Abstract:
A hose assembly, preferably a garden hose assembly, including a fabric jacketed tube that is lightweight, durable and versatile. The tube is radially expandable when pressurized by a fluid, such as water, but does not increase in length. The two layer construction of the hose assembly allows for storage in relatively compact spaces, similar flow rates, approximately one-half the weight, and improved maneuverability when compared to conventional hose constructions. In one embodiment the jacket is formed around the tube in a continuous process that welds a fabric, preferably using hot air, into the jacket. The welded joint forms a region of jacket that is preferably about twice the thickness of the rest of the jacket. This thicker region results in a stiffer section of jacket that makes the hose more controllable and consistent in use.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a hose assembly, preferably a garden hose assembly, including a fabric jacketed tube, that is lightweight, durable and versatile. The tube is circumferentially or radially expandable within the jacket when pressurized by a fluid, such as water, but does not increase in length in a preferred embodiment. The two layer construction of the hose assembly allows for storage in relatively compact spaces, similar flow rates, approximately one-half the weight, and improved maneuverability when compared to conventional hose constructions. In one embodiment, the jacket is formed around the tube in a continuous process that welds a fabric, preferably using hot air, into the jacket. The welded joint forms a region of jacket that is preferably about twice the thickness of the rest of the jacket. This thicker region results in a stiffer section of jacket that makes the hose more controllable and consistent in use. 
     BACKGROUND OF THE INVENTION 
     Numerous different types or styles of garden hoses are known in the art and commercially available. 
     For example, traditionally conventional hoses are polymeric and can be reinforced, have a substantially fixed longitudinal length, and have relatively low radial expansion upon internal application of fluid pressure. Due to their construction, some conventional hoses can be relatively heavy and cumbersome to use and store. 
     More recently, garden hoses longitudinally expandable along their length multiple times as compared to the length of the hose in an unpressurized or contracted state have been introduced. In some embodiments such hoses have a construction that includes a jacket that surrounds an expandable fluid conveying tube. Longitudinally and radially expandable hoses are popular for a variety of reasons including, but not limited to, lightweight construction and ease of storage when not in use. 
     Longitudinally expandable hoses are commercially available from a number of sources. The hoses are also described in various patents and publications, see for example: U.S. Pat. Nos. 6,948,527; 7,549,448; 8,371,143; 8,776,836; 8,291,942; 8,479,776; 8,757,213; as well as U.S. Patent Application Publication Nos. 2014/0150889; and 2014/0130930. 
     A problem with some of the length expandable hoses is that they can kink, bulge, fail and/or exhibit leakage, at one or more points along their length, for example at a connection point to a coupler or fitting at the end of the hose, after a number of expansion and contraction cycles. 
     SUMMARY OF THE INVENTION 
     The problems described above and others are solved by the hose assemblies of the present invention which are relatively lightweight, as compared to the traditionally conventional hoses, durable, and versatile. In some embodiments, the hose assemblies provide a flow rate similar to a conventional garden hose at approximately one-half the weight. The hose assemblies also provide improved maneuverability due to their light weight, kink resistance in view of the non-bonded, two-layer jacket construction and ease of storage over a conventional hose. 
     According to one embodiment or objective of the present invention, a hose assembly is disclosed comprising a lightweight elastomeric or thermoplastic inner tube surrounded by a fabric-like outer tube that serves as a jacket for the inner tube. This jacket also prevents the length of the product from changing at different pressure conditions. The length of the product is fixed by the outer jacket. The inner tube can expand along a radial axis of the tube when pressure at or above a minimum fluid pressure is applied to the inner tube. When the pressure falls below the minimum fluid pressure, the inner tube of the hose assembly will contract radially. The rate of contraction depends on the composition of the inner tube. The outer tube limits the radial expansion of the inner tube and does not allow any substantial longitudinal expansion of the hose assembly in one embodiment. 
     Still another embodiment or objective of the present invention is to provide a hose assembly including a fabric outer tube that is welded around the inner tube and includes a weld seam extending along a longitudinal axis of the hose assembly. The weld seam has a greater thickness, i.e. wall thickness, as compared to a wall thickness of the unwelded fabric. 
     Yet another embodiment or objective of the present invention is to provide a method for producing a hose assembly comprising a hot air welding or seaming process whereby the outer tube is formed via welding, preferably hot air welding, around the inner tube, preferably utilizing a continuous process. It is possible for the circumferential size of the outer tube to be varied in order to produce hose assemblies having different maximum internal diameters of the inner tube. 
     An additional embodiment or objective of the present invention is to provide a method for producing a hose assembly comprising the steps of obtaining a polymeric or synthetic fabric, heating lateral sides of the fabric at or above a melting temperature thereof and bonding the lateral sides together around an inner tube in order to form a weld. As the fabric is bonded along the length of the inner tube, the outer tube is formed having a weld seam along the longitudinal length of the hose assembly. Advantageously, the process for preparing the hose assembly of the present invention allows manufacture of an outer tube having a weld that is stronger than the original fabric has relatively low labor costs and also produces a construction having the inner tube inserted into the outer tube as part of the welding process. 
     An additional embodiment or objective of the present invention is to provide a hose assembly capable of resisting water pressures in the 400 psi range (pounds per square inch) 2758 kPa. Even though the hose is of a robust construction, the assembly is relatively light in weight, for example about 4 lbs per 50 feet (0.12 kg per meter) in one preferred embodiment. 
     In one aspect, a hose assembly is disclosed, comprising an inner tube comprising an elastomeric or thermoplastic material, wherein the inner tube has a longitudinal length and a first circumference below a minimum expansion pressure, wherein the inner tube and is expandable to a larger, second circumference upon application of fluid pressure on an inner surface of the inner tube at or above the minimum expansion pressure; and an outer tube covering the inner tube, the outer tube having a longitudinal length and a weld seam along the longitudinal length of the outer tube, the weld seam comprising melted fabric. The inner tube and outer fabric covering are the same length in a preferred embodiment. 
     In another aspect a process for producing a hose assembly is disclosed, comprising the steps of obtaining an inner tube comprising an elastomeric or thermoplastic material; obtaining a fabric having a first end, a second end a first side and a second side, the sides located between the ends; wrapping the fabric around the inner tube and abutting the first side and the second side of the fabric, and heating the fabric to melt and bond the first side to the second side along a length of the side thereby forming an outer tube having a weld seam along a longitudinal length of the hose assembly, wherein during formation of the outer tube a section of the inner tube is located inside the outer tube. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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: 
         FIG. 1  is a partial, cross-sectional, longitudinal side view of one embodiment of a hose assembly of the present invention in a circumferentially contracted position; 
         FIG. 2  is a partial, cross-sectional, longitudinal side view of one embodiment of a hose assembly of the present invention in a circumferentially expanded position; and 
         FIG. 3  is a partial, longitudinal side view of one embodiment of the hose assembly of the present invention particularly illustrating a weld seam of the outer tube produced by a hot air seaming method that encases an inner tube within the outer tube. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     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. 
     The hose assembly of the present invention includes a fabric jacketed inner tube, with the hose assembly being relatively light in weight, durable and versatile. The inner tube can expand circumferentially or radially to an expanded position or state in response to at least a minimum fluid pressure applied internally to the inner tube. The circumference of the fabric jacket controls radial expansion of the inner tube. The inner tube circumferentially or radially contracts when fluid pressure inside the tube falls below the minimum fluid pressure to a contracted or non-expanded position or state. Elastomer-containing inner tubes generally contract at faster rates than inner tubes formed from compositions comprising thermoplastic polymers, such as polyvinyl chloride. In one embodiment, the outer tube jacket is formed around the inner tube in a continuous process that welds a fabric, preferably using hot air, into the jacket. 
     Referring now to the drawings wherein like reference numbers refer to like parts throughout the several views, a hose assembly  10  is illustrated in  FIGS. 1 and 2 , wherein  FIG. 1  illustrates the hose assembly in an out-of-service or contracted position and  FIG. 2  an expanded position. Hose assembly  10  includes an inlet  14  and an outlet  16 , with fluid passage  12  being located therebetween. The hose assembly includes an inner tube  20  that extends between and fitting or couplers, see for example male coupler  60  and female coupler  50 . The inner tube  20  is self-expanding and self-contracting. Inner tube  20  has an inner surface  22  and an outer surface  24 , see  FIGS. 1-2 , for example. When a fluid, such as water when the hose assembly is utilized as a garden hose, is introduced into the inner tube  20  and exerts at least a minimum fluid pressure on an inner surface  22 , the inner tube  20  expands, generally radially, from a first circumference to a larger, second circumference in an expanded position. Inner tube  20  can be formed such that the second circumference provides the tube inner surface  22  with a desired inner diameter, for example about 0.5 inch (1.27 cm) or about 0.625 inch (1.59 cm). When fluid pressure decreases below the minimum fluid pressure, the inner tube  20  relaxes or contracts radially, preferably back to the first circumference in one embodiment. In other embodiments, the inner tube may not contract to the first circumference. 
     The thickness of the inner tube  20  can vary depending upon the materials utilized to construct the same. In various embodiments, the wall thickness of the inner tube ranges generally from about 1.0 to about 2.0 mm, desirably from about 1.2 to about 1.8 mm, preferably from about 1.40 to about 1.65 mm, as measured in a radial direction in a contracted position. 
     Hose assembly  10  also includes a jacket sheath or outer tube  40  that is also connected between first and second couplers, see for example male couplers  60  and female couplers  50 . In one embodiment, the outer tube  40  is not connected or attached to the inner tube  20  or an outer slip coating layer  30 , further described below, between the couplers. Stated in another manner, the outer tube  40  is preferably unattached, unconnected, unbonded, and unsecured to either the inner tube  20  or slip coating layer  30 , when present, along the entire length of the inner tube  20  and slip coating layer  30  between the first end and the second end of the outer tuber  40 , and thus the tube  40  is able to move freely with respect to the inner tube  20  and/or slip coating layer  30  when the hose assembly expands or contracts. In one embodiment, the circumferential or radial expansion of inner tube  20  is limited by the dimensions, i.e. maximum inner diameter or circumference of outer tube  40 . The outer tube  40  is configured to protect the inner tube  20  and slip coating layer  30 , when present, such as from cuts, friction, abrasion, puncture, over-expansion (bursting) or UV exposure. 
     In various embodiments the outer tube  40  can be braided or woven into a fabric that is subsequently formed into the tube. Suitable materials include, but are not limited to, polyolefins, polyesters, and polyamides such as nylon. Polyester is preferred in some embodiments. Outer tube  40  should be formed from a material that is pliable and strong enough to withstand a desired internal pressure that can be exerted by outer surface  24  of inner tube  20 . Thickness of the outer tube  40  is dependent on yarn denier used. This will be dictated by desired internal pressure as mentioned above. 
     In an important aspect of the present invention, the hose assembly jacket or outer tube  40  is formed around the inner tube  20 , preferably in a continuous process. In a preferred embodiment a hot air welding process is utilized. During the process, a piece of fabric having first and second ends and first and second sides located therebetween is formed into a tubular shape. A portion of the first side and the second side is heated to a temperature where the material, in particular polymer, that forms the fabric melts and the sides are bonded together, with the inner tube being present within or surrounded by the outer tube formed by the fabric. A weld  46  is formed in the area where the fabric is heated and the sides are joined. As the fabric is joined along the length of the sides, the welded fabric forms a spine or weld seam  48  extending longitudinally along the length of the fabric, comprising melted fabric. In a preferred embodiment, the weld seam has an overlap or weld width of 0.375 inch (9.5 mm)+/−0.0625 inch (+/−1.5 mm), generally measured perpendicular to the longitudinal length of the weld seam. In another embodiment, the variation is +/−3 mm. In one embodiment, the process that forms the welded seam is a continuous process that heats the fabric with hot air, with temperatures ranging between 550 and 750° C. and preferably between 600 and 700° C. The welding process also produces a weld seam having a wall thickness that is generally at least 50% greater, desirably at least 75% greater and preferably about 100% greater, i.e. two times greater, than the average thickness of the non-welded fabric of the outer tube. 
     In one embodiment, the inner tube  20  is supplied from a reel or spool. In another embodiment, the inner tube  20  is supplied directly from an upstream extrusion line. The inner tube enters a folding fixture which contains a series of guides and is combined with a flat, woven fabric. The fabric is supplied from a fabric source, such as a bulk container and straightened and tensioned as it enters the folding fixture. The folding fixture partially forms the fabric around the inner tube. The inner tube and fabric then enter a die which completes the forming process by shaping the fabric into a round, tubular shape. The tubular fabric profile and inner tube exit the die. At the exit of the die, a nozzle directs hot air between the overlapped fabric side surfaces. This hot air heats the fabric to or above its melting point just before the fabric and inner tube pass through a set of nip rollers which force the heated fabric surfaces against each other under pressure. A strong bond between the two fabric surfaces is formed at this point. The fabric and tube may be wound onto a reel for future assembly or cut to length and processed into a finished hose immediately. Hot air seaming devices are available from companies such as Miller Weldmaster of Navarre, Ohio. 
     Inner tube  20  can be formed from any suitable elastic or polymeric material. Suitable materials include, but are not limited to, rubbers including natural rubber, synthetic rubber and combinations thereof; thermoplastics; and various thermoplastic elastomers including thermoplastic vulcanizates. Suitable thermoplastic elastomers include but are not limited to styrenic block copolymers, for example SEBS, SEEPS, and SBS; and SIS. In one embodiment the elastomeric inner tube has a hardness that ranges from 20 to 60 Shore A, desirably from 25 to 60 Shore A, and preferably from 30 to 50 Shore A, as measured according to ASTM D-2240. Suitable thermoplastics include but are not limited to polyvinyl chloride (PVC). Non-limiting examples of suitable grades of PVC include standard and high molecular weight. Thermoplastic-containing inner tubes have a hardness that ranges from 50 to 80 Shore A, and preferably from 60 to 70 Shore A, as measured according to ASTM D-2240. 
     The inner tube compositions of the present invention may include additional additives including, but not limited to antioxidants, foam agent, pigments, heat stabilizers, UV absorber/stabilizer, processing aids, flow enhancing agents, nanoparticles, platelet fillers and non-platelet fillers. 
     In some embodiments of the present invention, slip coating layer  30  is provided on outer surface  24  of inner tube  20 , see  FIGS. 1 and 2 . In a preferred embodiment, the slip coating layer  30  can be extruded onto or coextruded with the inner tube  20  layer. Other application methods such as coating would also be acceptable so long as the slip coating performs its intended function. In some embodiments of the present invention, a slip coat may not be necessary depending on the inner tube materials selected and the manufacturing method. 
     The slip coating layer  30  can be a continuous or discontinuous layer or layers. In one preferred embodiment the slip coating layer is continuous, at least prior to a first expansion of inner tube  20  after the slip coating layer has been applied. Depending on the thickness of the slip coating layer  30  relatively thin layers, after one or more expansions of the inner tube  20 , may exhibit cracking, splitting, crazing, fracturing or the like. Importantly though, such layers have still been found to be effective. That said, the initial thickness of the slip coating layer  30  ranges generally from about 0.025 mm to about 0.51 mm, desirably from about 0.05 to about 0.25 and preferably from about 0.10 to about 0.20 mm, or about 0.15 mm measured in a radial direction. 
     As illustrated in  FIGS. 1 and 2 , the slip coating layer  30  is located between the inner tube  20  and the outer tube covering  40 . In a preferred embodiment, the slip coating layer is not directly connected to the outer tube covering  40  between the first coupler and the second coupler, e.g. male coupler  60  and female coupler  50 , such that the outer tube covering  40  can slide or otherwise move in relation to the slip coating layer  30  during expansion and contraction of hose assembly  10 . In an expanded position, the outer surface of the slip coating layer  30  is in contact with the inner surface of the outer tube covering  40 . 
     The slip coating layer comprises a lubricant, optionally incorporated into or blended with a carrier material. 
     In one embodiment, the lubricant is a siloxane polymer or copolymer, or a fluorinated polymer or a combination thereof. A siloxane polymer masterbatch is available from Dow-Corning as MB50-321™ and from Wacker as Genioplast™ Fluorinated polymer is available from McLube as MAC 1080™ In some embodiments lubricant is present in the slip coating layer in an amount generally from about 1 to about 40 parts, desirably from about 2 to about 30 parts and preferably in an amount from about 3 to about 20 parts based on 100 total parts by weight of the slip coating layer. In other embodiments, the lubricant can be a liquid, semi-solid or solid material that serves to reduce friction between the inner tube and the outer tube. Non-limiting examples of other lubricants include, but are not limited to, oils such as silicone oil, waxes, polymers, including elastomers. 
     As described herein, in one embodiment the lubricant is mixed with a carrier material that aids in affixing the lubricant on an outer surface of the inner tube. Suitable materials include, but are not limited to, polyolefins, thermoplastic elastomers or a combination thereof. In one embodiment, the carrier material comprises a polyolefin and one or more of the thermoplastic elastomers utilized in the inner tube layer. 
     Along with the lubricant, the slip coating layer may also include additional additives including, but not limited to, antioxidants, foaming agents, pigments, heat stabilizers, UV absorber/stabilizer, processing aids, flow enhancing agents, nanoparticles, platelet fillers and non-platelet fillers. 
     Hose assembly  10  includes male coupler  60  at a first end and female coupler  50  at a second end. The male coupler  60  includes an external threaded section  62  and an internal connector  63  fixedly connected, such as by a press fit, to main body  66  of male coupler  60 . Connector  63  includes a stem  64  initially having a smaller diameter portion  63  that is connected to a larger diameter portion connected to the inner side of threaded section  62 . Fluid passing through male coupler  60  passes through internal connector  63 , generally through aperture  67  in stem  64  and out through the end of connector  63  within threaded section  62 . In one embodiment, the stem  64  is inserted into the inner tube  20 . A portion of the outer tube covering  40  is also located between stem  64 , inner tube  20  and the ferrule  68  of male coupler  60 . Inner tube  20  and outer tube  40  are operatively connected and secured to male coupler  60  by expansion of the stem  64  outwardly towards ferrule  68 . In other embodiments the ferrule can be crimped towards a relatively rigid stem in order to capture the inner tube and outer tube therebetween, securing the tubes to the male coupler  60 . Other attachment mechanisms could also be utilized. 
     The female coupler  50  includes a main body  56  having an internal threaded section  52  that is operatively and rotatably connected to a second end of hose assembly  10  opposite the end containing male coupler  60 . Threaded section  52  is constructed such that it can be operatively connected to a male fitting of a spigot, faucet, or other similar valve control device. 
     The internal connector  53  of female coupler  50  is rotatable in relation to main body  56  such that the main body is also rotatable in relation to the inner tube  20  and outer tube  40  which are operatively connected or fixed to stem  54 . A ferrule  51  is placed onto the jacket or outer tube  40  and inner tube  20 . The ferrule  51 , inner tube  20 , and fabric jacket outer tube  40  are then fitted onto stem  63 . Stem  63  is then expanded to secure the hose to the fitting. As mentioned above with respect to the male coupler, alternative constructions can be utilized to secure the inner tube  20  and outer tube  40  to the female coupler  50 . As illustrated in  FIG. 1 , connector  53  includes a receptacle  55  in the form of a cavity, recess, or the like that accommodates flange  57  of the main body  56 . In the embodiment illustrated, the flange  57  is a ring-like feature projecting inwardly from the main body  56  and includes an end that is located within receptacle  55 . The flange structure allows the main body  56  to spin or rotate around connector  53 . A washer  59  is located at the base of threaded section  52  in order to provide a desired seal between the female coupler and a device that is threadably connectable to threaded section  52 . 
     Alternatively, other common couplers, fittings or hose end connections can be utilized and include, but are not limited, crimped (external), barbed, or clamped couplings made from plastics, metals, or combinations thereof. 
     The hose assembly  10  is illustrated in a contracted position with respect to circumference in  FIG. 1 . In this position, the elastic inner tube  20  is in a contracted or relaxed state with no internal force being applied to the inner surface  22  sufficient to expand or stretch inner tube  20 . Depending on the material utilized for outer tube covering  40 , space may exist between the same and the slip coating layer  30 , if present, and/or inner tube  20  when the hose assembly is in a contracted position. 
     The fluid pressure within inner tube  20  can be increased for example by preventing fluid from being expelled through outlet  16 , such as with the use of an associated nozzle or the like (not shown) and introducing fluid under pressure into the inlet  14  of hose assembly  10 . Once a minimum threshold pressure is met or exceeded, the inner tube  20  undergoes circumferential expansion. Expansion of inner tube  20  results in a decrease in wall thickness of the inner tube and an increase in the circumference or diameter of the inner tube. Thus, a higher volume of fluid can be present in inner tube  20  in the expanded position as compared to the volume of fluid that can be present in a contracted position, below the minimum fluid pressure. 
     Depending upon the construction of the outer tube covering  40 , in the expanded position, the covering may exhibit a relatively smooth, cylindrical character along its length, see  FIG. 2  for example. 
     Standard water pressure for water exiting a spigot from a municipal water system is about 45 to about 75 psi (310.3 to 517.1 kPa) and typically about 60 psi, 413.7 kPa. Such pressure is sufficiently above a minimum fluid pressure required for the hose to expand. The minimum fluid pressure that causes the inner tube  20  of hose assembly  10  to expand will vary depending on the construction or composition thereof. When a nozzle or other flow restricting device is connected to the male coupler  60  of hose assembly  10 , with the female coupler  70  being operatively connected to a spigot, the inner tube  20  will expand when the spigot valve is opened or turned on as water under pressure will flow into the hose. If the nozzle prevents the flow of fluid through the inner tube, the pressure inside the inner tube will achieve substantially the same pressure as that coming from the fluid pressure source, such as 60 psi (289.6 kPa) in the case of a standard municipal water supply. When fluid is released from the outlet  16  of hose assembly  10  through a suitable nozzle, the pressure inside the inner tube  20  is reduced. The hose assembly will remain in an expanded position when the fluid pressure remains above the minimum fluid pressure. In a preferred embodiment, the couplers are full flow fittings. They are not designed to create back pressure within the hose. 
     The hose assemblies formed by the present invention are relatively lightweight, when compared to a conventional garden hose. Hose assemblies of the present invention are capable of withstanding water pressures in the 400 psi (2758 kPa) range while still being relatively light. For example, a 50 foot hose assembly of the present invention including couplers or end fittings can weigh about 4 or 5 lbs. with inner and outer tubes that are about 50 feet in length. The hose assemblies are very flexible and can be easily stored in compact spaces that a conventional garden hose would not fit, such as a bucket or similar container. The hot air seaming or welding process according to the present invention allows manufacture of a hose assembly utilizing less labor input, while having the inner tube automatically inserted into the outer tube which is formed therearound as part of the welding process. 
     The hose assemblies of the present invention are particularly suitable for cold water applications. 
     Due to the flexibility and versatility of the hose assemblies, one can utilize a fastener system such as a hook and loop fastener system, for example VELCRO® to harness the hose assembly when not in use. A fastener strap can be attached to one end of the hose by threading an end of a fastener through a female eyelet thereof such that the fastener can be permanently affixed to the hose assembly. 
     The hose assemblies of the present invention can also be formed from FDA listed ingredients for non-food contact applications, such as RV and marine drinking water service. 
     Examples 
     Burst Testing 
     One embodiment of a garden hose assembly according to the present invention including a fabric outer tube having a weld seam formed from a hot air welding process, the weld seam extending along a longitudinal length of the outer tube, the weld seam comprising melted fabric, was pressurized to failure. The peak pressure was recorded. This product was comparable to heavy duty, conventional constructions. 
     Elevated Temperature Burst 
     Garden hose assemblies as described in the example above were burst tested at 120° F. to determine how they would perform in hot conditions. This inventive construction did not lose as much burst strength at high temperatures compared to existing constructions. 
     Puncture Resistance 
     A pointed penetrator was forced against a pressurized hose assembly as described above. The peak force required to form a leak was recorded. This construction was comparable to heavy duty, conventional constructions. 
     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.