Abstract:
Among the several aspects and features of the present invention may be noted the provision of an improved portable hose reel cart having a low-entry point for recoiling a hose in conjunction with an elevated hand crank for use in rotation of the reel. In an additional embodiment, the elevated hand crank is also used for movement of a level-wind hose guide for positioning of the flexible hose around the hose reel. The present invention also provides an enclosure that includes injection molded panels having integrally formed connectors adapted to cooperate with injection molded as well as extruded panels for assembly of a hose reel enclosure.

Description:
RELATED APPLICATIONS 
   This application is a continuation in part of Ser. No. 29/243,432 filed Nov. 23, 2005 entitled Bottom Feeding Hose Reel Enclosure with Wheels and a See Through Cover, Ser. No. 29/243,433 filed Nov. 23, 2005 entitled Bottom Feeding Hose Reel Enclosure With Wheels and Opaque Cover, Ser. No. 29/243,434 filed Nov. 23, 2005 entitled Bottom Feeding Hose Reel Enclosure with See-Through Cover, Ser. No. 29/243,435 filed Nov. 23, 2005 entitled Bottom Feeding Hose Reel Enclosure, Ser. No. 29/243,426 filed Nov. 23, 2005 entitled Ornamental Shape for a Hose Reel Enclosure with Wheels, Ser. No. 29/243,502 filed Nov. 23, 2005 entitled Ornamental Shape for a Hose Reel Enclosure with See-Through Cover, Ser. No. 29/243,503 filed Nov. 23, 2005 entitled Ornamental Shape for a Bottom Feeding Hose Reel Enclosure, the contents of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   This invention relates generally to garden tools, and more specifically to a hose reel device having an entry point below the centerline of the reel for stability of the enclosure and a crank operation point at or above the centerline of the reel for ease of operation. 
   BACKGROUND OF THE INVENTION 
   Portable hose reel carts for handling and storage of flexible water hoses, such as garden and air hoses, have gained wide public acceptance. While the construction of hose reel carts is quite varied, such carts are primarily constructed of molded plastic components having a centrally disposed rotatable spool for reeling of the flexible hose, a frame for supporting of the spool, wheels may be included at one end of the base of the frame, and a frame handle for tilting the frame onto the wheels to facilitate moving the cart. The frame handle may, or may not be foldable or telescoping for purposes of shipping and/or storage. For more information concerning the structure and operation of hose reel carts, reference may be made to U.S. Pat. RE. 32,510, and U.S. Pat. No. 5,998,552 the teachings of which are hereby incorporated by reference. 
   Common to hose reel carts is the use of a crank handle secured to a hub for use in rotation of a spool. The spools are typically arranged with the crank handle located at the center of the hub to wind the flexible hose. Attempts have been made to move the location of the crank handle, however, such attempts typically employ the use of a sprocket and chain assembly leaving little in the way of efficiency, ratio gearing, or the ability to compactly store such a device. The advantage of an elevated crank handle is to allow rotation of the spool by an operator who need not bend over to perform the operation. Standing upright lessens the strain on an individual&#39;s back, but typically crank movement does not address the change in location for gearing leverage, or address storage of such a device. 
   For instance, U.S. Pat. No. 1,115,325 discloses a garden hose reel storage device wherein the spool is rotated from a crank mounted a distance above the spool. The remotely mounted crank is coupled by a chain extending between a pair of sprockets for driving the spool. A smaller sprocket secured to the crank provides a gear reduction to the larger sprocket adjacent to the spool. The direct coupling requires a large diameter spool sprocket that is difficult to shield and creates dangerous pinch points. 
   U.S. Pat. No. 5,388,609 discloses a hose reel cart having a remotely mounted crank handle coupled to a spool by a chain and sprocket assembly. This disclosure utilizes an oversize crank handle thereby reducing the size of sprockets needed to transfer rotation from the hand crank to the hose reel spool. 
   U.S. Pat. No. 4,947,627 discloses a hose reel cart employing yet another sprocket and chain drive assembly. In this disclosure a crank sprocket is mounted along a side wall of the cart, at a slightly elevated position. The hand crank remains well below the cart handle. Thus, the device fails to take advantage of the highest point on the cart and continues to force the operator to crank the spool from a lower position. 
   U.S. Pat. Nos. 6,742,740, 6,908,058 and 6,976,649, assigned to same assignee as the instant invention, disclose hose carts with elevated cranking positions. These devices all utilize various combinations of intermeshing gears to transmit power between the crank, the reel and/or the level-wind device. However, one shortcoming with these devices is the elevated point from which the hose is recoiled onto the reel. The elevated recoil position may increase the likelihood of overturning the device during hose rewinding. 
   U.S. Pat. No. 5,404,900, assigned to the same assignee as the instant invention, discloses a hose enclosure with a level-wind apparatus for distributing the hose in an even manner across the face of a reel. 
   Thus, what is lacking in the art is a hose reel device having an elevated crank handle and a low-entry area for recoiling the hose. Also what is lacking in the art is a hose reel enclosure that includes a combination of injection molded and extruded panels for a low-cost yet robust enclosure. Prior art assemblies that utilize extruded panels require separate connectors to attach the panels together, increasing the number of components and connections required to assemble an enclosure, thereby increasing the complexity an cost of assembly. The hose reel device should include intermeshing gear drives for transfer of motion from the crank to the reel and/or level-wind components. 
   SUMMARY OF THE INVENTION 
   Among the several aspects and features of the present invention may be noted the provision of an improved portable hose reel cart having a low-entry point for recoiling a hose and an elevated hand crank for use in rotation of the reel spool. In an additional embodiment, the elevated hand crank is also used for movement of a level-wind hose guide for positioning of the flexible hose around the hose reel spool. 
   The hose reel cart of the present invention is of a shape and design so that the hose reel cart may be preassembled at the factory, thereby eliminating the need for assembly and associated product packaging. Preassembly of the hose reel cart permits the use of an enclosed construction for support of a hose to be wound into a coil of multiple layers with adjacent turns of each layer touching each other by use of a directional spool rotatably coupled to the enclosure. The hose is wound around the spool by use of a remotely located crank providing an direct or indirect rotational link between the crank and the winding of the spool. In the preferred embodiment, the crank is positioned in an upper portion of the enclosure assembly to allow for operation of the device with minimal bending or stooping. A hand-grip on the crank can also be placed in a storage position by pivoting the hand-grip about one end of the crank arm. The hand-grip has a releasable lock for securing the hand-grip in a parallel position with the crank arm for storage, and securing the crank hand-grip in a perpendicular position with respect to the crank arm for operation. In addition to providing the appropriate spacing, the intermeshing gears connect the crank to the reel and the optional level-wind components. 
   The instant invention utilizes a combination of injection molded and extruded panels to create a low-cost yet robust enclosure. Combining injection molded panels with extruded panels facilitates reducing the number of components required to assemble an enclosure when compared to enclosures comprised entirely of extruded panels. Injection molding facilitates integral formation of various connectors about the panel. The integrally formed connectors facilitate connecting the injection molded panel to extruded panels, blow molded panels and injection molded panels, eliminating the separate connectors required by the prior art devices. 
   Thus, an objective of the instant invention is to provide a portable hose reel enclosure having an elevated crank handle and a low-point of entry for retraction of a hose. 
   Another objective of the instant invention is to disclose a hose reel enclosure that includes injection molded as well as extruded panels to provide a lightweight yet robust enclosure assembly. 
   Yet another objective of the invention is to provide a portable hose reel cart having an elevated crank handle that can position a hose guide in addition to providing rotation to the hose reel hub. 
   Still another objective of the instant invention is to teach a combination of injection molded and extruded panels wherein connectors are integrally formed onto the edges of injection molded panels for connection to extruded and/or blow molded panels. 
   Still yet another objective of the instant invention is to provide an enclosure assembly which reduces the number of components required to assemble an enclosure to simplify construction. 
   A further objective of the instant invention is to provide a hose reel enclosure having a structural lid member having a lid strap for lid retention. 
   Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of the specification and include exemplary embodiments of the present invention and illustrate various objectives and features thereof. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  is a front perspective view illustrating a hose reel apparatus constructed with the teachings of the present invention; 
       FIG. 2  is a rear perspective view illustrating a hose reel apparatus constructed with the teachings of the present invention; 
       FIG. 3  is a front perspective view illustrating a the lid member of the enclosure in an open position; 
       FIG. 4  is a partial perspective view illustrating a gearbox and a level-wind assembly constructed with the teachings of the present invention; 
       FIG. 5  is a partial perspective view illustrating a gear-train constructed with the teachings of the present invention; 
       FIG. 6  is an exploded perspective view illustrating integrally formed bearing surfaces constructed with the teachings of the present invention; 
       FIG. 7  is a rear perspective view of the front panel constructed with the teachings of the instant invention; 
       FIG. 8  is a perspective view of one embodiment of a reel suitable for use in the instant invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
   Referring generally to the Figures, a hose reel apparatus  10  having an elevated point of operation and a low-entry point for hose retrieval is illustrated. The hose reel apparatus of the preferred embodiment includes an enclosure assembly  12 , a spool assembly  14 , a level-wind assembly  16 , a first gear train  18 , a second gear train  20 , and a crank assembly  22 . 
   The enclosure assembly includes a pair of side panels  24  secured in a substantially parallel arrangement. A front panel  26  extends between the side panels  24  at a front portion thereof to enclose the front portion of the enclosure and a rear panel  28  extends between the side panels at a rear portion thereof to enclose the rear portion of the enclosure. A lid member  30  encloses the top portion of the enclosure. In the preferred embodiment, the side members, front panel and lid member are formed by the process of injection molding to include integral connectors, ribs  46  and gussets  48 . The side panels  24  include integrally formed first connectors  32  along one edge thereof and integrally formed second connectors  34  along a second opposite edge thereof. The first connectors  32  are illustrated herein as at least one outwardly extending locking post  34  being constructed and arranged to cooperate in an interlocking manner with at least one inwardly extending socket  36  positioned along the edges of the front panel for interlocking cooperation therebetween. The locking posts  34  are constructed and arranged to cooperate with the front panel for connecting and maintaining a substantially perpendicular relationship between the front and side panel members. It should also be noted that while the locking posts are illustrated as being rectangular in shape when viewed from the end, other shapes suitable for locating and securing panels together may be utilized without departing from the scope of the invention. In a most preferred embodiment, each locking post  34  includes at least one detent or spring lock fastener  38  integrally formed thereto. The spring lock is constructed and arranged to cooperate with a catch surface  40  positioned within each socket for snap-together interlocking engagement. Those skilled in the art will appreciate that the snap-type fasteners  38  can be used throughout the hose reel device  10  to mount or secure components to one another, and to facilitate ready assembly of the cart if it is provided in an unassembled manner. 
   Referring to  FIGS. 2 and 4 , the second connectors  34  are illustrated herein as two spaced apart substantially parallel surfaces  42  extending outwardly from an end surface  44  forming a U-shape for connection to an adjacently positioned extruded or blow molded rear panel  28 . In a most preferred embodiment, at least one of the parallel surfaces include a spring lock fastener integrally formed thereto for cooperation with a catch surface positioned in the rear panel. 
   It should be noted that while the locking posts are illustrated as formed on the edges of the side panels, the locking bosses may be formed on the edges of the front or rear panel and the sockets formed into the side panels without departing from the scope of the invention. 
   Referring to  FIGS. 1-3 , the lid member is illustrated. The lid member includes a bottom surface  50  constructed and arranged to cooperate with the front panel, the rear panel and the side wall members in a closed position to maintain a weather-tight enclosure. The bottom surface  50  illustrates the ribs  46  and gussets  48  facilitated by injection molding of panels. In addition to the strengthening ribs  46 , the bottom surface of the lid member includes a depending lip  51  extending around the perimeter of the lid and a hinge means integrally formed to a rear portion thereof. The hinge means is illustrated herein as a pair of depending C-shaped members  52  and loop shaped receivers  54 . A latch means  56  is integrally formed to a front portion of the lid member for releasably securing the cover to the front panel. The latch means is illustrated herein as a depending spring-lock  58  that is constructed and arranged to cooperate with apertures  60  positioned in the upper edge of the front panel. It should be noted that other latch means well known in the art may be utilized without departing from the scope of the invention. In operation, when the lid is opened a portion of the depending lip  51  pivots to engage an inwardly extending recess  53 . The engagement between the depending lip  51  and the recess  53  control the rotation of the lid and prevent the lid prevent from being removed from the enclosure. Strap  47  may also be provided to control rotation of the lid and further tie the lid to the enclosure. Integrally formed mounts  49  allow the ends of the strap  47  to be snapped into engagement with the lid and the side panel. 
   Injection molding of the panel members offers significant strength, stability and versatility advantages over blow-molding, extrusion or vacuum molding as utilized in the prior art. Injection molding facilitates forming thicker and/or thinner portions within the same panel for areas of high or low stress concentrations such as is required with the first and second connectors to facilitate connection to panels manufactured by different methods. It should also be appreciated that the injection molded panels of the instant invention only require a single wall construction, while the extruded or blow molded panels may include two or more walls integrally connected together. It should also be noted that while only the rear panel is illustrated as being an extruded panel, the first and second connectors may be formed along the edges of any injection molded panel, used in construction of the enclosure, for cooperation with an adjacently positioned extruded or blow molded panel. In this manner, an enclosure comprising various combinations of extruded, injection molded and blow molded panels may be constructed for economy, strength and durability. 
   Referring to  FIG. 8 , a rotatable reel assembly suitable for use with the teachings of the instant invention is illustrated. The rotatable reel assembly  14  is operably connected between the side panels  24  for rotation about an axis of rotation A ( FIG. 4 ). The rotatable reel  14  provides for pick-up, storage and pay-out of an elongated hose member. The spool  14  includes a central hub  62  and a pair of radially extending flanges  64  that are configured to accommodate a length of flexible hose wrapped around the hub  62  between the flanges  64 . In a typical arrangement, the hose reel apparatus  10  may store between 50 to 300 feet of a ⅝ inch common hose. Those skilled in the art will recognize that the hose reel apparatus  10  may include a water/air inlet port or in-tube  66  ( FIG. 2 ) and an outlet port or out-tube (not shown). Typically the in-tube is mounted to the side panel  24  at about the axis of rotation A of the spool  14 . The in-tube is connected to the out-tube by a sliding seal arrangement (not shown) so that the in-tube remains fixed to the side panel  24 , while the out-tube rotates with the spool  14 , and the in-tube and out-tube remain in fluid communication with one another. This arrangement permits rotation of the spool  14  without twisting or torquing internal components, while maintaining sealed fluid communication between the water/air supply and the hose. The preferred in-tube and coupling arrangement can be viewed in U.S. Pat. No. 5,998,552, the contents of which are incorporated herein by reference. 
   Referring to  FIGS. 1 ,  3  and  6 , the crank assembly  22  is rotatably supported and journaled to one of the side wall members  24  at a position above the axis of rotation A to elevate the point of operation for the device. In an alternative embodiment, the crank assembly  22  is rotatably supported and journaled to one of the side wall members  24  at the axis of rotation A. In this manner, the crank could be directly connected to the reel as is well known in the art. 
   The crank assembly preferably includes a foldable handle  68  for a compact storage and shipping configuration. The foldable handle may include a sleeve  70  that is constructed and arranged to rotate about the handle during operation of the crank. In the preferred embodiment the crank  22  is indirectly connected to the spool assembly via a first gear train  18  to provide rotation thereto. A level-wind assembly  16  is optionally located between the side wall members  24  at a position below the axis of rotation A. The level-wind assembly is operably connected to said spool assembly via a second gear train  20  so that rotation of the spool assembly provides reciprocating movement to a hose guide  28  to uniformly and smoothly wrap a hose onto the spool assembly  14  to provide a compact storage configuration. It should also be noted that the device may be utilized without the level-wind or with a manually operated level-wind (not shown) without departing from the scope of the invention. In a preferred embodiment, the level-wind assembly  16  is automatically reciprocated with the reel. The automatic level-wind assembly  16  includes a double-helix lead screw  72  suitably supported and journaled in the side panels  24  for rotational movement and a single guide element  74  extends between the side panels. It should be noted that while a rod is illustrated as the guide element, other structures such as rails, cables, grooves and the like may be utilized without departing from the scope of the invention. When the spool  14  is rotated the second gear train  20  illustrated in  FIG. 6 , transfers rotary motion from the spool  14  to the double-helix lead screw  72 . A guide  28  cooperates with the double-helix lead screw  72  and slides along the guide element  74  to cause the guide  28  to reciprocate back and forth across the spool  14  facilitating even distribution of the flexible elongate member onto the spool. 
   Still referring to  FIG. 6 , in order to provide manual rotation of the hose reel  14  and reciprocation of the automatic level-wind assembly  16 , a first gear train  18  is positioned within one of the side panels  24 . The crank assembly  22  ( FIG. 3 ) includes an input shaft (not shown) extending inwardly through an opening  76  in an upper portion of the side panel  24  and rotatable with respect thereto. The input shaft is secured to the input gear  78  of the first gear train  18  at a position at or above the axis of rotation A. The spool gear  80  is suitably secured to the spool  14  so as to be rotatable therewith. Idler gears  82 A and  82 B are positioned within the side panel  24  to be freely rotating with respect to the side panel and directly meshed with the input gear  78 , one another, and the spool gear  80  to provide gear powering therebetween. Thus, rotational movement of the input gear  78  with handle assembly  22  will cause similar rotational movement of the spool gear  80  and spool  14 . Preferably the spool gear  80  will be larger in pitch diameter than the pitch diameter of the input gear  78  thereby achieving a torque increasing gear reduction desired by the present invention. It should be noted that while the crank is illustrated herein as connecting to the reel at a position above the axis of rotation, the crank may be directly coupled to the reel or any number of idler gears may be utilized for spacing to place the crank above the axis of rotation without departing from the scope of the invention. 
   Still referring to  FIG. 6 , the second gear-train  20  utilizes rotation of the spool  14  to cause rotation of the double-helix lead screw  72 . The lead screw gear  84  is suitably secured to the lead screw  72  to be rotatable therewith. Idler gears  86 A and  86 B are positioned within the side panel  24  to be freely rotating with respect to the side panel  24  and directly meshed with the spool gear  80 , one another, and the lead screw gear  84  to provide direct gear powering therebetween. Thus, rotational movement of the spool gear  80  will cause similar rotational movement of the lead screw gear  84  and reciprocation of the hose guide  28 . Preferably the spool gear  80  will be larger than the lead screw gear  84  thereby achieving the desired amount of hose guide  28  travel per spool  14  revolution for a compact hose storage configuration. It should be noted that while the level-wind assembly is illustrated herein as positioned at a lowermost position within the enclosure, the level wind assembly may utilize more or less idler gears for spacing to position the level-wind at any position at or below the axis of rotation without departing from the scope of the invention. 
   Referring now to  FIG. 3 , the enclosure includes a pair of spaced apart side members  24  and may include a storage bin  88  that extends between the side panels. The storage bin is preferably formed as a single piece having multiple living hinges  90  which facilitate assembly. A pair of tabs  92  extend outwardly from the sides of the storage bin to facilitate connection to storage bin receivers  94  which are preferably integrally formed to the inner surface of the side members  24 . Alternatively, the storage bin may be formed of multiple components that are glued or suitably fastened together and attached to the inner surface of the enclosure panels as is known in the art. The storage bin  88  can be used to store various hose attachments, such as, spray heads, nozzles and the like. Consumers will recognize the advantage to having the handy storage bin  88  mounted within the enclosure assembly, so that hose attachments can be readily stored with the hose and easily accessed, rather than stored in another location and possibly misplaced or lost. 
   All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. 
   It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein. 
   One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.