Abstract:
A hose extending and retrieval system and method used for loose-fill insulation operations that includes a hose member that is taken-up or fed-out from a hose storage container with a gear mechanism. A hose extending and retrieval system includes a hose member having a helical rib traversing therethrough, a hose storage container comprising an aperture forming a conduit, and a gear mechanism including a first gear and a second gear disposed on opposing sides of the hose member, wherein protrusions on the first and second gears interlock with the helical hose member. The gear mechanism interlocks with a helical component on the outside of the hose to provide sufficient operational impetus.

Description:
RELATED APPLICATIONS 
     The present invention is a CIP of U.S. patent application Ser. No. 09/282,409. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to hose extending and retrieving systems, and in particular, a hose extending and retrieving system for installing loose fill insulation. The extending and retrieving system of the present invention allows an operator to control the hose length while placing insulation into an area that is remote from the location of the loose fill source. 
     2. Brief Description of the Related Art 
     Loose fill insulation may be dispensed in a variety of ways. Generally, a hose is used to dispense the loose fill insulation. The operator positions a hose nozzle in a desired direction and dispenses the insulation from the loose fill source into the area at which the nozzle is aimed. Extending the hose from the source of loose fill into an area, such as an attic or basement, becomes problematic with the weight and configuration of the hose. The movement of the hose during the application process is generally cumbersome for the operator installing the insulation. Long lengths of hose are difficult to maneuver for an operator while being occupied with the task of installing the installation. Hoses resting on the ground also may create trip hazards or other problems. Forjobs requiring loose fill to be transported over long distances, control of the hose may require additional personnel for applying the loose fill insulation. 
     Several types of hose extending and retrieval devices have previously been disclosed. However, these previous systems suffer from various deficiencies which are described below. 
     U.S. Pat. No. 1,489,664 to Dowrelio discloses an automatic hose reel having a mesh gear to wind a hose  19  onto a drum  15 . However, Dowrelio fails to disclose or suggest a gear system that engages a hose. 
     U.S. Pat. No. 3,661,170 to Mitchell discloses an air start system for airplanes with a flexible hose (formed of airlines  14 ,  16 ) that retracts and extends. Similarly to Dowrelio, the patent to Mitchell fails to teach or suggest a gear system that engages a hose. 
     U.S. Pat. No. 3,911,944 to Hukuba et al. discloses an apparatus for housing a hose  2  of a suction cleaner having a pair of rollers  5  and  5 ′ that hold the hose therebetween that rotate in opposite directions. Each of the rollers  5 ,  5 ′ is tapered toward the center, and each has a plurality of vertical grooves formed around the periphery thereof. Each roller may be selectively rotated both clockwise and counter-clockwise by means of a reversible motor. The rollers  5 ,  5 ′ of Hukuba engage the exterior of the hose  2 , and frictional forces (between the hose and the rollers) are used to move the hose. Hukuba fails to disclose or suggest a gear system which engages projections formed on the hose. 
     U.S. Pat. No. 3,958,297 to Hukuba et al. discloses a suction cleaner having a pair of rotating rollers  14  and  14 ′ which are disposed above and below a hose  12  so as to hold it therebetween. The rollers are interlocked and one roller is so devised as to be selectively rotated both clockwise and counter-clockwise by means of a reversible motor. As with Hukuba &#39;944, Hukuba &#39;297 discloses rollers  14 ,  14 ′ which engage and move a hose by frictional forces. Hukuba &#39;297 also fails to disclose or suggest a gear system which engages projections formed on the hose. 
     U.S. Pat. No. 4,212,421 to Scott discloses a retrieving and storing apparatus for elongated flexible hoses with two wheels  40 ,  44  with peripheries having concave, generally semicircle annular groves with the bottoms of the grooves being serrated, knurled, axially grooved, or otherwise roughened to improve the grip on an elongated flexible element such as a water hose. As with the Hukuba patents discussed above, Scott uses frictional contact to extend or retrieve the hose. 
     U.S. Pat. No. 5,023,959 to Mercer discloses a system for extending and retracting a waste hose  12  from a recreational vehicle (RV). The system includes an external collar  20  that engages a continuous helical rib  22  formed around the outer periphery of the hose. An inner surface of the collar  20  engages the hose  12  so that rotation of the collar moves the hose. However, the rotating external collar  20  of Mercer generally provides a slow extension and retrieval of the hose, and may be easily jammed. 
     Due to the length, weight, and location of loose fill insulation hoses, frictional members that interact with the hose to move the hose are operationally inadequate for insulation hoses, as the frictional members would require excessive frictional forces to be functional. Additionally, systems such as the one taught by Mercer (U.S. Pat. No. 5,023,959) have proven too slow to accommodate the needs of the loose fill insulation dispensing industry. 
     Thus, there is currently a need for an improved system and method for facilitating the movement of the loose fill insulation hose between a loose fill source and an area of laying the loose fill insulation. 
     SUMMARY OF THE INVENTION 
     The present invention is a hose management system comprising a hose member having a helical rib traversing therethrough, a hose storage container comprising an aperture forming a conduit, wherein the hose member is capable of traversing through the conduit, and a gear mechanism including a first gear and a second gear disposed on opposing sides of the hose member, wherein protrusions on the first and second gears interlock with the helical hose member. 
     The above and other advantages and features of the present invention are better understood from the following detailed description of the preferred embodiments of the invention which is provided in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a hose extending and retrieval system of the present invention; and, 
     FIG. 2 illustrates a system for utilizing the hose extending and retrieval system shown in FIG.  1 . 
     FIG. 3 illustrates a side elevation view of a hose according to an exemplary embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention comprises a hose extending and retrieving system and method for operating the same. 
     In a conventional insulation dispensing apparatus, loose fill insulation is placed into a hopper or housing and conditioned, as described in U.S. patent application Ser. No. 09/282,409, filed Mar. 11, 1999, entitled “Improvement to Hose Used to install Loose Fill Insulation” by Kelley et al., the disclosure of which is herein incorporated by reference. The invention disclosed in the Kelley et al. Application is an improved hose or tube  100  for attachment to an insulation dispensing apparatus (See FIG.  3 ). In particular, and as shown in FIG. 3 of the present application, the hose  100  includes a helical rib  110  which traverses the length of the hose. Opposite the helical rib  110  on an interior surface of the hose  100  there is a projection (not shown) which also extends the length of the hose, and which serves to condition loose fill insulation as it passes through the tube. Insulation hoses, such as the type disclosed in the Kelley et al. Application, are often difficult to maneuver into and out of insulation dispensing apparatus or container. The present invention is directed to facilitating the easy movement of such insulation hoses. 
     Referring to FIG. 1, a hose extending and retrieval system  10  according to a preferred embodiment of the present invention is shown. The hose extending and retrieval system  10  includes a hose member  12  that may be stored within a hose storage container  20 . The hose member  12  may be paid-out or taken in by a gear mechanism  30  that is operationally positioned adjacent to an aperture  22 , with the gear mechanism  30  impelled by a motor  40  that is attached to the gear mechanism  30 . The gear mechanism  30  provides a planar impulse force to the hose member  12 , causing the hose member  12  to move. 
     The planar impulse force provided by the gear mechanism  30  to the hose member  12  is in contrast to the frictional forces used in prior art hose extension and retrieval systems (e.g., the patents to Hukuba discussed above). It has been discovered by the present inventor that planar impulse forces are much more efficient in transferring force from the moving member (e.g., gear mechanism) to the hose. 
     Planar impulse force includes the use of surface areas to push or impel one object with respect to another. In the present invention, the surface area of the gear teeth  32  of the gear mechanism  30  contact portions (i.e. front and rear contact surfaces  52 ,  54 , explained below) of the helical rib  14  of the hose member  12 . As the force between the two surfaces (i.e., the helical rib surface and the gear teeth surface) is aligned perpendicular to the pressing surfaces, the planar force constitutes a substantial amount of non-frictional force. This surface-to-surface, or planar, connection allows the gear mechanism  30  to impel the hose member  12  in a forward  16 , or rear  18 , direction. 
     Raised portions of the helical rib  14  form a front contact surface  52  and a rear contact surface  54 . As the surface area of the gear teeth  32  contact the surface area of either the front contact surface  52  or rear contact surface  54 , the gear teeth  32  are able to impart a planar force perpendicular to the front and rear contact surfaces, respectively. Movement of the gear mechanism  30  in the forward direction  16  forces the hose member  12  out of the hose storage container  20 , while movement in the rear direction  18  causes the hose member  12  into the hose storage container  20 . 
     In the preferred embodiment, the hose member  12  has a helical rib  14  that traverses along the length of the hose member  12 . The hose member  12  preferably is flexible, having a generally cylindrical circular cross-section, however, the hose member  12  may have a variety of cross-sectional shapes (e.g., oval, rectangular, polygonal), with the proper shape being determinable by those skilled in the art. Additionally, the hose member  12  may comprise an inner liner, or other known configurations. Preferably, the helical rib  14  traverses along the entire length of he hose member  12 , but shorter operational lengths may be used. The hose member  12  may comprise any suitable length for placing insulation, preferably having lengths of from about 10 feet to about 300 feet, more preferably from about 50 feet to about 200 feet, and most preferably from about 100 feet to about 200 feet. The hose member  12  also may comprise any suitable diameter for placing insulation, preferably having a diameter of from about 2 inches to about 10 inches, more preferably from about 3 inches to about 8 inches, and most preferably from about 4 inches to about 7 inches. 
     As shown in FIG. 1, the hose storage container  20  has sufficient size to store the hose member  12  therein. The hose storage container  20  includes an aperture  22  that forms a conduit  24 . The conduit  24  is sufficiently large and dimensioned to allow the hose member  12  to traverse through the aperture  22  while allowing a smooth, non-catching, edge  26 . The smooth edge  26  ensures that the folds  14  of the hose member  12  do not become snared onto the edge  26  as the hose member  12  enters or leaves the confines of the hose storage container  20 . Within the hose storage container  20 , the hose member  12  may be compressed along the longitudinal axis (i.e., along the length of the hose member  12 ) to store a larger amount of hose into a smaller area internally within the hose storage container  20 . Additionally, channels or paths  60  may be included within the hose storage container  20  to reliably compress the hose member  12  as it enters the hose storage container  20 . Take-up reels and/or other collecting devices for creating channels or paths  60  may be used within the hose storage container  20 , as appropriate. 
     The gear mechanism  30  includes at least a first set of gear heads  38  that comprises two or more gears  34  and  36 . The first set of the gears heads  38  is operationally positioned adjacent to the aperture  22 , allowing the gears  34  and  36  to engage the helical rib  14  along the length of the hose member  12 . The gears  34  and  36  engage the helical rib  14  with a planar impulse force that forces the hose member  12  into and out of the hose storage container  20 . Gear surfaces on the gears  34  and  36  contact lateral surface areas of the helical rib  14  of the hose member  12 , as the gears  34  and  36  are rotated in opposite directions, to force the hose member  12  in the forward  16  or rear  18  longitudinal directions. The gears  34  and  36  may include flat, worm and/or other appropriate gears, with flat gears being preferred. 
     The two gears  34  and  36  are substantially equilaterally positioned around the circumference of the hose member  12 . Additional gears  34 ′ and  36 ′ also may be included within the first set of gear heads  38 , with the additional gears  34 ′ and  36 ′ operating in concert with gears  34  and  36  to engage the folds  14  on the hose member  12 . The additional gears  34 ′ and  36 ′ may laterally displaced from the position of the gears  34  and  36  (i.e., contacting different diameters of the hose member  12  at a given moment in time), in an in-line configuration with the gears  34  and  36 , or may be placed adjacent to the gears  34  and  36  (i.e., contacting the same diameter of the hose member  12  at a given moment in time). When a particular set of gear heads  38  includes greater than two gears, such as three or four gears, the configuration of the multiple gears generally is arranged in a substantially equilateral position around the circumference of the hose member  12 . Preferably, the gears composing any particular set of gears are adjustable to accommodate various sizes of hose members  12 . The gears may be removable and interchangeable to accommodate various sizes of hose members  12  having different spacings of the helical rib  14 . 
     As seen in FIG. 2, the hose extending and retrieval system  10  may be mounted on a truck  80 , or other like transporting device to carry the hose extending and retrieval system  10  to an operating location. Additional sets of gears  42  and  44  may be used to allow greater control of the hose member  12  as it is forced into and out of the hose storage container  20  on the truck  80 , and maneuvered to properly position and dispense fill. With the first set of gears  38  located adjacent to the aperture  22 , the second set of gears  42  may be contained within the hose storage container  20 , preferably adjacent to the first set of gear heads  38 . Thin allows smooth take-up of the hose member  12  into the hose storage container  20  as the hose member  12  is being fed into the hose storage container  20  with the first set of gear heads  38 . With non-compressible hose members  12 , the second set of gears  42  may aid in positioning the hose member within the hose storage container  20  to economize the storage space therein. 
     Additional sets of gears (i.e., the third, fourth, fifth, etc.) may be located either inside of the hose storage container  20  or outside. Preferably, regardless of whether the additional sets of gears are inside or outside of the hose storage container  20 , the position and orientation of the additional sets of gears are fixed in relation to the hose storage container  20  to ensure that the hose member  12  does not become fouled as it is pushed and/or pulled by the first set of gear heads  38 , with the proper positioning being determinable by those skilled in the art. In the preferred embodiment, the hose extending and retrieval system  10  comprises a plurality of additional sets of gears, outside of the hose storage container  20 , and arranged along the path of the hose member  12 , extending from the hose storage container  20  to the area of insulation placement, or fill area,  14 . Each additional set of gears preferably has its own gear mechanism  30 . The additional sets of gears  42  and  44  may be located on remote transport platforms  70  and  72  to guide the hose member  12  along the longitudinal length of the hose member  12  positioning. With the use of the additional sets of gears  42  and  44 , significant control of the hose member  12  is obtained by a remote control operator  50  of the system. Although preferably the sets of gears  38 ,  42  and  44  act in unison to feed-out or take-in the hose member  12  in the forward  16  or rear  18  direction, the sets of gears  38 ,  42  and  44  more preferably are able to act individually in addition to being impelled jointly (i.e., as a group). Still more preferably, the set of gears  38 , 42  and  44  work in unison, while having the override or selection capability of an operator  28  causing one or more of the sets of gears  38 ,  42  and  44  to act independently, when desired. Most preferably, the first set of gears  38  is directly operated by the operator  28 , with the second and additional sets of gears  42  and  44  under a slave operation of the first set of gears  38  (i.e., they operate in unison to the first set of gears  38 , unless and until any of the second or additional sets of gears  42  and  44  individually register a specified amount of tension within the hose member  12 , at which time that set, or sets, of gears  42  and  44  automatically disengages from acting in unison with the other sets of gears, particularly the first set of gears  38 ). 
     The remote transport platforms  70  and  72  are generally light weight structures, preferably having wheels to aid in locating the remote transport platforms  70  and  72  to a location. The remote transport platforms  70  and  72  are fixed in place to guide the hose member  12  longitudinally into and out of the fill area  114 . Sensors along the hose member  12  may be used to allow the remote transport platforms  70  and  72  to indicate to the operator the tension of the hose member  12  at any particular remote transport platform  70  and  72 . The remote transport platforms  70  and  72  are configured to secure to common fixed structures normally encountered in fill operations, such as adapting to stairs, halls, doorway, entry way, window, etc., with the proper configuration of the remote transport platform  70  and  72  determinable by those skilled in the art to best fix the position of the remote transport platforms  70  and  72 . Preferably, each remote transport platform  70  and  72  possesses its own motor  40  for impelling the hose member  12 . 
     The motor  40  attached to the gear mechanism  30  possesses sufficient power to rotate the gears  34  and  36  in a given direction to feed-out and/or take-in the hose member  12 . This may be accomplished by having a drive member of the motor  40  operate in at least two different directions, or using a coupler to change the direction of the imparted motion from the motor  40  onto the gears  34  and  36 . Any suitable power source for the motor  40  may be used, with an electric motor  40  being preferred. 
     The hose extending and retrieval system  10  may include a remote control operator or activating device  50  that activates the motor  40  from a remote location, such as the fill area  114 . Preferably the activating device  50  includes a portable activating device  52 . Suitable activating devices  50  include activating devices  50  that may be attached and carried on a belt, placed on a wrist or waist band, incorporated into the nozzle section of the hose member  12 , stand-up control consoles placed within the fill area  114 , or other like devices  50  that facilitate operation of the in-take and out-lay of the hose member  12  while placing insulation. The activating device  50  preferably comprises a read-out for indicating the length of extended hose  12  and/or other like information for monitoring the operation of the hose member  12  movement. 
     Additionally, the hole extending and retrieval system  10  may include a status indicator, such as an alarm,  46  that indicates problems within the hose extending and retrieval system  10  while the operator  28  operates the hose extending and retrieval system  10 . This status indicator  46  for the hose extending and retrieval system  10  allows the operator  28  to become cognizant of dangerous conditions while remotely operating the hose extending and retrieval system  10 . The alarm  46  may include an automatic cutoff, or other like safety mechanisms, to ensure that the hose extending and retrieval system  10  does not present an unsafe or hazardous condition. 
     In operation, the hose extending and retrieval system  10  is transported by truck  80  to a house or other building having the fill area  114  to lay fill. The fill may be located in a container adjacent to the hose storage container  20  in on the same truck  80 , or transported on a separate truck. Once at the fill location, the hose member  12  is extended from the hose storage container  20  to the fill area  114  to receive the fill. The remote transport platforms  70  and  72  are located along the length of the hose member  12  between the truck  80  and the fill area  114 , generally in a “line-of-sight” configuration, allowing each set of gears to be aligned with one or more of the other sets of gears. The location of the sets of gears is generally fixed from the first set of gear heads  38 , with the second set of gears  42  located in a non-obstructed position from the first set of gear heads  38 , and the third set of gears  44  located in a non-obstructed position from the second set of gears  42 , etc. As the operator  28  positions each set of gears  38 ,  42  and  44 , the operator  28  uses the portable activating device  52  to feed out the hose member  12  from the hose storage container  20  to connect the hose member  12  with the remote transport platforms  70  and  72 . With the hose member  12  extended, the operator  28  activates the motor  40  to further extend the hose member  12  to the fill area  114 , and once positioned, the operator  28  begins placing fill. The operator  28  may activate the fill process by actuation of a pump to pump fill through the hose member  12  and into the fill area  114 , or alternatively, the operator  28  may charge the hose member  12  and use a release valve at the nozzle to flow fill into the fill area  114 . 
     The following is a prophetic example of the operation of the present invention: 
     EXAMPLE 1 
     The leading edge of a 200 foot loose fill hose (e.g. hose  12  described above), that is attached to a blowing unit including extending and retrieval mechanism (e.g., system  10  described above) is mounted on a truck. When the hose feed switch is engaged, the hose is fed through the gears and out of the truck. Preferably, an additional set of gears (e.g., gears  42 ; FIG. 2) is located close to the truck, and leading to the attic area to be insulated. The leading end of the hose is threaded through the second set of gears and up into the attic. The gears, guarded to prevent injury, are AC powered and activated by remote control. The remote device is located on the operator&#39;s belt. When hose is required, in or out of the attic, the remote control conveniently moves the hose to keep it out from under the operator&#39;s feet. When the job is complete, the hose feed is reversed an the hose automatically feeds back into the truck. 
     Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.