JP7315447B2 - Combustion device and method for manufacturing combustion device - Google Patents

Description

The present invention relates to a combustion device and a method for manufacturing a combustion device.

Conventionally, this type of engine has an exhaust port for discharging combustion gas to the outside, and has a louver body for regulating the flow direction of the combustion gas toward the exhaust port. (For example, see Patent Document 1.)

JP-A-9-196472

By the way, in this conventional louver, the plurality of long plate-shaped blades constituting the louver body and the outer frame for supporting the blades are separate members, which increases the number of parts and the number of steps required for assembly. In addition, when the combustion gas passes through the louver body, the combustion gas passes while coming into contact with the angular edges forming the long sides of the blades, resulting in loud wind noise.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a combustion device and a method of manufacturing a combustion device in which the louver body is not formed by combining separate members, and wind noise is less likely to occur when combustion gas passes through the combustion device.

In order to solve the above problems, in claim 1 of the present invention,, housingA combustion apparatus comprising a combustor for heating a fluid to be heated and an exhaust port for discharging combustion gas generated in the combustor, wherein a louver body is provided for regulating a flow direction of the combustion gas toward the exhaust port, the louver body comprising an outer frame portion forming an outer shell of the louver body, a plurality of long plate-like vane portions arranged at intervals inside the outer frame portion, and the louver body penetrating in the thickness direction of the louver body. an opening positioned between a plurality of long plate-shaped vanes and through which the combustion gas passes;projecting inwardly of the outer frame,a connecting portion connecting between the outer frame portion and the blade portion, wherein the outer frame portion, the blade portion and the connecting portion are integrally formed,The connecting portion has a bent portion between an outer frame boundary portion SL that is a boundary portion between the connecting portion and the outer frame portion and a blade boundary portion HL that is a boundary portion between the connecting portion and the blade portion,The blade portion has a pair of folded portions formed by folding back toward the same plane so that both edges forming the long sides face each other,The folded portion on the side of the exhaust port is formed longer in the long side direction than the folded portion on the side opposite to the exhaust port,The blade portion is inclined upward toward the exhaust port, and the surface with the folded portion faces the exhaust port side.

In a second aspect of the present invention, there is provided a method for manufacturing a combustion apparatus, wherein, in a manufacturing process of a louver body provided in the combustion apparatus and regulating the flow direction of combustion gas toward an exhaust port through which the combustion gas is discharged to the outside, an outer frame portion forming an outline of the louver body, a plurality of long plate-shaped blade portions provided inside the outer frame portion, an opening formed through the thickness direction of the louver body and positioned between the plurality of long plate-shaped blade portions,protruding inward of the outer frame portion and having a bent portion;A punching step of punching a flat plate member to integrally form a connecting portion connecting between the outer frame portion and the blade portion, and forming a long side of the blade portion.One edge on the side closer to the connecting part and the other on the side farther from the connecting part that forms the long side of the blade part and is longer in the long side direction than the one end edgeedgesandAn outer frame boundary portion that is a boundary portion between the connecting portion and the outer frame portion.SLand a blade boundary portion that is a boundary portion between the connecting portion and the blade portionHLestablished betweenSaidand a bending step of bending with the bent part as a fulcrum so that the blade part is inclined upward toward the exhaust port and the surface with the folded part faces the exhaust port side.

According to claim 1 of the present invention, the outer frame portion, the blade portion, and the connecting portion, which constitute the louver body, are integrally formed of the same material without being joined by welding or joined by a fastening member. In other words, since the louver body does not need to be constructed by combining separate members, and is formed integrally, it is possible to suppress an increase in the number of parts and the number of assembly man-hours, suppress an increase in manufacturing costs, and eliminate the risk of rattling because members are not assembled together.

Further, the blade part is folded back toward the same plane so that both edges forming the long sides of the blade part face each other to form a pair of folded parts, and the blade part in a state where both edges forming the long sides are folded upwards toward the exhaust port, and the surface with the folded parts faces the exhaust port side. Then, in the flow direction (front-rear direction) of the combustion gas, the position of the end of the blade on the most upstream side in the flow direction of the combustion gas and the position of the end of the blade on the most downstream side in the flow direction of the combustion gas are the folded portions of the folded portion. There is. Furthermore, in the blade portion, the surface with the folded portion faces the exhaust port side, and the combustion gas is less likely to hit the surface with the folded portion, so the combustion gas is less likely to hit the angular edge at the tip of the folded portion, the generation of wind noise can be suppressed, and the noise accompanying the blowing out of the combustion gas can be extremely reduced.

Further, according to claim 2, it is possible to manufacture a combustion device equipped with a louver body that can be integrally formed from the same material, that can suppress the generation of wind noise, and that greatly reduces the noise associated with blowing out combustion gas.

BRIEF DESCRIPTION OF THE DRAWINGS The perspective view which shows the combustion apparatus of one Embodiment of this invention. The schematic block diagram which shows the combustion apparatus of the same embodiment. Principal part perspective view. Principal part exploded perspective view. The perspective view which shows a louver body. The front view which shows a louver body. AA sectional drawing of a louver body. The figure which shows the flat plate-shaped louver body before bending each part. FIG. 4 is a view showing a folded portion or a bent portion of a flat louver body; The figure explaining the folding process which is a manufacturing process of a louver body. The figure explaining the bending process which is a manufacturing process of a louver body. FIG. 4 is a view for explaining the flow of combustion gas with respect to blades that constitute the louver body;

Next, a combustion device according to one embodiment of the present invention will be described with reference to the drawings.

Reference numeral 1 denotes a water heater as a combustion device of this embodiment, 2 a housing of the water heater 1, and 3 a burner as a combustor accommodated in the housing 2 and heating a fluid (water) to be heated. Here, the burner 3 is of a back-burning type that uses petroleum, gas, or the like as fuel and generates a flame downward.

4 is a blower that supplies combustion air to the burner 3, 5 is a combustion chamber formed below the burner 3, and 6 is provided in the combustion chamber 5 and recovers the heat of the combustion gas generated by the combustion of the burner 3. A heat exchanger of the fin tube type.

An exhaust collecting chamber 7 communicates with the combustion chamber 5 , is located downstream of the combustion chamber 5 in the flow direction of the combustion gas, and is arranged below the heat exchanger 6 . The exhaust collecting chamber 7 extends in the left-right direction, and is connected to the heat exchanger 6 on one side and to a silencer chamber 8 as a combustion gas circulation member on the other side.

The noise reduction chamber 8 is provided with a sound absorbing material inside to reduce the noise of the combustion gas generated by the combustion of the burner 3, communicates with the exhaust collection chamber 7, is located downstream of the exhaust collection chamber 7 in the flow direction of the combustion gas, and is arranged above the exhaust collection chamber 7. The muffling chamber 8 extends vertically and has a combustion gas passage port 9 for discharging combustion gas at its upper portion. In this embodiment, the noise reduction chamber 8 is arranged as the combustion gas circulation member, but instead of the noise reduction chamber 8, a latent heat exchanger for recovering latent heat from the combustion gas may be arranged as the combustion gas circulation member.

Reference numeral 10 denotes an exhaust top provided with an exhaust port 11 for discharging combustion gas generated by the burner 3 to the outside. The louver body 12 is attached to the front wall of the muffling chamber 8, positioned on the front side of the combustion gas passage 9 so as to cover the combustion gas passage 9, and regulates the flow direction of the combustion gas toward the exhaust port 11. Cover body 13 has exhaust port 11 for discharging combustion gas to the outside of water heater 1 . Also, the cover body 13 is attached to the front wall of the muffling chamber 8 and positioned on the front side of the louver body 12 so as to cover the louver body 12 . The louver body 12 and the cover body 13 are attached to the front wall of the noise reduction chamber 8 by an appropriate method such as screwing or welding.

14 is a water supply pipe, and 15 is a hot water supply pipe for supplying hot water to a hot water supply valve (not shown) outside the equipment of the water heater 1 .

The water supply from the water supply pipe 14 is introduced into the heat exchanger 6, where it is heat-exchanged with the high-temperature combustion gas generated by the combustion of the burner 3 in the heat exchanger 6, and is supplied from the hot water supply valve via the hot water supply pipe 15 at the hot water supply temperature set by the user.

Combustion gas generated by the combustion of the burner 3 flows downward in the combustion chamber 5 and passes through the heat exchanger 6 due to the blowing force of the blower 4 . Then, the combustion gas that has passed downward through the heat exchanger 6 is U-turned from downward to upward in the exhaust collection chamber 7, flows upward into the noise reduction chamber 8, passes through the noise reduction chamber 8, and is discharged from the exhaust port 11 through the exhaust top 10 to the outside of the equipment.

Next, details of the louver body 12 will be described with reference to FIGS. 5 to 7. FIG.
The louver body 12 has an outer frame portion 16 forming the outer shell of the louver body 12 . The outer frame portion 16 is composed of an upper frame 16a, a lower frame 16b, a left frame 16c and a right frame 16d.

The louver body 12 has a plurality of long plate-like vane portions 17 arranged inside the outer frame portion 16 and spaced apart from each other in the vertical direction (vertical direction). The blade portion 17 is inclined upward toward the exhaust port 11 of the cover body 13 located on the front side, and blows out the combustion gas obliquely upward to the outside. Further, the blade portion 17 has a pair of folded portions 18 that are formed by folding back toward the same plane so that both edges forming the long sides face each other. The surface with the folded portions 18 faces the exhaust port 11 side, and as shown in FIG.

The louver body 12 is formed so as to penetrate the louver body 12 in the thickness direction (front-rear direction) of the louver body 12, and has openings 19 positioned between a plurality of vanes 17 and through which combustion gas passes. A plurality of openings 19 are formed in the same direction as the arrangement direction (vertical direction) of the blades 17 .

The louver body 12 has a connecting portion 20 connecting between the outer frame portion 16 and the blade portion 17 . One end side of the connecting portion 20 is connected to the outer frame portion 16 (the left frame 16c or the right frame 16d), and the other end side is connected to the blade portion 17. The connecting portion 20 is provided on both sides of each blade portion 17 so as to form a pair. In the present embodiment, the boundary portion between the connecting portion 20 and the outer frame portion 16 (left frame 16c or right frame 16d) is referred to as an outer frame boundary portion SL (see FIG. 10), the boundary portion between the connecting portion 20 and the blade portion 17 is referred to as a blade boundary portion HL (see FIG. 10), and the connecting portion 20 has a bent portion 21 between the outer frame boundary portion SL and the blade boundary portion HL.

The outer frame portion 16, the blade portion 17, and the connecting portion 20 described above are integrally formed of the same material (here, the same metal plate) without being joined by welding or joined by a fastening member.

Next, the manufacturing process of the louver body 12 in the manufacturing method of the water heater 1 will be described with reference to FIGS. 8 to 11 as well. In FIG. 8, in order to clearly distinguish between portions where members exist and portions where members do not exist, portions where members exist are hatched with two-dot chain lines. That is, in FIG. 8, the outer frame portion 16, the blade portion 17, and the connecting portion 20 are hatched.

The manufacturing process of the louver body 12 includes a punching process, a folding process, and a bending process. As shown in FIG. 8, the punching process is a process for integrally forming the outer frame portion 16, the wing portions 17, the opening portions 19, and the connecting portions 20 by punching out a metal plate as a flat plate member that serves as the base material of the louver body 12. After the punching process is performed, the folding process is performed.

FIG. 9 shows the flat plate-like louver body 12 before folding or folding at each location, and the portions to be folded or folded are indicated by dashed lines, and reference numerals other than the folded portion OL and the folded portion ML are omitted for the sake of clarity of the drawing.

The folding step includes a step of folding back 180° both edges forming the long side of each blade portion 17, a step of folding 180° the lower edge of the upper frame 16a adjacent to the uppermost opening 19, and a step of folding 180° the upper edge of the lower frame 16b adjacent to the opening 19 formed at the lowest position.

In the process of folding the blades 17, all the blades 17 are folded at both ends forming the long sides of the blades 17. However, in order to simplify the description and drawings, the folding process of the blades 17 will be explained based on FIG.

In the flat plate-shaped louver body 12 after the punching process is performed, in the folding process of the blade part 17, the upper edge and the lower edge forming the long side of the blade part 17 are folded back at 180° so as to face the same plane (the downstream side of the combustion gas flow direction where the exhaust port 11 exists) so that the both edges face each other at the folded part OL. Although the description based on the drawings is omitted, the lower edge of the upper frame 16a and the upper edge of the lower frame 16b are also subjected to the folding process, and the lower edge of the upper frame 16a and the upper edge of the lower frame 16b are each folded back 180° toward the downstream side in the flow direction of the combustion gas where the exhaust port 11 exists. After the folding process is performed, the bending process is performed.

The bending process includes a bending process in which the blades 17 are bent at the bent parts 21 provided in the connecting part 20 as fulcrums so that the blade parts 17 with both long side edges folded back form an upward inclination toward the exhaust port 11, and a bending process in which the outer frame part 16 (upper frame 16a, lower frame 16b, left frame 16c, right frame 16d) is bent.

In the bending process at the bent portion 21 of the connecting portion 20, all the blade portions 17 are inclined upward toward the exhaust port 11, but in order to simplify the description and drawings, the bending process at the bent portion 21 of the connecting portion 20 will be described based on FIG.

In the louver body 12 after execution of the folding process, in the bending step at the bent portion 21 of the connecting portion 20, the bending portion 21 provided between the outer frame boundary portion SL, which is the boundary portion between the connecting portion 20 and the outer frame portion 16 (left frame 16c or right frame 16d), and the blade boundary portion HL, which is the boundary portion between the connecting portion 20 and the blade portion 17, is used as a fulcrum. side), the entire blade portion 17 is inclined upward toward the exhaust port 11, and the surface with the folded portion 18 is directed toward the exhaust port 11 side.

Here, the flow of the combustion gas to the vane portion 17 will be described with reference to FIG. 12 .
FIG. 12(a) shows an enlarged sectional view of the blade portion 17 of the present embodiment (sectional view taken along line BB in FIG. 11), and FIG. 12(b) shows an enlarged sectional view of the blade portion 170 of the comparative example.

In the present embodiment shown in FIG. 12(a), the position of the end R of the blade portion 17 on the most upstream side in the flow direction of the combustion gas in the combustion gas flow direction (front-rear direction) is exactly the folded portion of the folded portion 18, and that portion has a curved surface. In the portion 170, the position of the end portion of the blade portion 170 on the most upstream side in the flow direction of the combustion gas is an angular surface, and the position of the end portion of the blade portion 170 on the most downstream side in the flow direction of the combustion gas is also an angular surface.

Then, in the comparative example, when the combustion gas passes through the blade portion 170, a large wind noise is generated at the end portion of the blade portion 170 surrounded by the dashed circle in the drawing. However, in the present embodiment, the end portion R of the blade portion 17 is a curved surface. Very little noise is involved. Furthermore, in the present embodiment, the surface of the blade portion 17 with the folded portion 18 faces the exhaust port 11 side. Considering the direction in which the combustion gas flows, the combustion gas hits the surface of the blade portion 17 opposite to the surface on which the folded portion 18 is provided, but the combustion gas is less likely to hit the surface on which the folded portion 18 is provided.

The bending process of bending the outer frame portion 16 (upper frame 16a, lower frame 16b, left frame 16c, right frame 16d) will not be described with reference to the drawings, but the bending process of the upper frame 16a consists of bending the bending portion ML at the boundary between the upper frame 16a and the left frame 16c shown in FIG. 9 and the bending portion ML at the boundary between the upper frame 16a and the right frame 16d shown in FIG. In addition, the bent portion ML at the intermediate position of the upper frame 16a is bent at a right angle by a valley fold. In the step of bending the lower frame 16b, the bent portion ML at the boundary between the lower frame 16b and the left frame 16c and the bent portion ML at the boundary between the lower frame 16b and the right frame 16d shown in FIG. In the step of bending the left frame 16c, the boundary portion between the left frame 16c and the connecting portion 20 shown in FIG. 9, that is, the boundary portion SL of the outer frame is used as the bent portion ML, and the bent portion ML is bent at an acute angle to the extent that the mountain fold does not reach a right angle. In the step of bending the right frame 16d, the boundary portion between the right frame 16d and the connecting portion 20 shown in FIG. 9, i.e., the outer frame boundary portion SL is used as the bent portion ML, and the bent portion ML is bent at an acute angle to the extent that the mountain fold does not reach a right angle. The louver body 12 shown in FIGS. 5 and 6 is completed from the flat plate member serving as the base material of the louver body 12 through the punching process, folding process, and bending process described above.

According to the embodiment described above, in the water heater 1 provided with the burner 3 that is housed in the housing 2 and heats the fluid to be heated, and the exhaust port 11 that discharges the combustion gas generated by the burner 3 to the outside, the louver body 12 that regulates the flow direction of the combustion gas toward the exhaust port 11 is provided. The louver body 12 includes an outer frame portion 16 that forms the outline of the louver body 12, a plurality of long plate-shaped vane portions 17 that are vertically spaced apart from each other inside the outer frame portion 16, an opening 19 that penetrates the louver body 12 in the thickness direction thereof and is positioned between the plurality of long plate-shaped vane portions 17 and through which combustion gas passes, and which connects the outer frame portion 16 and the vane portions 17. and a connecting portion 20 . The outer frame portion 16, the blade portion 17, and the connecting portion 20 are integrally formed, and the blade portion 17 has a pair of folded portions 18 formed by folding back toward the same plane so that both ends forming the long sides face each other, the blade portion 17 is inclined upward toward the exhaust port 11, and the surface with the folded portions 18 faces the exhaust port 11 side.

Further, in the manufacturing method of the water heater 1, in the manufacturing process of the louver body 12 provided in the water heater 1 and regulating the flow direction of the combustion gas toward the exhaust port 11 for discharging the combustion gas to the outside, the outer frame portion 16 forming the outline of the louver body 12, the plurality of long plate-shaped blade portions 17 provided inside the outer frame portion 16, and the opening portion 1 formed penetrating in the thickness direction of the louver body 12 and positioned between the plurality of long plate-shaped blade portions 17. 9 and the connecting portion 20 connecting between the outer frame portion 16 and the blade portion 17 are formed integrally by punching out a flat plate member; a folding step of forming a pair of folded portions 18 by folding toward the same plane so that both edges forming the long sides of the blade portion 17 face each other; a bending step of bending the connecting part 20 so that the entire blade part 17 is inclined upward toward the exhaust port 11 with the bending part 21 as a fulcrum, and the surface with the pair of folding parts 18 faces the exhaust port 11 side.

According to these, the outer frame portion 16, the blade portion 17, and the connecting portion 20, which constitute the louver body 12, are integrally formed of the same material (here, a metal plate) without being joined by welding or joined by a fastening member. That is, since the louver body 12 does not need to be constructed by assembling separate members and is formed integrally, it is possible to suppress an increase in the number of parts and the number of assembly man-hours, suppress an increase in the manufacturing cost, and eliminate the risk of rattling because the members are not assembled together.

Further, the blade portion 17 is folded toward the same plane so that both edges forming the long sides of the blade portion 17 face each other to form a pair of folded portions 18. The blade portion 17 in a state in which both edges forming the long sides are folded upward slopes toward the exhaust port 11, and the surface with the folded portions 18 faces the exhaust port 11 side. Then, in the flow direction (front-rear direction) of the combustion gas, the position of the end R of the blade portion 17 on the most upstream side in the flow direction of the combustion gas and the position of the end R of the blade portion 17 on the most downstream side in the flow direction of the combustion gas are the folded portions of the folded portion 18, and the portions are curved surfaces. Therefore, it is possible to extremely reduce the noise caused by blowing out the combustion gas. Furthermore, in the blade portion 17, the surface of the folded portion 18 faces the exhaust port 11 side, and when considering the direction of combustion gas flow, the combustion gas is less likely to hit the surface of the folded portion 18. Therefore, it is difficult for the combustion gas to hit the angular edge at the tip of the folded portion 18, the occurrence of wind noise can be suppressed, and the noise accompanying the blowing out of the combustion gas can be extremely reduced.

In addition, the present invention is not limited to one embodiment, and in this embodiment, the present invention is applied to the hot water supply system 1 as a combustion device provided with the exhaust port 11 for discharging the combustion gas generated by the burner 3 to the outside. However, the present invention may be applied to a heating device as a combustion device provided with the exhaust port 11 for discharging the combustion gas generated by the burner 3 to the outside.

1 hot water supply device 2 housing 3 burner 11 exhaust port 12 louver body 16 outer frame portion 17 vane portion 18 pair of folded portions 19 opening 20 connecting portion 21 folded portion

Claims (2)

A combustion apparatus comprising: a combustor housed in a housing for heating a fluid to be heated; and an exhaust port for discharging combustion gas generated by the combustor to the outside,
providing a louver body for regulating the flow direction of the combustion gas toward the exhaust port;
The louver body is
an outer frame portion forming an outer shell of the louver body;
a plurality of long plate-shaped blades arranged inside the outer frame and spaced apart from each other;
an opening formed through the louver body in the thickness direction thereof, positioned between a plurality of long plate-shaped vanes, and through which the combustion gas passes;
a connecting portion that protrudes inward from the outer frame portion and connects between the outer frame portion and the blade portion;
The outer frame portion, the blade portion and the connecting portion are integrally formed,
The connecting portion has a bent portion between an outer frame boundary portion SL that is a boundary portion between the connecting portion and the outer frame portion and a blade boundary portion HL that is a boundary portion between the connecting portion and the blade portion,
The blade part has a pair of folded parts formed by folding back toward the same plane so that both edges forming the long side face each other,
The folded portion on the side of the exhaust port is formed longer in the long side direction than the folded portion on the side opposite to the exhaust port,
A combustion apparatus according to claim 1, wherein the blade portion is inclined upward toward the exhaust port, and a surface having the folded portion faces the exhaust port side. A method of manufacturing a combustion device, comprising:
In the manufacturing process of the louver body provided in the combustion apparatus and regulating the flow direction of the combustion gas toward the exhaust port for discharging the combustion gas to the outside,
a punching step of punching out a flat plate member to integrally form an outer frame portion that forms the outline of the louver body, a plurality of long plate-shaped blade portions provided inside the outer frame portion, an opening formed through the thickness direction of the louver body and positioned between the plurality of long plate-shaped blade portions, and a connecting portion that protrudes inward from the outer frame portion and has a bent portion that connects the outer frame portion and the blade portion;
a folding step of folding back toward the same plane so that one end edge of the long side of the wing portion near the connecting portion and the other end edge of the long side of the wing portion, which is longer in the long side direction than the one end edge and farther from the connecting portion, face each other ;
a bending step of bending around the bent portion provided between the outer frame boundary portion SL , which is the boundary portion between the connecting portion and the outer frame portion, and the blade boundary portion HL , which is the boundary portion between the connecting portion and the blade portion, so that the blade portion is inclined upward toward the exhaust port and the surface with the folded portion faces the exhaust port side;
A method of manufacturing a combustion device, comprising:

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