Abstract:
A package for containing and dispensing wire from a coil of welding wire. The package having an outer layer with a bottom and an outer side wall having an upper edge defining a box opening for removing the wire from the package. The package further including an inner core positioned within the inner cylindrical opening of the wire coil wherein the inner core has a base supported by the package bottom and an oppositely facing core top. The core base being generally maintained relatively to the package bottom to prevent the core from “walking-up” the wire coil and the core top being allowed to tilt as the wire exits the package.

Description:
[0001]    This application is a continuation of U.S. application Ser. No. 10/988,892, filed Nov. 15, 2004, the disclosure of such application is hereby incorporated by reference. 
         [0002]    The present invention relates to welding wire packaging and more particularly to a welding wire package with an improved central core configuration which maintains its position relative to the base of the package. 
     
    
     INCORPORATION BY REFERENCE 
       [0003]    Welding wire used in high production operations, such as robotic welding stations, is provided in a large package having over 200 pounds of wire. The package is often a drum or a box where a large volume of welding wire is looped in the package around a central core or a central clearance bore. During transportation a hold-down mechanism can be used to prevent the wire coil from shifting and to prevent the central core from shifting. To control the transportation and payout of the wire, it is standard practice to provide an upper retainer ring which can be utilized as a part of the hold-down mechanism to prevent wire shifting. One such package is shown in Cooper U.S. Pat. No. 5,819,934 which is incorporated by reference herein as background material showing the same. Another such packaging is shown in Kawasaki U.S. Pat. No. 4,869,367 which is also incorporated by reference herein for showing welding wire packages. Cipriani U.S. Pat. No. 6,481,575 shows a welding wire package which is also incorporated by reference for showing the same. 
       BACKGROUND OF INVENTION 
       [0004]    In the welding industry, tremendous numbers of robotic welding stations are operable to draw welding wire from a package as a continuous supply of wire to perform successive welding operations. The advent of this mass use of electric welding wire has created a need for large packages for containing and dispensing large quantities of welding wire. A common package is a drum where looped welding wire is deposited in the drum as a wire stack, or body, of wire having a top surface with an outer cylindrical surface against the drum and an inner cylindrical surface defining a central bore that is coaxial to a central package axis. The central bore is often occupied by a cardboard cylindrical core, as shown in Cooper U.S. Pat. No. 5,819,934, extending about a core axis that is coaxial to the package axis. It is common practice for the drum to have an upper retainer ring that is used in transportation to stabilize the body of welding wire as it settles. This ring, as is shown in Cooper U.S. Pat. No. 5,819,934, remains on the top of the welding wire to push downward by its weight so the wire can be pulled from the body of wire between the core and the ring. In addition, a hold-down mechanism can be utilized to increase the downward force. 
         [0005]    The welding wire in the package is in coils or convolutions wrapped about the package axis and the coil has a top and a bottom. The coil further includes radial inner and outer surfaces extending between the top and the bottom of the coil. As the welding wire is removed from the package, the wire is removed from the top coils or convolutions of wire wherein the top of the wire coil moves downwardly into the package. As a result, the top of the wire coil descends within the package and the outer and inner surfaces of the coil become shorter and shorter. 
         [0006]    In order to work in connection with the wire feeder of the welder, the welding wire must be dispensed in a non-twisted, non-distorted and non-canted condition which produces a more uniform weld without human attention. It is well known that wire has a tendency to seek a predetermined natural condition which can adversely affect the welding process. Accordingly, the wire must be sufficiently controlled by the interaction between the welding wire package and the wire feeder. To help in this respect, the manufacturers of welding wire produce a wire having natural cast, wherein, if a segment of the wire was laid on the floor, the natural shape of the wire would be essentially a straight line; however, in order to package large quantities of the wire, the wire is coiled into the package which can produce a significant amount of wire distortion and tangling as the wire is dispensed from the package. As a result, it is important to control the payout of the wire from the package in order to reduce twisting, tangling or canting of the welding wire. This condition is worsened with larger welding wire packages which are favored in automated or semi-automated welding. 
         [0007]    The payout portion of the welding wire package helps control the outflow of the welding wire from the package without introducing additional distortions in the welding wire to ensure the desired continuous smooth flow of welding wire. Both tangling or breaking of the welding wire can cause significant down time while the damaged wire is removed and the wire is re-fed into the wire feeder. In this respect, when the welding wire is payed out of the welding wire package, it is important that the memory or natural cast of the wire be controlled so that the wire does not tangle. The welding wire package comprises a coil of wire having many layers of wire convolutions laid from the bottom to the top of the package. These convolutions include an inner diameter and an outer diameter wherein the inner diameter is substantially smaller than the width or outer diameter of the welding wire package. The convolutions together form the radial inner and outer surface discussed above. The memory or natural cast of the wire causes a constant force in the convolutions of wire which is directed outwardly such that the diameter of the convolutions is under the influence of force to widen. The walls of the wire welding package prevent such widening. However, when the welding wire payout of the package, the walls of the package lose their influence on the wire and the wire is forced toward its natural cast. This causes the portion of the wire which is being withdrawn from the package to loosen and tend to spring back into the package thereby interfering and possibly becoming tangled with other convolutions of wire. In addition to the natural cast, the wire can have a certain amount of twist which causes the convolutions of welding wire in the coil to spring upwardly. 
         [0008]    Payout devices or retainer rings have been utilized to control the spring back and upward springing of the wire along with controlling the payout of the wire. This is accomplished by positioning the payout or retainer ring on the top of the coil and forcing it downwardly against the natural springing effect of the welding wire. The downward force is either the result of the weight of the retainer ring or a separate force producing member such as an elastic band connected between the retainer ring and the bottom of the package. Further, the optimal downward force during the shipment of the package is different than the optimal downward force for the payout of the welding wire. Accordingly, while elastic bands or other straps are utilized to maintain the position of the payout or retainer ring during shipping, the weight of the retainer ring can be used to maintain the position of the payout relative to the wire coils during the payout or the wire. 
         [0009]    In addition to the braking ring or retainer ring, which helps control the flow of wire from the package, welding wire packages can further include an inner core to help prevent the outgoing wire from looping across the central axis of the package. In this respect, the central core can be positioned in the wire package within the cylindrical inner region defined by the inner surface of the wire coil. The core is coaxial to a core axis in line with the central package axis. The inner core and the outer packaging together form a generally annular coil compartment wherein the wire can only move upwardly, not transversely of the package axis. In general terms, the central core produces an inner barrier for the wire coil to help direct the outgoing wire upwardly and out the top opening of the wire package such that one convolution of wire does not interfere with other convolution of wire. 
         [0010]    The welding wire is further controlled by external wire management systems that can include a payout hat that is placed over the top opening of the package and which includes a central opening for the welding wire to pass through. This, alone with other forces and conditions, causes the exiting wire to move toward the central axis of the package as it travels toward this central opening. Further, while the wire is being removed, convolutions of wire are being removed wherein the outgoing wire is constantly moving around the central axis of the package. As a result of the inward movement, the wire tends to engage the inner core is it travels upwardly in the package and as a result of the constant movement about the central axis, this point of engagement with the central core constantly moves around the central core. This produces inward forces on the central core that constantly move about the central core. Further, as the wire moving toward the top opening, it also produces an upward force. 
         [0011]    As can be appreciated, when the package is full of wire and the wire coil is nearly the same height of the central core, there is little or no space between the coil and the majority of the central core. This arrangement substantial prevents lateral and/or upward movement of the core relative to the central axis. As a result, the core is relatively stable with a full package. However, as the wire is removed from the package, the coil becomes shorter thereby exposing a greater portion of the top of the core. The lack of support by the inner surface of the coil near the top of the core allows core to move around the package axis at an angle to the package axis. More particularly, lack of support near the top cause the core to tilt about the package axis such the core axis near the top of the core becomes spaced radially outwardly from the package axis while the core axis near the bottom of the core is maintained closer to the package axis, but one side of the core bottom lifts from the bottom of the package. As the top of the wire coil nears the bottom of the package, this condition worsens such that the core axis near the top of the core moves further radially outwardly and the bottom of the core becomes looses even more of its engagement with the bottom such that it becomes unstable until the bottom of the core begins to “walk” up the inner surface of the core. Continued “walking” of the core will eventually cause the bottom of the core to reach the top of the coil. Once the bottom of the coil reaches the top of the coil it is free to move radially outwardly until it interferes with the flow of the outgoing wire and causes a tangle in the outgoing wire. As can be appreciated, a wire tangle will result in the welding operation being shut down until the tangle is removed. If the wire package is nearly empty, the nearly empty wire package may be replaced by a new wire package thereby wasting a significant amount of welding wire. 
         [0012]    In order to overcome the shortcomings in cylindrical cores described above, conical central cores have been used to reduce the tendency of the core to tilt and lift as the wire is removed from the package. While the conical core may reduce the tilting and lifting actions of the core, it reduces the effectiveness of the core to help control the removal of the wire from the package. In this respect, a cylindrical core better directs the welding wire to the outlet of the package. Further, the tilting action of the core can have beneficial effects on the outgoing wire if it is controlled and if the bottom of the core is prevented from “walking” up the coil. 
       STATEMENT OF INVENTION 
       [0013]    In accordance with the present invention, a welding wire package for containing and dispensing wire from a wire coil is provided which includes an inner core positioned within the inner cylindrical opening of the wire coil such that the core has a core base that is maintained laterally relative to the bottom of the package to prevent the core from “walking” up the wire coil and disrupting the outflow of the welding wire. In this respect, provided is a welding wire package having a bottom portion that provides a mounting structure to secure the base of the core relative to the bottom of the package while allowing only controlled movement of the top portion of core around the package axis as the wire is removed from the package. 
         [0014]    An object of the present invention is the provision of a welding wire package which includes a core that generally maintains its position within the package during the unwinding of the wire in the package. 
         [0015]    Another object of the present invention is the provision of a welding wire package which allows the wire to be wound from any known method into a wire package while still allowing the use of a stable inner core that helps guide the wire as it is removed from the welding package without disrupting the flow of the wire from the package. 
         [0016]    A further object of the present invention is the provision of a welding wire package which includes a stable inner core that helps guide the wire as it is removed from the welding package without disrupting the flow of the wire from the package and which can be easily removed and discarded after the welding wire is consumed. 
         [0017]    Yet a further object of the present invention is the provision of a welding wire package which includes a stable inner core that helps guide the wire as it is removed from the welding package without disrupting the flow of the wire from the package and which can be used in connection with hold-down mechanisms used for the transportation of the welding wire package. 
         [0018]    Even yet another object of the present invention is the provision of a welding wire package which includes an inner core that will not “walk” up the wire coil as the wire is removed from the welding package. 
         [0019]    Even yet a further object of the present invention is the provision of a welding wire package which includes components that are economical to produce, easy to use and discard after use. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0020]    The foregoing objects, and more, will in part be obvious and in part be pointed out more fully hereinafter in conjunction with a written description of preferred embodiments of the present invention illustrated in the accompanying drawings in which: 
           [0021]      FIG. 1  is a side sectional view of a prior art welding wire package which includes an inner core resting on the bottom of the package; 
           [0022]      FIG. 2  is a side sectional view of the prior art welding wire package shown in  FIG. 1  wherein the core has “walked-up” the coil; 
           [0023]      FIG. 3  is a side sectional view of another prior art welding wire package which includes a conical inner core resting on the bottom of the package; 
           [0024]      FIG. 4  is a side sectional view of a welding wire package according to the present invention wherein an inner core is being inserted into the package which contains a coil of wire; 
           [0025]      FIG. 5  is an enlarged sectional view of the package shown in  FIG. 4  wherein the core is a retained condition; 
           [0026]      FIG. 6  is a sectional view taken generally along line  6 - 6  of  FIG. 5 ; 
           [0027]      FIG. 7  is a cross sectional view taken generally along line  7 - 7  of  FIG. 6 ; 
           [0028]      FIG. 8  is an enlarged top plan view of a stabilizer with pre-cut retainers which is shown in the package shown in  FIG. 1 ; 
           [0029]      FIG. 9  is perspective view of the stabilizer shown in  FIG. 8  with the retainers folded into a receiving position; 
           [0030]      FIG. 10  is a side sectional view of another embodiment of the present invention; 
           [0031]      FIG. 11  is a sectional view of the package shown in  FIG. 10  taken along lines  11 - 11  in  FIG. 10 ; 
           [0032]      FIG. 12  is an enlarged perspective view of another stabilizer which is shown in  FIG. 11 ; 
           [0033]      FIG. 13  is a side sectional view of yet another embodiment of the present invention; 
           [0034]      FIG. 14  is a sectional view taken along line  14 - 14  in  FIG. 13 ; 
           [0035]      FIG. 15  is an enlarged perspective view of yet another stabilizer as is shown in  FIG. 13 ; 
           [0036]      FIG. 16  is a side sectional view of yet a further embodiment of the present invention shown in a transport condition; 
           [0037]      FIG. 17  is a side sectional view of the package shown in  FIG. 16  in an unwinding condition; and, 
           [0038]      FIG. 18  is a partially sectioned perspective view of a further stabilizer shown in the package shown in  FIG. 16 . 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0039]    Referring now in greater detail to the drawing wherein the showings are for the purpose of illustrating preferred embodiments of the invention only, and not for the purpose of limiting the invention,  FIGS. 1-3  show prior art welding wire packages which include an inner core that merely rests on the base of the package. In this respect,  FIGS. 1-2  show a prior art package P 1  and  FIG. 3  shows a prior art package P 2 . Package P 1  has a cylindrical side wall CW 1  and a round base B 1 . Package P 1  further includes an inner core IC 1  which is cylindrical and has a base ICB 1  that rests on a base sheet BS 1  on bottom B 1 . In  FIG. 1 , package P 1  is full of a welding wire W packaged as a wire coil C and a core axis CA 1  of inner core IC 1  in line with a package axis or center PC 1 . Coil C has a coil top CT, a coil bottom CB, a coil inner surface CIS and a coil outer surface COS wherein coil inner surface CIS defines an inner cylindrical space ICS coaxial with package axis PC 1 . Coil bottom CB is resting on base sheet BS 1  and coil outer surface COS is supported by side wall CW 1 . 
         [0040]    The welding wire coil has many layers of wire convolutions laid from the bottom to the top of the package. These convolutions are placed in the package by a machine that extends into the package and rotationally positions or places wire on the coil top. As can be appreciated, the wire placement begins at the bottom of the package and works its way to the top of the package. The inner core is therefore positioned in the package after the wire is deposited in the package. The convolutions include an inner diameter and an outer diameter wherein the inner diameter is substantially smaller than the width or outer diameter of the welding wire package. The convolutions together form coil inner surface CIS and coil outer surface COS. As the welding wire is removed from package P 1 , the wire convolutions can wrap around the inner core one after another as is shown in  FIG. 2 . As can be appreciated, core IC 1  helps direct the wire out of the package by preventing the wire from crossing over package center PC 1  such that one convolution can contact another convolution and cause a tangling. As the wire is removed more and more of core IC 1  becomes exposed to the outgoing wire and becomes unsupported. As coil top CT moves down toward bottom B 1 , core IC 1  can become unstable and core base ICB 1  can begin to lift away from base sheet BS 1 . 
         [0041]    Once the core becomes unstable, it can “walk up” coil inner surfaces CIS and interfere with the outflow of the welding wire. In this respect, the lack of support by the inner surface CIS above coil top CT allows the core to move more freely in the package. More particularly, this core movement relative to the outer packaging, which will hereinafter be referred to “rotational tilting,” is when the core moves such that core axis CA 1  essentially moves around package axis PC 1 . However, portions of the core axis near the top of the core move around package axis PC 1  at radial distance that is different than portions of the core near the bottom of the core. This produces a tilted motion, or rotational tilting, wherein the core is at an angle A from the package axis. For example, as is shown in  FIG. 2 , core IC 1  is tilted such that core axis CA 1  near the core top is spaced from package axis PC 1  a first radial distance RD 1  and the core axis is spaced a second radial distance RD 2  from the package axis near the core bottom wherein the core axis rotation angle is A to the package axis. As can be appreciated, angle A can change, and does change, based on the amount of wire in the package. In this respect, the more wire that is removed from the package worsens the rotational tilting wherein angle A increases. As can be appreciated, since the core bottom is flat, a portion of the core bottom lifts from base sheet BS 1  during the rotational tilting thereby reducing core stability. As coil top CT approaches base sheet BS 1 , the rotation tilting causes the base corner BC to contact coil inner surfaces CIS and the bottom of the core begins to “walk up” the inner surface of the core. Continued “walking” of the core will eventually cause core base ICB 1  to reach coil top CT. Once core base ICB 1  reaches core top CT it is also free to move radially outwardly and if it does, it will interfere with the flow of the outgoing wire and result in a wire tangle. As can also be appreciated, a wire tangle will result in the welding operation being shut-down until the tangle is removed. If the wire package is nearly empty, the nearly empty wire package may be replaced by a new wire package thereby wasting a significant amount of welding wire. 
         [0042]      FIG. 3  shows a conical core which has been developed to try and minimize rotational tilting. In this respect, shown is a welding wire package P 2  having a cylindrical side wall CW 2  and a round base B 2 . Package P 2  further includes an inner core IC 2  which is conical and has a base ICB 2  that rests on a base sheet BS 2  on bottom B 2 . Package P 2  is shown to be full of welding wire W packaged as wire coil C as described above. Core IC 2  also has a core axis CA 2  which is in line with a package axis or center PC 2 . The conical configuration of core IC 2  produces a spacing between the coil and the core that varies from the top of the core to the bottom of the core. As a result, the core has a different influence on the outgoing wire as the core top descends within the package. While this configuration can reduce rotational tipping, it does not eliminate this movement and further, the benefits of the core&#39;s influence on the outgoing wire is substantially lost. 
         [0043]      FIGS. 4-9  illustrate a welding wire package  10  wherein a wire W is stored in and payed out of package  10  having a bottom  12 , a top  14 , side walls  15   a ,  15   b ,  15   c  and  15   d  having an inner surfaces  16   a ,  16   b ,  16   c  and  16   d . Package  10  can further include corner supports  18  and even an inner liner known in the art, which is not shown. The inner liner can include, but is not limited to, octagonal inner liners known in the art. Further, package  10  can be a drum style package having a cylindrical configuration or other packaging configurations known in the art. Package  10  further includes an inner core  17  generally concentric with surface  16 . 
         [0044]    As is known and as is described above, package  10  is loaded with wire W at the wire manufacturing facility by looping the wire into the package. This looping process winds the convolutions of wire into a coil C of wire having a body wrapped about a coil or package axis  30 . Coil C has a coil top CT, a coil bottom CB, a coil inner surface CIS and a coil outer surface COS wherein coil inner surface CIS defines an inner cylindrical space ICS coaxial with package axis  30 . Package  10  can have a base sheet  32  wherein coil bottom CB rests on base sheet  32  and coil outer surface COS is supported by inner surfaces  16   a ,  16   b ,  16   c , and  16   d  of side wall  15   a ,  15   b ,  15   c , and  15   d , respectively. While not shown, package  10  can also include an inner packaging layer which separates COS from the side walls. Further, coil bottom CB can rest directly on bottom  12  and/or additional layers can be utilized which will be discussed in greater detail below. The wire is looped in a manner such that it has a cast to facilitate payout of the wire with a minimum of tangles and/or twists in the wire. This produces an upward springing effect which must be controlled during both the transport of packaging  10  and during the unwinding of the welding wire which will also be discussed in greater detail below. 
         [0045]    Once the wire has been looped in package  10 , inner core  17  can be positioned in the packaging. More particularly, inner core  17  has a bottom edge  40 , a top edge  42 , an outer surface  44  and an inner surface  46 . As is shown, core  17  can be cylindrical with an outer sectional diameter  48  and an inner sectional diameter  50 . However, core  17  could have other cross-sectional configurations including, but not limited to, polygonal cross-sectional configurations. Further, core  17  can be manufactured using any technique and/or material known in the art. Core  17  is positioned by lowering the core into the cylindrical opening defined by core inner surface CIS. As can be appreciated, outer diameter  48  must be approximately equal or less than an inner diameter  60  of inner surface CIS so that the core can be lowered into position. 
         [0046]    As core  17  is lowered into position in the package, it is received by a core stabilizer  70  and generally maintained in a retained condition  71  by the stabilizer, which will be discussed in greater detail below. As can be appreciated, stabilizer  70  can be a separate component, an extension of base sheet  32  or an extension of bottom  12  without detracting from the invention of this application. As shown, stabilizer  70  is a separate component of package  10  and includes a base  72  and four retainers  74  that are spaced about axis  30 . While four retainers are shown, there can be more or less than four retainers without detracting from the invention of this application. Stabilizer  70  can further include a central opening  75  for a hold-down mechanism that will be discussed in greater detail below. 
         [0047]    Retainers  74  each include a vertical member  76  and a cross member  78 , both of which can be cut from base  72 . In this respect, vertical member  76  and cross member  78  can be a unified component extending from base  72  at a base edge  80 . Cross member  78  is rectangular and includes side edges  90  and  92  that are parallel to one another and extend between base edge and a mid-fold  94  which joins members  76  and  78  and which allow the members to pivot relative to one another. Vertical member  76  extends between mid fold  94  and a tab edge  96 . More particularly, member  76  includes side edges  100  and  102  that are non-parallel and which extend away from one another from mid-fold  94  toward tab edge  96  to form retainer seats  104  and  106 . Member  76  further includes a tab  108  between seats  104  and  106  that extends beyond seats  104  and  106  and is defined by tab edge  96  and tab sides  110  and  112  wherein tab  108  has a tab width  114  between tab sides  110  and  112  and a tab length  116  between seats  104 / 106  and tab edge  96 . Retainers  74  further include locking slots  120  and  122  shaped to receive a portion of tab  108  to maintain tabs  74  in an upwardly extending position such that vertical member  76  is generally perpendicular to base  72  and cross member  78  extends at an angle between mid-fold  94  and base  72  wherein mid-fold  94  is spaced furthest from base  72 . 
         [0048]    As is shown in  FIG. 8 , retainers can be cut from base  72  such that the retainers are a portion of the base. For retainers cut from base  72 , they are first partially separated from base  72  by rotating the retainer about edge  80 . Then, the retainers are folded about mid-fold  94 , which can include a score, and tab  108  is then positioned in slots  120  and  122  until seats  104  and  106  engage base  72 . While retainers are shown to be cut from base  72 , it should be appreciated that they can also be a separate component attached to base  72  without detracting from the invention of this application. The inter-engagement between tab  108  and slots  120  and  122  along with the engagement by seats  104  and  106  retain tab  74  in an operating position as is shown in  FIG. 9 . Stabilizer  70  is fixed relative to the coil C so that it can control the movement of core  17  which will be discussed in greater detail below. More particularly, the weight of wire W and/or other package components can be used to fix the stabilizer relative to the coil. As is shown, base  72  of stabilizer  70  has outer edges  124 - 131  and is sized such that these edges engage the inner surfaces  16  of walls  15  and corner supports  18 . Base  72  further includes upper surface  132  and lower surface  134  wherein coil bottom CB is on surface  132  such that the weight of wire W is resting on base  72  and further prevents movement of the stabilizer relative to the coil. 
         [0049]    As core  17  is lowered into the central opening of the coil, it is directed toward tabs  74  such that bottom edge  40  engages cross members  78  and/or is closely adjacent to bases  80  of the retainers. Once in position, the retainers are substantially within an inner portion  140  of core  17  which advantageously separates the retainers from the wire coil to prevent interference with the unwinding of the wire from the package. Essentially, retainers engage bottom edge  40  and/or inner surface  46  of core  17  to control the movement of the core. By including a plurality of retainers about the base of the core, the base is substantially prevented from moving transversely relative to the package axis in all directions transverse to axis  30 , which helps prevent the bottom edge of the core from engaging inner surface CIS of the wire coil, thereby preventing unwanted “walking” of the core up the wire coil. Further, since the core is not permanently attached to the base of the package, it can be easily removed and discarded, which can help minimize the cost of discarding the used packaging, especially if unlike materials are used for the outer packaging and the core. Again, as is stated above, core  17  can be made from any known materials in the art, which can include materials that are not similar to the materials used for the outer packaging of package  10 . Even if common materials are used, removal of the core can help make the discarded packaging materials easier to compact without the need for mechanical compacting equipment. 
         [0050]    In operation, core  17  functions similar to prior art cores, wherein outer surface  44  helps direct wire W upwardly as the wire is unwound from the wire coil. However, stabilizer  70  allows only controlled rotational tilting of the core while the wire is unwound or payed out. As stated above, some rotational tilting can be advantageous in the control of the wire as it is unwound from the packaging. However, when the rotational tilting becomes violent or uncontrolled, it can interfere with the smooth removal of wire and/or can cause the core to “walk-up” the coil and eventually cause a wire tangle. Even though retainers can allow some movement of the bases of the core relative to bottom  12 , including some lifting of bottom edge  40  of core  17 , it is substantially controlled movement and the bottom edge is prevented from contacting the inner surface of the coil. 
         [0051]    In the following discussions concerning other embodiments of the present inventions, like components will be referenced by the same reference numbers as discussed above. 
         [0052]    Referring to  FIGS. 10-12 , package  150  is shown, which includes a coil stabilizer  160  and the same outer configuration as discussed above. Again, while this package design and the following designs are being described in connection with square box packages, the invention of this application is not limited to square box packages and has broader applications. Stabilizer  160  includes a base  162  and an upward protrusion  164  extending from base  162 . Upward protrusion  164  includes four vertically extending side walls  170 ,  172 ,  174  and  176  and a top  178 . While a square cross-sectionally configured protrusion is shown, it should be noted that other protrusions, including other polygonal configurations, could be used without detracting from the invention of this application. Protrusion  164  further includes a corner edge  180  between walls  170  and  172 , a corner edge  182  between walls  172  and  174 , a corner edge  184  between walls  174  and  176  and a corner edge  186  between walls  176  and  170 . As core  17  is lowered into the central opening of the coil, it is directed toward protrusion  164  such that the protrusion enters inner portion  140  and corners  180 ,  182 ,  184  and  186  engage inner surface  46  of core  17 . The bottom edge  40  rests on base  162 . Once in position, the protrusion is within inner portion  140 , which again advantageously separates the stabilizer from the wire core to prevent interference with the unwinding of the wire from the package. Essentially, the frictional engagement between corners  180 ,  182 ,  184  and  186  and inner surface  46  maintain the position of the core during the payout of the wire. As with the retainers described above, the protrusion controls the movement of the core thereby preventing the core from moving transversely relative to the package axis in all directions transverse to package axis  30 , which helps prevent the bottom edge of the core from engaging the wire coil thereby preventing unwanted “walking” of the core up the wire coil. While stabilizer  160  can be an extension of base sheet  32  (not shown), it can also be a separate component and can include flaps  190 ,  192 ,  194  and  196  extending from walls  170 ,  172 ,  174  and  176 , respectively, which are positioned between the bottom of the coil and bottom  12  without the base sheet. 
         [0053]    Package  150  can further include an additional base sheet  32  and/or an additional stabilizer sheet  198  positioned between sheet  32  and flaps  190 ,  192 ,  194  and  196 . As stated above, the weight of wire W and/or other package components can be used to fix the stabilizer relative to the coil. As is shown, sheet  198  has outer edges  200 - 207  and is sized such that these edges engage the inner surfaces  16  of walls  15  and corner supports  18 . 
         [0054]    Top  178  can include a hold-down opening  208  for a hold-down mechanism (not shown) that can be used with package  150  to prevent wire shifting during the transportation of package  150 . 
         [0055]    Referring to  FIGS. 13-15 , package  210  is shown, which includes a stabilizer  212 . More particularly, stabilizer  212  includes retainers or upward protrusions  220  that are spaced about package axis  30  and which extend from a base  222 . As with the other embodiments, protrusions  200  can be connected to a separate base or can be an extension of bottom  12  and/or base sheet  32  (not shown) without detracting from the invention of this application. Retainers  220 , in this embodiment, are separate components attached to base  222  that are made from a compressible foam. However, while foam is preferred, retainers  220  can be made from other materials known in the art including, but not limited to, cardboard. Retainers have a radial outer edge  230 , a radial inner edge  232  and sides  234  and  236 . Outer edge  230  is arcuate having a curvature corresponding to inner surface  46  of core  17 . While not required, by including an arcuate outer edge, retainers  220  have increased surface contact with inner surface  46  of the core thereby increasing the ability of the retainers to maintain the desired control of the core even with a minimal height. As can be appreciated, the costs to both produce and discard a component can often be reduced by minimizing the size of the component. 
         [0056]    As core  17  is lowered into the central opening of the coil, it is directed toward retainers  220  such that the retainers enter inner portion  140  and outer surfaces  230 , engage inner surface  46  of core  17 . The bottom edge  40  of core  17  rests on base  222 . Once in position, the retainers are within inner portion  140  which again advantageously separates the stabilizer from the wire core to prevent interference with the unwinding of the wire from the package. As with the retainers described above, the protrusion controls the movement of the core thereby preventing the core from moving transversely relative to package axis  30  in all directions transverse to the package axis which helps prevent the bottom edge of the core from engaging the wire coil thereby preventing unwanted “walking” of the core up the wire coil. Again, the weight of wire W and/or other package components can be used to fix the stabilizer relative to the coil. As is shown, base  222  has outer edges  240 - 247  and is sized such that these edges engage the inner surfaces  16  of walls  15  and corner supports  18 . Base  222  further includes upper surface  248  and lower surface  249  wherein coil bottom CB rests on surface  248  such that the weight of wire W is resting on base  222  and further prevents movement of the stabilizer relative to the coil. 
         [0057]    With reference to  FIGS. 16-18 , a package  250  is shown having a stabilizer  260 . As with the embodiments described above, package  250  can include a hold-down mechanism  270  having a hold-down bar  272 , a force producing member  274  and a top bar  276 . As is stated above, the hold-down mechanism prevents the shifting and/or upward springing of the wire in the wire coil during transport. This is accomplished by producing a downward force on top surface CT of coil C. More particularly, hold-down bar  272  is maintained relative to bottom  12  of the package. Bar  272  can be any known hold-down bar including, but not limited to, a straight elongated bar (not shown), a curved bar or a hook (not shown). Depending on the type of bar utilized, the bar is secured relative to the bottom of the package. In the case of curved hold-down bar  272 , the bar can be positioned between a base sheet  277  bottom  12  of package  250  wherein base sheet  32  has an opening  279  sized to receive bar  272 . The weight of coil C prevents upward movement of the bar. However, hold-down bar  272  can also be fastened to walls  15  and/or bottom  12 . Force member  274  is attached between hold-down bar  272  and top bar  276  such that member  274  produces a downward force in top bar  276 . Member  274  can be any know force producing member including, but not limited to, an elastic band and/or a spring. 
         [0058]    Core stabilizer  260  utilizes hold-down mechanism  270  to maintain an inner core  278  relative to bottom  12 . In this respect, stabilizer  260  includes a bar  280  having first and second ends  282  and  284 , respectively. End  282  includes a hook  286  and end  284  includes a hook  288  which are shaped to engage an inner core  278 . More particularly, core  278  includes a first set of openings  300  and  302  and a diametrically opposite two openings  304  and  306 . Openings  300  and  304  are elongated to allow hooks  286  and  288 , respectively to pass there through. Openings  302  and  306  are spaced from openings  300  and  304 , respectively, to create a cross member  310  and  312 , respectively, which are engaged by hooks  286  and  288 . Further, openings  304  and  306  allow ends  282  and  284  to at least partially pass there through, respectively, such that downward force by bar  280  is directed to cross members  310  and  312 . 
         [0059]    In operation, bar  280  can be placed through elastic band hold-down strap  274  such that bar  280  is shipped ready for operation. In another embodiment, bar  280  can be positioned after the hold-down mechanism has been released. If bar  280  is shipped with package  250 , once the package is in position for use, top bar  276  can be released from its engagement with coil top CT and a top  320  of elastic band  274  such that band top  320  moves downwardly within the package until it engages bar  280 . Once in engagement with bar  280 , band  274  produces a downward force on core  278  to prevent the core from “walking-up” the inner surface of the wire coil. However, as can be appreciated, a separate downward force producing element could be used to urge bar  280  downwardly, and thus core  278 , downwardly. By utilizing a separate element, an ideal downward force on the bar can be more easily achieved. As can also be appreciated, while this embodiment does not rigidly prevent later or transverse motion of the core, it prevents the core from “walking-up” the wire coil. Further, the downward force on the core also has a stabilizing effect on the core since it is not free to move within the wire coil. 
         [0060]    As with the embodiments discussed above, sheet  277  can be configured to help prevent motion of stabilizer  260  relative to coil C in addition to the weight of the coil. In this respect, base  277  has outer edges  290 - 297  and is sized such that these edges engage the inner surfaces  16  of walls  15  and corner supports  18 . Base  277  further includes upper surface  298  and lower surface  299  wherein coil bottom CB rests on surface  298  such that the weight of wire W is resting on base  277  and further prevents movement of the stabilizer relative to the coil. 
         [0061]    The embodiments of this application, described above, can also include a retainer or braking ring (not shown) to help control the unwinding of the wire from the wire coil. The hold-down mechanism can utilize the retainer ring to produce an even downward force on coil top CT. As is known in the art, the packages can further include a ring protection member (not shown) which extends between top bar  276  and the retainer. Further, the embodiments can include a protrusion(s) that at least partially extend(s) outwardly of the respective core without detracting from the invention of this application. 
         [0062]    As is stated above, while only a few package configurations are shown, the invention of this application can be used with a wide range of welding wire packages and package accessories known in the art. The accessories include, but are not limited to, package liners between the side wall(s) and outer surface walls  15 , vapor barriers, different corner supports, hold-down mechanisms and a wide range of retainer rings. 
         [0063]    While considerable emphasis has been placed on the preferred embodiments of the invention illustrated and described herein, it will be appreciated that other embodiments and/or equivalents thereof can be made and that many changes can be made in the preferred embodiments without departing from the principals of the invention. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.