Abstract:
A hose coupling and method of forming the same are disclosed, wherein a strength thereof is maximized and a cost of manufacture is minimized. The hose coupling utilizes a plastic ferrule which militates against a hose end being released from the hose coupling during use.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/619,840, filed on Oct. 18, 2004. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to hose couplings, and more particularly to hose couplings including a plastic ferrule which militates against a hose end being released from the hose coupling during use. 
       BACKGROUND OF THE INVENTION 
       [0003]    A traditional stamped coupling set consists of a male element or a female element and a ribbed ferrule. All of the elements are typically made of brass. A ribbed ferrule is placed over the outside circumference of a hose, and a tailpiece of the male/female element is inserted into the interior of the hose. A set of expandable fingers is inserted into the tailpiece and then activated, causing the fingers to expand and push the tailpiece outwardly, thereby pinching the hose between the tailpiece and the ribbed ferrule. Traditional couplings utilize fingers which shape the tailpiece in a wave or wrinkled form. 
         [0004]    When the coupling having the tailpiece in the wave form is subject to a pull test, the hose quickly loses contact with the tailpiece and the associated ribbed ferrule. When the hose elongation reaches the next corresponding rib of the ferrule, almost no surface area of the hose is sustained up to the next adjacent compressed area. 
         [0005]    It is considered to be advantageous if the present coupling structures could be designed to increase the overall strength and simultaneously reduce the cost to manufacture the product. 
         [0006]    It would be desirable to produce a garden hose coupling assembly which is of improved strength and is less expensively manufactured. 
       SUMMARY OF THE INVENTION 
       [0007]    In accordance with the current invention, a hose coupling wherein a strength thereof is maximized and a cost of manufacture is minimized has been surprisingly discovered. 
         [0008]    The invention is typically produced by changing the composition and geometry of a ferrule which is used together with a tailpiece of a male or female coupling to compressively retain a section of a hose. 
         [0009]    It is one purpose of the invention to embrace a new composition and geometry of the ferrule in order to maintain constant contact between the elements of the coupling and the associated hose. A ferrule in accordance with the current invention maintains a substantially constant inner diameter and acts as a boundary toward which the tailpiece is expanded. Once the expansion of the tailpiece is accomplished, the hose is tightly held in a compressed state between the outer surface of the expanded portion of the tailpiece and the inner surface of the surrounding ferrule. 
         [0010]    It is another purpose of the invention to utilize a ferrule made of plastic to reduce the cost of manufacturing. 
         [0011]    In one embodiment, the hose coupling comprises: a hollow cylindrical coupling having a first end and a second end, a threaded section formed adjacent the first end, and a tailpiece formed at the second end adapted to be received in an end of a hose; and a hollow plastic ferrule having a radially inwardly extending lip formed at a first end thereof, the ferrule surrounding at least a portion of the tailpiece of the coupling and cooperating with the tailpiece to secure the end of the hose therebetween. 
         [0012]    In another embodiment, the hose coupling comprises: a hollow cylindrical coupling having a first end and a second end, the first end including a threaded section for receiving a complimentary threaded section of an associated coupling, the second end including a tailpiece adapted to be received in an end of a hose, the coupling including a shoulder formed between the first end and the second end, and an annular groove formed between the shoulder and the second end of the coupling; and a hollow plastic ferrule having a first end and a second end, the first end having a radially inwardly extending lip which abuts the shoulder of the coupling, an inner surface of the ferrule having a substantially constant diameter, the ferrule surrounding at least a portion of the tailpiece of the coupling and cooperating with the tailpiece to secure the end of the hose therebetween. 
         [0013]    The invention also provides methods of forming hose couplings. In one embodiment, the method of forming the hose coupling comprises the steps of: providing a hollow cylindrical coupling having a first and a second end, a threaded section formed adjacent the first end for receiving a complimentary threaded section of an associated coupling, a tailpiece formed at the second end; causing the interior of a hose to be disposed around at least a portion of the tailpiece of the coupling; providing a hollow plastic ferrule having a first end and a second end, the first end of said ferrule terminating in radially inwardly extending lip; causing the hollow plastic ferrule to be disposed around the tailpiece and the hose; and causing the tailpiece of the coupling and to expand outwardly to secure the hose between the tailpiece and the ferrule. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from reading the following detailed description of several embodiments of the invention when considered in the light of the accompanying drawings, in which: 
           [0015]      FIG. 1  is a sectional side view of a hose coupling according to an embodiment of the invention; 
           [0016]      FIG. 2  is a side view partially in section of a hose coupling similar to the coupling illustrated in  FIG. 1  including a female coupling; 
           [0017]      FIG. 3  is a side sectional view of a hose coupling according to another embodiment of the invention; 
           [0018]      FIG. 4  is a side view partially in section of a hose coupling similar to the coupling illustrated in  FIG. 3  including a female coupling. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed and illustrated, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical. 
         [0020]      FIG. 1  illustrates a hose coupling  10  consisting of a male coupling  12  and an associated hollow ferrule  14 . The male coupling  12  is typically formed of metal, such as brass for example. The male coupling  12  includes a male threaded section  16  formed adjacent a first end thereof for receiving a complimentary threaded section of an associated female coupling (not shown). A tailpiece  18  is formed at a second end of the male coupling  12  and includes a plurality of ribs  20  formed thereon. It is understood that the number of ribs  20  is not regarded as critical. A shoulder  22  is formed between the threaded section  16  and the tailpiece  18 . An inwardly extending annular groove  23  is disposed between the shoulder  22  and the tailpiece  18 . 
         [0021]    The hollow ferrule  14  is positioned to surround the end of an associated hose  30 . The ferrule  14  may be formed of a plastic material, such as nylon, for example. A radially inwardly extending lip  24  is formed at a first end of the hollow ferrule  14 . An inner surface  26  of the hollow ferrule  14  includes a plurality of grooves  28  formed thereon. It is understood that more or fewer grooves than shown can be used as desired. 
         [0022]    The end of the hose  30  is disposed radially between the tailpiece  18  and the hollow ferrule  14 . The hose  30  is typically inserted a garden hose, for example. Additionally, the hose  30  can be formed of any conventional material such as rubber, for example. 
         [0023]    A method of forming the hose coupling  10  according to the embodiment of the invention shown in  FIG. 1  will now be described. The male coupling  12  is provided. The end of the hose  30  is disposed around the tailpiece  18 . The hollow ferrule  14  is disposed around the hose  30  and positioned as shown in  FIG. 1 . The radially inwardly extending lip  24  of the hollow ferrule  14  is caused to abut the shoulder  22  of the male coupling  12 . 
         [0024]    A tool having a set of expandable fingers (not shown) is inserted into the male coupling  12  and activated. The fingers are cause to expand, thereby causing the tailpiece  18  of the male coupling  12  to expand outwardly toward the hollow ferrule  14  to form the ribs  20  and the annular groove  23 . The hose  30  is secured between the tailpiece  18  and the hollow ferrule  14 . The lip  24  and the groove  23  cooperate to militate against relative movement between the male coupling  12  and the ferrule  14 . It is understood that alternate means of causing the tailpiece  18  to expand and secure the hose  30  can be utilized without departing form the scope of the invention. When the forming tool is removed from the male coupling  12 , the hose coupling  10  is assembled on the associated hose  30  and is ready for use. 
         [0025]      FIG. 2  illustrates a hose coupling  32  including a female coupling  34 . Structure similar to that illustrated in  FIG. 1  includes the same reference numeral and a prime (′) symbol for clarity. The female coupling  34  includes a female threaded section  36  for receiving a complimentary threaded section of an associated male coupling (not shown). A method of forming the hose coupling  32  is the same as described for  FIG. 1 . 
         [0026]      FIG. 3  illustrates a hose coupling  38  according to another embodiment of the invention. Structure similar to that illustrated in  FIGS. 1 and 2  includes the same reference numeral and a double prime (″) symbol for clarity. The hose coupling  38  includes a male coupling  12 ″ and an associated hollow ferrule  40 . The male coupling  12 ″ is typically formed of metal such as brass, for example. The male coupling  12 ″ includes a threaded section  16 ″ formed adjacent a first end thereof for receiving a cooperating with an associated internally threaded section of an associated female coupling (not shown). A tailpiece  18 ″ is formed at a second end of the male coupling  12 ″. A shoulder  22 ″ is formed between the threaded section  16 ″ and the tailpiece  18 ″. An annular groove  23 ″ is disposed between the shoulder  22 ″ and the tailpiece  18 ″. 
         [0027]    The hollow ferrule  40  may be formed of a plastic material such as nylon, for example. A radially inwardly extending lip  24 ″ is formed at a first end of the hollow ferrule  40 . An inner surface  42  of the hollow ferrule  40  is smooth and uninterrupted and has a substantially constant inner diameter from the radially inwardly extending lip  24 ″ to an opposing edge portion  44  thereof. 
         [0028]    The method of forming the hose coupling  38  will now be described. The male coupling  12 ″ is provided. The end of the hose  30 ″ is disposed around the tailpiece  18 ″ of the coupling  12 ″. The hollow ferrule  40  is disposed around a hose  30 ″ and is positioned as shown in  FIG. 3 . The radially inwardly extending lip  24 ″ of the hollow ferrule  40  is caused to abut against the shoulder  22 ″ of the male coupling  12 ″. 
         [0029]    A tool having a set of expandable fingers (not shown) is inserted into the male coupling  12 ″ and activated. The fingers are caused to expand, thereby causing the tailpiece  18 ″ of the male coupling  12 ″ to expand outwardly toward the hollow ferrule  40 . The hose  30 ″ is thereby secured between the tailpiece  18 ″ and the hollow ferrule  40 . The lip  24 ″ and the groove  23 ″ cooperate to militate against relative movement between the male coupling  12 ″ and the ferrule  40 . It is understood that alternate means of causing the tailpiece  18 ″ to expand and secure the hose  30 ″ can be utilized without departing form the scope of the invention. 
         [0030]      FIG. 4  illustrates a hose coupling  46  including a female coupling  34 ′″. Structure similar to that illustrated in  FIGS. 1 ,  2 , and  3  includes the same reference numeral and a triple prime (′″) symbol for clarity. The female coupling  34 ′″includes an internally threaded section  36 ′″ for receiving a complimentary threaded section of an associated male coupling (not shown). The method of forming the hose coupling  46  is the same as described for  FIG. 3 . 
         [0031]    The use of a plastic ferrule provides several advantages over the prior art, including a lower cost of manufacturing than the traditional structure typically utilizes a brass ferrule. In addition to the cost savings, the use of a plastic ferrule allows for variations in color and the addition of trademarks and other indicia on the plastic ferrule which would be attractive in the marketplace. 
         [0032]    From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of the invention and, without departing from the spirit and scope thereof, can make various changes and modifications to adapt it to various usages and conditions.