Cardboard Box for Welding Wire Dispensing
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Solution Overview
Problem
Conventional welding wire drums are not biodegradable and difficult to reclaim, leading to increased inventory needs and complexity in converting shipping containers to dispensing containers in welding operations.
Innovation Solution
A cardboard box with integrally formed flaps that convert from a shipping container to a dispensing container by assembling into a pyramid or tent configuration, eliminating the need for separate dispensing hats and allowing easy reclamation after use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welding wire drums are used, then wire dispensing function is provided, but the material is not biodegradable and difficult to reclaim
Solution Approach 1:
The patent changes the material parameter from non-biodegradable metal/fiber board to biodegradable corrugated cardboard, resolving the environmental harm issue while maintaining manufacturability and reclaimability through the cardboard's natural decomposition properties
Solution Approach 2:
The patent uses composite corrugated cardboard structure (fluted inner layer between outer liners) to achieve both environmental friendliness and structural functionality for wire dispensing, combining multiple material properties in a single biodegradable package
2Ease of operation
If separate dispensing hats are used with cardboard boxes, then wire dispensing is enabled, but inventory needs and complexity increase
Solution Approach 1:
The patent merges the shipping box and dispensing hat into a single integrated cardboard container structure, where the flaps form both the box closure and the dispensing hat structure, eliminating the need for separate components and reducing inventory needs
Solution Approach 2:
The cardboard flaps serve multiple functions: they close the shipping box during transport, then are folded upward to form the dispensing hat with wire outlet during use, providing both shipping and dispensing capabilities through a single structure
3Reliability
If conventional drums are used, then wire containment is provided, but conversion to dispensing container requires additional steps
Solution Approach 1:
The dispensing hat structure is pre-formed as part of the cardboard box during manufacturing, with flaps positioned and configured to automatically form the hat structure when folded upward, eliminating the need for separate conversion steps at the welding facility
Data Source
AI summary
A box for shipping and dispensing a welding wire wound into a generally cylindrical mass having a cylindrical core cavity concentric with a vertical axis. The box has four sidewalls with an integral generally triangular flap where at least one of the flaps has an upper generally square crown section with a wire outlet opening. The flaps have a folded down position wherein they overlap each other in a flat plane above the wire mass and an assembled up position defining a four sided pyramid shaped tent above the wire mass, with the crown section assembled in a plane generally parallel to the flat plane and at least 6.0 inches above the flat plane with the wire outlet opening aligned with the axis.