  is secured to cover  50  to couple the cover  50  and the conduit system  21 . The conduit adapter assembly  74  is inserted through hole  61  in the cover  50 . The conduit adapter assembly  74  is adapted to guide wire  20  from the fiber drum  18  into the conduit system  21 . 
     As best illustrated in  FIGS. 10A , the conduit adapter assembly  74  comprises a quick-disconnect  76 , a washer  78 , a wire guide  80 , and a plate  82 . The quick-disconnect  76  and wire guide  80  are adapted to secure to each other through the hole  61  in the top portion  59  of the cover  50  and through holes in the washer  78  and plate  82 , respectively. The quick-disconnect  76  and wire guide  80  form a path  84  for welding wire  20  to pass through the hole  61  in the fiber drum  18 . The conduit adapter assembly  74  thereby guides the wire into the conduit system  21  and protects the cover  50  of the fiber drum  18  from damage due to abrasion from the welding wire  20 . In addition, the quick-disconnect  76  is adapted to be quickly connected to or disconnected from the conduit system  21 . Furthermore, the washer  78  and plate  82  distribute stress caused by the conduit adapter assembly  74  over a larger area of the top portion  59  of the cover  50 . 
     While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. For example, the holes in the cylindrical portion and the supports may be arranged in a myriad of orientations to enable the fiber drum to be lifted from a number of different orientations. In addition, the holes in the cylindrical portion of the container may be adapted to receive a lifting member other than the forks of a forklift.