Corrugated hose with non-conforming outer layer for dispensing loose-fill insulation

A method for making a hose, comprising the steps of:

• 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 away from a longitudinal axis of the inner hose;
• and
• 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;
• and
• snuggly fitting about the inner hose a non-conforming outer 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 fitting step 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.

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 the second helical projections of adjacent outer edge portions of the tape to form a continuous helical tube;
• step (b) includes:
• wrapping a polymer sheet around the inner hose so that the outer hose contacts the U-shaped cap along the helical path of the U-shaped cap, and bonding two opposite longitudinal edges of the polymer sheet to each other to form a cylindrical tube around the inner hose using a hot melt adhesive to bond the opposite edges;
• the outer hose comprises a first layer of polyethylene and a second layer of nylon;
• and
• the inner hose comprises one of the group consisting of polypropylene, polyethylene, nylon, urethanes, and polyvinyl chloride.