Abstract:
A hose has a connector ( 12 ) at an end portion ( 10 ) thereof for providing a connection with a unit, the connector comprising a first moulded member ( 20 ) having an inner annular surface ( 22 ) moulded to an outer annular surface ( 24 ) of the end portion to provide a fluid-tight connection with the end portion, and a fastener ( 26 ) for fastening the connector to the unit. A method of manufacturing the hose comprises the steps of: inserting a core ( 80 ) inside the hose end portion ( 10 ) to support the hose end portion during moulding; moulding the first moulded member ( 20 ) with the inner annular surface ( 22 ) thereof moulded to an outer annular surface ( 24 ) of the end portion; withdrawing the core; and positioning the fastener ( 26 ) at the end portion for fastening the connector to the unit.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a hose having a connector at an end portion thereof for providing a connection with a unit for the supply of fluid.  
       BACKGROUND TO THE INVENTION  
       [0002]     A hose, or other fluid conduit, has many applications, such as the supply of water from a base unit to a shower head, the supply of water from a tap to a hose attachment, e.g. a sprinkler, or as part of a plumbing system. The present invention is particularly, although not exclusively, useful in the supply of fluid along a flexible hose.  
         [0003]     A prior art shower hose is manufactured with a connector at one end thereof for connection with a shower head unit or shower base unit. The connector comprises at least one metal sleeve which is crimped around an outer annular surface of the end portion so that the sleeve mechanically engages with the end portion. A fastener, such as a conical nut is arranged to engage the sleeve and to fasten the sleeve to the unit. Suitable seals are incorporated in the connector for providing a water-tight connection, between the fastener and unit, and between the fastener and sleeve.  
         [0004]     A disadvantage with the prior art arrangement is that when the sleeve is crimped to the hose end portion, the internal bore of the hose end portion is reduced in diameter and this affects the flow of fluid through the hose and into the unit. A further reduction in the diameter of the internal bore occurs because the connector connects the hose to the unit without allowing relative rotation between the hose and the unit. This results in a tendency for the hose to twist when the unit is moved, and particularly when the unit is rotated, which further reduces the diameter of the internal bore. When the hose is resilient, it resists against twisting, and therefore, resists free movement of the unit. In addition to these disadvantages, any reduction in the diameter of the internal bore may also result in pressure fluctuations at the showerhead such as to impair the overall performance of the system.  
         [0005]     It is therefore desirable to provide a hose having a connector at an end portion thereof which alleviates at least one of the above-mentioned problems with the prior art.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention provides a hose having a connector at an end portion thereof for providing a connection with a unit, the connector comprising a first moulded member having an inner annular surface moulded to an outer annular surface of said end portion to provide a fluid-tight connection with the end portion, and a fastener for fastening the connector to the unit.  
         [0007]     The hose may comprise a second moulded member, wherein said first moulded member is moulded between the second moulded member and the hose end portion so that an outer annular surface of the first moulded member corresponds in shape to an inner annular surface of the second moulded member to allow relative rotation between the first moulded member and the second moulded member, wherein the fastener is for fastening the second moulded member to the unit, and wherein, when the hose is connected to the unit, relative rotation between the hose and the unit is allowed.  
         [0008]     The present invention also provides a method of manufacturing a hose having a connector at an end portion thereof for providing a connection with a unit, the method comprising the steps of:  
         [0009]     inserting a core inside a hose end portion to support the hose end portion during moulding;  
         [0010]     moulding a first moulded member with an inner annular surface thereof moulded to an outer annular surface of said end portion;  
         [0011]     withdrawing said core; and  
         [0012]     positioning a fastener at said end portion for fastening the connector to the unit.  
         [0013]     The method may further comprise the steps of:  
         [0014]     moulding a second moulding member prior to moulding the first moulding member;  
         [0015]     positioning the second moulded member relative to the hose end portion so that the first moulded member is moulded between the second moulded member and the hose end portion so that an outer annular surface of the first moulded member corresponds in shape to an inner annular surface of the second moulded member to allow relative rotation between the first moulded member and the second moulded member;  
         [0016]     positioning the fastener at said end portion for fastening the second moulded member to a unit.  
         [0017]     The present invention also provides a shower assembly comprising:  
         [0018]     a shower base unit;  
         [0019]     a shower head unit;  
         [0020]     and a hose as claimed in any of claims  1  to  9  having a first said connector at one said end portion thereof for providing a connection with the shower base unit; and a second said connector at an opposing said end portion thereof for providing a connection with the shower head unit, for allowing the supply of water from the shower base unit to the shower head unit.  
         [0021]     The present invention also provides shower assembly comprising:  
         [0022]     a shower base unit;  
         [0023]     a shower head unit;  
         [0024]     and a hose for the supply of water from the shower base unit to the shower head unit, the hose having a connector at an end portion thereof for providing a connection with the shower head unit;  
         [0025]     wherein the connector comprises: a first moulded member and a second moulded member, the first moulded member being moulded between the second moulded member and the hose end portion, the first moulded member having:  
         [0026]     an inner annular surface moulded to an outer annular surface of said end portion to provide a fluid-tight connection with the end portion; and  
         [0027]     an outer annular surface which corresponds in shape to an inner annular surface of the second moulded member to allow relative rotation between the first moulded member and the second moulded member,  
         [0028]     wherein the connector further comprises a fastener for fastening the second moulded member to the shower head unit, and wherein, when the hose is connected to the shower head unit, relative rotation between the hose and the shower head unit is allowed. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0029]     In order that the present invention may be well understood, an embodiment thereof, which is given by way of example only, will now be described with reference to the accompanying drawings, in which:  
         [0030]      FIG. 1  shows a cross-section of a hose having a first connector at an end portion thereof;  
         [0031]      FIG. 2  shows a cross-section of a hose having a second connector at an end portion thereof;  
         [0032]     FIGS.  3  to  8  show method steps in manufacturing a hose as shown in  FIGS. 1 and 2 ;  
         [0033]      FIG. 9  shows a moulding tool for manufacturing a hose as shown in  FIGS. 1 and 2 ; and  
         [0034]      FIG. 10  shows a hose having a modified connector at an end portion thereof. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0035]     Referring to  FIG. 1 , a hose end portion  10  is shown having a connector  12  for providing a connection with a unit, such as a shower base unit (not shown). The hose, of which only the end portion  10  is shown, comprises an inner tube  14  for the passage of fluid and an outer sleeve  16  for providing support for the inner tube. The outer sleeve comprises a helically wound coil usually of metal surrounded by a plastics sheath. Thus, the sleeve resists the inner tube from collapsing inwardly during use. At the tip  18  of the hose, outer sleeve  16  is pared back to expose the inner tube  14 .  
         [0036]     Connector  12  comprises a first moulded member  20  having an inner annular surface  22  moulded to an outer annular surface  24  of the hose end portion  10  to provide a fluid-tight connection with the end portion. As shown, to provide a secure connection between the first moulded member  20  and the hose end portion  10 , the inner annular surface  22  of the first moulded member  20  is moulded to the outer annular surface  24  of both the inner tube  14  (at the tip of the hose) and the outer sleeve  16  adjacent the tip  18 .  
         [0037]     A fastener  26 , in the form of a conical nut, is positioned for fastening the connector to a unit Fastener  26  has a threaded internal bore  28  for engaging with a threaded sleeve of a port in the unit. The first moulded member  20  has a flared end  30  to which an annular seal  32  is seated. When the fastener engages with the unit, an inwardly extending shoulder  34  engages with an annular end face  36  of the first moulded member  20  to urge the annular seal  32  into abutment with a complementary sealing surface in the unit. When connected to the unit, the hose is not rotatable relative to the unit. The bond between the first moulded member  20  and the inner tube  14  and outer sleeve  16  ensures a fluid-tight connection therebetween and the annular seal  32  ensures a fluid-tight connection between the first moulded member  20  and the unit. As will be explained in more detail below, the inner tube  14  is supported by a core during moulding of the first moulded member  20  thereto, and therefore, the internal bore of the inner tube is not reduced during manufacture and hence the fluid flow passage defined by inner tube  14  is not restricted.  
         [0038]     An opposing end portion  40  of the hose is shown in  FIG. 2 . The opposing end portion has a connector  42  for providing a connection with a unit, such as a shower head unit. The fastener  26  is the same as fastener  26  in  FIG. 1 . The hose, similarly, has an inner tube  14  and an outer sleeve  16 . The inner tube  14  is pared back at its tip end prior to moulding.  
         [0039]     As will be described in more detail below, a second moulded member  44  is moulded prior to moulding a first moulded member  46 . After moulding, the second moulded member  44  is positioned relative to the hose end portion  40  so that the first moulded member is moulded between the second moulded member and the inner tube  14  of the hose end portion  40  so that an outer annular surface  48  of the first moulded member  46  corresponds in shape to an inner surface  50  of the second moulded member  44 . This arrangement allows relative rotation between the first moulded member and the second moulded member. Further, the first moulded member  46  has an outwardly tapering surface  52  which corresponds in shape to an inwardly tapering surface  54  of the second moulded member. This arrangement resists axial movement of the second moulded member relative to the first moulded member. In a similar way to the  FIG. 1  arrangement, the first moulded member  46  is moulded having an inner annular surface  56  moulded about an outer annular surface  24  of the hose end portion  40 , to provide a fluid-tight fit between the first moulded member  46  and the hose end portion  40 . The fastener  26  is positioned about the first and second moulded members  44 ,  46 , and fastens the connector to a shower head unit by engaging the threaded bore  28  with a complementary screw fitting on the shower head unit. The fastener  26  has an annular end face  58  which engages an annular end face  60  of the second moulded member  44  to urge an annular seal  62  into abutment with a complementary sealing surface in the shower head unit to create a fluid-tight connection between the shower head unit and the second moulded member  44 .  
         [0040]     The second moulded member  44  which is fixed relative to the shower head unit is allowed to rotate relative to the first moulded member  46  which is fixed relative to the hose. Accordingly, rotational movement of the shower head unit does not cause twisting of the hose, and therefore, the internal bore of inner tube  14  is not reduced during use of the shower. Further, similarly to the  FIG. 1  arrangement, a core is inserted in the inner tube  14  during manufacture so that when the first moulded member  46  is moulded thereto, the internal bore of inner tube  14  is not reduced as a result of the moulding process.  
         [0041]     A method of manufacturing the previously described hose with first and second end portions will now be described with reference to FIGS.  3  to  9 . A hose which may be stored on a reel or reels is cut to length as shown in  FIG. 3 . Fasteners  26 , or conical nuts as shown, are assembled over the hose as shown in  FIG. 4 . The tip end of hose end portions  10  and  40  are pared back to expose inner tube  14 , as shown in  FIG. 5 .  
         [0042]      FIG. 6  shows a step in the manufacture of the connector  42  at hose end portion  40 . The manufacturing method is described in relation to the manufacture of two hoses simultaneously. The method can be modified to manufacture a single hose or more than two hoses simultaneously as required.  
         [0043]     In  FIG. 6 , two cores  70  have been introduced to a moulding tool  72 . Second moulding members  44  are then moulded about cores  70 . Once moulded, moulding tool  72  is rotated through 180° about pivot  74  to the position shown in  FIG. 7 . Cores  70  may be withdrawn prior to rotation or afterwards.  
         [0044]      FIG. 7  shows two hoses  8  extending between moulding tools  72  and  76 . As previously indicated, moulding tool  72  is for manufacturing connector  42  at hose end portion  40 . Moulding tool  76  is for manufacturing connector  12  at hose end portion  10 . Broken lines indicate the arrangement of the hoses  8  between moulding tools  72  and  76 .  
         [0045]     Once cores  70  have been withdrawn, cores  78  are introduced radially inwardly of second moulded member  44  and hose end portion  40  is passed over cores  78 . First moulded member  46  is then moulded between the second moulded member  44  and the hose end portion  40 . The first moulded members  46  are moulded with inner annular surfaces  56  moulded to outer annular surfaces  24  of hose end portion  40 . Outer annular surfaces  48  of first moulded member  46  are moulded to correspond in shape to the inner annular surfaces  50  of the second moulded member  44  to allow relative rotation between the first moulded member and the second moulded member.  
         [0046]     Once moulding is complete, cores  78  are withdrawn and hose end portions  40  are removed from moulding tool  72 . Fastener  26  can then be positioned at hose end portion  40  for fastening connector  42  to a unit.  
         [0047]     Simultaneously or consecutively, connector  12  at hose end portion  10  is manufactured on moulding tool  76 . As shown, cores  80  are inserted in the internal bore of tube  14  at hose end portion  10 . First moulded member  20  is then moulded about end portion  10  and inner annular surface  22  of first moulded member  20  is moulded about outer annular surface  24  of hose end portion  10 . The first moulded member  20  is moulded about both the inner tube  14  and outer sleeve  16  to further ensure a fluid-tight connection between the first moulded member and hose end-portion  10 . Subsequently, cores  80  are withdrawn and fasteners  26  are positioned for fastening the connector  12  to a unit.  
         [0048]     As shown in  FIG. 8 , annular seals  32  and  62  are introduced axially to connectors  12 ,  42 , respectively, prior to securing each of the connectors  12 ,  42  to their respective mountings. Whilst the seals  32 ,  62  are preferably provided loose, they may alternatively be bonded in place to the first moulded member  20  and the second moulded member  44 , respectively.  
         [0049]     For ease of understanding, moulding tool  72  is shown in its entirety in  FIG. 9 . In  FIG. 9  it can be appreciated that the manufacturing method as described readily submits itself to the production of large numbers of hoses in a short time span. In this regard, the step of moulding second moulded member  44  can be carried out at the same time as the moulding of first moulded member  46 .  
         [0050]     In the manufacture of connectors  12  and  42 , first moulded member  20 ,  46  is moulded using the inner tube  14  and outer sleeve  16  as part of the mould therefor. Additionally, in connector  42 , first member  44  also forms part of the mould for first moulded member  46 . In this way, the manufacturing process is efficient and the cooperation between the components can be insured at low cost. In more detail, the connection between the first moulded member and the hose end portion must be fluid-tight and this is achieved because the first moulded member is moulded to the hose end portion. In connector  42 , relative rotation is required between the second moulded member  44  and the first moulded member  46 . This is achieved in the present manufacturing process by ensuring that an annular interface is provided between members  46  and  44 . In previous techniques, the corresponding surfaces of two components would have to be manufactured with very high tolerances to allow a connection which both allows relative rotation and which provides a sealing effect against fluid seepage.  
         [0051]     During moulding of first moulded members  20  and  46 , cores  80  and  78 , respectively, support the inner tube  14  and prevent it from deforming radially inwardly. Accordingly, the internal bore of tube  14  is not reduced in size and thus flow in internal bore  14  is not restricted.  
         [0052]     Although the present hose  8  has been described with a connector  12  at one end portion thereof and a connector  42  at an opposing end portion thereof, the invention is not restricted to this arrangement. Instead, a rotatable connector  42  can be provided at both end portions of the hose, or a static connector  12  can be provided at both end portions of the hose. It is further envisaged that a hose could be provided with a connector  12  or a connector  42  at one end portion thereof and no such connector at an opposing end portion thereof.  
         [0053]     In addition to the hose  8  described above, a further modification is shown in  FIG. 10 .  FIG. 10  illustrates connector  42  at hose end portion  40 . An additional manufacturing step provides a moulded annular sealing member  82  positioned between fastener  26  and an outer annular surface  84  of first moulded member  46 . The annular sealing member  82  can be moulded using the over annular surface  84  as a moulding part. Member  82  further ensures sealing between the fastener  26  and first moulded member  46 . Although sealing member  82  has been described with reference to connector  42 , it would also be possible to provide a moulded sealing member in connector  12 .