Abstract:
The present invention relates to portable hose reel carts for handling and storage of flexible hoses, such as garden or air hoses. The cart is primarily constructed of plastic components having a centrally rotatable spool for winding of the flexible hose, a frame for supporting the spool, wheels at one end of the base of the frame, and a handle assembly for tilting the frame onto the wheels to facilitate moving the cart. The handle assembly which may or may not be foldable includes a crank mounted near the top of the handle assembly. The crank remotely drives the spool, for winding the hose, through a series of gears located within the handle. The device may further include a reciprocating guide assembly that operates during rotation of the spool to rewind the hose into a compact configuration.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention pertains to carts for use in storage of flexible hoses and more particularly, to a hose reel cart having an elevated crank handle to allow an operator to manually wind a hose reel from an upright position.  
         BACKGROUND INFORMATION  
         [0002]    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 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 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. No. RE. 32,510, and U.S. Pat. No. 5,998,552 the teachings of which are hereby incorporated by reference.  
           [0003]    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.  
           [0004]    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 used of a chain sprocket for driving the spool mounted sprocket. A smaller sprocket by the hand crank provides a gear reduction from the larger sprocket adjacent to the spool. The direct coupling requires a large diameter spool sprocket that is difficult to shield and prohibits folding of the hand crank support arm.  
           [0005]    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.  
           [0006]    U.S. Pat. No. 4,974,627 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. Further, the chain assembly must be mounted in the side wall as there is no teaching to place the chain assembly into a foldable cart handle.  
           [0007]    Thus, what is lacking in the art is a hose reel cart having an elevated crank handle formed into a foldable cart handle support, the crank handle remaining in rotatable contact with hose reel spool at all times.  
         BRIEF DESCRIPTION OF THE INVENTION  
         [0008]    Among the several aspects and features of the present invention may be noted the provision of an improved portable hose reel cart having a elevated hand crank for use in rotation of the reel spool wherein the hand crank is positioned within a foldable handle. In an additional embodiment, the elevated hand crank is also used for movement of a hose guide for positioning of the flexibe hose around the hose reel spool.  
           [0009]    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 a modular frame 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 a frame. The hose is wound around the spool by use of a remotely located crank providing an indirect rotational link between the crank and the winding of the spool. In the preferred embodiment, the crank is positioned in a foldable handle assembly that allows for ease of transporting fully assembled hose reel carts and subsequent storage. 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 having 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 to the crank arm for operation.  
           [0010]    Thus, an objective of the instant invention is to provide a portable hose reel cart having an elevated crank handle formed integral with the hose reel cart handle wherein all components are preassembled so as to eliminate the need for assembly by the consumer, yet allow repeatable storage.  
           [0011]    Another objective of the instant invention is to disclose the use of a locking tab that allows the crank handle to be locked in either a storage position or an operating position.  
           [0012]    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 rotation of the hose reel hub.  
           [0013]    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  
       [0014]    [0014]FIG. 1 is a perspective view of a portable hose reel cart having a folding handle;  
         [0015]    [0015]FIG. 2 is a perspective view of a portable hose reel cart having a folding handle with a manual hose guide assembly;  
         [0016]    [0016]FIG. 3 is a perspective view of a portable hose reel cart having a folding handle with an automatic hose guide assembly;  
         [0017]    [0017]FIG. 4 is a front exploded perspective view of the handle assembly with the spool rotational drive means;  
         [0018]    [0018]FIG. 5 is a front exploded perspective view of the handle assembly with the guide support arms, the manual hose guide, and the spool rotational drive means;  
         [0019]    [0019]FIG. 6 is a front exploded perspective view of the handle assembly with the guide support arms, the automatic hose guide, and the spool rotational drive means;  
         [0020]    [0020]FIG. 7 is a partial cross-sectional view of a wheel and wheel support assembly; and  
         [0021]    [0021]FIG. 8 is a perspective and partially exploded view illustrating the wheel chock assembly and the rear lateral support beam.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]    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.  
         [0023]    Referring now to the figures, and generally to FIGS. 1-3, there is shown hose reel carts  100 ,  200 , and  300  embodying the principles of the present invention. The hose reel carts provide hose storage around a winding apparatus employing a winding crank mounted near the top of the handle assembly to minimize operator stooping when winding a hose about the spool  14 . The hose reel carts also provide for shipping and storing in a compact manner by folding of the handle assembly when not in use.  
         [0024]    Optionally the hose reel carts  100 ,  200 , and  300  provide a “base-station” when coupled to a water or air outlet; e.g., a water spigot or source of compressed air, so that an operator can pay-out as much hose as needed while one end of the hose remains coupled in fluid communication with the water or air supply.  
         [0025]    The hose reel carts  100 ,  200 , and  300  include a pair of side frames  12  that have a generally “A” or triangular shape. The side frames  12  support a spool assembly  14  at about the top or apex  16  of the frame  12 . The spool  14  is rotatable and provides for pick-up, storage and pay-out of the hose. The carts include wheels  18  at the bottom  20  of the one of the legs  22  of the A-shaped frame  12  and a foot or rest  24  at the bottom  26  of at least one of the other of the frame legs  28 .  
         [0026]    The spool  14  includes a central hub  30  and a pair of radially extending flanges  32  that are configured to accommodate a length of flexible hose wrapped around the hub  30  between the flanges  32 . In a typical arrangement, the cart  10  may store about 200 to 300 feet of a ⅝ inch common hose. Those skilled in the art will recognize that the cart  10  may include a water/air inlet port or in-tube (not shown) and an outlet port or out-tube  36 . Typically the in-tube is mounted to the frame  12  at about the axis of rotation A of the spool  14 . The in-tube is connected to the out-tube  36  by a sliding seal arrangement (not shown) so that the in-tube remains fixed to the frame  12 , while the out-tube  36  rotates with the spool  14 , and the in-tube and out-tube  36  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.  
         [0027]    In the preferred embodiment a folding handle assembly  40  extends from the carts  100 ,  200 , and  300  and includes a pair of arms  42  that are pivotally mounted to the carts  100 ,  200 , and  300  intermediate the spool flanges  32  and their respective frame  12  connections. In this manner, the cart handle assembly  40  pivots essentially co-axially with the spool  14 . That is, the cart handle  40  pivots about the axis of rotation A of the spool  14 . The handle  40  is pivotal between a storage position, (not shown), and an in-use position as shown in FIGS. 1-3. A crank assembly  38  is rotatably supported and journaled in the upper portion of one side of the handle assembly  40  and connected to the spool  14  via a gear-train  102  to facilitate spool  14  rotation from-an elevated position. A typical gear-train  102  arrangement for rotating the spool is illustrated in FIGS. 4-6. Optionally, as shown in FIGS. 2 and 3, the cart can include a manual guide assembly  244  or an automatic guide assembly  344  to guide the hose as it is picked-up onto the spool  14  to distribute the hose evenly across the spool  14 .  
         [0028]    In one embodiment, a manual guide assembly  244  includes a pair of guide support arms  246  integral with the handle assembly  40  that extend generally transverse to the handle assembly arms  42 . A pair of guide rails  248  extend between the support arms  246 . A guide  250  is manually slidable along the rails  248  to facilitate even distribution of the hose onto the spool  14 .  
         [0029]    In a preferred embodiment, the guide assembly is automatically reciprocated with the spool. The automatic guide assembly  344  includes a double-helix lead screw  352  suitably supported and journaled in the guide support arms  246  for rotational movement and a single guide rod  248  extending between the support arms  246 . When the spool  14  is rotated a guide gear train  354  illustrated in FIG. 6, transfers rotary motion from the spool  14  to the double-helix lead screw  352 . A guide  350  cooperates with the double-helix lead screw  352  and slides along the guide rod  248  to cause the guide  350  to reciprocate back and forth across the spool  14  facilitating even distribution of the flexible elongate member onto the spool.  
         [0030]    Referring now to FIGS. 1-6, the handle assembly  40  includes a pair of spaced apart mounting arms  42  and a gripping portion  52  that extends between the arms  42 . The gripping portion  52  defines an opening  54  and an upper portion or grip  56  for grasping the handle assembly  40 . In the illustrated embodiments, the handle assembly  40  includes a lower portion  58  (FIGS. 4-6) that is preferably configured as a storage bin  60 . The storage bin is formed in one piece as part of the gripping portion  52  with living hinges  62 A,  62 B, and  62 C. The storage bin sides are fastened to the lower portion  58  of the gripping portion  52  for stability and strength. The storage bin  60  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  60  mounted to the handle assembly  40 , 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.  
         [0031]    Referring now to FIGS. 4-6, the handle assembly  40  includes an open circular collar portion  96  that defines the pivot for the assembly  40 . A short connecting stub (not shown) extends from each side frame  12  and inserts into the collar  96  to provide a pivot about which the handle  40  assembly rotates. A pivot stop  98  extends outwardly from the handle assembly  40  into an arcuate channel formed in the side frame  12  (not shown). The channel defines the travel path and the length of travel or rotation of the handle assembly  40  as it pivots between the in-use and storage positions.  
         [0032]    Referring now to FIGS. 4-6, in order to provide manual rotation of the hose reel  14  and reciprocation of the automatic hose guide  344 , a rotational drive means is positioned longitudinally within one of the mounting arms  42 . The rotational drive means includes the crank assembly  38 , the reel gear-train  102  and optionally the hose guide gear-train  354 . The crank assembly  38  includes an input shaft  64  extending inwardly through an opening  66  in the outer wall of an upper portion of the mounting arm  42  and rotatable with respect thereto. The input shaft  64  is secured to the first input gear  68  of the gear train  102  at a position within the mounting arm  42 . The spool gear  70  is suitably secured to the spool  14  so as to be rotatable therewith. Idler gears  72 A,  72 B, and  72 C are positioned within the mounting arm  42  to be freely rotating with respect to the mounting arm and directly meshed with the input gear  68 , one another, and the spool gear  70  to provide direct gear powering therebetween. Thus, rotational movement of the input gear  68  with handle assembly  38  will cause similar rotational movement of the spool gear  70  and spool  14 . Preferably the spool gear  70  will be larger than the input gear  68  thereby achieving a torque increasing gear reduction desired by the present invention.  
         [0033]    The automatic hose guide gear-train  354  utilizes rotation of the spool  14  to cause rotation of the double-helix lead screw  352 . The lead screw gear  356  is suitably secured to the lead screw  352  to be rotatable therewith. Idler gears  358 A,  358 B, and  358 C are positioned within the transverse guide support arm  256  to be freely rotating with respect to the guide support arm  256  and directly meshed with the spool gear  70 , one another, and the lead screw gear  356  to provide direct gear powering therebetween. Thus, rotational movement of the spool gear  70  will cause similar rotational movement of the lead screw gear  356  and reciprocation of the hose guide  350 . Preferably the spool gear  70  will be larger than the lead screw gear  356  thereby achieving the desired amount of hose guide  350  travel per spool  14  revolution for a compact hose storage configuration. In order to provide additional rigidity to the carts  100 ,  200 , and  300  a front lateral support beam  74  may extend between and connect the bottom front frame legs  28  at about the foot  24 . The front beam  74  can be integral with the side frames  12 , or can be connected thereto by methods that will be recognized by those skilled in the art. The front beam  74  increases the structural integrity of the carts  100 ,  200 , and  300  overall by preventing the side frames  12  from bowing or bending, inwardly or outwardly, relative to one another and thus, adversely affecting the operation of the handle assembly  40  or the rotation of the spool  14 . The carts may also include a rear lateral support beam  76  (FIG. 7) that extends between and connects the side frames  12  at about the wheels  18 . The rear beam  76  is positioned rearward and off-center of the axis of rotation of the wheels  18 . In this manner, the rear support beam  76  provides a foot rest, essentially independent of any wheel  18  rotation device or mechanism, for securing the cart while pulling rearward on the handle  40  to tilt the cart for movement.  
         [0034]    Referring now to FIG. 7, there is shown the wheel support assembly  78 . Each wheel support assembly  78  secures a wheel  18  to the cart  10 . The side frames  12  each include an outwardly extending tubular-like projection or hub  80 , that is configured for receipt in a central opening  82  formed in the wheel  18 . In this manner, support for each wheel  18  is independent of support for the other wheel  18 , and is provided by the side frames  12 , rather than an axle that extends across or traverses the rear portion of the cart. The hub  80  can include gussets  84  extending between the hub  80  and the outer wall of the side frame  12  to provide additional structural rigidity to the wheel support assembly  78 .  
         [0035]    The wheel support assembly  78  includes a locking plate  86  having a wheel plate  88  and a stub  90  extending from the plate  88 . The stub  90  is configured for insertion through the central opening  82  of the wheel  18 . The plate  88  abuts the wheel  18  as the stub  90  extends through the wheel opening  82  and hub  80 . Detent or snap-type fasteners, such as those illustrated at  92 , can be used to secure the stub  90  to the inner wall  72 . Those skilled in the art will appreciate that the snap-type fasteners  92  can be used throughout the carts  100 ,  200 , and  300  to mount or secure components to one another, and to facilitate ready assembly of the carts if it is provided in an unassembled manner.  
         [0036]    Referring now to FIG. 8, there is shown a rotatable wheel chock  102 . The wheel chock  102  includes a foot plate  104 , a chock plate  106  and a chock stub  108 . The chock stub  108  is configured for insertion through the central opening  94  of the wheel stub  90 . The chock plate  106  abuts the wheel  18  and wheel plate  88  as the chock stub  108  extends through the wheel stub opening  94  and hub  80 . Detent or snap-type fasteners, such as those illustrated at  92 , can be used to secure the chock stub  108  to the central opening of the wheel stud  94 . The foot plate  104  may be formed integral to the chock plate  106  and be configured to wedge between the wheel  18  and a surface to resist unwanted movement of the portable reel during manual winding of the hose.  
         [0037]    As will be appreciated by those skilled in the art from a study of the figures and the above description, the carts  100 ,  200 , and  300  are formed primarily from molded components. In a present form, the carts  100 ,  200 , and  300  are formed primarily from high density polyethylene (HDPE) using an injection molding process. Those skilled in the art will recognize that there are various other materials that can be used to form the carts  100 ,  200 , and  300  components and various other processes by which the components can be made, which other materials and process are within the scope of the present invention.  
         [0038]    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.  
         [0039]    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.  
         [0040]    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.