Abstract:
A hose includes a reinforcement structure and a layer exterior to the reinforcement structure. The layer includes a plurality of extensions projecting outwardly. Wear of the plurality of extensions provides a visual indication of the degree of wear of the hose.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/410,307, filed Nov. 4, 2010, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present application relates to a hose, such as a hose designed for use with a high-pressure water flow of a pressure washer. 
         [0003]    A pressure washer typically includes a high pressure hose or line extending between a pump and a spray gun of the pressure washer. Another hose, such as a standard garden hose, supplies water to the pump. During operation, an engine or other motor of the pressure washer drives the pump, which pressurizes water received from the garden hose and provides the water to the high pressure hose and the spray gun. 
         [0004]    Some pressure washers are configured to provide water at pressures exceeding 2000 pounds per square inch (psi), and the high pressure hose between the pump and gun is designed to withstand such pressures without rupturing. Accordingly, some pressure washer hoses include a mesh of strengthening members to reinforce the hose. The strengthening members may be embedded within walls of the hose, and may be integrated in a matrix of plastic or other material forming the walls of the hose. 
         [0005]    Over time a pressure washer hose may be pulled over a broad range of abrasive surfaces, such as asphalt, cement, or rocks hose, and may become worn. Eventually, the outer surface of the hose may be removed, exposing the mesh of strengthening members. The exposed strengthening members may slide against abrasive surfaces, one another, and the remaining layers of the hose, further weakening the hose as well as the strengthening members themselves. However, the degree of wear of the hose may be difficult to ascertain at first glance. 
       SUMMARY 
       [0006]    One embodiment of the invention relates to a hose. The hose includes a reinforcement structure and a layer exterior to the reinforcement structure. The layer includes a plurality of extensions projecting outwardly. Wear of the plurality of extensions provides a visual indication of the degree of wear of the hose. 
         [0007]    Another embodiment of the invention relates to a pressure washer, which includes a pump, a spray gun, and a hose configured to connect the spray gun to the pump. The hose includes a plurality of extensions projecting outwardly from the hose. Wear of the plurality of extensions provides a visual indication of the degree of wear of the hose. 
         [0008]    Still another embodiment of the invention relates to a method of manufacturing a hose. The method includes providing an extrusion die, and extruding a layer of a hose using the extrusion die. The layer includes a plurality of extensions projecting outwardly. Wear of the plurality of extensions provides a visual indication of the degree of wear of the hose. 
         [0009]    Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0010]    The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, in which: 
           [0011]      FIG. 1  is a perspective view of a pressure washer according to an exemplary embodiment of the invention. 
           [0012]      FIG. 2  is a perspective view of a hose for the pressure washer of  FIG. 1 . 
           [0013]      FIG. 3  is cut-away perspective view of a section of a hose according to an exemplary embodiment of the invention. 
           [0014]      FIG. 4  is a sectional view of a layer of a hose according to an exemplary embodiment of the invention. 
           [0015]      FIG. 5  is a sectional view of the outer layer of  FIG. 4  with a portion removed. 
           [0016]      FIG. 6  is a front view of a hose and an extrusion die according to an exemplary embodiment of the invention. 
           [0017]      FIG. 7  is a sectional view of a layer of a hose according to an exemplary embodiment. 
           [0018]      FIGS. 8-10  are perspective views of layers of hoses according to other exemplary embodiments of the invention. 
           [0019]      FIGS. 11-12  are side views of hoses according to still other exemplary embodiments of the invention. 
           [0020]      FIGS. 13-14  are sectional views of hoses according to other exemplary embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting. 
         [0022]    Referring to  FIG. 1 , a pressure washer  110  includes a high pressure water pump  112 , such as an axial cam or triplex water pump, and a spray gun  114  (e.g., sprayer, wand). In some embodiments, the pump  112  is driven by an internal combustion engine  116  mounted to a base plate  118  on a frame  120  above the pump  112 . The pump  112  is designed to receive water from a standard garden hose (not shown), pressurize the water (e.g., from about 60 psi to over 1000 psi), and supply the pressurized water to a high pressure hose  122  connected to the spray gun  114 . The hose  122  may be coiled and stored on the frame  120  and the gun  114  may also be stored on the frame  120 , as shown in  FIG. 1 . In some contemplated embodiments, a horizontally-shafted engine may be coupled to a pump on the same side of a base plate. In other contemplated embodiments, an electric motor may be used to drive the pump. 
         [0023]    According to an exemplary embodiment, the pressure washer  110  is designed to help clean dirt, paint, or mold from pavement, brick face, or other surfaces. To achieve such results, the pressure washer  110  is configured to provide a stream of water at a high pressure, such as approximately 2000 to 3000 psi. In some contemplated embodiments, a heavy-duty pressure washer is configured to provide streams with even higher pressures, such as about 3000 to 5000 psi, and may be designed to perform other tasks, such as resurfacing or cutting of materials that require extremely powerful flows. Accordingly, high-pressure hose lines and spray guns are designed to operate under the pressures associated with such heavy-duty pressure washers. 
         [0024]    Referring to  FIG. 2 , the pressure washer hose  122  includes a first fitting  124  to be coupled to an outlet of the high pressure water pump  112  and a second fitting  126  to be coupled to an inlet of the water gun  114 . The fittings  124 ,  126  may include quick connect fittings, threaded fittings, or other types of connectors. Extending between the fittings  124 ,  126 , the hose  122  includes an elongate body  128  (e.g., conduit), which may exceed ten feet in length. In some embodiments, the fittings  124 ,  126  and body  128  are configured to withstand the operating pressures of the pressure washer  110 , as well as trapped pressures between the gun  114  and pump  112  when the gun  114  is not spraying but the pump  112  is still active (e.g., increasing the pressure by about 100-400 psi above the operating pressures). Such pressures may exceed 2000 psi. In other embodiments, pumps include flow-activated unloaders that do not have trapped-line pressure. 
         [0025]    Referring to  FIG. 3 , a hose  210 , such as a pressure washer hose, includes an inner layer  212  (e.g., core), a reinforced layer  214  (e.g., support layer, middle layer, reinforcement structure), and an outer layer  216  (e.g., outer jacket). In some embodiments, the inner layer  212  is formed via extrusion of a thermoplastic or rubber, and the reinforced layer  214  includes a mesh of strengthening members  218  (e.g., weave, fabric, cross-ply), such as metal fibers (e.g., steel) or fibers used with continuous or discontinuous fiber composites (e.g., nylon webbing, carbon fibers, Kevlar, etc.). The mesh of strengthening members  218  may be integrated in a matrix of thermoplastic, resin, or other material, or may fully form the reinforced layer  214 . In other embodiments, the hose does not include a reinforcement layer and/or inner layer. According to an exemplary embodiment, the outer layer  216  is formed via extrusion of a thermoplastic or rubber, and in some embodiments is formed from the same material as the inner layer. 
         [0026]    Wearing of the outer layer  216  may expose the mesh of strengthening members  218  of the reinforced layer  214 . Exposure of the mesh of strengthening members  218  of the reinforced layer  214  may allow for movement of different strengthening members relative to one another, or may allow for direct contact between the mesh of strengthening members  218  of the reinforced layer  214  and the ground or other surfaces, which may hasten wear of the mesh of strengthening members  218  and the hose  210  in general. As such, exposure of the mesh of strengthening members  218  of the reinforced layer  214  may eventually lead to failure of the hose  210 . 
         [0027]    According to an exemplary embodiment, the outer layer  216  includes an annular portion  220  that is adjacent to the reinforced layer  214 . Extensions  222  (e.g., wear bars, indicators) project from the annular portion  220  of the outer layer  216 . In some embodiments, the extensions  222  are uniformly sized and are spaced around the periphery of the outer layer  216 . The extensions  222  may project from the annular portion  220  by a distance that is at least a sixteenth of an inch (e.g., an eighth of an inch). In some embodiments, the hose  210  further includes grooves  224  formed between the extensions  222 . In other embodiments, the extensions  222  may project from the annular portion  220  by a distance that is less than a sixteenth of an inch, such as at least a thirty-second or sixty-fourth of an inch. 
         [0028]    Referring to  FIGS. 4-5 , layer  312  of a hose  310  includes extensions  314  and grooves  316 . Wearing of the extensions  314  provides a visual indication of the degree of wear of the layer  312 . Upon visual inspection of the hose  310 , wear of the extensions  314  may be shown with reference to the grooves  316 . As the extensions  314  wear, in some embodiments the extensions  314  get wider and eventually merge to be level with adjacent grooves  316 . Accordingly, the extensions  314  may provide an operator of a pressure washer (see, e.g., pressure washer  110  as shown in  FIG. 1 ) the ability to quickly inspect the integrity of the pressure washer hose (see, e.g., hose  122  as shown in  FIG. 2 ). When the extensions  314  are sufficiently worn, such as when extensions  318  ( FIG. 5 ) on a portion of the hose tend to merge or have merged with the adjacent grooves  320  ( FIG. 5 ), then the state of the extensions  318  provides notice to the operator that the hose  310  may need to be replaced. 
         [0029]    Referring to  FIG. 6 , a hose  410  includes an inner layer  412 , reinforced layer  414 , and outer layer  416 , where the outer layer  416  is formed via extrusion. In some cases there may be more than one reinforced layer. The shape of the extrusion die  418  is configured to provide extensions  420 . In some embodiments, fingers  422  of the extrusion die  418  are inversely contoured to match the extensions  420  of the hose  410 . In contemplated embodiments, the extrusion die  418  is moved (e.g., rotated, narrowed/widened) to change the shape of the outer layer  416  as the outer layer  416  is extruded (see  FIGS. 11-12 ). In other embodiments, the extrusion die  418  is fixed, and the shape of the extensions  420  and grooves  424  are constant along the length of the hose  410  (see  FIGS. 8-10 ). In other embodiments, the hose  410  or layers  412 ,  414 ,  416  of the hose  410  are formed by processes other than extrusion. 
         [0030]    Referring now to  FIGS. 6-7 , extensions  420 ,  512  of hoses  410 ,  510  may be pointed (e.g., spiked), and grooves  424 ,  514  between the respective extensions  420 ,  512  may be “V”-shaped ( FIG. 6 ), “U”-shaped ( FIG. 7 ), or otherwise shaped. A pointed extension may provide a good indication of wear because the area of the top of the extension increases as the extension is worn, where the degree of area increase is a function of the remaining height of the extension. In some embodiments, the pointed extensions form longitudinal ridges, while in other embodiments, the pointed extensions are individual spikes on the outer layer. In some embodiments, the hoses  410 ,  510  include about ten to twenty extensions  420 ,  512  and grooves  424 ,  514 . In other embodiments, more than twenty, or less than ten extensions are used. 
         [0031]    Referring now to  FIGS. 8-10 , hoses  610 ,  710 ,  810  include layers  612 ,  712 ,  812  having extensions  614 ,  714 ,  814  that may be square ( FIGS. 9-10 ) or rounded ( FIG. 8 ), and grooves  616 ,  716 ,  816  between the extensions  614 ,  714 ,  814  may also be square ( FIG. 9 ) or rounded ( FIGS. 8 and 10 ). Use of rounded grooves may provide reduced stress concentrations within the grooves (e.g., at the bottom of the groove), which may increase the life of the associated hose. In other contemplated embodiments, rounded or square extensions may be used with “V”-shaped grooves (see, e.g., grooves  424  as shown in  FIG. 6 ). In still other embodiments, otherwise shaped extensions and grooves may be used. 
         [0032]    Referring to  FIGS. 11-12 , hoses  910 ,  1010  include extensions  912 ,  1012  and grooves  914 ,  1014 . The extensions  912 ,  1012  may be continuously connected to each other or may be discontinuous. The grooves  914 ,  1014  may also be continuously connected to each other or may be discontinuous. According to an exemplary embodiment, the extension  912  of hose  910  projects in a spiral manner around the hose  910 . According to another exemplary embodiment, the extensions  1012  project as discontinuous bumps or bulges from the hose  1010 . Use of diagonal, transverse, discontinuous, or otherwise contoured extensions  912 ,  1012  and grooves  914 ,  1014  may provide increased flexibility of the hoses  910 ,  1010 , increased strength, indications of wear, and may also allow fluid to pass under the hoses  910 ,  1010 . 
         [0033]    Referring now to  FIGS. 13-14 , hoses  1110 ,  1210  include outer layers  1112 ,  1212  formed from two separate sub-layers: a sub-layer  1114 ,  1214  of a first colored material and a sub-layer  1116 ,  1216  of a second colored material. The sub-layers  1114 ,  1214  and  1116 ,  1216  may be respectively formed via separate extrusions. In some embodiments, the first color is black and the second color visually contrasts with black, such as red, yellow, or white such that it is relatively easy to see differences in the first and second colors. As the hoses  1110 ,  1210  wear, the sub-layer  1114 ,  1214  of the first color is removed, exposing the sub-layer  1116 ,  1216  of the second color. Visibility of the second color provides an indication of wear of the outer layers  1112 ,  1212 . In other contemplated embodiments, more than two colored sub-layers  1114 ,  1214  and  1116 ,  1216  are used. As shown in  FIG. 14 , the differently colored sub layers  1214 ,  1216  may be used in combination with grooves  1218  and extensions  1220 . 
         [0034]    While  FIGS. 1-2  show the pressure washer  110  and hose  122  for use with the pressure washer  110 , in other contemplated embodiments, hoses or features thereof disclosed herein may be used with a broad range of equipment, such as hydraulic circuits, high-pressure gas lines, or other conduits of fluid. In still other contemplated embodiments, an outer layer, such as those as disclosed herein, may be used with electrical cables or other lines that may be damaged by wear, to provide an indication of the degree of wear, reinforce the lines, increase flexibility of the lines, or for other reasons. 
         [0035]    The construction and arrangements of the hoses, as shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.