JP2002284906A - Front panel for heat source instrument - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a front panel for a heat source instrument capable of reducing the weight and suppressing the generation of noise. SOLUTION: The front panel of a heat source instrument is produced by molding a thermoplastic resin having a glass transition temperature of >=120 deg.C or a thermosetting resin (e.g. phenolic resin) having a thermal decomposition temperature of >=120 deg.C. The molded article usually at least contains an inorganic reinforcing agent (fibrous or particulate reinforcing agent). An outer case (casing) of the front panel for protecting the heat source instrument and/or a rain- proofing plate for preventing the intrusion of water are produced by the above molded resin article.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat source unit front panel (front plate) useful for reducing the weight of a heat source unit (such as a water heater) and reducing noise due to vibration during operation.

[0002]

2. Description of the Related Art In homes and offices, many heat sources using gas or electricity, such as water heaters and air conditioners, are used. A heat source device using gas in this heat source device usually includes an intake port, a gas combustion unit including a heat exchanger through which tap water can flow, and an exhaust port for discharging burned exhaust gas. The front panel (front panel) of a heat source unit such as a water heater has an outer case (casing) for protecting the heat source unit and a protection panel for preventing water from entering the unit due to rainfall. The outer case and the rain-prevention plate are made of a coated steel plate. In some cases, the rain-proof plate is provided in a portion corresponding to the intake port in the outer case (casing), and is usually provided upright at the front of the combustion unit.

[0003] However, since a steel plate is used as the front panel, the weight is large, and the noise due to the vibration of the rainproof plate during operation increases. Further, since a steel plate is used, the steel plate is not only easily corroded, but may be burned due to high thermal conductivity when disposed close to a heat source.

[0004]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a front panel for a heat source unit which can reduce the weight and suppress the generation of noise.

It is another object of the present invention to provide a front panel for a heat source device having high heat resistance and high safety even if it is disposed near a heat source.

[0006]

Means for Solving the Problems The inventors of the present invention have made intensive studies to achieve the above object, and as a result, when a front panel is formed using a specific resin or a resin composition, the front panel is disposed close to a heat source. However, the present invention has been found to be highly safe, can be reduced in weight and can suppress generation of noise, and have completed the present invention.

That is, the front panel for a heat source device of the present invention is formed of a molded article of a thermoplastic resin having a glass transition temperature of 120 ° C. or more or a molded article of a thermosetting resin having a thermal decomposition temperature of 120 ° C. or more. . The resin includes, for example, a phenol resin. The molded body may contain a reinforcing agent (for example, a fibrous reinforcing agent and / or a granular reinforcing agent), particularly at least an inorganic reinforcing agent. further,
The front panel for a heat source unit includes at least one of an outer case (casing) for protecting the heat source unit and a rainproof plate (waterproof plate) for preventing water from entering inside the device. It may be formed.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The thermoplastic resin constituting the front panel for a heat source unit of the present invention has a glass transition temperature (glass transition temperature by a differential scanning calorimeter DSC) of 120 ° C. or more (for example, 120 to 350 ° C.). Preferably 150 to 35
(About 0 ° C.). Examples of such a thermoplastic resin include an aromatic polycarbonate resin (such as bisphenol A-type polycarbonate), a polyester resin (a polyarylate resin, and 9,9-bis (4- (2-hydroxyethoxy) having a fluorenone side chain). ) Phenyl) fluorene as a diol component, polyester resins, liquid crystalline polyester resins composed of wholly aromatic polyesters, etc.), aromatic polyamide resins, polysulfone resins (polyethersulfone, polysulfone, etc.), polyphenylene ethers Resin (such as a polymer of 2,6-xylenol), polyarylene sulfide-based resin (such as polyphenylene sulfide ketone, polyphenylene sulfide sulfone, and polybiphenylene sulfide), and thermoplastic polyimide resin (polyether ether). De resins, polyamide-imide resins, and polyimide sulfone resins), polyether ether ketone, polyether nitrile, etc. polyparabanic acid can be exemplified. These resins can be used alone or in combination of two or more.

Among these resins, aromatic polycarbonate resin, polyarylate resin, 9,9-bis (4-
(2-hydroxyethoxy) phenyl) aromatic polyester resin containing diol component as a diol component, wholly aromatic liquid crystalline polyester resin, aromatic polyamide resin,
Polysulfone resin, polyphenylene ether resin,
Polyarylene sulfide resins, thermoplastic polyimide resins, polyparabanic acid, and the like have high glass transition temperatures and heat resistance.

The thermosetting resin has a thermal decomposition temperature of 120 ° C. or higher (for example, 150 to 500 ° C.).
The resin is not particularly limited as long as it is a resin having a temperature of about 200 ° C., preferably about 200 to 500 ° C .; Glycidyl ether type epoxy resin, glycidylamine type epoxy resin, etc.), vinyl ester resin, diallyl phthalate resin, unsaturated polyester resin, polyurethane resin (aromatic polyisocyanate or multimer of polyisocyanate (having isocyanurate ring Polyisocyanate) and an aromatic polyol, an aromatic polyester polyol and / or an aromatic polyamine, etc., and an aromatic polyurethane-based resin obtained by a reaction with an aromatic polyamine), a polyimide resin (an aromatic tetracarboxylic acid and an aromatic diamine) Condensation type polyimide resins produced by a condensation reaction, and addition type polyimide resins such as bismaleimide resins produced by reaction between a bismaleimide and an aromatic diamine), and silicone resins can be exemplified. These resins can be used alone or in combination of two or more, and may be a copolymer. For example, a co-condensate of a phenol and a co-condensation component (urea, melamine, furfural, etc.), an aromatic polyisocyanate or a polyisocyanate polymer (such as a polyisocyanate having an isocyanurate ring) and an epoxy resin (bisphenol A type) A copolymer of an aromatic epoxy resin and an aromatic polyamine can be used as the copolymer. For curing the thermosetting resin, a conventional curing agent according to the type of the resin can be used.

[0011] Examples of thermosetting resins having high heat resistance include phenol resins (including co-condensed phenol resins).
Examples thereof include an aromatic epoxy resin, a vinyl ester resin, an aromatic polyurethane resin, and a polyimide resin.

A preferred thermosetting resin is a phenol resin having a high retention of mechanical strength at high temperatures. The phenol resin may be a resol-type phenol resin or a novolak-type phenol resin. A phenol resin can be obtained by reacting a phenol (for example, phenol, cresols, alkylphenols, aminophenols, etc.) with an aldehyde (formaldehyde) in the presence of an acid catalyst or a basic catalyst.

The front panel may be composed of a polymer alloy composed of a plurality of resins. The polymer alloy is not limited to thermoplastic resins and thermosetting resins, but may be composed of a thermoplastic resin and a thermosetting resin. May be formed in combination. Further, if desired, the polymer alloy may include a compatibilizer.

The molded article may be formed of a resin alone, but is formed of a resin composition containing a reinforcing agent in order to improve heat resistance (thermal deformation temperature, thermal decomposition temperature, etc.) and mechanical properties. Is preferred. The reinforcing agent may be a fibrous reinforcing agent or a granular reinforcing agent. Examples of the fibrous reinforcing agent include inorganic fibers (glass fibers, carbon fibers, alumina fibers, silica fibers, boron fibers, metal fibers, whiskers, etc.), organic fibers (natural fibers such as pulp, semi-synthetic fibers, aramid fibers, Synthetic fibers such as rayon). Examples of the powdery reinforcing agent include silica, alumina, titanium oxide, shirasu balloon,
Examples include mica, talc, calcium carbonate, barium sulfate and the like. These reinforcing agents can be used alone or in combination of two or more (two or more of the same or different reinforcing agents). As these reinforcing agents, it is preferable to use at least an inorganic reinforcing agent (particularly, a fibrous reinforcing agent such as a fibrous inorganic reinforcing agent). Further, the reinforcing agent is preferably a flame retardant reinforcing agent.

The resin and the reinforcing agent can be combined in accordance with the type of the resin and the reinforcing agent. For example, a phenol resin and a fibrous reinforcing agent (for example, natural fibers such as glass fiber and pulp) can be used. It may be configured in combination.

The average fiber diameter of the fibrous reinforcing agent is, for example, 1
The average aspect ratio is, for example, about 10 to 10000, preferably about 10 to 1000 (for example, about 50 to 500). The average particle diameter of the powdery reinforcing agent is, for example, 1 to 50 μm.
m, preferably in the range of about 1 to 30 μm.

The content of the reinforcing agent is not particularly limited as long as the mechanical properties of the molded article are not impaired, and is, for example, 1 to 300 parts by weight, preferably 5 to 250 parts by weight, per 100 parts by weight of the resin.
Parts by weight, more preferably about 10 to 200 parts by weight.

Further, the front panel may contain a flame retardant. Examples of the flame retardant include halogen-based flame retardants (such as brominated epoxy resins and brominated polycarbonate resins), combinations of halogen-based flame retardants and antimony oxide, and phosphate ester-based flame retardants (tricresyl phosphate, tris (dibromo) Propyl) phosphate, condensed phosphate and the like. These flame retardants can be used alone or in combination of two or more. The amount of the flame retardant used is, for example, 1 to 100 parts by weight of the resin.
To 30 parts by weight, preferably about 2 to 25 parts by weight.

Further, if necessary, various additives such as stabilizers (antioxidants, ultraviolet absorbers, heat stabilizers, etc.), coloring agents, antistatic agents and the like may be added to the resin composition. Good.

The front panel for a heat source device of the present invention can be constituted by a molded product obtained by molding the resin or the resin composition into a predetermined shape. The shape of the molded body can be selected according to the shape of the heat source device, and may be a flat plate, a curved plate, an uneven shape, or the like, and is usually a curved or flat plate. The thickness of the molded body is
It can be carried out within a range that does not impair the mechanical properties and weight reduction, and for example, can be appropriately selected from a range of about 1 to 10 mm, preferably about 2 to 5 mm.

The heat source unit front panel has at least one of an outer case (casing) for protecting the heat source unit and a rainproof plate (waterproof plate) for preventing water from entering the inside of the device. The member may be formed of the resin molded body, and both the outer case (casing) and the rainproof plate (or the waterproof plate) may be formed of the resin molded body.

The front panel may be composed of the above-mentioned molded body alone, or may be constructed in combination with another molded body or member as long as the mechanical properties and weight reduction are not impaired. For example, a front panel includes a front portion (a casing, a rainproof plate, or the like) formed of the resin molded body, and a frame formed of metal, which is positioned around the front portion and holds the front portion. You may comprise with a member. Further, a front panel is constituted by the resin molded body and a reinforcing member (eg, a mesh body such as a glass fiber, a carbon fiber, and a metal fiber) embedded in the resin molded body in the form of a mesh or a lattice. May be. Such a composite front panel can improve mechanical strength without significantly impairing weight reduction. Note that the resin molded body and the metal member may be integrally formed by insert molding or the like in order to enhance the integrity.

Further, if necessary, a heat reflecting member (for example, a metal thin film such as an aluminum foil) may be formed or laminated on the inner surface (heat source side) of the front panel or its constituent members. The entire surface of the member may be covered with a heat-resistant member (metal such as aluminum foil). The front panel can be formed into a desired shape by processing such as punching (drilling, punching, etc.) after being formed by a press or the like.

The front panel according to the present invention includes various heat source devices, for example, a preheater or a heater for directly or indirectly heating a body to be heated (such as water or air) by a combustion gas or electric heating by a heat exchange unit. (For example, a feed water heater such as a water heater, a heater, a heat exchanger, and the like). In such a heat source unit, the front panel can be disposed close to a combustion or heating unit (particularly a heat exchange unit) of the heat source unit. 5cm (preferably 2cm
４4 cm).

Since the metal front panel has high thermal conductivity and high electrical conductivity, it is not only necessary to dispose the front panel away from the heat source, but also there is a risk of burns and electric leakage. On the other hand, by using the front panel made of the molded body, it is possible to prevent electric leakage by utilizing the characteristics of the resin,
Burns can also be reduced. Moreover, unlike metal, it does not corrode.

[0026]

According to the present invention, since the front panel for the heat source unit is constituted by the resin molded body, the weight can be reduced, and the noise caused by the rain-proof plate or the like can be largely suppressed even during operation. Further, even when the heat source is disposed near the heat source, the heat conductivity and the conductivity are small, so that not only safety is high but also heat radiation can be suppressed.

[0027]

The present invention will be described below in more detail with reference to Examples, but the present invention is not limited to these Examples.

Example 1 A novolak type phenol resin, glass fiber and pulp were kneaded at a weight ratio of 30%, 40% and 30%, respectively, to prepare a resin composition. The specific gravity of the obtained resin composition was 1.5. As a front plate member of a heat source unit, the resin composition is put into a mold having a cavity corresponding to a front plate outer casing portion and a rainproof plate portion, and then annealed at 400 ° C. for 2 hours to a thickness of 3.6 mm. Was produced. As for the rainproof plate, the outer surface of the molded product was covered with aluminum foil. Similarly, a bending test specimen according to JIS standard was prepared.

As a heat resistance test, 2 minutes at 130 ° C. in air.
The appearance change, weight change and strength change after holding for 00 hours were evaluated. As a result, in visual appearance inspection, no change was observed before and after the test, and the weight change rate was less than 1% by weight, and the maximum stress at the bending strength test, elongation at break, and the change rate of the elastic modulus Was less than 1%, and no deterioration was observed.

As a corrosion resistance test using a test piece, 35 ° C.
After a salt spray test was performed for 168 hours, the appearance of the test piece was visually inspected, and no deterioration such as swelling or cracking was observed. As a water resistance test, after immersion in warm water of 50 ° C. for 168 hours, the appearance of the test piece was visually inspected.
No deterioration such as cracking was observed.

The sound insulation was evaluated by using a test piece (150 mm × 150 mm) cut out of a rainproof plate at a frequency of 20 mm.
The degree to which the oscillating sound of ~ 140 Hz is shielded was compared with the current painted steel plate (0.8 mm thick). As a result, the frequency 60
The passing sound was suppressed by 20% in the region of up to 120 Hz, and the passing sound was suppressed by 40% at the frequency of 50 Hz.

Further, a heat resistance test and a corrosion resistance test were performed on a member (test product) in which the front plate and the rainproof plate were screwed. The heat resistance test is performed by placing a test sample in an electric furnace and placing it in air.
The appearance change and weight change after holding at 30 ° C. for 200 hours were evaluated. As a result, in the same manner as in the case of the test piece, no change was observed before and after the test in the visual appearance inspection of the molded product. The weight change before and after the test was less than 1% by weight. In addition, about corrosion resistance,
A salt spray test was performed at 35 ° C. for 168 hours, and the appearance of the test piece was visually inspected. As a result, no deterioration such as swelling or cracking was observed. Also, the weight of the member could be reduced by 57% as compared with the case of manufacturing with a steel plate.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme court ゛ (Reference) C08L 101: 00 C08L 101: 00 (72) Inventor Shinichi Kawasaki 4-1-2 Hiranocho, Chuo-ku, Osaka-shi Inside Osaka Gas Co., Ltd. (72) Inventor Masahiro Yamada 4-1-2, Hirano-cho, Chuo-ku, Osaka City Inside Osaka Gas Co., Ltd. (72) Inventor Mariko Kato 4-1-2, Hirano-cho, Chuo-ku, Osaka Osaka Gas (72) Inventor Eiji Shintaku 4-1-2 Hirano-cho, Chuo-ku, Osaka-shi F-term in Osaka Gas Co., Ltd. (reference) 3L037 AA04 AB04 AB07 4F071 AA41 AF45Y AH04 BC01 4F072 AA01 AA02 AA07 AB08 AD13 AK05 AL01

Claims (7)

[Claims] 1. A front panel for a heat source device comprising a molded article of a thermoplastic resin having a glass transition temperature of 120 ° C. or higher. 2. A front panel for a heat source device comprising a thermosetting resin molded body having a thermal decomposition temperature of 120 ° C. or higher. 3. The front panel for a heat source device according to claim 1, wherein the molded body contains at least an inorganic reinforcing agent. 4. The front panel for a heat source device according to claim 3, wherein the reinforcing agent is at least one selected from a fibrous reinforcing agent and a granular reinforcing agent. 5. The front panel according to claim 2, wherein the thermosetting resin is a phenol resin. 6. The front panel for a heat source device according to claim 5, wherein the front panel is composed of a phenol resin and a fibrous reinforcing agent. 7. The heat source device according to claim 1, wherein at least one of the rainproof plates is formed of a molded body to prevent water from entering the outer case and the inside. front panel.