Note: Descriptions are shown in the official language in which they were submitted.
CA 02460380 2006-05-08
VYIRE PAYOUT
L-13173
This invention relates to the art of dispensing wire and; more particularly to
a wire payout
for controlling the dispensing of large quantities of a continuous wire
without tangling.
The present invention relates to feeding large quantities of a continuous wire
from a
container to a welding operation wherein the wire must be fed without tangling
or interruption.
Such containers are known in the art and are generally shown and described in
Cooper
5,277,314; Cooper 5,819,934; Chtng 5,746,380; Kawasaki 4,869,367 and Gelmetti
5,494,160.
These patents describe background information illustrating
packaging and dispensing large quantities of wire. Further, these patents
illustrate the
importance of controlling the wire as it is being dispensed from the package
to prevent tangling.
Seufer 5,816,466 illustrates the interaction between the wire package and the
wire feeder
which is a part of the welding apparatus.
BACKGROUND OF THE INVENTION
The present invention is particularly applicable for use in connection with
welding wire
and, therefore, the invention will be described with particular reference to a
payout or retainer
ring used with a package containing a large quantity of welding wire stored
therein as a coil
containing many convolutions formed into layers. Flowever, the invention has
broader
applications and may be used with any type of wire or other wire-like
materials.
It is, of course, well known that welding is an effective method of joining
metal
components. Further, it is well known that utilizing a welding wire as a
consumable electrode in
the welding process enhances the weld. Accordingly, it is desirous to package
welding wire so
that it can be cost effectively utilized. Furthermore, welding applications
wherein large
quantities of welding wire are consumed necessitate welding wire packages
which contain large-
quantities of a continuous. welding wire. Accordingly, large welding wire
packages have been
created for 'these applications which allow for a significant amount of
welding run time before
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CA 02460380 2004-03-09
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the operation must be shut down to restring a new package of welding wire.
This is particularly
important for automated or semi-automated welding operations.
In 'order to work in connection with the wire feeder of the welder, the
welding wire must
be dispensed in a non-rivisted, non-distorted and non-canted condition which
produces a more
uniform weld without human attention. It is well kno'vn that wire has a
tendency to seek a
predetermined natural condition which can adversely affect the wE;lding
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.
The payout portion of the welding wire package helps control the outflow of
the welding
wire from the package without introducing additional distortions iin 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 sub.>tantially
smaller than the width
or outer diameter of the welding wire package. 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
welding wire package
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prevent such widening. However, when the welding wire pays out of the package,
the walls of
the package loose 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
S 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.
There are two aspects of controlling the unwinding of wire from a wire coil
package.
First is to prevent the upward springing of the wire convolutions within the
wire coil package.
The second is management of the wire as it travels from the wire coil package
to the wire feeder
20 so that it doesn't spring back. Controlling the upward springing effect of
the wire convolutions
is achieved by maintaining the position of the wire convolutions at the top of
the wire coil and
especially at a point where the upward springing effect is at its greatest
which is towards the
radially outer portions of the package. With respect to controlling the wire
as it travels between
the payout and the wire feeder, it has been found that tensioning; along with
guiding the wire can
15 reduce the t~.visting and tangling effects. In this respect, by creating a
slight tension along with
using a guiding mechanism, the wire is controlled as it moves between the wire
coil package and
the wire feeder and is prevented from springing back into the package.
Payout devices or retainer rings have been utilized to control the spring back
and upward
springing of the wire and to control the payout of the wire. This is
accomplished by positioning
20 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 do~.vnward
force during the
shipment of the package is typically different than the optimal downward force
for the payout of
25 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 is often
used to maintain the position of the payout relative to the wire coil during
the payout of the wire.
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The outward flow of wire, or payout, is managed by the payout or retainer
ring's position
on the top of the wire coil which holds the upper layers of the convolutions
in place as the wire is
withdrawn one convolution at a time. In addition, the payout or retainer ring
includes an edge or
surface, typically a radially inwardly facing edge or surface, which controls
the payout of the
wire. Ln this respect, the wire is pulled from the center of a ring shaped
device and engages the
radially inwardly facing portion thereof. The retainer ring further includes a
mechanism to
prevent the wire from springing around the radially outer side of the retainer
ring. Prior art
retainer rings utilize a unified ring structure which includes resilient
members that tightly engage
the inner surface of the outer package to protect the outer convolutions of
the welding wire coil
and prevent the wire from springing around the outside of the retainer ring.
SUMMARY OF THE INVENTION
In accordance with the present invention, provided is a payout for use in
connection with
a welding wire package which includes at least two separate andL independent
retaining rings of a
Iight weight disposable material which cooperably control the p~ayout of the
welding wire. In
this respect, a payout in accordance with the present invention includes at
Ieast one ring which
rests on fop of the coil of wire and which prevents the coil of wire from
springing upwardly, and
a second ring which at least partially rests on the one ring and which is
spaced above the top of
the coil of wire. The two rings, one of which may be a floating ring,
cooperatively control the
payout of the wire from the wire coil. By utilizing at least two rings, one of
which may move
independently of the other, simple ring structures can be used tc> optimize
restraint of the wire
from springing upwardly and to improve control of the payout of the wire from
the wire coil.
A payout according to one aspect of the present invention can utilize both a
radially inner
and a radially outer stationary ring, which rings engage the top of the coil
of wire and are radially
spaced from one another to produce a circurnferentially continuous wire payout
gap
therebetween which preferably is radially centrally of the inner and outer
sides of the coil wire.
In another embodiment, a floating ring is of the size and shape to partially
cover the gap between
the inner and outer rings. The wire, as it is payed out of the wire coil
package, passes between
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one of the edges of the inner or outer rings and one of the edges of the
floating ring which rotates
about the coil axis and eccentrically relative thereto during payoui;. As a
result, as stated above,
simple payout or ring designs which are easy to manufacture can be used, and
the individual
rings can be designed for its specific purpose. This can include different
material choices and
different textures used along the guiding edges or other surfaces without
requiring complex
components or materials.
In accordance ~.vith another aspect of the invention the payout has only an
outer stationary
ring with a floating ring overlying the latter and surrounding the inner core
of the welding wire
package. In this embodiment, the wire is payed out between the inner edge of
the outer ring and
the inner core of the welding wire package and the inner edge of the floating
ring controls the
payout of the wire. Jn yet another embodiment, the gap between radially inner
and outer rings is
covered by the bristles of a brush ring secured to one or the other of the
inner and outer rings,
whereby payout of the wire is controlled by the resistance of the bristles.
The primary object of the present invention is the provision of a payout for a
wire coil
package which allows the continuous and uninterrupted withdrawal of a
~,velding wire from the
package smoothly and without tangling.
Another object is the provision of a payout of the foregoing character that
utilizes non-
intricate components which complement one another to achieve l:he desired
continuous and
uninterrupted withdrawal of the welding wire:
Still another obj ect is the provision of a payout of the foregoing character
which is light
weight and disposable.
A further object is the provision of a payout of the foregoing character
wherein the wire
is withdrawn from the package along a circumferential path which i.s radially
central with respect
to the coil of wire.
Yet a further object is the provision of a payout of the foregoing character
that utilizes at
least one ring which rests on the top of the wire coil and a floating ring
which rests on the top of
the one ring wherein the one ring and either a second ring or a core component
are spaced from
CA 02460380 2004-03-09
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c
L-13173
one another forming a continuous gap therebetween and the floating ring
partially covers the gap
progressively about the axis of the coil during payout with the.we~.ding wire
passing through the
gap.
Another obj ect is the provision of a welding wire package of the foregoing
character
which utilizes components that are economical to manufacture, easy to use in
the field and
which are economically disposable.
BRIEF DESCRIPTION OF THE DRA.~VINGS
The foregoing obj ects, and others, will in part be obvious and in part be
pointed out more
fully hereinafter in connection with a written description of preferred
embodiments of the present
invention illustrated in the accompanying drawings in which:
FIGURE 1 is a partially sectioned perspective view of a v~relding wire package
including
welding wire and a payout in accordance with the present invention;
FTGURE 2 is a sectional elevational view taken along line 2-2 in FIGURE I ;
FIGURE 3 is a top view of the welding wire package and payout shown in FIGURE
1;
FIGURE 4 is a top view of a welding wire package including another embodiment
of a
payout in accordance with the present invention;
FIGURE 5 is a sectional elevational view of the upper portion of the wire
package taken
along line 5-S in FIGURE 4;
FIGURE 6 is a top view of a welding wire package including yet another
embodiment of
a payout in accordance with the present invention;
FIGURE 7 is a sectional elevational view of the upper portion of the package
taken along
line 7-7 in FIGURE 6;
FIGURE 8 is a top view of a welding wire package including still another
embodiment of
a payout in accordance with the present invention;
FIGURE 9 is a sectional elevational view of the upper portion of the package
taken along
Iine 9-9 in FIGURE 8;
FIGURE 10 is a top view of a welding wire package including another embodiment
of a
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L-13173
payout in accordance with the present invention; and
FIGURE 11 is a sectional elevational view of the upper portion of the package
taken
along line 11-11 in FIGURE 10.
DESCRIPTION OF PREFERRED EMBODIMENTS
Refernng now in greater detail to the drawings wherein the showings are for
the puzpose
of illustrating preferred embodiments of the invention only, and not for the
purpose of limiting
the invention, Figure 1-3 illustrate a welding wire package 10 which is shown
as a welding wire
drum and will be described hereinafter with relation to such a wire dmm even
though the
invention of this application can be used in connection with other styles of
welding wire
packages. Welding wire package 10 includes a wire drum 12, an inner core 14, a
coil of wire 16
and a payout 20. Wire drum 12 has a cylindrical outer drum body 22 which is
coaxial with a
drum axis 24 and which has an inwardly facing surface 26 and an outwardly
facing surface 28.
Wire drum 12 further includes a drum bottom 30 having an upwardly facing
surface 32 and an
outside surface 34. Wire drum 12 can be made from any well-known packaging
material such as
paper, plastic, wood or steel. However, it must be able.to withstand the
outward forces and the
weight of the wire coil 16. Inner core 14 is also cylindrical and coaxial with
drum axis 24 and
therefore coaxial with outer drum body 22. Inner core 14 has a height which is
preferably
slightly less than the height of drum body 22. Core 14 comprisEa an outer
surface 40 and an
inner surface 42 and has a top and a bottom edge 44 and 46, respectively. Wire
coil 16 is
positioned within wire receiving opening 50 which is defined b;y the drum body
surface 26,
upwardly facing surface 32, and core surface 40. Wire coil 16 i.s made up of
many convolutions
of a single strand of wire 52 and is packaged in opening 50 by wrapping wire
52 around inner
core 14 and between the latter and wire drum 12 starting at surface 32 and
continuing until the
top 54 of the wire coil is close to the top edge 56 of outer drum body 22.
Payout 20 includes an inner ring 60 and an outer ring 6:? positioned on coil
top 54. In this
respect, inner ring 60 has a bottom 64 juxtaposed wire coil top 54 and an
oppositely facing top
66 with an inner edge 68 adjacent to core surface 40 and an outer edge 70
radially spaced from
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and opposite to inner edge 68. Ring 60 has a substantially rectangular cross-
sectional
configuration with a radial width 72 and a axial thickness 74. .Outer ring 62
has a bottom 76
juxtaposed wire coil tap 54 such that bottom 76 is substantially coplanar to
inner ring bottom 64.
Outer ring 62 further includes an outer edge 78 adjacent to drum surface 26
and an oppositely
facing inner edge 80. Inner edge 80 is spaced from inner zing outer edge 70,
thereby forming a
circumferentially extending radial gap Gl between inner and outer rings 60 and
62. Gap G1 is a
continuous circular gap coaxial with drum axis 24 and which has a generally
consistent width w
about wire coil top 54. Outer ring 62 further includes a top 82 which is
substantially coplanar
with inner ring top 66. As with inner ring 60, outer ring 62 has a rectangular
cross-sectional
configuration with a thickness 84 and a width 86. Payout 20 further includes a
floating ring 90
resting on and moving relative to izuzer and outer rings 60 and 62 during
payout as will become
more apparent hereinafter. Floating zing 90 includes a bottom 92; which rests
on portions of
inner ring top 66 and outer ring top 82. Floating ring 90 further includes a
top 94 which is
opposite to an spaced from bottom 92 and oppositely facing inner and outer
edges 96 and 98,
respectively. Therefore, floating ring 90 has a substantially rectangular
cross-sectional
configuration with a thickness 100 and a width 102. Inner ring 60, outer ring
62 and floating
zing 90 can be made from many different types of material such as cardboard,
press board,
plastics, or metals. In addition, while the rings 60, 62, and 90 are shown
with a rectangular
cross-sectional configuration, other configurations could be used without
departing from the
invention.
Payout 20 controls the unwinding of wire 52 by the interaction between inner
ring 60,
outer ring 62 and floating ring 90. As stated above, there are two aspects of
controlling the
unwinding of wire 52 from a wire coil package 10 which include preventing the
upward
springing of the wire convolutions within the wire coil package 10 and
managing wire 52 as it
travels from package 10 to the wire feeder. Inner and outer rings 60 and 62
are stationary rings
in that they essentially remain laterally stationary relative to one; another
and relative to drum
body 22 as the rings descend into wire receiving opening 50. Inner and outer
rings 60 and 62 are
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the primary factor in controlling the upward springing effect of th.e wire
convolutions.
Conversely, as will become more apparent hereinafter, during payout floating
ring 90
continuously moves eccentrically relative to axis 24, relative to inner and
outer rings 60 and 62,
and relative to core 14 and drum body 22 as the wire is unwound from welding
wire coil.
Floating ring 90 is the primary factor in controlling wire 52 as it travels
between payout 20 and
the wire feeder at the welder by creating a slight tension in wire 52 and by
guiding wire 52 as it
is unwound from wire coil 16.
Rings 60 and 62 primarily control the upward springing effect of the wire
convolutions
by covering a majority of wire coil top 54 and minimizing the space between
inner ring 60 and
inner core 14 and outer ring 62 and drum body 22. Further, the weight of rings
60 and 62 and.
floating ring 90 apply a downward force to the wire coil top 54. The weight of
floating ring 90
along with its coverage of a majority of gap GI assists nags 60 and 62 in
controlling the upward
springing of wire 52. In this respect, floating ring 90 rests on top of zings
60 and 62 such that
floating ring bottom 92 is juxtaposed inner and outer ring tops 66 and 82
respectively. Due to
the shape and size of floating ring 90 relative to drum body 22, core 14 and
rings 60 and 62, as
wire 52 passes through gap Gl, it moves in gap Gl about drum axis 24 and
engages floating ring
90 about its inner edge 96 as shown in Figures l and 2, causing floating ring
90 to move, or float,
relative to rings 60 and 62 and thus gap G1. More particularly in this
respect, as will be
appreciated from Figure 1 and considering the positions of the parts therein
to be an initial
position, wire 52 engages inner edge 96 of ring 90 at engagement point 104
which urges ring 90
radially outwardly toward drum body 22 until outer edge 98 thereof engages
drum surface 26.
Width 102 of ring 90 is such that as outer edge 96 engages drum surface 26,
inner edge 96 is
positioned above gap GI between outer ring inner edge 80 and inner ring outer
edge 70.
Furthermore, the diameters of outer edge 70 of ring 60 and inner edge 80 of
ring 62 and the
diameters of inner edge 96 and outer edge 98 of the floating ring, are such
that the majority of
gap G1 is covered by floating ring 90 and an opening 106 is formed at
engagement point 104.
Opening 106 is crescent shaped and, preferably, extends circumferential of gap
G1 about one-
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half the circumference thereof. This provides a limited opening for wire 52 to
pass through
payout 20, thereby assisting in preventing upward springing by the
convolutions of wire. Ring
width 102 is greater than the width of gap GI so that ring 90 remains on top
of inner and outer
rings 60 and 62 as it moves relative to rings 60 and 62. As will be
appreciated from Figure 1, as
wire 52 is pulled from the package in the direction of arro~,v A, ring 90 is
displaced eccentrically
relative to axis 24 and opening I06 moves, progressively, clockwise about axis
24.
Floating ring 90 creates tension in wire 52 and guides wire 52 in two ways.
First, as wire
52 is unwound from wire coil 16 it moves about axis 24 thereby moving floating
ring 90 relative
to rings 60 and 62 as described above. The frictional resistance of ring 90 is
it moves relative to
rings 60 and 62 creates tension in wire 52. Second, as wire 52 moves through
gap G1 and
opening 106, it engages floating ring edge 96 and one of edges 70 and 80 of
rings 60 and 62,
respectively, which creates tension in wire 52 and also guides the ~,vire.
T~ue to the floating ring
width 102, and the diameters of inner and outer edges 96 and 98, wire 52 is
constantly urging
floating ring 90 outwardly at a differing point about axis 24. In this
respect, as wire 52 urges
floating ring 90 outward at engagement paint I04, which is shown in Figures I -
3 as being at a
f rst ring portion I 12, second ring portion 114, which is opposite first ring
portion 112, and third
and fourth ring portions I 15 and 1 I7 which are between the first and second
portions and
opposite one another become positioned over gap G1. As wire 52 moves from
first portion 112
toward second portion I 14, engagement point I04 moves clockwise about axis 24
toward ring
portion 114 and, ultimately, portion l I4 is urged outwardly toward drum
surface 26 and first
portion 112 is urged inwardly over gap G1. At this point, opening 106 is
diametrically opposite
the position thereof in Figures 1-3. This movement continues as wire 52 is
unwound from wire
coil 16 and causes the floating action of floating ring 90. As wire 52 passes
through opening 106
it is directed by its engagement with the edges of the rings, and, as the
engagement point I04
moves about drum axis 24, opening 106 moves relative to engag ement point 104
about axis 24 in
a similar fashion. Furthermore, by removing wire 52 through gap Gl and opening
I06, a central
removal point is achieved thereby reducing the stresses imparted on wire 52 as
it is unwound
CA 02460380 2004-03-09
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from wire coil 16 and removed from package 10. These advantages are
accomplished by
utilizing rings 60, 62 and 90 which are simple in structure.
In order to maximize the effectiveness of the rings, the following functional
relationships
beriveen the rings, which are generally shown in the drawings, ca.n be
utilized. In this respect, if
floating ring width 102 is less than %2 the diameter of the outer ring inner
edge 80 minus %2 the
diameter of the inner core surface 40, opening 106 is formed as wire 52 urges
second portion 114
of floating ring 90 inwardly against inner core surface 40. Furthc~rmare, if
the floating ring width
102 is greater than inner ring width 74, floating ring outer edge S~8 is
maintained over gap Gl as
floating ring inner edge 96 engages core surface 40. In similar fashion,
floating ring inner edge
96 will be generally centered over gap G1, relative to engagement point 104,
if floating ring
width 102 is generally equal to 1/4 the diameter of inner ring outer edge 70
plus '/4 the diameter of
outer ring inner edge 80 minus '/2 the diameter of inner core surface 40. The
portion of floating
ring 90 at second portion 1 I4 can fully cover gap GI, while engagement point
104 is at first
portion 112, if the diameter of floating ring inner edge 96 is less than I/a
the diameter of inner
core surface 40 plus %Z the diameter of inner ring outer edge 70. In addition,
floating ring width
102 must be greater than the width of gap GI. In similar fashion, the diameter
of floating ring
inner edge 96 is to be less than the diameter of inner core surface 40 plus
inner ring width 74 for
floating ring inner edge 96 to be maintained on inner ring top 66~ at second
portion 114 while
engagement point 104 is at first portion 112. Furthermore, the diameter of
floating ring outer
edge 98 should be greater than the diameter of inner ring outer edge 70 plus
the width of gap G1
in order for floating ring 90 to fully cover gap G1 at second portion 114
while engagement point
104 is at first portion 112. However, the diameter of floating ring outer edge
98 should be less
than %2 the diameter of drum surface 26 plus %z the diameter of outer ring
inner edge 80 so that
gap 106 can be formed at engagement point 104 as floating ring inner edge 96
engages inner core
surface 40.
In the following discussions concerning other embodiments, the components of
the
welding wire package 10 which remain the same, as discussed above, will
include the same
lI
CA 02460380 2004-03-09
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reference numbers as above.
Referring to Figures 4 and S, a payout 120 is shown. Payout 120 includes inner
and outer
rings 60 and 62 which function as described above and further includes
floating ring 122.
Floating ring 122 is similar to floating ring 90 in that it includes a bottom
124 which rests on
S inner ring top 66 and outer ring top 82 and a top 126 which is opposite to
and spaced from
bottom 124. Floating ring 122 f~uther includes an inner edge 128 and an
oppositely facing outer
edge 130. Furthermore, floating ring 122 has a substantially rectangular cross-
sectional
configuration with a thickness 132 and a width 134. However, floating ring 122
is a different
size than floating ring 90 and therefore, wire 52 passes about floating ring
outer edge 130 as it is
unwound from wire coil 16 through gap Gl. More particularly, wire 52 engages
floating ring
122 at an engagement point I36 which urges ring portion 137 inwardly towards
inner core 14.
The width I34 of ring 122 is such that as the ring engages inner core surface
40, outer edge 130
thereof is positioned above and between outer edge 70 of ring 60 and inner
edge 80 of ring 62,
and over gap G1. Thus, outer edge 130 of ring I22 and inner edge 80 of ring 62
define a
1S restricted opening 138 which Iike opening I06 is crescent shaped and
extends about one-half the
circumference of the gap GI . The diameters of inner edge 128 and outer edge
130, of ring 122
are such that the ring covers an increasing portion of gap G1 moving from ring
portion 137
toward ring portion I39 when engagement point 136 is at ring portion 137.
Accordingly, wire S2
can only pass through opening 138. As wire S2 is unwound fond wire coil 16,
the engagement
point 136 and opening 138 move clockwise about the drum axis 24 toward ring
portion 139 and
back again toward ring portion 137 for each convolution of wire. Engagement of
wire S2 with
edge 130 of ring 122 results in the floating ring moving eccentrically
relative tv inner and outer
rings 60 and 62 and axis 24. This creates tension in wire S2. Furthermore,
during payout wile
S2 engages floating ring edge 130 along with one or the other of inner ring
edge 70 and outer
ring edge 80 thereby further controlling the payout the of wire.
Referring to Figures 6 and 7, a payout 1S0 is shown which includes a single
stationary
ring 1S2 and a floating ring 154. Since upward springing of the convolutions
is most prevalent at
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the outer portions of wire coil top 54, near drum body 22, stationary ring 152
is positioned
adjacent to drum surface 26. In this respect, stationary ring I52 has an outer
edge 156 adjacent
to drum surface 26 and an oppositely facing inner edge 158 spaced from inner
core surface 40,
thereby producing gap G2 therebetween. Ring 152 further includes a bottom 160
juxtaposed
wire coil top 54 and an oppositely facing top 162. Ring 152 is laterally
stationary relative to
drum body 22 and essentially moves vertically only, not horizontally.
Stationary ring I52 has a
rectangular cross-sectional configuration having a thickness 164 and a width
I66. Since only
one stationary ring is utilized, ring width 166 is greater than that of the
rings discussed in
previous embodiments. Floating ring 154 has a bottom 170 which rests on ring
top 162 and
further includes an outer edge 172, an inner edge 174 and a top 17b. Inner
edge 174 includes an
upwardly curved portion 178 having a rounded shoulder 180. Shoulder 180
reduces the chances
of wire 52 being scarred or distorted by its engagement with floating ring
154. As with the
embodiments discussed above, wire 52 passes through gap G2 and an opening 184
bet<veen core
14 and inner edge 174 and moves about drum axis 24 as it is unwound from wire
coil I6. Wire
52 engages floating ring 154 at engagement point 182 which moves about ring
edge I74 as wire
52 is unwound. The engagement between wire 52 and ring edge 174 causes the
floating ring to
move outwardly to the left in Figures 6 and 7 until it engages dnzm surface 26
thus forming the
opening 184 which in this embodiment is crescent shaped and extends about
three-quarters the
circumference of gap G2. Floating ring 154 has a thickness 186 and a width
188. Width 188 is
such that when floating ring 154 is urged outwardly by wire 52 to engage drum
surface 26, inner
edge 174 of the ring is positioned inwardly of stationary ring edge 158 and
spaced from inner
core surface 40 and above and generally centrally of gap G2. Furthermore; ring
width 188 is
greater than the width of gap G2 so that the dimensions of opening 184 are
minimized.
Referring to Figures 8 and 9, a payout 200 is shown which includes an inner
ring 202 and
an outer ring 204. Payout 200 advantageously allows wire 52 to be unwound from
wire coil I6
along a circumferential path which is radially central with respect to wire
receiving opening 50.
Inner and outer rings 202 and 204 are both stationary, laterally, and outer
ring 204 has an outer
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L-13173
edge 206 adjacent to drum surface 26 and inner ring 202 has an iru~er edge 212
adjacent to core
surface 40. This prevents the convolutions of wire from springin;; upwardly
about the outside or
the inside of payout 200. As stated above, the upwardly springing effect of
the convolutions
primarily takes place at the outermost regions of the container, namely, at
places neax drum
surface 26. However, by also including inner ring 202, payout is from a
central portion of wire
coil Z 6 and the upward springing is further controlled. As with the
embodiments discussed
above, outer ring 204 further includes an inner edge 208 which is spaced from
and opposite to
outer edge 206, and a bottom 210 juxtaposed wire coil top 54. Inner ring 202
further includes an
outwardly facing outer edge 214 which is spaced from outer ring edge 208,
thereby forming gap
G3. Inner ring 202 further includes bottom surface 2I6 juxtaposf°d wire
coil top 54 and generally
coplanar with outer ring bottom 2I0. Gap G3 is a continuous, generally
circular gap about drum
axis 24 and is generally centered within wire receiving opening 50 about drum
axis 24.
Accordingly, as wire 52 is unwound from wire coil 16, it passes l:hrough gap
G3 about drum axis
24 and the engagement with inner ring 202 and/or outer ring 204 and edges 208
and 214 thereof
helps control the unwinding of wire 52 from wire coil 16 and prevents the
upwardly springing of
the wire convolutions.
Refernng to Figures 10 and 11, shown is a payout 230 which includes inner and
outer
rings 202 and 204, respectively, as shown in Figures 8 and 9, and further
includes a brush ring
232. Brush ring 232 creates tension in wire 56 by the frictional f,ngagement
between wire 52 and
the many brush fibers or bristles 236 attached to the ring. Brush ring 232 is
a stationary ring and
is attached to top surface 238 of outer ring 204 such that brush fibers 236
extend radially
inwardly toward inner ring 202 and cover gap G3. Brush fibers 236 have lengths
240 which are
greater than the width 242 of gap G3 and, therefore, fibers 236 extend from
brush retainer ring
234 over gap G3 to a point over and inwardly of edge 214 of inner ring 204.
Since fibers 236 are
retained at one of their ends by retainer 234, the fibers deflect upwardly
against the natural
resiliency thereof to allow wire 52 to move about drum axis 24 in gap G3 as it
is unwound from
wire coil 16 while imposing a force on the wire which tensions the latter. In
addition, wire 52
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CA 02460380 2004-03-09
L-13173
engages inner ring edge 214 and/or outer ring edge 208 which further tensions
and guide the wire
out of package I0. While brush fibers are preferred, it will be appreciated
that a thin film of latex
or the like would provide the desired resiliency to control the payout and
tension the wire.
While considerable emphasis has been placed on the preferred embodiments of
the
invention illustrated and described herein, it will be appreciated that other
embodiments can be
made and that many changes can be made in the preferred embodiments without
departing from
the principles of the invention. Accordingly, if 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.
to
