Abstract:
A flexible hose assembly, in particular a garden hose, having an end fitting including a protective, strain reducing sleeve fixedly secured at the male end segment of a fluid conveying tube. The sleeve is flexible and provides strain relief to the portion of the tube surrounded by the sleeve and reduces the ability of the tube to kink in the area adjacent to the end fitting. The prevention of kinks at the male end of the tube reduces stresses in this area of the tube and greatly extends the working life of the sleeve and tube assembly. The sleeve additionally serves as a gripping surface for one or more of facilitating the attachment of the hose assembly to another device such as a flow control device and holding the end of the hose during use.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a flexible hose assembly, in particular a garden hose, having an end fitting including a protective, strain reducing sleeve fixedly secured at the male end segment of a fluid conveying tube. The sleeve is flexible and provides strain relief to the portion of the tube surrounded by the sleeve and reduces the ability of the tube to kink in the area adjacent to the end fitting. The prevention of kinks at the male end of the tube reduces stresses in this area of the tube and greatly extends the working life of the sleeve and tube assembly. The sleeve additionally serves as a gripping surface for one or more of facilitating the attachment of the hose assembly to another device such as a flow control device and holding the end of the hose during use. 
       BACKGROUND OF THE INVENTION 
       [0002]    Hoses are commonly attached to end fittings or couplings which serve as a connection point, for example, to a fluid supply in a case where the end fitting is an inlet or to a flow control device such as a nozzle where the end fitting is an outlet. Many different types of end fittings are known in the art, with the fittings being fixed to the hose or tube through a connection to one or more of the outer surface of the hose and inner surface of the hose. Regardless of the connection type, problems exist as the section of the hose adjacent to its connection to the end fitting can kink or collapse if the hose is moved transversely to the axial length of the coupling or hose thereby restricting flow through the hose and/or leading to premature mechanical failure. Additional problems include premature mechanical failure from loss of adhesion between the inner and outer layers of the hose, color change or stress whitening in the jacket area, and holes or tears in the outer jacket due to repeated bending during use of the hose. 
         [0003]    Various devices have been proposed in order to alleviate the problems noted above and others, see U.S. Pat. Nos. 4,489,961; 5,143,409; 5,181,750; 5,286,068; 5,333,650; 5,816,622; 6,068,622; 7,357,424 and D356858; and U.S. Publication No. 2013/0113205. 
         [0004]    In view of the above, the need still exists for an improved flexible hose assembly including a protective sleeve that allows the hose to have a degree of flex at a connection area to the end fitting while relieving strain in the immediate area. 
       SUMMARY OF THE INVENTION 
       [0005]    Accordingly, it is an object of the present invention to provide a flexible hose assembly, in particular a garden hose, having an end fitting comprising a protective sleeve permanently fixed to the end fitting and providing strain relief to the tube or hose of the assembly adjacent the end fitting. 
         [0006]    It is a further object of the present invention to provide a permanent sleeve affixed to a male end fitting that serves as a gripping surface in addition to functioning as a strain reducing feature. 
         [0007]    An additional object of the present invention is to provide a hose assembly including an end fitting comprising a male stem inserted into a tube end, with the tube being secured, along with the protective sleeve, between the stem and a ferrule of the end fitting. 
         [0008]    Still another object of the present invention is to provide an end fitting that permanently captures and secures the protective sleeve, wherein the sleeve has a substantially constant wall thickness along the connection segment of the sleeve longitudinally coextensive with the length of the ferrule or has a wall thickness that varies less than 10% along the length of the sleeve between longitudinal ends of the ferrule; and wherein the sleeve has a tapered section and/or a section of decreased wall thickness in a strain reducing segment that intends longitudinally from the second end of the ferrule to a second end of the sleeve opposite the end fitting. 
         [0009]    Another object of the present invention is to provide a hose assembly including a protective sleeve having a wall thickness in a strain reducing segment that extends longitudinally from the second end of the ferrule to a second end of the sleeve opposite the end fitting that has a decreased wall thickness as compared to a minimum wall thickness of connection segment of the sleeve longitudinally coextensive with the length of the ferrule, with the minimum strain reducing segment wall thickness being greater than 50 or 55% of the minimum thickness of the sleeve in the connection segment. 
         [0010]    Still an additional object of the present invention is provide a protective polymeric sleeve having a tapered wall section extending adjacent the ferrule to a distal end of the sleeve opposite the end fitting, with the distal end having a wall thickness that is at least 50 or 55% of the wall thickness of the sleeve directly adjacent the ferrule. 
         [0011]    A further object of the present invention is to provide a protective, polymeric sleeve having a distal, lower end that is rounded, and without sharp edges, in order to prevent the sleeve from damaging the outer surface of the hose or injuring the user. 
         [0012]    In one aspect, an embodiment of the hose assembly is described, comprising a tube comprising a polymeric material, the tube having a first end and a second end, an end fitting comprising a coupler comprising a threaded section, a flexible polymeric sleeve having a first end and a second end, wherein the sleeve extends over a portion of the tube with the first end of the sleeve located adjacent the first end of the tube, wherein the first end of the sleeve and the first end of the hose are fixedly secured to the end fitting, wherein the sleeve has a first wall thickness in a connection segment extending a distance from the first end of the sleeve and a lesser, variable wall thickness along a length of the sleeve inwardly from the connection segment in a strain reducing segment that tapers down in wall thickness in a direction towards the second end. 
         [0013]    In another aspect, an embodiment of the hose assembly is described, comprising a tube comprising polymeric material, the tube having a first end and a second end, an end fitting comprising a coupler comprising a threaded section and a stem; and a ferrule, a flexible polymeric sleeve having a first end and a second end, wherein the first end of the tube is disposed over the stem, wherein the sleeve extends over the tube with the first end of the sleeve located adjacent the first end of the tube, wherein the first end of sleeve and the first end of the hose are fixedly secured between the ferrule and the stem, wherein the sleeve has a substantially constant wall thickness in a connection segment longitudinally coextensive with the ferrule, wherein the sleeve has a wall thickness in a strain reducing segment adjacent the ferrule that tapers down in wall thickness in a direction towards the second end of the sleeve. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The invention will be better understood and other features and advantages will become apparent by reading the detailed description of the invention, taken together with the drawings, wherein: 
           [0015]      FIG. 1  is a perspective view of one embodiment of a hose assembly of the present invention including a fitting having a protective, polymeric sleeve fixedly secured at the end segment of the hose; 
           [0016]      FIG. 2  is cross-sectional side view of one embodiment of the hose assembly; 
           [0017]      FIG. 3  is a cross-sectional view of the hose assembly shown through line  3 - 3  of  FIG. 2 ; and 
           [0018]      FIG. 4  is a cross-sectional view of the hose assembly shown through line  4 - 4  of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    In this specification, all numbers disclosed herein designate a set value, individually, in one embodiment, regardless of whether the word “about” or “approximate” or the like is used in connection therewith. In addition, when the term such as “about” or “approximate” is used in conjunction with a value, the numerical range may also vary, for example by 1%, 2%, 5%, or more in various other, independent, embodiments. 
         [0020]    The hose assembly of the present invention includes a fluid conveying tube and an end fitting attached to each end of the tube that allows connection to a fluid source, such as a water supply; or a fluid control device, such as a nozzle or the like. A sleeve is fixedly secured to at least one end of the hose assembly, preferably a male end in one embodiment, in order to provide strain relief to the portion of the tube that the sleeve surrounds and reduces the ability of the tube to kink in the area adjacent to the end fitting. When utilized herein, the term “wall thickness” refers to a thickness of a construction, such as the sleeve, tube or hose, measured in a radial direction, unless otherwise specified. 
         [0021]    Referring now to the drawings, wherein like reference numbers refer to like parts throughout the several views, a hose assembly  10  is partially illustrated in  FIG. 1 , in a perspective view. Hose assembly  10  includes a fluid passage  12 , see  FIG. 2 , located between an inlet and an outlet, see outlet  14 , for example in  FIG. 1 . Hose assembly  10  includes a tube  20  that extends between end fittings  30  with the end fittings  30  preferably including a male coupler  34  and a female coupler. Tube  20  has an inner surface  22  and an outer surface  24 , see  FIGS. 1 and 2 , for example. 
         [0022]      FIGS. 1 and 2  illustrate male coupler  34  secured to first end  26  of hose or tube  20  with male coupler  34  designed to mateably engage a female coupler of another device, such as a nozzle or other fluid flow regulating device, in a threaded detachable fashion. Male coupler  34  includes multiple components, including threaded section  35 , stem  36 , ferrule  37  and nut  38 . The stem  36  is located on male coupler  34  below or inward from nut  38  or the bottom of threaded section  35  in a case where nut  38  is not present. 
         [0023]    The male coupler preferably has a machined outer body and a stamped inner stem. The machined outer body contains threads that mate with various nozzles, sprinklers, or other attachments. The machined outer body can be machined from brass, aluminum, stainless steel, or other corrosion resistant materials. The machined outer body can use different designs for aesthetic or functional benefit. The stamped inner stem is pressed into the machined outer body. In one embodiment, the stamped inner stem contains a rolled edge that is part of the sealing surface between the assembled coupler and the washer in the attachment (nozzle, sprinkler, etc.). This rolled edge is pressed against the threaded end of the machined outer body. The stamped inner stem is typically made out of brass but can be formed from different materials if desired. The inner stem material must be soft enough to radially expand without cracking. The opposite end  39  of the stamped inner stem is designed to slide into the internal diameter of tube  12 . Stem  36  is then radially expanded to permanently secure the male coupler  34 , ferrule  37 , and flexible sleeve  40  to the end of tube  12 . 
         [0024]    As illustrated in  FIGS. 1 and 2 , sleeve  40  has a first end  41  a second end  42 , with the first end  41  preferably being aligned with first end  26  of tube  20 , perpendicular to the longitudinal axis of the tube. Sleeve  40  has an inner diameter that is preferably cylindrical and equal to or greater than the outer diameter of tube  20  in order to allow the sleeve  40  to be positioned over the first end portion of tube  20  as illustrated. The inner diameter of the sleeve is in contact with the outer diameter of the tube along the longitudinal length of the sleeve in one embodiment. In one embodiment the sleeve has a connection segment  43  and a strain reducing segment  44 , see  FIGS. 1 and 2 . Connection segment  43  is the section of the sleeve that is coextensive with the length of ferrule  37 , between first end  51  and second end  50  and thus is located beneath ferrule  37  as measured in an axial or lengthwise direction of hose assembly  10 . Strain reducing segment  44  extends from the second, inward end  50  of ferrule  37  to the second end  42  of sleeve and is the visible portion of sleeve  40  illustrated in  FIG. 1 . 
         [0025]    Sleeve  40  has a wall thickness in the connection segment along the longitudinal axis of the hose assembly, coextensive with the ferrule that is greater than a wall thickness in at least one area of the strain reducing segment, see  FIGS. 3 and 4  for example. Stated in another manner, the sleeve  40  has a minimum wall thickness in the connection segment that is greater than a wall thickness in an area laterally adjacent the ferrule in the strain reducing segment  44  of the sleeve  40 . In one embodiment the sleeve has a substantially constant wall thickness in the connection segment axially coextensive with the ferrule. The term “substantially” with respect to wall thickness means that the wall thickness varies less than 5%, desirably less than 3% and preferably less than 1%. The wall thickness in the connection segment is about 2.5 to about 3.0 mm, desirably about 2.6 to about 2.9 and preferably is about 2.8 mm. The wall thickness in the connection segment  43  in one preferred embodiment does not taper from the first end towards the second end of the sleeve. This particular construction of the connection segment  43  aids in forming a consistent, reliable connection of the sleeve  40  and the tube  20  to end fitting  30 . 
         [0026]    The strain reducing segment  44  is provided with a variable wall thickness in at least one area thereof. In a preferred embodiment, the variable wall thickness in the strain reducing segment  44  tapers downwardly in wall thickness in a direction from the first end  41  of sleeve  40  to second end  42  of sleeve  40 . 
         [0027]    In a further embodiment of the present invention, the strain reducing segment  44  has a section of substantially constant wall thickness in an area adjacent to the connection segment  43  that can extend for example about 1, 5 or 25 to about 75 mm, desirably about 30 to about 70 mm and preferably about 40 to about 60 mm from the second end of the ferrule, distal to the end fitting, prior to tapering downwardly in wall thickness. 
         [0028]    In an important aspect of the present invention, the sleeve  40  is provided with a minimum wall thickness at the second end  42  of the sleeve directly adjacent the rounded end that is at least 50%, or at least 55% of a minimum wall thickness of the sleeve in the connection segment  43  in order to provide desirable protective, strain reducing characteristics to the first end of the tube and also retain a desired stiffness to the second end of the sleeve. Maintaining the wall thicknesses described above also results in a sleeve that easily fits the hand and is easier to hold during use of the hose and any attachments. 
         [0029]    As additionally mentioned herein, the second end  42  of sleeve  40  is rounded and therefore free of any sharp edges. The rounded end feature prevents the sleeve from abrading tube  20  in the end region of sleeve  40 , such as when lateral pressure is applied to the tube in said area. In a preferred embodiment, the first end of the sleeve  41  has a flat end in order to facilitate connection of the sleeve  40  to end fitting  30 . The surface on the first end is preferably square and true to the constant internal diameter of the sleeve. The sleeve surface is preferably smooth and free of lumps, bumps, or other imperfections. 
         [0030]    The longitudinal length of sleeve  40  can vary depending upon the strain relieving characteristics desired to be imparted to tube  20 . In various embodiments, the sleeve has a length that ranges about 5 to about 25 cm, desirably about 10 to about 20 cm and preferably is about 15.2 cm. 
         [0031]    The tube utilized in the hose assembly of the present invention can be constructed as known to those of ordinary skill in the art. Tubes used for garden hoses are typically polymeric in nature and can be formed from one or more of various polymers; elastomers; and rubbers, including natural rubber, synthetic rubber and combinations thereof. The tube can have one or more reinforcing layers or portion formed from a fabric and/or various fibers as known in the art. The tube compositions of the present invention may comprise additional additives including, but not limited to, antioxidants, foaming agents, pigments, heat stabilizers, UV absorbers/stabilizers, processing aids, flow enhancing agents, nanoparticles and various fillers. The tube can be formed having any desired internal diameter, such as 0.5 inch (1.27 cm) or 0.75 inch (1.91 cm). 
         [0032]    The sleeve according to the present invention is formed from a polymer. Any suitable polymer that provides the desirable flexibility and strain relief properties can be utilized including, but not limited to, thermoplastic elastomers, including thermoplastic vulcanizates, polyolefins, polyvinyl chloride, polyamides, polyesters, polyurethanes, with polyvinyl chloride preferred in one embodiment. Suitable thermoplastic elastomers include, but are not limited to styrenic block copolymers for example SEBS, SEEPS, SBS and SIS. In order to provide desirable strain reducing benefits, the sleeve has a hardness that ranges generally about 60 to about 90 Shore A, desirably about 65 to about 85 Shore A and preferably from about 70 to 80 Shore A measured according to ASTM-D-2240. 
         [0033]    The sleeve can be produced utilizing various methods including, but not limited to, molding, extruding, and dip molding. In one embodiment, the dip molding process involves the use of a form, such as a cylindrical rod that is dipped in a polymeric solution. Wall thickness of each section of the tube is controlled by varying the amount of time the form is exposed to the polymeric solution which is deposited onto the form over a period of time. The number of dip cycles can also be varied to change wall thickness. For example, more dip/cure cycles will produce a thicker sleeve. 
         [0034]    The hose assembly of the present invention can be formed in one embodiment as follows. A tube having a desired length is formed or obtained. A sleeve according to the invention is slid or otherwise located over the end of the tube such that the first end  41  of sleeve  40  and first end  26  of tube  20  are substantially aligned, for example so that the first end of the sleeve is flush with the first end of the tube. A ferrule is applied over an outside diameter of the sleeve. The stem of the male coupler is inserted into the inner diameter of the tube having the sleeve and ferrule disposed thereon. After checking desired alignment between the tube, sleeve and ferrule against the seat of the male fitting adjacent the stem, a fitting expansion machine is utilized to expand the stem of the male coupler into the hose and against the ferrule, with the sleeve connection segment located therebetween. The fitting expansion step holds the sleeve and hose securely in place between the ferrule and the stem. The present sleeve includes a line around the circumference of the sleeve to ensure the sleeve is located correctly between the ferrule and the hose. 
       EXAMPLES 
       [0035]    A quantitative self-developed test was performed that used an air cylinder to force an impactor against the side of the hose. A hose was forced between a set of rollers to simulate a sharp bend with each cycle of the air cylinder. Identical hoses with and without the sleeve of the present invention were tested. A mechanical timer was connected to the air cylinder control circuit to count the number of times the impactor struck and deformed the test sample. The hose without the protective sleeve installed lasted for 2000 cycles before a hole was worn through an outer jacket of the tube of the hose assembly. The same hose model with the protective sleeve installed lasted for 8000 cycles before a hole was worn through the protective sleeve. The hose underneath the protective sleeve was still fully intact and expected to last for additional cycles. Accordingly, the test method utilized illustrates the benefits of the hose assembly of the present invention including the protective sleeve. This test method shows that even after 8000 cycles, the hose is still undamaged and expected to continue to function normally for an extended period of time. 
         [0036]    While in accordance with the patent statutes the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.