Abstract:
A reel assembly is provided with a hub and opposing flanges that may be disassembled into at least two primary components that may be at least partially nested with one another for compact storage and transport. A stepped or tapered axle is axially received by the hub from only one direction to promote ease of assembly. A mounting plate secures to one end of the axle for mounting the reel assembly to any generally planar surface. A braking system is provided that simply permits free rotational movement of the reel one direction and a drag brake in the opposite direction. A swivel cap of unitized design incorporates retention in the axial and linear directions simultaneously.

Description:
BACKGROUND 
     Reel assemblies are commonly used for storing and using many types of hoses. The common reel assembly design is comprised of a hub, a pair of opposing flanges disposed at the opposite ends of the hub, and an axle upon which the hub may turn. Most reel assemblies leave a manufacturer&#39;s location, mostly, if not fully, assembled. This can create a bulky shipment that consumes valued shipping resources. Prior art designs have failed to produce a reel assembly that may be shipped in a compact, disassembled form. Any attempts at such a design have merely created an assembly nightmare for the end consumer. Accordingly, a reel assembly design is needed that permits shipment, storage and sale of the reel assembly in a partially disassembled form. However, such a design should be relatively simple for assembly by end users. 
     Another common problem found in typical reel assemblies is the fact that the reel assemblies will freely rotate in either direction. Accordingly, when a user pulls hose from the reel assemblies and then stops, the forward momentum of the rotating reel assembly will continue to unreel hose. This can lead to tangling of the hose and simply creates additional reeling for the end user once they are finished using the hose. Braking systems have been previously utilized in various reel assemblies but are either complex in design, which tends to create higher manufacturing costs and propensity for breakdowns, or the braking systems simply provide too little or too much resistance to the unreeling of hose. Furthermore, most prior art braking systems are engaged at all times. Operators must manually disengage such braking systems or reel the hose with the brake engaged. Accordingly, a novel braking system is needed that is simple in design but provides an adjustable measure of braking to the reel assembly, according to a user&#39;s needs. Such a braking system should also function so that it is only engaged while the reel is being unreeled. 
     SUMMARY OF THE INVENTION 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter. 
     A preferred reel assembly of the present invention is provided with a hub, having opposite end portions and an exterior surface that is adapted for supporting a length of hose. In one preferred embodiment, the hub is selectively divisible into at least first and second hub members that are each provided with mating surfaces, which engage one another when the hub is disposed in an assembled position. A pair of opposing flanges project radially outwardly from the opposite end portions of the hub to form an annular channel for receiving the hose. An axle is provided, having first and second end portions, coaxial with the hub, and coupled with the hub in a manner which permits selective rotation of the hub about the axle. In one preferred embodiment, the opposing flanges and the first and second end portions are shaped and sized to permit nesting of the structures into a compact form when the reel assembly is at least partially disassembled. In another preferred embodiment, the axle may be provided in a tapered or stepped form that may only be received by the hub in one direction, thus promoting simplicity of assembly. 
     One preferred embodiment of the reel assembly includes the use of a braking system that allows free reeling in one direction and a drag brake in the opposite direction to prevent self-unwinding of the hose. In still another preferred embodiment, the reel assembly comprises a rotary water union, having a rotor cap of unitized design, which incorporates retention in axial and linear directions simultaneously. While designed for easy removal, the design eliminates the need for separate fastening pins or clips. The design further permits the reel assembly and hose to be easily removed from its point of use for winter storage. 
     It is therefore a principal object of the present invention to provide a reel assembly that is configured to provide a compact, partially disassembled form for shipping and storage. 
     A further object of the present invention is to provide a reel assembly that is provided in at least two component parts that are shaped and sized to at least partially nest with one another to provide a compact unit when disassembled. 
     Still another object of the present invention is to provide a reel assembly that utilizes a tapered or stepped axle that may be axially received within the hub of the reel assembly in only one direction, thus promoting simplicity of assembly. 
     Another object of the present invention is to provide a reel assembly having a braking system that permits free reeling in one direction and a drag brake in the opposite direction. 
     A further object of the present invention is to provide a reel assembly having a braking system that is relatively simple in design, while providing adjustability of braking action. 
     Still another object of the present invention is to provide a reel assembly having a rotary water union with a rotor cap of unitized design that incorporates retention in the axial and linear directions simultaneously. 
     Yet another object of the present invention is to provide a reel assembly that is relatively simple in design and assembly 
     A further object of the present invention is to provide a reel assembly having a mounting plate that is coupled to one end of the reel assembly axle for securing the reel assembly to nearly any generally planar surface. 
     These and other objects of the present invention will be apparent after consideration of the Detailed Description and Figures herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  depicts a perspective view of one embodiment of the reel assembly as the same could be used with an optional mounting bracket; 
         FIG. 2  depicts an exploded view of the reel assembly and mounting bracket depicted in  FIG. 1 ; 
         FIG. 3  depicts a front elevation view of the reel assembly and mounting bracket depicted in  FIG. 1 ; and 
         FIG. 4  depicts a partially cut-away, front elevation view of the reel assembly and mounting bracket depicted in  FIG. 1 ; 
         FIG. 5  depicts a partially disassembled, isometric view of one embodiment of an axle, bushings and braking assembly of the reel assembly; 
         FIG. 6  depicts a partially disassembled, isometric view of on embodiment of a swivel, end-cap and one end of an axle of the reel assembly; 
         FIG. 7  depicts a partially cut-away, side elevation view of the swivel, enc-cap and axle depicted in  FIG. 8 ; 
         FIG. 8  depicts a partially cut-away, end view of one embodiment of a braking assembly of the reel assembly as it rotates in a braking direction; 
         FIG. 9  depicts the braking assembly of  FIG. 8  as the same may rotate in a free-reeling direction; 
         FIG. 10  depicts a partial, isometric view of one embodiment of a hose clamping system of the reel assembly; and 
         FIG. 11  depicts a partial, cut-away, side elevation view of the hose clamping system depicted in  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims. 
     The reel assembly  10  of the present invention is provided for use with a hose  12 . The reel assembly  10  is generally comprised of a hub  14 , having opposite end portions  16  and  18  and an exterior surface  20 , which is adapted for supporting a length of the hose  12 . In a preferred embodiment, the hub  14  is selectively divisible into at least a first hub member  22  and a second hub member  24 . The first hub member  22  and second hub member  24  are each provided with mating surfaces  26  and  28 , respectively, which engage one another when the hub  14  is disposed in an assembled position. While the hub  14  depicted in the Figures is shown to be divided along a plane normal to the long axis of the hub  14 , it is contemplated that the hub  14  could be separable along a plane that is co-planar with the long axis of the hub  14 . A pair of opposing flanges  30  and  32  project radially, outwardly from the opposing end portions  16  and  18  of the hub  14 , to form an annular channel for receiving a length of the hose  12 . While not depicted, it is contemplated that, in the event that the hub  14  is divided along a plane that is co-planar to the long axis of the hub, the opposing flanges  30  and  32  could similarly be divided at their midpoints. 
     An axle  34 , having a first end portion  36  and a second end portion  38 , is provided to extend co-axially with the hub  14  and be operatively coupled with the hub  14  in a manner that permits selective rotation of the hub  14  about the axle  34 . In one preferred embodiment a first bushing  40  and second bushing  42  may be provided to be received adjacent the opposite end portions  16  and  18  of the hub  14  to assist in the rotational movement between the hub  14  and the axle  34 . In one embodiment, locking fingers  44  may be positioned adjacent end portions of the first and second bushings  40  and  42 , as depicted in  FIGS. 5 and 11 . The locking fingers  44  may be provided with engagement tabs  46 , which are shaped and positioned with respect to the bushings to engage an inner lip  48  of either end portion of the hub  14 , as depicted in  FIG. 11 . In this manner, undesired travel of the first and second bushings along the axle  34  or with respect to the hub  14  is substantially prevented. 
     To assist in the relative ease with which the reel assembly  10  may be assembled, the axle  34  may be provided to have a shape that is stepped or tapered along its length, leaving the first end portion  36  and second end portion  38  with diameters that are different from one another. In a preferred embodiment, the openings formed through the first bushing  40  and second bushing  42  will be shaped and sized to only properly receive one of the first end portion  36  or second end portion  38  of the axle  34 . Likewise, it is contemplated that a preferred embodiment will shape and size the first bushing  40  and second bushing  42  so that they have different outer diameters from one another, so that they may each be properly received by one of the opposite end portions of the hub  14 . Accordingly, in this manner, the hub  14 , axle  34 , first bushing  40  and second bushing  42  may only be properly coupled with one another in one manner. Keys  50  may also be provided along the exterior surface of either bushings that are positioned to mate with keyways  52 , formed in one end portion of the hub  14 , to ensure that the bushings may only be coupled with their intended end portion of the hub  14 . Key  50  further prevents bushing  42  from spinning with respect to the hub  14 . By limiting the number of component parts and creating a single manner in which they may properly receive one another, relative ease of assembly is increased greatly. Moreover, assembly is made virtually mistake proof. 
     In one embodiment, the reel assembly  10  may be mounted to any generally planar surface, using a mounting plate  54 , such as that depicted in  FIG. 2 . Mounting tabs  56  and other such commonly known structures may be provided along the mounting plate  54  to secure the mounting plate  54  to the generally planar operating surface, such as a wall or a frame assembly to any portable or stationary device. An opening  58  should be formed through the mounting plate  54  and sized to accommodate the first end portion  36  of the axle  34 . A key  60  and keyway  62  may also be provided on the axle  34 , adjacent the first end portion  36 , and the mounting plate  54 , adjacent the opening  58 , to ensure one way alignment for ease of assembly and to substantially limit undesirable rotation of the axle  34  with respect to the mounting plate  54 . A lock nut  64  may be axially received along the axle  34  to secure the mounting plate  54  adjacent the first end portion  36  of the axle  34 . In this manner, the mounting plate  54  is secured between the lock nut  64  and the first end portion  36  of the axle  34 . Mating threads  66  may be provided along the axle  34  to receive the lock nut  64  in a secure fashion. Providing the first end portion  36  of the axle  34  with a diameter greater than the diameter of the opening  58  in the mounting plate  54  will ensure that the axle  34  may not be passed completely through the opening  58  as the lock nut  64  is secured. 
     In one preferred embodiment, the mounting plate  54  is shaped to have a generally concave rearward surface  68  sufficient to provide a passageway for a length of the hose  12  to extend adjacent the generally planar mounting surface and under the mounting plate  54 . In this manner, a feed hose (not depicted) may be passed under the mounting plate  54 , through its opening  58 , and through an open interior portion of the axle  34 . An end portion of the hose  12  may then be joined with a swivel fitting  70 , such as that depicted in  FIGS. 6 and 7 . In one preferred embodiment, a swivel cap  72  is disposed around one end portion of the swivel fitting  70 . The swivel cap  72  is provided with a pair of locking tabs  74  that are shaped and sized to be releasably received within recesses or openings  76  formed in the second end portion  38  of the axle  34 . Accordingly, as depicted  FIG. 7 , the swivel cap  72  is dimensioned to be received by the second end portion  38  of the axle  34  in manner that aligns the locking tab  74  with the opening  76 . In a preferred embodiment, the locking tabs  34  are provided to be generally resiliently deformable, so that they may be selectively removed from the openings  76 . Arms  78  may be provided to extend outwardly from the locking tab  74  in a manner that permits manual engagement of the arms  78  to bias the locking tabs  74  outwardly, thus permitting easy removal of the swivel cap  72  from the second end portion  38  of the axle  34 . In its assembled position, the swivel cap  72  prevents the hub  14  from being unintentionally removed from the second end portion  38  of the axle  34 . The swivel cap  72  further prevents the torque of the distal end of the swivel fitting  70  from twisting the hose  12 , which is attached to the opposite end of the swivel fitting  70 . 
     An elongated hose  12  may be provided to extend from the distal end portion of the swivel fitting  70 , through an opening  80  formed through the flange  32 . Once the hose  12  is passed through the opening  80  it may be preferable to secure the hose  12  closely adjacent the flange  32 , adjacent the hub  14  to provide an orderly and secure position of the hose  12  adjacent the exterior surface  20  of the hub  14 . As depicted in  FIGS. 10 and 11 , a releasable hose clamp  82  may be passed through a pair of openings  84  and  86  formed through the flange  32  and hub  14 , and looped around the hose  12 . The free end of the hose clamp may be passed through the hose clamp buckle and tightened accordingly. The flexible and releasable nature of the hose clamp  82  will provide it with a long usable life that permit the removal and replacement of the hose  12  with ease. 
     In one embodiment a braking means is operatively coupled with the hub  14  for resisting rotation of the hub  14  with respect to the axle  34  in at least one direction. One contemplated embodiment of the braking means is depicted in  FIGS. 5 ,  8  and  9 . Specifically, a braking ring  88  is shaped and sized to be at least partially received by one end portion of the second bushing  42 . At least one finger  90  may be provided to extend outwardly from an exterior surface of the braking ring  88 . The finger  90  is preferably shaped and positioned to engage at least one tooth  92  formed in an inner surface of the second bushing  42 . While variations on the specific design depicted are contemplated, the stepped and tapered design of the fingers  90  engage the teeth  92  when the braking ring  88  and the second bushing  42  are rotated in one direction, as depicted in  FIG. 9 . In this manner, the braking ring  88  is frictionally drug by the second bushing  42  across the surface of the axle  34 , retarding free advancement of the reel assembly  10 . However, rotation of the reel assembly in the opposite direction, typically in the reeling direction, the braking ring  88  remains in a fixed position with respect to the axle  34  and the teeth  92  briefly engage the opposite, tapered surfaces of the fingers  90 . In one preferred embodiment, the teeth  92  are disposed at the distal ends of resiliently deformable arms  94 . Accordingly, as the fingers  90  and the teeth  92  come into contact with one another the arms  94  and teeth  92  are biased outwardly to permit the fingers  90  and teeth  92  to pass one another. This permits the reel assembly to be reeled with minimal resistance. It is contemplated that the braking ring  88  may be split along at least one portion of its circumference, as depicted in  FIG. 5 . An adjustment screw  96  may be secured to the braking ring  88  across the split in order to permit selective widening and narrowing of the split. In this manner, the inner diameter of the braking ring  88  may be increased or decreased selectively to adjust the level of frictional engagement between the braking ring  88  and the axle  34  as the braking ring  88  is rotated. 
     It will be desirable to provide the reel assembly  10  in a form that permits a compact, disassembled structure for shipping and storage. Accordingly, in one preferred embodiment, the first hub member  22  and second hub member  24  should be shaped and sized to permit the two components to be nested closely adjacent one another. More specifically, the end portion  16  of the hub  14  may be provided with an open cavity  98  that is shaped and sized to at least partially nest with the mating surface  28  and exterior surface  20  of the second hub member  24  when the hub  14  is disposed in disassembled position. The generally concave outer surface of the flanges  30  and  32 , while promoting the nesting function of the reel assembly  10 , further provide a cavity beneath the second hub member  24  that may receive some or all of the remaining component parts to the reel assembly  10  when the reel assembly  10  is packaged for shipment or storage. 
     Although the invention has been described in language that is specific to structural features and/or methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or steps described. Rather, the specific features and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.