JP2019190667A - Hot water storage tank unit and method for manufacturing the same - Google Patents

Abstract

To provide a hot water storage tank unit made more compact and lightweight than a conventional hot water storage tank unit while having required heat insulation performance.SOLUTION: A hot water storage tank unit 100 comprises a hot water storage tank 1, a heat insulation part 2 covering at least a portion of the hot water storage tank 1, and a case 4 internally housing the hot water storage tank 1 and the heat storage part 2. The hot water storage tank 1 includes a drum part 10 having a cylindrical shape, a first end part 11 connected to one end of the drum part 10, and a second end part 12 connected to another end of the drum part 10. A material constituting the heat insulation part 2 includes a foam heat insulating material. The heat insulation part 2 covers at least respective portions of the drum part 10, the first end part 11, and the second end part 12, and is integrally formed. At least a portion of an outer peripheral surface of the heat insulation part 2 is arranged at a distance from an inner peripheral surface of the case 4.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a hot water storage tank unit and a method for manufacturing the same, and more particularly to a hot water storage tank unit including a heat insulating portion provided to cover the hot water storage tank and a method for manufacturing the same.

  Conventionally, a hot water storage tank unit including a hot water storage tank and a plurality of heat insulating members attached around the hot water storage tank is known. Moreover, in order to improve heat insulation with respect to such a hot water storage tank unit, the hot water storage tank unit provided with the heat insulation member shape | molded integrally around the hot water storage tank is known.

  Japanese Patent Laying-Open No. 2015-178912 discloses a hot water storage tank unit including a foam heat insulating material that is filled in a space between a hot water storage tank and an outer box and formed by foaming.

JP2015-178912A

  However, the volume of the foam heat insulating material in the hot water storage tank unit is determined by the dimensions of the hot water storage tank and the outer box. Therefore, in the hot water storage tank unit, it is very difficult to control the volume and weight of the foam heat insulating material based on the heat insulating performance required for the hot water storage tank unit. As a result, the hot water storage tank unit is supposed to have a heat insulation performance exceeding the generally required performance, and the heat insulation performance is optimized with respect to the target performance, that is, the hot water storage tank unit is reduced in size and It has been difficult to reduce the weight.

  The main object of the present invention is to provide a hot water storage tank unit that has the required heat insulation performance but is smaller and lighter than conventional hot water storage tank units.

  The hot water storage tank unit according to the present invention includes a hot water storage tank, a heat insulating portion that covers at least a part of the hot water storage tank, and a case that houses the hot water storage tank and the heat insulating portion. The hot water storage tank includes a barrel having a cylindrical shape, a first end connected to one end of the barrel, and a second end connected to the other end of the barrel. The material which comprises a heat insulation part contains a foam heat insulating material. The heat insulating part covers at least a part of the body part and the first end part and is integrally formed. At least a part of the outer peripheral surface of the heat insulating portion is disposed with a space from the inner peripheral surface of the case.

  In the hot water storage tank unit according to the present invention, at least a part of the outer peripheral surface of the heat insulating portion is disposed at a distance from the inner peripheral surface of the case. The heat insulating portion is not molded using a case, but is molded using a mold separate from the case. The mold is designed so as to be able to form a heat insulating part optimal for the heat insulating performance required for the hot water storage tank unit. Therefore, the volume and weight of the heat insulating part can be controlled based on the heat insulating performance required for the hot water storage tank unit. As a result, the hot water storage tank unit has a target performance, but is smaller and lighter than the conventional hot water storage tank unit.

1 is a perspective view of a hot water storage tank unit according to Embodiment 1. FIG. It is a perspective view which shows the hot water storage tank and heat insulation which were accommodated in the inside of the case of the hot water storage tank unit shown by FIG. It is sectional drawing along the axial direction of the trunk | drum of a hot water storage tank of the heat insulation part shown by FIG. It is sectional drawing perpendicular | vertical to the axial direction of the trunk | drum of a hot water storage tank of the heat insulation part shown by FIG. It is a circuit diagram of the hot water storage type water heater provided with the hot water storage tank unit shown in FIG. 3 is a flowchart of a method for manufacturing a hot water storage tank unit according to Embodiment 1. In the manufacturing method of the hot water storage tank unit which concerns on Embodiment 1, it is sectional drawing which shows the process of forming a heat insulation part. It is sectional drawing along the axial direction of the trunk | drum of a hot water storage tank of the heat insulation part of the hot water storage tank unit which concerns on Embodiment 4. FIG. It is sectional drawing perpendicular | vertical to the axial direction of the trunk | drum of a hot water storage tank of the heat insulation part of the hot water storage tank unit which concerns on Embodiment 4. It is sectional drawing along the axial direction of the trunk | drum of a hot water storage tank of the heat insulation part of the hot water storage tank unit which concerns on Embodiment 5. FIG. It is the elements on larger scale of the area | region XI in FIG. In the manufacturing method of the hot water storage tank unit which concerns on Embodiment 5, it is sectional drawing which shows the process of forming a heat insulation part.

  Embodiments of the present invention will be described below with reference to the drawings. In the following drawings, the same or corresponding parts are denoted by the same reference numerals, and description thereof will not be repeated.

Embodiment 1 FIG.
<Configuration of hot water storage tank unit>
As shown in FIG. 1, the hot water storage tank unit 100 according to Embodiment 1 is used in, for example, a hot water storage type water heater 200.

  As shown in FIGS. 2 and 3, the hot water storage tank unit 100 includes, for example, a hot water storage tank 1, a heat insulating portion 2 provided to cover at least a part of the hot water storage tank 1, and a plurality of supports that support the hot water storage tank 1. It mainly includes a part 3 and a case 4 that accommodates the hot water storage tank 1 and the heat insulating part 2 supported by the support part 3.

  The hot water storage tank 1 stores water or hot water. The hot water storage tank 1 includes a body portion 10 having a cylindrical shape, and a first end portion 11 and a second end portion 12 having a bowl shape. The first end portion 11 is connected to one open end in the extending direction of the central axis of the trunk portion 10 (hereinafter simply referred to as the axial direction). The second end portion 12 is connected to the other opening end in the axial direction. The first end portion 11 and the second end portion 12 form a so-called end plate. The shape of the first end portion 11 and the second end portion 12 is, for example, a bowl shape. The trunk | drum 10 and the 1st end part 11 are welded. The trunk | drum 10 and the 2nd end part 12 are welded.

  The first end portion 11 is disposed above the second end portion 12. The first end portion 11 is provided with a joint 1 a for flowing hot water from the hot water storage tank 1 and a joint 1 b for flowing hot water into the hot water storage tank 1. The second end 12 includes a joint 1 c for flowing hot water into the hot water storage tank 1, a joint 1 d for flowing hot water into and out of the hot water storage tank 1, and a joint 1 e for flowing hot water into the hot water storage tank 1. Is provided. The plurality of joints 1a, 1b, 1c and 1d are connected to a water supply pipe or a hot water supply pipe which will be described later. A part of the region where the joints 1b, 1c, and 1d are not provided in the second end portion 12 is welded to a base member 30 of the support portion 3 described later. The hot water storage tank 1 is supported by a support portion 3. The hot water storage tank 1 is arrange | positioned, for example so that the said axial direction may follow a perpendicular direction. The temperature of the hot water stored in the hot water storage tank 1 increases stepwise from the second end 12 side toward the first end 11 side.

  The heat insulating part 2 covers at least a part of the body part 10, the first end part 11 and the second end part 12 of the hot water storage tank 1. The heat insulating part 2 is provided so as to expose the joints 1 a, 1 b, 1 c, 1 d of the hot water storage tank 1 and the portion welded to the base member 30 at the second end 12. Preferably, the heat insulating portion 2 covers the first end portion 11 other than the joint 1a and the entire body portion 10. As shown in FIG. 4, the heat insulating portion 2 covers the entire circumference of the first end portion 11 and the trunk portion 10 other than the joint 1 a of the hot water storage tank 1, for example, in the circumferential direction with respect to the axial direction. The heat insulating portion 2 has, for example, a portion disposed above the first end portion 11 and a portion disposed below the second end portion 12. The heat insulating part 2 may expose an arbitrary region on the outer peripheral surface of the hot water storage tank 1 according to required heat insulating performance. As shown in FIG. 3, the heat insulating portion 2 is provided so as to expose a part of the second end portion 12, for example.

  The heat insulating part 2 is formed as a single unit. That is, the heat insulation part 2 is not what the some heat insulation member joined.

  The material which comprises the heat insulation part 2 contains a foam heat insulating material. Although a foaming heat insulating material is not specifically limited, For example, it is a rigid polyurethane foam. In this case, the heat insulating part 2 is formed by collision reaction of two solvents of a polyol component including a foaming agent, a catalyst, and a foam stabilizer and an isocyanate component including a curing agent. The blowing agent is at least one selected from the group consisting of, for example, hydrofluoroolefin, hydrochlorofluoroolefin, cyclopentane, water, and carbon dioxide. The foam heat insulating material may be, for example, polyurea foam or polystyrene foam.

  A plurality of holes (not shown) are formed in the heat insulating portion 2. The plurality of holes are formed by foaming of the foaming agent. The plurality of holes form so-called closed cells and are partitioned from the outside of the heat insulating portion 2. Each hole formed in the heat insulating portion 2 is filled with a gas having a composition derived from the foaming agent. The composition of the gas in each hole formed in the heat insulating portion 2 is constant regardless of the position of the hole in the axial direction and the circumferential direction, for example. The expansion ratio of the heat insulating portion 2 is constant, for example, in the axial direction and the circumferential direction.

  The heat insulating portion 2 has an inner peripheral surface that is in contact with the hot water storage tank 1 and an outer peripheral surface 2 a that is located on the opposite side of the inner peripheral surface. At least a part of the outer peripheral surface 2 a of the heat insulating portion 2 is disposed with a space from the inner peripheral surface 4 a of the case 4. The volume of the integrated body of the hot water storage tank 1 and the heat insulating portion 2 is smaller than the volume surrounded by the inner peripheral surface 4 a of the case 4.

  Each support part 3 is arrange | positioned at intervals in the said circumferential direction. Each support part 3 has the mutually equivalent structure. Each support portion 3 includes a base member 30, an inner leg 31, an outer leg 32, and a lower surface plate 33. The base member 30 is welded to the outer peripheral surface of the hot water storage tank 1 and is fixed to the upper end portion of the internal leg 31 with, for example, a screw. The lower end portion of the inner leg 31 is fixed to the lower surface plate 33 by screws, for example. The internal leg 31 is disposed on the upper surface of the lower surface plate 33 facing the internal space. The upper end portion of the external leg 32 is fixed to the lower surface plate 33 by screws, for example. The inner leg 31 and the outer leg 32 are arranged so as to sandwich the lower surface plate 33, for example.

  The case 4 accommodates at least the hot water storage tank 1 and the heat insulating portion 2 therein. The case 4 is provided with a first internal space in which the hot water storage tank 1 and the heat insulating portion 2 are accommodated. The case 4 has an inner peripheral surface 4a facing the first internal space. As described above, the inner peripheral surface 4 a of the case 4 is arranged at a distance from at least a part of the outer peripheral surface 2 a of the heat insulating portion 2. The case 4 protects the hot water storage tank 1 and the heat insulating part 2 or the like, or imparts design properties to their appearance. Although the material which comprises the case 4 should just be the arbitrary materials which have a weather resistance and a flame retardance, it is steel or resin, for example.

  Case 4 includes, for example, a plurality of plate portions arranged so as to surround hot water storage tank 1 and heat insulating portion 2. The plurality of plate portions include, for example, a front plate 41, side plates 42 and 43, a back plate 44, a top plate 45, and a rake plate 46. An inner circumference in which at least one of the front plate 41, the side plates 42 and 43, the back plate 44, the upper plate 45, and the squeezing plate 46 is disposed at a distance from at least a part of the outer circumferential surface 2a of the heat insulating portion 2. It has a surface 4a. The plate portions are connected to each other by, for example, fitting or screws. The side plates 42 and 43, the back plate 44, and the dent plate 46 are connected to, for example, the bottom plate 33 of the support portion 3.

  In order to detect the temperature distribution of the hot water stored in the hot water storage tank 1, a plurality of temperature sensors (not shown) may be installed on the outer peripheral surface of the hot water storage tank 1. In this case, a portion where a plurality of temperature sensors are installed on the outer peripheral surface of the hot water storage tank 1 may be exposed from the heat insulating portion 2 or may be inserted into the heat insulating portion 2. Each temperature sensor is a thermistor, for example. The plurality of temperature sensors are disposed, for example, at intervals in the axial direction. The intervals in the axial direction of the plurality of temperature sensors may be equal or unequal.

<Configuration of hot water storage type water heater>
As shown in FIG. 5, the hot water storage type water heater 200 includes the hot water storage tank unit 100 and a heat pump unit 110. The heat pump unit 110 heats relatively low-temperature water, and makes hot water that is hotter than the water. The hot water storage tank unit 100 stores the hot water produced by the heat pump unit 110 and supplies it to the outside.

  The hot water storage tank unit 100 includes, in addition to the hot water storage tank 1 and the heat insulating portion 2, a water supply pipe 120, hot water supply pipes 122 and 124, a water discharge pipe 126, and a hot water supply pipe 127 connected to each joint of the hot water storage tank 1. Further prepare. One end of the water supply pipe 120 is connected to the joint 1 c of the hot water storage tank 1. One end of the hot water supply line 122 is connected to the joint 1 a of the hot water storage tank 1. One end of the hot water supply pipe 124 is connected to the joint 1 a of the hot water storage tank 1. One end of the outlet pipe 126 is connected to a joint 1 d of the hot water storage tank 1. One end of the hot water pipe 127 is connected to the joint 1 a of the hot water storage tank 1.

  The water supply pipeline 120 supplies low temperature water, which is city water, to the hot water storage tank 1. The hot water supply pipe 122 supplies high temperature water from the hot water storage tank 1 to a hot water supply end 123 such as a shower or a faucet. The hot water supply pipe 124 supplies high temperature water from the hot water storage tank 1 to the hot water supply end 125 disposed in the bathtub. The outlet pipe 126 supplies low temperature water to the heat pump unit 110. The hot water pipe 127 supplies hot water from the heat pump unit 110 to the hot water storage tank 1.

  The hot water storage tank unit 100 further includes a pressure reducing valve 130, a relief valve 131, a mixing valve 132, a first switching valve 133, a second switching valve 134, and a check valve 135. The pressure reducing valve 130 is connected to the water supply pipeline 120. The relief valve 131 is connected to the hot water supply pipe 122. The mixing valve 132 includes a first mixing valve connected to the hot water supply pipe 122 and the water supply pipe 120 and a second mixing valve connected to the hot water supply pipe 124 and the water supply pipe 120. The first switching valve 133 switches the supply source of the low temperature water supplied to the heat pump unit 110. The second switching valve 134 switches the flow path of hot water flowing between the hot water storage tank 1 and the heat pump unit 110.

  The pressure reducing valve 130, the relief valve 131, the mixing valve 132, the first switching valve 133, the second switching valve 134, and the check valve 135 are housed inside the case 4. The pressure reducing valve 130, the relief valve 131, the mixing valve 132, the first switching valve 133, the second switching valve 134, and the check valve 135 are disposed, for example, between the outer peripheral surface of the heat insulating portion 2 and the inner peripheral surface of the case 4. Has been. The components of the hot water storage water heater 200 disposed inside the case 4 and the components of the hot water storage water heater 200 disposed outside the case 4 are connected via, for example, a scooping plate 46 of the case 4. Yes.

<Manufacturing method of hot water storage tank unit>
Next, with reference to FIG. 6 and FIG. 7, the manufacturing method of the hot water storage tank unit 100 is demonstrated.

  In the method for manufacturing the hot water storage tank unit 100, first, the hot water storage tank 1, the case 4 provided with the first internal space for storing the hot water storage tank 1, and the mold 500 provided with the second internal space for storing the hot water storage tank 1. Is prepared (step S10). The hot water storage tank 1 has the above-described configuration. The hot water storage tank 1 is supported by the support part 3, for example. That is, the base member 30 of the support portion 3 is welded to the outer peripheral surface of the hot water storage tank 1.

  The volume of the second internal space of the mold 500 is larger than the volume surrounded by the outer peripheral surface of the hot water storage tank 1 and smaller than the volume of the first internal space of the case 4. The volume and shape of the second internal space of the mold 500 are designed so as to satisfy the heat insulating performance required for the hot water storage tank unit 100 and to reduce the size or weight of the hot water storage tank unit 100. Preferably, the volume and shape of the second internal space of the mold 500 are such that the components of the hot water storage water heater 200 such as the mixing valve 132 are disposed outside the heat insulating portion 2 and inside the case 4. Designed. In other words, the volume of the second internal space is smaller than the sum of the volumes of the components arranged inside the case 4 such as the mixing valve 132 as compared with the volume of the first internal space.

  Next, as shown in FIG. 7, the hot water storage tank 1 is accommodated in the second internal space of the mold 500 (step S20). At this time, the support portion 3 is disposed outside the second internal space.

  Next, the heat insulating portion 2 that covers at least a part of the hot water storage tank 1 is formed by filling the second internal space of the mold 500 with the foam heat insulating material and foaming the foamed heat insulating material (step S30). First, the foam heat insulating material is filled in the second internal space of the mold 500. After filling, the foaming agent is foamed. After foaming, the hot water storage tank 1 and the heat insulating part 2 are taken out from the second internal space of the mold 500.

  Next, the hot water storage tank 1 and the heat insulating part 2 are accommodated in the first internal space of the case 4 (step S40). Specifically, the front plate 41, the side plates 42 and 43, the back plate 44, the top plate 45, and the lever plate 46 are connected to the bottom plate 33 of the support unit 3. As a result, a first internal space surrounded by the lower surface plate 33, the front surface plate 41, the side surface plates 42 and 43, the rear surface plate 44, the upper surface plate 45, and the scooping plate 46 is formed, and the hot water storage tank is formed in the first internal space. 1, the heat insulation part 2, the base member 30 of the support part 3, and the internal leg 31 are accommodated. In this way, the hot water storage tank unit 100 is manufactured.

<Effect>
A hot water storage tank unit 100 according to Embodiment 1 includes a hot water storage tank 1, a heat insulating portion 2 that covers at least a part of the hot water storage tank 1, and a case 4 that accommodates the hot water storage tank 1 and the heat insulating portion 2 therein. The hot water storage tank 1 includes a body portion 10 having a cylindrical shape, a first end portion 11 connected to one end of the body portion 10, and a second end portion 12 connected to the other end of the body portion 10. . The material which comprises the heat insulation part 2 contains a foam heat insulating material. The heat insulating portion 2 covers at least a part of the body portion 10, the first end portion 11 and the second end portion 12, and is formed integrally. At least a part of the outer peripheral surface of the heat insulating portion 2 is disposed with a gap from the inner peripheral surface of the case 4.

  In the hot water storage tank unit 100, since the heat insulating portion 2 is molded using a mold 500 that is separate from the case 4, at least a part of the outer peripheral surface of the heat insulating portion 2 is spaced from the inner peripheral surface of the case 4. Are arranged apart from each other. The mold 500 is designed so as to be able to form the heat insulating portion 2 optimum for the heat insulating performance (target performance) required for the hot water storage tank unit 100. Therefore, the volume and weight of the heat insulating part 2 can be controlled based on the target performance. As a result, the hot water storage tank unit 100 can be reduced in size and weight as compared with the conventional hot water storage tank unit.

  Furthermore, in the hot water storage tank unit 100, components of the hot water storage water heater 200 such as the mixing valve 132 can be disposed between the outer peripheral surface of the heat insulating portion 2 and the inner peripheral surface of the case 4.

  In the hot water storage tank unit described in Patent Document 1, in order to arrange such a component in the case, the foam insulation is placed in the case in a state in which the spacer is arranged at a predetermined position in the case. Need to be filled. In some cases, a plurality of spacers are required. Therefore, in the hot water storage tank unit described in Patent Document 1, the process of forming the heat insulating portion is relatively complicated, and the manufacturing cost is relatively high.

  On the other hand, in the hot water storage tank unit 100, the above configuration is provided between the outer peripheral surface of the heat insulating portion 2 and the inner peripheral surface of the case 4 without arranging the spacer as described above in the first internal space of the mold 500. A space for arranging the components can be formed. Therefore, the hot water storage tank unit 100 can be easily manufactured as compared with the hot water storage tank unit described in Patent Document 1, and the manufacturing cost of the hot water storage tank unit 100 is higher than that of the hot water storage tank unit described in Patent Document 1. Can be reduced.

Embodiment 2. FIG.
The hot water storage tank unit according to the second embodiment has basically the same configuration as the hot water storage tank unit 100 according to the first embodiment, but the thermal conductivity of the gas in each hole formed in the heat insulating portion 2 is the above. It differs in that it depends on the position of the hole in the axial direction.

  The heat insulating portion 2 can be divided into a first portion that covers at least a part of the first end portion 11 and a second portion that is located closer to the second end portion 12 than the first portion. The 2nd part of the heat insulation part 2 has covered at least one part of the 2nd end part 12 of the hot water storage tank 1, for example. The first part and the second part of the heat insulating part 2 are formed as one piece.

  The thermal conductivity of the gas in each hole formed in the first portion of the heat insulating portion 2 is lower than the thermal conductivity of the gas in each hole formed in the second portion of the heat insulating portion 2. The position in the axial direction of the boundary between the first part and the second part can be arbitrarily set according to the temperature distribution in the axial direction of the hot water stored in the hot water storage tank 1.

  The method for manufacturing a hot water storage tank unit according to Embodiment 2 differs from the method for manufacturing hot water storage tank unit 100 according to Embodiment 1 in the following points.

  In the step (S30), a first foaming agent that generates a gas having a relatively low thermal conductivity and a second foaming agent that generates a gas having a relatively high thermal conductivity are used. Specifically, first, a second foam heat insulating material containing a second foaming agent that generates a gas having relatively high thermal conductivity is filled on the second end 12 side of the second internal space of the mold 500, The second blowing agent is foamed. Thereby, the second portion is formed. Next, a first foam heat insulating material containing a first foaming agent that generates a gas having a relatively low thermal conductivity is filled in the remaining portion of the second internal space, and the first foaming agent is foamed. Thereby, the first portion is formed. At this time, the second portion formed earlier and the first portion formed later are bonded together by heat generated during foaming (foaming heat). As a result, the gas derived from the first foaming agent is sealed in each hole of the first part of the heat insulating part 2, and the gas derived from the second foaming agent is contained in each hole of the second part of the heat insulating part 2. Gas is enclosed.

  In the hot water storage tank unit according to Embodiment 2, the heat insulating performance of the first portion of the heat insulating portion 2 is higher than the heat insulating performance of the second portion of the heat insulating portion 2. Therefore, the energy saving performance such as the annual hot water storage efficiency of the hot water storage tank unit and the hot water storage type water heater according to the second embodiment can be equivalent to that of the hot water storage tank unit 100 and the hot water storage type water heater 200 according to the first embodiment.

  On the other hand, since the temperature of the hot water stored on the second end portion 12 side of the hot water storage tank 1 is lower than the temperature of the hot water stored on the first end portion 11 side of the hot water storage tank 1, it is required for the second portion. The heat insulation performance is low compared to the heat insulation performance required for the first part. Therefore, the heat insulation performance of the heat insulation part 2 which concerns on Embodiment 2 is further optimized with respect to the target performance compared with the heat insulation performance of the heat insulation part 2 which concerns on Embodiment 1. FIG. In general, the cost of a blowing agent that generates a gas having low thermal conductivity is higher than the cost of a blowing agent that generates a gas having high thermal conductivity. Therefore, in the method for manufacturing a hot water storage tank unit according to Embodiment 2, a foaming agent that generates a gas having low thermal conductivity is used only in a portion where the required heat insulation performance is relatively high, and the required heat insulation performance is Since a foaming agent that generates a gas having high thermal conductivity can be used in a portion lower than the portion, the manufacturing cost is reduced as compared with the manufacturing method of the hot water storage tank unit 100 according to the first embodiment. .

Embodiment 3 FIG.
The hot water storage tank unit according to the third embodiment has basically the same configuration as the hot water storage tank unit 100 according to the first embodiment, but the expansion ratio of the heat insulating portion 2 differs depending on the position of the hole in the axial direction. Is different.

  The heat insulating portion 2 can be divided into a first portion that covers at least a part of the first end portion 11 and a second portion that is located closer to the second end portion 12 than the first portion. The 2nd part of the heat insulation part 2 has covered at least one part of the 2nd end part 12 of the hot water storage tank 1, for example. The first part and the second part of the heat insulating part 2 are formed as one piece.

  The expansion ratio of the first part of the heat insulating part 2 is lower than the expansion ratio of the second part of the heat insulating part 2. If it says from a different viewpoint, the density of the said 1st part of the heat insulation part 2 is higher than the density of the said 2nd part of the heat insulation part 2. FIG. The position in the axial direction of the boundary between the first part and the second part can be arbitrarily set according to the temperature distribution in the axial direction of the hot water stored in the hot water storage tank 1.

  The method for manufacturing a hot water storage tank unit according to Embodiment 3 differs from the method for manufacturing hot water storage tank unit 100 according to Embodiment 1 in the following points.

  In the step (S30), filling of the foam heat insulating material into the second internal space of the mold 500 is performed in at least two stages. Further, the foam heat insulating material to be filled later is filled in the mold 500 after the foam heat insulating material previously filled is foamed in the mold 500. Specifically, first, foaming is performed in a region where the first portion having a relatively low density in the second internal space of the mold 500 is to be formed, that is, on the second end 12 side of the second internal space. Insulation is filled. The foam heat insulating material is foamed in a free state in the second internal space. The area in which the second portion having a relatively high density is to be formed in the second internal space of the mold 500 just before the foaming in the second internal space is completed, that is, the remainder of the second internal space. This area is filled with foam insulation. The filling amount of the foamed heat insulating material is set so that the density of the foamed heat insulating material is higher than the density of the foamed heat insulating material to be the first portion that has been filled and foamed first. The foamed heat insulating material is foamed after the remaining amount of the foamed heat insulating material is filled in the remaining area of the second internal space. By the heat (foaming heat) generated at the time of foaming in the second internal space, the previously filled second portion and the later filled first portion are integrated. Thereby, the heat insulation part 2 in which the second portion having a relatively low density and the first portion having a relatively high density are integrally formed is formed. Note that the timing of starting filling the remaining region of the second internal space with the foam heat insulating material may be, for example, immediately after completion of the foaming in the second state of the mold 500 in the free state. .

  In the hot water storage tank unit according to Embodiment 3, the heat insulating performance of the first portion of the heat insulating portion 2 is higher than the heat insulating performance of the second portion of the heat insulating portion 2. Therefore, the energy-saving performance such as the annual hot water storage efficiency of the hot water storage tank unit and hot water storage type water heater according to the third embodiment can be equivalent to that of the hot water storage tank unit 100 and hot water storage type water heater 200 according to the first embodiment.

  On the other hand, since the temperature of the hot water stored on the second end portion 12 side of the hot water storage tank 1 is lower than the temperature of the hot water stored on the first end portion 11 side of the hot water storage tank 1, it is required for the second portion. The heat insulation performance is low compared to the heat insulation performance required for the first part. Therefore, the heat insulation performance of the heat insulation part 2 which concerns on Embodiment 3 is further optimized with respect to the target performance compared with the heat insulation performance of the heat insulation part 2 which concerns on Embodiment 1. FIG. In addition, when comparing the weights of two heat insulation parts having the same volume and different densities, the weight of the high density heat insulation part is larger than the weight of the low density heat insulation part. Higher than the manufacturing cost of high-density heat insulation parts. Therefore, in the method for manufacturing a hot water storage tank unit according to Embodiment 3, a foaming agent that generates a gas having low thermal conductivity is used only in a portion where the required heat insulation performance is relatively high, and the required heat insulation performance is Since a foaming agent that generates a gas having high thermal conductivity can be used in a portion lower than the portion, the manufacturing cost is reduced as compared with the manufacturing method of the hot water storage tank unit 100 according to the first embodiment. .

  The hot water storage tank unit according to Embodiment 3 may have the same configuration as the hot water storage tank unit according to Embodiment 2. The heat conductivity of the gas in each hole formed in the first part of the heat insulating part 2 is lower than the heat conductivity of the gas in each hole formed in the second part of the heat insulating part 2, and the heat insulating part The expansion ratio of the first part 2 may be lower than the expansion ratio of the second part of the heat insulating portion 2.

Embodiment 4 FIG.
As shown in FIGS. 8 and 9, the hot water storage tank unit according to the fourth embodiment is basically provided with the same configuration as the hot water storage tank unit 100 according to the first embodiment, but further includes a vacuum heat insulating material 5. It is different in point.

  The vacuum heat insulating material 5 is inserted in the inside of the heat insulation part 2, for example. The periphery of the vacuum heat insulating material 5 is covered with the heat insulating portion 2. The vacuum heat insulating material 5 has a shape along the outer peripheral surface of the hot water storage tank 1. The vacuum heat insulating material 5 has a curvature corresponding to the distance from the center of the hot water storage tank 1. The distance from the said center of the vacuum heat insulating material 5 is shorter than the distance from the said center of the outer peripheral surface of the heat insulation part 2, and is longer than the distance from the said center of the inner peripheral surface of the heat insulation part 2. FIG. The vacuum heat insulating material 5 is arrange | positioned so that the hot water storage tank 1 may be enclosed over the perimeter of the said circumferential direction, for example. The vacuum heat insulating material 5 is, for example, disposed so as to surround a portion located above the body portion 10 and a portion located below the first end portion 11 while being covered with a relatively thin portion in the heat insulating portion 2. .

  In addition, the vacuum heat insulating material 5 may be arrange | positioned, for example only in a part of the said circumferential direction. For example, when the thickness of the heat insulating portion 2 is not constant in the circumferential direction, the vacuum heat insulating material 5 may be disposed only in a portion where the thickness of the heat insulating portion 2 is relatively thin. The thickness of the heat insulation part 2 is the width | variety of the heat insulation part 2 in the radial direction with respect to the said axial direction.

  The method for manufacturing a hot water storage tank unit according to Embodiment 4 differs from the method for manufacturing hot water storage tank unit 100 according to Embodiment 1 in the following points.

  First, in the step (S10), the vacuum heat insulating material 5 is prepared. The vacuum heat insulating material 5 is manufactured by a well-known method. Next, in the step (S <b> 20), the vacuum heat insulating material 5 is accommodated in the second internal space of the mold 500 together with the hot water storage tank 1. Next, in the step (S30), the foam heat insulating material is filled in the second internal space of the mold 500 and foamed. At this time, the foam heat insulating material is filled between the hot water storage tank 1 and the vacuum heat insulating material 5 and between the vacuum heat insulating material 5 and the mold 500. Thereby, the heat insulation part 2 in which the vacuum heat insulating material 5 was inserted is formed.

  Since the hot water storage tank unit according to the fourth embodiment further includes the vacuum heat insulating material 5, the heat insulating performance can be improved as compared with the hot water storage tank unit 100 according to the first embodiment. Moreover, in the hot water storage tank unit according to Embodiment 4, since the vacuum heat insulating material 5 is covered with the heat insulating portion 2, damage to the vacuum heat insulating material 5 is suppressed as compared with the case where the vacuum heat insulating material 5 is exposed. ing.

  In addition, the hot water storage tank unit according to Embodiment 4 may have a configuration in which the hot water storage tank unit according to Embodiment 2 or 3 further includes a vacuum heat insulating material 5.

Embodiment 5 FIG.
As shown in FIGS. 10 and 11, the hot water storage tank unit according to the fifth embodiment is basically provided with the same configuration as the hot water storage tank unit according to the fourth embodiment, but further includes a second heat insulating portion 6. It is different in point.

  The 2nd heat insulation part 6 is arrange | positioned in the part whose heat insulation performance requested | required in the hot water storage tank unit 100 is comparatively low. The second heat insulating portion 6 covers at least a part of the second end portion 12 of the hot water storage tank 1. At least a part of the outer peripheral surface 6 a of the second heat insulating portion 6 is disposed with a space from the inner peripheral surface 4 a of the case 4. For example, the second heat insulating portion 6 covers the part of the second end portion 12 over the entire circumference in the circumferential direction.

  The heat conductivity of the second heat insulating part 6 is higher than the heat conductivity of the heat insulating part 2. The cost of the material which comprises the 2nd heat insulation part 6 is low compared with the cost of the material which comprises the heat insulation part 2. FIG.

  The 2nd heat insulation part 6 has the recessed part 6b. The recess 6b opens to the first end 11 side. The recessed part 6b is recessed with respect to the upper surface of the second heat insulating part 6 facing the first end part 11 side. The recess 6b is continuous in the circumferential direction, for example. The recessed part 6b is recessed with respect to the internal peripheral surface of the 2nd heat insulation part 6, for example.

  The heat insulation part 2 has the convex part 2b which protruded in the 2nd edge part 12 side. The convex part 2b of the heat insulation part 2 is fitted in the concave part 6b of the second heat insulation part 6, for example. The 2nd heat insulation part 6 is comprised as the heat insulation part 2 and a different body, for example.

  The method for manufacturing a hot water storage tank unit according to Embodiment 5 differs from the method for manufacturing hot water storage tank unit 100 according to Embodiment 1 in the following points.

  First, in the said process (S10), the 2nd heat insulation part 6 is further prepared. The 2nd heat insulation part 6 is manufactured by a well-known method. The hot water storage tank 1 is prepared in a state where it is not supported by the support portion 3. Then, the 2nd heat insulation part 6 is fitted by the heat insulation part 2 formed by the said process (S30). At this time, the region to be welded to the base member 30 of the support portion 3 on the outer peripheral surface of the hot water storage tank 1 is exposed from the heat insulating portion 2 and the second heat insulating portion 6. Thereafter, the base member 30 is welded to the region. In this way, a hot water storage tank unit including the second heat insulating portion 6 is formed.

  In the hot water storage tank unit according to the fifth embodiment, the heat insulating performance realized by the heat insulating portion 2 and the second heat insulating portion 6 is compared with the heat insulating performance realized by one heat insulating portion 2 that covers a region equivalent to these. It can be further optimized for performance. In addition, the manufacturing cost of the hot water storage tank unit according to the fifth embodiment is compared with the manufacturing cost of the hot water storage tank unit 100 including one heat insulating portion 2 that covers an area equivalent to the heat insulating portion 2 and the second heat insulating portion 6. Can be reduced.

  The second heat insulating part 6 may be formed integrally with the heat insulating part 2. At least a part of the concave portion 6 b of the second heat insulating portion 6 may be bonded to the convex portion 2 b of the heat insulating portion 2. For example, as shown in FIG. 12, after the hot water storage tank 1 and the second heat insulating portion 6 are accommodated in the second internal space of the mold 500 in the step (S20), the foam heat insulating material in the step (S20). Is filled in the second internal space and foamed, whereby the heat insulating part 2 having the convex part 2b bonded to the concave part 6b of the second heat insulating part 6 may be formed. In this case, the mold 500 is provided with a filling hole for efficiently filling the foamed heat insulating material into the concave portion 6b of the second heat insulating portion 6 arranged at a predetermined position in the second internal space. It is preferred that A gap may also be formed between the heat insulating portion 2 and the second heat insulating portion 6 formed in this way, but the gap is a case where the second heat insulating portion 6 is fitted to the heat insulating portion 2 formed in advance. This is smaller than the gap between the two. Therefore, the heat insulation part 2 and the 2nd heat insulation part 6 which were integrally formed as mentioned above can prevent a heat leak compared with the heat insulation part 2 and the 2nd heat insulation part 6 which were fitted. Moreover, in the said process (S30), since the 2nd heat insulation part 6 is hold | maintained with the foaming pressure of the foam heat insulating material with which the recessed part 6b was filled, the position shift of the 2nd heat insulation part 6 with respect to the hot water storage tank 1 is prevented. .

  Note that the hot water storage tank unit according to Embodiment 5 may have a configuration in which the hot water storage tank unit according to Embodiments 1 to 3 further includes the second heat insulating portion 6. Further, the hot water storage tank unit according to Embodiment 5 may include a plurality of second heat insulating portions 6. Each second heat insulating portion 6 may have a plurality of recesses 6b.

<Modification>
In the hot water storage tank unit according to Embodiments 1 to 5, the heat insulating portion 2 may be provided so as to expose the entire second end portion 12. Such a heat insulating portion 2 can also be easily molded by appropriately designing the second internal space of the mold 500.

  Each embodiment disclosed this time is also planned to be implemented in appropriate combinations including combinations not mentioned in the specification. The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is shown not by the above description of the embodiment but by the scope of claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

  DESCRIPTION OF SYMBOLS 1 Hot water storage tank, 1a, 1b, 1c, 1d, 1e Joint, 2 Heat insulation part, 2a, 6a Outer peripheral surface, 2b Convex part, 3 Support part, 4a Inner peripheral surface, 4 Case, 5 Vacuum heat insulating material, 6 2nd heat insulation Part, 6b concave part, 10 trunk part, 11 first end part, 12 second end part, 30 base member, 31 internal leg, 32 external leg, 33 bottom plate, 41 front plate, 42, 43 side plate, 44 back plate , 45 Top plate, 46 Indentation plate, 100 Hot water storage tank unit, 110 Heat pump unit, 120 Water supply pipe, 122,124 Hot water supply pipe, 123 Hot water supply end, 126 Water discharge pipe, 127 Hot water supply pipe, 130 Pressure reducing valve, 131 Relief valve, 132 mixing valve, 133 first switching valve, 134 second switching valve, 135 check valve, 200 hot water storage type water heater, 500 mold.

Claims (10)

A hot water storage tank,
A heat insulating part covering at least a part of the hot water storage tank;
A case for accommodating the hot water storage tank and the heat insulating part inside,
The hot water storage tank includes a barrel having a cylindrical shape, a first end connected to one end of the barrel, and a second end connected to the other end of the barrel,
The material constituting the heat insulating portion includes a foam heat insulating material,
The heat insulating part covers at least a part of the body part and the first end part, and is formed integrally.
At least a part of the outer peripheral surface of the heat insulating part is a hot water storage tank unit that is disposed at a distance from the inner peripheral surface of the case. The heat insulating portion includes a first portion that covers at least a part of the first end portion, and a second portion that is located closer to the second end portion than the first portion,
The hot water storage tank unit according to claim 1, wherein the foaming ratio of the first part is lower than the foaming ratio of the second part. The heat insulating portion includes a first portion that covers at least a part of the first end portion, and a second portion that is located closer to the second end portion than the first portion,
In the first part and the second part, a plurality of holes partitioned from the outside are formed,
The thermal conductivity of the gas filled in the hole formed in the first portion is higher than the thermal conductivity of the gas filled in the hole formed in the second portion. Hot water storage tank unit.   The hot water storage tank unit according to any one of claims 1 to 3, wherein at least a part of the second end portion is exposed from the heat insulating portion. A second heat insulating part covering at least a part of the second end;
5. The hot water storage tank unit according to claim 4, wherein at least a part of an outer peripheral surface of the second heat insulating portion is disposed at a distance from the inner peripheral surface of the case. The second heat insulating portion has a concave portion opened to the first end portion side,
The hot water storage tank unit according to claim 5, wherein the heat insulating portion is fitted in the concave portion and has a convex portion protruding toward the second end portion.   The hot water storage tank unit according to claim 6, wherein at least a part of the concave portion of the second heat insulating portion is bonded to the convex portion of the heat insulating portion.   The hot water storage tank unit according to any one of claims 1 to 7, wherein the first end portion is disposed above the second end portion. Preparing a hot water storage tank, a case provided with a first internal space for storing the hot water storage tank, and a mold provided with a second internal space for storing the hot water storage tank;
Disposing the hot water storage tank in the second internal space of the mold;
Filling and foaming the second internal space of the mold with a foam heat insulating material to form a heat insulating portion covering at least a part of the hot water storage tank;
Arranging the hot water storage tank and the heat insulating part in the first internal space of the case,
The method for manufacturing a hot water storage tank unit, wherein the volume of the second internal space is smaller than the volume of the first internal space. The hot water storage tank includes a barrel having a cylindrical shape, a first end connected to one end of the barrel, and a second end connected to the other end of the barrel,
A step of preparing a second heat insulating portion covering at least one of the second end portions;
The manufacturing method of the hot water storage tank unit of Claim 9 which arrange | positions the said hot water storage tank and the said 2nd heat insulation part inside the said metal mold | die in the said process to arrange | position.

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