Patent Publication Number: US-7905439-B2

Title: Apparatus and method for tapered core drum package payoff

Description:
TECHNICAL FIELD 
     Certain embodiments relate to paying off a coil of wire. More particularly, certain embodiments relate to arrangements and methods for paying off wire from a welding wire stack. 
     BACKGROUND 
     Welding wire for electric arc welding is typically provided in a box or drum referred to as a payout drum package. The wire sits in the drum package, for example, coiled on a reel or spool and is referred to as the wire stack. A cover is attached to the drum package having a conduit attached to the cover. The wire is pulled through the conduit by a wire feeder of the welding machine and is used as an electrode in electric arc welding, for example. The term “pay off” is used in the wire industry and means pulling the wire out of the drum/box package or off the reel/spool. 
     When a welding wire is withdrawn or payed off from a welding wire stack residing in a payout drum package during an electric arc welding operation, for example, the spirals of the welding wire may tend to flip causing cork screws which result in tangling of the wire. Also, the stack may move within the drum with respect to the opening in the cover where the conduit is attached. Such movement of the wire stack with respect to the conduit may change the tension on the wire causing poor wire feedability and preventing smooth pay off. Such unwanted occurrences can reduce, if not totally destroy, welding effectiveness. 
     Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such systems and methods with the present invention as set forth in the remainder of the present application with reference to the drawings. 
     BRIEF SUMMARY 
     A first embodiment of the present invention comprises a welding wire payoff arrangement. The welding wire payoff arrangement includes a base plate and a tapered core centrally connected to the base plate. The base plate may include a plurality of tab receptors and the tapered core may include a plurality of tabs adapted to be received into the plurality of tab receptors of the base plate to centrally connect the tapered core to the base plate. The base plate may be substantially octagonal in shape and the tapered core may include two slots on opposing surfaces of the tapered core for receiving a rod through the tapered core. The welding wire payoff arrangement may include a payout drum package in which the connected base plate and tapered core reside. A wire stack may reside in the payout drum package such that the wire stack rests on the base plate and the tapered core protrudes through a centrally open region of the wire stack. A first diameter or width of the unconnected end of the tapered core is less than a second diameter or a second width of a connected base end of the tapered core. 
     Another embodiment of the present invention comprises a method of assembling a welding wire source. The method includes centrally connecting a tapered core to a base plate to form a first assembly. The method further includes placing the first assembly into a payout drum package such that the tapered core is substantially centered within the payout drum package. The method also includes placing a coiled wire stack into the payout drum package over the tapered core such that the wire stack rests on the base plate and the tapered core protrudes through a centrally open region of the wire stack. The method may further include inserting a holding member through the tapered core such that the holding member sits on top of the wire stack, and attaching at least one tension member between the holding member and the base plate or a bottom surface of the payout drum package such that the tension member pulls the holding member against the wire stack. The holding member may comprise a steel rod and the tension member may comprise a rubber band. The method may further include releasing a wire of the wire stack such that the wire spirals upward around the tapered core and feeding an end of the released wire through an opening in a cover. The method may further include attaching the cover to the payout drum package, feeding the end of the released wire through a conduit, and attaching the conduit to the cover. 
     A further embodiment of the present invention comprises a welding wire payoff arrangement. The welding wire payoff arrangement includes a tapered core means for spirally guiding a wire payed off from a wire stack. The welding wire payoff arrangement further includes a base means for centrally supporting the tapered core means within a payout drum package. The base means may include at least one first connector means for connecting the tapered core means to the base means. The tapered core means may include at least one second connector means for connecting the tapered core means to the base means via the first connector means. The base means may be substantially octagonal in shape. The rod means may be provided for securing the wire stack within the payout drum package. Two opening means may be present on opposing surfaces of the tapered core means for receiving the rod means through the tapered core means. A first diameter or a first width of a first end of the tapered core means may be less than a second diameter or a second width of a second end of the tapered core means. 
     These and other advantages and novel features of the present invention, as well as details of illustrated embodiments thereof, will be more fully understood from the following description and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an illustration of an embodiment of a welding wire assembly or welding wire source; 
         FIG. 2  is an exploded view of the welding wire assembly of  FIG. 1 ; 
         FIG. 3  is an illustration of a side view of an embodiment of a tapered core centrally connected to a base plate as used in the welding wire assembly of  FIG. 1  and  FIG. 2 ; 
         FIG. 4  is an illustration of a top view of an embodiment of the base plate shown in  FIG. 3 ; 
         FIG. 5  is an illustration of an unfolded side view of an embodiment of the tapered core shown in  FIG. 3 ; 
         FIGS. 6A-6B  are illustrations of an embodiment of a holding member and a tension member as used during shipment of at least a portion of the welding wire assembly of  FIG. 1 ; 
         FIG. 7  is a flowchart of a first embodiment of a method of assembling a welding wire source for shipment; 
         FIG. 8  is a flowchart of a first embodiment of a method of assembling a welding wire source for use in welding; 
         FIG. 9  is an illustration of a first embodiment of a wire guide insert as may be used in the welding wire assemby of  FIG. 1  and  FIG. 2 ; 
         FIG. 10  is a flowchart of a second embodiment of a method of assembling a welding wire source for shipment; 
         FIG. 11  is a flowchart of a second embodiment of a method of assembling a welding wire source for use in welding; 
         FIGS. 12A-12B  illustrate two unfolded views of a second embodiment of a wire guide insert capable of being used in the welding wire assembly of  FIG. 1  and  FIG. 2 ; 
         FIGS. 13A-13C  are illustrations of several folded views of the second embodiment of the wire guide insert of  FIGS. 12A-12B ; and 
         FIG. 14  is an illustration of a side view of an embodiment of a tapered core centrally connected to a base plate as used in the welding wire assembly of  FIG. 1  and  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is an illustration of an embodiment of a welding wire assembly  100  (also referred to herein as a welding wire source).  FIG. 2  is an exploded view of the welding wire assembly  100  of  FIG. 1 . The welding wire assembly  100  includes a payout drum package  110 , a cover  120 , a welding wire stack  130 , a base plate  140 , a tapered core  150 , and optionally a wire guide insert  160 . In certain embodiments, the wire guide insert  160  may or may not be used. 
     The tapered core  150  is connected to the base plate  140  at a center of the base plate  140 . The base plate  140  may be placed to rest within the payout drum package  110  on the bottom interior surface of the payout drum package  110  such that the tapered core  150  is substantially centered within the payout drum package  110 . The base plate  140  is relatively flat and the edges of the base plate  140  fit snug against the side walls of the payout drum package  110  to prevent lateral movement of the base plate  140  and connected tapered core  150  within the drum package  110 . 
     In accordance with an embodiment of the present invention, the base plate  140  is octagonal in shape. Furthermore, the inner surface of the drum package  110  may be octagonal in shape as well, as shown in  FIG. 1 , to match the octagonal base plate  140 . Such an octagonal shape of the interior surface of the drum package  110  helps to better hold a circular wire stack  130  in place when the outer diameter of the wire stack  130  substantially matches the inner diameter or width of the octagonal interior surface of the drum package  110 . 
     The wire stack  130  may be placed over the tapered core  150  such that the wire stack  130  rests on the base plate  140  within the drum package  110  and such that the tapered core  150  protrudes upward through a centrally open region  133  of the wire stack  130 . The wire stack  130  has an inner diameter and an outer diameter where the outer diameter of the wire stack  130  is substantially the same as the inner diameter or inner width of the drum package  110  such that the wire stack  130  does not tend to move laterally within the drum package  110 . 
     The cover  120  attaches to the top of the drum package  110 . In accordance with an embodiment, the cover is made of a transparent plastic material. The cover  120  has an opening  125  in the top where a conduit  170  may be connected via a connector  175 . The wire from the wire stack  130  spirals upward around the tapered core  150  and is fed through the opening  125  when the wire is payed off. The conduit  170  guides the wire toward a wire feeder of a welding machine, in accordance with an embodiment of the present invention. 
     As the wire is payed off from the wire stack  130 , the tapered core  150  remains in the center of the drum package  110 . The tapered core  150  has a first diameter or width at its top end which is smaller or less than a second diameter or width at its base end (i.e., the tapered core is tapered). The tapered core  150  provides a smooth pay off of the wire from the drum package  110 . The tapered core  150  applies enough tension on the wire to prevent the wire from flipping, which may cause cork screws and tangles in the wire. Keeping the tapered core  150  centered in the drum package  110  and, therefore, with respect to the opening  125  in the cover  120  also helps to provide for a smooth pay off. 
       FIG. 3  is an illustration of a side view of an embodiment of a tapered core  150  centrally connected to a base plate  140  as used in the welding wire assembly  100  of  FIG. 1  and  FIG. 2 .  FIG. 4  is an illustration of a top view of an embodiment of the base plate  140  shown in  FIG. 3 .  FIG. 5  is an illustration of an unfolded side view of an embodiment of the tapered core  150  shown in  FIG. 3 . The unfolded tapered core  150  of  FIG. 5  may be folded around to form the folded tapered core  150  of  FIG. 1  and  FIG. 2 . In accordance with an embodiment of the present invention, upon folding around, tabs  156  may be inserted into tab receptors  157  to secure the tapered core  150  in a folded state. Other means of securing the tapered core  150  in a folded state are possible as well. For example, the one side edge of the tapered core  150  may be glued to the other side edge of the tapered core  150 . The tapered core  150  may have a plurality of corrugated sides as shown in  FIG. 1  and  FIG. 5 . 
     The base plate  140  may include a plurality of tab receptors  145 . The tapered core  150  may include a plurality of tabs  155  adapted to insert (be received) into the plurality of tab receptors  145  in order to connect the tapered core  150  to the base plate  140 . Again, the tapered core  150  may be substantially centered with respect to the base plate  140 . 
     Other means may be provided to connect the tapered core  150  to the base plate  140 . For example, the tapered core  150  may be glued to the base plate  140 , or the tapered core  150  and the base plate  140  may be a single integrated piece, such as from a mold, for example. The tapered core  150  and base plate  140  may be made of cardboard, plastic, or any other material suitable for providing the functionality of the tapered core  150  and base plate  140 . The tapered core  150  may be hollow or solid, in accordance with various embodiments. 
     The tapered core  150  may include opposing slots  151  on each side of the tapered core  150  for accepting a holding member such as a steel rod.  FIGS. 6A-6B  illustrate an embodiment of a holding member  610  and a tension member  620  as used during shipment of at least a portion of the welding wire assembly  100  of  FIG. 1 .  FIG. 6A  is an exploded view of the shipping assembly  600  shown in  FIG. 6B . 
     Again, the tapered core  150  is connected to the base plate  140  and placed into the payout drum package  110 . The wire stack  130  is placed over the tapered core  150  and into the drum package  110 , resting on the base plate  140 . A holding member  610  (e.g., a steel rod) is inserted through the tapered core  150  via the slots  151  such that the holding member  610  rests on top of the wire stack  130 . A tension member  620  (e.g., a rubber band) is connected between the holding member  610  and the base plate  140  or the bottom of the drum package  110  such that the tension member  620  pulls the holding member  610  against the wire stack  130 . This helps hold the wire stack  130  in place during shipment, helping to avoid damage to the wire stack. Alternatively, two or more tension members  620  may be used (e.g., one on each side of the holding member  610 ). The drum package  110  includes a flat lid or flat top cover to enclose the drum package  110  during shipment. The flat lid may simply comprise four cardboard flaps attached to the sides of the drum package  110  which may be folded closed. 
     As an example of use of a tension member  620 , a first end of a rubber band may loop around the holding member  610 , and a second end of the rubber band may hook to a catch at the bottom of the drum package  110 . An opening may be provided in the base plate  140  to provide access to the catch. In accordance with certain embodiments of the present invention, the tension member  620  may be connected between the holding member  610  and the base plate  140  (or bottom surface of the drum package  110 ) before the tapered core  150  is connected to the base plate  140 , which may be more practical to accomplish in some embodiments. 
     In accordance with various embodiments, the holding member  610  may comprise a rod of metal (e.g., steel), plastic, or some other suitable material. The holding member  610  may instead comprise a flat plate and the slots  151  may be oriented horizontally instead of vertically, for example, to accommodate the flat plate. Furthermore, in accordance with various embodiments, the tension member may comprise a rubber band, an elastic strap, a bungee cord, a spring, or some other suitable tension member. 
     After shipment of the assembly  600 , the drum package may be opened and the holding member  610  may be removed (e.g., by simply pulling the holding member  610  through the tapered core  150  via the slots  151 ) and the wire from the wire stack  130  may be released to spiral up around the tapered core  150 . Again, the end of the wire may be fed through an opening  125  in a cover  120  to which a conduit  170  is attached. The cover  120  may then be secured to the top of the payout drum package  110 , for example, via clips  115  or some other securing means. 
       FIG. 7  is a flowchart of a first embodiment of a method  700  of assembling a welding wire source  600  for shipment. In step  710 , centrally connect a tapered core  150  to a base plate  140  to form a first assembly. In step  720 , place the first assembly into a payout drum package  110  such that the tapered core  150  is substantially centered within the payout drum package  110 . In step  730 , place a coiled wire stack  130  into the payout drum package  110  over the tapered core  150  such that the wire stack  130  rests on the base plate  140  and the tapered core  150  protrudes through a centrally open region  133  of the wire stack  130 . In step  740 , insert a holding member  610  through the tapered core  150  such that the holding member  610  sits on top of the wire stack  130 . In step  750 , attach at least one tension member  620  between the holding member  610  and the base plate  140  or a bottom surface of the payout drum package  110  such that the tension member  620  pulls the holding member  610  against the wire stack  130 . 
     These steps may be performed in this order or in another order as may be practical to do so. For example, the tension member  620  may be connected between the holding member  610  and the base plate  140  before the tapered core  150  is connected to the base plate  140 . Furthermore, any given step may be divided into at least two sub-steps as may be practical to do so. For example, a first end of the tension member  620  may be first connected to the base plate  140 , then a second end of the tension member  620  may be connected to (e.g., placed around) the holding member  610 . Also, an additional step or steps may be performed in between any two successive steps. For example, the tension member  620  may be significantly stretched before connecting the tension member  620  between the holding member  610  and the base plate  140 . Again, in accordance with various embodiments of the present invention, more than one tension member may be used. In certain embodiments, the tapered core  150  and the base plate  140  may be a single integral piece (first assembly), such as when molded. In such an embodiment, the step of centrally connecting the tapered core to the base plate need not be performed. 
       FIG. 8  is a flowchart of a first embodiment of a method  800  of assembling a welding wire source  100  for use in welding. In step  810 , centrally connect a tapered core  150  to a base plate  140  to form a first assembly. In step  820 , place the first assembly into a payout drum package  110  such that the tapered core  150  is substantially centered within the payout drum package  110 . In step  830 , place a coiled wire stack  130  into the payout drum package  110  over the tapered core  150  such that the wire stack  130  rests on the base plate  140  and the tapered core  150  protrudes through a centrally open region  133  of the wire stack  130 . In step  840 , release a wire of the wire stack  130  such that the wire spirals upward around the tapered core  150 . In step  850 , feed an end of the released wire through an opening  125  in a cover  120 . In step  860 , attach the cover  120  to the payout drum package  110 . In step  870 , feed the end of the released wire through a conduit  170 . In step  880 , attach the conduit  170  to the cover  120 . The conduit  170  may attach to the cover  120  via a male/female type screw-on connection  175 , for example. 
     Again, these steps may be performed in this order or in another order as may be practical to do so. For example, the base plate  140  may be placed into the drum package  110 , and then the tapered core  150  may be connected to the base plate  140 . Furthermore, any given step or steps may be divided into at least two sub-steps, or combined into one step, as may be practical to do so. For example, the end of the wire may be fed through both the cover  120  and the conduit  170  essentially at the same time in a single step if the conduit  170  is first connected to the cover  120 . Also, an additional step or steps may be performed in between any two successive steps. For example, a holding member  610  may be removed from the tapered core  150  before releasing a wire of the wire stack  130 . In certain embodiments, the tapered core  150  and the base plate  140  may be a single integral piece (first assembly), such as when molded. In such an embodiment, the step of centrally connecting the tapered core to the base plate need not be performed. 
       FIG. 9  is an illustration of a first embodiment of a wire guide insert  160  as may be used in the welding wire assembly  100  of  FIG. 1  and  FIG. 2 . The wire guide insert  160  (also generically referred to as a welding wire payoff arrangement herein) includes a base portion  910  having a first opening  911  located substantially in a central location of the base portion  910 . The wire guide insert  160  also includes a top portion  920  being spatially offset from the base portion  910  and having a second opening  921  being smaller than the first opening  911 , and being substantially aligned with the first opening  911  as shown by the dashed line  915 . The wire guide insert  160  further includes an offset portion  930  connected between the top portion  920  and the base portion  910  for maintaining a spatial offset  935  between the top portion  920  and the base portion  910 . 
     In accordance with an embodiment of the present invention, the base portion  910  is substantially longer than the top portion  920  and the base portion  910  is substantially parallel to the top portion  920 . The offset portion  930  is angled with respect to the parallel top and base portions such that the top portion  920 , the base portion  910 , and the offset portion  930  characterize a substantially truncated triangular volume. 
     In accordance with an embodiment of the present invention, the offset portion  930  and the top portion  920  may be all one integral piece which is then connected to the base portion  910  (e.g., by snapping or glueing). As an alternative, the base portion  910 , the offset portion  930 , and the top portion  920  may all be one integral piece. Other piecewise or integral constructions are possible as well that characterize a substantially truncated triangular volume. 
     Referring to  FIG. 1  and  FIG. 2 , the top portion  920  may be connected inside the cover  120  such that the opening  921  is adjacent to and substantially aligned with the opening  125  in the cover  120 . The wire from the wire stack  130  may be fed upward from around the tapered core  150 , through the opening  911 , through the opening  921 , and through the opening  125  and into the conduit  170 . 
     When connected to the cover  120 , the angled offset portions  930  of the wire guide insert  160  substantially follow a contour of an interior surface of the cover  120 . This allows the wire guide insert  160  to just fit up into the interior of the cover  120 . The base portion  910  of the wire insert guide  160  helps to hold the spirals of wire off of the wire stack  130  down around the tapered core  150 , helping to provide the desired tension on the wire for smooth pay off. The wire guide insert  160  effectively bridges the gap across the inside of the cover  120  to prevent the wire loops (spirals) from springing up. The wire guide insert  160  may be made of thermoformed plastic or cardboard, or any other suitable material. 
       FIG. 10  is a flowchart of a second embodiment of a method  1000  of assembling a welding wire source for shipment. In step  1010 , centrally connect a tapered core  150  to a base plate  140  to form a first assembly. In step  1020 , place the first assembly into a payout drum package  110  such that the tapered core  150  is substantially centered and laterally immovable within the payout drum package  110 . In step  1030 , place a coiled wire stack  130  into the payout drum package  110  over the tapered core  150  such that the wire stack  130  rests on the base plate  140  and the tapered core  150  protrudes upward through a centrally open region  133  of the wire stack  130 . 
     In step  1040 , connect a wire guiding structure  160 , having a base portion  910  which is longer than a top portion  920 , to an interior portion of a cover  120  such that a first opening  911  in the base portion  910 , a second opening  921  in the top portion  920 , and a third opening  125  in the cover are substantially aligned. In step  1050 , insert a holding member  610  through the tapered core  150  such that the holding member  610  sits on top of the wire stack  130 . In step  1060 , attach at least one tension member  620  between the holding member  610  and the base plate  140  or a bottom surface of the payout drum package  110  such that the tension member  620  pulls the holding member  610  against the wire stack  130 . 
     Again, these steps may be performed in this order or in another order as may be practical to do so. For example, the tension member  620  may be connected between the holding member  610  and the base plate  140  before the tapered core  150  is connected to the base plate  140 . Furthermore, any given step may be divided into at least two sub-steps as may be practical to do so. For example, a first end of the tension member  620  may be first connected to the base plate  140 , then a second end of the tension member  620  may be connected to (e.g., placed around) the holding member  610 . Also, an additional step or steps may be performed in between any two successive steps. For example, the tension member  620  may be significantly stretched before connecting the tension member  620  between the holding member  610  and the base plate  140 . Again, in accordance with various embodiments of the present invention, more than one tension member may be used. In certain embodiments, the tapered core  150  and the base plate  140  may be a single integral piece (first assembly), such as when molded. In such an embodiment, the step of centrally connecting the tapered core to the base plate need not be performed. 
       FIG. 11  is a flowchart of a second embodiment of a method  1100  of assembling a welding wire source  100  for use in welding. In step  1110 , centrally connect a tapered core  150  to a base plate  140  to form a first assembly. In step  1120 , place the first assembly into a payout drum package  110  such that the tapered core  150  is substantially centered and laterally immovable within the payout drum package  110 . In step  1130 , place a coiled wire stack  130  into the payout drum package  110  over the tapered core  150  such that the wire stack  130  rests on the base plate  140  and the tapered core  150  protrudes upward through a centrally open region  133  of the wire stack  130 . 
     In step  1140 , connect a wire guiding structure  160 , having a base portion  910  which is longer than a top portion  920 , to an interior side of a cover  120  such that a first opening  911  in the base portion  910 , a second opening  921  in the top portion  920 , and a third opening  125  in the cover  120  are substantially aligned. In step  1150 , release a wire of the wire stack  130  such that the wire spirals upward around the tapered core  150 . In step  1160 , feed an end of the released wire through the first opening  911 , the second opening,  921 , and the third opening  125 . In step  1170 , attach the cover  120  to the payout drum package  110 . In step  1180 , feed the end of the release wire through a conduit  170 . In step  1190 , attach the conduit  170  to the cover  120  adjacent to the third opening  125 . The conduit  170  may attach to the cover  120  via a male/female type screw-on connection  175 , for example. 
     Again, these steps may be performed in this order or in another order as may be practical to do so. For example, the base plate  140  may be placed into the drum package  110 , and then the tapered core  150  may be connected to the base plate  140 . Furthermore, any given step or steps may be divided into at least two sub-steps, or combined into one step, as may be practical to do so. For example, the end of the wire may be fed through both the cover  120  and the conduit  170  essentially at the same time in a single step if the conduit  170  is first connected to the cover  120 . Also, an additional step or steps may be performed in between any two successive steps. For example, a holding member  610  may be removed from the tapered core  150  before releasing a wire of the wire stack  130 . In certain embodiments, the tapered core  150  and the base plate  140  may be a single integral piece (first assembly), such as when molded. In such an embodiment, the step of centrally connecting the tapered core to the base plate need not be performed. 
       FIGS. 12A-12B  are illustrations of two unfolded views of a second embodiment of a wire guide insert  1200  capable of being used in the welding wire assembly  100  of  FIG. 1  and  FIG. 2 . The wire guide insert  1200  performs the same function in the welding wire source  100  as the wire guide insert  160  previously described herein.  FIG. 12A  is a top view and  FIG. 12B  is a perspective view. 
     The wire guide insert  1200  (also generically referred to as a welding wire payoff arrangement or welding wire structure herein) includes a base means  1210  for holding down spirals of coiled wire payed off from a wire stack  130  within a payout drum package  110 . The base means  1210  has a first opening  1211  for guiding the wire through the base means  1210  as the wire is payed off from the wire stack  130 . The wire guide insert  1200  also includes a first top means  1220  offset from the base means  1210  for receiving the wire from the base means  1210  as the wire is payed off. The first top means  1220  has a second opening  1221  for guiding the wire through the first top means  1220  toward a cover  120  of the payout drum package  110  as the wire is payed off. The cover  120  has a fourth opening means  125  as previously described herein. 
     The wire guide insert  1200  also includes a first offset means  1230  hingedly connecting the base means  1210  to the first top means  1220  at hinged points  1231  and  1232 . The wire guide insert  1200  further includes a second top means  1240  spatially offset from the base means  1210  for receiving the wire from the first top means  1220  as the wire is payed off. The second top means  1240  has a third opening means  1241  for guiding the wire through the second top means  1240  toward the cover  120  as the wire is payed off. The wire guide insert  1200  also includes a second offset means  1250  hingedly connecting the base means  1210  to the second top means  1240  at hinged points  1251  and  1252 . 
     The base means  1210  is substantially longer than either of the top means  1220  or  1240 . The length and other dimensions of the first top means  1220  and the second top means  1240  are substantially the same. The base means  1210 , the first offset means  1230 , the second offset means  1250 , the first top means  1220 , and the second top means  1240  are capable of being hingedly unfolded with respect to each other to characterize a substantially outstretched surface as shown in  FIGS. 12A-12B . Such an outstretched configuration may result when manufacturing the wire guide insert  1200 , and the wire guide insert  1200  may be shipped (not yet connected to a cover  120 ) in such an outstretched manner. 
       FIGS. 13A-13C  are illustrations of several folded views of the second embodiment of the wire guide insert  1200  of  FIGS. 12A-12B , as would be used in the welding wire arrangement  100  of  FIGS. 1-2 . The base means  1210 , the first offset means  1230 , the second offset means  1250 , the first top means  1220 , and the second top means  1240  are capable of being hingedly folded with respect to each other to characterize a substantially truncated triangular volume as shown in  FIGS. 13A-13C . 
     The hinged points  1231 ,  1232 ,  1251  and  1252  may comprise, for example, flexible plastic that is easily folded or may comprise actual hinges that are connected between the base means and offset means and the offset means and the top means. In accordance with an embodiment of the present invention, the wire guide insert  1200  is all one molded piece made of a plastic material. Other materials are possible as well such as, for example, cardboard. 
     The opening means  1211  is substantially larger than either of the opening means  1221  and  1241 , in accordance with an embodiment of the present invetion. When folded, the first top means  1220 , the second top means  1240 , and the cover  120  are capable of being configured such that the first opening means  1211 , the second opening means  1221 , the third opening means  1241 , and the fourth opening means  125  are substantially aligned. The wire guiding structure  1200  connects to the cover  120  in much the same manner as the wire guiding insert  160  (see  FIGS. 1-2 ) and serves the same purpose. 
     When folded, the second top means  1240  overlaps onto the first top means  1220  and may snap onto the first top means  1220  to hold the structure  1200  together in the folded configuration. As an alternative, the two top means  1220  and  1240  may be held together only when installed in the interior of the cover  120  by, for example, a connector  175  having, for example, a bolt and nut assembly. 
     In accordance with an alternative embodiment, the wire guide insert  1200  may be manufactured as a single molded piece, already in the folded configuration and not having any hinged connections. Similarly, the wire guide insert  1200  may be manufactured as a plurality of pieces (e.g., a base means  1210 , a first offset means  1230 , a second offset means  1250 , and a top means  1220 ) that are connected (e.g., snapped) together to characterize the substantially truncated triangular volume. Other piecewise or integral constructions are possible as well. 
     In summary, arrangements and methods are disclosed for welding wire payoff sources. A tapered core and base plate, optionally along with a wire guide insert, may be configured with a payout drum package and a cover containing a welding wire stack such that the welding wire is payed off smoothly from the wire stack during an arc welding operation, without the welding wire flipping or tangling. 
     While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.