Abstract:
A hose which includes an inner tube having an inside and an outside, with adhesive affixed to the outside of the inner tube is disclosed. At least one electrical conductor is embedded in the adhesive. The conductor(s) may be used for the transmission of signals or for the supply of electrical energy. A woven outer jacket resides outside the inner tube and the inner tube is secured to the outer tube by heat-activated adhesive. A process for making the hose is also disclosed and claimed. Another embodiment includes securing a wire or wires to the exterior of a composite hose by applying a hot-melted thermoplastic material over the entire circumference of the composite hose. Still another embodiment discloses application of the thermoplastic material selectively over the wires only, and not the entire outer circumference of the outer jacket.

Description:
FIELD OF THE INVENTION  
       [0001]     The invention is in the field of hoses having electrical lines therein.  
       BACKGROUND OF THE INVENTION  
       [0002]     U.S. Pat. No. 5,109,534 to Naito et al. illustrates a cable communication system with a transmission line incorporated in the hose. The specification of the &#39;534 patent states at column 6, lines 27 et seq., “[t]he communication line-incorporated water hose 3 is comprised, as typically shown in FIGS. 3(A) and (B), of a tubular hose jacket 26 and a lining tube of a plastic resin or a rubber 27 lined upon the interior surface of the hose jacket 26, and there is an electric cable 28 disposed in sandwiched fashion between the hose jacket 26 and the lining tube.” The specification of the &#39;534 patent describes the electric cable as a coaxial cable which has the ability to stretch without failing. Drawing FIGS. 3(A) and 3(B) of the &#39;534 patent have been reproduced as drawing  FIGS. 1 and 2  of the instant application.  
         [0003]      FIG. 1  is a cross-sectional longitudinal view 1 of the prior art as disclosed in U.S. Pat. No. 5,109,534 to Naito et al. FIG. 2 is a cross-sectional transverse view 2 taken along the lines A-A of FIG. 1 as disclosed in U.S. Pat. No. 5,109,534 to Naito et al.  
         [0004]     The &#39;534 patent, in regard to electric cable 28, is silent as to its construction other than to recite that it is disposed in sandwiched fashion between the tubular hose jacket 26 and the lining tube. Apparently the coaxial cable of the &#39;534 patent enables communication and control and does not pertain to the transfer of power. No adhesive is disclosed in the teachings of the &#39;534 patent.  
         [0005]     Other patents indicating the state of the art are: U.S. Pat. No. 6,666,274 B2; U.S. Pat. No. 5,713,864; U.S. Pat. No. 6,392,317; U.S. Pat. No. 5,637,168;U.S. Pat. No. 3,899,631; U.S. Pat. No. 5,932,842; U.S. Pat. No. RE37,775 E; U.S. Pat. No. 5,267,670; U.S. Pat. No. 5,442,810; U.S. Pat. No. 6,668,934 B2; U.S. Pat. No. 6,296,066 B1; U.S. Pat. No. 6,235,232 B1; U.S. Pat. No. 4,098,342; U.S. Pat. No. 3,285,629; U.S. Pat. No. 3,378,811; and U.S. Pat. No. 4,229,613.  
         [0006]     Endot Industries discloses a potable water pipe and an outer sheath made from polyethylene with conductors located therearound in a sheath.  
         [0007]     It is desirable to utilize a woven jacketed hose having electrical conductors contained therein in a water well application such that the conductors enable communication and power transfer to a pump in the well. It is also desirable to have conductors absorb and resist torque applied to the pump motor.  
       SUMMARY OF THE INVENTION  
       [0008]     A plurality of conductors is affixed by adhesive previously applied to the exterior of a polyurethane tube. The conductors and the polyurethane tube are then placed inside a woven outer jacket. The woven outer jacket includes a latex sealant applied before the polyurethane tube is inserted therein. Pressurized and heated by steam the polyurethane tube expands against the woven outer jacket and activates the adhesive which secures the polyurethane to the woven outer jacket.  
         [0009]     The process for making the hose includes the following steps: weaving the outer jacket; applying latex coating onto, into and through the outer jacket; removing excess coating from the coated outer jacket; curing the latex coated outer jacket; forming a polyurethane tube; applying adhesive to the exterior of the polyurethane tube; attaching conductors to the polyurethane tube; inserting the polyurethane tube in said outer jacket; and, applying steam to the interior of said polyurethane tube.  
         [0010]     Alternatively, the steps of affixing wires to the outside of the woven jacket and then passing the composite hose through an extruder to secure the wires may be employed. Still alternatively, the steps of passing the woven jacket through a secondary extruder to selectively apply molten polyurethane locally over the wires may be employed.  
         [0011]     Other embodiments of the invention are directed to placement of the conductors (wires) on the exterior of the composite hose. A thermoplastic material is extruded onto the exterior of the hose and secures the conductors to the exterior of the hose. The extrusion may extend around the circumference of the exterior of the hose. The extrusion may, alternatively, be selectively applied just over the conductors where they reside adjacent the exterior of the hose. The conductors add rigidity and resistance to counteract pump motor torque.  
         [0012]     It is an object of the present invention to provide a hose or a series of hoses having conductors therein for the transmission of electrical power to an electric motor such as a pump motor.  
         [0013]     It is a further object of the present invention to provide a hose having conductors therein where said conductors are adhesively affixed to a polyurethane liner.  
         [0014]     It is a further object of the present invention to provide a hose having a woven outer jacket and conductors therein.  
         [0015]     It is a further object of the present invention to provide a water hose having electrical conductors therein for use in combination with a well pump.  
         [0016]     It is a further object of the present invention to provide a water hose having electrical conductors which provide rigidity against pump motor torque when the hose is affixed to a pump motor.  
         [0017]     It is a further object of the present invention to provide a water hose having electrical conductors affixed to the exterior of the hose. The conductors may be affixed by a thermoplastic material applied to the entire exterior circumference of the composite hose or the thermoplastic material may only be applied locally over the wire(s) to be affixed to the hose.  
         [0018]     These and other objects will be better understood when reference is made to the Brief Description of the Drawings, Description of the Invention, and Claims which follow hereinbelow.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is a cross-sectional longitudinal view of the prior art as disclosed in U.S. Pat. No. 5,109,534 to Naito et al.  
         [0020]      FIG. 2  is a cross-sectional transverse view of the prior art as disclosed in U.S. Pat. No. 5,109,534 to Naito et al.  
         [0021]      FIG. 3  is an illustration of the process steps for manufacturing the present invention.  
         [0022]      FIG. 3A  is an illustration of the process steps for manufacturing another embodiment of the present invention.  
         [0023]      FIG. 3B  is an illustration of the process steps for manufacturing another embodiment of the present invention.  
         [0024]      FIG. 4  is a perspective view of the woven outer jacket of the present invention.  
         [0025]      FIG. 5  is a schematic illustration for dipping the woven outer jacket of the present invention in a latex coating.  
         [0026]      FIG. 5A  is cross-sectional view of the outer jacket being drawn through a wiper assembly to remove excess latex from the outer jacket.  
         [0027]      FIG. 5B  is a cross-sectional view taken along the lines  5 B- 5 B of  FIG. 5A  illustrating the hose having latex on, in and through the woven outer jacket.  
         [0028]      FIG. 5C  is a schematic of the latex curing process.  
         [0029]      FIG. 6  is a perspective view of the polyurethane tube.  
         [0030]      FIG. 6A  is a view of the polyurethane tube laid flat.  
         [0031]      FIG. 7  is a perspective view of a polyurethane tube with adhesive being sprayed thereon.  
         [0032]      FIG. 7A  is a view of the laid-flat polyurethane tube of  FIG. 6A  with adhesive being applied thereto.  
         [0033]      FIG. 8  is a perspective view of the polyurethane tube of  FIG. 7  with four conductors affixed thereto.  
         [0034]      FIG. 8A  is a top view of  FIG. 8 .  
         [0035]      FIG. 8B  is a front view of  FIG. 8 .  
         [0036]      FIG. 8C  is a view similar to  FIG. 8A  only the conductors aren&#39;t insulated.  
         [0037]      FIG. 8D  is a view similar to  FIG. 8A  only coaxial conductors are utilized.  
         [0038]      FIG. 8E  is a view of the laid-flat hose with conductors applied thereto.  
         [0039]      FIG. 9  illustrates the polyurethane tube partially inserted into the woven outer jacket.  
         [0040]      FIG. 9A  illustrates the polyurethane tube fully inserted into the woven outer jacket.  
         [0041]      FIG. 9B  illustrates the laid-flat polyurethane tube partially into the woven outer jacket.  
         [0042]      FIG. 10  illustrates pressurizing the inner tube with steam.  
         [0043]      FIG. 10A  illustrates pressurizing the inner tube with steam and the use of a flange to seal the polyurethane tube.  
         [0044]      FIG. 11  is a perspective view of the inner tube, the polyurethane tube, and the outer jacket secured with the conductors affixed between the tube and the outer jacket.  
         [0045]      FIG. 11A  is a top view of  FIG. 11 .  
         [0046]      Fig. 11B  is a front view of  FIG. 11 .  
         [0047]      FIG. 11C  is an enlargement of a portion of  FIG. 11A  illustrating adhesive between the inner tube and the conductors and between the inner tube and the outer jacket.  
         [0048]      Fig. 11D  is a cross-sectional view of another embodiment of composite hose made by the process illustrated in  FIG. 3A  illustrating adhesive applied over conductors on the exterior of a composite hose.  
         [0049]      Fig. 11E  is a cross-sectional view of another embodiment of composite hose made by the process illustrated in  FIG. 3B  illustrating a hot-melted polyurethane or polyethylene bonded and applied over the conductors securing the conductors to the outside of the hose.  
         [0050]      FIG. 12  is an illustration of the hose used in combination with a well casing and a well pump.  
         [0051]      FIG. 12A  is an illustration of a hose union which enables the joinder of two sections of hose together. 
     
    
       [0052]     The drawings will be better understood when reference is made to the Description of the Invention and Claims which follow hereinbelow.  
       DESCRIPTION OF THE INVENTION  
       [0053]      FIG. 3  is an illustration  300  of the process steps of the present invention. The first step is weaving  301  an outer jacket and then applying  302  a latex sealant onto, into and through the outer jacket  401 .  FIG. 4  is a perspective view  400  of the woven outer jacket  401  of the present invention.  FIG. 5  is a schematic illustration for dipping  500  the woven outer jacket of the present invention in a latex sealant bath  501 . Bath  501  is filled with the latex coating  502 . The outer woven jacket  401  is allowed to soak in the latex sealant bath so that the sealant is absorbed by the jacket.  
         [0054]      FIG. 5A  is cross-sectional view  500 A of the outer jacket  401  being drawn through a wiper assembly to remove excess latex sealant  502  from the inside and outside of the jacket. Referring to  FIGS. 3 and 5 A, the woven outer jacket is wiped to remove the excess latex sealant  502  therefrom. The exterior of the woven jacket is wiped by exterior wiper  510  and the interior of the woven jacket is wiped by interior wiper  511 .  FIG. 5B  is a cross-sectional view  500 B taken along the lines  5 B- 5 B of  Fig. 5A  illustrating the hose having latex on, in and through the woven outer jacket.  FIG. 5B  illustrates warp and weft fibers of the woven jacket  401  and also illustrates a thin layer  503  of sealant applied to the exterior of the woven outer jacket  401  and a thin layer  504  of sealant applied to the interior of the woven outer jacket  401 .  
         [0055]     After wiping  303  the excess latex sealant from the woven outer jacket, curing  304  the hose as illustrated in  FIG. 5C  occurs. A curing station  520  emits energy  521  to cure the latex sealant of the outer jacket. Energy  521  may in the form of heat energy or microwave energy.  Fig. 5C  is a schematic  500 C of the latex curing process.  
         [0056]      FIG. 6  is a perspective view  600  of the polyurethane tube  601 . The polyurethane tube  601  is formed  305  by known tube-forming processes.  FIG. 6A  is a view  600 A of the polyurethane tube  601  laid-flat. Preferably the laid-flat polyurethane tubular hose is employed because it slidably fits within the woven outer jacket.  
         [0057]      FIG. 7  is a perspective view  700  of a polyurethane tube with adhesive  702  being sprayed  701  thereon.  FIG. 7A  is a view of the laid-flat polyurethane tube of  FIG. 6A  with adhesive being sprayed  701  thereon. Preferably the adhesive  702  is a heat-activated adhesive as this enables the polyurethane tube to be placed inside the woven outer jacket  401  as illustrated in  FIGS. 9, 9A  and  9 B. Heat-activated adhesive becomes stickier and tackier when heat is applied to it. The step of applying  306  adhesive may be performed by methods other than spraying. For instance, the adhesive may be applied with rollers or the polyurethane tube in its laid-flat condition may be submersed in a bath of adhesive.  
         [0058]      FIG. 8  is a perspective view  800  of the polyurethane tube of  FIG. 7  with four conductors  801 ,  802 ,  803  and  804  affixed thereto. Attaching  307  the conductors to the polyurethane tube is preferably performed while the hose is laid-flat. See  FIG. 7A  which illustrates the laid-flat hose with adhesive applied thereto. The conductors are spaced  90  degrees from each other and this provides rigidity against torque of the pump motor as illustrated in  FIG. 12 . More or fewer conductors may be utilized. Increasing the number of conductors increases the ability of the hose to resist torque.  
         [0059]      FIG. 8A  is a top view  800 A of  FIG. 8  and reference numerals  801 A,  802 A,  803 A and  804 A indicate insulation around the respective conductors.  FIG. 8B  is a front view  800 B of  FIG. 8 .  
         [0060]     The conductors  801 ,  802 ,  803  and  804  are placed into engagement with the adhesive  702  of the polyurethane tube when the tube is laid-flat as illustrated in  FIGS. 6A, 7A  and  8 E.  FIG. 8C  is a view similar to  FIG. 8A  only the conductors aren&#39;t insulated.  
         [0061]      FIG. 8D  is a view  800 D similar to  FIG. 8A  only coaxial conductors  801 D,  802 D,  803 D and  804 D are utilized. These conductors are applied when the hose is laid flat so that the polyurethane tube may be easily inserted into the woven outer jacket.  FIG. 8E  is a view  800 E of the laid-flat hose with the coaxial conductors applied thereto. Any conductor, insulated or non-insulated, may be applied as illustrated in  FIG. 8E .  
         [0062]      FIG. 9  is a view  900  illustrating the polyurethane tube  601  partially inserted into the woven outer jacket  401 .  FIG. 9A  is a view  900 A illustrating the polyurethane tube  401  fully inserted into the woven outer jacket. An annular gap  901  exists between the polyurethane tube  601  and the woven outer jacket  401 .  
         [0063]     Inserting  308  the polyurethane tube  601  into the outer woven jacket is performed with the conductors attached thereto.  FIG. 9B  is a view  900 B illustrating the laid-flat polyurethane tube inserted into the woven outer jacket. While  FIGS. 9 and 9 A schematically illustrate the polyurethane tube  601  as concentric with the outer woven jacket  401 , the installation of the polyurethane tube will preferably be in its laid-flat state as indicated in  FIG. 9B . In this way, the laid-flat condition of the polyurethane hose is more conducive to insertion within the woven outer jacket.  
         [0064]     The outer woven jacket is pulled over a metal string, rod or other similar structure and then the polyurethane hose being attached to the metal string, rod or other similar structure and is pulled through the outer woven jacket. The adhesive does not interfere with threading the polyurethane hose through the outer woven jacket because it is not yet activated.  
         [0065]      FIG. 10  is a view  1000  illustrating the pressurization of the inner polyurethane tube with steam. Nozzle or valve  1001  admits steam to the polyurethane tube  601 .  
         [0066]     In practice, the step of steaming  309  to form the hose is performed on a table. If polyurethane tube  601  is in its laid-flat state, it may have to be opened to admit the steam to its inner portion for expansion and heat activation of the adhesive.  FIG. 10B  is a view  1000 B which illustrates the polyurethane tube  601  over a flange  1005  which admits steam to the interior of the tube. As steam is admitted to the interior of the polyurethane tube, it expands and the adhesive is activated which increases its tackiness and hence its ability to act as an adhesive. As the polyurethane tube expands it is melting to conform to the shape of the inside of the outer woven jacket.  
         [0067]      FIG. 11  is a perspective view  1100  of the inner tube, the polyurethane tube, and the outer jacket secured with the conductors affixed between the adhesive on the exterior of the tube and the outer jacket. This view illustrates the composite hose.  FIG. 11A  is a top view  1100 A of  FIG. 11  and illustrates the conductors embedded in the adhesive.  
         [0068]      FIG. 11B  is a front view of  FIG. 11 .  FIG. 11C  is an enlargement of a portion of  FIG. 11A  illustrating the polyurethane inner tube or liner  601 , heat-activated adhesive  702  between the polyurethane tube  601  and the conductors and between the polyurethane tube  601  and the outer jacket  401 .  FIG. 11C  also illustrates the latex sealant layers  503 ,  504 .  
         [0069]      FIG. 12  is an illustration  1200  of the hose  1100  used in combination with a well casing  1201  and a well pump  1202  in a well  1206 . Connector  1204  connects hose  1100  to pump  1202  and connector  1205  connects hose  1100  to the upper flange at the top of the casing. Water within pump casing  1201  is indicated by reference numeral  1207 . Water is taken in the pump through pump suction  1203  at the bottom of pump  1202  and is raised within hose  1100 , piping  1210  and into surge tank  1208  where it is stored for usage by load  1209 .  
         [0070]     Referring to  FIG. 11A , water within the hose does not contact any of the conductors whether or not they are insulated. The polyurethane tube  601  is an insulator as indicated in  FIG. 11C .  
         [0071]      FIG. 3A  is an illustration  300 A of the process steps for manufacturing another embodiment of the present invention.  FIG. 3A  includes the step  310  of passing the composite hose through adhesive to affix wires to the exterior of the composite hose. This can be accomplished by extruding a thermoplastic material such as polyurethane or polyethylene on the exterior of the composite hose.  FIG. 11D  is a cross-sectional view  1100 D of another embodiment of composite hose made by the process illustrated in  FIG. 3A  illustrating a thermoplastic adhesive  1180  applied over conductors  801  on the exterior of a composite hose. The composite hose includes, as discussed before, a polyurethane or polyethylene liner applied to a woven outer jacket. A conductor (or a plurality of conductors) such as conductor  801  is/(are) secured to the exterior of the outer woven jacket  401  by a thermoplastic adhesive applied by an extruder.  
         [0072]      FIG. 3B  is an illustration  300 B of the process steps for manufacturing another embodiment of the present invention. This process includes affixing  311  wires to the outside of a woven outer jacket  1190 . Outer woven jacket  1190  is a through the weave extrusion having a thin lining of approximately 0.035 inches. This embodiment includes the step of passing  312  the woven outer jacket through a secondary extruder to apply molten polyurethane selectively over just the wires.  FIG. 11E  is a cross-sectional view  1100 E of another embodiment of composite hose made by the process illustrated in  FIG. 3B  illustrating hot-melted polyurethane or polyethylene  1191  bonding  1193  the wires  1192  to the outside of the hose  1190 . Polyurethane or polyethylene is applied just over the wire or wires by an extruder designed to extrude locally over the wires. Multiple wires may be employed as set forth in previous figures and in this description above and they can be located in proximity with each other.  
         [0073]      FIG. 12A  illustrates hose union  1200 A which enables joinder of two sections of hose  1250 ,  1256 . Hose section  1250  includes conductors  1251  and  1252  which mate with conductor receptacles  1255 ,  1254  respectively. Conductors  1257 ,  1258  electrically communicate with receptacles  1254 ,  1255  respectively. Threaded member  1253  is affixed to hose section  1250  and threaded member  1262  rotates with respect to hose member  1256  and stop  1260 . Seal  1261  prevents water from escaping.  
         [0074]     As mentioned before, a plurality of conductors may be used in the hose. Wire diameter size and material is a function of ampacity needed to drive the pump motor. Additionally, larger diameter wire can be used and a larger number or wires may be used to counteract the torque of the pump motor to maintain the hose in an untwisted condition.  
         [0075]     The composite hose as set forth in  FIG. 11A , for example, may be produced in different sizes for use in different diameter wells. Most wells will utilize hose having diameters of 4, 6 or 8 inches but other sizes are specifically contemplated.  
         [0076]     It will be understood by those of skill in the art that the invention has been described by way of example only and that changes may be made to the invention without departing from the spirit and scope of the appended claims.