Patent ID: 7887662

Claim:
A method for making a hose assembly, comprising the steps of: (a) forming a flexible corrugated inner hose on a mandrel, the inner hose suitable for conveying and dispensing loose-fill insulation material, including: wrapping a tape extrusion helically around the mandrel while the mandrel rotates, the tape having outer edge members, so that outer edges of the tape form a first helical projection extending inward toward a longitudinal axis of the inner hose; and (b) snugly fitting a non-conforming outer hose about the inner hose while the inner hose is on the mandrel, the outer hose having a substantially cylindrical outer surface that is substantially free of corrugations, wherein the outer edges of the tape further comprise an outwardly extending member, so that the forming step forms a second helical projection extending away from a longitudinal axis of the inner hose; and the forming step further includes: wrapping an extruded U-shaped cap helically around the tape extrusion, to join adjacent outer edge portions of the tape to form a continuous helical tube, wherein step (b) includes wrapping the outer hose around the inner hose so that the outer hose contacts the U-shaped cap along the helical path of the U-shaped cap wherein the outer hose is interference fit over the inner hose by wrapping a polymer sheet around the inner hose and bonding two overlapping opposite edges of the polymer sheet to each other using a hot melt adhesive to form a substantially cylindrical tube around the inner hose, wherein the outer hose comprises a first layer of polyethylene and a second layer of nylon.