CN109595796B - Manufacturing method of heat insulation layer of water heater and water heater - Google Patents

Manufacturing method of heat insulation layer of water heater and water heater Download PDF

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Publication number
CN109595796B
CN109595796B CN201811614172.2A CN201811614172A CN109595796B CN 109595796 B CN109595796 B CN 109595796B CN 201811614172 A CN201811614172 A CN 201811614172A CN 109595796 B CN109595796 B CN 109595796B
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layer
foaming
water heater
heat
polyurethane
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CN109595796A (en
Inventor
苏进
盛保敬
孙强
王军
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Qingdao Economic and Technological Development Zone Haier Water Heater Co Ltd
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Qingdao Economic and Technological Development Zone Haier Water Heater Co Ltd
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24HFLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00Details
    • F24H9/0005Details for water heaters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24HFLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H1/00Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
    • F24H1/18Water-storage heaters
    • F24H1/181Construction of the tank
    • F24H1/182Insulation

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Thermal Insulation (AREA)

Abstract

The invention discloses a manufacturing method of a water heater heat preservation layer and a water heater, which belong to the technical field of water heaters, and the manufacturing method of the water heater heat preservation layer comprises the following steps: coating a polyurethane layer outside the vacuum insulation panel to obtain a part of heat preservation layer; the part of heat preservation layer is adhered to the part of the outer surface of the inner container of the water heater; and coating a foaming layer on the outer surface of the rest part of the inner container, so that the foaming layer and the part of the heat insulation layer are integrated into a whole. The water heater adopts the manufacturing method of the heat-insulating layer of the water heater to manufacture the heat-insulating layer, and can be a double-liner water heater. The integral heat preservation effect of the heat preservation layer is improved through the high heat insulation characteristic of the vacuum heat insulation plate; in addition, the polyurethane layer can effectively protect the vacuum insulation panel, so that the vacuum insulation effect is prevented from being lost due to the fact that the vacuum insulation panel is punctured by foreign objects in assembly and subsequent use; the heat preservation layer manufactured by the manufacturing method can be suitable for inner containers with different shapes and different structures, and can be suitable for special-shaped water heater shells, and the application range is wide.

Description

Manufacturing method of heat insulation layer of water heater and water heater
Technical Field
The invention relates to the technical field of water heaters, in particular to a manufacturing method of a heat preservation layer of a water heater and the water heater.
Background
In the production process of the electric water heater, in order to reduce heat loss and improve the heat insulation performance of the product, the current common method is to perform polyurethane integral foaming heat insulation on the inner container of the electric water heater. The specific operation is as follows: the inner container and the outer shell are fixed through the positioning block or the tool, a certain gap is reserved between the inner container and the outer shell, polyurethane foaming materials are injected into the gap, and after the polyurethane foaming materials react and solidify, the tool, the die and the like are removed.
In water heaters, the overall thickness is a critical dimension. In order to ensure that the energy efficiency coefficient reaches the standard, the thickness of the heat preservation layer cannot be reduced under the premise of a certain heat conductivity coefficient of the heat preservation layer material. The appearance of the electric water heater is gradually increased compared with that of a conventional barrel-shaped special-shaped machine (square, capsule-shaped and the like), and the thickness of the heat-insulating layer is uneven due to uneven stress during foaming when the special-shaped machine is produced; in order to reduce deformation, a foaming tool is required to be used in foaming, and the foaming efficiency is seriously affected.
Disclosure of Invention
The invention aims to provide a manufacturing method of a heat-insulating layer of a water heater and the water heater, which improve the unit heat-insulating capability of the existing polyurethane foaming layer so as to reduce the thickness of the heat-insulating layer and omit a foaming tool so as to improve the production efficiency.
The technical scheme adopted by the invention is as follows:
a manufacturing method of a heat insulation layer of a water heater comprises the following steps:
s1: coating a polyurethane layer outside the vacuum insulation panel to obtain a part of heat preservation layer;
s2: the part of heat preservation layer is adhered to the part of the outer surface of the inner container of the water heater;
s3: and coating a foaming layer on the outer surface of the rest part of the inner container, so that the foaming layer and the part of the heat insulation layer are integrated into a whole.
Wherein, the S1 comprises: and fixing the vacuum insulation panel in a first foaming mold, so that a gap is formed between the vacuum insulation panel and the first foaming mold, injecting polyurethane foaming material into the gap, and removing the first foaming mold after the polyurethane foaming material is reacted and solidified to obtain the part of heat preservation layer.
And after the first foaming mold is buckled, gaps are reserved between all surfaces of the vacuum insulation panel and the first foaming mold.
Before S1, the vacuum insulation panel is pre-bent into an arc-shaped plate, so that the vacuum insulation panel is matched with the outer surface of the liner.
Wherein, the S3 includes: and fixedly connecting the inner container with a second foaming mold, so that a gap is reserved between the outer surface of the inner container and the second foaming mold and is used for filling polyurethane foaming materials.
After the second foaming mold is buckled, polyurethane foaming material is injected into the gap to obtain the foaming layer, and the foaming layer and the polyurethane layer in the part of the heat insulation layer are integrated into a whole.
The water inlet, the water outlet and the flange opening which are arranged on the inner container are respectively opposite to the through holes which are correspondingly arranged on the second foaming mould, and the through holes which are communicated with the outside on the second foaming mould are blocked before the polyurethane foaming material is injected.
Before polyurethane foaming materials are injected, a tool or an auxiliary die is used for reserving an avoidance space between the inner container and the second foaming die.
In the step S1, the thickness of the part of the heat preservation layer is not larger than the thickness of a gap between the shell and the liner of the water heater.
A water heater is provided with the heat insulation layer manufactured by the manufacturing method of the heat insulation layer of the water heater.
The invention has the beneficial effects that:
the method for manufacturing the heat-insulating layer of the water heater comprises the steps of firstly manufacturing the vacuum heat-insulating plate coated with the polyurethane layer to obtain a part of heat-insulating layer, pasting the part of heat-insulating layer on a part of the outer surface of the liner, and then coating the foaming layer on the other part of the outer surface of the liner by adopting a polyurethane foaming technology to integrate the foaming layer and the part of heat-insulating layer. Because the unit heat conductivity coefficient of the vacuum heat-insulating plate is far lower than that of the polyurethane layer, the polyurethane layer is coated outside the vacuum heat-insulating plate, and the integral heat-insulating effect of the heat-insulating layer can be improved through the high heat-insulating characteristic of the vacuum heat-insulating plate; in addition, the polyurethane layer can effectively protect the vacuum insulation panel, so that the vacuum insulation effect is prevented from being lost due to the fact that the vacuum insulation panel is punctured by foreign objects in assembly and subsequent use; the heat preservation layer adopting the manufacturing method can adapt to the inner containers with different shapes and different structures, and can be suitable for the special-shaped water heater shell, and the application range is wide. The manufacturing method of the heat-insulating layer of the water heater can be suitable for a double-liner water heater.
Drawings
FIG. 1 is a schematic view of a portion of a heat-insulating layer manufactured by a method for manufacturing a heat-insulating layer of a water heater according to an embodiment of the present invention;
FIG. 2 is a sectional view showing a part of the structure of a water heater according to an embodiment of the present invention;
FIG. 3 is an enlarged view at A in FIG. 2;
FIG. 4 is a schematic diagram of a water heater according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of another water heater according to an embodiment of the present invention.
In the figure:
10. a heat preservation layer; 20. a housing; 30. an inner container;
11. vacuum insulation panels; 12. a polyurethane layer; 13. and (3) a foaming layer.
Detailed Description
In order to make the technical problems solved, the technical scheme adopted and the technical effects achieved by the invention more clear, the technical scheme of the invention is further described below by a specific embodiment in combination with the attached drawings. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting thereof. It should be further noted that, for convenience of description, only some, but not all of the drawings related to the present invention are shown.
Referring to fig. 1 to 5, the embodiment of the invention provides a method for manufacturing a heat insulation layer of a water heater, which is used for manufacturing a heat insulation layer 10 of the water heater, and can be used for manufacturing heat insulation layers of other parts needing heat insulation. The embodiment of the invention also provides a water heater, which is provided with the heat preservation layer 10 manufactured by adopting the manufacturing method of the heat preservation layer of the water heater. The water heater comprises a shell 20 and an inner container 30, and the heat preservation layer 10 is arranged between the shell 20 and the inner container 30. The water heater may be a single-liner water heater or a double-liner water heater, and is not limited herein.
The manufacturing method of the heat preservation layer 10 comprises the following steps:
s1: coating a polyurethane layer 12 outside the vacuum insulation panel 11 to obtain a part of heat preservation layer;
s2: attaching a part of the heat-insulating layer to a part of the outer surface of the liner 30;
s3: the outer surface of the rest of the inner container 30 is coated with the foaming layer 13, so that the foaming layer 13 and part of the heat insulation layer are integrated.
Because the vacuum insulation panel 11 has a better heat-insulating effect than the polyurethane layer 12, the vacuum insulation panel 11 is not required to be covered by the whole machine in order to achieve the target heat-insulating effect, such as primary energy efficiency. Therefore, the vacuum insulation panel 11 and polyurethane foaming are combined to perform heat preservation, namely, the split foaming technology is adopted to manufacture the heat preservation layer 10.
Firstly, manufacturing a vacuum insulation panel 11 coated with a polyurethane layer 12 to obtain a part of heat preservation layer, coating the part of heat preservation layer on the outer surface of the liner 30, and then coating the foaming layer 13 on the outer surface of the rest part of the liner 30 by adopting a polyurethane foaming technology, so that the foaming layer 13 and the part of heat preservation layer are integrated into a whole to form the heat preservation layer 10. Because the unit heat conductivity coefficient of the vacuum heat insulation plate 11 is far lower than that of the polyurethane layer 12, the polyurethane layer 12 is coated outside the vacuum heat insulation plate 11, and the integral heat insulation effect of the heat insulation layer 10 can be improved through the high heat insulation characteristic of the vacuum heat insulation plate 11; in addition, the polyurethane layer 12 can effectively protect the vacuum insulation panel 11, and the vacuum insulation effect is prevented from being lost due to the fact that the vacuum insulation panel is punctured by foreign objects in assembly and subsequent use. Here, the proportion of the partial heat insulating layer including the vacuum insulation panel 11 to the whole heat insulating layer 10 is 0 to 100%, and may be set according to actual conditions, and is not limited thereto. The heat preservation layer manufactured by the split foaming technology can adapt to inner containers with different shapes and different structures, and can be suitable for special-shaped water heater shells, and the application range is wide. The manufacturing method of the heat-insulating layer of the water heater can be suitable for a double-liner water heater.
In S1, the vacuum insulation panel 11 is fixed in a first foaming mold, so that a gap is formed between the vacuum insulation panel 11 and the first foaming mold, polyurethane foaming material is injected into the gap, and after the polyurethane foaming material is reacted and cured, the first foaming mold is removed, and the vacuum insulation panel 11, namely a part of heat preservation layer, with the polyurethane layer 12 coated outside is obtained. Here, the structure of the first foaming mold is not limited, and the first foaming mold may be provided according to the size and shape of the vacuum insulation panel 11. Meanwhile, the surface of the inner cavity of the first foaming mold should be ensured to be smooth and not easy to adhere so as to ensure easy demolding after foaming is finished.
In S2, a part of the heat-insulating layer is attached to a part of the outer surface of the liner 30, and the edge of the part of the heat-insulating layer can be attached to the liner 30 by adopting measures such as heat-insulating tape to perform heat-insulating sealing.
The vacuum insulation panel 11 and the first foaming mold are relatively fixed by adopting a positioning block or a tooling, and after the first foaming mold is buckled, gaps are reserved between all surfaces of the vacuum insulation panel 11 and the first foaming mold, so that polyurethane foaming materials cover all surfaces of the vacuum insulation panel 11, and the vacuum insulation panel 11 is coated.
Before S1, the vacuum insulation panel 11 is pre-bent into an arc-shaped plate, so that the vacuum insulation panel 11 is adapted to the outer surface of the liner 30. If the outer surface of the liner 30 is cylindrical, pre-bending the vacuum insulation panel 11 into an arc-shaped plate; if the inner container 30 is in other irregular arc shapes, the vacuum insulation panel 11 is pre-bent into an arc shape matched with the outer surface of the inner container 30, and the vacuum insulation panel is arranged according to actual conditions. When the outer surface of the liner 30 is cylindrical, the arc of the vacuum insulation panel 11 may be pi-3 pi/4, covering most of the surface of the liner 30.
The division and perforation of the vacuum insulation panel 11 should be minimized due to the edge heat dissipation phenomenon of the vacuum insulation panel 11. Therefore, the liner 30 structure should be combined when the heat-insulating layer 10 is laid out, and the vacuum heat-insulating plate 11 should adopt a whole large plate or reduce splicing as much as possible except the liner support, the water inlet and outlet pipe and other structures needing to be avoided. Under the condition of reducing the segmentation and the perforation of the vacuum insulated panel 11, the vacuum insulated panel 11 covers part of the outer surface of the liner 30, and the rest of the outer surface of the liner 30 is covered by adopting a polyurethane foaming technology.
In S3, the inner container 30 is fixedly connected with the second foaming mold, such that a gap is formed between the outer surface of the inner container 30 and the second foaming mold for filling the polyurethane foaming material. After the second foaming mold is buckled, polyurethane foaming material is injected into the gaps to obtain the foaming layer 13, so that the foaming layer 13 and the polyurethane layer 12 in the part of the heat insulation layer obtained in the step S1 are integrated into a whole. Here, the structure of the second foaming mold is not limited, and the second foaming mold may be provided according to the size and shape of the inner container 30.
When the polyurethane foaming material is filled, the second foaming mold can be heated, so that the fluidity of the polyurethane foaming material is ensured, the polyurethane foaming material fully fills the gap between the outer surface of the liner 30 and the second foaming mold, and the polyurethane foaming material has fluidity and can be fully fused with the polyurethane layer 12 of the coated vacuum insulation panel 11, so that the heat insulation performance is ensured.
The inner container 30 is provided with openings such as a water inlet, a water outlet, a flange opening and the like, and when the polyurethane split type foaming prefabricated heat insulation layer 10 is adopted to treat the openings, the vacuum insulation panel 11 coated with the polyurethane layer 12 can be arranged on one side which does not contain the openings, so that holes are formed in the vacuum insulation panel 11, and heat loss is reduced.
The water inlet, the water outlet and the flange opening arranged on the liner 30 are respectively connected with the through holes correspondingly arranged on the second foaming mould, and the through holes communicated with the outside on the second foaming mould are blocked before the polyurethane foaming material is injected, so that the polyurethane foaming material is prevented from leaking. The gap and the through hole which are communicated with the outside on the second foaming mould can be plugged by using sponge.
The liner 30 comprises a liner support, a water pipe, a magnesium rod seat and other convex structures, and the polyurethane split type foaming prefabricated heat preservation layer 10 is adopted, when the convex structures are processed, the vacuum heat insulation plate 11 coated with the polyurethane layer 12 can be arranged on one side far away from the convex structures as far as possible, so that the vacuum heat insulation plate 11 is prevented from being divided, and heat loss is reduced. Except that the water pipe and the magnesium rod seat need to integrally penetrate through the heat insulation layer 10, the liner support can be mostly hidden in the heat insulation layer 10, and only the connecting bolts are allowed to penetrate through the heat insulation layer 10 so as to improve the heat insulation effect.
In S3, before the polyurethane foam is injected, a space is reserved between the liner 30 and the second foaming mold by using a tool or an auxiliary mold, so as to effectively avoid the above convex structure. After the polyurethane foaming material is fused with the polyurethane layer 12 coating the vacuum insulation panel 11, the overall heat preservation of the liner 30 is realized.
After the insulation layer 10 is manufactured, the housing 20 is installed such that the insulation layer 10 is located between the housing 20 and the liner 30. Because the polyurethane layer 12 coating the vacuum insulation panel 11 has better heat preservation effect, the vacuum insulation panel 11 is arranged at a position close to a heat source, namely a position close to a heating pipe, so as to improve the heat preservation effect.
When the split foaming technology is adopted to manufacture the heat preservation layer 10, the structures of the shell 20 and the liner 30 of the water heater are fully considered, the shape following with the shell 20 and the liner 30 is realized as much as possible, so that the gap between the liner 30 and the shell 20 is reduced to the greatest extent, the heat preservation effect is improved, and the relative shaking of the shell 20 and the liner 30 is avoided.
In S1, the thickness of the partial heat-insulating layer is not greater than the thickness of the gap between the outer case 20 and the inner case 30. Since the polyurethane foam for producing the foam layer 13 in S3 has fluidity, if a gap is formed between a portion of the insulation layer in S1 and the second foaming mold, the polyurethane foam is also filled, and thus, the thickness of the portion of the insulation layer may be smaller than the thickness of the gap between the outer shell 20 and the inner liner 30. In addition, the polyurethane layers 12 on both sides of the vacuum insulation panel 11 may have the same thickness or may have different thicknesses.
The above embodiments merely illustrate the basic principle and features of the present invention, and the present invention is not limited to the above embodiments, but may be varied and altered without departing from the spirit and scope of the present invention. The scope of the invention is defined by the appended claims and equivalents thereof.

Claims (5)

1. The manufacturing method of the heat preservation layer of the water heater is characterized by comprising the following steps:
s1: coating a polyurethane layer (12) outside the vacuum insulation panel (11) to obtain a part of heat preservation layer;
s2: the part of the heat preservation layer is adhered to the part of the outer surface of the inner container (30) of the water heater;
s3: coating a foaming layer (13) on the outer surface of the rest part of the inner container (30) so that the foaming layer (13) and the part of the heat insulation layer are integrated into a whole;
the S1 comprises the following steps: fixing the vacuum insulation panel (11) in a first foaming mold, so that a gap is formed between the vacuum insulation panel (11) and the first foaming mold, injecting polyurethane foaming material into the gap, and removing the first foaming mold after the polyurethane foaming material is reacted and solidified to obtain the part of heat preservation layer;
the vacuum insulation panel (11) and the first foaming mold are relatively fixed by adopting a positioning block or a tool, and after the first foaming mold is buckled, gaps are reserved between all surfaces of the vacuum insulation panel (11) and the first foaming mold;
pre-bending the vacuum insulation panel (11) into an arc-shaped plate before the step S1, so that the vacuum insulation panel (11) is matched with the outer surface of the liner (30);
the step S3 comprises the following steps: fixedly connecting the inner container (30) with a second foaming mould, so that a gap is formed between the outer surface of the inner container (30) and the second foaming mould and is used for filling polyurethane foaming materials;
after the second foaming mold is buckled, polyurethane foaming material is injected into the gaps to obtain the foaming layer (13), and the foaming layer (13) and the polyurethane layer (12) in the part of the heat insulation layer are integrated into a whole.
2. The method for manufacturing a heat insulation layer of a water heater according to claim 1, wherein the water inlet, the water outlet and the flange opening arranged on the inner container (30) are respectively opposite to the through holes correspondingly arranged on the second foaming mold, and the through holes communicated with the outside on the second foaming mold are blocked before the polyurethane foaming material is injected.
3. The method for manufacturing a heat insulation layer of a water heater according to claim 1, wherein a tool or an auxiliary mold is used to reserve an avoiding space between the inner container (30) and the second foaming mold before the polyurethane foaming material is injected.
4. The method for manufacturing a heat insulation layer of a water heater according to claim 1, wherein in S1, the thickness of the part of the heat insulation layer is not greater than the thickness of a gap between a housing (20) and the liner (30) of the water heater.
5. A water heater, characterized by having a thermal insulation layer (10) made by the method of making a thermal insulation layer of a water heater as claimed in any one of claims 1-4.
CN201811614172.2A 2018-12-27 2018-12-27 Manufacturing method of heat insulation layer of water heater and water heater Active CN109595796B (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112316465B (en) * 2019-08-05 2022-03-18 哈尔滨工程大学 Distillation flask coated with polyimide foam layer and preparation method thereof
CN113443852B (en) * 2021-07-21 2022-11-22 江西宏柏新材料股份有限公司 Nano thermal insulation material and preparation method and application thereof

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JP2011163580A (en) * 2010-02-05 2011-08-25 Panasonic Corp Storage type water heater
CN204548941U (en) * 2014-12-29 2015-08-12 林晓月 A kind of super insulation can
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CN206247637U (en) * 2016-11-24 2017-06-13 江苏山由帝奥节能新材股份有限公司 Adiabatic heat-insulation shell and cool-bag, the water heater using the insulation cladding
CN207174480U (en) * 2017-08-21 2018-04-03 苏州维艾普新材料股份有限公司 It is a kind of based on foamed material and the compound incubator of vacuum heat-insulating plate

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101032854A (en) * 2006-12-30 2007-09-12 美的集团有限公司 Method for manufacturing water heater liner heat-insulation assembly
CN201522164U (en) * 2009-11-04 2010-07-07 合肥美菱股份有限公司 Refrigerator equipped with vacuum heat-insulation board
JP2011163580A (en) * 2010-02-05 2011-08-25 Panasonic Corp Storage type water heater
JP2016102580A (en) * 2014-11-28 2016-06-02 明星工業株式会社 Heat insulation cover and manufacturing method of heat insulation cover
CN204548941U (en) * 2014-12-29 2015-08-12 林晓月 A kind of super insulation can
CN206247637U (en) * 2016-11-24 2017-06-13 江苏山由帝奥节能新材股份有限公司 Adiabatic heat-insulation shell and cool-bag, the water heater using the insulation cladding
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