Recyclable drum having inwardly folded end portions

A wire container having a housing consisting essentially of recyclable material is provided. The housing has a peripheral wall defining a boundary leading from a first end to a second end of the housing, a plurality of end portions folded inwardly at the second end to define an end wall, and a plurality of support structures coplanar with and coupled to the end wall and extending across the plurality of end portions. A welding wire and container assembly is also provided, in which a coil of welding wire is disposed in the housing and support by the base.

BACKGROUND

Drums are used to store a variety of products and materials, such as welding wire, for example. 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 for the weld and is consumed during the welding process. Typically, the welding wire is fed from a wire feeder to a hand-held welding gun. A drum may be used to supply the welding wire to the wire feeder. A typical drum used for storing welding wire, or other products and materials, is a hollow cylinder formed of a cellulosic material, such as cardboard, along with various metal parts for support. During lifting, the base of the drum cannot support the weight of the welding wire without some type of non-cellulosic support, such as a pallet straps or metal structures.

Once the wire is consumed, the drums typically are discarded because the drums cannot be recycled easily. Recycling is difficult because the fibrous portion of the drum must be separated from the metal portion to recycle either the fibrous portion or the metal portion. That operation can be complex and time consuming. Thus, a typical drum owner ultimately pays to dispose of the empty drum as refuse, rather than regaining some of the cost of the fiber drum by recycling.

BRIEF DESCRIPTION

In certain embodiments, a wire container is provided with a housing made of a recyclable material. The wire container has a peripheral wall defining a boundary from a first end to a second end of the housing, a plurality of end portions folded inwardly across the second end to define an end wall, and a plurality of support structures coupled to the end wall. In some embodiments, the housing has a cylindrical wall and the second end has a plurality of triangular portions folded radially inward.

DETAILED DESCRIPTION

As discussed in detail below, some of the embodiments of the present technique provide for a recyclable drum with a base of inwardly folded portions, laminated support structures and a flanged cylindrical lid. The base provides enough strength to support lifting the drum from the top of the drum; in other embodiments, the drum may be lifted from the bottom. Another embodiment provides for a method of manufacturing the drum and constructing the base from inwardly folded portions, laminated support structures, and a flanged cylindrical lid, as is explained in greater detail below. In some embodiments, an outside-fitting cover is used, while in others an inside-fitting cover is used. Of course, such embodiments are merely exemplary of the present technique, and the appended claims should not be viewed as limited to those embodiments.

Referring generally toFIG. 1, a wire-welding system12, such as a MIG welding system, is featured. In the illustrated embodiment, wire-welding system12comprises a wire feeder13, a power source14, a gas cylinder16, and a recyclable container18containing welding wire20and covered with an outside-fitting cover50. Preferably, the recyclable container18is comprised of a fiber material, such as cellulosic paper, paperboard, or cardboard. As discussed below, the container18has a wire support or base, e.g., base52, which includes inwardly folded portions and laminations to increase the carrying capacity of the container18without the use of metal, extended straps, and so forth.

The power source14provides electricity to the wire feeder13; the gas cylinder16provides inert gas to the wire feeder13; and the container18provides welding wire20to the wire feeder13via a conduit system21. In the illustrated embodiment, the wire feeder13provides electricity, welding wire20, and inert gas to a welding torch22. The wire, gas, and electricity are coupled to the torch22by a welding cable24. In addition, a work clamp26is coupled to the wire feeder13by a ground cable28. The work clamp26is secured to a workpiece30to electrically couple the workpiece30to the wire feeder13. The torch22controls the operation of the system12. When the torch22is activated, welding wire20is fed through the torch22by the wire feeder13. When the welding wire20contacts the workpiece30, an electrical circuit between the workpiece30and the wire feeder13is completed and an electric arc is produced. The electric arc melts the workpiece30and welding wire20at the point of contact. The inert gas shields the molten area from contaminants. A power cable32conducts electricity from the power source14to the wire feeder13. A hose34channels gas from the gas cylinder16to the wire feeder13.

In the illustrated embodiment, the container18is a hollow, generally cylindrical fiber drum. However, the container18may have a shape other than a cylindrical shape. For example, the container18may be square, hexagonal, octagonal, etc. A spool of welding wire20is disposed within the hollow interior of the container18.

In the illustrated embodiment, the container18rests on or is secured to a separate bottom support38. Bottom support38has at least one, and as illustrated, a plurality of holes, or recesses,40. As best illustrated inFIG. 2, bottom support38is adapted to enable the forks42of a forklift44, or other member of a lifting device, to enter one or more of the plurality of holes, or recesses,40and be positioned below the base52of the container18to lift the container18. In the illustrated embodiment, two holes40are used, one for each fork42of the forklift44. However, the container18also may be adapted with a single hole, or recess, that enables two forks42, or a single lifting member to enter the bottom support38. In addition, exit holes may be provided to enable the forks42to extend through the bottom support38. Furthermore, a lifting device other than a forklift44may be used to lift the container18via one or more of the holes40, or other passages or recesses. For example, lifting straps could be passed through the openings of bottom support38to enable an overhead crane to lift the container18. Other lifting devices adapted to lift the container from the bottom may also be used, either through the use of the holes40or inserted directly under the base52.

FIG. 3shows an alternative embodiment in which the container18is lifted from the top. In the illustrated embodiment, a lifting mechanism46is shown and includes clamps48that grip the container18at the open end. In this manner, a bottom support38as illustrated inFIGS. 1 and 2is not used to lift the drum. The lifting mechanism46may include any type of clamps, grips, or other device that can attach to and lift the drum from the top. Such clamps or grips may be adapted to grip a portion of the top of the drum or to grip the entire circumference of the top of the drum. As discussed below, the illustrated container18has a base52strong enough to support the weight of the welding wire20when lifted from the top. For example, the base of the container18may include inwardly folded portions and laminations to increase the wire carrying capacity of the container without any non-cellulosic supports.

Referring now toFIG. 4, an exemplary manufacturing process for creating a container18is shown. A sheet of recyclable fiber material60is secured on a rotating mandrel62. In this exemplary process, the fiber sheet60has a length of 87.5 inches and a diameter of 23 inches, but other lengths, diameters or dimensions may be used depending on the desired drum size. A cylindrical cutter64is positioned adjacent to the fiber sheet60and mandrel62. The cylindrical cutter64has zig-zagging cutting edges66, and the cutter is positioned such that the cutting edges66align with the center of the mandrel62and the fiber sheet60. To cut the fiber sheet60, the mandrel62rotates and the fiber sheet60is brought into contact with the cutter64. The cutting edges66cut a zig-zagging pattern68of folding portions into the fiber sheet60. In this exemplary process, the folding portions have a triangular shape; however, such shapes are determined by the cutting edges66of the cutter60, and other shapes may be used.

Turning now toFIG. 5, the result of the cutting process described inFIG. 4is shown. After the cutting process, the fiber sheet60is split into two fiber cylinders68. In this exemplary embodiment, the length70of each cylinder68, excluding the folding portions, is 32.25 inches. As a result of the cutting process described inFIG. 4, each cylinder68has triangular-shaped folding portions72. In this exemplary embodiment the length74of each folding portion72is 11.5 inches, and the distance76between the centerpoints of adjacent folding portion is 6 inches. As will be described below, the folding portions are folded inward to form an enclosed end75of the cylinder68.

FIG. 6shows an exemplary embodiment of a recyclable drum80after folding portions72have been folded inward to form the enclosed end75. The drum80has the enclosed end75and an opposite open end77. In the exemplary embodiment, the folding portions76are triangular-shaped and folded radially inward to seal and form the enclosed end75. In alternate embodiments, the folding portions76may have a different shape or may overlap when folded inward. The enclosed end75, in conjunction with the additional support structures described below, generally provide the desired bottom strength of the drum80. In certain embodiments, the drum80may be constructed to support over 500 lbs, over 1000 lbs, or over 1500 lbs.

Referring now toFIG. 7, an exploded view of an exemplary fiber drum80and all the components that construct the base52of the drum are shown. As discussed above, the enclosed end of the drum80is formed by the folding portions76being folded inward. A plurality of support structures82,84, and86are secured to the enclosed end75of the drum80, such as by glue or other adhesive. The support structures82,84, and86are constructed from fiber sheets, but may be constructed from other suitable material. Further, the material may be chosen to provide additional strengthening properties to the enclosed end of the drum, and all of the support structures need not be constructed of the same material. Circular support structure82is secured to the inside of the enclosed end75of the drum80. A second circular support structure of fiber sheet84is secured to the outside of the enclosed end75of the drum80, such that the folding portions76that form the enclosed end75of the drum80are laminated by circular support structures82and84. A third circular support structure86is secured to circular support structure82inside the drum80. The third circular support86structure has a hole88in the center for insertion of a plastic tie down plug. To further seal and support the enclosed end75of the drum80, a flanged cylindrical lid91is secured to the outside of the enclosed end75of the drum80over the circular support piece84. The bottom of the cylindrical lid91extends about 0.5-2 inches toward the center of the enclosed end75of the drum80. In this exemplary embodiment, the outside diameter of the cylindrical lid91is about 23 inches, and the inside diameter of the lid is about 21-22.5 inches. The lid extends about 6 inches along the side wall of the drum80towards open end77. As with the circular support pieces82,84, and86, the cylindrical lid91may be constructed from a fiber sheet or composed of other suitable recyclable material. In certain embodiments, the drum80, the support structures82,84, and86, and the lid91are made entirely of cellulosic material without any metal or other dissimilar material that cannot be recycled together.

Referring now toFIG. 8, a cross-section of a the fiber drum80, constructed in accordance with an embodiment of the present technique, is shown with an outside-fitting cover50over the open end77of the drum80. The drum80has a base52formed and sealed by folded portions76, the inside-fitting circular support structure82, the outside-fitting circular support structure84, the inside-fitting circular support structure86, and the flanged cylindrical lid91coupled together to form a layered structure as discussed above. For example, the layered structure may have the layers76,82,84,86, and91laminated together with a suitable adhesive. To enclose the open end77of the drum80, an outside-fitting cover50is secured on the open end of the drum80as shown inFIG. 8. The outside-fitting cover50extends down the sides of the drum80towards the enclosed end75. The outside-fitting cover50may be adapted from fiber sheets or other suitable material. Further, the outside-fitting lid50need not be comprised of recyclable material and may be reused on different drums, instead of being recycled along with the drum80.

Turning now toFIG. 9, a cross-section of the fiber drum80, constructed in accordance with an embodiment the present technique, is shown with an inside-fitting cover92. The inside-fitting cover92is recessed into the open end77of the drum80. The edges of the inside-fitting cover92extend up towards the open end77of the drum80. As with the outside-fitting cover50discussed above, the inside-fitting cover92may be constructed from fiber sheets or composed of other suitable material, and may be reused on different drums. In this alternative embodiment, the inside-fitting cover92enables lifting the drum with the cover92in place, using an overhead lifting mechanism, also shown inFIG. 3. As shown in the figure, when lifting, lowering, or otherwise moving the drum, the clamps48grab the outside edge of the drum80and the inside edge of the extended portions of the inside-fitting cover92. The folding portions76, the circular support structures82,84, and86, and the flanged cylindrical lid91cooperatively provide enough strength at the bottom of the drum80to support the weight of the welding wire during overhead lifting.

Referring generally toFIG. 10, a cross-sectional view of the container ofFIG. 1is illustrated. A conduit adapter assembly94is secured to outside-fitting cover50to couple the cover50and the conduit system21. The conduit adapter assembly94is inserted through the hole96in the cover50. The conduit adapter assembly94is adapted to guide wire20from the container18into the conduit system21. Other adapter assemblies, such as a conical adapter, may also be used in conjunction with the outside-fitting cover50or inside-fitting cover92. The bottom support38is shown attached to the container18. The cylindrical lid91has been modified to extend over bottom support38to provide for attachment of bottom support38.

As best illustrated inFIG. 11, the conduit adapter assembly94comprises a quick-disconnect98, a washer100, a wire guide102, and a plate104. The quick-disconnect98and wire guide102are adapted to secure to each other through the hole96in the top portion59of the cover50and through holes in the washer100and plate104, respectively. The quick-disconnect98and wire guide102form a path106for welding wire20to pass through a hole96in the container18. The conduit adapter assembly94thereby guides the wire into the conduit system21and protects the outside-fitting cover50of the container18from damage due to abrasion from the welding wire20. In addition, the quick-disconnect98is adapted to be quickly connected to or disconnected from the conduit system21. Furthermore, the washer100and plate104distribute stress caused by the conduit adapter assembly94over a larger area of the top portion59of the cover50.