Outer case

Abstract

The present invention provides an exterior case that minimizes gaps at the attachment point of the top lid to the case body, facilitates and optimizes the creation of curved sections in the stepped recesses, and effectively facilitates manufacturing and reduces manufacturing costs. [Solution] The outer case C comprises a case body Ca and a top lid 3. A stepped recess 21 provided in the upper region of the side plate 2A of the case body Ca has first and second bent lines 22a and 22b. The region between the first and second bent lines 22a and 22b is an inclined wall portion 21B located inward towards the case as it rises. The region above the first bent line portion 22a is an upper non-inclined wall portion 21A. The protruding piece 31 of the top lid 3 faces the upper non-inclined wall portion 21A and abuts against the inclined wall portion 21B. The curved portion 4 of the side plate 2A is provided with an upper opening-shaped notch 41 that extends in the vertical direction, straddling both the upper non-inclined wall portion 21A' and the inclined wall portion 21B'.

Description

Technical Field

[0001] The present invention relates to an exterior case used for applications such as housing and protecting hot water equipment therein.

Background Art

[0002] Specific examples of the exterior case include those described in Patent Documents 1 and 2. The exterior cases described in these documents house the hot water storage tank of a water supply device, and an upper lid is attached to the upper side of a case body portion formed by connecting a plurality of substantially rectangular side plates in a rectangular cylindrical shape. The plurality of side plates and the upper lid are formed by bending a metal panel material, and it is possible to suitably achieve weight reduction and durability of the whole while improving the appearance of the exterior case.

[0003] However, in the above prior art, as described below, there is still room for improvement.

[0004] That is, as a means for attaching the upper lid to the case body portion, the upper part of the case body portion is a stepped portion positioned more inward of the case than other general portions, and there is a means for fitting a downwardly projecting projecting piece portion provided on the outer peripheral edge portion of the upper lid to this stepped portion. However, even if such a means is adopted, there is a possibility that a gap may occur between them due to dimensional errors of the stepped portion of the case body portion and the projecting piece portion of the upper lid. Such a possibility leads to a decrease in the airtightness of the upper part of the exterior case and becomes a factor for dust, rainwater, etc. to enter the exterior case, so it is required to eliminate it as much as possible. On the other hand, the side panels that make up the case body often have a curved section that is arc-shaped in plan view at the corners of the case body. However, when a curved section is provided on the side panel, bending the curved section in the stepped recess is difficult. More specifically, when bending is performed to create a curved section in the stepped recess, a phenomenon called excess material occurs, resulting in numerous processing wrinkles (compression distortion), making it difficult to finish the curved section in the intended shape and size. To resolve this, for example, it becomes necessary to form the aforementioned curved section by press processing using a special mold, but this leads to increased complexity in the manufacturing process of the outer case and higher manufacturing costs. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2019-39614 [Patent Document 2] Japanese Patent Publication No. 2018-31519 [Patent Document 3] Japanese Patent Publication No. 2007-113861 [Patent Document 4] Japanese Patent Publication No. 2009-138951 [Overview of the project] [Problems that the invention aims to solve]

[0006] The present invention was conceived under the circumstances described above, and its objective is to provide an exterior case that makes it difficult for gaps to form at the attachment point of the top lid to the case body, facilitates and optimizes the provision of curved sections in the stepped recessed sections, and thereby facilitates manufacturing and reduces manufacturing costs. [Means for solving the problem]

[0007] To solve the above problems, the present invention employs the following technical measures.

[0008] The exterior case provided by the present invention comprises: a case body formed by combining a plurality of side plates that are upright in the vertical direction in a rectangular tube shape having an opening at the top, and a stepped recess provided in the upper region of the plurality of side plates that is located further inward than other general regions of the case; a top cover having a downwardly projecting projection on its outer edge, and attached to the upper part of the case body so as to overlap the outer surface of the stepped recess and covering the opening at the top; and curved portions that are provided on all or part of the plurality of side plates and form the corners of the case body in a plan view, wherein the stepped recess is The lid has first and second curved sections that extend horizontally and are spaced apart vertically, and the region between these first and second curved sections is an inclined wall section that is inclined so that the upper part is located inward towards the case, and the region above the first curved section is an upper non-inclined wall section that is vertical or stands upward at an angle smaller than the inclined wall section, and the protruding piece of the top lid is set to face the upper non-inclined wall section and to abut against the inclined wall section, and the curved section is provided with an upper opening-shaped notch that extends in the vertical direction, straddling both the upper non-inclined wall section and the inclined wall section.

[0009] This configuration yields the following effects: In other words, the stepped recesses provided in the upper regions of the multiple side plates that make up the case body are configured such that an inclined wall section is connected to the lower side of the upper non-inclined wall section, which is either non-inclined or has a small inclination angle, and the inclined wall section is positioned further inward towards the case as it rises. In contrast, the protruding piece of the top lid faces the upper non-inclined wall section and abuts against the inclined wall section. Therefore, it is possible to prevent the formation of an improper gap between the stepped recess of the case body and the protruding piece of the top lid, which could allow dust, rainwater, and other elements to enter. On the other hand, the curved section that forms the corner of the case body is provided with an upper opening-shaped notch that extends in the vertical direction, spanning both the upper non-sloping wall and the sloping wall of the stepped embossed section. This suppresses the occurrence of excess material, such as processing wrinkles (compression distortion), when forming the curved section, and allows the curved section to be smoothly finished to the intended shape and size. Therefore, it is not necessary to form the curved section using a special mold and a separate press process from other parts, and it can be easily formed using, for example, a panel bender. As a result, the manufacturing process of the outer case is simplified and manufacturing costs are reduced.

[0010] In the present invention, preferably, the lower portion of the notch corresponding to the inclined wall portion is narrower towards the bottom, with the circumferential width of the curved portion becoming narrower towards the bottom, and the upper portion corresponding to the upper non-inclined wall portion is not narrower towards the bottom.

[0011] This configuration yields the following effects: The inclined wall portion of the stepped recess on the side plate is sloped so that the upper part is located further inward towards the case. Therefore, when this inclined wall portion is bent, there is more excess material at the upper part of the inclined wall portion and less at the lower part. The lower part of the notch is narrowed at the bottom and has a width that corresponds to the aforementioned excess material, which is preferable for facilitating and optimizing the bending of the inclined wall portion. On the other hand, the upper part of the notch is not narrowed at the bottom, so the width of the upper non-sloping wall portion of the stepped recess can be prevented from becoming too narrow. Furthermore, since the upper non-sloping wall portion of the stepped recess is vertical or has a small angle of inclination, even if the upper part of the notch is not narrowed at the bottom, the bending of this upper portion can be performed appropriately.

[0012] In the present invention, preferably, the lowest part of the notch is located at an intermediate point in the vertical height direction of the inclined wall.

[0013] According to such a configuration, it is convenient for all or part of the notch portion to be covered by the protruding piece portion of the upper lid so as not to be visible or difficult to see from the outside.

[0014] In the present invention, preferably, as the notch portion, a plurality of notch portions are provided at the bending start point, bending end point of the curved portion, and intermediate positions between these bending start points and bending end points.

[0015] According to such a configuration, it is possible to more thoroughly facilitate and optimize the bending process when forming the curved portion.

[0016] In the present invention, preferably, the upper non-inclined wall portion in the curved portion is lower in height than the upper non-inclined wall portion in the non-curved portion of the side plate.

[0017] According to such a configuration, the volume of the curved portion can be reduced, so that the bending process when forming the curved portion is further facilitated.

[0018] Other features and advantages of the present invention will become more apparent from the following description of the embodiments of the invention with reference to the accompanying drawings.

Brief Description of the Drawings

[0019] [Figure 1] It is a schematic perspective view of a main part showing an example of an exterior case according to the present invention. [Figure 2] It is an exploded perspective view of the main part of FIG. 1. [Figure 3] (a) is a cross-sectional view of the main part of IIIa-IIIa in FIG. 1 (the internal structure is omitted), and (b) is a partially enlarged view of (a). [Figure 4] It is an enlarged perspective view of part IV of FIG. 2. [Figure 5] (a) is a plan view of the main part of FIG. 4, and (b) is a front view of the main part as viewed in the direction of arrow Vb in (a). [Figure 6] It is a front view of the main part of the developed state of the curved portion shown in FIGS. 4 and 5. [Modes for carrying out the invention]

[0020] Preferred embodiments of the present invention will be described in detail below with reference to the drawings.

[0021] The outer casing C shown in Figure 1 is an outer casing for a hot water storage tank, which houses the hot water storage tank 19, a component of a hot water storage system. As clearly shown in Figure 2, the outer case C comprises a top lid 3 and a plurality of side plates 2 (2A to 2D) that constitute the case body Ca. Both the top lid 3 and the plurality of side plates 2 are manufactured by processing metal plates. The plurality of side plates 2 include a pair of left and right side plates 2A and 2B, a front side plate 2C, and a rear side plate 2D. The pair of side plates 2A and 2B are positioned opposite each other with a gap between them, and their side edges 20a and 20b are connected to the side edges 20c of side plate 2C and the side edges 20d of side plate 2D by contact (e.g., fastening with screws not shown), thereby forming a rectangular cylindrical case body Ca.

[0022] A stepped recess 21 is provided in the upper region of the side plate 2A (see also the partially enlarged cross-sectional view in Figure 2, as well as Figures 3 and 4). The stepped recess 21 is a portion processed to be located further inward from the case than other general areas of the side plate 2A. This stepped recess 21 extends horizontally over approximately the entire width of the side plate 2A and forms first and second bent sections 22a and 22b that are spaced apart vertically from each other. The region between the first and second bent sections 22a and 22b is an inclined wall section 21B that is inclined so that the upper part is located further inward from the case, with an inclination angle of approximately 45° relative to the vertical. The region above the first bent section 22a is an upper non-inclined wall section 21A that is vertical or stands upward at a smaller inclination angle than the inclined wall section 21B.

[0023] One side edge 20a of the side plate 2A forms the corner portion Nb of the case body Ca, and this side edge 20a is provided with a curved portion 4 that is arc-shaped in plan view. The area indicated by the symbol S in Figures 4 and 5 is the curved portion 4. In the drawings, the upper non-sloping wall section 21A and the sloping wall section 21B that are located in the curved section 4 are referred to as the upper non-sloping wall section 21A' and the sloping wall section 21B'.

[0024] The curved portion 4 is provided with a plurality of notches 41, and the curved portion 4 has a plurality of convex portions 40 sandwiched between the plurality of notches 41. The height Ha of the upper non-inclined wall portion 21A' in the curved portion 4 (the height Ha of each convex portion 40) is lower than the height Hb of the upper non-inclined wall portion 21A in the non-curved portion of the side plate 2A.

[0025] Each notch 41 is an upper opening that extends in the vertical direction, straddling both the upper non-inclined wall portion 21A' and the inclined wall portion 21B' of the stepped pressing portion 21. Of each notch 41, the lower portion corresponding to the inclined wall portion 21B' (the portion below the first bent line portion 22a) is narrower towards the bottom (approximately V-shaped), with the circumferential width Wb of the curved portion 4 becoming narrower towards the bottom. On the other hand, of each notch 41, the upper portion corresponding to the upper non-inclined wall portion 21A' (the portion above the first bent line portion 22a) is not narrower towards the bottom, with a constant circumferential width Wa. The multiple notches 41 include a notch 41a located at the starting point of the bend of the curved portion 4, a notch 41b located at the ending point of the bend, and at least one notch 41c located at an intermediate point between them (a position somewhere between the starting point and the ending point of the bend, and not necessarily in the center).

[0026] At one end of the curved section 4, L-shaped extensions 29a and 29b are connected via an extension 28. The extensions 29a and 29b are used to connect the side plate 2C to the side plate 2A. As shown by the dashed line in Figure 5(a), an L-shaped portion 29c is provided at one end of the side plate 2C, and this portion 29c is superimposed on and connected to the extensions 29a and 29b.

[0027] Figure 6 shows the panel material 2A' in an unfolded state near the curved portion 4 (parts corresponding to each part of the side plate 2A are indicated by the same reference numerals as the side plate 2A). The curved portion 4 can be formed by bending the panel material 2A' shown in the figure.

[0028] Figures 4 and 5 show the configuration of one side edge 20a of side plate 2A. In Figure 2, side plate 2A is symmetrical, and both side edges 20a of side plate 2A have similar configurations. Side plate 2B has the same configuration as side plate A. Side plate 2C does not have a curved portion 4, as can be understood from the configuration shown by the dashed line in Figure 5. The same applies to side plate 2D. The case body Ca is provided with a total of four curved portions 4.

[0029] As clearly shown in Figure 3, the top cover 3 has a structure in which a rectangular flat plate portion 30 and a protruding piece portion 31 that protrudes downward from the outer peripheral edge of the plate portion 30 are integrally formed. Preferably, the protruding piece portion 31 is provided with a folded portion 31a, and the lower end of the protruding piece portion 31 is not sharp. The protruding piece portion 31 is a rectangular loop in plan view, and the top cover 3 is attached to the case body portion Ca with the protruding piece portion 31 fitted onto the stepped recess portion 21. The protruding piece portion 31 faces the outer surface of the upper non-inclined wall portion 21A, and the lower end of the protruding piece portion 31 is set to abut against the inclined wall portion 21B.

[0030] At the four corners Na of the top lid 3, the protruding pieces 31 are formed in a curved shape corresponding to the curved portion 4 of the case body Ca, and in this portion as well, the protruding pieces 31 are positioned to face the upper non-inclined wall portion 21A' of the curved portion 4 and to abut against the inclined wall portion 21B'. It is being done. The lowest part 410 of the notch 41 is located at an intermediate point, such as approximately the center in the vertical height direction of the inclined wall portion 21B' (see Figures 4 and 5). In contrast, although not shown in the drawings, preferably the lower end height of the protruding piece 31 of the top cover 3 is set to be equal to or lower than the lowest part of the notch 41, so that the entire notch 41 is hidden by the protruding piece 31.

[0031] Next, the function of the aforementioned outer casing will be explained.

[0032] First, when the top cover 3 is attached to the case body Ca, the downward-projecting protruding piece 31 of the top cover 3 approaches or comes into contact with the upper non-inclined wall portion 21A of the stepped recess portion 21 of the case body Ca, and also abuts against the inclined wall portion 21B. Therefore, it is possible to prevent the formation of an improper gap between the protruding piece 31 and the stepped recess portion 21 that could allow dust, rainwater, and other elements to enter.

[0033] The curved portion 4 of the corner portion Nb of the case body Ca is provided with an upper open notch 41 that extends across both the upper non-inclined wall portion 21A' and the inclined wall portion 21B'. This suppresses the excess material phenomenon, which causes frequent processing wrinkles (compression distortion), when the curved portion 4 is formed by bending. Therefore, the curved portion 4 can be finished precisely to the intended shape and size. According to this embodiment, the curved portion 4 does not need to be formed by press working using a special mold, and can be easily formed using, for example, a panel bender. Therefore, the manufacturing work of the outer case C is simplified, and manufacturing costs are reduced.

[0034] The inclined wall portion 21B of the stepped recess portion 21 of the side plate 2A is an inclined wall portion that is positioned more towards the inside of the case at the top. Therefore, when forming the curved portion 4 by bending, the amount of excess material will be greater at the top of the inclined wall portion 21B' of the curved portion 4 and less at the bottom. In contrast, the lower part of the notch portion 41 is narrower at the bottom, which further reduces the amount of excess material during bending and improves the workability of the curved portion 4. On the other hand, the upper part of the notch portion 41 is not narrower at the bottom and has a constant width, which prevents the width of the upper part of each convex portion 40 of the curved portion 4 (the width of the upper non-inclined wall portion 21A') from becoming too small.

[0035] In this embodiment, the processability of the curved portion 4 can be improved by providing multiple notches 41 at the bending start point, bending end point, and bending midpoint of the curved portion 4, and by ensuring that the height Ha of the upper non-inclined wall portion 21A' in the curved portion 4 is lower than the height Hb of the upper non-inclined wall portion 21A in the non-curved portion.

[0036] The present invention is not limited to the embodiments described above. The specific configuration of each part of the exterior case according to the present invention can be modified in various ways within the scope intended by the present invention.

[0037] The case body can be a rectangular tube or a square tube, and the specific shape, size, and material of the case body and lid are not limited. The curved portion of the side plate is not limited to being located on the side edge of the side plate. For example, the present invention can also be applied when the side plate is bent at an angle of approximately 90° in an L-shape, and the bent portion (corner portion) is the curved portion intended by the present invention. The exterior case according to the present invention is not limited to housing a hot water storage tank, but can also be used as an exterior case for a hot water unit housing other hot water equipment and devices, as well as for housing various other items such as heat pumps and air conditioning systems. The specific use of the exterior case is not limited. [Explanation of Symbols]

[0038] C Outer case Ca case body Nb corner section (case body section) 2(2A~2D) Side plate 21-step push section 21A,21A' Upper non-slanted wall 21B,21B' Slanted wall section 22a, 22b First and second bent sections 3 Top lid 31 Projecting piece 4. Curved section 41 Notch 410 Bottom (notch)

Claims

1. The case body is constructed by combining multiple side plates that are upright in the vertical direction into a rectangular tube shape with an opening at the top, and the upper region of the multiple side plates is provided with a stepped recess that is located further inward than other general areas of the case, A top cover having a downward-facing projection on its outer edge, and attached to the upper part of the case body so as to overlap the outer surface of the stepped portion, covering the top opening, A curved portion in the shape of an arc in plan view is provided on all or part of the plurality of side plates and forms the corner portion of the case body, An outer case equipped with, The stepped portion has first and second bent sections that extend horizontally and are spaced apart vertically, and the region between these first and second bent sections is an inclined wall section that is inclined so that the upper part is located further inward towards the case, and the region above the first bent section is an upper non-inclined wall section that is vertical or stands upward at a smaller angle of inclination than the inclined wall section. The protruding piece of the upper lid is set to face the upper non-inclined wall portion and to abut against the inclined wall portion. The exterior case is characterized in that the curved portion is provided with an upper opening-shaped notch that extends in the vertical direction, straddling both the upper non-inclined wall portion and the inclined wall portion.

2. The outer case according to claim 1, An outer casing case in which, of the notched portion, the lower portion corresponding to the inclined wall portion is tapered downwards, with the circumferential width of the curved portion becoming narrower towards the bottom, and the upper portion corresponding to the upper non-inclined wall portion is not tapered downwards.

3. The outer case according to claim 1, The outer casing is located at the lower end of the notch, which is midway along the vertical height of the inclined wall.

4. An outer case according to any one of claims 1 to 3, An outer casing is provided with the aforementioned notches, which include the starting point of the bend, the ending point of the bend in the curved portion, and a plurality of notches located at intermediate points between these starting and ending points.

5. The outer case according to claim 4, An outer casing in which the upper non-sloping wall portion in the curved portion is lower in height than the upper non-sloping wall portion in the non-curved portion of the side plate.

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