JP7380852B2 - Manufacturing method for resin molding mold and hot water storage tank unit - Google Patents

Description

The present disclosure relates to a resin molding mold, a method for manufacturing a hot water storage tank unit using the resin molding mold, and a hot water storage tank unit.

Conventionally, a heat insulating member used in a hot water storage tank unit of a hot water storage type water heater is formed by being divided into a plurality of parts each having a shape according to the external shape of the hot water storage tank, and is attached around the hot water storage tank. The heat insulating member is formed of a foamed heat insulating material such as rigid polyurethane foam or expanded polystyrene, and is foam-molded using a resin molding mold consisting of an upper mold and a lower mold (for example, see Patent Document 1).

Japanese Patent Application Publication No. 2008-107015

However, in the conventional manufacturing method of heat insulating members using a resin mold, gas is trapped in the upper part of the cavity of the resin mold when the heat insulating member is foam-molded, and the resin material covers the entire cavity. There was a problem that it did not spread and had poor moldability.

The present disclosure has been made to solve the above-mentioned problems, and provides a resin molding mold and hot water storage in which a resin material can be spread throughout the cavity of the resin molding mold and the moldability of a heat insulating member is improved. The purpose is to obtain tank units.

A resin molding mold according to the present disclosure includes a lower mold having a recess and a first outer edge that is an outer edge of the recess, and a convex part that can be accommodated in the recess and a second outer edge that is an outer edge of the convex part. A resin molding mold for foam-molding an insulating resin member, comprising an upper mold, in which when the upper mold is closed to the lower mold, a second outer edge comes into contact with the first outer edge, A convex portion is housed within the concave portion to form a cavity, and a plurality of concave surfaces functioning as air vents are formed on at least the first outer edge, and each of the plurality of concave surfaces functioning as an air vent is located at the top of the cavity. and the outside of the resin molding mold, and the width of the recessed surfaces is larger than the interval between the recessed surfaces.

The resin molding die according to the present disclosure has the effect of improving moldability in foam molding of a heat insulating member.

The hot water storage tank unit according to the present disclosure has the effect that the heat insulation performance of the entire hot water storage tank unit can be improved by improving the moldability of the heat insulation member.

1 is a perspective view showing a hot water storage type water heater including a hot water storage tank unit according to a first embodiment; FIG. 1 is a circuit diagram of a hot water storage type water heater equipped with a hot water storage tank unit according to a first embodiment; FIG. 1 is a perspective view showing a hot water storage tank unit of Embodiment 1. FIG. 1 is a sectional view showing a hot water storage tank unit of Embodiment 1. FIG. FIG. 2 is a perspective view showing a foamed heat insulating member of the hot water tank unit of Embodiment 1. FIG. 2 is a cross-sectional view showing a foamed heat insulating member of the hot water tank unit of Embodiment 1. FIG. 2 is a perspective view showing a resin molding die for molding the front body heat insulating member of the first embodiment. FIG. 2 is a plan view showing a resin molding die for molding the front body heat insulating member of the first embodiment. FIG. 2 is a perspective view for explaining a method of manufacturing the hot water tank unit of Embodiment 1. FIG. FIG. 3 is a cross-sectional view for explaining a method of manufacturing a hot water storage tank unit using a resin molding die for molding the front body heat insulating member of the first embodiment. FIG. 3 is a schematic diagram showing a front body heat insulating member molded using the resin molding die of Embodiment 1. FIG. FIG. 2 is a plan view showing a resin molding die for molding the upper heat insulating member of the first embodiment. FIG. 3 is a cross-sectional view for explaining a method of manufacturing a hot water storage tank unit using a resin molding die for molding the upper heat insulating member of Embodiment 1. FIG. FIG. 2 is a schematic diagram showing an upper heat insulating member molded using the resin molding die of Embodiment 1. FIG. FIG. 7 is a perspective view showing a modification of the foamed heat insulating member of the hot water storage tank unit of Embodiment 1; FIG. 7 is a plan view showing a modification of the resin molding die for molding the front body heat insulating member of Embodiment 1; FIG. 7 is a plan view showing a first modification of the resin molding die for molding the upper heat insulating member of the first embodiment. FIG. 7 is a plan view showing a second modification of the resin molding die for molding the upper heat insulating member of Embodiment 1; FIG. 7 is a perspective view showing a resin molding die for molding the front body heat insulating member of Embodiment 2; FIG. 7 is a plan view showing a resin molding die for molding the front body heat insulating member of Embodiment 2; FIG. 7 is a cross-sectional view for explaining a method of manufacturing a hot water storage tank unit using a resin molding die for molding a front body heat insulating member according to a second embodiment. FIG. 7 is a perspective view showing a resin molding die for molding the front body heat insulating member of Embodiment 3; FIG. 7 is a plan view showing a resin molding die for molding the front body heat insulating member of Embodiment 3; FIG. 7 is a cross-sectional view for explaining a method of manufacturing a hot water storage tank unit using a resin molding die for molding a front body heat insulating member according to a third embodiment.

Embodiments will be described below based on the drawings. In the following drawings, the same or corresponding parts are denoted by the same reference numerals, and the description thereof will not be repeated. Furthermore, in the following description, the term "water" basically means liquid water, and may include anything from low-temperature water to high-temperature hot water.

Embodiment 1.
A resin molding mold of Embodiment 1, a method for manufacturing a hot water storage tank unit using the resin molding mold, and a hot water storage tank unit will be described with reference to FIGS. 1 to 11.

First, the overall configuration of a hot water storage type water heater including a hot water storage tank unit according to Embodiment 1 will be described using FIGS. 1 and 2. FIG. 1 is a perspective view showing a hot water storage type water heater 1000 including a hot water storage tank unit 100 of the present embodiment, and FIG. 2 is a circuit diagram of the hot water storage type water heater 1000.

As shown in FIGS. 1 and 2, the hot water storage type water heater 1000 includes a heat pump unit 110 as a heating means for heating water, and a hot water storage tank unit 100 for storing and supplying water heated by the heat pump unit 110. Equipped with. The heat pump unit 110 and the hot water storage tank unit 100 are connected via a heat pump outgoing pipe 21, a heat pump return pipe 22, and electrical wiring (not shown). Note that in FIG. 1, illustration of the heat pump outgoing pipe 21 and the heat pump return pipe 22 is omitted.

As shown in FIG. 2, the hot water storage tank unit 100 includes a hot water storage tank 10 for storing water, a pressure reducing valve 23 as a functional valve for performing various functions such as boiling, hot water supply, and filling of hot water by the hot water storage type water heater 1000; It includes a relief valve 24, a mixing valve 25, a switching valve 26, and a check valve 27. A cold water pipe 28 is connected to the lower part of the hot water storage tank 10 to which water is supplied from a water source such as city water.

Water stored in the lower part of the hot water storage tank 10 is sent to the heat pump unit 110 via the heat pump piping 21 by the heat source pump 29. The water heated to a high temperature by the heat pump unit 110 using the heat in the atmosphere is returned to the upper part of the hot water storage tank 10 through the heat pump return pipe 22 and stored therein.

Since the temperature inside the hot water storage tank 10 increases from the bottom to the top, water with a temperature distribution of low temperature, medium temperature, and high temperature is stored in layers from the bottom to the top inside the hot water storage tank 10. A plurality of temperature sensors 30 are provided vertically on the outer surface of the hot water storage tank 10 to measure the temperature of the water in the hot water storage tank 10. As the temperature sensor 30, for example, a thermistor is used.

The heat pump unit 110 is a heating unit that heats low-temperature water sent from the hot water storage tank 10 to a high temperature. The heat pump unit 110 includes a compressor that compresses a refrigerant such as carbon dioxide (CO ₂ ) to high temperature and high pressure, and condenses the refrigerant discharged from the compressor and exchanges heat with low-temperature water sent from the hot water storage tank 10. It is equipped with a condenser that heats water with heat of condensation, a pressure reducing valve that reduces the pressure of the refrigerant from the condenser, and an evaporator that absorbs heat from the atmosphere and evaporates the reduced pressure refrigerant. Note that illustration of the internal configuration of the heat pump unit 110 is omitted.

Water heated by the heat pump unit 110 and stored in the hot water storage tank 10 is taken out from the upper part of the hot water storage tank 10, passed through the hot water pipe 31, and sent to the mixing valve 25, and is then fed from the branch water supply pipe 32 branched from the cold water pipe 28. After being mixed with water at a mixing valve 25 to a desired temperature, the water is used by being supplied with hot water through a hot water supply pipe 33 from a hot water supply terminal 34 such as a faucet or shower.

Next, the structure of the hot water storage tank unit 100 will be explained using FIGS. 3 to 6. 3 is a perspective view showing the hot water storage tank unit 100, and FIG. 4 is a sectional view showing the hot water storage tank unit 100. In addition, in FIG. 3, a part of the exterior case 50 of the hot water storage tank unit 100 shown in FIG. 1 is omitted, and the interior accommodated in the exterior case 50 is mainly shown. 5 is a perspective view for explaining the foam insulation member 40 of the hot water storage tank unit 100, and FIG. 6 is a sectional view taken along line AA in FIG.

In addition to the hot water storage tank 10 (not shown in FIG. 3) described in FIG. 2, the hot water storage tank unit 100 includes a foam insulation member 40 provided to cover the hot water storage tank 10, a foam insulation member 40, and the hot water storage tank. 10, and a leg portion 60 provided below the exterior case 50.

The exterior case 50 accommodates the hot water storage tank 10 and the foamed heat insulating member 40 therein, and is provided for the purpose of improving the design of the device, protecting the hot water storage tank 10, and insulating the hot water storage tank 10. The exterior case 50 is made of, for example, a thin steel plate or a weather-resistant and flame-retardant resin.

As shown in FIG. 1, the exterior case 50 includes a front panel 51 that is located in front of the hot water storage tank 10 and can be opened and closed for maintenance, etc., and an exterior outside of the hot water storage tank unit 100 for water supply, hot water supply, heat pump, and return to and from the bathtub. A recessed plate 52 for connecting piping, two side plates 53 and 54 located on the sides of the hot water storage tank 10, a back plate 55 located at the rear of the hot water storage tank 10, and a top plate located above the hot water storage tank 10. The face plate 56 and the bottom plate 57 located below the hot water storage tank 10 form a vertically elongated box shape with respect to the height direction of the hot water storage tank unit 100. The front plate 51, the recessed plate 52, the side plates 53, 54, the back plate 55, the top plate 56, and the bottom plate 57 are joined at necessary points by fitting or bolting, thereby forming the exterior case 50. has been done.

The legs 60 are fixedly provided inside the exterior case 50 by an internal leg provided below the hot water storage tank 10 and an external leg attached below the bottom plate 57 of the exterior case 50. I support it. In this embodiment, as shown in FIG. 3, an example is shown in which three leg portions 60 are provided.

As shown in FIG. 4, the hot water storage tank 10 includes a body plate 11 formed in a cylindrical shape using a material such as stainless steel, and a curved upper part having a bowl-shaped curvature that covers the upper opening of the body plate 11. It is constructed by welding three members consisting of a plate 12 and a lower curved plate 13 having a bowl-shaped curvature that covers the lower opening of the body plate 11. The upper curved plate 12 and lower curved plate 13 of the hot water storage tank 10 are provided with joints 12a and 13a for connecting the cold water pipe 28 and the hot water pipe 31.

The foamed heat insulating member 40 is provided to cover the periphery of the hot water storage tank 10, and as shown in FIGS. 4 and 5, it includes an upper heat insulating member 41, a front body heat insulating member 42, a rear body heat insulating member 43, and a lower body heat insulating member. It is composed of 44 divided heat insulation members.

The upper heat insulating member 41 and the lower heat insulating member 44 are provided to cover the upper curved plate 12 and lower curved plate 13, respectively, which have a bowl-shaped curvature of the hot water storage tank 10, and have an inner surface shape that is bowl-shaped. It has a curved surface. Further, as shown in FIG. 4, the upper heat insulating member 41 and the lower heat insulating member 44 may have a structure in which a part of the hot water storage tank 10 is exposed in order to connect pipes to the joints 12a and 13a.

The front body heat insulating member 42 and the rear body heat insulating member 43 have a cylindrical shape, that is, a cross section, by the front body heat insulating member 42 and the rear body heat insulating member 43, as shown in FIG. It is formed to cover the circular body plate 11 when viewed, and the line BB is the dividing position of the two divided heat insulating members. The front body insulation member 42 is provided to cover the front side of the hot water storage tank 10 , and the rear body insulation member 43 is provided to cover the rear side of the hot water storage tank 10 . Note that the front and rear directions of the hot water storage tank 10 are not limited to the directions described in this embodiment.

In addition, the upper heat insulating member 41, the front body heat insulating member 42, the rear body heat insulating member 43, and the lower heat insulating member 44 are divided into contacting divided heat insulating members that are in contact with each other at the split surfaces that are the contact surfaces with other split heat insulating members. A plurality of burrs are formed on at least one of them. The dividing plane is, for example, the plane at the dividing position shown by line BB in FIG. 6, and in FIG. are in contact with each other. Note that details regarding the burr will be described later when the method for manufacturing the foamed heat insulating member 40 is explained.

The thickness of the four divided heat insulating members, the upper heat insulating member 41, the front heat insulating member 42, the rear heat insulating member 43, and the lower heat insulating member 44, is determined in consideration of ease of installation around the hot water tank 10. , is preferably formed to have a length of 1 mm or more and 400 mm or less.

In addition, since various necessary members are attached to the upper heat insulating member 41, the front body heat insulating member 42, the rear body heat insulating member 43, and the lower heat insulating member 44 from the outside, as shown in FIG. It has an uneven shape. Note that a divided heat insulating member that does not have an uneven shape on its surface may be used.

The foamed heat insulating member 40 has an upper heat insulating member 41, a front body heat insulating member 42, and a rear body heat insulating member 43 made of hard polyurethane foam, and a lower heat insulating member 44 made of expanded polystyrene. Since rigid polyurethane foam has low thermal conductivity, particularly excellent heat insulation performance can be obtained by using the foamed heat insulating member 40 formed of rigid polyurethane foam. Furthermore, as described above, since the lower part of the hot water storage tank 10 is at a low temperature, the lower heat insulating member 44 does not require as much insulation performance as the upper heat insulating member 41, the front body heat insulating member 42, and the rear body heat insulating member 43. In some cases. Therefore, by forming the lower heat insulating member 44 from styrene foam, which has greater mechanical strength than rigid polyurethane foam, the hot water storage tank 10 can be stably held.

In this embodiment, a case will be described in which the foamed heat insulating member 40 is formed of rigid polyurethane foam and expanded polystyrene; however, the invention is not limited to this, and the entire body may be formed of rigid polyurethane foam, or other materials may be used. It may also be formed using a foamed resin material.

Here, rigid polyurethane foam will be explained. Polyurethane foam has a cell structure and is classified into flexible polyurethane foam and rigid polyurethane foam. Among these, flexible polyurethane foam has an open cell shape with a torn cell membrane, and has a structure that allows heat to escape easily, so it has low insulation properties and is used in mattresses and car seats that require performance as an elastic body. It is used for. On the other hand, rigid polyurethane foam is used as a heat insulating material because it has a closed cell shape with unbroken cell membranes and has excellent strength and heat insulation properties. Therefore, when polyurethane foam is used as the material for the foamed heat insulating member 40 of this embodiment, it is limited to rigid polyurethane foam.

Next, the resin molding mold of Embodiment 1 and a method of manufacturing a hot water storage tank unit using the resin molding mold will be described with reference to FIGS. 7 to 14.

The configuration of the resin molding mold will be described below.

First, a resin molding die 500 for molding the front body heat insulating member 42 of the foam heat insulating member 40 as a resin member will be described with reference to FIGS. 7 and 8. FIG. 7 is a perspective view showing a resin molding die 500 for molding the front body heat insulating member 42 of this embodiment, and FIG. 8 is a plan view showing the resin molding die 500.

As shown in FIG. 7, the resin molding die 500 for molding the front body heat insulating member 42 consists of a lower mold 510 and an upper mold 520, and by closing the upper mold 520 to the lower mold 510, A resin material filled in a cavity surrounded by the lower mold 510 and the upper mold 520 can be molded.

The lower die 510 has a recess 512 surrounded by a first outer edge 511 . More specifically, the recessed portion 512 is a portion that is recessed from the first outer edge portion 511 of the lower mold 510. Further, the recess 512 has a shape obtained by dividing a substantially cylindrical shape into two in the height direction. Note that the surface forming the recess 512 is not limited to a curved surface or a flat surface, and may have unevenness.

The upper die 520 has a convex portion 522 surrounded by a second outer edge portion 521 . More specifically, the convex portion 522 is a portion provided to protrude from the second outer edge portion 521 of the upper die 520. Further, the convex portion 522 has a substantially cylindrical shape divided into two in the height direction. When the upper mold 520 is closed to the lower mold 510 and the first outer edge 511 and the second outer edge 521 touch and the convex part 522 is accommodated in the concave part 512, the relationship between the concave part 512 and the convex part 522 is A cavity 501 is formed in between. Note that the surface forming the convex portion 522 is not limited to a curved surface or a flat surface, and may have unevenness.

Here, the cavity 501 will be explained in detail. As shown in the cross-sectional view in FIG. 10, the cavity 501 is a region surrounded by the lower mold 510 and the upper mold 520 within the recess 512 of the lower mold 510. That is, the cavity 501 is formed only within the recess 512 of the lower mold 510 and is not formed on the upper mold 520 side. At the top of the cavity 501, there is an air vent extending in a horizontal direction perpendicular to the vertical direction, which is the direction in which gravity acts, and parallel to the surfaces of the first outer edge 511 and the second outer edge 521. 502 is provided, and the top of the cavity 501 and the outside of the resin molding mold 500 are communicated with each other by the air vent 502.

The first outer edge 511 of the lower mold 510 and the second outer edge 521 of the upper mold 520 are parts that face each other and partially contact when the upper mold 520 is closed to the lower mold 510. A plurality of recessed surfaces 513 and 523, which function as air vents, are formed at intervals at opposing positions of the upper mold 520 and the upper mold 520, respectively. As shown in FIG. 8(A) and FIG. 8(B), respectively, a plan view of the upper die 520 and a plan view of the lower die 510, the concave surfaces 513 and 523 have the same width, The distances between the concave surfaces 513 and 523 are the same.

Here, the air vent 502 will be explained in detail. As shown in FIG. 10, the air vent 502 is a portion where the first outer edge portion 511 and the second outer edge portion face each other with a space formed by the recessed surfaces 513 and 523 when the upper mold 520 is closed to the lower mold 510. It is formed at the top of the cavity 501. That is, the air vent 502 is formed by a plurality of concave surfaces 513 and 523, each having the same width. The air vent 502 communicates the top of the cavity 501 with the outside of the resin molding die 500. Therefore, the air vent 502 releases the gas present in the cavity 501 of the resin molding die 500 to the outside of the resin molding die 500. Further, as shown in FIG. 8, the cavity 501 formed in the recess 512 of the lower mold 510 is rectangular in plan view, and there are recesses at the four corners of the rectangle indicated by broken lines in FIG. 8(B). Since the surface 513 is provided, when the upper mold 520 is closed to the lower mold 510, an air vent 502 is formed that communicates the rectangular corner with the outside of the resin molding mold 500.

Next, details of the resin molding mold 600 for molding the upper heat insulating member 41 of the foamed heat insulating member 40 as a resin member will be described using FIG. 12. FIG. 12 is a plan view showing a resin molding die 600 for molding the upper heat insulating member 41 of this embodiment.

A resin molding mold 600 for molding the upper heat insulating member 41 includes an upper mold 620 shown in FIG. 12(A) and a lower mold 610 shown in FIG. 12(B). By closing, the resin material filled in the cavity surrounded by the lower mold 610 and the upper mold 620 can be molded.

The lower mold 610 has a recess 612 surrounded by a first outer edge 611, as shown in FIG. 12(B). More specifically, the recessed portion 612 is a portion that is recessed from the first outer edge portion 611 of the lower mold 610. Further, the recess 612 has a substantially circular bowl-like shape when viewed from above. Note that the surface forming the recess 612 is not limited to a curved surface or a flat surface, and may have unevenness.

The upper mold 620 has a convex portion 622 surrounded by a second outer edge portion 621, as shown in FIG. 12(A). More specifically, the convex portion 622 is a portion provided to protrude from the second outer edge portion 621 of the upper die 620. Further, the convex portion 622 is approximately circular in plan view and has a curved shape. When the upper mold 620 is closed to the lower mold 610 and the first outer edge 611 and the second outer edge 621 touch and the convex part 622 is accommodated in the concave part 612, the relationship between the concave part 612 and the convex part 622 is A cavity 601 is formed in between. Note that the surface forming the convex portion 622 is not limited to a curved surface or a flat surface, and may have unevenness.

Here, the cavity 601 will be explained in detail. As shown in a cross-sectional view in FIG. 13, the cavity 601 is a region surrounded by the lower mold 610 and the upper mold 620 within the recess 612 of the lower mold 610. That is, the cavity 601 is formed only in the recess 612 of the lower mold 610 and is not formed on the upper mold 620 side. At the top of the cavity 601, there is an air vent extending in a horizontal direction perpendicular to the vertical direction, which is the direction in which gravity acts, and parallel to the surfaces of the first outer edge 611 and the second outer edge 621. 602 is provided, and the top of the cavity 601 and the outside of the resin molding mold 600 are communicated with each other by the air vent 602.

The first outer edge 611 of the lower mold 610 and the second outer edge 621 of the upper mold 620 are parts that face each other and partially contact when the upper mold 620 is closed to the lower mold 610. A plurality of recessed surfaces 613 and 623, which function as air vents, are formed at intervals at opposing positions of the upper mold 620 and the upper mold 620, respectively. As shown in FIG. 12, the recessed surfaces 613 and 623 each have the same width, and the distances between adjacent recessed surfaces 613 and 623 are the same.

Here, the air vent 602 will be explained in detail. As shown in FIG. 13, the air vent 602 is a portion where a first outer edge portion 611 and a second outer edge portion 621 face each other with a space between concave surfaces 613 and 623 when the upper die 620 is closed to the lower die 610. It is formed at the top of the cavity 601. That is, the air vent 602 is formed by a plurality of concave surfaces 613 and 623, each having the same width. The air vent 602 communicates the top of the cavity 601 with the outside of the resin molding die 600. Therefore, the air vent 602 releases the gas present in the cavity 601 of the resin molding die 600 to the outside of the resin molding die 600.

Hereinafter, a method of manufacturing the hot water storage tank unit 100 using the resin molding molds 500, 600 described above will be described.

In the method for manufacturing the hot water storage tank unit 100, first, the hot water storage tank 10, the exterior case 50 that accommodates the hot water storage tank 10, and the resin molding molds 500 and 600 for forming the foamed heat insulating member 40 are prepared. Note that the hot water storage tank 10 has the structure described above.

Next, using a resin mold, the upper heat insulating member 41, the front body heat insulating member 42, the rear body heat insulating member 43, and the lower heat insulating member 44, which constitute the foam heat insulating member 40, are each foam-molded.

Here, a method for molding the front body heat insulating member 42 using the resin molding die 500 will be described in detail with reference to FIGS. 9 to 11. FIG. 9 is a perspective view for explaining a method of manufacturing a hot water storage tank unit 100 using a resin molding mold 500, and FIG. 10 is a perspective view for explaining a method of manufacturing a hot water storage tank unit 100 using a resin molding mold 500. FIG. Moreover, FIG. 11 is a schematic diagram showing the front body heat insulating member 42 molded using the resin molding die 500.

First, as shown in FIG. 9, a resin molding mold 500 is prepared, and while an injection head 900 for injecting resin is moved as shown by the arrow, a liquid mixture of resin is poured into a recess 512 of a lower mold 510. Inject the material. At this time, overpacking or overfilling is performed to fill an amount of resin material in an amount larger than the required amount obtained by multiplying the volume of the product shape by the free form density of the resin material, that is, the density after foaming under no load. .

After the resin material is injected into the recess 512 of the lower mold 510, the upper mold 520 is closed to the lower mold 510 and pressure is applied. Then, as shown in FIG. 10, the resin material 400 is foamed and filled into the cavity 501 between the upper mold 520 and the lower mold 510. At this time, the gas existing in the cavity 501 is released from the air vent 502 to the outside of the resin molding die 500 as the resin material 400 foams and fills the cavity 501 from the bottom to the top. be done. Since the resin material 400 is overfilled, the entire cavity 501 is filled, and then the air vent 502 formed by the upper mold 520, the lower mold 510, and the recessed surfaces 513 and 523 is also filled and hardened. .

Note that at this time, the gas in the cavity 501 is released to the outside of the resin molding mold 500 by a plurality of air vents 502 formed in communication with the top of the cavity 501, so there is no need to perform vacuuming. . Therefore, a mold having a simpler structure can be used.

After the front body heat insulating member 42 is molded as described above, it is taken out from the resin molding mold 500. The taken out front body heat insulating member 42 has a plurality of burrs 42b made of the resin material filled in the air vent 502 of the resin molding die 500, as shown in a schematic diagram in FIG. That is, the front body heat insulating member 42 has a plurality of burrs 42b on the dividing surface 42a in contact with the rear body heat insulating member 43. Further, since the air vent 502 has the same width, the plurality of burrs 42b also have the same width W. Further, the thickness H of the burr 42b shown in FIG. 10 is, for example, 1 mm or more and 20 mm or less.

When the periphery of the hot water storage tank 10 is covered using each divided heat insulation member, a part of the burr 42b protrudes parallel to the dividing surface 42a of the front body heat insulation member 42 to the opposite side of the hot water storage tank 10. This is the part formed by

Further, in the same manner, the rear body heat insulating member 43 can be foam-molded using a resin molding mold having the same configuration as the resin molding mold 500. Similarly to the front body heat insulating member 42, the rear body heat insulating member 43 also has a plurality of burrs formed in parallel to the opposite side of the hot water storage tank 10 along the dividing plane in contact with the front body heat insulating member 42.

Here, if the thickness of the burr is small, the burr 42b formed on the dividing surface 42a of the front body heat insulating member 42 and the burr formed on the dividing surface of the rear body heat insulating member 43 may be in contact with each other. Even if the split surfaces are aligned, the hot water storage tank 10 can be covered. In addition, in order to prevent the contact surfaces consisting of dividing surfaces and burrs from interfering with each other between the front body heat insulating member 42 and the rear body heat insulating member 43, the positions of the air vents are staggered in each resin molding mold. Alternatively, a structure may be provided in which burrs are alternately formed when the hot water tank is attached to the hot water storage tank.

Further, here, a method for molding the upper heat insulating member 41 using the resin molding mold 600 will be described in detail with reference to FIGS. 13 and 14. FIG. 13 is a cross-sectional view for explaining a method of manufacturing the hot water storage tank unit 100 using the resin molding die 600. Moreover, FIG. 14 is a schematic diagram showing the upper heat insulating member 41 molded using the resin molding die 600.

First, a resin molding mold 600 is prepared, and a resin material, which is a liquid mixture, is injected into the recess 612 of the lower mold 610 using an injection head for injecting resin. At this time, overpacking or overfilling is performed to fill an amount of resin material in an amount larger than the required amount obtained by multiplying the volume of the product shape by the free form density of the resin material, that is, the density after foaming under no load. .

After the resin material is injected into the recess 612 of the lower mold 610, the upper mold 620 is closed to the lower mold 610 and pressure is applied. Then, as shown in FIG. 13, the resin material 400 is foamed and filled into the cavity 601 between the upper mold 620 and the lower mold 610. At this time, the gas existing in the cavity 601 is released from the air vent 602 to the outside of the resin molding die 600 as the resin material 400 foams and fills the cavity 601 from the bottom to the top. be done. Since the resin material 400 is overfilled, the entire cavity 601 is filled, and then the air vent 602 formed by the upper mold 620, the lower mold 610, and the recessed surfaces 613 and 623 is also filled and hardened. .

Note that at this time, the gas inside the cavity 601 is released to the outside of the resin molding mold 600 by a plurality of air vents 602 formed in communication with the top of the cavity 601, so there is no need to draw a vacuum. . Therefore, a mold having a simpler structure can be used.

After the upper heat insulating member 41 is molded as described above, it is taken out from the resin molding mold 600. The taken-out upper heat insulating member 41 has a plurality of burrs 41b made of the resin material filled in the air vent 602 of the resin molding die 600, as shown in a schematic diagram in FIG. That is, the upper heat insulating member 41 has a plurality of burrs 41b on the dividing surface 41a that is in contact with the front body heat insulating member 42 and the rear body heat insulating member 43. Further, since the air vent 602 has the same width, the plurality of burrs 41b also have the same width. The thickness of the burr 41b is, for example, 1 mm or more and 20 mm or less.

The burr 41b is formed when a portion of the burr 41b protrudes parallel to the dividing surface 41a of the upper insulation member 41 to the opposite side of the hot water storage tank 10 when the periphery of the hot water storage tank 10 is covered using each divided insulation member. This is the part that was

Here, in the upper heat insulating member 41, the dividing surface in contact with the front torso heat insulating member 42 and the rear torso heat insulating member 43 is designed to align with the front torso heat insulating member 42 and the rear torso heat insulating member 43. A protruding portion may be formed that partially projects toward the front body heat insulating member 42 or the rear body heat insulating member 43 side. Then, a part of the dividing surface of the front body heat insulating member 42 or the rear body heat insulating member 43 corresponding to the protrusion is formed by being depressed, so that they are engaged and alignment becomes easy. Note that this protrusion is for facilitating alignment between the divided heat insulating members, and is formed to protrude beyond the thickness of the burr formed on the divided surface.

Further, in a similar manner, the lower heat insulating member 44 can be foam-molded using a resin molding die having a configuration similar to that of the resin molding die 600. Similarly to the upper heat insulating member 41, the lower heat insulating member 44 also has a plurality of burrs formed parallel to the opposite side of the hot water storage tank 10 along the dividing plane in contact with the front body heat insulating member 42 and the rear body heat insulating member 43. have

Note that the burr formed on each divided heat insulating member may be cut with the root portion remaining, if necessary. By doing so, it is possible to ensure ease of assembly of the divided foam insulation member 40 and reduce burr breakage due to contact with other parts, etc., thereby obtaining a hot water storage tank unit 100 with improved insulation properties. becomes possible.

After each divided heat insulating member is formed in this way, a foam heat insulating member 40 consisting of an upper heat insulating member 41, a front body heat insulating member 42, a rear body heat insulating member 43, and a lower body heat insulating member 44 is formed around the hot water storage tank 10. Attach. At this time, the dividing surface 42a of the front body heat insulating member 42 and the dividing surface of the rear body heat insulating member 43 are aligned. Further, the upper part division plane of the front body heat insulation member 42 and the rear body heat insulation member 43 and the division face of the upper body heat insulation member 41 are aligned, and the lower part of the front body heat insulation member 42 and the rear body heat insulation member 43 is divided. The plane and the dividing plane of the lower heat insulating member 44 are aligned. Then, the hot water storage tank 10 and the foamed heat insulating member 40 are housed in the exterior case 50. In this way, the hot water storage tank unit 100 is manufactured.

The resin molding mold, the method for manufacturing a hot water storage tank unit, and the effects of the hot water storage tank unit of this embodiment will be described.

In the conventional manufacturing method for insulation members using resin molding molds, gas is trapped in the upper part of the cavity when the insulation member is foam-molded, and the resin material does not spread throughout the cavity of the resin molding mold. There was a problem. Therefore, in the resin molding mold of this embodiment, an air vent communicating with the top of the cavity is formed, so that the resin material can be spread throughout the entire cavity while suppressing gas from being trapped in the upper part of the cavity. This has the effect of improving the formability of the heat insulating member.

The hot water storage tank unit of this embodiment has a complicated uneven shape on the surface of each divided heat insulating member as shown in FIG. Since an air vent is formed and trapping of gas within the cavity can be suppressed, the effect of improving moldability is particularly large.

In addition, in the method for manufacturing a hot water storage tank unit of this embodiment, the resin material can reach the position of the dividing surface and be molded, so it is possible to suppress the formation of gaps at the dividing positions of the heat insulating member, and improve the heat insulation performance. It is possible to obtain an improved hot water storage tank unit.

Furthermore, the burr formed on the hot water storage tank unit of this embodiment is characterized in that it extends parallel to the dividing plane to the opposite side of the hot water storage tank. Therefore, the burr does not interfere at the boundary with other divided heat insulating members, and it is possible to easily attach the split heat insulating member around the hot water storage tank. In addition, since the burrs extend parallel to each other from the dividing surface, by aligning them with the burrs formed on other divided heat insulating members, the contact area becomes larger and the installation becomes easier.

In addition, particularly for the resin molding mold 500 forming the front body heat insulating member 42 and the rear body heat insulating member 43, a cavity 501 is formed in a rectangular recess 512 in plan view, but in this case, as shown in FIG. There is a concern that gas may be trapped in the four corners, which are the vertices of the rectangle indicated by dotted lines in (B). Therefore, in the resin molding mold 500 of the present embodiment, air vents 502 communicating with the outside of the resin molding mold 500 are formed at the four corner positions of the rectangle. This has the effect of further improving moldability.

Furthermore, in the resin molding mold and hot water tank unit manufacturing method of this embodiment, since the air vents are provided with the same width, the flow of the resin material during foam molding can be made uniform, and furthermore, the width of the air vents is the same. It has the effect of improving sexual performance.

Furthermore, in order to make the flow of the resin material uniform, in addition to making the width of the air vents the same, it is also effective to provide adjacent air vents at equal intervals as explained in this embodiment mode. .

Note that, for example, when the surface is uneven and the overall thickness is not uniform, as in the case of each divided heat insulating member constituting the foamed heat insulating member 40 shown in this embodiment, the thickness is large and a large amount of resin material is required. The width of the air vent may be increased at certain locations. By doing so, even if the thickness of the divided heat insulating members differs greatly throughout, the resin material can easily spread uniformly, and the moldability of the divided surfaces can be improved.

In this embodiment, a configuration has been described in which the hot water storage tank 10 is covered with the foamed heat insulating member 40 for insulation, but a configuration in which a vacuum heat insulating material is further provided to improve the heat insulation performance is also possible.

A modification of the hot water storage tank unit of Embodiment 1 will be described using FIG. 15. FIG. 15 is a perspective view showing the division positions of the heat insulating members of the hot water storage tank unit of each modification of the present embodiment.

In the hot water storage tank unit 100 of the present embodiment, the foamed heat insulating member 40 is composed of four divided heat insulating members: an upper heat insulating member 41, a front body heat insulating member 42, a rear body heat insulating member 43, and a lower body heat insulating member 44. Although described above, the present invention is not limited to this, and as shown in FIGS. 15(A) to 15(D), the dividing position may be changed to form two or more pieces.

In FIG. 15(A), a foamed heat insulating member 410 is formed from two members, a front heat insulating member 411 and a rear heat insulating member 412. In this case as well, by using a resin molding mold in which an air vent communicating with the top of the cavity is formed, a burr is formed on the dividing surface and a hot water storage tank unit with improved heat insulation performance can be obtained.

In FIG. 15(B), a foamed heat insulating member 420 is formed from three members: a front body heat insulating member 421, a rear body heat insulating member 422, and a lower heat insulating member 423. In this case as well, by using a resin molding mold in which an air vent communicating with the top of the cavity is formed, a burr is formed on the dividing surface and a hot water storage tank unit with improved heat insulation performance can be obtained.

In FIG. 15C, a foamed heat insulating member 430 is formed from three members: an upper heat insulating member 431, a body heat insulating member 432, and a lower heat insulating member 433. In this case as well, by using a resin molding mold in which an air vent communicating with the top of the cavity is formed, a burr is formed on the dividing surface and a hot water storage tank unit with improved heat insulation performance can be obtained.

In FIG. 15(D), a foamed heat insulating member 440 is formed from two members, an upper heat insulating member 441 and a lower heat insulating member 442. In this case as well, by using a resin molding mold in which an air vent communicating with the top of the cavity is formed, a burr is formed on the dividing surface and a hot water storage tank unit with improved heat insulation performance can be obtained. In particular, design changes can be easily made as necessary, such as by forming the upper heat insulating member 441 with rigid polyurethane foam and forming the lower heat insulating member 442 with expanded polystyrene.

Note that the position of the dividing plane is not limited to this. Furthermore, in consideration of manufacturing efficiency, it is preferable that the number of parts of the divided heat insulating member attached to one hot water storage tank 10 is smaller because the number of assembly steps is reduced.

Each modification of the resin molding die of Embodiment 1 will be explained using FIGS. 16 to 18. In the resin molding molds 500 and 600 of this embodiment, a case has been described in which concave surfaces forming air vents are uniformly formed at the first outer edge portion and the second outer edge portion, but the present invention is not limited to this. , as shown in FIGS. 16 to 18, the positions where the air vents are provided and the intervals between them may be changed.

FIG. 16 is a plan view of a lower die 510 of a modification of the resin molding die 500 for forming the front body heat insulating member 42. As shown in FIG. Note that the plan view of the upper mold 520 corresponds to the plan view of the lower mold 510, and is therefore omitted. The front body heat insulating member 42 may have an air vent at least at the position of the dividing surface 42a that is in contact with the rear body heat insulating member 43, that is, on the long axis side, and does not have an air vent on the short axis side. It can be done. With such a configuration, the dividing surface 42a can be molded with better moldability. Note that even in the case of a resin molding die for molding the rear body heat insulating member 43, an air vent can be provided at a similar position.

17 and 18 are plan views respectively showing a lower mold 610 of a modification of the resin molding mold 600 for forming the upper heat insulating member 41. FIG. Note that the plan view of the upper mold 620 corresponds to the plan view of the lower mold 610, and is therefore omitted. Since the upper heat insulating member 41 has the dividing surface 41a on the entire outer periphery of the recessed portion 612 in a plan view, it is sufficient that the upper heat insulating member 41 has a configuration in which air vents are provided throughout the entire outer periphery of the recess 612. Furthermore, it goes without saying that the number of air vents is not limited to the number shown in FIG. 12. Note that even in the resin molding mold for molding the lower heat insulating member 44, air vents can be provided at similar positions.

Embodiment 2.
A resin molding mold, a method for manufacturing a hot water storage tank unit using the resin molding mold, and a hot water storage tank unit according to the second embodiment will be described with reference to FIGS. 19 to 21. FIG. 19 is a perspective view showing a resin molding mold 500 for molding the front body heat insulating member provided in the hot water storage tank unit of this embodiment, and FIG. 20 is a plan view showing the resin molding mold 500. be. Further, FIG. 21 is a cross-sectional view for explaining a method of manufacturing a hot water storage tank unit using the resin molding die 500.

As shown in FIGS. 19 to 21, the resin molding mold 500 of this embodiment further includes a flat surface 524 for forming a flat dividing surface at the second outer edge 521 of the upper mold 520. This is different from the resin molding die 500 of the first embodiment. The resin molding mold of this embodiment, the method for manufacturing a hot water storage tank unit using the resin molding mold, and the other configuration of the hot water storage tank unit are the same as those of Embodiment 1, so the following points will focus on the differences. Explain.

As shown in FIGS. 19 and 20, the flat surface 524 is a part of the second outer edge portion 521 of the upper die 520 and is located on the inner circumferential side rather than the outer circumferential side where the air vent 502 is formed. That is, the flat surface 524 is a portion that forms the upper surface of the cavity 501 when the upper mold 520 is closed to the lower mold 510, as shown in FIG. 21, and the portion formed in contact with the flat surface 524 is This becomes the dividing surface of the front body heat insulating member 42. Further, the recessed surface 523 provided on the second outer edge portion 521 of the upper mold 520 is provided to be recessed more than the flat surface 524.

Therefore, when the upper mold 520 is closed to the lower mold 510, the flat surface 524 faces the recess 512 of the lower mold 510, while the outer peripheral portion of the second outer edge 521 excluding the flat surface 524 It faces the first outer edge portion 511 of 510 . The recessed surface 513 provided on the first outer edge 511 of the lower mold 510 and the recessed surface 523 provided on the second outer edge 521 of the upper mold face each other, thereby creating an air vent as shown in FIG. 502 is formed, and the upper surface of the air vent 502 is located above the top of the cavity 501.

Here, as shown in FIG. 21, the front body heat insulating member 42 molded using the resin molding die 500 of this embodiment has a dividing surface due to the height difference between the flat surface 524 and the concave surface 523. There may be a difference in level between the burr and the burr. Even in this case, it can be said that the burr is formed along the dividing surface because the difference in level between the dividing surface and the burr is slight. Note that in order to prevent burrs from interfering with each other at the boundary between the front body heat insulating member and the rear body heat insulating member, the positions where the air vents are formed in each resin molding mold may be alternated. In cases where the thickness H of the burrs filling the inside of the air vent 502 is small, there is no problem even if the positions of the air vents are not alternated.

Similarly, the resin molding die 600 forming the upper heat insulating member described in Embodiment 1 can be configured to have a flat surface on the inner peripheral side of the second outer edge portion 621 of the upper die 620. .

The resin molding mold, the method of manufacturing a hot water storage tank unit using the resin molding mold, and the hot water storage tank unit of the present embodiment configured as described above have the same effects as those of the first embodiment. Of course, since the dividing surface can be formed flat, it is possible to obtain a heat insulating member with further improved heat insulating performance.

Embodiment 3.
A resin molding mold, a method for manufacturing a hot water storage tank unit using the resin molding mold, and a hot water storage tank unit according to the third embodiment will be described with reference to FIGS. 22 to 24. FIG. 22 is a perspective view showing a resin molding mold 500 for molding the front body heat insulating member provided in the hot water storage tank unit of this embodiment, and FIG. 23 is a plan view showing the resin molding mold 500. be. Further, FIG. 24 is a cross-sectional view for explaining a method of manufacturing a hot water storage tank unit using the resin molding die 500.

As shown in FIGS. 22 to 24, the resin molding mold 500 of the present embodiment is different from the resin molding mold of the first embodiment in that the second outer edge 521 of the upper mold 520 does not have a recessed surface 523. This is different from the mold 500 for use. The resin molding mold of this embodiment, the method for manufacturing a hot water storage tank unit using the resin molding mold, and the other configuration of the hot water storage tank unit are the same as those of Embodiment 1, so the following points will focus on the differences. Explain.

The second outer edge portion 521 of the upper die 520 has no concave surface, and therefore is a flat surface without any unevenness. Note that in FIGS. 22 to 24, a portion corresponding to the flat surface 524 of the second embodiment is illustrated as a flat surface 524, but there is no step or the like at the boundary thereof. The flat surface 524 is a surface for forming a dividing surface, and is located at a position facing the recess 512 of the lower die 510. On the other hand, the outer peripheral portion of the second outer edge portion 521 excluding the flat surface 524 faces the first outer edge portion 511 of the lower mold 510 . Therefore, the recessed surface 513 provided on the first outer edge 511 of the lower mold 510 and the flat surface on the outer peripheral side of the second outer edge 521 of the upper mold face each other, so that the air vent 502 is formed.

Similarly, the resin molding mold 600 for forming the upper heat insulating member described in the first embodiment can be configured so that the second outer edge portion 621 of the upper mold 620 does not have the recessed surface 623.

The resin molding mold, the method of manufacturing a hot water storage tank unit using the resin molding mold, and the hot water storage tank unit of the present embodiment configured as described above have the same effects as those of the first embodiment. Not only that, but the split surface can be formed flat and the burrs are formed parallel to the split surface, making it easy to align the split insulation members with each other, making it possible to create insulation members with even higher insulation performance. It produces the effect that can be obtained.

Note that it is also within the scope of the present disclosure to appropriately combine, modify, or omit each embodiment.

10 hot water storage tank,
21 Heat pump outgoing piping, 22 Heat pump return piping,
23 pressure reducing valve, 24 relief valve, 25 mixing valve, 26 switching valve, 27 check valve,
28 cold water piping, 29 heat source pump, 30 temperature sensor, 31 hot water piping, 32 branch water supply pipe, 33 hot water supply piping, 34 hot water supply terminal,
40, 410, 420, 430, 440 foam insulation member,
41 Upper insulation member, 41a dividing surface, 41b burr,
42 front body insulation member, 42a dividing surface, 42b burr,
43 Rear body heat insulation member, 44 Lower heat insulation member,
50 Exterior case, 51 Front plate, 52 Recessed plate, 53, 54 Side plate, 55 Rear plate, 56 Top plate, 57 Bottom plate,
60 legs,
100 hot water storage tank unit,
110 heat pump unit,
400 resin material,
411 front heat insulation member, 412 rear heat insulation member,
421 front body heat insulation member, 422 rear body heat insulation member, 423 lower body heat insulation member,
431 Upper heat insulating member, 432 Body heat insulating member, 433 Lower heat insulating member,
441 upper heat insulating member, 442 lower heat insulating member,
500, 600 Resin molding mold,
501, 601 cavity,
502, 602 air vent,
510, 610 lower mold, 511, 611 first outer edge portion, 512, 612 recessed portion, 513, 613 recessed surface,
520, 620 Upper mold, 521, 621 Second outer edge portion, 522, 622 Convex portion, 523, 623 Concave surface, 524 Flat surface,
1000 Hot water storage type water heater

Claims (11)

It consists of a lower mold having a recess and a first outer edge that is the outer edge of the recess, and an upper mold that has a convex part that can be accommodated in the recess and a second outer edge that is the outer edge of the convex part, and has heat insulation properties. A resin molding mold for foam molding a resin member,
When the upper mold is closed to the lower mold,
the second outer edge is in contact with the first outer edge;
The convex portion is accommodated within the concave portion to form a cavity, and further,
a plurality of concave surfaces functioning as air vents are formed at least on the first outer edge;
Each of the plurality of recessed surfaces functioning as the air vent communicates between the top of the cavity and the outside of the resin molding mold,
A mold for resin molding, characterized in that the width of the recessed surfaces is larger than the interval between the recessed surfaces. The resin molding die according to claim 1, wherein each of the plurality of air vents has an equal width. The resin molding mold according to claim 1 or 2, wherein the plurality of air vents are provided to extend in a horizontal direction. Any one of claims 1 to 3, wherein the plurality of air vents are formed such that a recessed surface provided on the first outer edge portion and a recessed surface provided on the second outer edge portion are opposed to each other. The mold for resin molding described in . According to any one of claims 1 to 3, the plurality of air vents are formed such that a concave surface provided on the first outer edge portion and a flat surface of the second outer edge portion face each other. The mold for resin molding described. The cavity is rectangular in plan view,
The resin molding mold according to any one of claims 1 to 5, wherein the air vent is provided to communicate between four corners of the cavity and the outside of the resin molding mold. The recessed portion of the lower mold is approximately circular in plan view,
The mold for resin molding according to any one of claims 1 to 5, wherein the convex portion of the upper mold has a substantially circular shape in plan view. The recessed portion of the lower mold has a substantially cylindrical shape divided into two in the height direction,
The mold for resin molding according to any one of claims 1 to 6, wherein the convex portion of the upper mold has a substantially cylindrical shape divided into two in the height direction. The mold for resin molding according to any one of claims 1 to 8, wherein the cavity is formed only in the recess of the lower mold. The resin molding according to any one of claims 1 to 9, wherein the air vent is provided in a horizontal direction perpendicular to the up-down direction, which is the direction in which gravity acts, and extends only in the horizontal direction. Mold for use. Injecting a resin material into the recess of the lower mold of the resin molding mold according to any one of claims 1 to 10;
foam-molding the resin member by closing and pressurizing the upper mold onto the lower mold, causing the resin material to foam and fill the cavity and the air vent, and then harden;
attaching the foam-molded resin member around the hot water storage tank;
A method of manufacturing a hot water storage tank unit including:

Images