Patent Publication Number: US-10329080-B1

Title: Welding consumable packaging

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     FIELD OF THE INVENTION 
     The present invention relates generally to packaging and methods for the shipping of wire, and more particularly to spools wound with welding wire electrodes. 
     BACKGROUND OF THE INVENTION 
     In recent times, a substantial industry has been developed around providing coils of electric welding wire in square cardboard boxes. This is because welding has become a dominant process in fabricating industrial and commercial products. Applications for welding are wide spread and used throughout the world. Examples include the construction of ships, buildings, vehicles and pipe lines. Welding is also used in repairing or modifying existing products. Among the various methods of joining metal components, arc welding is one well known and very common process. 
     Arc welding may employ consumable welding wire, which in some instances may be wound on a spool for ease of dispensing. For purposes of protection during storage and shipping, such spools may be placed in cardboard cartons. Conventional cardboard boxes have been modified by a variety of structural elements in an effort to solve the many and diverse problems experienced by use of these boxes. While such cartons have provided sufficient protection during bulk shipment of spooled electrodes to distributors, the market for direct-to-consumer shipping requires additional safeguards for spools. For example, where a single spool of wire is shipped in a single container, there is a tendency of the wire spool to deform when the carton is dropped or otherwise impacted due to the weight/inertia of the welding wire and the forces it imparts onto the spool when dropped. If the wire spool deforms, it may become unusable for a welding procedure (e.g., causes problems during wire feeding). 
     BRIEF SUMMARY OF THE INVENTION 
     The following presents a simplified summary of the invention in order to provide a basic understanding of some example aspects of the invention. This summary is not an extensive overview of the invention. Moreover, this summary is not intended to identify critical elements of the invention nor delineate the scope of the invention. The sole purpose of the summary is to present some concepts of the invention in simplified form as a prelude to the more detailed description that is presented later. 
     In accordance with one aspect of the present invention, a container for packaging a welding wire comprises a box comprising opposed first and second face panels that are separated by four vertical side walls and four vertically extending corners. Each corner defines a corner void within an interior of the box. At least one aperture is on the four vertical side walls, located adjacent to one of the four vertically extending corners and being defined by a frangible connection on one of the four vertical side walls so that the interior of the box is initially inaccessible. At least one corner blocking insert comprises an outer profile that corresponds to a spool containing a coil of welding wire located within said box. After said frangible connection of the at least one aperture is breached, the at least one corner blocking is inserted into the interior of the box via said at least one aperture at one of the four vertical side walls. The at least one corner blocking insert engages at least one of an outer perimeter rim of said spool containing a coil of welding wire, or an outer perimeter of the coil of welding wire, located within said box. The corner blocking insert that is inserted into the interior of the box through the at least one aperture is arranged to abut against an interior surface of two adjacent vertical side walls located at said one vertically extending corner. 
     It is to be understood that both the foregoing general description and the following detailed description present example and explanatory embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various example embodiments of the invention, and together with the description, serve to explain the principles and operations of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other aspects of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which: 
         FIG. 1  illustrates a perspective view of one example container for a welding wire; 
         FIG. 2  illustrates a detailed view of  FIG. 1 ; 
         FIG. 3  illustrates a top view of the container of  FIG. 1 ; 
         FIG. 4  illustrates a schematic view of a first embodiment of a corner blocking insert within the container; 
         FIG. 5  illustrates a top view of a second embodiment of a corner blocking insert; 
         FIG. 6  illustrates a perspective view of an assembled corner blocking insert of  FIG. 5 ; 
         FIGS. 7A-7C  illustrate various computer-generated perspective views of the corner blocking insert of  FIG. 6 ; 
         FIG. 8  illustrates a top view of an unassembled corner blocking insert of  FIG. 5 ; 
         FIG. 9  illustrates a schematic view of the corner blocking insert of  FIG. 5  within the container; 
         FIG. 10  illustrates an example cradle of an overwrap assembly; and 
         FIG. 11  illustrates an example manner of packaging the container for shipment within the overwrap assembly. 
     
    
    
     DESCRIPTION OF EXAMPLE EMBODIMENTS 
     Example embodiments that incorporate one or more aspects of the present invention are described and illustrated in the drawings. These illustrated examples are not intended to be a limitation on the present invention. For example, one or more aspects of the present invention can be utilized in other embodiments and even other types of devices. Moreover, certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. Still further, in the drawings, the same reference numerals are employed for designating the same elements. 
     It is common for manufacturers to provide coils of consumable welding wire electrodes in square cardboard boxes. However, round wire spools that are packaged in a square carton provide little protection to the edges and faces of the spool during the shipping process. Typical handling by common shipping carriers (i.e., UPS/FedEx) in the package shipping environments (as represented by ISTA-3A testing protocols) can damage the spool and thereby render the spool unable to dispense the welding wire after shipment. For example, the carton wall provides little protection of the spool faces in flat drops, and the round spool face edge has limited contact with the straight carton edge allowing it to easily lance through the carton wall on edge drops. Further, the empty corners of the carton provide only token resistance to crushing in corner drops. Conventionally, the prior art required the spool to be removed from its original labelled carton packaging to be properly packaged for the tougher common shipping carrier environment. Additionally, the prior art required a pre-glued assembly of the overpack components. 
     In short summary, the structure and method described in the instant application allows the spool to remain in its original labelled carton, but provides access to the corner voids of the carton for the insertion of void-filling cushion components. The inserted elements provide structural strength to the empty corners of the carton in corner drops. 
     The structure and method used to accomplish the foregoing can have various embodiments. In one example, a spool carton can have nicked, die-cut or score-line features (i.e., a perforation or kiss-cut) that can later be punched inward to create openings near the corners of the carton for insertion of support components that upgrade the structural strength of the package for shipping via common shipping carriers. The result is the formation of an integrated cradle that provides location and cushioning to the spool without having to remove the spool from its original carton packaging, as well as adding structural strength to the previously-empty corners of the carton. After the void filling elements are inserted, a foam cradle and a corrugate over-pack may be used to complete the package. The package may further include a facer plate on each flat face of the original carton to keep the flange faces supported flat in corner drops. 
     Turning to the shown example of  FIG. 1 , an example container  10  for packaging a welding wire is illustrated schematically. Typically, the welding wire is wound in a coil about a round spool  12  (wire not shown on spool for clarity), which is ultimately packaged within the container  10 . As shown, the container  10  is in the form of a box comprising opposed first and second face panels  14 ,  16  that are separated by four vertical side walls  18 ,  20 ,  22 ,  24  and four vertically extending corners  19 , each defining an apex  21 . Preferably, the box is has a square geometry in order to accommodate the round wire spool, although different geometries are contemplated. Preferably, the first and second face panels  14 ,  16  are connected to the four vertical side walls  18 ,  20 ,  22 ,  24  so that the spool  12  is entirely enclosed within the container  10 . As so far described, the container  10  is standard and is constructed as an optimum type of square cardboard container for shipping and unwinding welding wire. 
     The container  10  further comprises a plurality of apertures  30 ,  32  that are preferably located on the on at least two of the vertical side walls  18 ,  20 ,  22 ,  24 . More preferably, at least one aperture  30 ,  32  is located adjacent each of the four vertically extending corners  19 . However, it is contemplated that only two apertures could be used to provide access to all four corner areas within the container  10 . For the sake of clarity, only the apertures  30  on the first side wall  18  will be described in detail, with the understanding that the apertures  32  on some or all of the other vertical side walls  20 ,  22 ,  24  can be similar, or even different. Preferably, the apertures  30 ,  32  are disposed on opposite sides of the container  10  to thereby provide access to all four vertically extending corners  19 . For example, when apertures  30  are located on the first side wall  18 , then apertures  32  could be provided on the opposite vertical side wall  22 . Moreover, although the apertures  30  on the first side wall  18  are shown as identical, it is understood that multiple different apertures can be used. Each aperture  30  is adjacent to, and optionally bounded on, one or more sides  34 ,  36  by adjacent side walls of the box. In  FIG. 1 , for example, the aperture  30  is adjacent to first and second face panels  14 ,  16 , and spaced a distance therefrom. Depending upon the location and size of the aperture  30 , it is further contemplated that one or more sides  34 ,  36  can be bounded by the first and second face panels  14 ,  16 . 
     Although ultimately the apertures  30  will provide access into an interior of the box, each aperture is initially closed-off and defined by a frangible connection on one of the associated vertical side wall  18 ,  20 ,  22 ,  24  so that an interior of the box is initially inaccessible. The frangible connection of each aperture  30  comprises at least one non-frangible hinge side  38  that is secured to one of the face panels or vertical side walls to form a pivotable flap  40  once the frangible connection is breached. In the shown example, the two sides  34 ,  36  are frangible, while the hinge side  38  adjacent the vertically extending corner  19  is non-frangible, to later provide the pivotable flap(s). 
     As shown in  FIG. 2 , the frangible connection of each aperture  30  will be described in detail, with reference to the example shown on vertical side wall  18 . It is understood that the other apertures  30  on other vertical side walls can have similar structure. The aperture  30  comprises at least one side  42  with an at least partial die-cut or score-line (i.e., a through-cut, a kiss-cut, or a perforated cut). The die-cut or score-line extends along the least one side  42  and either partially or completely through the associated vertical side wall  18 . The die-cut or score-line may extend only partially through the vertical side wall  18  so that the container  10  initially retains some structural rigidity about the corners until the frangible connection is breached. Further, whether extending partially or completely through the face panel, the die-cut or score-line may be continuous or dis-continuous. The frangible connection provided by the at least one side  42  allows the flap  40  to be pulled outwards or punched inward to allow the aperture  30 , when desired, to create openings at the corners of the container  10  for insertion of corner reinforcing elements. 
     The at least one side  42  may extend between and connect other sides  34 ,  36  of the aperture  30 . In one example, some or all of these apertures can have a generally rectangular geometry, as shown, but other geometries are contemplated (square, triangular, quadrilateral, polygonal, random, etc.). Additionally, it is understood that the at least one side  42  may be straight or curved. Where the aperture  30  has a generally rectangular geometry, the at least one side  42  can comprise two major sides  42  that are connected by a minor side  44 . In the orientation shown in  FIG. 1 , the major sides  42  can be relatively longer and the minor side  44  can be relatively shorter. Preferably, the frangible connection of the aperture  30  is a die-cut or score-line can be a through-cut, a kiss-cut, or a perforated cut that extends along substantially the entire length of both majors sides  42  and minor side  44 . The frangible connection may be continuous or dis-continuous along the major and minor sides  42 ,  44 . Furthermore, the major and minor sides  42 ,  44  may have multiple features, such as various curved or straight sections that ultimately connect to the sides  34 ,  36 . In one example, the major and minor sides  42 ,  44  may be sized so that the resulting apertures  30  provide suitable access to an internal corner void area  49  within the container  10  that is approximate to the outer diameter of the spool  12 . 
     Optionally, the frangible connection of each aperture  30  may also comprise an at least partial secondary die-cut or score-line (not shown) to thereby separate the pivotable flap  40  into a pair of independent pivotable flaps. For example, such a secondary die-cut or score-line could horizontally bifurcate the aperture  30  into two separate and independent flaps that could be vertically separable. As before, the secondary die-cut or score-line can be a through-cut, a kiss-cut, or a perforated cut, and may be continuous or dis-continuous. 
     After the frangible connection(s) of an aperture  30  is breached along major and minor sides  42 ,  44 , the single or multiple flap(s) pivot about the hinge side  38 , which acts as a living hinge. The flap(s)  40  are pulled outwards so that the aperture  30  exposes the interior of the box, and in particular, access to the associated corner void of the container  10 . Optionally, the flap(s) can be pressed inwardly to be received within the interior of the box. 
     Turning briefly to  FIG. 3 , a top view of the container  10  is shown with an outer profile of the spool  12  shown in dashed lines, with the distance D being approximate to the outer diameter of the spool  12 . As can be seen, the diameter of the spool  12  is similar to the size of the container  10  across the four side walls  18 ,  20 ,  22 ,  24 . However, as can also be seen, the container  10  includes four corner voids  49  (i.e., empty corners) of the carton at which the spool  12  is generally not supported and which provide only token resistance to crushing in corner drops. The corner voids  49  extend vertically within the container interior along the full extent of each of the four extending corners  19 , from apex  21  (at panel  14 ) to apex  21  (at panel  16 ). Additionally, each corner voids  49  extends laterally along corresponding ones of the side walls  18 ,  20 ,  22 ,  24  up to the outer diameter of the spool  12 . 
     Turning now to  FIGS. 4-8  several embodiments of void-filling cushion components that act as corner reinforcing elements will be discussed, referred to herein as a corner blocking inserts  50 . Each corner blocking insert  50  will be inserted into the container  10  via one of the apertures  30 ,  32  and will be positioned within a corner void  49  to provide structural strength to at least one empty corner of the container  10 . The corner blocking insert(s)  50  are used to rigidify the corners of the container  10 , and otherwise maintain the squareness of the box. The at least one corner blocking insert  50  penetrates into the interior of the box via the aperture  30 ,  32  after said frangible connection of said aperture is breached. Thus, during assembly, the frangible connection is first breached and then the corner blocking insert  50  is inserted into the container  10 . Still, it is optionally contemplated that the act of forcibly inserting the corner blocking insert  50  into the box can be the mechanism that causes the breach of the frangible connection. In preparation for shipping a coil of welding wire, at least one corner blocking insert  50  thereby engages an outer perimeter rim of said spool  12  containing a coil of welding wire located within said container  10 . Preferably, a total of four corner blocking inserts  50  are used, with one each located at and filling each of the four corner voids  49  within container  10 . Still, it is understood that the instant application can be used with various numbers of corner blocking inserts  50 , such as 1, 2, 4, 8, or other numbers. If only a single corner blocking insert  50  is used, it is contemplated that it could engage multiple outer perimeter rims (i.e., each rim of the spool adjacent to the first and second face panels  14 ,  16 ) on both sides of the spool containing a coil of welding wire located within said box. If multiple corner blocking inserts  50  are used, then preferably all of the corner blocking inserts  50  are substantially identical, so as to be cost effective to manufacture. Use of the corner blocking inserts  50  will serve to reduce the impact on the side walls  18 - 24  of the box from the spool during transportation, and will further distribute impact energy that results from dropping the packaged spool. 
     Each corner blocking insert  50  is configured to contact both the interior walls of the container  10  and the outer perimeter rim  13  of the spool  12  to act as a buffer therebetween. The corner blocking insert  50  includes a profile that corresponds to, and is preferably complementary to, an outer perimeter rim  13  of a spool  12  containing a coil of welding wire located within the box. As also shown in  FIG. 3 , the coil of welding wire on each spool  12  can have an outer perimeter  15  defining an outer diameter W slightly less than that of the spool  12 . Preferably, the corner blocking insert  50  includes a profile that also corresponds to, and is preferably complementary to, the outer perimeter  15  of the coil of welding wire. Having the corner blocking insert  50  directly engage the outer perimeter  15  of the welding wire can help prevent the wire and core of the spool  12  from moving relative to the outer perimeter rim  13  of the spool, and help prevent the spool from deforming should the spool of wire be dropped. For example, the wire rim of a wire cage style spool as shown in dashed lines in  FIG. 1  can deform when dropped, due to the inertia of the welding wire at the core of the spool. Having the corner blocking insert  50  directly engage the outer perimeter  15  of the welding wire can help prevent deformation of the wire rim of the spool. In this manner, each corner blocking insert  50  acts as a buffer directly between the interior walls of the container  10  and the welding wire on each spool  12  at each corner void  49 . 
     Turning now to  FIG. 4 , in a first embodiment, the corner blocking insert  50  can comprise an expanding foam package  52  that is malleable when inserted into the cardboard box, and cures quickly to a rigid foam thereafter. One advantage is that the foam expands to fill substantially all available space in the corner void  49  of the container  10 , and provides a “custom form fit” against the spool and container interior. Another advantage is that the foam, once cured, provides a monolithic body that generally prevents both movement of the spool within its box and possible lancing of the box by the rim of the spool, and movement of the wire and core of the spool relative to the spool rim, which tends to deform the spool. 
     Preferably, the foam corner blocking insert  50  is provided as a self-contained package whereby the expanded foam is retained within a thin bag or other intermediary structure that acts as a barrier to enable the expanding foam to conform to the interior of the box and exterior of the spool, without the foam material itself seeping into and between the coil of welding wire. In this way, the many benefits of the foam are utilized while reducing clean-up upon opening the container  10 . Various types of foam packages may be utilized. In some examples, the foam package  52  may be a foam-in-bag packaging system sold under the trade name Instapak® by the company Sealed Air®, although other similar types of expanding foam may be used from other manufacturers. The foam packages  52  can be filled with the expanding foam material on-site immediately prior to use, or alternatively, the foam packages  52  can be self-contained packages that are pre-filled with expanding foam and which have chemical activation system required before use, such as a manual mixing of chemicals. 
     In either case, the foam package  52  generally includes a malleable bag  54  formed of plastic or other similar thin body material. Optionally, the bag  54  also comprises a stretchable material. The bag  54  initially contains un-cured foam material  56   a  and optionally an activator chemical (not shown). Mixing of the un-cured foam material  56   a  and activator causes a chemical reaction to occur whereby the foam begins to expand in size and volume, and ultimately cure into a substantially rigid foam  56   b . If the foam packages  52  are of the type that is filled with the expanding foam material  56   a  on-site immediately prior to use, then the activator chemical may similarly be added and/or mixed at that time. In this case, the bag  54  can include an opening  58 , such as at one end of the bag  54  or other suitable location, through which the foam material  56   a  and/or activator chemical can be received. Thereafter, the opening  58  can be sealed in various manners, such as by a heat seal, welding, adhesives, mechanical valve, clamp, or other fastener, etc. 
     When the foam package  52  is ready to use and the un-cured foam material  56   a  has been activated (i.e., begins the chemical reaction to expand and cure), the malleable foam package  52  is inserted into the container  10  at a corner void  49 . First, the frangible connection is breached along the sides  42 ,  44  of the pivotable flap  40 , and the flap  40  is then pulled outwards about the hinge side  38  to expose the aperture  30  (optionally, the flap  40  could be pushed inside the container  10 ). Next, the activated foam package  52  is inserted into the interior of the container  10  and is located at the corner void  49 . The foam package  52  may be located in abutment with the outer perimeter rim  13  of the spool  12  and/or outer perimeter  15  of the coil of welding wire, or in abutment with interior walls of the container  10  along the vertically extending corner  19 , or at a location intermediate these items. After the foam package  52  is inserted, the flap  40  may be pivoted back to the closed position thereby closing off the aperture  30 . Preferably, the flap  40  is then secured in place by application of an adhesive tape or the like applied to the exterior of the container  10  along the respective side wall  18 ,  20 ,  22 ,  24 . 
     At this time, the foam material  56   a  within the activated foam package  52  will be expanding in size and volume to fill the corner void  49 , and will begin to cure into the rigid foam  56   b . The foam package  52  should be selected and sized so that once the foam material  56   a  completely cures, the expanded, rigid foam  56   b  will substantially completely fill the corner void  49  and be in contact with the interior walls of the container  10  (e.g., as shown in  FIG. 4 , side walls  18  and  24 , and panels  14  and  16 ) as well as the outer perimeter rims  13 ,  15  of the spool  12  and welding wire coil, respectively, to act as a buffer therebetween. The cured foam package  52 B is shown schematically within the container  10  in  FIG. 4 . It is contemplated that during the curing process, the initially uncured foam is highly conformable to its environment and to the shapes it contacts, so that an outer profile of the finally cured foam corresponds to the spool containing a coil of welding wire located within said box. In this way, each foam package  52  will be custom-fit to the unique and specific geometry of each corner void  19  of each container  10 . This can be especially advantageous since the amount of welding wire contained on each spool  12  (and its ultimate diameter) may vary from item to item. Preferably, a total of four corner blocking inserts  50  (i.e., four foam package  52 ) is used at in the container  10  (i.e., one per each of the four corner voids  49 ). However, it is contemplated that less than four, such as two or even one, foam package  52  can be used. For example, two elongated foam packages  52  could be used that are of sufficient size to extend between and fill two corner voids (for example, one elongated foam package could extend along the entire length of side wall  24 , and fill the corner voids  49  at the intersection of side walls  18 ,  24 , and also at the intersection of side walls  22 ,  24 ). The use of such elongated foam packages  52  could be advantageous to reduce the number of flaps and apertures on the container  10 , as well as speed up the product packaging time. After the container  10  is delivered to the end customer and the spool  12  is removed from the container  10 , the corner blocking insert(s)  50  are discarded or recycled. 
     Turning now to  FIGS. 5-9 , in a second embodiment, the corner blocking insert  50  can comprise a folded cardboard insert  60 . Preferably, the folded cardboard insert  60  is a combination of two folded inserts so that the cardboard flutes are oriented in two perpendicular planes (i.e., 90 degrees to each other). This provides structural rigidity along two axes. With reference to the top view of  FIG. 5 , one edge  62  of the folded cardboard insert  60  has a curved, concave profile that mates against the wire spool  12 , against either or both of the outer perimeter rim  13  of the spool  12  and/or the outer perimeter  15  of the coil of welding wire. Two other edges  64 ,  66  of the folded cardboard insert  60  are generally straight and preferably perpendicular, and are configured to abut two adjacent interior vertical side walls  18 ,  20 ,  22 ,  24  of the container  10  when the folded cardboard insert  60  is installed in a corner voids  49  of the container  10 . Additionally, the corner intersection  61  of the folded cardboard insert  60  is positioned at the vertically extending corner  19  of the container  10 . For example, as shown in  FIG. 9 , the installed folded cardboard insert  60  can abut against the interior surface of side walls  18  and  24 . In this way, any force applied to the spool  12 , such as by a corner drop of the container  10 , are absorbed and supported by the folded cardboard insert  60  against the vertical side walls  18 ,  20 ,  22 ,  24 . 
     In the shown example, the curved edge  62  includes a curved or angled profile that has a radius substantially the same as that of the outer perimeter rim  13  of the spool  12 . In another example, the curved edge  62  may include a curved or angled profile that has radius substantially the same as the outer perimeter  15  of the coil of welding wire. In either case, the curved edge  62  preferably has a profile that also corresponds to, and is preferably complementary to, the outer perimeter rim  13  of the spool  12  or the exterior surface at the outer perimeter  15  of the coil of welding wire. Additionally, the curved or angled profile of the curved edge  62  can have a radius slightly less than that of the outer perimeter rim  13  of the spool  12  or the exterior surface at the outer perimeter  15  of the coil of welding wire so as to apply a resilient force upon the spool  12  and/or welding wire. Such a force, when applied by one or more corner blocking inserts  50 , can help to maintain the spool  12  in the center of the container  10 . Still, other profiles are contemplated. 
     Preferably, a total of four corner blocking inserts  50  (i.e., four folded cardboard inserts  60 ) are used at in the container  10  (i.e., one per each of the four corner voids  49 ). However, it is contemplated that less than four, such as two or even one, folded cardboard insert  60  can be used. Additionally, it is contemplated that the folded cardboard insert  60  can have various horizontal lengths and vertical thicknesses. In one example, as shown in  FIG. 9 , the length and width of the folded cardboard insert  60  is similar to, or preferably slightly smaller than, the size of the flap  40  and associated aperture  30 . That is, the folded cardboard insert  60  is generally similar in size to the major and minor sides  42 ,  44  so that the folded cardboard insert  60  can be readily inserted into the container  10  via the aperture  30 . However, it is contemplated that the folded cardboard insert  60  could have a size and geometry that is relatively larger than either or both of the flap  40  and associated aperture  30 ; in this case, the folded cardboard insert  60  could be inserted by re-orienting it during insertion and/or temporary compression during insertion, etc. For example, the insert  60  can be compressed down vertically during insertion to fit through the aperture  30 , and then expand (e.g., like an accordion) upward once inserted into the box. 
     Where the folded cardboard insert  60  has a vertical height similar to that of the aperture  30 , which is generally less than the height of the vertical side walls  18 ,  20 ,  22 ,  24 , the folded cardboard insert  60  is also less than the height of the vertical side walls  18 ,  20 ,  22 ,  24 . That is, absent the ability to expand as described above, it would not extend vertically within the container interior along the full extent of each of the four extending corners  19 , from apex  21  (at panel  14 ) to apex  21  (at panel  16 ), but instead would only float generally at a location therebetween. For example, the vertical position of the folded cardboard insert  60  can be generally in the middle of the vertical side walls  18 ,  20 ,  22 ,  24 , as shown in  FIG. 9 . The folded cardboard insert  60  can be sized to have a compressed fitting against the exterior of the spool  12  to thereby maintain its location within the corner void  49 . In other optional embodiments, any of the edges  62 ,  64 ,  66  of the folded cardboard insert  60  can include a pressure sensitive adhesive or the like that adhere to the interior of the container and/or exterior of the spool to help maintain the position. In yet another optional embodiment, the folded cardboard insert  60  may fall by gravity to the bottom of the corner void  49  and rest against one of the face panels  14 ,  16 . In a further embodiment, the insert  60  can expand vertically once inserted into the corner void  49  to generally fill the void and prevent radial movement of the spool and its wire core. 
     Turning now to  FIGS. 6 and 7A-7C , a side profile of the side edges  64 ,  66  is shown in greater detail. As noted above, the corner blocking insert  50  can comprise a folded cardboard insert  60 . Corrugated cardboard possesses increased strength and dimensional stability compared to un-corrugated (i.e. flat) webs of the same material. In particular, corrugated cardboard is strongest in the longitudinal direction of the corrugated flutes. Corrugated paperboard or cardboard is widely used in storage and shipping boxes and other packaging materials to impart strength. A typical corrugated cardboard structure known as single-wall includes a corrugated paperboard web comprising flutes sandwiched between opposing un-corrugated paperboard webs referred to as liners (i.e., two liners and one corrugated web). The opposing liners are adhered to opposite surfaces of the corrugated web to produce a composite corrugated structure, typically by gluing each liner to the adjacent flute crests of the corrugated web. This structure is manufactured initially in planar composite boards, which can then be cut, folded, glued or otherwise formed into a desired configuration to produce a box or other form for packaging. Additionally, a double-wall corrugated cardboard construction can be used, as shown in  FIG. 6 , which includes two corrugated webs connected together by three liners (two exterior liners, and one middle liner). Other configurations of corrugated cardboard (e.g., triple-wall, etc.) could also be used. 
     As noted above, folded cardboard insert  60  is a combination of two folded inserts so that the cardboard flutes of the corrugated web are oriented preferably in two perpendicular planes (i.e., 90 degrees to each other) that correspond to the two perpendicular vertical side walls  18 ,  20 ,  22 ,  24  of the container  10 . That is, the longitudinal direction of the corrugated flutes of the two folded inserts are oriented to be perpendicular to each other. In this way, the folded cardboard insert  60  has improved strength along both directions associated with the two perpendicular vertical side walls  18 ,  20 ,  22 ,  24  that the folded cardboard insert  60  abuts within the container  10 . However, it is contemplated that the cardboard flutes of the folded cardboard insert  60  could be oriented at different other angles relative to each other as may be desired. 
     As shown in  FIG. 6 , the folded cardboard insert  60  is a combination of two folded inserts, referred to as a first insert  70  and a second insert  80 . Although this embodiment will be described as being formed of two folded inserts, it is contemplated that three, four, or more inserts can be combined together as desired. In the example shown, the first insert  70  comprises three layers  71 ,  73 ,  75  that are interwoven with three corresponding layers  81 ,  83 ,  85  of the second insert  80 . That is, as shown, the three layers  71 ,  73 ,  75  are interleaved in an alternating pattern with the three corresponding layers  81 ,  83 ,  85 . The respective top and bottom faces of the layers  71 ,  73 ,  75  abut and are pressed against the top and bottom faces of the three corresponding layers  81 ,  83 ,  85 . 
     The first and second inserts  70 ,  80  are arranged relative to each other so that the longitudinal direction F 1  of the first corrugated flutes  76   a - 76   c  of the first insert  70  are arranged at an angle α, preferably perpendicular (i.e., 90 degrees), to the longitudinal direction F 2  of the second corrugated flutes  86   a - 86   c  of the second insert  80 . Due to the interleaved arrangement, it is understood that the first corrugated flutes  76   a ,  76   b ,  76   c  of the layers  71 ,  73 ,  75 , respectively, are all arranged are all oriented along the longitudinal direction F 1 , and similarly the second corrugated flutes  86   a ,  86   b ,  86   c  of the layers  81 ,  83 ,  85 , respectively, are all arranged are all oriented along the longitudinal direction F 2 . 
       FIGS. 7A-7C  illustrate various computer-generated perspective views of the corner blocking insert of  FIG. 6 . That is, while  FIG. 6  appears to show a more photographic corner blocking insert,  FIGS. 7A-7C  illustrate a more schematic depiction of the corner blocking insert rotated at various angles to show different sides thereof.  FIG. 7C  most closely resembles the orientation of  FIG. 6 . Additionally, it is appreciated that while  FIG. 6  illustrates the corrugated flutes of the layers and their corresponding orientation, such flutes are not illustrated in  FIGS. 7A-7C . However, it is understood that one of skill in the art could readily understand the position and orientation thereof from the illustration of  FIG. 6  and the written description herein. 
     Turning now to  FIG. 8 , one example construction of the folded cardboard insert  60  will be described. Preferably, the folded cardboard insert  60  will be constructed from a single planar composite board or sheet  90  from which both of the first insert  70  and the second insert  80  are cut out. That is, as shown, the single planar sheet  90  can be a unitary, continuous sheet that has selected portions cut out and discarded to provide the specific shape of each of the first and second inserts  70 ,  80 . Preferably, the shape and size of the first and second inserts  70 ,  80  are identical, although reversed for efficient space usage of the single planar sheet. Further, in the example shown in  FIG. 8 , the single planar sheet  90  is of a size capable of provide a similar or identical second cardboard insert  60 B with first and second inserts  70 B,  80 B. Depending on the size and geometry of the single planar sheet  90 , various numbers of sheets for folded cardboard inserts can be obtained. For brevity, only construction of one folded cardboard insert  60  will be described. 
     Each of the first and second inserts  70 ,  80  are a continuous, unitary element that will be folded together to obtain the final folded cardboard insert  60 . That is, the three layers  71 ,  73 ,  75  of the first insert  70  are interconnected to each other along two fold points, a primary fold point  72  along one of the long edges  64 ,  66 , and a secondary fold point  74  along one of the short edges along the curved edge  62 . Preferably, the primary fold point  72  is positioned to correspond to the center of one of the long edges  64 ,  66  of the folded cardboard insert  60 , and the secondary fold point  74  is positioned to correspond to the center or vertex of the curved edge  62  of the folded cardboard insert  60 . 
     When the first insert  70  is cut out of the planar sheet  90 , a spacing gap  76  is defined between the layers  71 ,  73 . The spacing gap  76  has a width that is generally similar to a thickness of the alternate layer  81  that will be interposed the layers  71 ,  73 . The cut out spacing gap  76  does not include a flap  77  that is defined by the primary fold point  72 . Instead, the primary fold point  72  is defined by the flap  77  that interconnects layer  71  and layer  73 . Optionally, one or more side edges of the flap  77  can include slits at the respective connection to the layers  71 ,  73  to facilitate the folding over of the primer fold point  72 . In order to make the folded cardboard insert  60  compact, and further strengthen the connection between the first and second inserts  70 ,  80 , another long side of layer  75  (i.e., the layer that is interconnected by the secondary fold point  74 ) may include a cut out  79  that corresponds generally to the shape and location of the flap  87  of the opposite layer, as will be described. 
     Similarly, the second insert  80  also includes substantially identical layers  81 ,  83 ,  85 , with a primary fold point  82  and secondary fold point  84 , as well as spacing gap  86 , flap  87 , and cut-out  89 . 
     Once the first and second inserts  70 ,  80  are cut out, they can then be folded and interleaved together to form the folded cardboard insert  60 . It is to be appreciated that to obtain the configuration wherein the first corrugated flutes  76   a - 76   c  of the first insert  70  (longitudinal direction F 1 ) are arranged perpendicular to the second corrugated flutes  86   a - 86   c  of the second insert  80  (longitudinal direction F 2 ), the first and second inserts  70 ,  80  are arranged and folded opposite to each other. 
     To create the folded cardboard insert  60 , the layer  71  is folded over to be co-facial over layer  73  at the primary fold point  72 . Due to the spacing gap  76 , a space or void is created between layers  71  and  73 . layer  81  of second insert  80  is then inserted into this gap or void between layers  71 ,  73  and is oriented so that the longitudinal flutes of layer  81  are arranged perpendicular to the longitudinal flutes of both of layers  71 ,  73 . Additionally, the flap  77  defining the primary fold point  72  is disposed within the corresponding cut-out  89  of layer  81 . 
     Next, layer  81  is folded over the secondary fold point  84  so that layer  83  is disposed underneath and co-facial with layer  73 . Again, the longitudinal direction of the flutes of layer  83  is oriented perpendicular to the flutes of layers  71 ,  73 . Next layer  83  is folded over the primary fold point  82  so that there is a spacing gap between layers  83 ,  85 . Lastly layers  73 ,  75  are folded over the secondary fold point  74  and layer  75  is interposed between layers  83 ,  85 . Again the flap  87  of the primary fold point  82  is inserted into the cut-out  79  of layers  75 . Preferably, the cut-outs  79 ,  89  are generally equal in width, or even slightly smaller, than the width of the corresponding flaps  77 ,  87  so that friction can help to hold the flaps  77 ,  87  in place. 
     Construction of the folded cardboard insert  60  is now complete. Due to this opposite and alternating folded construction, all of the corrugated flutes  76   a - 76   c  of layers  71 ,  73 ,  75  are oriented perpendicular to the corrugated flutes  86   a - 86   c  of layers  81 ,  83 ,  85 . Additionally, insertion of the flaps  77 ,  87  into the corresponding cut-outs  79 ,  89  further help to maintain attachment of the first insert  72  to the second insert  80 . Optionally, adhesives and/or glues may be used between any of the various layers of layers  71 ,  73 ,  75 ,  81 ,  83 ,  85 , and/or various tapes may be used externally to maintain the assembled unitary body construction and shape of the folded cardboard insert  60 . 
     Optionally, it is possible for further cutouts in the various layers of layers  71 ,  73 ,  75 ,  81 ,  83 ,  85  of either or both of the first and second inserts  70 ,  80  to create a hollow interior within the interior of the completed folded cardboard insert  60  to provide spacing for an impact “crush zone.” Thus, if the container  10  is accidentally dropped, the resulting force impact that may occur on a corner  19  of the container  10  may be at least partially absorbed by a deformation of the impact “crush zone”, without allowing the rim of the wire spool to lance through or puncture the shipping box. 
     Turning out to  FIGS. 10-11 , final packaging of the container  10  for shipment will be described. The spool  12  of welding wire to be shipped to a customer is placed within the container  10 , and then the corner blocking insert(s)  50  are inserted into the corner voids  49  of the container  10  as previously described herein. The container  10  is then placed in an overwrap assembly. As shown in  FIG. 10 , the overwrap assembly may comprise a two-piece crate comprising a pair of malleable cradles  100  that are positioned external to each side of the container  10 . In one example, and malleable cradle comprises a rigid, but malleable foam material contained preferably within a plastic outer wrap (e.g., a shrink-wrapped rigid foam). 
     The malleable cradle  100  preferably has a shape complementary to the exterior shape of the container  10 , and provides shock absorbency in along all faces of the container  10 . The malleable cradle  100  comprises an outer ring  102 A- 102 D that extends along all four vertical side walls  18 ,  20 ,  22 ,  24  of the container  10 . The interior wall surfaces of the outer ring  102 A- 102 D may optionally include slots or recesses to facilitate insertion and extraction of the container  10  into/from the malleable cradle  100 . The malleable cradle  100  further comprises a central recess  104  sized to accept the container  10  in a snug, form-fitting fashion. The central recess  104  is defined by and bounded by the outer ring  102 A- 102 D. The planar bottom surface  106  of the central recess  104  is configured to support and extend along face  14  or  16  of the container  10 . Additionally, surface  106  further comprises a rigid backing plate  110  that extends across a majority of surface  106 . The rigid backing plate  110  can be substantially more rigid relative to the malleable material of the malleable cradle  100 . In one example, the backing plate  110  comprises a wood sheet, such as OSB, plywood, or chipboard. When the malleable cradle  100  is constructed, the rigid backing plate  110  is placed within the recess  104  before the foam material of the shell is encapsulated by the outer plastic wrap, thereby securely affixing the backing plate  110  to the bottom surface  106 . 
     The purpose of the rigid backing plate  110  is to effectively transfer the forces that occur during a corner edge drop of the container  10  into a radial load so that said forces are successfully directed to and absorbed by the corners of the malleable cradle  100 . That is, the impact force experienced during a corner edge drop of the container  10  is translated linearly across the backing plate  110  and is thereby directed specifically into one or more of the corner blocking inserts  50 . The rigid backing plate  110  may also directly protect faces  14 ,  16  of the container  10 . Moreover, during flat face drops, the rigid backing plate  110  also protects the flange portions of the wire spool from deformation or breakage due to the coil of wire tending to punch through the flange portions. The rigid backing plate  110  is interposed between the resiliency of the cradle and the face of the shipping carton (and by extension the flange portions of the wire spool), to prevent the core of wire from moving relative to the flange portions of the spool and deforming or breaking the flange portions. 
     Turning now to  FIG. 11 , in preparation for shipping the container  10  is inserted into the recess  104  of the malleable cradle  100 . Preferably, a height of the outer ring  102 A- 102 D is approximately half the total height of the container  10  between the apex  21  of the vertical side walls  18 ,  20 ,  22 ,  24 . Thereafter a second and substantially identical malleable cradle  100  is placed on top of the container  10 , whereby the container  10  is now completely encapsulated by the two malleable cradles  100 . This effectively creates the two-piece crate where the container  10  is held in the center of a pair of rigid foam packing protectors (one on top, one on bottom) that completely encapsulate the container  10 . It is appreciated that in  FIG. 11 , only malleable cradle  100  is shown for clarity. Lastly, the combined assembly of the two malleable cradles  100  with the container  10  is then placed within an outer cardboard box (not shown), which is sealed and finally shipped to a customer. It is appreciated that the fully packaged assembly may be shipped directly and/or placed on a pallet with other similar boxes for bulk shipment. 
     Preferably, the container  10  is formed from corrugated cardboard material and the corner blocking inserts  50  are formed, as discussed herein either from expanding foam or from arranged corrugated cardboard material (or even a strengthened paperboard material). After the container is used, some or preferably all parts of the box can be recycled. Still, other materials are contemplated. 
     The invention has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Examples embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.