Stackable hose reel cart
FIELD OF THE INVENTION 
     This invention relates to the storage of flexible garden hoses and, more particularly, to an improved portable hose cart that can be preassembled and shipped in a stacked array. 
     BACKGROUND INFORMATION 
     Portable hose carts for convenient handling and storage of a flexible garden hose have gained wide public acceptance. Such carts are primarily constructed of molded plastic components having a centrally disposed rotatable spool for reeling inward or outward the flexible hose, a frame including a pair of frame sides for supporting the spool, wheels at one end of the base of the frame, and a handle for tilting the frame onto the wheels so that the cart may be easily moved. For more information concerning the structure and operation of such a hose cart, reference may be made to U.S. Pat. No. RE. 32,510, the teachings of which are hereby incorporated by reference. 
     Hose carts are commonly purchased by the general consumer wherein it is desirable that the hose cart can be easily assembled using minimal hand tools. The use of such fasteners can be time consuming and requires the use of hand tools. Commercially available hose carts typically make extensive use of threaded fasteners to join major components. U.S. Pat. No. 4,913,580 teaches the use of a connector assembly for joining components of a hose cart. A male component of the assembly is molded with one piece of the cart, and a female component of the assembly is molded with a second piece of the cart to be joined to the first piece. These components are easily unlatched to permit disassembly of the hose cart. 
     A problem with portable hose carts of the prior art is that, despite the directions for assembly, a majority of the consuming public is unable or have no desire to assemble such devices. Cottage industries have developed solely for the purpose of assembling products that have been purchased in a disassembled state. Many stores that inventory unassembled product have personnel on staff capable of assembling the product for the customer. If the store performs this assembly at no charge to the customer, it is a burden on the store. Alternatively, the store may assemble the product and pass the cost onto the consumer. 
     One of the problems with any assembly outside of the factory is that improper assembly can damage the product. This typically occurs when the assembler does not read the instructions or tries to force fit a component. The result is aggravation by the purchaser who may ask the store to take back the product and refund their money. Obtaining a refund is a time consuming and expensive process to both the store and the producing factory. The store may return the product to the factory who then attempts to salvage the damaged product. Not unexpectedly, most returned items are damaged as a result of improper assembly. 
     Most large products produced by a manufacturer are not assembled due to the size of the packaging required once an assembled product is put into an operating form. For instance, a typical hose cart is shipped in a disassembled state so that it can fit in a box that allows the device to be shipped on a pallet together with numerous other boxes. Under such circumstances it is not unusual to have ten or more boxes of portable hose reels placed on a pallet wherein a forklift can be used for lifting of the pallet for placement. A receiving store may leave a shipment of boxed hose carts on a shipping pallet above the normal reach of the consuming public. Boxed product is brought down to replenish those items purchased causing the store to decide whether or not to assemble the product before display. 
     Unassembled hose carts are packaged in a shipping carton to protect the product during shipping and storage, and more importantly, prevent loss of individual components before assembly. A great deal of time and expense goes into packaging of the product so as to provide as compact packaging as possible. The shipping carton must include indicia to indicate to the public what is within the contents of the carton. Adding an expense to the carton is the use of color graphics which is preferred by store owners so that potential purchasers do not break open the cartons in an effort to determine the contents of the carton. The unassembled hose carts further require the inclusion of assembly instructions. 
     Disposal of shipping containers is also wasteful. Once a hose cart is assembled, the shipping carton is unusable for nearly any other purpose. The carton becomes a waste product that will hopefully be recycled but realistically adds mass to a landfill. U.S. Pat. Nos. 4,512,361; 5,046,520 and 5,056,553 all set forth hose cart storage apparatuses which consist of various preassembled components that are easily assembled upon receipt by the average consumer. Common among these devices is the need for shipping cartons so that the components are not lost in transit. Thus, despite the simplicity of the assembly, all such devices are dependent upon the use of properly sized shipping cartons which further require graphics so as the consumer can determine the contents of the carton. 
     Another problem with the prior art hose cart device is the securement of a reel hub necessary for the introduction of water. The reel hub must allow rotation yet allow the device to be hooked up to a water supply wherein the hose can be reeled inward or outward without interfering with the flow of water. Seals within the hub allow rotation without leakage. The problem occurs when the seals require service, either in the form of lubrication or replacement. This is a common problem in the northern states should the device be allowed to freeze. As exemplified by the &#39;361 and &#39;520 patents, the hub is coupled to the reel by the use of fasteners such as a metal screw. When the seals require service, the hub must be removed to facilitate replacement. Without proper tools, the unit will be damaged. Should the attachment screws be displaced, the use of improperly sized substitutes may cause the screw threads to strip, damaging the unit. The necessity of tools may intimidate the average consumer from performing even routine maintenance such as lubrication, leading to early failure of the seals. 
     Another problem with the prior art is that the winding reels do not accommodate the natural curvature of a hose connection which may lead to a premature failure of the hose. To compensate for the curvature, prior art devices employ an extension pipe to direct the water supply to a position external the hub surface. Without such piping, should a flexible hose be wrapped around the reel, the hose is forced into a position placing the hose in a stressed or kinked position. 
     Thus, what is lacking in the art is a portable hose cart that can be preassembled at the factory, shipped without the necessity of a conventional shipping container, and of such design that the carts can be nested together to reduce storage space. Further, a portable hose cart is needed having an improved reel assembly that can be disassembled without tools and includes a means for reducing stress from a hose wrapped around the reel. 
     SUMMARY OF THE INVENTION 
     Among the several aspects and features of the present invention may be noted the provision of all improved portable garden hose cart. The hose cart of the present invention is of a shape and design so that the hose cart may be preassembled at the factory thereby eliminating the need for instruction manuals and associated product packaging. The teaching of the instant invention allows for a plurality of preassembled portable hose carts to be placed upon a skid decreasing the amount of space necessary for storage and transportation thereby increasing the number of units that can be shipped per a given cubic volume of space. In order to accomplish efficiency in shipping and the elimination of shipping cartons, the instant invention incorporates the use of foldable handles, an oblong shaped reel flange, and a one-piece inverted V-shaped frame so as to permit nesting of multiple units. 
     Preassembling of the hose reel cart of the instant invention permits the use of a single unitary frame construction for support of a flexible garden hose to be wound into a coil of multiple layers with adjacent turns of each layer touching each other by use of a directional reel forming a spool rotatably coupled to the frame. Reel flanges forming the side walls of the spool are oblong shaped for holding of the hose within the spindle of the reel in a similar manner as the prior art, yet allowing for the aforementioned nesting of assembled hose carts. 
     The surface of reel used for winding of the hose includes a provision for coupling to an end of the hose in such a manner as to reduce or eliminate stress normally placed on the flexible hose eliminating the need for a water extension pipe. The reel surface has a ramped directional cavity allowing for placement of a hose further adding a directional aspect for the hose. The cavity allows winding of a hose in a clockwise or counter clockwise direction. The flexible hose is wound around the reel by use of a hand crank coupled through a hub providing a direct rotational link between the crank and the winding of the spool. During non-use a handle on the crank is placed in a storage position by pivoting the handle about one end of the crank so as to place the handle in a position perpendicular to the crank. The crank can be positioned on either side of the frame providing a left or right handed operation. Despite the unit being preassembled by the factory, this interchangeable feature allows a water connector to be easily removed from the hub by depressing a syringe type pulling mechanism surrounding the connector to release tabs biased on the inside of the hub. The quick release water connector provides ease of access to internal sealing O-rings should they need maintenance. 
     Thus, a primary objective of the instant invention is to provide a portable hose cart having a one piece frame with all components preassembled so as to eliminate the need for packaging and instruction manuals commonly used in the prior art. 
     Yet another objective of the instant invention is to provide a portable hose cart that can be stacked on top of similar hose carts in a nesting fashion teaching the ability to ship more units per cubic foot volume than possible with the prior art if packaged individually even in a completely disassembled state. 
     Another objective of the instant invention is to disclose the use of quick release locking tabs that allow the crank of a winding spool to be placed on either side of the frame permitting left or right handed operation. 
     Yet another objective of the instant invention is to provide a functional cross support in the handle allowing a reduction in the mass of the handle and further providing a means for holding the free end of a flexible hose in an upright position so as to prevent water dripping during storage. 
     Yet still another objective of the instant invention is to provide a water connector that can be installed and removed without the use of hand tools. In particular, the connector will use a syringe type attachment mechanism that engages tabs on the inner surface of the hub to be disengaged for access to replaceable O-rings. 
     Still another objective of the invention is to teach the use of a handle locking mechanism that eliminates the need for a hook pin and can be incorporated into the frame of a portable hose cart wherein it can be positioned so as not to cause accidental release. 
     Other objects 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. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a portable hose cart embodying various aspects of the present invention; 
     FIG. 2 is a rear elevational view of the portable hose cart of FIG. 1; 
     FIG. 3 is an exploded view of the hose cart structural components; 
     FIG. 4 is an enlarged exploded view of the hub hose connector; 
     FIG. 4A is a cross sectional view of FIG. 4 in an assembled position; 
     FIG. 5 is an enlarged side view of the reel crank; 
     FIG. 5A is an end view of the crank handle socket of FIG. 5; 
     FIG. 6 is a pictorial side view of a plurality of hose carts shown in FIG. 1 illustrated in a nesting arrangement on a pallet; 
     FIG. 7 is an enlarged fragmentary cross sectional view showing a portion of the handle and frame with a lock securing the handle to the frame; 
     FIG. 8 is similar to FIG. 7 but showing the lock in a released attitude with the handle in a partially pivoted position; 
     FIG. 9 is an enlarged front view of the lock; 
     FIG. 10 is a front side view of the reel flange; and 
     FIG. 11 is a back side view of the reel flange shown in FIG. 10. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings and especially to FIG. 1, a hose storage apparatus embodying the present invention, generally indicated by numeral 20, is shown therein. The major components of the hose storage apparatus include a frame 22 having a collapsible handle 24 wherein a reel 26 is rotatably mounted to the frame 22. The reel 26 is rotated by use of a crank 28 which is fixed to the reel and permits rotating of the reel in the frame to wind a flexible hose onto the reel. 
     The frame 22 consists of a one-piece molded plastic frame, such as polyethylene, defined by a front crossbar 30 molded to the front legs of inverted V-shaped frame sides 32 and 34. Rear crossbar 35, as shown in FIG. 2, is molded to the back legs of the frame sides further providing support for wheels 36 and 38 rotatably coupled by axle 37 allowing ease of transfer when the front crossbar 30 is lifted thus pivoting weight to the wheels thereby permitting the operator to pull or push the apparatus effortlessly. The frame sides 32 and 34 are mirror image of one another including hub shape and design allowing for the interchange of hubs coupling devices, namely a crank and hose connector as described in detail later in this specification. Upper portion 40 of frame side 32 and an upper portion 42 of frame side 34 is substantially flat with pivot ears 44 and 46 available for connecting to the handle 24. Pivot ears 44 and 46 are formed integrally with said upper portions 40 and 42 of their respective frame sides 32 and 34. 
     Handle 24 is generally U-shaped and constructed of a single piece of plastic such as polyethylene with ribbed reinforcement 51 along the rear of the handle. The handle 24 is further defined by a pair of lateral bars 48 and 50 each of which have an enlarged base 52 and 54 conforming to the upper portions 40 and 42 of the frame 22. Each base includes a pivot ear 56 and 58 operatively associated with the frame pivot ears 44 and 46 allowing pivotable rotation of the handle about the front surface of the frame sides. By release of a locking mechanism 70, the handle is available to pivot about the frame 22 for storage in a flat position against the front surface of frame sides 32 and 34. When the apparatus is not in a storage position, the lifting of the handle 24 into an upright position will engage the locking mechanism 70 causing the handle 24 to lock in an upright position biased against the upper portion of the frames sides. As shown by illustration, the base of the handle is enlarged conforming to the upper portions of the frame sides so that when the apparatus is being transported, the handle provides stability in structure providing leverage ability should undue weight be present. Hand grip bar 59 is formed integral to the handle sides 48 as is crossbar 60 which performs a dual function of providing rigidity to the handle allowing a reduction in mass otherwise necessary for a free-standing handle, and further providing a location for placement of the free end of the flexible hose. Slot 62 opens the cross bar to a formed hook 64 and 66 on either side of the opening wherein placement of the free end of a hose through slot 62 allows sliding of the hose into either hook portion 64 or 66 for entrapment of the hose in an upright position so as to eliminate water dripping typical of a hose stored immediately after use. By placement of the hose in an upright position, evaporation will allow removal of excess water and provide the free end with immediate access. 
     The pair of identical locks 70, detailed in FIGS. 7-9, releasably secure the handle 24 to the frame 22 in an upright position. Since the locks are identical, only one of the locks is described in detail. The lock base is secured to its respective portion of the handle lock screw 74. The lock base 72 has a resilient section formed integral therewith. A push plate 78 is also formed integrally with the resilient section. A lip 80 formed along the bottom end of the lock is available for engaging a respective lock opening 82 formed in the upper portion of each frame side 32 and 34. FIG. 7 illustrates the locking mechanism 70 in the locked position wherein the upper surface of the lip 80 has passed through the opening 82. The bottom of the lip is rounded so as to assist in deflection during the locking stage by sliding over the engagement surface 86 formed on one end of the opening 82 of the frame 22. Now referring to FIG. 8, the push plate 78 is illustrated as it is being depressed by a human finger. The depression causes the resilient section 72 of the lock to move inward thus releasing the lip 80 from the engagement surface 86 allowing the handle 24 to pivot about thereby removing the lip portion of the lock from the frame cavity 82. The front surface 88 of the handle 24 is then available to lay flat against the front surface 89 of the frame 22. The positioning of the lock mechanism 70 is incorporated into the handle between the enlarged base of the handle so as to hide the lock thereby providing an aesthetically pleasing design that is interrupted by the locking mechanism. Further, the placement of the lock within the handle base prevents accidental release of the lock. 
     Reel 26 is made up of two identically molded cross braces which form reel halves 90 and 92 having approximately a twelve inch width with a preformed hose cavity 94 extending from a first edge 96 to a second edge 98. The cavity forms an inward slope from the first edge 96 of approximately a 0.63 inch radius R 1  about 21/2 inches inward from side edge 104 to the second edge 98 wherein the cavity 94 is continuous across the surface of the reel and tapers to approximately a 0.3 inch radius R 2  placed inboard from side edge 104 about 1 inch. Openings 100 are of sufficient size to receive the hand of an operator allowing the operator to thread the female hose end connector of a hose 102 to the male outlet of the hub centrally disposed on the end of the hub found within the reel cavity. 
     Additionally, the separation of the two reel halves 90 and 92 further provide sufficient area allowing the operator to attach the end of a flexible hose as shown by a portion 108 of hose 102 as it follows the cavity 94 on one side of the reel 90. It should be noted that each reel 90 and 92 have the aforementioned cavities place along each side edge allowing a single piece part application and further allowing the hose to be wrapped in either a clockwise or counter clockwise motion. Further, the winding of the hose can be made from left to right, or reversed, based upon consumer preference movement of the crank to the preferred hub. 
     The reel halves 90 and 92 are coupled to a pair of spaced apart reel flanges 110, 112 forming a spool upon assembly. Flange tabs 114 are insertable into flange opening 116 to secure the components in a fixed predetermined position of which the surface of the reel faces outwardly providing sufficient surface space for winding of a large or long flexible hose. Unique to the flanges 110 and 112 is the oblong shape wherein the shape is rectangular with rounded edges. The shape provides sufficient surface area for maintaining a flexible hose within the spool yet allows the ability to stack the frames. Reel flanges 110 and 112 are identical, each part having an oblong shape defined by a first side 118 and second side 120 and a first end 122 and a second end 124. Centrally disposed in each flange is a hub 126 which is insertable into journaled apertures 128 or 130 located on the frame 22. The aperture is reinforced by ribs 132 on the inner side of the frame providing reinforcement to the aperture without distracting from the aesthetic appearance of the frame. The ribs 132 are hidden from view once the flanges are installed. 
     As further detailed in FIGS. 10 front side of the reel flange includes flange opening 116 disposed between parallel spaced apart support ribs 131, the opening 116 made available to secure the reel half in a fixed predetermined position. The flange oblong shape is rectangular having a length L of approximately 15 inches and a width W of approximately 7.5 inches. The shape is critical for nesting of like hose carts providing the instant invention with stackability. During storage, as shown by FIG. 6, each flange is set at an angle allowing compact stacking the angular placement of the nesting hose cart. The oblong shape has a first side 118 and second side 120 providing the length and a first end 122 and a second end 124 providing the width. The length and width meet with a curved corner. The back surface of the hub 126 is reinforced by ribs 132, the front surface 129 is flush.. The inner surface 129 of the hub employs four equal spaced indentations for receipt of hose coupler or crank. Plastic is removed from openings 125 to lessen the use of material in non-critical areas. 
     FIG. 6 is pictorial side view of a plurality of hose carts 20 illustrating the utility of the reel flanges 112 when the frames 22 are placed in a nesting position. As shown by way of illustration, the reel flanges 112 nest while in a stacked position. Hidden lines illustrate the angular direction of the reel flange 112. The handles 24 are folded at the pivot point 44 placing the handles in a storage position wherein bottom 130 of the frame can be situated on the top portion of a similar frame 22. Similarly, the wheels fit behind the frame so as not to interfere with the nesting. The crank 30 can be placed in a position in conjunction with the reel flanges so as not to interfere with the mounting frame, the crank having a folding handle as described in detail later in this specification. 
     The nesting feature allows for a plurality of preassembled portable hose carts 20 to be placed upon a skid or pallet 200 decreasing the amount of space necessary for storage and transportation thereby increasing the number of units that can be shipped per a given cubic volume of space. By preassembling the hose carts, the shipping cartons and assembly instructions can be eliminated. The nesting can be described as a method of storing hose apparatus for windably holding an elongated flexible garden hose said method comprising: molding a single piece support frame having two inverted V-shaped frame sides, each frame side having a top surface and split legs depending therefrom forming a front leg and a rear leg, said frame sides formed integral with a front cross bar supporting said front legs and a rear cross bar supporting said rear legs, each frame side having a hub bearing surface disposed between said top surface and said split legs; securing a handle having a first leg pivotally connected to said top surface of one frame side and a second leg pivotally connected to said top surface of the second frame side, said handle storable juxtaposition to said frame side; attaching a spool disposed between said frame sides, said spool having a plurality of cross-braces defining a reel surface for receipt of a flexible hose, said reel surface coupled between a first and second oblong shaped reel flange, each said,reel flange having a centrally disposed hub operatively associated with each said frame side; inserting a hose connector comprising a hose male connector being adaptable for connection to flexible hose available for winding about the spool, a hose female adapter being adaptable for connection to an inlet hose, and a coupling sleeve, said hose male connector having at least one O-ring contacting the hose female adapter to form a seal therebetween, said hose connector releasably insertable through one of said hubs providing an inlet connection mounted in a fixed position on one side oil a reel flange fluidly communicated to an outlet adapter on a second side of said flange; joining a crank releasably insertable through one of said hubs providing a direct coupling to said spool allowing rotation thereof, said crank including a handle pivotally attached to a the crank being positionable from a perpendicular position for hand operation to a raised position to facilitate storage; placing a pair of wheels journaled to each rear leg; and stacking the assembled hose cart on top of similarly assembled hose carts whereby said crank and said reel flanges are rotated allowing a lower portion of said frame sides to reside against an upper portion of similar shaped frame sides. 
     The hose connector is composed of a hose male coupler 150, a hose female adapter 152, and a syringe type coupling sleeve 154 for releasably coupling the hose male coupler 150 to the female adapter 152 as best seen in FIG. 4 and 4A. Water from a conventional hose outlet is delivered to the hose female adapter 152 having alignment tabs 156 for securement to the hub of the reel flange to prevent rotation. The hose female adapter 152 includes a molded outlet tube 158 having a plurality of O-rings 160 for engagement with the interior of the hose male connector 150 to form a seal between the coupler 150 and the adapter 152. A groove 162 is provided for insertion of a plurality of locking tabs 164. The end 166 of the adapter has internal, hose threads formed therein for attachment to the male end of a conventional garden hose. The hose male coupler 150 has an end 168 having external hose threads formed thereon for attachment to the female end of a conventional garden hose, in this instance, to the end of the flexible hose 102 as shown in FIG. 2 for winding about the reel. The hose male coupler 150 is formed of a pipe with reinforcement ribs 170 with an elongated slot 172 located on a lower portion 174 of the coupler insertable through release sleeve 154 formed from a tubular body 176 with the aforementioned locking tabs 164. The sleeve 154 includes finger pulls 176 and 178. The adapter 152 fits within the coupler 150 so that the seals 160 frictionally engage the inner surface of the coupler 150 forming a water tight seal between the inlet 166 and the outlet 168. The sleeve 154 locks the coupler 150 to the adapter 152 by insertion of the tabs 164 into groove 162. In operation the pressing of the coupler 150 into the adapter 152 engages the lock tabs 164 through the hub of the flanges 110 and 112. To release the coupling, the finger tabs 176 and 178 are pulled toward the coupling collar 180 wherein the leading edge 182 of the coupler 150 biases the locking tab 164 into a raised position so as to disengage the lock from the groove 162 allowing disassembly of the connection. Thus, lubrication or replacement of the O-rings 160 is readily accessible by pulling the tabs 176 in a syringe type movement. Upon maintenance of the O-rings, the adapter and coupler can be snapped back into position. 
     FIGS. 5 and 5A illustrate the crank 30 having a handle 186 that is foldable into a storage position as depicted by numeral 186A. The base of the handle includes an aperture 188 in which the pivot ears 190 provide a force fit attachment allowing pivotal rotation without further securement. During use, extension 192 of handle 186 rests against surface 194 allowing handle 186 to reside in a perpendicular position to the crank 30 providing optimum leverage during rotation of the reel. Lock tab 191 hooks extension 192 ill the perpendicular position. The crank 30 couples to the hub by use of independent locking tabs 196 which are biased outward into slots for engaging the hub. When the handle 186 is not in use, the handle 186 can fold into a cavity 198 formed in the shank of the crank having a close tolerance so to frictionally engage the handle in a fixed position. 
     It is to be understood that while we have illustrated and described certain forms of my invention, it is not to be limited to the specific forms 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 in the drawings and described in the specification.