JP2017032176A - Water heater and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a water heater exhibiting a high heat insulation performance and ensuring low cost, and a manufacturing method of the same.SOLUTION: A hot water storage tank unit of the present disclosure comprises: a hot water storage tank 2 storing heated hot water; an outer case 3 accommodating therein the hot water storage tank 2; and a foam insulation material 6 formed by being injected and foamed between the hot water storage tank 2 and the outer case 3, and is configured such that pipe projection parts 11t and 12t are disposed on a front plate 3a of the outer case 3, and the foam insulation material 6 is injected between the outer case 3a and the hot water storage tank 2 from inlets 3c1 and 3c2 in a rear plate 3c of the outer case 3.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a water heater and a method for manufacturing the same.

  Conventionally, a hot water storage tank unit of a water heater has been proposed in which a hot water storage tank is covered with a plurality of molded heat insulating materials and a molded heat insulating material is covered with an exterior case (see Patent Document 1). In addition, a hot water storage tank unit has been proposed in which the hot water storage tank is covered with a heat insulating material such as a vacuum heat insulating material (see Patent Document 2). Some tank units inject foamable heat insulating material.

JP 2011-106791 A Japanese Patent No. 4745269

By the way, in the shaping | molding heat insulating material of the conventional patent document 1, heat leak becomes large by the clearance gap between the fitting parts of a shaping | molding heat insulating material, and it cannot necessarily be said that heat insulation performance is favorable.
Therefore, as described in Patent Document 2, a technique of using a vacuum heat insulating material in combination has been developed.

  However, when a vacuum insulation material and a molded insulation material are used in combination, a plate-like vacuum insulation material is attached to the outer wall of the hot water storage tank, which is a curved surface. And a lot of man-hours such as application of adhesive. Further, in the configuration in which the molded heat insulating material is pressed against the outer wall of the hot water storage tank or the inner wall of the exterior material, a space is generated between the vacuum flexible heat insulating material having low flexibility and the molded heat insulating material having low flexibility, which may reduce the heat insulating performance. .

  Furthermore, since the vacuum heat insulating material may deteriorate due to the high temperature of the hot water storage tank, the vacuum heat insulating material cannot be brought into close contact with the hot water storage tank. For example, when a gap is generated between the hot water storage tank and the vacuum heat insulating material, There is a problem that leakage cannot be prevented sufficiently.

  This invention solves the said conventional problem, and it aims at providing a low-cost water heater and its manufacturing method while having high heat insulation performance.

  In order to solve the above-mentioned problems, a hot water supply apparatus according to a first aspect of the present invention includes a heating unit that heats low-temperature water to produce hot water, and a hot water storage tank unit that stores and supplies the hot water, and the hot water storage tank unit Is a hot water storage tank in which heated hot water is stored, the hot water storage tank is accommodated therein, an outer box having a front plate and a rear plate, and injected between the hot water storage tank and the outer box to foam. A foam protruding portion is disposed on the front plate, and the foam heat insulating material is injected between the outer box and the hot water storage tank from the inlet of the rear plate. It is configured.

  ADVANTAGE OF THE INVENTION According to this invention, while providing high heat insulation performance, a low-cost water heater and its manufacturing method can be provided.

The whole block diagram which shows the water heater provided with the hot water storage tank unit which concerns on embodiment. The perspective view which looked at the hot water storage tank unit from the downward direction. The cross-sectional view which cut | disconnected the hot water storage tank unit at the substantially horizontal surface. (A) is the perspective view from the side of the hot water storage tank unit which shows the state which fills a foam heat insulating material between a hot water storage tank and an outer case, (b) is the perspective view from the right side of (a). (a), (b), (c) is a perspective view from the side of the outer box and the hot water storage tank showing an example of before and during the injection of the foamed heat insulating material, and at the end of filling. (a)-(c) is a schematic diagram including the partial cross section which looked at the tank outer box assembly which shows an example of the filling process of the foam heat insulating material using a foam management jig | tool from the upper-plate side. (a) is a perspective view which shows the state before cap attachment of a water supply pipe protrusion part and a heat pump forward pipe protrusion part, (b) is a perspective view which shows the state after cap attachment of a water supply pipe protrusion part and a heat pump forward pipe protrusion part. (a) is an enlarged cross-sectional view of the vicinity of the injection port before injection of the liquid foam insulation, (b) is an enlarged cross-sectional view of the vicinity of the injection port at the time of injection of the liquid foam insulation, (c) is a liquid The cross-sectional enlarged view of the injection port vicinity of the state after foaming of a foam heat insulating material. (a) is the figure which shows before injection | pouring of the foam heat insulating material of a comparative example, (b) is the figure which shows during injection | pouring of the foam heat insulating material of a comparative example, (c) shows the completion | finish time of filling of the foam heat insulating material of a comparative example Figure. (a)-(c) is the schematic diagram which looked at the outer box and hot water storage tank which show an example of the filling process of the foam heat insulating material using the foam management jig | tool of a comparative example from the upper direction.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings as appropriate.
FIG. 1 is an overall configuration diagram showing a water heater provided with a hot water storage tank unit according to an embodiment. In FIG. 2 and subsequent figures, illustration of piping connected to the hot water storage tank is omitted.
The hot water heater K provided with the hot water storage tank unit 1 of the embodiment will be described.
The water heater K includes a heat pump unit 10 serving as a heating unit that heats low-temperature water to produce hot water (hot water), and a hot water storage tank unit 1 that stores and supplies the hot water.
In the present embodiment, the heat pump unit 10 is described as an example of the heating means, but other heating means such as a gas water heater other than the heat pump unit 10 may be used.

The hot water storage tank unit 1 includes a hot water storage tank 2 that stores hot water, an outer box 3 that covers the hot water storage tank 2, and a foam heat insulating material 6 that insulates the hot water storage tank 2 (see FIG. 3).
A water supply pipe 11 into which low-temperature water (water such as tap water) is introduced is connected to the lower part of the hot water storage tank 2. The low temperature water in the lower part of the hot water storage tank 2 is introduced into the heat pump unit 10 via the heat pump forward pipe 12 by a pump (not shown). Hot water heated to a high temperature by the heat pump unit 10 is introduced into the upper part of the hot water storage tank 2 through the heat pump return pipe 13.

  The hot water storage tank 2 is made of, for example, a cylindrical body plate 2a, a curved upper plate 2b having a substantially bowl-shaped curvature covering the upper opening of the body plate 2a, and a body plate 2a using a material such as stainless steel. Three members of a curved lower end plate 2c having a substantially bowl-shaped curvature covering the lower opening are connected by welding.

  The temperature of the hot water in the hot water storage tank 2 increases as it goes from below to above. That is, from the lower part to the upper part in the hot water storage tank 2, the hot water (or water) has a low temperature, medium temperature, and high temperature distribution. Therefore, a plurality of temperature sensors for measuring the temperature of the hot water in the hot water storage tank 2 or the temperature of the water in the vertical direction are provided on the outer surface of the hot water storage tank 2 in the vertical direction. As the temperature sensor, for example, a thermistor is used.

<Heat pump unit 10>
The heat pump unit 10 heats water (low temperature water) taken out from the hot water storage tank 2 to high temperature hot water. For example, the heat pump unit 10 compresses a refrigerant (for example, carbon dioxide) to a high temperature and a high pressure, condenses the refrigerant discharged from the compressor, and exchanges heat with water from the hot water storage tank 2. The condenser includes a condenser that heats water with condensation heat, a pressure-reducing valve that decompresses the refrigerant from the condenser, and an evaporator that absorbs heat in the atmosphere and evaporates the decompressed refrigerant.

  Hot water (hot water) taken out from the upper part of the hot water storage tank 2 is sent to the mixing valve (not shown) through the hot water supply pipe 14, and water from a branched water supply pipe (not shown) branched from the water supply pipe 11; After being mixed by a mixing valve and heated to a desired temperature, hot water is supplied from a hot water supply terminal 18 through a hot water supply pipe 17.

<Outer box 3>
The outer box 3 houses the hot water storage tank 2 and is provided for the purpose of protecting the hot water storage tank 2 and heat insulation. The outer box 3 is made of a thin steel plate that has been rust-proofed or has anti-rust properties. Yes.
The outer box 3 includes a front plate 3a (see FIG. 1) positioned in front of the hot water storage tank 2, side plates 3b and 3b positioned on the side, a rear plate 3c positioned on the rear, an upper plate 3d positioned on the upper side, and a lower side. The bottom plate 3e is formed into a vertically long box shape. The front plate 3a, the side plates 3b and 3b, the rear plate 3c, the upper plate 3d, and the bottom plate 3e are joined together by fitting, bolting, or the like to form the outer box 3.

  A pipe cover 3s is provided in front of the outer box 3 (front side). The piping cover 3s houses and covers a heat pump return pipe 13, a branch water supply pipe, a mixing valve, a pressure reducing valve, and the like from the heat pump unit 10 toward the hot water storage tank 2, and protects it from the external space.

  Three inner legs 2 d are fixed to the lower part of the hot water storage tank 2. The hot water storage tank 2 has three inner legs 2d fixed to and supported by outer legs 7 attached to the outside of the bottom plate 3a of the outer box 3. The number of inner legs 2d and outer legs 7 may be three or more, but in the case of three inner legs 2d and three outer legs 7, one hot water tank unit 1 is installed by three outer legs 7. Two planes are determined and the hot water storage tank 2 is most stable. Therefore, the three inner legs 2d and the outer legs 7 are most desirable.

<Outer leg 7 of outer box 3>
FIG. 2 is a perspective view of the hot water storage tank unit 1 as viewed from below.
A plurality of outer legs 7 are fixed to an inner leg 2d that supports the hot water storage tank 2 in the outer box 3 by bolts b1 or the like on a bottom plate 3e that forms the lower surface of the outer case 3 of the hot water tank unit 1.
Therefore, an attachment hole 7a1 into which the bolt b1 is inserted is provided in the upper plate 7a that contacts the bottom plate 3e of the outer box 3 in the outer leg 7.

  On the other hand, an attachment hole 7b1 through which an anchor bolt for fixing to the foundation is inserted is formed in the lower plate 7b that abuts the foundation (generally a foundation cured with concrete) of the installation location G of the hot water storage tank unit 1 of the outer leg 7. Is provided.

<Foam insulation 6 between the hot water storage tank 2 and the outer box 3>
FIG. 3 is a cross-sectional view of the hot water storage tank unit cut along a substantially horizontal plane.
As shown by dot display in FIG. 3, the space s <b> 1 between the hot water storage tank 2 and the outer box 3 is filled with a foam heat insulating material 6 that is a foam heat insulating material.

  The foamable heat insulating material (foamed heat insulating material 6) is constituted by injecting a liquid foamable heat insulating material between the hot water storage tank 2 and the outer box 3 and foaming after filling. As the foam heat insulating material 6, for example, a rigid polyurethane foam is used. This rigid polyurethane foam is obtained by reacting two urethane stock solutions of a polyol component and an isocyanate component in the presence of a foaming agent, a catalyst, and a foam stabilizer. Examples of the foaming agent include cyclopentane, water, and carbon dioxide gas. In addition, you may use things other than a rigid polyurethane foam for the foam heat insulating material 6. FIG.

  Thus, by providing the space s1 between the hot water storage tank 2 and the outer box 3 and filling the space s1 with the foamed heat insulating material 6 as a heat insulating material, the heat of the hot water in the hot water storage tank 2 is changed to the outer box. 3 is suppressed from leaking into the external space.

<Filling of foam insulation 6 between hot water storage tank 2 and outer box 3>
FIG. 4A is a perspective view from the side of the hot water storage tank unit showing a state in which the foam heat insulating material 6 is filled between the hot water storage tank and the outer box, and FIG. 4B is a perspective view of FIG. ) Is a perspective view from the right side of FIG.

  When filling the space between the hot water storage tank 2 and the outer box 3 with the foam heat insulating material 6, as shown in FIG. 4A, the hot water storage tank 2 in a state before the pipe cover 3 s (see FIG. 1) is attached. The outer box 3 housing the housing 3 is laid down (laid down) horizontally, the front plate 3a to which the piping cover 3s is attached faces downward and the rear plate 3c faces upward, and the vertical direction when the outer box 3 is installed is horizontal. Set the direction.

  For this reason, the rear plate 3c of the outer box 3 is formed with inlets 3c1 and 3c2 that serve as inlets when the foam heat insulating material 6 is injected. The inlet 3c1 of the outer box 3 is formed on the bottom plate 3e side of the lower portion of the rear plate 3c, and the inlet 3c2 of the outer box 3 is formed on the upper plate 3d side of the upper portion of the rear plate 3c.

  FIG. 5 is a perspective view from the side of the outer box and hot water storage tank showing an example of the filling process of the foam heat insulating material, FIG. 5 (a) shows before the foam heat insulating material is injected, and FIG. FIG. 5 (c) shows the end of filling of the foam heat insulating material. 5 indicate the direction of the hot water storage tank 2.

FIGS. 6A to 6C are schematic views including a partial cross section of a tank outer box assembly showing an example of a filling process of the foam heat insulating material using the foam management jig, as viewed from the upper plate side. As described above, the liquid foam heat insulating material 6 is injected into the tank outer box assembly 3A in a state where the tank outer box assembly 3A is laid down.
The tank outer box assembly 3A is an assembly of the hot water storage tank 2 and the outer box 3 before the foam heat insulating material 6 is injected. Therefore, FIG. 6 is a view of the outer box assembly 3A laid sideways as viewed from the upper plate 3d side of the outer box 3b.

  When the foam heat insulating material 6 is foamed, the outer box 3 is swelled by receiving an internal pressure from the foam heat insulating material 6. Therefore, as shown in FIGS. 6A to 6C, the foam management jig (also called yato) 30 is brought into close contact with the outer surface of the outer box 3 in the state where the outer box 3 is tilted (laid down). Then, the liquid foam heat insulating material 6 is injected and foamed in a state of covering the periphery.

Hereinafter, the filling process of the foam heat insulating material 6 using the foam management jig 30 (hereinafter, referred to as “yaito 30”) will be described.
The foam management jig 30 surrounds the entire periphery of the outer box 3 in order to withstand the internal pressure due to foaming of the foam heat insulating material 6, and all of the front plate 3a, side plates 3b, 3b, rear plate 3c, upper plate 3d, and bottom plate 3e. Is provided with a plate-shaped jig that is pressed inward so as not to deform.

The plate-shaped jig includes a fixed collar 30a, a first movable collar 30b, a second movable collar 30c, a third movable collar 30d, a fourth movable collar, and a fifth movable collar.
The fixed sheath 30a is fixed on the floor. The first movable edge 30b, the second movable edge 30c, the third movable edge 30d, the fourth movable edge, and the fifth movable edge are movable edges that can be freely opened and closed.

  The fourth movable sheath, the fixed sheath 30a, the first movable sheath 30b, the second movable sheath 30c, the third movable sheath 30d, and the fifth movable sheath are respectively the upper plate 3d and the front of the outer box 3. It plays a role of suppressing the plate 3a, the rear plate 3c, the side plates 3b, 3b, and the bottom plate 3e, respectively. In FIGS. 6A to 6C, the fourth movable beam and the fifth movable beam are not shown.

  Before the tank outer box assembly 3A is filled with the foam heat insulating material 6, as shown in FIG. 6 (a), the first movable sheath 30b, the second movable sheath 30c, the third movable sheath 30d, and the fourth movable The first and fifth movable ones are open.

  When the liquid foam insulation 6 is filled between the hot water storage tank 2 and the outer box 3, the front plate 3a side of the outer box 3 of the tank outer box assembly 3A is placed on the lower fixing sheath 30a. It becomes. As shown in FIG. 1, a water supply pipe protrusion 11t and a heat pump forward pipe protrusion 12t protrude from the front plate 3a of the outer box 3 to the outside of the front plate 3a.

  The rear plate 3c of the outer box 3 is formed with injection ports 3c1, 3c2 (see FIG. 4) of the foam heat insulating material 6. Nozzle insertion port into which the nozzle n (see FIG. 5) for injecting foam insulation material is inserted into the first movable sheath 30b fitted to the rear plate 3c at a position facing the injection ports 3c1, 3c2 of the rear plate 3c. 30b1 and 30b2 are formed.

  That is, the inlets 3c1 and 3c2 of the foam insulation 6 on the rear plate 3c of the outer box 3 and the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t of the front plate 3a of the outer box 3 are not the same side but opposite. Located on the side.

  Therefore, escape holes 30a1 and 30a2 for accommodating the water supply pipe protruding part 11t and the heat pump forward pipe protruding part 12t protruding from the front plate 3a of the outer box 3 are recessed in the lower fixing sheath 30a. The escape holes 30a1 and 30a2 are fixed so that the front plate 3a side of the outer box 3 is moved downward substantially vertically when the tank outer box assembly 3A is placed in the short 30 when the foam heat insulating material 6 is injected. Placed on top. Therefore, the escape holes 30a1 and 30a2 of the fixing sheath 30a can be slightly larger than the pipe diameters of the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t, respectively.

Then, as shown by the white arrow in FIG. 6 (b), the tank outer box assembly 3A is lowered from above the opened short 30 with the front plate 3a on the front side down. Since the front side (front plate 3a side) of the outer box assembly 3A is located below, the front plate 3a of the outer box 3 is placed on the fixed sheath 30a. At the time of mounting, the water supply pipe projecting part 11t and the heat pump forward pipe projecting part 12t projecting from the front plate 3a of the outer box 3 are fitted into the escape holes 30a1 and 30a2 of the fixed sheath 30a.

  As shown in FIG. 6B, substantially triangular pyramid-shaped caps c1 and c2 are fitted in the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t of the front plate 3a of the tank outer box assembly 3A, respectively. Then, they are fitted and positioned in the relief holes 30a1 and 30a2 of the fixing sheath 30a. FIG. 7 (a) shows the state before the cap of the water supply pipe protrusion and the heat pump forward pipe protrusion, and FIG. 7 (b) shows the state after the cap of the water supply pipe protrusion and the heat pump forward pipe protrusion. Show.

  When the tank outer box assembly 3A is lowered into the end 30 by the substantially triangular pyramid caps c1 and c2, the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12 are fixed by the substantially triangular pyramid caps c1 and c2. It can be easily positioned by being guided into the escape holes 30a1 and 30a2 of the short 30a, and can be smoothly fitted.

As described above, the tank outer box assembly 3A can be positioned at a predetermined position on the fixed sheath 30a by fitting the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t into the relief holes 30a1 and 30a2.
As a result, when the tank outer box assembly 3A is placed on the fixed sheath 30a, it can be confirmed that the tank outer box assembly 3A can be positioned at a predetermined position on the fixed sheath 30a. it can.

Thereafter, the first movable sheath 30b, the second movable sheath 30c, the third movable upper sheath 30d, the fourth movable sheath and the fifth movable sheath, as shown by the arrows in FIG. 6 (b), Closed inward.
Then, the first movable sheath 30b, the second movable sheath 30c, the third movable sheath 30d, the fourth movable sheath and the fifth movable sheath shown in FIG. In a state where the outer box 3 of 3A is held by the quick 30, the quick 30 is locked.

  Thereafter, as shown in FIG. 6C, from the outside of the sheath 30, the nozzle n is inserted into the nozzle insertion ports 30 b 1 and 30 b 2 of the first movable sheath 30 and is inserted into the inlets 3 c 1 and 3 c 2 of the rear plate 3 c. The liquid foam heat insulating material is injected between the outer box 3 and the hot water storage tank 2 through the inlets 3 c 1 and 3 c 2.

  FIG. 8A is an enlarged cross-sectional view of the vicinity of the inlets 3c1 and 3c2 before the liquid foam insulation 6 is injected, and FIG. 8B is a note when the liquid foam insulation 6 is injected. FIG. 8C is an enlarged cross-sectional view of the vicinity of the inlets 3 c 1 and 3 c 2 in the state after the foaming of the liquid foam heat insulating material 6.

  As shown in FIG. 8A, before the liquid foam heat insulating material 6 is injected, the injection ports 3c1 and 3c2 of the rear plate 3c of the outer box 3 are elastic inner lids such as thin resin films. If is in a state of substantially blocking the inlets 3c1 and 3c2. There are a total of four inlets 3c1, 3c2. That is, the liquid foam heat insulating material 6 is injected from the four inlets 3c1 and 3c2.

  Thereafter, as shown in FIG. 8B, a liquid foam heat insulating material 6 is injected from the nozzle n. Then, since the elastic inner lid if is an elastic material, it is elastically deformed inward (the space s1 between the hot water storage tank 2 and the outer box 3) by the injection pressure of the liquid foam heat insulating material 6 from the nozzle n.

  Thereafter, the foamed heat insulating material 6 is filled in the space s1 between the hot water storage tank 2 and the outer box 3 of the tank outer box assembly 3A by foaming. At this time, the elastic inner lid if which has been deformed inward (the space s1 between the hot water storage tank 2 and the outer box 3) by the injection of the foam heat insulating material 6 is foamed as shown in FIG. It is pressed by the foaming heat insulating material 6 to be moved so as to come into contact with the rear plate 3c, and the inlets 3c1, 3c2 of the rear plate 3c are closed from the inside. In this way, the liquid foam heat insulating material 6 is foamed, and the filling of the foam heat insulating material 6 into the space s1 between the hot water storage tank 2 and the outer box 3 of the tank outer box assembly 3A is completed.

When the filling of the foam heat insulating material 6 is completed, the lock to the sheath 30 is released, and the first movable sheath 30b, the second movable sheath 30c, the third movable sheath 30d, the fourth movable sheath, and the fifth The movable outer sheath is opened, and the tank outer box assembly 3A filled with the foam heat insulating material 6 is taken out from the early 30.
The above is the filling process of the foam heat insulating material 6 into the tank outer box assembly 3A.

By the way, the hot water storage tank unit 1 is practically installed outdoors and exposed to wind and rain. Here, the foam heat insulating material 6 such as urethane is vulnerable to moisture. Therefore, the inlet 3c1 (3c2) is closed from the outside of the outer box 3 of the tank outer box assembly 3A with an outer lid of (see FIG. 8C) larger than its diameter. The outer lid of is an adhesive-attached resin film, a metal thin plate, a coating agent, or the like. The outer lid of may be other as long as it can protect the inlet 3c1 (3c2) from the outside.
Here, a shape having no space between the elastic inner lid if and the outer lid of shown in FIG. 8C is preferable. If the space is eliminated, the effect of eliminating the possibility of condensation is added.

Accordingly, when the hot water storage tank unit 1 is put into practical use, even when the inlet 3c1 (3c2) of the outer box 3 is exposed to wind and rain, the inlet 3c1 (3c2) is covered with the outer lid of, so that the inlet 3c1 ( It is suppressed that moisture adheres to the foam heat insulating material 6 in 3c2).
Note that the above-described configuration can be applied to either equipment in which the quick 30 is moved and the nozzle is stationary, or equipment in which the nozzle is moved and the quick 30 is stationary.

<Comparative example>
Next, a comparative example will be described.
In the comparative example, the inlets 103 a 1 and 103 a 2 of the liquid foam heat insulating material 106 are provided on the front plate 103 a of the outer box 103.

  FIG. 9 is a perspective view from the side of the outer box and hot water storage tank showing an example of the filling process of the liquid foam heat insulating material of the comparative example, and FIG. 9A is an injection of the liquid foam heat insulating material of the comparative example. FIG. 9 (b) shows the state during injection of the liquid foam insulation of the comparative example, and FIG. 9 (c) shows the end of filling of the liquid foam insulation of the comparative example. 9 indicate the direction of the hot water storage tank 2.

  In the comparative example, the liquid foam insulation 106 is filled from the front plate 103a side of the outer box 103, unlike the embodiment. That is, as shown in FIG. 9A, when the foam heat insulating material 106 is injected into the tank outer box assembly 103A, the front plate of the outer box 103 is placed in a foam management jig 130 (hereinafter referred to as “yaito 130”). This is performed in such a posture that 103a is upward and the rear plate 103c of the outer box 103 is downward. The tank outer box assembly 103 </ b> A is an assembly of the hot water storage tank 102 and the outer box 103 before the foam heat insulating material 106 is injected.

In view of this, the front plate 103a of the outer box 103 is provided with injection ports 103a1 and 103a2.
FIGS. 10A to 10C are schematic views of an outer box and a hot water storage tank as viewed from above, showing an example of a filling process of the foam heat insulating material using the foam management jig of the comparative example.

As shown in FIGS. 10 (a) to 10 (c), the foam insulation material 106 of the comparative example is filled with the outer surface of the outer box 103 in a state where the outer box 3 is laid down, and the periphery thereof is quickly 130. It is done by covering.
The shield 130 surrounds the entire periphery of the outer box 103 to resist the internal pressure due to foaming of the foam heat insulating material 106, and deforms all of the front plate 103a, the side plates 103b and 103b, the rear plate 103c, the upper plate 103d, and the bottom plate 103e. A plate-shaped jig that is pressed inward is provided.

  The jig includes a fixed sheath 130a, a first movable sheath 130b, a second movable sheath 130c, a third movable sheath 130d, a fourth movable sheath 130, and a fifth movable sheath. The fixed sheath 130a is fixed on the floor. The first movable collar 130b, the second movable collar 130c, the third movable collar 130d, the fourth movable collar, and the fifth movable collar are openable and movable movable collars.

  The fourth movable collar, the first movable collar 130b, the second movable collar 130c, the third movable collar 130d, the fixed collar 130a, and the fifth movable collar are respectively the upper plate 103d and the front plate of the outer box 103. 103a, side plates 103b, 103b, rear plate 103c, and bottom plate 103e are restrained. In FIGS. 10A to 10C, the fourth movable beam and the fifth movable beam are not shown.

The filling process of the foam heat insulating material 106 into the space between the tank 102 and the outer box 103 of the tank outer box assembly 103A will be described.
Before the tank outer box assembly 103A is transported, as shown in FIG. 10 (a), the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath, and The fifth movable string is open.

  Thereafter, as shown in FIG. 10B, the tank outer box assembly 103 </ b> A before being filled with the foam heat insulating material 106 is conveyed to the upper side of the end 130 in a state where the front plate 103 a is turned upside down. Then, as shown by the white arrow in FIG. 10B, the tank outer box assembly 103A before filling is placed on the fixed sheath 130a.

  As shown in FIG. 10 (c), the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath 130, and the fifth movable sheath are foamed heat insulating materials. 106 is closed to cover the tank outer box assembly 103A before filling.

  Here, on the front plate 103a located on the upper side of the tank outer box assembly 103A shown in FIG. 10C, a water supply pipe protrusion 111t and a heat pump forward pipe protrusion 112t protrude outward (see FIG. 1).

Therefore, the first movable sheath 130b that suppresses the front plate 103a is formed with relief holes 130b3 and 130b4 for escaping the water supply pipe projection 11t and the heat pump forward pipe projection 12t that project outside the front plate 103a.
Further, nozzle insertion holes 130b1 and 130b2 are formed in the first movable sheath 130b at positions facing the four inlets 103a1 and 103a2 of the front plate 103a.

  That is, as shown in FIG. 10 (c), when closing the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath 130, and the fifth movable sheath. An opening (nozzle insertion holes 130b1, 130b2, 130b2, 130b2, 130b2, Escape holes 130b3, 130b4) are provided. That is, the injection side of the foam heat insulating material 106, the water supply pipe protrusion 111t, and the heat pump forward pipe protrusion 112t are on the same side.

  Then, in the state shown in FIG. 10 (c), the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath 130, and the fifth movable sheath are pre-filled. The tank is locked while covering the tank outer box assembly 103A.

  The nozzle n is set through the nozzle insertion holes 130b1 and 130b2 of the first movable sheath 130b and the inlets 103a1 and 103a2 of the front plate 103a, and the liquid foam heat insulating material 106 is injected from the nozzle n. .

  And when injection | pouring of the foam heat insulating material 106 is complete | finished, the nozzle n is removed. Then, the liquid foam heat insulating material 106 placed in the space between the hot water storage tank 102 and the outer box 103 of the tank outer box assembly 103A is foamed, and the foam heat insulating material 106 is formed between the hot water storage tank 102 and the outer box 103. Filled.

  When the filling of the foam heat insulating material 106 into the tank outer box assembly 103A is completed, the lock is released, and the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath, and The fifth movable sheath is opened, and the tank outer box assembly 103A filled with the foam insulation 106 is taken out from the sheath 130.

Here, when the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath 130d, and the fifth movable sheath 130 are opened and closed, the nozzle insertion of the first movable sheath 130b is performed. The holes 130b1 and 130b2 and the escape holes 130b3 and 130b4 are oblique trajectories with respect to the inlets 103a1 and 103a2 of the front plate 103a of the stationary tank outer box assembly 103A, the water supply pipe protrusion 111t, and the heat pump forward pipe protrusion 112t. Draw and move.
Therefore, the escape holes 130b3 and 130b4 of the first movable sheath 130b are configured to escape with a diameter larger than the outer diameter of the water supply pipe protrusion 111t of the front plate 103a and the outer diameter of the heat pump forward pipe protrusion 112t. .

  Accordingly, in the comparative example, the vicinity of the nozzle insertion holes 130b1 and 130b2 and the escape holes 130b3 and 130b4 of the first movable sheath 130b is an opening, and the suppression becomes weak. Therefore, when the liquid foam heat insulating material 6 is foamed, the outer box 103 may protrude to the outside. In addition, the vicinity of the nozzle insertion holes 130b1 and 130b2 and the escape holes 130b3 and 130b4 of the first movable sheath 130b has a low degree of design freedom, such as no sheet metal mating portion being provided.

  In the comparative example, since the first movable sheath 130b has many openings (nozzle insertion holes 130b1, 130b2, escape holes 130b3, 130b4), the strength is lowered. If the strength of the inner layer 130 is not strong, problems such as losing the foaming pressure and deformation of the outer box 103 occur.

  In the comparative example, the first movable sheath 130b is closed by closing the first movable sheath 130b, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath 130d, and the fifth movable sheath 130b. Until the nozzle insertion holes 130b1 and 130b2 and the escape holes 130b3 and 130b4 are inserted into the inlets 103a1 and 103a2 of the front plate 103a of the tank outer box assembly 103A, the water supply pipe protrusion 111t, and the heat pump forward pipe protrusion 112t, It is impossible to confirm whether the assembly 103A is positioned at a predetermined position in the end 130.

  That is, in the comparative example, the tank outer box assembly 103A is slightly closed until the first movable sheath 130, the second movable sheath 130c, the third movable sheath 130d, the fourth movable sheath 130, and the fifth movable sheath are closed. It is not known whether it is positioned at a predetermined position in the door 130.

  For this reason, if the tank outer box assembly 103A before filling is not positioned at a predetermined position in the hood 130, the first movable hood 130b, the second movable hood 130c, and the third movable hood 130d are again formed. It is necessary to reposition by opening the fourth movable shaft and the fifth movable shaft. Therefore, the workability of positioning the tank outer box assembly 103A before filling into the end 130 is poor.

  In addition, the triangular pyramid-shaped caps c1 and c2 similar to the embodiment are attached to the outer diameter of the water supply pipe protrusion 111t and the heat pump forward pipe protrusion 112t.

In contrast, the hot water storage tank unit 1 of the embodiment has the following effects.
1. The foam insulation 6 is injected from the upper rear plate 3c side with the front plate 3a of the tank outer box assembly 3A on the lower side. Therefore, the water supply pipe protrusion 111t and the heat pump forward pipe protrusion 112t of the front plate 3a are placed in the escape holes 30a1 and 30a2 of the fixed sheath 30a. Therefore, when the liquid foam insulation 6 is injected into the tank outer box assembly 3A, the tank outer box assembly 3A is installed in the sheath 130, that is, the front plate 3a of the tank outer box assembly 3A is fixed to the sheath 30a. On the other hand, the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t of the front plate 3a are fitted into the relief holes 30a1 and 30a2 of the fixed sheath 30a when being lowered in the vertical direction.
Therefore, the tank outer box assembly 3 </ b> A can be positioned at a predetermined position in the end 30 during the insertion.

  In other words, when the tank outer box assembly 3A is placed on the fixed sheath 30a, it can be determined whether or not it has been positioned at a predetermined position in the sheath 30. Therefore, unlike the comparative example, whether the tank outer box assembly 3A can be positioned is determined based on whether the first movable beam 30b, the second movable beam 30c, the third movable beam 30d, the fourth movable beam, and the fifth movable beam. It can be recognized before closing and positioning can be performed quickly. Therefore, the workability of positioning the tank outer box assembly 3A before filling into the end 30 is good.

2. Since the tank outer box assembly 3A can be positioned when it is lowered vertically onto the fixed sheath 30a, positioning of the tank outer box assembly 3A into the jacket 30 is easy.

3. Since the tank outer box assembly 3A is vertically lowered and positioned on the fixed sheath 30a, the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t of the tank outer box assembly 3A draw a vertical trajectory at the time of positioning. Moving. Therefore, the diameters of the water supply pipe protrusion 11t of the front plate 3a of the tank outer box assembly 3A and the escape holes 30a1 and 30a2 of the fixed sheath 30a for accommodating the heat pump forward pipe protrusion 12t are the same as the diameter of the water supply pipe protrusion of the front plate 3a. 11t, and can be formed with a diameter slightly larger than each diameter of the heat pump forward pipe protrusion 12t.

4). In addition, as shown in FIG. 6, the first movable sheath 30b does not need the accommodation holes for the water supply pipe protrusion 11t and the heat pump forward pipe protrusion 12t, and it is only necessary to form the nozzle fitting openings 30b1 and 30b2. Therefore, since the strength of the first movable sheath 30b is high, the first movable sheath 30b is strongly suppressed. Therefore, it is possible to prevent the outer case 3 from traveling on the outside during foaming after the foam heat insulating material 6 has been injected.

5. Further, the fixed sheath 30a is provided with a water supply pipe protrusion 11t and escape holes 30a1 and 30a2 of the heat pump forward pipe protrusion 12t, and the first movable sheath 30b is provided with a water supply pipe protrusion 11t of the front plate 3a and a heat pump forward. Since there is no escape hole in the tube protruding portion 12t, the area where the sheet metal mating portion is provided is large, and the degree of freedom in design is higher than in the comparative example.

6). Since the inlet 3c1 (3c2) of the outer box 3 of the tank outer box assembly 3A is covered by the outer lid of, it is possible to suppress moisture from adhering to the foam heat insulating material 6.

7). The fixed sheath 30a is provided with the water supply pipe protrusion 11t and the escape holes 30a1 and 30a2 of the heat pump forward pipe protrusion 12t, and the first movable sheath 30b is provided with the nozzle insertion openings 30b1 and 30b2, so that the quick 30 Becomes easier.
8). From the above, it is possible to provide a low-cost water heater K and a method for manufacturing the same while having high heat insulation performance.

<< Other Embodiments >>
1. In addition, the injection port of the liquid foam heat insulating material 6 may be plural or single, and is not limited.

2. In the embodiment described above, the escape holes 30a1 and 30a2 of the fixed sheath 30a have been described as having a diameter slightly larger than the diameter of the water supply pipe protrusion 11t and the diameter of the heat pump forward pipe protrusion 12t. The holes 30a1 and 30a2 may have a conical shape having a vertex on the lower side, and the water supply pipe projecting part 11t and the heat pump forward pipe projecting part 12t may be guided when the tank outer box assembly 3A before filling is positioned and the positioning 30a is positioned. . As a result, the tank outer box assembly 3A before filling can be more easily fixed and positioned on the edge 30a.

3. In the above embodiment, the case where the liquid foam heat insulating material 6 is injected by providing the inlet 3c1 (3c2) on the rear plate 3c of the outer box 3 is illustrated. However, the inlet is provided on the side plate 3b of the outer box 3. The liquid foam heat insulating material 6 may be injected. In this case, by adjusting the positions of the inner leg 2d and the outer leg 7 of the hot water storage tank unit 1, the liquid foam heat insulating material 6 can be injected without delay.

4). The configuration described in the above embodiment shows an example of the present invention, and various specific forms are possible within the scope of the claims.

DESCRIPTION OF SYMBOLS 1 Hot water storage tank unit 2 Hot water storage tank 3 Outer box 3a Front plate 3c Rear plate 3c1, 3c2 Inlet 6 Foam insulation 10 Heat pump unit (heating means)
11t Water supply pipe protrusion (pipe protrusion)
12t heat pump forward pipe protrusion (pipe protrusion)
30 Yaoi (Jig)
30a Fixed anchor (fixed jig)
30b Movable yam (movable jig)
30a1, 30a2 Relief hole (relief part)
30b1, 30b2 Nozzle insertion port (insertion hole)
n Nozzle of outer lid K water heater

Claims (3)

Comprising heating means for heating hot water to produce hot water, and a hot water storage tank unit for storing and supplying the hot water,
The hot water tank unit is
A hot water storage tank in which heated hot water is stored;
Containing the hot water storage tank inside, an outer box having a front plate and a rear plate;
A foam heat insulating material that is injected and foamed between the hot water storage tank and the outer box, and a pipe protruding portion is disposed on the front plate,
The hot water heater is characterized in that the foam heat insulating material is injected between the outer box and the hot water storage tank from the inlet of the rear plate. In the water heater according to claim 1,
An outer lid that covers the inlet from the outside is provided. In the manufacturing method of the water heater according to claim 1,
Upon injection of the foam insulation, the outer box is suppressed from the outside by a jig,
The fixing jig for holding the front plate is provided with a recess for escaping the pipe protruding portion,
The movable jig for holding the rear plate is provided with an insertion hole through which a nozzle for injecting the foam heat insulating material is inserted,
The foam heat insulating material is injected between the outer box and the hot water storage tank from the inlet of the rear plate.

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