Abstract:
The present device provides a composite rotary union assembly which overcomes the disadvantages of prior art rotary union assemblies. The composite rotary union assembly of the present invention provides for supplying water or gas to a rotatable reel assembly, it also provides metal inserts for high wear areas of the rotary union assembly, including the threads, for longer useful life of the assembly while providing a resin structure for supporting and placing the metal portions.

Description:
RELATED APPLICATIONS 
     This application is related to U.S. patent application Ser. No. 13/024,956, entitled Strengthened Inlet/Outlet Swivel Union Fluid Conduit For a Hose Reel, filed Feb. 10, 2011, the contents of which are incorporated herein by reference. 
     FIELD OF INVENTION 
     The present invention relates to hose reels, and more particularly to a rotary union assembly for transferring fluids from a pressurized fluid source to a hose reel storage device. 
     BACKGROUND INFORMATION 
     Garden hoses are a necessity for homeowners and business owners for lawn and garden care, as well as general all-around home care. Typically, hoses are found either wound and left on the ground near a water spigot, or wound on one of many known hose reel-type storage devices. These devices include stationary frames, stationary hose reel hangers that can be mounted to a surface of a building such as an outer wall of a house, and hose reel carts that include wheels for portability. A typical hose reel cart includes a rotatable reel or spool which includes a crank handle extending through the frame such that the spool can be rotated by hand and the hose can be wound or unwound about the spool for storage or use. To provide for flow of water from a water source to the hose, hose reel structures further contain rotary unions. Typical rotary unions have a stationary inlet tube and a movable outlet tube. The stationary inlet tube of the rotary union extends away from the reel and is structured to be coupled to a supply hose, which is further coupled to a water supply. The movable outlet tube cooperates with the inlet tube on one end so that it is rotatable with the spool and includes a second end that is disposed on the circumference of the reel. A hose is coupled to the second end of the movable outlet and is used to deliver water to the end use. The hose is merely wound upon the reel for storage, and pulled or dispensed from the reel for use. Often, these hose reel carts include wheels to permit ready transport of the hose from one location to another. 
     Hose carts are commonly purchased by the general consumer, wherein it is desirable that the hose cart can be easily assembled with minimal use of hand tools. In an effort to provide easy-to-assemble hose reel assemblies, they are typically made of plastic and sold with as many preassembled parts as possible. Many hose reels are currently sold in a ready to use condition, whereby the user merely needs to hook the device to a supply of water or air to use the device. 
     While such efforts have provided the general consumer with a product that is ready to use out of the box, disassembly for maintenance or repair can be difficult. The components are typically formed from resin, e.g. plastic, thereby including plastic threads for cooperation with the hoses that connect to the water or air supply and to the distribution hose. Plastic threads wear quickly and are easily cross-threaded during assembly of the hoses, resulting in leaks that can only be cured with component replacement. In addition, plastic degrades quickly in many environments causing the plastic to become brittle, whereby threads are easily broken. 
     Metal rotary union assemblies have been suggested, however, the complexity of the parts requires expensive tooling. In addition, machining operations are typically required to provide the finishes necessary for proper operation. The nature of molding hot metal necessarily requires extensive maintenance to keep the tooling in operation, increasing the cost of metal rotary union assemblies. 
     Therefore, what is needed in the art is a rotary union assembly for a hose reel that is formed predominantly from resin materials while including metal inserts in high wear and typical fail points of rotary union assemblies. 
     Thus, the present invention provides a rotary union assembly which overcomes the disadvantages of prior art rotary union assemblies. The rotary union assembly of the present invention not only provides for supplying water or gas to a rotatable reel assembly, it also provides metal inserts for threads and high wear areas for longer useful life of the components. 
     SUMMARY OF THE INVENTION 
     Briefly, the present invention provides a composite rotary union assembly which overcomes the disadvantages of prior art rotary union assemblies. The composite rotary union assembly of the present invention provides for supplying water or gas to a rotatable reel assembly; it also provides metal inserts for high wear areas of the rotary union assembly including the threads for longer useful life of the assembly while providing a resin structure for supporting and placing the metal portions. 
     Accordingly, it is an objective of the present invention to provide a composite rotary union assembly for rotatable hose reels whereby the rotary union assembly is formed as a composite of metal and resin. 
     It is a further objective of the present invention to provide a composite rotary union assembly wherein the metal portions are molded into place within the resin material. 
     It is yet a further objective of the present invention to provide a composite rotary union assembly wherein the metal portions are pressed onto the resin and retained with snap-locks. 
     It is another objective of the instant invention to provide a composite rotary union assembly wherein the metal portions are pressed or slipped onto the resin components and a portion of the resin is heat formed to retain the metal in position. 
     It is still another objective of the present invention to provide a composite rotary union assembly wherein the metal portions are slipped onto the resin components and a portion of the metal is roll formed or stamped to retain the metal in position. 
     It is still yet another objective of the present invention to provide a composite rotary union assembly wherein the metal portions are slipped onto the resin components and a fastener member is adhered to the resin to retain the metal in position. 
     Still yet another objective of the present invention is to provide a composite rotary union assembly wherein the in-tube is formed from a metal while the out-tube is formed from a resin material. 
     Yet another objective of the present invention is to provide a composite rotary union assembly wherein the portions of the rotary union assembly are metal plated resin. 
     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 this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is an exploded view of one embodiment of a composite rotary union of the present invention; 
         FIG. 2  is a partial top perspective view of the in-tube shown in  FIG. 1  illustrating a formed in place construction for the composite in-tube; 
         FIG. 3  is an exploded view of the embodiment shown in  FIG. 2 ; 
         FIG. 4  is a front view of the in-tube shown in  FIG. 2 ; 
         FIG. 5  is a section view taken along lines  5 - 5  of  FIG. 4  illustrating the metal and resin portions of the composite in-tube; 
         FIG. 6  is a partial top perspective view of one embodiment of the in-tube shown in  FIG. 1  illustrating a push on type of construction for the composite in-tube; 
         FIG. 7  is an exploded view of the embodiment shown in  FIG. 6 ; 
         FIG. 8  is a front view of the in-tube shown in  FIG. 6 ; 
         FIG. 9  is a section view taken along lines  9 - 9  of  FIG. 6  illustrating the metal and resin portions of the composite in-tube; 
         FIG. 10  is a partial top perspective view of one embodiment of the in-tube shown in  FIG. 1  illustrating a hot form type of construction for the composite in-tube; 
         FIG. 11  is an exploded view of the embodiment shown in  FIG. 10 ; 
         FIG. 12  is a front view of the in-tube shown in  FIG. 10 ; 
         FIG. 13  is a section view taken along lines  13 - 13  of  FIG. 12  illustrating the metal and resin portions of the composite in-tube; 
         FIG. 14  is a partial top perspective view of one embodiment of the in-tube shown in  FIG. 1  illustrating a crimp-on type of construction for the composite in-tube; 
         FIG. 15  is an exploded view of the embodiment shown in  FIG. 14 ; 
         FIG. 16  is a front view of the in-tube shown in  FIG. 14 ; 
         FIG. 17  is a section view taken along lines  17 - 17  of  FIG. 16  illustrating the metal and resin portions of the composite in-tube; 
         FIG. 18  is a partial top perspective view of one embodiment of the in-tube shown in  FIG. 1  illustrating a glue-on type of construction for the composite in-tube; 
         FIG. 19  is an exploded view of the embodiment shown in  FIG. 18 ; 
         FIG. 20  is a front view of the in-tube shown in  FIG. 18 ; 
         FIG. 21  is a section view taken along lines  21 - 21  of  FIG. 20  illustrating the metal and resin portions of the composite in-tube; 
         FIG. 22  is a partial top perspective view of one embodiment of the in-tube shown in  FIG. 1  illustrating a solid metal type of construction for the composite in-tube; 
         FIG. 23  is a front view of the in-tube shown in  FIG. 22 ; 
         FIG. 24  is a section view taken along lines  24 - 24  of  FIG. 23  illustrating the metal and resin portions of the composite in-tube; 
         FIG. 25  is a partial top perspective view of one embodiment of the in-tube shown in  FIG. 1  illustrating a metal plated resin type of construction for the composite in-tube; 
         FIG. 26  is a front view of the in-tube shown in  FIG. 25 ; and 
         FIG. 27  is a section view taken along lines  27 - 27  of  FIG. 26  illustrating the metal and resin portions of the composite in-tube. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     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 composite rotary union, generally referred to as  10 , is illustrated. While the composite rotary union assembly can be made of any material, it is preferably made of a combination of resin, e.g. plastic with metal inserts  100 ,  200 ,  300 ,  400 ,  500 ,  600 , and  700  positioned in high wear or high stress areas, which provides the necessary strength, durability, and precision needed to perform its required functions. The metal inserts  100 ,  200 ,  300 ,  400 ,  500 ,  600 , and  700  further provide stronger engagement with mating hose couplings and reduce the possibility of cross threading when attaching the inlet tube  12  or outlet conduit  14  to an elongated hose member. The composite rotary union assembly  10  may be used for various applications that require transfer of fluids from one place to another when one assembly needs to rotate while the other remains fixed. A common application of the composite rotary union assembly  10  includes being part of a hose reel assembly. Accordingly, the instant invention will be described using such an application. However, placement or use in hose reel assemblies is not a limiting application as the composite rotary union assembly  10  can be placed in other devices as well. In should be noted that while the primary embodiments are illustrated in the form of the inlet tube, all the embodiments may be applied to the outlet conduit without departing from the scope of the present disclosure. It should also be appreciated that while the metal inserts  100 ,  200 ,  300 ,  400 ,  500 ,  600 , and  700  are illustrated as solid metal, resins coated or plated with metal may be utilized without departing from the scope of the invention. 
     Referring to the Figures, the composite rotary union assembly  10  includes an inlet tube  12 , an outlet conduit  14 , and a securing member  16 . The inlet tube  12  includes a first end  18  and a second end  20 . The distance between the first end  18  and the second end  20  defines the inlet tube main body  22 . In the preferred embodiment, the inlet tube main body  22  is generally cylindrical in shape and tubular in construction. The inlet tube main body  22  has an inner diameter  23 , which is larger than the outer diameter  66  of a first end  56  of the outlet conduit  14 . The first end  18  of the inlet tube is designed to be coupled or attached to an external fluid supply, such as a hose connected to water supply line (not illustrated). For connection to the hose, the inlet tube  12  includes a metal insert  100 ,  200 ,  300 ,  400 ,  500 ,  600 , and  700  secured or otherwise formed to a polymeric resin, e.g. plastic, which forms the remainder of the inlet tube  12 . As such, the metal insert  100  contains helical threads  24  or other hose connectors for attachment to a hose member; such connections may include bayonet mount, quick connector, barbed connections and the like. The first end  18  further includes an opening  26  for transfer of fluids through the inlet tube. The second end  20  is constructed and arranged to couple or engage with a first end of the outlet conduit  14  and contains an opening  28 . The inner diameter  23  is a generally smooth bore extending from the second end  20  sufficiently toward the first end  18  to cooperate with seals or O-rings  96  positioned along the outer diameter  66  of the outlet conduit  14 . A keying window  46  ( FIG. 5 ) is provided along the second end  20  which cooperates with the securing member  16  and the snap ring groove  93  for securing the inlet tube to the outlet conduit so that one may rotate with respect to the other while maintaining a fluid tight seal therebetween. Arranged circumferentially around the outer surface  30  of the inlet tube main body  22  is a flange  32 . The flange  32  is illustrated as having a generally circular shape. However, such shape is illustrative of a particular embodiment and such shape is not limiting. The flange  32  contains a front surface  34 , a back surface  36 , an outer edge  38  and an inner edge  40  ( FIG. 5 ). Positioned along the circumference of the flange  32  and extending inwardly toward the center are horizontal edges  42  and  44 . Between horizontal edges  42  and  44  is an open space or keying window  46 . The window  46  is sized and shaped to receive a lever portion  47  of the securing member  16 . In this manner, the securing member  16  is forced to rotate or remain stationary with the inlet tube  12 . Groove  93  provides a track for the distal ends  17  of the securing member during rotation. In a preferred embodiment, opposing the horizontal edges  42  and  44  is tab  48  ( FIG. 5 ), which secures to or engages the wall or frame of a hose reel assembly to prevent the flange and/or the inlet tube  12  from rotating during use. The tab  48  contains a rounded front portion  52 , and a second generally rectangular member  54  which extends in an outward direction from the back surface  36 . The metal insert  100 ,  200 ,  300 ,  400 ,  500 ,  600 , and  700  may be made by any number of processes for manufacturing metal including, but not limited to, machining, casting, forging, 3D printing, roll forming, plating and the like. 
     Referring to  FIG. 1 , in this embodiment, the metal insert portion  600  is molded in place during the molding process of the in-tube. The metal insert  600  includes a first bore  102  that is generally smooth and cylindrical in shape. A second bore  104  includes undulations or contours  106  which engage mirrored contours  108  on the core  19  to prevent rotation of the metal insert with respect to the inlet tube  12  ( FIGS. 2-5 ). In a preferred embodiment, the metal insert  600  is placed into the plastic mold (not shown) and the plastic is injected under pressure to fill in the remainder of the mold cavity forming the core  19  at the first end  18  of the main body  22  within the metal insert  600 . Whereby the mirrored contours  108  are formed in place. The end flange  610  is formed as a portion of the metal insert  600  to create a sealing surface  612  for the hose member. 
     Still referring to  FIG. 1 , the outlet conduit  14  includes a first end  56  and a second end  58 . The distance between the first end and the second end defines a generally cylindrically shaped outlet conduit body  60 . The first end  56  is sized and shaped to couple or engage the inlet tube  12  through insertion within the second end  20  of the inlet tube  12 . The connector portion  67  includes O-ring or seal grooves  94  and snap ring grooves  93 , which cooperates with the securing member  16  to maintain watertight engagement between the inlet tube  12  and the outlet conduit  14 . Positioned along the outer surface  66  of the horizontal outlet conduit body  60  are gussets  68  and  70 . A plurality of outwardly extending keyed flanges  72  and  74  are sized and shaped to provide support for, coupling to and/or engaging with the hose reel spool or the wall or frame of the hose reel assembly. The keyed flanges  72  and  74  prevent the hose reel spool from rotating separately from the outlet conduit  14 . The horizontal portion of the outlet conduit body  60  is shaped to extend through the central portion of a hose spool. Accordingly, the length can be varied depending on the length and diameter of the hose spool, while the vertical outlet conduit body  78  includes a length to reach the outer diameter of the hose spool. The vertical outlet conduit body  78  includes a top end  80 , a bottom end  82 , and a vertical outlet conduit main body  84 . The interior of the vertical outlet conduit main body contains a bore  85 , which is sized and shaped to flow a suitable volume of fluid for a garden hose. The top portion  80  contains a transverse positioned L-shaped portion  86  terminating in opening  88 . The opening  88  may define the second end of the outlet conduit  14 . The L-shaped portion  86  is designed to be coupled or attached to a fluid dispensing device, such as an elongated hose member (not illustrated). As such, the metal insert  600  on the L-shaped portion  86  contains threading  24  or other hose connectors, which may employ the teachings of the present invention. It should be noted that while the outlet conduit is illustrated as being inserted into the inlet tube, this arrangement may be reversed without departing from the scope of the invention. 
     Referring to  FIGS. 2-5 , one embodiment of the composite in-tube is illustrated. In this embodiment, the metal insert portion  100  is molded in place during the molding process of the in-tube. The metal insert  100  includes a first bore  102  that is generally smooth and cylindrical in shape. A second bore  104  includes undulations or contours  106  which engage mirrored contours  108  on the core  19  to prevent rotation of the metal insert with respect to the inlet tube  12 . In a preferred embodiment, the metal insert  100  is placed into the plastic mold (not shown) and the plastic is injected under pressure to fill in the remainder of the mold cavity forming the core  19  at the first end  18  of the main body  22  within the metal insert  100 . Whereby the mirrored contours  108  and the end flange  110  are formed in place. The end flange  110  prevents the metal insert from being pulled off of the first end of the main body under pressure or when the hose member is connected to the inlet tube  12 . 
     Referring to  FIGS. 6-9 , an alternative embodiment of the inlet tube  12  is illustrated. In this embodiment, the metal insert  200  is pressed onto the first end  18  of the inlet tube  12  after injection molding of the inlet tube  12  is completed. In order to prevent rotation of the metal insert  200 , the first end  18  of the inlet tube  12  is provided with at least one, and more preferably two key members  202  which are preferably molded in place on opposite sides of the first end  18  core  19  of the inlet tube. However, it should be noted, the key member may be glued, fused, placed in a keyway, or otherwise suitably secured to the inlet tube to prevent rotation of the metal insert  200  without departing from the scope of the invention. The key members  202  are positioned and sized to cooperate with keyways  206  integrally formed into the first bore  102  of the metal insert  200 . The core  19  of the first end  18  of the inlet tube  12  also includes at least one, and more preferably two-ramp lock catches  204  positioned to cooperate with ramp locks  208 . In operation, the metal insert  200  is aligned with the core  19  on the first end  18  of the inlet tube  12 , whereby the first bore  102  is sized for a slip or slight interference fit with the core. As the metal insert is slid toward the main body  22 , the keys  202  are aligned with the key members  206 . Thereafter, the sloped portion  212  of the ramp locks  208  engage the chamfer  210  causing the plastic to deform enough to allow the ramp locks  208  to pass over the core  19  until it enters the ramp lock catches  204  allowing the vertical face  214  of the ramp lock to engage the front face  216  of the ramp catches  204  securing the metal insert in position. 
     Referring to  FIGS. 10-13 , an alternative embodiment of the inlet tube  12  is illustrated. In this embodiment, the metal insert  300  is slipped onto the first end  18  of the inlet tube  12  after injection molding of the inlet tube  12  is completed. Hot forming is then utilized to form the end flange  110 . The end flange  110  prevents the metal insert from being pulled off of the first end of the main body under pressure or when the hose member is connected to the inlet tube  12 . In order to prevent rotation of the metal insert  300 , the first end  18  of the inlet tube  12  is provided with at least one, and more preferably two key members  202  which are preferably molded in place on opposite sides of the core  19  on the first end  18  of the inlet tube  12 . However, it should be noted, the key members  202  may be glued, fused, placed in a keyway, or otherwise suitably secured to the inlet tube core  19  to prevent rotation of the metal insert  300  without departing from the scope of the invention. The key members  202  are positioned and sized to cooperate with keyways  206  integrally formed into the first bore  102  of the metal insert  300 . In operation, the metal insert  300  is aligned with the core  19  on the first end  18  of the inlet tube  12  whereby the first bore  102  is sized for a slip or slight interference fit with the core. As the metal insert is slid toward the main body  22 , the keys  202  are aligned with the key members  206 . Thereafter, a hot or ultrasonic tool (not shown) is used to form end flange  110  securing the metal insert in position. 
     Referring to  FIGS. 14-17 , an alternative embodiment of the inlet tube  12  is illustrated. In this embodiment, the metal insert  400  is slipped onto the core  19  of the first end  18  of the inlet tube  12  as illustrated in  FIG. 15 . Roll forming is then utilized to form the second end  402  of the metal insert. In order to prevent rotation of the metal insert  400 , the core  19  of the inlet tube  12  is provided with at least one, and more preferably two roll beads  404  which are preferably molded in place on the core  19  positioned on the first end  18  of the inlet tube  12 . The roll forming of the metal insert  400  pushes a portion of the insert into the roll beads, also preventing the metal insert from being pulled off of the first end of the main body under pressure or when the hose member is connected to the inlet tube  12 . In operation, the metal insert  400  is aligned with the core  19  on the first end  18  of the inlet tube  12  whereby the first bore  102  is sized for a slip or slight interference fit with the core. Once the metal insert has been seated in place, a roll form machine is used to force portions of the metal insert into the roll beads  404  securing the metal insert in position. 
     Referring to  FIGS. 18-21 , an alternative embodiment of the inlet tube  12  is illustrated. In this embodiment, the metal insert  500  is slipped onto the first end  18  of the inlet tube  12  after injection molding of the inlet tube  12  is completed. The end flange  502  is thereafter pressed or adhered into place. The end cap  502  prevents the metal insert  500  from being pulled off of the first end of the main body under pressure or when the hose member is connected to the inlet tube  12 . In order to prevent rotation of the metal insert  500 , the first end  18  of the inlet tube  12  is provided with at least one, and more preferably two key slots  504  which are preferably molded in place on opposite sides of the core  19  on the first end  18  of the inlet tube  12 . However, it should be noted, the key slots  504  may be machined or otherwise suitably formed into the inlet tube core  19  to prevent rotation of the metal insert  500  without departing from the scope of the invention. The key slots  504  are positioned and sized to cooperate with keys  506  integrally formed into the first bore  102  of the metal insert  500 . In operation, the metal insert  500  is aligned with the core  19  on the first end  18  of the inlet tube  12  whereby the first bore  102  is sized for a slip or slight interference fit with the core. As the metal insert is slid toward the main body  22 , the keys  506  are aligned with the key slots  504 . Thereafter, the end cap  502  is glued, pressed or welded into the bore of the inlet tube to secure the metal insert in position. The end cap  502  preferably includes a stem portion  508 , a cone portion  510  and a flange portion  512 . The stem portion is preferably round and tubular in shape to fit within the inner diameter  23  of the inlet tube. The cone portion  510  cooperates with a tapered portion  514  within the inner diameter to center the end cap, and in some embodiments cause the core to expand slightly, engaging the inside diameter of the metal insert. The flange portion  512  prevents the metal insert from being pulled off of the stem during use. 
     Referring to  FIGS. 22-24 , an alternative embodiment of the inlet tube  12  is illustrated. In this embodiment, the entire inlet tube  12  is formed from a suitable metal such as aluminum or zinc to cooperate with the outlet conduit, which may be constructed entirely of plastic. Alternatively, the outlet conduit may be constructed from plastic and include one of the metal inserts described above. 
     Referring to  FIGS. 25-27 , an alternative embodiment of the inlet tube  12  is illustrated. In this embodiment, the metal insert  700  is plated onto the core  19  of the first end  18  of the inlet tube  12  as illustrated in  FIG. 27 . Bead or sand blasting, chemical etching, copper cladding or the like may be utilized to prepare the core  19  for the metal plating which also prevents the metal insert  700  from being pulled off of the first end of the main body under pressure or when the hose member is connected to the inlet tube  12 .