Abstract:
A hose includes a tube assembly surrounded by a textile reinforcement that is surrounded by a cover assembly. The tube assembly includes an inner non-foamed layer that is surrounded by a foamed layer that is surrounded by an outer non-foamed layer. The textile reinforcement surrounds the outer non-foamed layer of the tube assembly and preferably consists of a first spiral threading and a second mesh threading. The cover assembly includes an inner non-foamed layer that is surrounded by a foamed layer that is surrounded by an outer non-foamed layer. The adjacent relationship of the outer non-foamed layer of the tube assembly and the inner non-foamed layer of the cover assembly provide a substantial increase in adhesion between the two assemblies. Further, this configuration reduces the tendency for water seepage between the layer or plies that can cause bubbles and separation. Still further, the present configuration allows the foam layers to be blown with lighter densities for softness and reduced weight while not compromising hose integrity. Even further, the present configuration improves hose strength with a concomitant reduction in the amount of textile reinforcement.

Description:
PROVISIONAL PATENT APPLICATION  
       [0001]    This application claims the benefit of U.S. Provisional Application Serial No. 60/202,710, filed May 10, 2000. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates generally to a conduit which is used to convey fluid, and more particularly to a flexible hose which is used to convey water such as a garden hose. The present invention also relates to a method of manufacturing such a hose.  
           [0003]    Various hoses have been designed in the past which convey a fluid such as water from a fluid source to a desired location remote from the fluid source. For example, existing garden hoses have been designed to include an elongate tubular structure which has a first end which is configured to connect to an outside water faucet or spigot and a second end which is configured to connect to a lawn sprinkler or similar mechanism.  
           [0004]    The elongate tubular structure of such existing garden hoses have been constructed in various manners. For instance, U.S. Pat. No. 4,044,799 issued to Higbee et al. discloses a hose having an outer cover, an inner tube, and a knit reinforcing fabric interposed therebetween. The outer cover includes a wall structure having a multitude of gas-filled cells interspersed throughout the wall structure of the outer cover. The inner tube has a multitude of closed gas-filled cells interspersed throughout its walls. Another example of an existing hose construction is disclosed in U.S. Pat. No. 4,644,977 issued to Arterburn. The hose of Arterburn includes an inner tube assembly, an outer cover assembly, and a textile reinforcement interposed therebetween. The inner tube assembly of Arterburn includes a thin, non-foamed inner liner and a foamed interlayer circumferentially encompassing the inner liner. Auterburn&#39;s outer cover assembly includes a first thermoplastic layer with a multitude of closed gas-filled cells and a second thermoplastic layer which is nonfoamed.  
           [0005]    One potential drawback with hoses of the above-described construction is separation of the inner tube from the outer cover at the site of its textile reinforcement. In particular, during extended use of such hoses, water or moisture may seep between the inner tube and the outer cover at an end of the hose where a coupling is attached to the inner tube and the outer cover. Seepage between the inner tube and the outer cover may cause bubbles to form thereby causing the inner tube to become separated or otherwise detached from the outer cover. Such separation tends to cause the hose to fail.  
           [0006]    Also, it is a continuing goal of hose designers to create a hose having improved strength. For example, when a hose is grasped and pulled by a user at one end while the other end is coupled to a water facet or spigot in order to move the outlet end of the hose as would normally occur when the user is moving the hose in order to water another part of his/her lawn, the intermediate portion of the hose is subjected to significant stresses and strains. Improving the strength of the hose to endure such stresses and strains is advantageous. Another continuing goal of hose designers to create a hose which is relatively light weight, while still possessing the strength necessary to endure such stresses and strains.  
           [0007]    What is needed therefore is a hose which overcomes one or more drawbacks of the previously designed devices. For example, what is needed is a hose that is relatively less susceptible to having its inner tube become separated or otherwise detached from its outer cover at the site of its textile reinforcement as compared to existing hoses. Moreover, for example, what is needed is a hose that has relatively increased strength, and is relatively lighter in weight as compared to existing hoses.  
         SUMMARY OF THE INVENTION  
         [0008]    In accordance with one embodiment of the present invention, there is provided a hose. The hose a tube assembly having (i) a first inner non-foamed layer, (ii) a first outer non-foamed layer positioned around the first inner non-foamed layer, and (iii) a first foamed layer interposed between the first inner non-foamed layer and the first outer non-foamed layer. The hose further includes a textile reinforcement positioned over the tube assembly. Moreover, the hose includes a cover assembly positioned over the textile reinforcement, the cover assembly having (i) a second inner non-foamed layer, (ii) a second outer non-foamed layer positioned around the second inner non-foamed layer, and (iii) a second foamed layer interposed between the second inner non-foamed layer and the second outer non-foamed layer.  
           [0009]    Pursuant to another embodiment of the present invention, there is provided a method of manufacturing a hose. The method includes the step of extruding a tube assembly comprising (i) a first inner non-foamed layer, (ii) a first outer non-foamed layer positioned around the first inner non-foamed layer, and (iii) a first foamed layer interposed between the first inner non-foamed layer and the first outer non-foamed layer. The hose further includes the step of positioning a textile reinforcement on the tube assembly. In addition, the hose includes the step of extruding a cover assembly over the textile reinforcement after the positioning step, the cover assembly comprising (i) a second inner non-foamed layer, (ii) a second outer non-foamed layer positioned around the second inner non-foamed layer, and (iii) a second foamed layer interposed between the second inner non-foamed layer and the second outer non-foamed layer.  
           [0010]    Pursuant to yet another embodiment of the present invention, there is provided a hose which includes a tube assembly defining a liquid passage, the tube assembly being prepared by a process which includes extruding a first inner non-foamed layer, a first foamed layer around the first inner non-foamed layer, and a first outer non-foamed layer around the first foamed layer. The further includes a textile reinforcement positioned around the tube assembly. Additionally, the hose includes a cover assembly positioned around the tube assembly, the cover assembly being prepared by a process which includes extruding a second inner non-foamed layer around the first outer non-foamed layer, a second foamed layer around the second inner non-foamed layer, and a second outer non-foamed layer around the second foamed layer.  
           [0011]    According to still another embodiment of the present invention, there is provided a hose assembly which includes (i) a tri-lamina tube assembly having an outer surface that is made of a thermoplastic, (ii) a textile reinforcement in contact with the outer surface of the tri-lamina tube assembly, and (iii) a tri-lamina cover assembly having an inner surface that is made of the thermoplastic and surrounding the textile reinforcement and the outer surface of the tri-lamina tube assembly.  
           [0012]    According to further embodiment of the present invention, there is provided a method of manufacturing a hose comprising the steps of (i) extruding a tri-lamina tube assembly, (ii) positioning a textile reinforcement in contact with an outer surface of the tri-lamina tube assembly, and (iii) extruding a tri-lamina cover assembly over the textile reinforcement after the positioning step so that an inner surface of the tri-lamina cover assembly contacts the outer surface of the tri-lamina tube assembly through a plurality of interstices defined in the textile reinforcement.  
           [0013]    It is therefore an object of the present invention to provide a new and useful hose.  
           [0014]    It is another object of the present invention to provide an improved hose.  
           [0015]    It is yet another object of the present invention to provide a hose that is relatively less susceptible to having its inner tube become separated or otherwise detached from its outer cover at the site of its textile reinforcement as compared to existing hoses.  
           [0016]    It is still another object of the present invention to provide a hose that has relatively increased strength as compared to existing hoses.  
           [0017]    It is yet another object of the present invention to provide a hose that is relatively lightweight as compared to existing hoses.  
           [0018]    It is yet an object of the present invention to provide a new and useful method of manufacturing a hose.  
           [0019]    It is additionally an object of the present invention to provide an improved method of manufacturing a hose.  
           [0020]    Other objects and benefits of the present invention can be discerned from the following description and accompanying drawings.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings wherein:  
         [0022]    [0022]FIG. 1 is a partially cut away cross-sectional view of a section of a multiple layer hose in accordance with the principles of the present invention;  
         [0023]    [0023]FIG. 2 is a cross-sectional view of a portion of an inner tube of the multiple layer hose of FIG. 1;  
         [0024]    [0024]FIG. 3 is a perspective view of a wall section of the inner tube of FIG. 2;  
         [0025]    [0025]FIG. 4 is a cross-sectional view of a portion of an outer cover of the multiple layer hose of FIG. 1;  
         [0026]    [0026]FIG. 5 is a perspective view of a wall section of the outer cover of FIG. 4;  
         [0027]    [0027]FIG. 6 is an enlarged cross-sectional view of a head of an extrusion machine with an extrusion die therein which is operable to extrude a tube assembly in accordance with the principles of the present invention;  
         [0028]    [0028]FIG. 7 is an enlarged cross-sectional view of a head of an extrusion machine with an extrusion die therein which is operable to extrude a cover assembly in accordance with the principles of the present invention; and  
         [0029]    [0029]FIG. 8 is a block diagram of the general process of forming a hose in accordance with the principles of the present invention.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0030]    While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.  
         [0031]    Referring now to FIG. 1, there is shown a hose  10  having a tube assembly  12 , a cover assembly  20  disposed about, over and/or around the tube assembly  12 , and a textile reinforcement  30  disposed between the tube assembly  12  and the cover assembly  20 . In general, the tube assembly  12  is radially inside of the cover assembly  20 , while the textile reinforcement  30  is interposed between the cover assembly  20  and the tube assembly  12 . It should be appreciated that at a first end of the hose  10  will include a first coupling (not shown) which is configured to connect to an outside water faucet or spigot, and similarly, a second end of the hose  10  will include a second coupling (not shown) which is configured to connect to a lawn sprinkler or similar mechanism.  
         [0032]    The textile reinforcement  30  is preferably composed of a first textile layer  32  and a second textile layer  34 . The first textile layer  32  is spirally wound around or wrapped about an outer surface  58  of an outer layer  18  of the tube assembly  12 . The second textile layer  34  is in the form of a mesh, netting, woven braid, knit, webbing, or the like configuration that is circumferentially wrapped about the first textile layer  32 . The first and second textile layers  32  and  34  collectively form a plurality of openings or interstices  29 . It should be appreciated that the first and second textile layers  32  and  34  are positionally interchangeable. In the preferred embodiment, the first and second textile layers  32  and  34  are made from polyester. However, it should be appreciated that other textile materials may be utilized such as nylon, Kevlar®, and the like. Further, a different textile material from that described above may be used for each textile reinforcement layer.  
         [0033]    With reference to FIGS. 2 and 3 the tube assembly  12  is shown. The tube assembly  12  is a three component tube which includes a non-foamed inner tube layer  14 , a foamed intermediate tube layer or core  16  radially disposed about the non-foamed inner tube layer  14 , and a non-foamed outer tube layer  18  radially disposed about the foamed tube layer  16 . Note that what is termed a layer herein may be also be properly called a ply, a sheet, a lamina, or the like. The non-foamed inner tube layer  14  is preferably made from a suitably flexible polymer or thermoplastic. The foamed intermediate tube layer  16  is preferably made from a suitably flexible polymer or thermoplastic that is blown to a relatively light density onto the non-foamed inner tube layer  14  with the aid of a blowing agent such as axodicarbonamide. The blowing agent causes tiny closed air pockets to be dispersed throughout the material increasing the volume and thereby decreasing the density thereof. The non-foamed outer tube layer  18  is preferably made from a suitably flexible polymer or thermoplastic and is formed about the foamed intermediate tube layer  16 . The foamed intermediate tube layer  16  is preferably thicker than the non-foamed inner tube layer  14  and the non-foamed outer tube layer  18 .  
         [0034]    The polymer or thermoplastic material used for any one or all of the various layers  14 ,  16 , and  18  of the tube assembly  12  can be any suitable polymer or thermoplastic such as polyethylene, EVA, polyvinylchloride (PVC), nylon, or the like as are known in the art, but is preferably a flexible PVC. In the preferred embodiment, all of the layers  14 ,  16 , and  18  of the tube assembly  12  are formed from flexible PVC.  
         [0035]    The inner non-foamed layer  14  defines an inner surface  44  and an outer surface  46 . The inner surface  42  is configured to be essentially tubular or annular in shape. The inner surface  42  defines a conduit through which a liquid (e.g. water) flows. The outer surface  46  of the non-foamed layer  14  is, as well, essentially annular. The foamed intermediate or middle layer  16  is contiguously adjacent to the outer surface  46  of the inner non-foamed layer  14 . The foamed intermediate layer  16  defines an essentially annular inner surface  50  and an essentially annular outer surface  52 . The inner surface  50  is in contact with the outer surface  46  of the inner non-foamed layer  14 . The non-foamed outer layer  18  is contiguously adjacent to the outer surface  52  of the intermediate layer  16 . The non-foamed outer layer  18  thus defines an essentially annular inner surface  56  that is in contact with the outer surface  52  of the intermediate layer  16 . The non-foamed outer layer further defines an essentially annular outer surface  58 . The outer surface  58  of the non-foamed outer layer  18  receives the textile reinforcement  30  (see FIG. 1) and contacts an inner surface  21  of the non-foamed inner layer  22  of the cover assembly  20  through the interstices  29  defined by the textile reinforcement  30 .  
         [0036]    With reference to FIGS. 4 and 5, the cover assembly  20  is shown. The cover assembly  20  is a three component cover which includes a non-foamed inner cover layer  22 , a foamed intermediate cover layer or core  24  radially disposed about the non-foamed inner cover layer  22 , and a non-foamed outer cover layer  26  radially disposed about the foamed cover layer  24 . The non-foamed inner cover layer  22  is preferably made from a suitably flexible polymer or thermoplastic. The foamed intermediate cover layer  24  is preferably made from a suitably flexible polymer or thermoplastic that is blown to a relatively light density onto the non-foamed inner cover layer  22  with the aid of a blowing agent such as axodicarbonamide. The blowing agent causes tiny closed air pockets to be dispersed throughout the material increasing the volume and thereby decreasing the density thereof. The non-foamed outer cover layer  26  is preferably made from a suitably flexible polymer or thermoplastic and is formed about the foamed intermediate cover layer  24 . The foamed intermediate cover layer  24  is preferably thicker than the non-foamed inner cover layer  22  and the non-foamed outer cover layer  26 .  
         [0037]    The polymer or thermoplastic material used for any one or all of the various layers  22 ,  24 , and  26  of the cover assembly  20  can be any suitable polymer or thermoplastic such as polyethylene, EVA, polyvinylchloride (PVC), nylon, or the like as are known in the art, but is preferably a flexible PVC. In the preferred embodiment, all of the layers  22 ,  24 , and  26  of the cover assembly  20  are formed from flexible PVC.  
         [0038]    The inner non-foamed layer  22  defines an inner surface  21  and an outer surface  60 . The inner surface  21  is configured to be essentially tubular or annular in shape. The outer surface  60  of the inner non-foamed layer  22  is, as well, essentially annular. The foamed intermediate or middle layer  24  is contiguously adjacent to the outer surface  60  of the inner non-foamed layer  22 . The foamed intermediate layer  24  defines an essentially annular inner surface  62  and an essentially annular outer surface  64 . The inner surface  62  is in contact with the outer surface  60  of the inner non-foamed layer  22 . The non-foamed outer layer  26  is contiguously adjacent to the outer surface  64  of the intermediate layer  24 . The non-foamed outer layer  26  thus defines an essentially annular inner surface  66  that is in contact with the outer surface  64  of the intermediate layer  24 . The non-foamed outer layer further defines an essentially annular outer surface  68 . The outer surface  68  is in contact with the environment.  
         [0039]    Method of Manufacture  
         [0040]    One method for making a hose in accordance with the principles of the present invention will now be discussed. In the best mode currently known, the hose  10  is preferably manufactured by extrusion technology. While many advantages of the present invention are achieved by manufacturing the hose  10  with the use of extrusion technology, some of the advantages of the present invention may be achieved by manufacturing the hose  10  with the use of other technologies. It should therefore be appreciated that the following description of the process set forth in FIG. 8 and the extrusion machines set forth in FIGS. 6 and 7 are not limiting of the various methods that may be used to manufacture the present hose.  
         [0041]    With reference to FIG. 8, there is shown a block diagram of the present process generally designated  70 . The process generally first includes the manufacture of the tube assembly  12  (Block  80 ). After the tube assembly  12  has been manufactured or as the tube assembly is formed, the textile reinforcement  30  (either the spiral threading  32  or the mesh threading  34 , or both) is added around the tube assembly  12  (Block  85 ). Specifically, the textile reinforcement  30  is added around the outer surface  58  of the outer layer  18  of the tube assembly  12 . After the textile reinforcement  30  is added to the tube assembly  12 , the cover assembly is manufactured over, onto, or around the tube and textile reinforcement assembly which produces the completed hose  10 .  
         [0042]    With reference to FIG. 6, there is shown a portion of an extrusion machine generally designated  100 . The extrusion machine  100  includes a housing  102  formed from a plurality of components as is known in the art, including a die or extrusion head  104  that is bolted to a component of the housing  102 . The die head  104  fits over an opening of an extrusion chamber  116  defined by the housing  102 . The die head  104  includes a nozzle plate  106  having a nozzle opening  110  through which the tube assembly is extruded. Behind the nozzle plate  106  is a nozzle cone or head  112  that has a nozzle  108  that extends toward the nozzle opening  110 . The nozzle  108  defines the essentially annular nozzle opening  110  that essentially corresponds to the diameter of the finished tube assembly  12 .  
         [0043]    The housing  102  includes an opening, bin, hopper, or the like  118  that is in communication with passages  124 . The passages  124  lead into nozzle chamber  125 . The opening  118  and passages  124  accept material to form the outer layer  18  of the tube assembly  12 . The opening  118  is in communication with a source of the material for the outer layer  18 . The source is typically in a viscous liquid state as is known in the art.  
         [0044]    The housing  102  also includes an opening, bin, hopper, or the like  122  that is in communication with passages  128 . The passages  128  lead into nozzle chamber  125 . The opening  122  and passages  128  accept material to form the middle or intermediate layer  16  of the tube assembly  12 . The opening  122  is in communication with a source of the material for the intermediate layer  16  or core. The source is typically in a viscous liquid state as is known in the art.  
         [0045]    The intermediate layer  16  is blown with the blowing agent to introduce bubbles into the material that form cells. This makes the material foamy and lightweight (less dense) that a non-blown layer of the material.  
         [0046]    The housing  102  further includes an opening, bin, hopper, or the like  120  that is in communication with passages  126 . The passages  126  lead into nozzle chamber  125 . The opening  120  and passages  126  accept material to form the inner layer  14  of the tube assembly  12 . The opening  120  is in communication with a source of the material for the inner layer  14 . The source is typically in a viscous liquid state as is known in the art.  
         [0047]    As the appropriate material enters the respective opening  118 ,  120 , and  122 , and flows along the respective passages  124 ,  126 , and  128 , they meet to form the various layers within the nozzle chamber  124 , with one layer deposited upon another layer. This material is then extruded from the nozzle opening  110  to form the tri-lamina tube assembly  12  in any desirable length. Air or other injection gas may blown through the nozzle bore  114 , introduced through the extrusion chamber  116 .  
         [0048]    The textile reinforcement is then added around the extruded tube assembly. After the textile reinforcement is added, the tube and textile assembly is fed into a second extrusion machine such as that depicted in FIG. 7. With reference now to FIG. 7 there is depicted an extrusion machine  150 .  
         [0049]    The extrusion machine  150  includes a housing  152  formed from a plurality of components as is known in the art, including a die or extrusion head  154  that is bolted to a component of the housing  152 . The die head  154  fits over an opening of an extrusion chamber  166  defined by the housing  152 . The die head  154  includes a nozzle plate  156  having a nozzle opening  160  through which the hose is extruded (i.e. the cover assembly over the textile and tube assembly). Behind the nozzle plate  156  is a nozzle cone or head  162  that has a nozzle  158  that extends toward the nozzle opening  160 . The nozzle  158  defines the essentially annular nozzle opening  160  which corresponds to the diameter of the cover assembly  20 .  
         [0050]    The housing  152  includes an opening, bin, hopper, or the like  168  that is in communication with passages  174 . The passages  174  lead into nozzle chamber  175 . The opening  168  and passages  174  accept material to form the outer layer  26  of the cover assembly  20 . The opening  168  is in communication with a source of the material for the outer layer  26 . The source is typically in a viscous liquid state as is known in the art.  
         [0051]    The housing  152  also includes an opening, bin, hopper, or the like  172  that is in communication with passages  178 . The passages  178  lead into nozzle chamber  175 . The opening  172  and passages  178  accept material to form the middle or intermediate layer  24  of the cover assembly  20 . The opening  172  is in communication with a source of the material for the intermediate layer  24  or core. The source is typically in a viscous liquid state as is known in the art.  
         [0052]    The intermediate layer  24  is blown with the blowing agent to introduce bubbles into the material that form cells. This makes the material foamy and lightweight (less dense) in comparison to a non-blown layer of the material.  
         [0053]    The housing  152  further includes an opening, bin, hopper, or the like  170  that is in communication with passages  176 . The passages  176  lead into nozzle chamber  175 . The opening  170  and passages  176  accept material to form the inner layer  22  of the cover assembly  20 . The opening  170  is in communication with a source of the material for the inner layer  22 . The source is typically in a viscous liquid state as is known in the art.  
         [0054]    As the appropriate material enters the respective opening  168 ,  170 , and  172 , and flows along the respective passages  174 ,  176 , and  178 , they meet to form the various layers within the nozzle chamber  175 , with one layer deposited upon another layer. As well, the textile and tube assembly is fed through the extrusion chamber  166  and out of opening  164  which, when it exits the opening  164  receives the inner layer  22  thereover. The tri-lamina material is then extruded from the nozzle opening  160  to form the tri-lamina cover assembly  20  onto, over and around the textile material  30  and the outer surface  58  of the outer layer  18  of the tube assembly  12 . The hose  10  that results therefrom may be extruded and/or cut into any desirable length.  
         [0055]    It should be appreciated that the tube assembly and the cover assembly may be formed in separate extrusion machines with the textile reinforcement threading applied therebetween or from one extrusion machine designed to allow a double extrusion with integral textile reinforcement threading.  
         [0056]    The present hose  10  has advantages over prior art hoses. Specifically, there is a substantial increase in adhesion between the tube assembly  12  and the cover assembly  20 . This reduces the likelihood of water seepage between the plies that create bubbles and separation. It allows the blowing of the foam material to a lighter density for softness and lightweightness with minimal or no loss of hose integrity. Further, the non-blown inner tube layer  14  contains the liquid (e.g. water) flow. Still further, the non-blown outer cover layer  26  seals the hose assembly  10  against dirt and abrasion. Even further, the non-blown outer tube layer  18  and the non-blown inner cover layer  22  tends to allow a reduction in the amount of textile reinforcement  30  needed for adequate hose strength.  
         [0057]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.  
         [0058]    There are a plurality of advantages of the present invention arising from the various features of the hose described herein. It will be noted that alternative embodiments of the hose of the present invention may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the hose that incorporate one or more of the features of the present invention and fall within the spirit and scope of the present invention as defined by the appended claims.