Installation method of insulating pad for electric water heater

Abstract

The present invention relates to the technical field of electric water heater insulation pad installation, and more specifically, to a method for installing an electric water heater insulation pad. The method comprises the following steps: placing the insulation pad in water at a set temperature and boiling it for a first set time; removing the insulation pad from the water and airing it to dry; fitting the insulation pad onto the rear bolt of a heat pipe, and using a nut to press the insulation pad between the side wall of the water storage electric water heater and the nut. This method solves the problem in the prior art where a nylon insulation pad is pressed against the side wall of the water storage electric water heater by the nut, causing the nylon insulation pad to be flattened by the force applied, and excessive torque can cause the insulation pad to break, ultimately resulting in a decrease in resistance and a potential safety hazard.

Description

Technical Field

[0001] The invention relates to the technical field of installing an insulating pad of an electric water heater, and in particular to an installing method of an insulating pad of an electric water heater. Background Art

[0002] When a storage electric water heater is produced, it is necessary to use a nut to fix the tail bolt of the heating tube, but it is necessary to ensure that the resistance value between the nut and the heating tube bolt reaches 0.5*106 ohms or more, otherwise the user may be at risk of electric shock. Nylon insulating pads are used in the industry.

[0003] During actual production, the nylon insulating gasket will be pressed against the side wall of the storage electric water heater by the nut during the rotation and fixing process of the nut and the tail bolt of the heating tube. The nylon insulating gasket will be flattened under the force. Excessive torque may also cause the insulating gasket to break, eventually causing the resistance value to drop and posing a safety hazard. Summary of the Invention

[0004] In response to the defects in the prior art, the purpose of the present invention is to provide an installation method for an electric water heater insulating gasket, which can solve the problem in the prior art that the nylon insulating gasket is pressed against the side wall of the water storage electric water heater by a nut, and the nylon insulating gasket is flattened under the force, and excessive torque may cause the insulating gasket to break, eventually leading to a decrease in resistance and ultimately causing a safety hazard.

[0005] In order to achieve the above purpose, the technical solution adopted by the present invention is:

[0006] The present invention provides a method for installing an insulating pad of an electric water heater, which is characterized by comprising the following steps:

[0007] Place the insulating pad in water at a set temperature and boil for the first set time;

[0008] Remove the insulating pad from the water and dry it in a ventilated and shaded place;

[0009] An insulating pad is put onto the bolt at the tail end of the heat pipe, and a nut is used to press the insulating pad between the side wall of the storage electric water heater and the nut.

[0010] In some optional solutions, when the insulating pad is sleeved onto the tail bolt of the heat pipe and the insulating pad is pressed between the side wall of the storage electric water heater and the nut using the nut, the method further includes:

[0011] Monitor the humidity in the assembly workshop and determine whether the humidity in the assembly workshop is within the set humidity range;

[0012] When the humidity in the assembly workshop is greater than the upper limit of the set humidity range, the assembly workshop is dehumidified;

[0013] When the humidity in the assembly workshop is lower than the lower limit of the set humidity range, the insulating pad is placed in a moisturizing box with the set humidity. After moisturizing for the second set time, the insulating pad is pressed between the side wall and the nut of the storage electric water heater using a nut.

[0014] In some optional solutions, the set humidity of the moisturizing box is 75%, and the set humidity range is 35-80%.

[0015] In some optional schemes, when using a nut to press the insulating gasket between the side wall of the water storage electric water heater and the nut, it also includes: if the torque of rotating the nut to press the insulating gasket between the side wall of the water storage electric water heater and the nut is a set torque, then when the torque of rotating the nut is less than a set percentage of the set torque, the nut is rotated at a first set speed; when the torque of rotating the nut is greater than the set percentage of the set torque and less than the set torque, the nut is rotated at a second set speed, and the second set speed is less than the first set speed.

[0016] In some optional solutions, the set percentage is 70%.

[0017] In some optional solutions, the second set speed is 100 rpm and the first set speed is 200 rpm.

[0018] In some optional solutions, the insulating pad is placed in water of a set temperature and boiled within a third time after the injection molding is completed.

[0019] In some optional embodiments, the third time is 24 hours.

[0020] In some optional solutions, the first set time is 30 minutes.

[0021] In some optional solutions, after the insulating pads are ventilated and shade-dried, an inspection and screening step is performed to screen out unqualified insulating pads.

[0022] Compared with existing technologies, the present invention has the following advantages: the insulating mat is boiled in water at a set temperature for a set time; the insulating mat is removed from the water and aired to dry; and the insulating mat is held between the sidewall of the storage electric water heater and the nut using a nut, thereby improving the product's pass rate. After boiling, the insulating mat shrinks less and is more dimensionally stable. Although both its volume resistivity and machine-measured resistance values ​​are reduced, they are still within the acceptable range. The boiling insulating mat also exhibits increased toughness and a significantly reduced breakage rate.

[0023] In addition, when the humidity in the assembly workshop is lower than the lower limit of the set humidity range, the insulating gasket 1 is placed in a moisturizing box at the set humidity. After moisturizing for a second set time, the insulating gasket is pressed between the side wall of the storage electric water heater and the nut using a nut. Moisturizing the insulating gasket 1 to be installed can maintain its toughness and reduce the possibility of the insulating gasket being crushed during installation.

[0024] When the torque applied by the rotating nut to press the insulating gasket between the side wall of the storage electric water heater and the nut is a set torque, the nut is rotated at a first set speed when the torque applied is less than a set percentage of the set torque. When the torque applied is greater than a set percentage of the set torque but less than the set torque, the nut is rotated at a second set speed, which is less than the first set speed. This reduces the impact of the pressure generated by the rotating torque on the insulating gasket, thereby reducing the possibility of the nut crushing the insulating gasket.

[0025] Through the combined effect of these three means, the crushing rate of the insulating pad can be reduced from 1000ppm to 10ppm, and the shrinkage rate of the insulating pad is reduced, so that the size qualification rate of the insulating pad is also improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0027] Figure 1 Schematic diagram of the installation of the insulating pad of the electric water heater in an embodiment of the present invention.

[0028] In the figure: 1. Insulation pad; 2. Heat pipe tail bolt; 3. Nut; 4. Storage-type electric water heater. DETAILED DESCRIPTION

[0029] To make the purpose, technical solutions, and advantages of the embodiments of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0030] The embodiments of the present invention are further described in detail below with reference to the accompanying drawings.

[0031] The present invention provides a method for installing an insulating pad of an electric water heater, comprising the following steps:

[0032] S1: Put the insulating pad 1 into water at a set temperature and boil it for a first set time.

[0033] In some optional embodiments, the insulating pad 1 is placed in water of a set temperature and boiled within the third time after the injection molding is completed.

[0034] In this example, the insulating pad 1 is placed in water to boil after injection molding and before it has completely cooled. If the insulating pad 1 is allowed to completely cool, it will shrink and set, and then boiling it in water will not effectively reduce the shrinkage of the insulating pad 1. In this example, the insulating pad 1 is a PA66 nylon insulating pad.

[0035] Generally, the insulating pad 1 is placed in water at a set temperature and boiled within 24 hours after injection molding. In this example, the insulating pad 1 is placed in a cooling environment for about 48 hours after injection molding. In this solution, the insulating pad 1 is placed in water at a set temperature and boiled within 24 hours after injection molding. Of course, the cooling time will vary depending on the ambient temperature and placement method. In order to avoid boiling the insulating pad 1 in water after it has completely cooled, which would not achieve the desired effect, in other embodiments, a suitable time for boiling the insulating pad 1 can be selected based on the cooling time of the insulating pad 1.

[0036] In this example, the shrinkage rate of the insulating pad 1 after boiling in water is 1.5%, and the shrinkage rate of the insulating pad without boiling in water is 2.0%. Therefore, by boiling the insulating pad 1 in water at a set temperature within the third time after the injection molding is completed, the shrinkage rate of the insulating pad 1 can be reduced, and the problem of the insulating pad 1 failing to meet the design requirements due to the shrinkage diameter being too small can be avoided.

[0037] In some optional embodiments, the first set time is 30 minutes.

[0038] During the injection molding process, if the insulating pad 1 is cooled very quickly, the material will not be able to naturally crystallize and take shape, resulting in strong internal stress inside the material. Therefore, in this solution, after the injection molding of the insulating pad 1 is completed, the insulating pad 1 is placed in a cooling environment for 48 hours. And within 24 hours, the insulating pad 1 is placed in water at a set temperature and boiled for 30 minutes. Placing the insulating pad 1 in a cooling environment for 48 hours can slow down the cooling rate of the insulating pad 1 and reduce the internal stress generated inside the insulating pad 1. And within 24 hours, the insulating pad 1 is placed in water at a set temperature and boiled for 30 minutes, so that the macromolecules inside the insulating pad 1 tend to naturally orient themselves and reach a balance between internal crystallization and decrystallization, thereby eliminating its internal stress. In addition, its shrinkage is slowed down, reducing the shrinkage rate by 0.5%.

[0039] In this example, the set temperature of the water is 95-100 degrees Celsius, and pure water is used, which can minimize the impact on the insulation of the insulating pad 1 after boiling in water and avoid leaving watermarks on the surface of the insulating pad 1 after boiling in water.

[0040] During the 20-minute boiling process, the volume shrinkage of the insulating pad 1 was 1.5%, and the volume resistivity was 1.63*10 9 Ωcm, the resistance value measured by the machine is 0.6*10 7 Ω, much larger than the qualified index 0.5*10 6 The index of Ω, the crushing rate is 60ppm.

[0041] The volume shrinkage of the insulation pad 1 without water boiling is 2.0%, and the volume resistivity is 1.83*10 9 Ωcm, the resistance value measured by the machine is 0.8*10 7 Ω, the actual resistance value of the broken machine is 1.63*10 2 Ωcm, far less than the qualified index 0.5*10 6 The index of Ω, the crushing rate is 1000ppm.

[0042] Therefore, after boiling, the insulation mat 1 exhibits less shrinkage and more stable dimensions. Although both its volume resistivity and the resistance value measured by the machine have decreased, they are still within the acceptable range. Furthermore, the breakage rate of the insulation mat 1 after boiling is significantly reduced, from 1000ppm to 60ppm. This indicates that the insulation mat 1 exhibits enhanced toughness after boiling.

[0043] S2: Take out the insulating pad 1 from the water and dry it in a ventilated and shaded place.

[0044] In this example, after the insulating pad 1 is boiled in water, it is placed in a ventilated and cool environment to dry in the shade, so that the toughness change of the insulating pad 1 can be maintained and the toughness of the insulating pad 1 can be prevented from being reversed.

[0045] In this example, after the insulating pads are ventilated and dried, an inspection and screening step is performed to screen out unqualified insulating pads 1. Specifically, the insulating pads 1 that are broken, or that do not meet the injection molding standards, or that do not meet the size standards are screened out.

[0046] Figure 1 FIG. 1 is a schematic diagram of the installation of an insulating pad for an electric water heater according to an embodiment of the present invention. Figure 1 As shown, S3: Sleeve the insulating pad 1 onto the bolt 2 at the tail end of the heat pipe, and use the nut 3 to press the insulating pad between the side wall of the storage electric water heater 4 and the nut.

[0047] When the ambient humidity is too low, the toughness of the insulating pad 1 will also change inversely. Therefore, the insulating pad 1 needs to be kept at a relatively suitable ambient humidity before installation.

[0048] In some optional embodiments, when the insulating pad 1 is sleeved onto the heat pipe tail bolt 2 and the nut 3 is used to press the insulating pad between the side wall of the storage electric water heater 4 and the nut, the method further includes:

[0049] Monitor the humidity in the assembly workshop and determine whether the humidity in the assembly workshop is within the set humidity range.

[0050] In this example, the humidity range is set to 35-80%. When the ambient humidity is greater than 80%, the insulating pad 1 installed on the storage electric water heater 4 may not meet the resistance requirements. Such an environment is not conducive to the long-term work of the installation workers, and it is also easy to cause the equipment to rust, affecting the life of the equipment.

[0051] When the humidity in the assembly workshop exceeds the upper limit of the set humidity range, the assembly workshop is dehumidified. That is, when the humidity in the assembly workshop exceeds 80%, the assembly workshop is dehumidified. This can reduce the possibility that the insulating pad 1 cannot meet the resistance requirements, and keep the working environment relatively dry, thereby extending the service life of the equipment.

[0052] When the humidity in the assembly workshop is lower than the lower limit of the set humidity range, the insulating pad 1 is placed in a moisturizing box with the set humidity. After moisturizing for the second set time, the insulating pad is pressed between the side wall and the nut of the storage electric water heater using a nut.

[0053] That is, when the humidity in the assembly workshop is less than 35%, the insulating pad 1 to be installed is subjected to a moisturizing treatment, which can maintain the toughness of the insulating pad 1 and reduce the possibility of the insulating pad 1 being crushed during the installation process.

[0054] Based on extensive practical data, we found that the breakage rate of an insulation mat that had been boiled and then moisturized was 30 ppm during installation. The breakage rate of an insulation mat that had only been boiled was 50 ppm when installed in an environment with a humidity below 35%. The breakage rate of an insulation mat that had only been moisturized and not boiled was 500 ppm.

[0055] In this example, the set humidity of the moisturizing box is 75%, and the second set time is 2 hours. After the insulating pad 1 is moisturized in the moisturizing box with 75% humidity for 2 hours, the insulating pad 1 can maintain good toughness and reduce the possibility of cracking during installation of the insulating pad 1.

[0056] When using a nut to press the insulating gasket between the side wall of the water storage electric water heater and the nut, it also includes: if the torque used to rotate the nut to press the insulating gasket between the side wall of the water storage electric water heater and the nut is a set torque, then when the torque of the rotating nut is less than a set percentage of the set torque, the nut is rotated at a first set speed; when the torque of the rotating nut is greater than the set percentage of the set torque and less than the set torque, the nut is rotated at a second set speed, and the second set speed is less than the first set speed.

[0057] Specifically, the nut is rotated to a set torque so that the nut presses the insulating gasket between the side wall of the storage electric water heater and the nut. When the torque applied to the nut is less than 70% of the set torque, the nut is rotated at 200 rpm. When the torque applied to the nut is greater than 70% of the set torque but less than the set torque, the nut is rotated at 100 rpm. This reduces the impact of the pressure generated by the rotational torque on the insulating gasket 1, thereby reducing the possibility of the nut crushing the insulating gasket 1.

[0058] Based on extensive practical data, the breakage rate of a water-boiled insulation mat, then moisturized, was 10 ppm when installed using a torque-speed relationship. The breakage rate of an unwatered insulation mat, when installed in an environment with a humidity below 35%, was 600 ppm.

[0059] In summary, boiling the insulating mat in water at a set temperature for a set time; removing the insulating mat from the water and air-drying it; and using a nut to press the insulating mat between the sidewall of the storage electric water heater and the nut can improve the product's pass rate. After boiling, the insulating mat 1 has less shrinkage and more stable dimensions. Although its volume resistivity and machine-measured resistance values ​​have decreased, both remain within the acceptable product range. The insulating mat 1 also exhibits increased toughness and a significantly reduced breakage rate.

[0060] When the humidity in the assembly workshop is lower than the lower limit of the set humidity range, the insulating pad 1 is placed in a moisturizing box at the set humidity. After moisturizing for a second set time, the insulating pad is then pressed between the side wall of the storage electric water heater and the nut using a nut. Moisturizing the insulating pad 1 to be installed can maintain the toughness of the insulating pad 1 and reduce the possibility of the insulating pad 1 being crushed during the installation process.

[0061] If the torque required to hold the insulating gasket between the sidewall of the storage electric water heater and the nut is a set torque, then when the torque required to rotate the nut is less than a set percentage of the set torque, the nut is rotated at a first set speed. When the torque required to rotate the nut is greater than a set percentage of the set torque but less than the set torque, the nut is rotated at a second set speed, which is less than the first set speed. This reduces the impact of the pressure generated by the rotational torque on the insulating gasket 1, thereby reducing the possibility of the nut crushing the insulating gasket 1.

[0062] Through the combined effect of the three means, the crushing rate of the insulating pad 1 can be reduced from 1000 ppm to 10 ppm, and the shrinkage rate of the insulating pad 1 is reduced, so that the size qualification rate of the insulating pad 1 is also improved.

[0063] In the description of this application, it should be noted that the terms "upper" and "lower" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application. Unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be internal communication between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances.

[0064] It should be noted that, in this application, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprising a ..." does not exclude the presence of other identical elements in the process, method, article or device comprising the element.

[0065] The foregoing is merely a list of specific embodiments of the present application, intended to enable those skilled in the art to understand or implement the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the broadest scope consistent with the principles and novel features of the present application.

Claims

1. A method for installing an insulating pad for an electric water heater, characterized in that: The following steps are involved: Place the insulating pad in water at a set temperature and boil for the first set time; Remove the insulating pad from the water and dry it in a ventilated and shaded place; Sleeve the insulating pad onto the bolt at the tail end of the heat pipe, and use the nut to press the insulating pad between the side wall of the storage electric water heater and the nut; When an insulating gasket is sleeved onto the bolt at the tail end of the heat pipe and the insulating gasket is pressed between the side wall of the storage type electric water heater and the nut using a nut, the method further includes: Monitor the humidity in the assembly workshop and determine whether the humidity in the assembly workshop is within the set humidity range; When the humidity in the assembly workshop is greater than the upper limit of the set humidity range, the assembly workshop is dehumidified; When the humidity in the assembly workshop is lower than the lower limit of the set humidity range, the insulating pad is placed in a moisturizing box with the set humidity. After moisturizing for the second set time, the insulating pad is pressed between the side wall and the nut of the storage electric water heater using a nut.

2. The method for installing an insulating pad for an electric water heater according to claim 1, wherein: The set humidity of the moisturizing box is 75%, and the set humidity range is 35-80%.

3. The method for installing an insulating pad for an electric water heater according to claim 1, wherein: When using a nut to press the insulating gasket between the side wall of the water storage electric water heater and the nut, it also includes: if the torque used to rotate the nut to press the insulating gasket between the side wall of the water storage electric water heater and the nut is a set torque, then when the torque of the rotating nut is less than a set percentage of the set torque, the nut is rotated at a first set speed; when the torque of the rotating nut is greater than the set percentage of the set torque and less than the set torque, the nut is rotated at a second set speed, and the second set speed is less than the first set speed.

4. The method for installing an insulating pad for an electric water heater according to claim 3, wherein: The set percentage is 70%.

5. The method for installing an insulating pad for an electric water heater according to claim 3, wherein: The second set speed is 100 rpm, and the first set speed is 200 rpm.

6. The method for installing an insulating pad for an electric water heater according to claim 1, wherein: The third time after the injection molding is completed, the insulating pad is put into the water of set temperature and boiled.

7. The method for installing an insulating pad for an electric water heater according to claim 6, wherein: The third time is 24 hours.

8. The method for installing an insulating pad for an electric water heater according to claim 1, wherein: The first set time is 30 minutes.

9. The method for installing an insulating pad for an electric water heater according to claim 1, wherein: After the insulating pads are ventilated and dried, an inspection and screening step is carried out to screen out unqualified insulating pads.

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