Production process of water heater and water heater

Abstract

The present application relates to the technical field of water heaters, and discloses a production process of a water heater and the water heater, the production process of the water heater comprising the following steps: S1, foaming adhesive tape is sleeved in a shell of the water heater, and the foaming adhesive tape is stretched apart by a shape-following device, so that the foaming adhesive tape is attached to side walls of cavities formed between the shell and gaskets on end covers of the water heater; S2, an inner container is placed in the foaming adhesive tape and supported on the gaskets; and S3, foaming material is injected between the foaming adhesive tape and the inner container to perform foaming. The production process of the water heater has the advantages that the foaming adhesive tape is stretched apart by the shape-following device and attached to the side walls of the cavities, so that the foaming material can fill the cavities by gravity, the phenomenon of cavities is avoided, and in turn, the phenomenon of shell concave of the water heater is avoided. The water heater can avoid the cavities between the shell and the gaskets, improve the overall strength of the water heater, and avoid the phenomenon of shell concave caused by collision.

Description

Technical Field

[0001] This invention relates to the field of water heater technology, and in particular to a water heater manufacturing process and a water heater. Background Technology

[0002] The typical manufacturing process for storage-type electric water heaters involves: installing end caps onto the casing, then covering the outer side of the inner tank with expanding foam tape, placing the inner tank and expanding foam tape inside the casing, and filling the space between the expanding foam tape and the inner tank with expanding foam material. However, due to the excessive force during foaming, the expanding foam material can deform the end cap. Therefore, a thick padding layer is placed between the end cap and the inner tank. This padding layer creates a cavity between the casing and the padding layer. When the expanding foam material is filled, it enters the space between the expanding foam tape and the inner tank by gravity and flows downwards. However, because the cavity volume is small, the weight of the expanding foam material alone is insufficient to expand the expanding foam tape, preventing it from adhering to the inner wall of the cavity. This results in a cavity between the casing and the expanding foam tape, making the cavity prone to denting during water heater transportation due to impacts. Therefore, there is an urgent need to design a water heater manufacturing process and a water heater design to avoid the formation of such cavities. Summary of the Invention

[0003] The purpose of this invention is to propose a manufacturing process and a water heater that solves the technical problem that the presence of a cavity between the end cap and the shell due to the padding layer on the end cap can easily lead to cavities during foaming.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] This invention provides a manufacturing process for a water heater, comprising the following steps:

[0006] S1. Foam tape is inserted into the housing of the water heater, and the foam tape is stretched open by a conformal device so that the foam tape fits against the side wall of the cavity formed between the housing and the padding layer on the end cap of the water heater.

[0007] S2. Place the inner liner inside the foam tape and support it on the padding layer;

[0008] S3. Inject the foaming material between the foamed tape and the inner liner to foam.

[0009] The manufacturing process of this water heater involves inserting foam tape into the water heater's casing and using a conforming device to expand the foam tape so that it adheres to the sidewall of the cavity formed between the foam tape and the padding layer on the end cap of the water heater. Then, the inner tank is placed inside the foam tape and supported on the padding layer. Foaming material is injected between the foam tape and the inner tank for foaming. Because the foam tape is expanded by the conforming device and adheres to the sidewall of the cavity, the foaming material can fill the cavity by its own weight, avoiding the phenomenon of empty cavities and thus preventing the casing from being dented due to collisions during the transportation of the water heater.

[0010] As a preferred embodiment of the production process of the aforementioned water heater, in step S1, the foamed tape adheres to the entire inner wall of the shell along its axial direction.

[0011] The foam tape adheres to the entire inner wall of the shell along its axial direction to avoid affecting the injection of the foam material.

[0012] As a preferred embodiment of the manufacturing process of the aforementioned water heater, the conformal device includes a pressing member. The pressing member extends into the foamed tape from one open end and moves along the axial direction of the housing to press the foamed tape into the cavity and make the foamed tape adhere to the side wall of the cavity.

[0013] The pressing member of the conformal device can extend into the foam tape from one end of the opening of the foam tape and move along the axial direction of the shell to press the foam tape into the cavity and make the foam tape fit against the side wall of the cavity to prevent the cavity from having a cavity during the foaming stage.

[0014] As a preferred embodiment of the manufacturing process for the aforementioned water heater, the conformal device further includes:

[0015] A driving device, the output end of which is connected to the pressing member, and drives the pressing member to move along the axial direction of the housing.

[0016] The drive unit is designed to move the pressing component along the axial direction of the housing, which facilitates control of the movement of the pressing component and results in a high degree of automation.

[0017] As a preferred embodiment of the manufacturing process of the aforementioned water heater, the pressing component is an annular structure, the diameter of which is smaller than the inner diameter of the shell and larger than the diameter of the pad layer.

[0018] The above configuration ensures that the pressure member extends into the cavity between the housing and the padding layer. Moreover, the pressure member has a ring structure, which reduces the overall weight and facilitates the movement of the pressure member.

[0019] As a preferred embodiment of the manufacturing process for the aforementioned water heater, the pressing component includes:

[0020] Connector, wherein the connector is a ring structure; and

[0021] Multiple arc-shaped components are spaced apart on the circumference of the connector so that the multiple arc-shaped components can be spliced ​​together to form a discontinuous ring structure.

[0022] Multiple arc-shaped components are spaced apart around the circumference of the connector so that they can be spliced ​​together to form a discontinuous ring structure, which can further reduce the overall weight of the pressing component and facilitate its movement.

[0023] As a preferred embodiment of the manufacturing process of the aforementioned water heater, the conformal device is removed from the housing before the inner tank is placed inside the foam tape.

[0024] Before placing the inner liner inside the foam tape, remove the conformal device from the shell to facilitate subsequent foaming.

[0025] As a preferred embodiment of the production process of the above-mentioned water heater, in step S2, a cover plate is installed on the end of the shell that is not covered by the end cover, and an accommodating space is formed between the cover plate, the foam tape and the inner tank.

[0026] The end of the shell without an end cap is covered with a cover plate, and a receiving space is formed between the cover plate, the foam tape and the inner liner to facilitate the subsequent foaming process.

[0027] As a preferred embodiment of the production process of the above-mentioned water heater, in step S3, the foaming material is injected into the accommodating space for foaming.

[0028] Foaming material is injected into the containment space to form an insulation layer between the shell and the inner liner, which in turn insulates the inner liner.

[0029] The present invention also provides a water heater, which is manufactured using the above-described water heater manufacturing process.

[0030] This water heater is manufactured using the aforementioned production process, which avoids cavities between the shell and the padding layer, thus improving the overall strength of the water heater and preventing shell dents caused by impacts.

[0031] The beneficial effects of this invention are:

[0032] The water heater manufacturing process proposed in this invention involves inserting foam tape into the water heater shell and using a conforming device to expand the foam tape so that it adheres to the side wall of the cavity formed between the foam tape and the padding layer on the shell and end cap of the water heater. Then, the inner tank is placed inside the foam tape and supported on the padding layer. Foaming material is injected between the foam tape and the inner tank for foaming. Because the foam tape is expanded by the conforming device and adheres to the side wall of the cavity, the foaming material can fill the cavity by gravity, avoiding the phenomenon of empty cavities, and thus avoiding shell dents caused by collisions during the transportation of the water heater.

[0033] The beneficial effects of this invention are:

[0034] The water heater proposed in this invention, manufactured using the aforementioned production process, avoids the formation of cavities between the shell and the padding layer, thereby improving the overall strength of the water heater and preventing shell dents caused by impacts. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the structure provided by the present invention, which shows how a conformal device expands the foamed tape during the production process of a water heater.

[0036] Figure 2 yes Figure 1 A magnified view of point A in the diagram.

[0037] In the picture:

[0038] 1. Shell; 2. Foam tape; 3. End cap; 4. Padding layer; 5. Cavity; 6. Inner liner;

[0039] 100. Irregular device. Detailed Implementation

[0040] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0041] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0042] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0043] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0044] This embodiment provides a manufacturing process for a water heater, such as... Figure 1 and Figure 2 As shown, it includes the following steps:

[0045] S1. Foam tape 2 is inserted into the housing 1 of the water heater, and the foam tape 2 is stretched open by the conformal device 100 so that the foam tape 2 fits against the side wall of the cavity 5 formed between the housing 1 and the padding layer 4 on the end cover 3 of the water heater.

[0046] In step S1, the water heater shell 1 and end cap 3 are first assembled. The shell 1 has openings at both ends, and the end cap 3 is installed at the bottom of the shell 1. A pad 4 is provided on the end cap 3. The pad 4 has a cushioning function to prevent the end cap 3 from being squeezed and deformed due to excessive foaming force of the foaming material during the foaming process. However, due to the pad 4, a cavity 5 is formed between the pad 4 and the shell 1. When the foaming material is filled, the foaming material enters between the foaming tape 2 and the inner tank 6 by gravity and flows downward. Because of the cavity 5 around the pad 4, the foaming tape 2 cannot adhere to the inner wall of the cavity 5. The weight of the foaming material alone cannot open the foaming tape 2, resulting in a cavity between the shell 1 and the foaming tape 2. This cavity is prone to denting due to mutual collisions during the transportation of the water heater. Therefore, in order to solve the above problems, after the foam tape 2 is inserted into the shell 1, the foam tape 2 is stretched open by the conformal device 100 so that the foam tape 2 fits against the side wall of the cavity 5, so that the foam material can fill the cavity 5 by gravity, avoiding the phenomenon of empty cavity, and thus avoiding the shell 1 being dented due to collision during the transportation of the water heater.

[0047] It should be noted that the foam tape 2 is inserted into the end of the housing 1 where the end cap 3 is not installed. The end of the foam tape 2 away from the end cap 3 is open to form a foam material injection port. The conforming device 100 presses down the bottom of the foam tape 2.

[0048] Preferably, the foamed tape 2 adheres to the entire inner wall of the shell 1 along its axial direction, allowing the foamed material to flow smoothly downwards and reducing obstruction to its downward flow. The height of the conformal device 100 may be equal to, or slightly greater than, or slightly less than, the height of the shell 1, so that when the conformal device 100 is placed inside the foamed tape 2, the foamed tape 2 adheres to the entire inner wall of the shell 1, facilitating the filling of the foamed material.

[0049] Specifically, the conformal device 100 includes a pressing member that can extend into the foamed tape 2 from one open end of the foamed tape 2 and move along the axial direction of the housing 1 to press the foamed tape 2 into the cavity 5 and make the foamed tape 2 fit against the side wall of the cavity 5 to prevent voids from appearing in the cavity 5 during the foaming stage.

[0050] Optionally, the pressing member is an annular structure, with a diameter smaller than the inner diameter of the housing 1 and larger than the diameter of the padding layer 4. This arrangement ensures that the pressing member extends into the cavity 5 between the housing 1 and the padding layer 4. Furthermore, the annular structure of the pressing member reduces the overall weight and facilitates its movement. It should be noted that the shape of the pressing member is adapted to that of the housing 1, and the outer contour of the pressing member is adapted to the inner cavity of the housing 1. When the inner cavity structure of the housing 1 is cylindrical, the outer contour shape of the pressing member is also cylindrical. To reduce the weight of the pressing member, it is designed as an annular structure. Of course, the shape of the inner cavity of the housing 1 is not limited to a cylindrical structure; it can also be other shapes. No specific limitation is made here, as long as the shape of the pressing member is adapted to the shape of the housing 1.

[0051] Optionally, the conformal device 100 further includes a driving device, the output end of which is connected to the pressing member and drives the pressing member to move along the axial direction of the housing 1. The driving device enables the pressing member to move along the axial direction of the housing 1, facilitating control of the pressing member's movement and achieving a high degree of automation. The specific structure of the driving device is not limited here, as long as it can drive the pressing member along the axial direction of the housing 1.

[0052] S2. Place the inner liner 6 inside the foam tape 2 and support it on the padding layer 4.

[0053] Before placing the inner liner 6 into the foam tape 2, remove the conformal device 100 to facilitate subsequent foaming.

[0054] The inlet of the inner liner 6 faces the end of the outer shell 1 without the end cap 3, and the bottom of the inner liner 6 is supported on the padding layer 4. The end of the outer shell 1 without the end cap 3 is covered with a cover plate, and a receiving space is formed between the cover plate, the foam tape 2 and the inner liner 6 to facilitate the subsequent foaming process.

[0055] S3. Inject the foaming material between the foaming tape 2 and the inner liner 6 to foam.

[0056] Foaming material is injected into the containment space for foaming, so as to form an insulation layer between the shell 1 and the inner liner 6, which provides insulation for the inner liner 6. Optionally, the foaming material is polyurethane foam material, and the foaming temperature is generally room temperature. The required foaming temperature is low, and the molding process is relatively simple.

[0057] It should be noted that the cover plate is provided with through holes, which are connected to the receiving space. Foaming material is injected into the receiving space through the through holes. After the foaming material foams, it forms an insulation layer, which serves to keep the inner liner 6 warm and heat-insulating.

[0058] The manufacturing process of this water heater involves inserting a foamed tape 2 inside the water heater's casing 1 and using a conforming device 100 to expand the foamed tape 2 so that it adheres to the side wall of the cavity 5 formed between the foamed tape 2 and the padding layer 4 on the end cap 3 of the water heater. Then, the inner tank 6 is placed inside the foamed tape 2 and supported on the padding layer 4. Foaming material is injected between the foamed tape 2 and the inner tank 6 for foaming. Because the foamed tape 2 is expanded by the conforming device 100 and adheres to the side wall of the cavity 5, the foaming material can fill the cavity 5 by its own gravity, avoiding the phenomenon of empty cavities and thus preventing the casing 1 from being dented due to collisions during the transportation of the water heater.

[0059] This embodiment also provides a water heater manufactured using the aforementioned water heater manufacturing process. By manufacturing this water heater using the aforementioned process, cavities can be avoided in the cavity 5 between the shell 1 and the padding layer 4, thus improving the overall strength of the water heater and preventing dents in the shell 1 due to impact.

[0060] Specifically, the water heater includes a shell 1 and an inner tank 6 disposed inside the shell 1. The shell 1 has openings at both ends, an end cap 3 is installed at one end of the shell 1, and a cover plate is installed at the other end of the shell 1. The opening of the inner tank 6 faces the cover plate. A foam tape 2 is sleeved between the shell 1 and the inner tank 6. The foam tape 2, the foam material filling the space between the inner tank 6 and the cover plate form a foam layer to insulate the inner tank 6.

[0061] like Figure 1 As shown, a pad 4 is provided between the end cap 3 and the inner tank 6, and a cavity 5 is formed between the pad 4 and the shell 1. When the foam tape 2 and the inner tank 6 are filled with foam material, the foam tape 2 can adhere to the side wall of the cavity 5, and the cavity 5 is filled with foam material, avoiding the occurrence of cavities and improving the strength of the water heater.

[0062] Example 2:

[0063] This embodiment provides a manufacturing process for a water heater. The difference between this embodiment and Embodiment 1 lies in the structure of the pressing component of the conformal device used in step S1. In Embodiment 1, the pressing component is an arc-shaped structure, while in this embodiment, the pressing component includes a connector and multiple arc-shaped components. The connector is a circular ring structure, and the multiple arc-shaped components are spaced apart on the circumference of the connector, so that the multiple arc-shaped components are spliced ​​together to form a discontinuous ring structure. The multiple arc-shaped components spaced apart on the circumference of the connector, so that the multiple arc-shaped components are spliced ​​together to form a discontinuous ring structure, can further reduce the overall weight of the pressing component and facilitate its movement.

[0064] Optionally, the conformal device further includes a drive mechanism for driving the pressing member to move along the axial direction of the housing to extend into or out of the housing.

[0065] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A manufacturing process for a water heater, characterized in that, Includes the following steps: S1. Foam tape (2) is inserted into the housing (1) of the water heater and the foam tape (2) is spread open by the conformal device (100) so that the foam tape (2) fits against the side wall of the cavity (5) formed between the housing (1) and the pad (4) on the end cap (3) of the water heater; S2. Place the inner liner (6) inside the foam tape (2) and support it on the padding layer (4); S3. Inject the foaming material between the foamed tape (2) and the inner liner (6) to foam; The conformal device (100) includes a pressing member that extends into the foam tape (2) from one end of the foam tape (2) with an opening and moves along the axial direction of the housing (1) to press the foam tape (2) into the cavity (5) and make the foam tape (2) fit against the side wall of the cavity (5); The pressing component includes: The connector is a ring structure; and Multiple arc-shaped components are spaced apart on the circumference of the connector so that the multiple arc-shaped components can be spliced ​​together to form a discontinuous ring structure.

2. The manufacturing process of the water heater according to claim 1, characterized in that, In step S1, the foamed tape (2) is adhered to the entire inner wall of the housing (1) along its axial direction.

3. The manufacturing process of the water heater according to claim 1, characterized in that, The conformal device (100) further includes: A driving device, the output end of which is connected to the pressing member, and drives the pressing member to move along the axial direction of the housing (1).

4. The manufacturing process of the water heater according to any one of claims 1-3, characterized in that, Before placing the inner liner (6) inside the foam tape (2), the conformal device (100) is removed from the housing (1).

5. The manufacturing process of the water heater according to any one of claims 1-3, characterized in that, In step S2, a cover plate is installed on the end of the housing (1) that is not covered by the end cap (3), and an accommodating space is formed between the cover plate, the foam tape (2) and the inner liner (6).

6. The manufacturing process of the water heater according to claim 5, characterized in that, In step S3, the foaming material is injected into the containment space for foaming.

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