Abstract:
Provided is a pail-pack for welding wire including: an outer cylinder forming a main body; a bottom plate provided inside a lower end of the outer cylinder and having a support part that is bent downward from an edge of the bottom plate to contact an inner circumferential surface of the lower end of the outer cylinder; and a polygonal tube inscribed in the outer cylinder and having a polygonal cross-section containing a welding wire winding layer therein. Accordingly, the pail-pack for welding wire is easy to recycle and carry and has increased strength.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of Korean Patent Application No. 2006-127131, filed on Dec. 13, 2006, which is hereby incorporated by reference as if fully set forth herein. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a pail-pack for welding wire, and more particularly, to a pail-pack for welding wire which is easy to recycle and carry and has increased strength. 
         [0004]    2. Discussion of Related Art 
         [0005]    In general, methods of winding welding wire used for automatic and semiautomatic welding apparatuses may be classified into a spool winding method and a pail-pack winding method. 
         [0006]    In the case of the pail-pack winding method, welding wire is wound in a pail-pack container. Here, the structure of the pail-pack container may be largely divided into a single cylindrical structure having only an outer cylinder and a double cylindrical structure having outer and inner cylinders. 
         [0007]    In the pail-pack winding method, since a large amount of welding wire is kept in a wound state, it is necessary to efficiently feed the welding wire. The pail-pack winding method is mainly employed in long-duration welding operations because a large amount of welding wire can be wound. 
         [0008]    Since a pail-pack for welding wire may improve the efficiency of a long-duration welding operation or a step-by-step welding operation, it is widely used. 
         [0009]    However, the foregoing conventional pail-pack for welding wire has the following problems. 
         [0010]    First, while welding wire is being withdrawn from a conventional pail-pack for welding wire, the welding wire may become kinked and tangled. Thus, the conventional pail-pack for welding wire is provided with a pressure plate that applies pressure to the top of the wound welding wire in order to efficiently feed the welding wire without kinks and tangles. 
         [0011]    However, a space is formed between an outer cylinder in which the welding wire is contained and the pressure plate, so it is difficult to bind a portion of the welding wire that is withdrawn to the outside of the pressure plate. In order to solve this problem, an additional component is required, thereby complicating the structure of the pail-pack and increasing production cost. 
         [0012]    Second, since the outer cylinder of the conventional pail-pack is formed of paper, the pail-pack is not strong enough to hold a load of more than 300 kg of welding wire. In order to increase the strength of the outer cylinder, a bottom plate of the outer cylinder may be formed of steel or a plurality of portions of the outer cylinder may be reinforced with frame bolts formed of steel. In this case, however, it is troublesome to separate a frame formed of steel from a main body formed of paper in order to recycle the materials. 
         [0013]    Third, when the paper is destroyed by fire, an adhesive used to adhere the paper to the pail-pack burns and generates poisonous gases which may pollute the air and may harm workers. 
       SUMMARY OF THE INVENTION 
       [0014]    The present invention is directed to a pail-pack for welding wire which is easy to recycle and carry and has increased strength. 
         [0015]    According to an aspect of the invention, a pail-pack for welding wire comprises: an outer cylinder forming a main body; a bottom plate provided inside a lower end of the outer cylinder and having a support part that is bent downward from an edge of the bottom plate to contact an inner circumferential surface of the lower end of the outer cylinder; and a polygonal tube inscribed in the outer cylinder and having a polygonal cross-section containing a welding wire winding layer therein. 
         [0016]    A pressure plate may be provided on the welding wire winding layer. The pressure plate may have a shape corresponding to an inner cross-section of the polygonal tube. 
         [0017]    A pressure part having the shape of a hollow circular plate may be provided on the welding wire winding layer. Also, a spring-loaded protrusion part may radially protrude from an outer peripheral edge of the pressure part to correspond to each corner of the polygonal tube. 
         [0018]    A hanging band may comprise: two ends having hanging parts and exposed through both sides of the outer cylinder; and a central portion enclosing a bottom surface of the bottom plate through openings formed on both sides of the bottom plate. 
         [0019]    The openings may be formed in portions in which the support parts are bent to face each other from opposite sides of the bottom plate to correspond to the width and thickness of the hanging band. 
         [0020]    The central portion of the hanging band may be combined with a bolt member and a nut member, which are provided through the center of the bottom plate, and fixed to the bottom plate. The hanging band may be formed of polypropylene. 
         [0021]    A support member may be provided in a lengthwise direction of the polygonal tube between the outer cylinder and the polygonal tube, and have one side contacting an inner surface of the outer cylinder and the other side contacting an outer surface of each side of the polygonal tube to form a support structure. 
         [0022]    The support member may have a cylindrical cross-section. 
         [0023]    A bottom reinforcing plate may be further provided between a top surface of the bottom plate and a lower portion of the polygonal tube. The bottom reinforcing plate may have a shape corresponding to an inner cross-section of the outer cylinder. 
         [0024]    Also, an internal reinforcing member may be further provided and closely adhered to an inner circumferential surface of the support part. 
         [0025]    The outer cylinder, the bottom plate, the polygonal tube, and the support member may be formed of a paper material that is obtained by compressing multifold paper layers using a press processing technique. 
         [0026]    A moisture-proof bag formed of vinyl may be provided between the outer cylinder and the polygonal tube to enclose the polygonal tube. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    The above and other objects, features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments thereof with reference to the attached drawings in which: 
           [0028]      FIG. 1  is an exploded perspective view of a pail-pack for welding wire according to an exemplary embodiment of the present invention; 
           [0029]      FIG. 2  is a partially cutaway perspective view of the pail-pack for welding wire shown in  FIG. 1 ; 
           [0030]      FIGS. 3 and 4  are plan views of the pail-pack for welding wire shown in  FIG. 1 ; 
           [0031]      FIG. 5  is a cross-sectional view of the pail-pack for welding wire shown in  FIG. 1 ; 
           [0032]      FIG. 6  is a rear side view of the pail-pack for welding wire shown in  FIG. 1 ; 
           [0033]      FIG. 7  is a perspective view of a bottom plate of the pail-pack for welding wire shown in  FIG. 1 ; and 
           [0034]      FIG. 8  is a cross-sectional view of a pail-pack for welding wire according to another exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0035]    Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, in which like reference numerals refer to like elements. 
         [0036]      FIGS. 1 and 2  are an exploded perspective view and a partially cutaway perspective view of a pail-pack for welding wire according to an exemplary embodiment of the present invention, respectively. 
         [0037]    Referring to  FIGS. 1 and 2 , the pail-pack for welding wire may include an outer cylinder  10 , a bottom plate  20 , a polygonal tube  30 , and a support member  40 . 
         [0038]    The bottom plate  20  is provided in a lower end of the outer cylinder  10 , and the polygonal tube  30  having a polygonal section is inside the outer cylinder  10  such that a welding wire winding layer  80  is contained in the polygonal tube  30 . 
         [0039]    The support member  40  is provided between the polygonal tube  30  and the outer cylinder  10  and supports the polygonal tube  30 . 
         [0040]    Specifically, the outer cylinder  10  may have a cylindrical shape. The bottom plate  20  may be provided inside the lower end of the outer cylinder  10 , and an edge of the bottom plate  20  may be bent downward to function as a support part  22 . 
         [0041]    In this case, the support part  22  is closely adhered to and combined with an inner circumferential surface of the lower end of the outer cylinder  10 , and thus the support part  22  and the lower end of the outer cylinder  10  are both in contact with the ground. 
         [0042]    The support part  22  forms a space where the outer cylinder  10  is combined with the bottom plate  20  and stably supports a lower portion of the bottom plate  20 . 
         [0043]    In other words, the support part  22  increases resistance to bending and tensile stress applied to an outer peripheral edge of the bottom plate  20 , thereby structurally reinforcing the strength of a lower support structure of the bottom plate  20 . 
         [0044]    Accordingly, it is possible to stably maintain the supporting state even when the heavy welding wire winding layer  80  is disposed on the lower plate. 
         [0045]    Here, a portion of the support part  22  which contacts the lower end of the outer cylinder  10  may be fixed by a plurality of stapler pins  25  which are connected by a stapler at intervals of a predetermined angle in a circumferential direction. 
         [0046]    As an alternative to the stapler pins  25 , the support part  22  may be combined with the lower end of the outer cylinder  10  by a string sewed in the circumferential direction. 
         [0047]    Meanwhile, the polygonal tube  30  having a polygonal section may be provided inside the outer cylinder  10 . The polygonal tube  30  may have the same length as the outer cylinder  10 . Also, an inner cylinder (not shown) may be selectively provided in the center of the inside of the polygonal tube  30 . 
         [0048]    An outer surface of the polygonal tube  30  may contact an inner circumferential surface of the outer cylinder  10 , and a lower end of the polygonal tube  30  may contact an upper surface of the bottom plate  20 . 
         [0049]    Also, the welding wire winding layer  80  in which welding wire is stacked in a wound state is contained in the polygonal tube  30 . 
         [0050]    Also, the support member  40  may be provided between the outer surface of each side of the polygonal tube  30  and an inner surface of the outer cylinder  10  to support each side of the polygonal tube  30 . 
         [0051]    The support member  40  may have the same length as the polygonal tube  30 . 
         [0052]    The outer cylinder  10 , the bottom plate  20 , the polygonal tube  30 , and the support member  40  may be formed of a paper material obtained by compressing multifold paper layers by means of a press processing technique using a mold, thereby making the pail-pack easier to recycle. 
         [0053]    A bolt member  34  may be connected through the center of the bottom plate  20 , and a fixing ring  32  may be provided at an upper end of the bolt member  34 . 
         [0054]    A nut member  36  may be combined with each of the inner and outer surfaces of the bottom plate  20 . The nut member  36  may be combined with the bolt member  34  to fix the bolt member  34 . 
         [0055]    A pressure plate  35  may be provide on the welding wire winding layer  80  to apply pressure to the welding wire winding layer  80 , and a mounting bracket  91  may be provided on the pressure plate  35 . 
         [0056]    Here, the mounting bracket  91  may be provided across the pressure plate  35  to contact a top surface of the pressure plate  35 . 
         [0057]    Also, both ends of the mounting bracket  92  may be located in corners of the polygonal tube  30 , so that the mounting bracket  91  can contact an inner surface of the polygonal tube  30 , thereby preventing rotation of the mounting bracket  91 . 
         [0058]    One end of a spring  92  is connected to the fixing ring  32 , and the other end of the spring  92  is connected to the mounting bracket  91 . The spring  92  pulls the pressure plate  35  downward. 
         [0059]    Thus, the pressure plate  35  can continuously apply downward pressure to the welding wire winding layer  80  so that the welding wire winding layer  80  can be stably maintained in a fixed state. 
         [0060]    Here, the other end of the spring  92  can be connected to the mounting bracket  80  using various methods. 
         [0061]    Also, the mounting bracket  91  is not limited to any specific shape and may have various cross-sections, for example, a plate shape, a rod shape, or a square shape. Thus, the spring  92  may be replaced by an elastic string. 
         [0062]    Meanwhile, a moisture-proof bag  50  may be provided between the outer cylinder  10  and the polygonal tube  30  to enclose the polygonal tube  30 . The moisture-proof bag  50  may be formed of vinyl not to allow moisture to pass therethrough. 
         [0063]    The moisture-proof bag  50 , which functions to protect the welding wire contained in the polygonal tube  30  from moisture, may enclose a lower portion of the polygonal tube  30  between each of the support members  40  and the polygonal tube  30 . 
         [0064]    Further, although the moisture-proof bag  50  may be provided between each of the support members  40  and the polygonal tube  30 , it may be selectively provided between each of the support members  40  and the outer cylinder  10 . 
         [0065]    Also, a hanging band  60  may be provided at an upper portion of the outer cylinder  10  to carry the pail-pack for welding wire. 
         [0066]      FIGS. 3 and 4  are plan views of the pail-pack for welding wire shown in  FIG. 1 . 
         [0067]    Referring to  FIG. 3 , the support member  40  may have a cross-section that is bent in a lengthwise direction thereof. 
         [0068]    The bent cross-section of the support member  40  may include a bent part  42  which corresponds to a central portion of the support member  40 , and extension parts  44  which extend the same length from the bent part  42  on both sides thereof. 
         [0069]    Also, the bent part  42  may contact the center of the polygonal tube  30 , and the extension parts  44  may contact the inner circumferential surface of the outer cylinder  10 . 
         [0070]    The bent part  42  may be formed to have various radii of curvature. 
         [0071]    Thus, external force applied to the center of each side of the polygonal tube  30  while the welding wire is wound in the polygonal tube  30 , and external force continuously applied to the center of each side of the polygonal tube  30  about which the welding wire winding layer  80  is circumscribed, can be counterbalanced by support force applied by the bent part  42 . 
         [0072]    Thus, each side of the polygonal tube  30  can be prevented from being bent outward. 
         [0073]    Also, since the support member  40  has a bent cross-section, support strength required to support each side of the polygonal tube  30  can be further reinforced. 
         [0074]    Furthermore, the support member  40  is provided such that the bent part  42  contacts the center of each side of the polygonal tube  30  and the extension parts  44  contact the inner surface of the outer cylinder  10 . 
         [0075]    Therefore, the support member  40  is located in the center of a space formed between the outer surface of each side of the polygonal tube  30  and the inner surface of the outer cylinder  10 . 
         [0076]    Also, even if the support member  40  is not adhered using an adhesive, it may be fixed rather than movable and rotatable. Without the adhesive, it is easy to recycle the pail-pack for welding wire and prevent the generation of poisonous gases from the adhesive in a burn-up process. 
         [0077]    Meanwhile, the polygonal tube  30  may have at least one of a hexagonal cross-section and an octagonal cross-section in order to increase the inner area of the polygonal tube  30  and permit the support member  40  to have an appropriate size. As a result, a larger amount of welding wire can be contained in the polygonal tube  30  and the support member  40  can perform its function sufficiently. 
         [0078]    In this case, the polygonal tube  30  may have a hexagonal cross-section. 
         [0079]    Also, the pressure plate  35  is provided on the welding wire winding layer  80  to apply pressure to the welding wire winding layer  35 . 
         [0080]    The pressure plate  35  may have an outer portion whose shape corresponds to an inner cross-section of the polygonal tube  30 , so that the pressure plate  35  cannot rotate in the polygonal tube  30 . 
         [0081]    In this construction, the pail-pack for welding wire can be structurally simplified and made lightweight because no additional component for preventing rotation of the pressure plate  35  is required. 
         [0082]    Also, even if a portion of the welding wire withdrawn from the welding wire winding layer  80  protrudes to the outside of the pressure plate  35 , the portion of the welding wire is bound by respective surfaces of the polygonal tube  30  that form a predetermined angle. 
         [0083]    Therefore, further protrusion of the withdrawn welding wire outside of the pressure plate  35  can be prevented. 
         [0084]    Referring to  FIG. 4 , a support member  140  may have a cylindrical cross-section. 
         [0085]    One side of the support member  140  may contact the inner surface of the outer cylinder  10 , and the other side of the support member  140  may contact the outer surface of the polygonal tube  30 . 
         [0086]    In this case, the other side of the support member  140  may contact the center of the outer surface of the polygonal tube  30 . 
         [0087]    Thus, external force applied to the center of each side of the polygonal tube  30  while the welding wire is being wound in the polygonal tube  30 , and external force continuously applied to the center of each side of the polygonal tube  30  about which the welding wire winding layer  80  is circumscribed, can be counterbalanced by support force applied by the bent part  42 . 
         [0088]    Thus, each side of the polygonal tube  30  can be prevented from being bent outward. 
         [0089]    Meanwhile, a pressure plate  135  may be provided on the welding wire winding layer  80 . The pressure plate  135  may include a pressure part  137  having the form of a hollow circular plate, and a spring-loaded protrusion part  138  protruding from an outer peripheral edge of the pressure part  137 . 
         [0090]    In this case, the spring-loaded protrusion part  138  may radially protrude from the outer peripheral edge of the pressure part  137  to contact each corner of the polygonal tube  30 . 
         [0091]    Also, each end of the spring-loaded protrusion part  138  may have a shape corresponding to an angle formed by the respective surfaces of the polygonal tube  30 . Also, each end of the spring-loaded protrusion part  138  may contact a predetermined length of the inner surface of the polygonal tube  30 . 
         [0092]    In this construction, the spring-loaded protrusion part  138  is closely bound by each corner of the polygonal tube  30  and cannot be rotated in the polygonal tube  30 . 
         [0093]    Also, the spring-loaded protrusion part  138  may be combined with the pressure part  137  by a joint member  139  such as a bolt or adhesive. 
         [0094]    Meanwhile, a mounting bracket  191  provided on the pressure plate  135  may include extension parts which form a predetermined angle with one another and extend from the center in three directions. 
         [0095]    In this case, an end of each of the extension parts may be located in a corner of the polygonal tube  30 , thereby preventing rotation of the mounting bracket  191 . 
         [0096]    Also, a spring  192  is connected to the mounting bracket  191  and the fixing ring  32  and permits the mounting bracket  191  to apply downward pressure to the pressure plate  135 . 
         [0097]    In this case, the mounting bracket  191  may include extension parts that extend in three or more directions, and the spring  92  may be replaced by an elastic member such as an elastic string. 
         [0098]      FIGS. 5 ,  6 , and  7  are a cross-sectional view, a rear side view, and a perspective view of the pail-pack for welding wire shown in  FIG. 1 , respectively. 
         [0099]    Referring to  FIGS. 5 through 7 , penetration parts  12  may be formed through an upper portion of the outer cylinder  10  to face each other. The penetration parts  12  may be formed to a width corresponding to the thickness of the hanging band  60 . 
         [0100]    Also, openings  23  may be formed in portions in which the support part  22  is bent on both sides of the bottom plate  20  provided at a lower end of the outer cylinder  10  to face each other from opposite sides of the bottom plate  20 . The openings  23  may be cut to a width corresponding to the thickness of the hanging band  60 . 
         [0101]    Also, the bottom plate  20  may be combined with the outer cylinder  10  such that each of the openings  23  is located below the penetration part  12  in a vertical direction. 
         [0102]    Therefore, the hanging band  60  is brought from the outside of the outer cylinder  10  into the outer cylinder  10  through any one of the penetration parts  12 , extends downward in a vertical direction, and is drawn to the outside of the bottom plate  20  through one of the openings  23 . 
         [0103]    As described above, the drawn hanging band  60  encloses the bottom plate  20  and is brought into the outer cylinder  10  again through another opening  23  formed opposite to the first opening  23 . 
         [0104]    Thereafter, the hanging band  60  extends upward and is drawn out of the outer cylinder  10  through another penetration part  12  formed in one side of the outer cylinder  10 . 
         [0105]    As described above, the hanging band  60  is provided in a vertical direction to enclose the center of the bottom plate  20 , so that the pail-pack for welding wire does not lean to one side and can be stably carried. 
         [0106]    Meanwhile, a portion of the hanging band  60  brought in the outer cylinder  10  may be provided outside the moisture-proof bag  50  to prevent damage to the moisture-proof bag  50 . 
         [0107]    Also, the center of a portion of the hanging band  60  that is drawn out of the bottom plate  20  and contacts the outer surface of the bottom plate  20  in the diametrical direction of the bottom plate  20  may be fixedly combined with the bolt member  34  and the nut member  36 . 
         [0108]    Also, both ends of the hanging band  60 , which are drawn out through the penetration parts  12 , are each folded and combined with a connecting portion  62  such as a rivet or a string to form a handle-type hanging part  64 . 
         [0109]    In this case, a transfer apparatus for transferring the pail-pack for welding wire may be combined with the hanging part  64 . 
         [0110]    Thus, when the hanging band  60  is lifted by the transfer apparatus combined with the hanging part  64 , the pail-pack for welding wire is also lifted up. 
         [0111]    In this case, a central portion of the hanging band  60  protrudes outside of the bottom plate  20  and fixedly contacts the bottom plate  20  in the diametrical direction of the bottom plate  20 , thereby facilitating transfer of the pail-pack for welding wire. 
         [0112]    Also, the hanging band  60  may be formed of the same material as automobile seat belts having enough strength to transfer the pail-pack for welding wire. For example, the hanging band  60  may be formed of nylon, polyester, or polypropylene. 
         [0113]    Further, the hanging band  60  may be webbed to increase tensile force. 
         [0114]      FIG. 8  is a cross-sectional view of a pail-pack for welding wire according to another exemplary embodiment of the present invention. 
         [0115]    The pail-pack for welding wire according to another exemplary embodiment of the present invention has the same construction as the pail-pack for welding wire according to the previous exemplary embodiment except that a bottom reinforcing plate  70  and an internal reinforcing member  72  are further provided. Thus, a description of the same components as in the previous exemplary embodiment will be omitted here. 
         [0116]    Referring to  FIG. 8 , the bottom reinforcing plate  70  may be provided on a top surface of a bottom plate  10 . The bottom reinforcing plate  70  may have a shape corresponding to an inner cross-section of an outer cylinder  10 . 
         [0117]    Thus, the bottom reinforcing plate  70  may reinforce the strength of the bottom plate  10  and protect the bottom plate  10  from the load of the welding wire winding layer  80 . 
         [0118]    The bottom reinforcing plate  70  may be provided on the moisture-proof bag  50  located on the bottom plate  20  or provided between the bottom plate  20  and the moisture-proof bag  50 . 
         [0119]    Also, grooves (not shown) corresponding to the thickness and width of the hanging band  60  may be formed on both sides of the bottom reinforcing plate  70  such that the hanging band  60  can be smoothly brought into the outer cylinder  10 . 
         [0120]    Meanwhile, the internal reinforcing member  72  may be further provided and closely adhered to an inner circumferential surface of the support part  22  of the bottom plate  20 . The internal reinforcing member  72  can prevent the support part  22  from being internally bent due to an excessive load applied to the bottom plate  20 . 
         [0121]    One or both of the bottom reinforcing plate  70  and the internal reinforcing member  72  may be selectively provided. 
         [0122]    Also, the bottom reinforcing plate  70  and the internal reinforcing member  72  may be formed of a paper material obtained by compressing multifold paper layers by means of a press processing technique using a mold, thereby making the pail-pack for welding wire easier to recycle. 
         [0123]    As explained thus far, a pail-pack for welding wire according to the present invention has the following effects. 
         [0124]    First, an outer cylinder, a bottom plate, a polygonal tube, and a support member may be formed of a paper material obtained by compressing multifold paper layers by means of a press processing technique using a mold, thereby reinforcing the strength and making the pail-pack for welding wire easier to recycle. 
         [0125]    Second, a central portion of a hanging band is provided through openings formed on both sides of the bottom plate to enclose an outer bottom surface of the bottom plate, so that the pail-pack for welding wire can be stably carried. 
         [0126]    Third, since the polygonal tube has a polygonal cross-section, even if a portion of the welding wire withdrawn from a welding wire winding layer protrudes outside of the pressure plate, the portion of the welding wire is bound by the respective surfaces of the polygonal tube that form a predetermined angle, thereby preventing the welding wire from being further withdrawn. 
         [0127]    Fourth, one side of the pressure plate contacts and is bound by the inner surface of the polygonal tube, thereby preventing rotation and facilitating vertical movement of the pressure plate without an additional guide apparatus. 
         [0128]    Fifth, since no additional guide apparatus is required, process simplicity and productivity can be improved. 
         [0129]    While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.