Abstract:
The present invention relates to portable hose reel carts for handling and storage of large lengths of flexible hoses, such as garden or air hoses. The cart is constructed of plastic and steel components having a centrally rotatable spool for winding of the flexible hose, a frame for supporting the spool, wheels at each end of the base of the frame, and a handle assembly attached to the frame to facilitate moving the cart. The crank handle assembly which may or may not be foldable for easy storage. The cart includes a large tray for storage and transport of garden supplies.

Description:
FIELD OF THE INVENTION 
     This invention pertains to carts for use in storage of flexible hoses, and more particularly to a hose reel cart having structural components made from both metal and plastic thereby creating a lightweight and durable hose reel cart having improved stability and maneuverability. 
     BACKGROUND INFORMATION 
     Portable hose reel carts for handling and storage of flexible elongate tubular members, such as garden hoses, air hoses and the like, have gained wide public acceptance. While the construction of hose reel carts is quite varied, such carts are primarily constructed entirely from metal or entirely of molded plastic components. Hose reel carts generally have a centrally disposed rotatable spool and crank handle for reeling of the flexible hose, a frame for supporting the spool rotatable by a crank, two wheels at one end of the base of the frame, and a frame handle for tilting the frame onto the two wheels to facilitate moving the cart. The frame handle and/or crank 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, the teachings of which are hereby incorporated by reference. 
     It is generally recognized that hose reels are often stored outside and thus are subjected to the adverse elements, e.g. hot and cold temperatures, rain, snow, ice and dirt. It has been found that hose reel carts formed exclusively from molded plastic or polymeric material are lightweight and resistant to corrosion caused by the elements. However, the plastic structures are currently unable to withstand the elements for extended periods of time without becoming brittle or warping. It has also been found in practice that prior art hose reel carts made predominantly of metal are robust and sturdy. However, metal hose reel carts have a tendency to corrode when their protective surface becomes damaged or worn away through usage. 
     It is also generally recognized that some end users may drain fluid from the hose prior to rewinding it about the hose spool while others rewind the hose about the spool while it is still full of water. Each situation creates its own unique set of problems. Lightweight polymeric structures are generally unable to withstand the weight of large amounts of filled water hose and thus are limited in size and/or hose capacity. Still yet, many of these polymeric hose reel structures are not able to withstand the peripheral forces transmitted to a hose reel when an empty hose is communicated with a fluid source under pressure while still wound around the reel. Often, the repeated application of such forces results in structural failure of the hose spool. 
     Hose reel carts constructed predominantly of metal are robust and sturdy, and able to accommodate repeated application of peripheral forces. However, these carts tend to be exceptionally heavy, making them less amenable to being pushed or pulled by the user over rough surfaces. Large amounts of heavy filled hose compound the problem of portability and are likely to raise the center of gravity. The raised center of gravity may make the cart easy to tip over and dangerous for the user. 
     Additionally, most of the prior art hose reel carts, whether plastic or steel, utilize injection molded hard plastic tires. While these tires are lightweight and inexpensive to manufacture, they are often prone to damage, especially when used directly upon rough surfaces, such as gravel, sand or brushed concrete. Additionally, plastic tires do not respond well to static or dynamic loads when used on soft surfaces. That is, as the load increases the tread width remains the same allowing the tire to sink into the surface. In contrast, floatation tires, such as rubber pneumatic tires, provide compression. As the compressive load increases the tire gets wider, increasing the hose reel footprint. The increased footprint allows the cart to float over soft surfaces and reduces the forces required to move the cart. 
     To this end, what is needed in the art is a portable hose reel cart capable of storing a large amount, e.g. more than 150 feet, of filled or unfilled hose. The hose reel cart should be capable of withstanding adverse conditions for extended periods of time without warping or cracking. The hose reel cart should have a supporting enclosure able to provide optimum strength while maintaining minimal weight through the use of both plastic and metal components. The hose reel cart should include durable pneumatic tires for increased load portability across soft and rough surfaces. 
     The present invention utilizes four plastic coated metal corner-posts, floatation tires and hollow metal transverse frame members that are tightly fitted or integrally molded into plastic side frame members for lightweight yet durable construction. Utilization of the combination of plastic and metal permits the construction of large lightweight portable hose reel carts when compared to those taught by the prior art. As used herein the terms “plastic coated metal” and “metal reinforced polymeric structural panel” refers to a structural component formed from one or more polymeric resins in combination with at least one metallic reinforcing structure. The polymeric portion of the component may be formed to tightly accept the metallic structure after molding or the polymeric portion of the component may be molding around the metallic structure. U.S. Pat. No. 5,007,598 illustrates a commonly found portable hose cart including a molded plastic handle connected to the plastic frame sides. This disclosure requires the user place their foot behind a rear bar and pull the handle rearwardly and down such that the cart can be tilted to such a degree as to allow the front feet of the cart to be lifted off the ground and onto the two back wheels in order to transport it from location to location. It can be difficult for a user of small stature to tip the hose laden cart backward, as well as dangerous should the user tip the cart too far back causing the cart to topple over on top of them. 
     Similarly, U.S. Pat. No. 6,338,360 shows a hose reel carrier assembly with a tray for storage. The cart also has two plastic wheels which can be mounted on common or separate axles. In order to move this hose carrier, the user must lift the side opposite of the wheels upward by a handle, such that the feet underneath the handle are off the ground. In order to move it forward, the user must then push against the carrier while still lifting the weight of the carrier and hose, making it extremely difficult for many individuals to use, especially on uneven or rough terrain. 
     “Suncast Metal Hose Reel” model no. MHR300 illustrates a metal frame construction capable of holding 300 feet of hose on four pneumatic wheels. Similarly, the Ames® “Steel Hose Caddy” model no. HR93 illustrates a similar solid steel construction for storage of 200 ft of ⅝ inch hose on two pneumatic 20 inch rear tires with two smaller front tires. However, these hose carts do not include a tray to carry garden tools. Additionally, the cart frames are made entirely of metal making them heavy, especially when laden with over 150 feet of hose, and therefore not easily transported across uneven or soft ground. 
     While the foregoing described prior art devices have improved the art and in some instances enjoyed commercial success, there remains nonetheless a continuing need in the art for a corrosion resistant lightweight hose reel cart with tray, which uses a combination of polymeric and steel components of stable construction so as to support large lengths of hose and other garden accessories while maintaining the portability to be easily navigated over difficult terrain without having to tilt the cart. 
     SUMMARY OF THE INVENTION 
     The hose reel cart of the present invention utilizes construction consisting of plastic and steel components for increased durability and stability while still remaining lightweight for increased hose capacity and portability. By utilizing four plastic coated steel corner-posts, floatation tires, and hollow steel transverse frame members that are fitted or integrally molded into plastic side frame members, a lightweight yet durable hose reel cart may be constructed. Additionally, the hose reel cart is provided with corrosion resistant plastic wheels. The wheels are provided with roller bearings for ease of mobility. The hose reel cart may be preassembled at the factory thereby eliminating the need for assembly and associated product packaging. The hose is wound around the spool by use of a crank providing a direct rotational link between the crank and the winding of the spool. During non-use, a handle on the crank is placed into a storage position by pivoting the handle about one end of the crank arm. Moreover, the crank arm and handle can be positioned on either side of the frame providing left or right handed operation. Utilization of the combination of plastic and steel permits the construction of large lightweight portable hose reel carts. 
     Thus, an objective of the instant invention is to provide a readily portable hose reel cart wherein all components are preassembled so as to eliminate the need for assembly by the consumer, yet allow repeatable storage by providing for the use of a foldable crank handle. 
     Another objective of the invention is to provide a portable hose reel cart utilizing a combination of molded plastic and plastic covered metal components for improved corrosion resistance, strength and rigidity. 
     A further objective of the present invention is to provide a portable hose reel cart with tray atop a combination plastic and steel frame structure having four large floatation tires to easily transport heavy and/or large lengths of hose across uneven or rough terrain. 
     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 
         FIG. 1  is a front perspective view of the instant invention; 
         FIG. 2  is a rear perspective view of the instant invention; 
         FIG. 3  is an exploded view of the instant invention; 
         FIG. 4  is a top view of the instant invention; 
         FIG. 5  is a bottom view of the instant invention; 
         FIG. 6 . is a front view of the instant invention; 
         FIG. 7 . is a rear view of the instant invention; 
         FIG. 8 . is a left side view of the instant invention; 
         FIG. 9 . is a perspective of the folding crank handle utilized by the instant invention; 
         FIG. 10 . is a cross sectional view of the folding crank handle of  FIG. 9  taken along lines  1 — 1  of  FIG. 6 ; 
         FIG. 11 . is a perspective view of the sliding seal arrangement utilized in the instant invention; 
         FIG. 12 . is a cross sectional view of the floatation tires utilized in the instant invention taken along lines  2 — 2  of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIGS. 1–8 , wherein like elements are numbered consistently throughout, there is shown a portable hose cart generally indicated by the reference number  20 , embodying the principles of the present invention. The hose reel cart  20  is useful for holding, paying out and transporting large amounts of hose  22  between a storage location and a use location. The major components of the hose reel cart include an enclosure assembly  21 , a spool or reel assembly  26  coupled to a crank handle assembly  28 , a tray  52 , a handle member  82  and four of wheel assemblies  48 . In a typical arrangement, the cart  20  is able store upwards of 300 feet of a ⅝ inch common hose on the reel  26 . 
     The enclosure assembly  21  includes a pair of generally vertical front support posts  38  and a pair of generally vertical rear support posts  42 . The support posts are preferably constructed having an inner metal portion  37  and an outer polymeric portion  39  ( FIG. 3 ). In this manner the support posts provide increased structural rigidity as well as corrosion resistance. Moreover, tabs, supports and other structural enhancements (not shown) may be integrally formed onto the outer surface of the vertical support posts. The upper portion of the rear support posts  42  preferably includes an integral elbow portion  40  for attachment of a structural handle  82 . The structural handle  82 , shown in  FIGS. 1–8 , is linked to the elbow portion  40  of rear frame members  42  and extends rearwardly from the tray  52 . The handle  82  includes a handgrip portion  84  which extends between the mounting arms  85  and is attached to the upper end  43  of the support posts  42  via a bolt assembly  150 , or by any other fastener means well known in the art. The handgrip portion  84  provides a comfortable handhold to receive the fingers of both hands of the person pushing or pulling the cart  20 . 
     Interconnecting the top end portions  36 ,  43  of the frame members  38 ,  42  is a storage box or tray  52  for storing gardening supplies or tools (not shown) so they can be easily accessed. The tray  52  comprises a generally rectangular floor or base  62 , a vertical front wall  54 , a rear wall  56 , left and right side walls  58 . The base  62  preferably includes a plurality of openings  70  of such a size as to permit draining of water, dirt, and other small particles of debris. 
     In a preferred embodiment, the tray  52  includes a plurality of integrally formed vertical sleeves  110  located at the corners of the tray, such that the support posts  38 ,  42  snugly fit into the sleeves  110 . Similarly, the rear support posts  42  extend through sleeves  110  connected to the rear wall  56 , such that the elbow  40  is located at or above the sleeve  110 . In this manner the handle  82  is located at a convenient height for gripping by the user. Fasteners  150  are utilized to extend through suitable openings  152  formed in sleeves  110  to effect the final rigid securement. One of ordinary skill will recognize that a variety of fasteners as well as other fastening means well known in the art may alternatively be utilized. 
     The tray  52  includes a plurality of vertical slots  74  formed within one or more of the tray walls, herein illustrated in rear wall  56 , for storing the free end of a hose when not connected to a fluid source to prevent hose ends from dragging along the ground when the cart is moving. The slots  74  can be used to hold other tools, e.g. hose nozzle, or the like (not shown). The slots can include a retaining lip (not shown) to prevent objects from sliding out, as discussed in U.S. Pat. No. 6,086,073 herein incorporated by reference. As best seen in  FIG. 5 , the bottom surface of the tray can comprise additional material integrally attached thereto forming reinforcement ribs  101  for enhanced rigidity of the tray. In an alternative embodiment the tray may include metal reinforcements (not shown) integrally molded therein to provide additional rigidity and weight capacity. 
     In the preferred embodiment, the front and rear support posts  38  and  42  are constructed to extend through integral congruent sleeves  110  formed along at least one edge portion of a pair of structural panels  66 , the corners of the upper tray  52  and the wheel support assemblies  48  for connection thereto. However other means of connection will be recognized by those skilled in the art, e.g. clips, split collars, clamps and the like. The generally rectangular shaped structural sides  66  are complementary to each other and both include centrally disposed journaled apertures  140  sized for receipt of hub portions  130 , crank assembly and sliding seal arrangement as discussed below. 
     In one preferred embodiment, the front support posts  38  are constructed to extend through at least one of the integral sleeves  110  formed on the front edge portions of each pair of wheel support assemblies  48 . Similarly, the rear support posts  42  are constructed to extend through each of the integral sleeves  110  formed on the rear edge portions of wheel support assembly  48 . Fasteners  150  designed to extend through suitable openings  152  formed in sleeves  110  and vertical support members  38 ,  42  effect the final rigid securement. One of ordinary skill will recognize that a variety of fasteners as well as other fastening means well known in the art may alternatively be utilized. 
     Additionally, the enclosure includes a pair of generally horizontally guide rails  34  along which a movable hose guide  72  slides to facilitate even distribution of the hose  22  onto the spool  26 . The pair of guide rails  42  are secured to and extend between the structural panels  66  and increase the structural integrity of the cart  20 . The lower portion of the enclosure  21  includes a pair of spaced apart and opposing wheel support panels  48  for attaching floatation type tires  300 . 
     Referring now to  FIG. 3 , there is shown the two substantially identical wheel support panels  48 . Each wheel support panel  48  includes a hub, or aperture,  304 . Two transverse axles  86  extend laterally across the cart  20  such that the end portion of each axle  86  extends through the hub  304  of each opposing wheel support panel  48  to rotatably secure four floatation wheels  300  thereto. Additionally, the wheel support panels  48  include gussets  49  extending between the hubs  304  and the outer wall of the support panels  48  to provide additional structural rigidity. In an alternative embodiment, not shown, the wheel support panels may include integrally formed metal to provide additional structural rigidity and weight capacity. 
     As shown in  FIG. 12 , each of the four wheel assemblies  300  include a rim  306  with a central opening  302  for receipt of the axle  86 . In a preferred embodiment the rim  306  includes a bore  303  for mounting at least one bearing member  312 , e.g. ball bearing, roller bearing or bushing. Such bearings  312  include an inner ring having an axial opening for receiving an axle therein and an outer ring seated within the bore  303  of the wheel. This facilitates rotation of the wheel and tire when the cart is moved. Moreover, the rim  306  can include radial spokes  308  ( FIG. 2 ) extending radially from the central opening  302  for increased rigidity. 
     In a preferred embodiment, floatation tires  310 , e.g. pneumatic tires are annularly and circumferentially placed around the outer circumference of rim  306  to provide shock absorption, large footprint, improved handling and maneuvering. The tire  310  may be made from any natural rubber, synthetic rubber or suitable combination thereof as is well known in the art. The floatation tires are preferably greater than 8 inches in diameter to substantially elevate the wheel support assemblies  48  above tall grass, rocks, etc. Additionally, as illustrated in  FIGS. 5 and 13 , the floatation tires  310  can include treads  314  for better traction. 
     Referring to  FIG. 3 , the spool assembly  26  includes a central hub  28  constructed from two identical halves  114  and  116  which are secured to each other and to the radially extending flanges  32 . The connection can be accomplished via interlocking tabs or screws (not shown), such an arrangement can be viewed in U.S. Pat. No. 5,007,598 the contents of which are incorporated herein by reference. The hose  22  is wrapped around the reel  26  between the flanges  32 . Centrally disposed in each flange  32  is an axial extending hub  130  which is inserted into the journaled apertures  140  formed in either of structural panel  66 . In this manner the spool is rotatable about axis A ( FIGS. 1 ,  2 ). The reel halves  114 ,  116  and flanges  32  can be made of plastic material such as, polyethylene, or any other plastic, metal or suitable combination thereof known in the art. 
     As best illustrated in  FIG. 3  and  FIG. 11 , the hose reel  26  includes a hose connector  150  composed of a out-tube coupler  78  and a in-tube coupler  152 . The in-tube coupler  152  contains female threads for attachment to leader hose  80  ( FIG. 1 ) which is in fluid communication with a pressurized fluid source. The in-tube coupler  152  can be mounted to either one of the vertical panels  66  at about the axis of rotation A of the reel  26 . Alignment tabs  156  formed on the In-tube coupler  152  extend through the structural panel  66  and engage four equal spaced indentations (not shown) formed on the inside surface of the hub  130 . The in-tube coupler  152  includes a molded outlet tube  158  having o-rings  160  for engagement with the interior of the out-tube  78  by a sliding seal arrangement so that the female adapter  152  remains fixed to the structural panels  66 , while the out-tube  78  rotates with the reel  26  such that the female adapter  152  and out-tube  78  remain in fluid communication with one another as described in U.S. Patent. No. RE. 32,510, herein incorporated by reference. This arrangement permits rotation of the reel  26  without twisting or torquing internal components, while maintaining sealed fluid communication between the fluid supply and the hose. The coupling arrangement can also include a syringe type attachment means (not shown) for quick access to replaceable o-rings as discussed in U.S. Pat. No. 5,425,391 herein incorporated herein by reference. 
     As illustrated in  FIGS. 3 ,  10  and  11 , the crank handle assembly  28  is operably connected to the reel  26  so that rotation of the crank  28  rotates the spool to pick-up or payout the hose  22  for storage or use. The crank  28  has a split axle  183  which telescopes into either hub  130  and resiliently engages the spaced indentations (not shown) formed on the hub with tangs  184 . The crank  28  is held in place by the interrupted flange  185 . The split axle  183  can be compressed to remove the crank  28  from the reel  26  for placement on either end of the reel as desired. 
     The crank  28  is formed with an elongated depression which is shaped to accept the handle  186  when in the stored position. The handle  186  rotates about pin  206  fixed on the end of the crank  28  and journaled to the end of the handle  186 . The connection  200  between the handle  186  and the crank  28  permits repeated locking movement of the handle  186  from the stored position to the operative position. 
     The handle  186 , shown in  FIGS. 10–11 , turns in the operator&#39;s hand as the reel is manually rotated to wind the hose  22 . As shown in  FIG. 10 , the handle  186  has a flange  203  which turns about the pin  206  in conjunction with the handle  186  to cooperate with locator ridge  202  on locking tab  205  as the handle  186  is manually rotated to the operative position to lock the handle in place. The handle may thereafter be released by depressing the locking tab  205  allowing the handle  186  to be rotated to the stored position. 
     Referring to  FIG. 8 , the hose guide  72  prevents the user from touching the potentially dirty hose when winding up the hose. The hose guide  72  comprises an opening  32  though which the hose  22  passes and a handle  118  for gripping by the user. By rotating the spool  26  in concert with reciprocating the hose guide  72 , the user is able to neatly and evenly distribute the hose  22  across the spool  26 , with adjacent turns of each layer aligned next to the previous one. The hose reel cart  20  provides 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  22  as needed while the leader hose  78  remains coupled in fluid communication with the water or air supply (not shown). 
     In a preferred embodiment the various enclosure members, e.g. handle portion  85 , crank  28 , wheel support assemblies  48 , tray  52 , spool  26 , flanges  32 , hose guide  72 , rim  306  and structural panels  66  are formed primarily from high density polyethylene (HDPE) using an injection molding process, this provides increased corrosion resistance and thereby helps to decreases the overall weight of the cart. Those skilled in the art will recognize that there are other various high strength polymeric (plastic) material, such as polystyrene or the like that can be used to form the above mentioned enclosure members. Additionally, the various enclosure members can include a plurality of reinforcing metal members and or ribs  100  ( FIG. 3 ) for additional structural strength and support, without detracting from the aesthetic appearance of the cart once assembled. 
     Referring to  FIG. 3 , in the preferred embodiment the support posts  38 ,  42 , guide rails  64  and axles  86  are made from metal and include an impact resistant coating such as polyethylene or polypropylene, as disclosed in U.S. Pat. No. 5,998,552, the contents of which are incorporated herein by reference. The plastic coating protects the steel frame members from water, liquid fertilizer, corrosive chemicals and other liquid to prevent rust and corrosion of the metal, while providing structural rigidity to the cart  20 . Additionally, the metal members may be hollow or extruded forms which will also aid in decreasing the overall weight of the assembly without sacrificing rigidity. One of ordinary skill will recognize the shape of the tubular members is not restricted and can be circular, oval, rectangular, etc. In yet a further alternative embodiment tabs, supports and other structural enhancements (not shown) may be integrally formed onto the outer surface of the metal vertical support posts. 
     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. 
     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 of parts 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. 
     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any compounds, 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.