Methods and Apparatus for Continuous Winding of Spools and Products Made Therefrom

Abstract

A method of winding a wire about a plurality of spools is provided. The method includes locating the plurality of spools on a winding shaft in a side-by-side fashion. An adaptor plate is located between adjacent spools. The adaptor plate includes a wire catch feature configured for catching the wire as a traveler feeding the wire to the spools moves from one spool to the next spool while the winding shaft rotates.

1 . A method of winding a wire about a plurality of spools, the method comprising:
 locating the plurality of spools on a winding shaft in a side-by-side fashion; and   locating an adaptor plate between adjacent spools, the adaptor plate including a wire catch feature configured for catching the wire as a traveler feeding the wire to the spools moves from one spool to the next spool while the winding shaft rotates.   
     
     
         2 . The method of  claim 1 , wherein the wire is a welding wire. 
     
     
         3 . The method of  claim 1 , wherein the step of locating the plurality of spools on the winding shaft includes locating at least three spools on the winding shaft in a side-by-side fashion. 
     
     
         4 . The method of  claim 3 , wherein the step of locating the adaptor plate between adjacent spools includes locating a first adaptor plate between adjacent spools and locating a second adaptor plate between adjacent spools, the first and second adaptor plates each including a plurality of notches extending inwardly from an outer periphery of each of the first and second adaptor plates for catching the wire as the traveler feeding the wire to the spools moves between adjacent spools. 
     
     
         5 . The method of  claim 1  further comprising severing the wire between adjacent spools thereby forming a terminating end for the one spool and a starting end for the next spool. 
     
     
         6 . The method of  claim 5  further comprising affixing the starting end of the wire of the next spool to a first spool flange of the next spool after the next spool is wound with the wire. 
     
     
         7 . The method of  claim 6  further comprising affixing a terminating end of the wire of the next spool to a second spool flange of the next spool after the next spool is wound with the wire. 
     
     
         8 . The method of  claim 7 , wherein at least one of the starting end and the terminating end of the wire is affixed by electric heat to the respective first or second spool flange. 
     
     
         9 . The method of  claim 7 , wherein at least one of the starting end and the terminating end of the wire is affixed to the first or second spool flange by inserting the at least one of the starting end and the terminating end of the wire into an opening through the respective first or second spool flange. 
     
     
         10 . The method of  claim 7 , wherein at least one of the starting end and the terminating end of the wire is affixed by punching the at least one of the starting end and the terminating end of the wire into the respective first or second spool flange. 
     
     
         11 . A wire winding assembly for winding wire onto a plurality of spools, the assembly comprising:
 a first spool located on a winding shaft;   a second spool located on the winding shaft; and   an adaptor plate located between the first spool and the second spool, the adaptor plate including a wire catch feature configured for catching the wire as a traveler feeding the wire to the first and second spools moves from the first spool to the second spool.   
     
     
         12 . The assembly of  claim 11 , wherein the wire is a welding wire. 
     
     
         13 . The assembly of  claim 11  further comprising:
 a third spool located on the winding shaft; and 
 a second adaptor plate located between the second spool and the third spool, the second adaptor plate including a notch extending inwardly from an outer periphery of the second adaptor plate for catching the wire as the traveler feeding the wire to the first, second and third spools moves from the second spool to the third spool. 
 
     
     
         14 . A metal welding wire product, comprising:
 a spool including a core, a first spool flange at one end of the core and a second spool flange at an opposite end of the core; and   a metal welding wire wound about the core forming windings, the metal welding wire including a starting end and a terminating end;   wherein both the starting end and the terminating end of the welding wire are located outside the windings.   
     
     
         15 . The product of  claim 14 , wherein the starting end of the wire is affixed to the first spool flange. 
     
     
         16 . The product of  claim 15 , wherein the terminating end of the wire is affixed to the second spool flange. 
     
     
         17 . The product of  claim 16 , wherein at least one of the starting end and the terminating end of the wire is affixed by electric heat to the respective first or second spool flange. 
     
     
         18 . The product of  claim 16 , wherein at least one of the starting end and the terminating end of the wire is affixed to the first or second spool flange by inserting the at least one of the starting end and the terminating end of the wire into an opening through the respective first or second spool flange. 
     
     
         19 . The product of  claim 16 , wherein at least one of the starting end and the terminating end of the wire is affixed by punching the at least one of the starting end and the terminating end of the wire into the respective first or second spool flange. 
     
     
         20 . The product of  claim 14 , wherein at least one of the starting end and the terminating end of the wire is affixed to the first or second spool flange by inserting the at least one of the starting end and the terminating end of the wire into a groove extending inwardly from a periphery of the respective first or second spool flange.