Hot water tank unit

Abstract

To provide a hot water storage tank unit capable of exhibiting improved moldability of a heat insulation member.SOLUTION: A hot water storage tank unit of this disclosure includes a hot water storage tank for storing water, and a foamed heat insulation member covering the periphery of the hot water storage tank. The foamed heat insulation member is constituted by a plurality of divided heat insulation members, and has a plurality of burrs 42b formed on a side opposite from the hot water storage tank along a division surface 42a of the divided heat insulation members. A thickness of the burr is 1 mm or more and 20 mm or less. In the hot water storage tank unit including the hot water storage tank for storing water and the foamed heat insulation member covering the periphery of the hot water storage tank, the foamed heat insulation member is constituted by the plurality of divided heat insulation members, and has the plurality of burrs formed on the side opposite from the hot water storage tank along the division surface of the divided heat insulation members. The burrs are cut with roots left behind.SELECTED DRAWING: Figure 11

Description

[Technical Field]

[0001] The present disclosure relates to a hot water storage tank unit. [Background technology]

[0002] Conventionally, the insulating member used in the hot water storage tank unit of a hot water heater is formed by dividing it into multiple parts shaped according to the outer shape of the hot water storage tank, and attached to the periphery of the hot water storage tank. The insulating member is formed from a foam insulating material such as rigid polyurethane foam or expanded polystyrene, and is foam-molded using a resin molding die consisting of an upper die and a lower die (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-107015 Summary of the Invention [Problem to be solved by the invention]

[0004] However, conventional methods for manufacturing insulating members using resin molding dies have had the problem that when foam molding the insulating member, gas becomes trapped in the upper part of the cavity of the resin molding die, preventing the resin material from spreading throughout the cavity, resulting in poor moldability.

[0005] The present disclosure has been made to solve the above-mentioned problems, and aims to obtain a hot water storage tank unit with improved formability of the insulating member. [Means for solving the problem]

[0006] The hot water storage tank unit according to the present disclosure is a hot water storage tank unit including a hot water storage tank for storing water and a foam insulation member covering the periphery of the hot water storage tank, wherein the foam insulation member is composed of a plurality of divided insulation members and has a plurality of burrs formed on the opposite side of the hot water storage tank along the dividing surfaces between the divided insulation members, Multiple The thickness of the burr is between 1mm and 20mm, and multiple burrs are cut off leaving the base. Among the multiple burrs, the width of the burrs at the locations where the foam insulation material is thicker is larger than that at the locations where the foam insulation material is thin. It is characterized by:

[0007] The hot water storage tank unit according to the present disclosure is a hot water storage tank unit including a hot water storage tank for storing water and a foam insulation member covering the periphery of the hot water storage tank, wherein the foam insulation member is composed of a plurality of divided insulation members, and has a plurality of burrs formed on the opposite side of the hot water storage tank along the dividing surfaces of the divided insulation members, and the plurality of burrs are cut off while leaving their bases. Among the multiple burrs, the width of the burrs at the locations where the foam insulation material is thicker is larger than that at the locations where the foam insulation material is thin. It is characterized by: [Effects of the Invention]

[0008] The hot water storage tank unit according to the present disclosure has the advantage of being able to improve the heat insulating performance of the entire hot water storage tank unit by improving the formability of the heat insulating member. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view showing a hot water storage type water heater equipped with a hot water storage tank unit according to a first embodiment. [Figure 2] 1 is a circuit diagram of a hot water storage type water heater equipped with a hot water storage tank unit of embodiment 1. FIG. [Figure 3] FIG. 1 is a perspective view showing a hot water storage tank unit according to a first embodiment. [Figure 4] 1 is a cross-sectional view showing a hot water storage tank unit according to a first embodiment. [Figure 5] FIG. 2 is a perspective view showing a foam insulation member of the hot water storage tank unit of the first embodiment. [Figure 6]3 is a cross-sectional view showing a foam insulation member of the hot water storage tank unit of the first embodiment. FIG. [Figure 7] FIG. 2 is a perspective view showing a resin molding die for molding the forward body heat insulating member of the first embodiment. [Figure 8] FIG. 2 is a plan view showing a resin molding die for molding the forward body heat insulating member of the first embodiment. [Figure 9] FIG. 2 is a perspective view for explaining a manufacturing method of the hot water storage tank unit of the first embodiment. [Figure 10] 10 is a cross-sectional view illustrating a manufacturing method of a hot water storage tank unit using a resin molding die for molding a front body insulating member according to the first embodiment. FIG. [Figure 11] 3 is a schematic view showing a forward body heat insulating member molded using the resin molding die of the first embodiment. FIG. [Figure 12] FIG. 2 is a plan view showing a resin molding die for molding the upper heat insulating member of the first embodiment. [Figure 13] 10 is a cross-sectional view illustrating a method for manufacturing a hot water storage tank unit using a resin molding die for molding an upper insulation member according to the first embodiment. FIG. [Figure 14] 3 is a schematic view showing an upper heat insulating member molded using the resin molding die of the first embodiment. FIG. [Figure 15] FIG. 10 is a perspective view showing a modified example of the foam insulation member of the hot water storage tank unit of the first embodiment. [Figure 16] FIG. 10 is a plan view showing a modified example of a resin molding die for molding the forward body heat insulating member of the first embodiment. [Figure 17] FIG. 10 is a plan view showing a first modified example of the resin molding die for molding the upper heat insulating member of the first embodiment. [Figure 18] FIG. 10 is a plan view showing a second modified example of the resin molding die for molding the upper heat insulating member of the first embodiment. [Figure 19] FIG. 10 is a perspective view showing a resin molding die for molding a forward body heat insulating member according to the second embodiment. [Figure 20] FIG. 10 is a plan view showing a resin molding die for molding a forward body heat insulating member according to the second embodiment. [Figure 21] FIG. 10 is a cross-sectional view illustrating a method for manufacturing a hot water storage tank unit using a resin molding die for molding a front body insulating member according to the second embodiment. [Figure 22] FIG. 11 is a perspective view showing a resin molding die for molding a forward body heat insulating member according to the third embodiment. [Figure 23] FIG. 11 is a plan view showing a resin molding die for molding a forward body heat insulating member according to the third embodiment. [Figure 24] A cross-sectional view for explaining a manufacturing method of a hot water storage tank unit using a resin molding die for molding a forward body insulating member of embodiment 3. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment will be described with reference to the drawings. In the following drawings, the same or corresponding parts are designated by the same reference numerals, and the description thereof will not be repeated. In the following description, the term "water" generally means liquid water, and can include water ranging from low temperature water to high temperature hot water.

[0011] Embodiment 1 A resin molding die, a method for manufacturing a hot water storage tank unit using the resin molding die, and the hot water storage tank unit according to the first embodiment will be described with reference to FIGS. 1 to 11. FIG.

[0012] First, the overall configuration of a hot water storage type water heater equipped with a hot water storage tank unit of embodiment 1 will be described with reference to Figures 1 and 2. Figure 1 is a perspective view showing a hot water storage type water heater 1000 equipped with a hot water storage tank unit 100 of this embodiment, and Figure 2 is a circuit diagram of the hot water storage type water heater 1000.

[0013] 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. The heat pump unit 110 and the hot water storage tank unit 100 are connected via a heat pump supply pipe 21, a heat pump return pipe 22, and electrical wiring (not shown). Note that the heat pump supply pipe 21 and the heat pump return pipe 22 are not shown in FIG. 1.

[0014] 2, the hot water storage tank unit 100 includes a hot water storage tank 10 for storing hot water, and a pressure reducing valve 23, a relief valve 24, a mixing valve 25, a switching valve 26, and a check valve 27 as functional valves for performing the functions of heating, hot water supply, filling, etc., by the hot water storage type water heater 1000. A cold water pipe 28 is connected to the bottom of the hot water storage tank 10 to supply water from a water source such as city water.

[0015] Water stored in the lower part of the hot water storage tank 10 is sent by the heat source pump 29 to the heat pump unit 110 via the heat pump supply pipe 21. The water is then heated to a high temperature by the heat pump unit 110 using heat from the atmosphere, and is returned to the upper part of the hot water storage tank 10 through the heat pump return pipe 22 and stored there.

[0016] The temperature inside the hot water storage tank 10 increases from the bottom to the top, so water with low, medium, and high temperature distributions 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 inside the hot water storage tank 10. The temperature sensors 30 may be, for example, thermistors.

[0017] The heat pump unit 110 is a heating means 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 (CO2) to a high temperature and high pressure, a condenser that condenses the refrigerant discharged from the compressor and heats the water with the heat of condensation by exchanging heat with the low-temperature water sent from the hot water storage tank 10, 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. The internal configuration of the heat pump unit 110 is not shown in the drawings.

[0018] The water heated by the heat pump unit 110 and stored in the hot water storage tank 10 is taken out from the top of the hot water storage tank 10 and sent through the hot water pipe 31 to the mixing valve 25, where it is mixed with water from the branch water supply pipe 32 branching off from the cold water pipe 28 in the mixing valve 25 to the desired temperature, and then passed through the hot water supply pipe 33 and supplied to a hot water terminal 34 such as a faucet or shower for use.

[0019] Next, the structure of the hot water storage tank unit 100 will be described with reference to Figs. 3 to 6. Fig. 3 is a perspective view showing the hot water storage tank unit 100, and Fig. 4 is a cross-sectional view showing the hot water storage tank unit 100. Note that Fig. 3 omits a portion of the exterior case 50 of the hot water storage tank unit 100 shown in Fig. 1, and mainly shows the interior housed in the exterior case 50. Fig. 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 cross-sectional view taken along line AA of Fig. 5.

[0020] In addition to the components such as the hot water storage tank 10 (not shown in Figure 3) described in Figure 2, the hot water storage tank unit 100 further includes a foam insulation member 40 that covers the hot water storage tank 10, an outer case 50 that houses the foam insulation member 40 and the hot water storage tank 10 inside, and legs 60 that are provided below the outer case 50.

[0021] The exterior case 50 houses the hot water storage tank 10 and the foam insulation member 40 inside, and is provided for the purposes of improving the design of the equipment, protecting the hot water storage tank 10, and providing insulation. The exterior case 50 is made of, for example, a thin steel plate or a weather-resistant and flame-retardant resin.

[0022] 1, the exterior case 50 is configured in a vertically long box shape in the height direction of the hot water storage tank unit 100, and is made up of a front panel 51 located in front of the hot water storage tank 10 and openable for maintenance, a riser plate 52 for connecting external piping outside the hot water storage tank unit 100 for water supply, hot water supply, the heat pump, and water returning to and from the bathtub, two side panels 53 and 54 located on the sides of the hot water storage tank 10, a back panel 55 located behind the hot water storage tank 10, a top panel 56 located above the hot water storage tank 10, and a bottom panel 57 located below the hot water storage tank 10. The front panel 51, riser plate 52, side panels 53 and 54, back panel 55, top panel 56, and bottom panel 57 are joined together by fitting, bolting, or the like where necessary to form the exterior case 50.

[0023] The legs 60 are fixed inside the exterior case 50, with internal legs provided below the hot water storage tank 10 and external legs attached below the bottom plate 57 of the exterior case 50, and support the hot water storage tank 10. In this embodiment, as shown in Fig. 3, an example in which three legs 60 are provided is shown.

[0024] As shown in Fig. 4, the hot water storage tank 10 is constructed by welding three members together: a cylindrical body plate 11 made of a material such as stainless steel; an upper curved plate 12 having a curved surface with a bowl-shaped curvature that covers the upper opening of the body plate 11; and a lower curved plate 13 having a curved surface with a bowl-shaped curvature that covers the lower opening of the body plate 11. The upper curved plate 12 and the lower curved plate 13 of the hot water storage tank 10 are provided with joints 12a and 13a for connecting a cold water pipe 28 and a hot water pipe 31.

[0025] The foam insulation member 40 is arranged to cover the periphery of the hot water storage tank 10, and as shown in Figures 4 and 5, is composed of four divided insulation members: an upper insulation member 41, a front body insulation member 42, a rear body insulation member 43, and a lower insulation member 44.

[0026] The upper insulating member 41 and the lower insulating member 44 are provided to cover the curved upper curved plate 12 and the curved lower curved plate 13 of the hot water storage tank 10, respectively, and their inner surfaces are bowl-shaped and curved. Also, as shown in Fig. 4, the upper insulating member 41 and the lower insulating member 44 may have a structure in which a part of the hot water storage tank 10 is exposed in order to connect piping to the joints 12a and 13a.

[0027] As shown in Figure 6, which is a cross-sectional view taken along line AA in Figure 5, the front and rear insulating members 42 and 43 are formed to cover the cylindrical body panel 11, i.e., the body panel 11 is circular in cross section, and line BB is the division position of the two separate insulating members. The front insulating member 42 covers the front side of the hot water storage tank 10, and the rear insulating member 43 covers the rear side of the hot water storage tank 10. The front and rear of the hot water storage tank 10 are not limited to the direction described in this embodiment.

[0028] Furthermore, at least one of the upper insulation member 41, forward insulation member 42, aft insulation member 43, and lower insulation member 44 has multiple burrs at the dividing surfaces, which are the contact surfaces with other divided insulation members. The dividing surface is, for example, the surface at the dividing position indicated by line BB in Fig. 6, and in Fig. 6, the forward insulation member 42 and the aft insulation member 43 are in contact at the surface indicated by line BB. Details of the burrs will be described later when explaining the manufacturing method of the foam insulation member 40.

[0029] The thickness of the four divided insulating members, the upper insulating member 41, the front insulating member 42, the rear insulating member 43, and the lower insulating member 44, is preferably formed to be 1 mm or more and 400 mm or less, taking into consideration ease of installation around the hot water storage tank 10.

[0030] Furthermore, since various necessary components are attached to the upper insulation member 41, the forward insulation member 42, the aft insulation member 43, and the lower insulation member 44 from the outside, they have an uneven surface as shown in Fig. 5. Note that segment insulation members without an uneven surface may also be used.

[0031] The foam insulation member 40 has an upper insulation member 41, a forward insulation member 42, and an aft insulation member 43 formed from rigid polyurethane foam, and a lower insulation member 44 formed from expanded polystyrene. Rigid polyurethane foam has low thermal conductivity, so using a foam insulation member 40 formed from rigid polyurethane foam provides particularly excellent insulation performance. Also, as mentioned above, since the lower part of the hot water storage tank 10 is at a low temperature, the lower insulation member 44 may not require the same insulation performance as the upper insulation member 41, the forward insulation member 42, and the aft insulation member 43. Therefore, by forming the lower insulation member 44 from expanded polystyrene, which has greater mechanical strength than rigid polyurethane foam, the hot water storage tank 10 can be stably supported.

[0032] In this embodiment, the foam insulation member 40 is described as being formed from rigid polyurethane foam and expanded polystyrene, but this is not limited to this, and the entire member may be formed from rigid polyurethane foam, or may be formed using other foamed resin materials.

[0033] Here, rigid polyurethane foam will be explained. Polyurethane foam has a cellular structure and is classified into flexible polyurethane foam and rigid polyurethane foam. Of these, flexible polyurethane foam has a cell shape with interconnected cells (open cells) where the cell membrane is broken, and has a structure that allows heat to escape easily, resulting in low thermal insulation properties. It is used in mattresses, car seats, and other products that require elastic performance. On the other hand, rigid polyurethane foam has a cell shape with closed cells (closed cells) where the cell membrane is not broken, and is used as a thermal insulation material because it has excellent strength and thermal insulation properties. Therefore, when polyurethane foam is used as the material for the foam insulation member 40 of this embodiment, it is limited to rigid polyurethane foam.

[0034] Next, the resin molding die and the method for manufacturing the hot water storage tank unit using the resin molding die according to the first embodiment will be described with reference to FIGS.

[0035] The configuration of the resin molding die will be described below.

[0036] First, a resin molding die 500 for molding the forward section heat insulating member 42 of the foam heat insulating member 40 as a resin member will be described with reference to Figures 7 and 8. Figure 7 is a perspective view showing the resin molding die 500 for molding the forward section heat insulating member 42 of this embodiment, and Figure 8 is a plan view showing the resin molding die 500.

[0037] As shown in Figure 7, the resin molding mold 500 for molding the forward body insulation member 42 consists of a lower mold 510 and an upper mold 520, and by closing the upper mold 520 on the lower mold 510, the resin material filled in the cavity formed by the lower mold 510 and the upper mold 520 can be molded.

[0038] The lower mold 510 has a recess 512 surrounded by a first outer edge portion 511. More specifically, the recess 512 is a portion recessed from the first outer edge portion 511 of the lower mold 510. The recess 512 has a shape obtained by dividing a substantially cylindrical shape into two in the height direction. The surface forming the recess 512 is not limited to being a curved surface or a flat surface, and may have projections and recesses.

[0039] The upper mold 520 has a convex portion 522 surrounded by a second outer edge portion 521. More specifically, the convex portion 522 is a portion that protrudes further than the second outer edge portion 521 of the upper mold 520. The convex portion 522 has a shape obtained by dividing a substantially cylindrical shape into two in the height direction. When the upper mold 520 is closed on the lower mold 510, the first outer edge portion 511 and the second outer edge portion 521 come into contact with each other, and the convex portion 522 is housed in the concave portion 512, thereby forming a cavity 501 between the concave portion 512 and the convex portion 522. The surface on which the convex portion 522 is formed is not limited to being curved or flat, and may have irregularities.

[0040] Here, the cavity 501 will be described in detail. As shown in the cross-sectional view of Fig. 10, the cavity 501 is an area surrounded by the lower mold 510 and the upper mold 520 within the recess 512 of the lower mold 510. In other words, 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. An air vent 502 is provided at the top of the cavity 501, extending in a horizontal direction perpendicular to the up-down direction in which gravity acts and in a direction parallel to the surfaces of the first outer edge 511 and the second outer edge 521. The air vent 502 connects the top of the cavity 501 to the outside of the resin molding die 500.

[0041] A first outer edge portion 511 of lower mold 510 and a second outer edge portion 521 of upper mold 520 are portions that face each other and are in partial contact when upper mold 520 is closed on lower mold 510, and a plurality of recessed surfaces 513, 523 that function as air vents are formed at intervals at opposing positions on lower mold 510 and upper mold 520. As shown in Fig. 8(A) which is a plan view of upper mold 520 and Fig. 8(B) which is a plan view of lower mold 510, each recessed surface 513, 523 has the same width, and the distance between each adjacent recessed surface 513, 523 is the same.

[0042] Here, air vent 502 will be described in detail. As shown in FIG. 10 , air vent 502 is formed at the top of cavity 501, where first outer edge 511 and second outer edge 512 face each other across a space defined by recessed surfaces 513 and 523 when upper mold 520 is closed on lower mold 510. That is, air vent 502 is formed by a plurality of recessed surfaces 513 and 523, each having the same width. Air vent 502 communicates between the top of cavity 501 and the outside of resin molding die 500. Therefore, air vent 502 allows gas present in cavity 501 of resin molding die 500 to be released to the outside of resin molding die 500. As shown in FIG. 8, the cavity 501 formed in the recess 512 of the lower mold 510 is rectangular in plan view, and recessed surfaces 513 are provided at the four corners of the rectangle indicated by dashed lines in FIG. 8(B). Therefore, when the upper mold 520 is closed on the lower mold 510, air vents 502 are formed that connect the rectangular corners to the outside of the resin molding die 500.

[0043] Next, a resin molding die 600 for molding the upper insulation member 41 of the foam insulation member 40 as a resin member will be described in detail with reference to Fig. 12. Fig. 12 is a plan view showing the resin molding die 600 for molding the upper insulation member 41 of this embodiment.

[0044] The resin molding mold 600 for molding the upper insulation member 41 consists of an upper mold 620 shown in Figure 12(A) and a lower mold 610 shown in Figure 12(B), and by closing the upper mold 620 on the lower mold 610, the resin material filled in the cavity formed by the lower mold 610 and the upper mold 620 can be molded.

[0045] 12(B), the lower mold 610 has a recess 612 surrounded by a first outer edge portion 611. More specifically, the recess 612 is a portion recessed from the first outer edge portion 611 of the lower mold 610. The recess 612 has a substantially circular bowl shape in a plan view. The surface forming the recess 612 is not limited to a curved surface or a flat surface, and may have projections and recesses.

[0046] As shown in FIG. 12(A), the upper mold 620 has a convex portion 622 surrounded by a second outer edge portion 621. More specifically, the convex portion 622 is a portion that protrudes further than the second outer edge portion 621 of the upper mold 620. The convex portion 622 is substantially circular in plan view and has a curved shape. When the upper mold 620 is closed on the lower mold 610, the first outer edge portion 611 and the second outer edge portion 621 come into contact with each other, and the convex portion 622 is housed in the concave portion 612, thereby forming a cavity 601 between the concave portion 612 and the convex portion 622. The surface on which the convex portion 622 is formed is not limited to a curved surface or a flat surface, and may have irregularities.

[0047] Here, the cavity 601 will be described in detail. As shown in the cross-sectional view of Fig. 13, the cavity 601 is an area surrounded by the lower mold 610 and the upper mold 620 within the recess 612 of the lower mold 610. In other words, the cavity 601 is formed only within the recess 612 of the lower mold 610, and is not formed on the upper mold 620 side. An air vent 602 is provided at the top of the cavity 601, extending in a horizontal direction perpendicular to the up-down direction in which gravity acts and in a direction parallel to the surfaces of the first outer edge 611 and the second outer edge 621. The air vent 602 connects the top of the cavity 601 to the outside of the resin molding die 600.

[0048] A first outer edge 611 of lower mold 610 and a second outer edge 621 of upper mold 620 are portions that face each other and are in partial contact when upper mold 620 is closed on lower mold 610, and a plurality of recessed surfaces 613, 623 that function as air vents are formed at intervals at opposing positions on lower mold 610 and upper mold 620. As shown in Fig. 12, each of recessed surfaces 613, 623 has the same width, and the distance between each adjacent recessed surface 613, 623 is the same.

[0049] Here, air vent 602 will be described in detail. As shown in FIG. 13 , when upper mold 620 is closed on lower mold 610, air vent 602 is formed at the top of cavity 601, where first outer edge 611 and second outer edge 621 face each other across a space defined by recessed surfaces 613, 623. That is, air vent 602 is formed by a plurality of recessed surfaces 613, 623, and each air vent has the same width. Air vent 602 communicates between the top of cavity 601 and the outside of resin molding die 600. Therefore, air vent 602 allows gas present in cavity 601 of resin molding die 600 to be released to the outside of resin molding die 600.

[0050] Hereinafter, a method for manufacturing the hot water storage tank unit 100 using the above-described resin molding dies 500 and 600 will be described.

[0051] In the manufacturing method of the hot water storage tank unit 100, first, the hot water storage tank 10, the outer case 50 that houses the hot water storage tank 10, and the resin molding dies 500, 600 for forming the foamed insulation member 40 are prepared. The hot water storage tank 10 has the structure described above.

[0052] Next, the upper insulating member 41, the forward insulating member 42, the aft insulating member 43, and the lower insulating member 44 that make up the foam insulating member 40 are foam-molded using a resin molding die.

[0053] Here, a method for molding the front body insulation member 42 using the resin molding die 500 will be described in detail with reference to Fig. 9 to Fig. 11. Fig. 9 is a perspective view for explaining the method for manufacturing the hot water storage tank unit 100 using the resin molding die 500, and Fig. 10 is a cross-sectional view for explaining the method for manufacturing the hot water storage tank unit 100 using the resin molding die 500. Fig. 11 is a schematic diagram showing the front body insulation member 42 molded using the resin molding die 500.

[0054] First, as shown in Figure 9, a resin molding die 500 is prepared, and a resin material, which is a liquid mixture, is injected into recess 512 of lower die 510 while an injection head 900 for injecting resin is moved as shown by the arrow. At this time, an overpack, or overfilling, is performed in which an amount of resin material is filled that is greater than the required amount obtained by multiplying the volume of the product shape by the free-form density of the resin material, i.e., the density after foaming in an unloaded state.

[0055] After the resin material is injected into the recess 512 of the lower mold 510, the upper mold 520 is closed on the lower mold 510 to apply pressure. Then, as shown in FIG. 10 , the resin material 400 foams and fills the cavity 501 between the upper mold 520 and the lower mold 510. At this time, the gas that was present in the cavity 501 is released to the outside of the resin molding die 500 through the air vent 502 as the resin material 400 foams and fills the cavity 501 from the bottom to the top. Because the resin material 400 is overfilled, after filling the entire cavity 501, it also fills the air vent 502 formed by the upper mold 520, the lower mold 510, and the recessed surfaces 513 and 523 and is then cured.

[0056] At this time, there is no need to evacuate the cavity 501 because the gas inside the cavity 501 is released to the outside of the resin molding die 500 through a plurality of air vents 502 formed in communication with the top of the cavity 501. Therefore, a die having a simpler structure can be used.

[0057] After the forward section insulation member 42 has been molded in the above manner, it is removed from the resin molding die 500. As shown in the schematic diagram of FIG. 11 , the removed forward section insulation member 42 has multiple burrs 42b caused by the resin material filled in the air vents 502 of the resin molding die 500. That is, the forward section insulation member 42 has multiple burrs 42b on the parting surface 42a that contacts the aft section insulation member 43. Furthermore, since the air vents 502 have the same width, the multiple burrs 42b also have the same width W. Furthermore, the thickness H of the burrs 42b shown in FIG. 10 is, for example, 1 mm or more and 20 mm or less.

[0058] The burr 42b is a part that protrudes parallel to the dividing surface 42a of the front body insulating member 42 to the opposite side of the hot water storage tank 10 when each divided insulating member is used to cover the hot water storage tank 10.

[0059] Similarly, the rear section insulating member 43 can be foam-molded using a resin molding die having a configuration similar to that of the resin molding die 500. Like the forward section insulating member 42, the rear section insulating member 43 also has multiple burrs formed on the opposite side of the hot water storage tank 10, parallel to the dividing surface that contacts the forward section insulating member 42.

[0060] Here, if the thickness of the burr is small, even if the burr 42b formed on the dividing surface 42a of the forward section insulation member 42 and the burr formed on the dividing surface of the aft section insulation member 43 are arranged to come into contact with each other, the dividing surfaces can be aligned to cover the hot water storage tank 10. Note that in order to prevent the contact surfaces consisting of the dividing surfaces and burrs of the forward section insulation member 42 and the aft section insulation member 43 from interfering with each other, the positions of the air vents in each resin molding mold may be staggered, and a structure in which burrs are formed alternately when the molds are attached to the hot water storage tank may be used.

[0061] Here, a method for molding the upper insulation member 41 using the resin molding die 600 will be described in detail with reference to Fig. 13 and Fig. 14. Fig. 13 is a cross-sectional view for explaining a method for manufacturing the hot water storage tank unit 100 using the resin molding die 600. Fig. 14 is a schematic view showing the upper insulation member 41 molded using the resin molding die 600.

[0062] First, a resin molding die 600 is prepared, and an injection head for injecting resin is used to inject a liquid mixture of resin material into the recess 612 of the lower die 610. At this time, overpacking, or overfilling, is performed in which an amount of resin material is filled that is greater than the required amount obtained by multiplying the volume of the product shape by the free-form density of the resin material, i.e., the density after foaming in an unloaded state.

[0063] After the resin material is injected into the recess 612 of the lower mold 610, the upper mold 620 is closed on the lower mold 610 and pressure is applied. Then, as shown in FIG. 13 , the resin material 400 foams and fills the cavity 601 between the upper mold 620 and the lower mold 610. At this time, the gas that was present in the cavity 601 is released to the outside of the resin molding die 600 through the air vent 602 as the resin material 400 foams and fills the cavity 601 from the bottom to the top. Because the resin material 400 is overfilled, after filling the entire cavity 601, it also fills the air vent 602 formed by the upper mold 620, the lower mold 610, and the recessed surfaces 613 and 623 and is then cured.

[0064] At this time, there is no need to evacuate the cavity 601 because the gas inside the cavity 601 is released to the outside of the resin molding die 600 through a plurality of air vents 602 formed in communication with the top of the cavity 601. Therefore, a die with a simpler structure can be used.

[0065] After the upper insulation member 41 is molded as described above, it is removed from the resin molding die 600. As shown in a schematic diagram in FIG. 14 , the removed upper insulation member 41 has multiple burrs 41b caused by the resin material filled in the air vents 602 of the resin molding die 600. That is, the upper insulation member 41 has multiple burrs 41b on the parting surfaces 41a that contact the forward section insulation member 42 and the aft section insulation member 43. Furthermore, since the air vents 602 have the same width, the multiple burrs 41b also have the same width. The thickness of the burrs 41b is, for example, 1 mm or more and 20 mm or less.

[0066] The burr 41b is a part that protrudes parallel to the divided surface 41a of the upper insulating member 41 to the opposite side of the hot water storage tank 10 when each divided insulating member is used to cover the hot water storage tank 10.

[0067] Here, the divided surfaces of the upper insulation member 41 that contact the forward insulation member 42 and the aft insulation member 43 may have protruding portions that protrude toward the forward insulation member 42 or the aft insulation member 43 in order to align the forward insulation member 42 and the aft insulation member 43. If a portion of the divided surface of the forward insulation member 42 or the aft insulation member 43 that corresponds to the protruding portion is recessed, they will engage with each other, facilitating alignment. Note that this protruding portion is intended to facilitate alignment between the divided insulation members, and is formed to protrude beyond the thickness of the burr formed on the divided surfaces.

[0068] Similarly, the lower insulating member 44 can be foam-molded using a resin molding die having a configuration similar to that of the resin molding die 600. Like the upper insulating member 41, the lower insulating member 44 also has multiple burrs formed on the opposite side of the hot water storage tank 10, parallel to the dividing surface that contacts the front insulating member 42 and the rear insulating member 43.

[0069] If necessary, burrs formed on each divided insulation member may be cut off while leaving the base portion. This ensures ease of assembly of the divided foam insulation members 40 and reduces burr damage due to contact with other parts, making it possible to obtain a hot water storage tank unit 100 with improved insulation properties.

[0070] After each divided insulation member is formed in this manner, a foam insulation member 40 consisting of an upper insulation member 41, a front insulation member 42, an aft insulation member 43, and a lower insulation member 44 is attached around the hot water storage tank 10. At this time, the dividing surface 42a of the front insulation member 42 is aligned with the dividing surface of the aft insulation member 43. Furthermore, the upper dividing surfaces of the front insulation member 42 and the aft insulation member 43 are aligned with the dividing surface of the upper insulation member 41, and the lower dividing surface of the front insulation member 42 and the aft insulation member 43 is aligned with the dividing surface of the lower insulation member 44. The hot water storage tank 10 and the foam insulation member 40 are then housed in an exterior case 50. In this manner, the hot water storage tank unit 100 is manufactured.

[0071] The resin molding die, the method for manufacturing the hot water storage tank unit, and the effects of the hot water storage tank unit according to this embodiment will be described.

[0072] In conventional methods for manufacturing heat insulating members using a mold for resin molding, there is a problem in that gas is trapped in the upper part of the cavity when foam molding the heat insulating member, preventing the resin material from spreading throughout the cavity of the mold for resin molding. Therefore, in the mold for resin molding of this embodiment, an air vent that communicates with the top of the cavity is formed, which prevents gas from being trapped in the upper part of the cavity and allows the resin material to spread throughout the cavity, thereby improving the moldability of the heat insulating member.

[0073] The hot water storage tank unit of this embodiment has a complex uneven shape on the surface of each divided insulation member as shown in Figure 5, but by using the resin molding mold described above, an air vent communicating with the top of the cavity is formed, which makes it possible to prevent gas from being trapped inside the cavity, thereby having a particularly significant effect on improving moldability.

[0074] In addition, in the manufacturing method of the hot water storage tank unit of this embodiment, the resin material can reach the position of the dividing surface and be molded, which prevents gaps from occurring at the dividing position of the insulating member, thereby achieving the effect of obtaining a hot water storage tank unit with improved insulating performance.

[0075] Furthermore, the burrs formed on the hot water storage tank unit of this embodiment are characterized by extending parallel to the dividing surface to the opposite side of the hot water storage tank. Therefore, the burrs do not interfere with the boundaries with other divided insulation members, and the unit can be easily attached around the hot water storage tank. Furthermore, because the burrs extend parallel to the dividing surface, aligning them with the burrs formed on the other divided insulation members increases the contact area, further facilitating installation.

[0076] Furthermore, in particular, with regard to the resin molding die 500 that forms the forward section insulation member 42 and the aft section insulation member 43, a cavity 501 is formed in a recess 512 that is rectangular in plan view, but in this case, there is a concern that gas may be trapped in the four corners that are the vertices of the rectangle indicated by dotted lines in Fig. 8(B) . Therefore, in the resin molding die 500 of this embodiment, air vents 502 that communicate with the outside of the resin molding die 500 are formed at the four corner positions that are the corners of the rectangle, thereby achieving the effect of further improving moldability at the end of the parting surface.

[0077] Furthermore, in the resin molding mold and hot water storage tank unit manufacturing method of this embodiment, the width of the air vents is set to be the same, which has the effect of making the flow of resin material during foam molding uniform and further improving moldability.

[0078] Furthermore, in order to make the flow of resin material uniform, it is effective to make the widths of the air vents the same, and also to provide adjacent air vents at equal intervals, as described in this embodiment.

[0079] In addition, when the surface is uneven and the overall thickness is not uniform, as in the case of each divided insulation member that constitutes the foam insulation member 40 shown in this embodiment, the width of the air vent may be made larger in areas where the thickness is large and a large amount of resin material is required. By doing so, even if the thickness of the divided insulation members varies greatly overall, the resin material can be more easily spread evenly, which has the effect of improving the moldability of the divided surfaces.

[0080] In this embodiment, the hot water storage tank 10 is covered with the foam insulation member 40 to provide thermal insulation, but it may also be configured to further provide a vacuum insulation material to improve thermal insulation performance.

[0081] Modified examples of the hot water storage tank unit of the first embodiment will be described with reference to Fig. 15. Fig. 15 is a perspective view showing the dividing positions of the heat insulating member of the hot water storage tank unit of each modified example of the present embodiment.

[0082] In the hot water storage tank unit 100 of this embodiment, the foam insulation member 40 is described as consisting of four divided insulation members: an upper insulation member 41, a front body insulation member 42, a rear body insulation member 43, and a lower insulation member 44. However, this is not limited to this, and the member may be divided into two or more members by changing the dividing position, as shown in Figures 15(A) to (D).

[0083] In Figure 15(A), a foam insulation member 410 is formed from two members: a front insulation member 411 and a rear insulation member 412. In this case, too, by using a resin molding die in which an air vent communicating with the top of the cavity is formed, flash is formed on the dividing surface, and a hot water storage tank unit with improved insulation performance can be obtained.

[0084] In Figure 15(B), a foam insulation member 420 is formed from three members: a front body insulation member 421, a rear body insulation member 422, and a lower insulation member 423. In this case, too, by using a resin molding die in which an air vent communicating with the top of the cavity is formed, flash is formed on the dividing surface, and a hot water storage tank unit with improved insulation performance can be obtained.

[0085] In Figure 15(C), a foam insulation member 430 is formed from three members: an upper insulation member 431, a body insulation member 432, and a lower insulation member 433. In this case, too, by using a resin molding die in which an air vent communicating with the top of the cavity is formed, flash is formed on the dividing surface, and a hot water storage tank unit with improved insulation performance can be obtained.

[0086] In Figure 15(D), a foam insulation member 440 is formed from two members: an upper insulation member 441 and a lower insulation member 442. In this case, too, by using a resin molding die in which an air vent communicating with the top of the cavity is formed, flash is formed on the dividing surface, and a hot water storage tank unit with improved insulation performance can be obtained. In particular, it is easy to make design changes as needed, such as forming the upper insulation member 441 from hard polyurethane foam and the lower insulation member 442 from expanded polystyrene.

[0087] However, the position of the dividing surface is not limited to this. In addition, in consideration of manufacturing efficiency, the fewer the number of parts of the divided heat insulating members attached to one hot water storage tank 10, the fewer the assembly steps will be, which is preferable.

[0088] Modified examples of the resin molding die of Embodiment 1 will be described with reference to Figures 16 to 18. In the resin molding die 500, 600 of this embodiment, the recessed surfaces that form the air vents are uniformly formed in the first outer edge portion and the second outer edge portion, but this is not limited to this, and the positions and intervals at which the air vents are provided may be changed, as shown in Figures 16 to 18.

[0089] 16 is a plan view of the lower mold 510 of a modified example of the resin molding die 500 for forming the forward section insulation member 42. The plan view of the upper mold 520 corresponds to the plan view of the lower mold 510 and is therefore omitted. The forward section insulation member 42 only needs to have an air vent at least at the position of the dividing surface 42a, which is the position where it comes into contact with the aft section insulation member 43, i.e., on the major axis side, and may be configured without an air vent on the minor axis side. This configuration allows the dividing surface 42a to be molded with improved formability. Air vents can also be provided in similar positions in the resin molding die for molding the aft section insulation member 43.

[0090] 17 and 18 are plan views showing a lower mold 610 of a modified example of a resin molding die 600 for forming the upper insulation member 41. The plan view of the upper mold 620 corresponds to the plan view of the lower mold 610, and is therefore omitted. In the upper insulation member 41, the dividing surface 41a is formed around the entire outer periphery of the recess 612 in plan view, so it is sufficient that air vents are provided all over. It goes without saying that the number of air vents is not limited to the number shown in FIG. 12. Air vents can also be provided in similar positions in a resin molding die for molding the lower insulation member 44.

[0091] Embodiment 2 The resin molding die, the manufacturing method of the hot water storage tank unit using the resin molding die, and the hot water storage tank unit according to the second embodiment will be described with reference to Fig. 19 to Fig. 21. Fig. 19 is a perspective view showing a resin molding die 500 for molding a front body insulating member provided in the hot water storage tank unit of the present embodiment, and Fig. 20 is a plan view showing the resin molding die 500. Also, Fig. 21 is a cross-sectional view for explaining the manufacturing method of the hot water storage tank unit using the resin molding die 500.

[0092] 19 to 21, the resin molding die 500 of this embodiment differs from the resin molding die 500 of embodiment 1 in that it further has a flat surface 524 for forming a flat parting surface at a second outer edge portion 521 of an upper die 520. The resin molding die of this embodiment, the manufacturing method of a hot water storage tank unit using the resin molding die, and other configurations of the hot water storage tank unit are the same as those of embodiment 1, so the following description will focus on the differences.

[0093] 19 and 20, the flat surface 524 is a part of the second outer edge portion 521 of the upper mold 520, and is located closer to the inner periphery than the outer periphery where the air vents 502 are 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 on the lower mold 510, as shown in FIG. 21, and the portion formed in contact with the flat surface 524 becomes the dividing surface of the front body section insulation member 42. In addition, the recessed surface 523 provided in the second outer edge portion 521 of the upper mold 520 is recessed from the flat surface 524.

[0094] Therefore, when upper mold 520 is closed on lower mold 510, flat surface 524 faces recessed portion 512 of lower mold 510, while the outer periphery of second outer edge portion 521 excluding flat surface 524 faces first outer edge portion 511 of lower mold 510. Then, recessed surface 513 provided in first outer edge portion 511 of lower mold 510 faces recessed surface 523 provided in second outer edge portion 521 of the upper mold, thereby forming air vent 502, as shown in FIG. 21 , and the upper surface of air vent 502 is located above the top of cavity 501.

[0095] 21, the forward section insulation member 42 molded using the resin molding die 500 of this embodiment may have a step between the parting surface and the burr due to the difference in height between the flat surface 524 and the recessed surface 523. Even in this case, the step between the parting surface and the burr is slight, so it can be said that the burr is formed along the parting surface. Note that the positions at which the air vents are formed in each resin molding die may be alternated to prevent the burrs from interfering with each other at the boundary between the forward section insulation member and the aft section insulation member. However, if the thickness H of the burr filling the air vent 502 is small, for example, it does not matter if the positions of the air vents are not alternated.

[0096] Similarly, the resin molding die 600 for forming the upper heat insulating member described in the first embodiment can also be configured so that the second outer edge portion 621 of the upper die 620 has a flat surface on the inner circumferential side.

[0097] The resin molding die of this embodiment, the manufacturing method of the hot water storage tank unit using the resin molding die, and the hot water storage tank unit configured in this manner not only achieve the same effects as those of embodiment 1, but also have the effect of being able to obtain an insulating member with even improved insulating performance because the dividing surface can be formed flat.

[0098] Embodiment 3 The resin molding die, the manufacturing method of the hot water storage tank unit using the resin molding die, and the 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 die 500 for molding a front body insulating member provided in the hot water storage tank unit of the present embodiment, and Fig. 23 is a plan view showing the resin molding die 500. Also, Fig. 24 is a cross-sectional view for explaining the manufacturing method of the hot water storage tank unit using the resin molding die 500.

[0099] 22 to 24, the resin molding die 500 of this embodiment differs from the resin molding die 500 of embodiment 1 in that it does not have a recessed surface 523 in the second outer edge portion 521 of the upper die 520. The resin molding die of this embodiment, the manufacturing method of the hot water storage tank unit using the resin molding die, and other configurations of the hot water storage tank unit are the same as those of embodiment 1, so the following description will focus on the differences.

[0100] Since no recessed surface is formed on second outer edge portion 521 of upper mold 520, the second outer edge portion 521 is a flat surface without any irregularities. In FIGS. 22 to 24, the portion corresponding to flat surface 524 of embodiment 2 is illustrated as flat surface 524, but there is no step or the like at the boundary therebetween. Flat surface 524 is a surface for forming a dividing surface and is located opposite recessed portion 512 of lower mold 510. Meanwhile, the outer periphery of second outer edge portion 521, excluding flat surface 524, faces first outer edge portion 511 of lower mold 510. Therefore, recessed surface 513 provided on first outer edge portion 511 of lower mold 510 faces the flat surface on the outer periphery side of second outer edge portion 521 of the upper mold, thereby forming air vent 502 as shown in FIG. 24.

[0101] Similarly, the resin molding die 600 for forming the upper heat insulating member explained in the first embodiment can also be configured so that the second outer edge portion 621 of the upper die 620 does not have the recessed surface 623 .

[0102] The resin molding die of this embodiment, the manufacturing method of the hot water storage tank unit using the resin molding die, and the hot water storage tank unit configured in this manner not only achieve the same effects as those of embodiment 1, but also have the advantage that the dividing surfaces can be formed flat and burrs are formed parallel to the dividing surfaces, making it easier to align the divided insulating members with each other, and making it possible to obtain insulating members with even improved insulating performance.

[0103] It should be noted that the scope of the present disclosure also includes appropriate combinations, modifications, and omissions of the respective embodiments. [Explanation of symbols]

[0104] 10 hot water tanks, 21 Heat pump supply 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 materials, 41 upper heat insulating member, 41a dividing surface, 41b burr, 42 forward body insulation member, 42a division surface, 42b burr, 43 rear body insulation member, 44 lower insulation member, 50 outer case, 51 front panel, 52 recessed panel, 53, 54 side panel, 55 rear panel, 56 top panel, 57 bottom panel, 60 legs, 100 hot water storage tank units, 110 heat pump units, 400 resin material, 411 front heat insulating member, 412 rear heat insulating member, 421 forward body insulation member, 422 aft body insulation member, 423 lower insulation member, 431 upper insulation member, 432 body insulation member, 433 lower insulation member, 441 upper insulation member, 442 lower insulation member, 500, 600 Resin molds, 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 Storage water heater

Claims

1. A hot water storage tank unit including a hot water storage tank for storing water and a foam insulation member covering the periphery of the hot water storage tank, The foam insulation member is composed of a plurality of divided insulation members, and has a plurality of burrs formed on the opposite side of the hot water storage tank along the dividing surfaces of the divided insulation members, The thickness of the plurality of burrs is 1 mm or more and 20 mm or less, The plurality of burrs are cut off while leaving their root portions, Among the plurality of burrs, the width of the burrs at the portions where the foam insulation member is thicker is larger than that at the portions where the foam insulation member is thin. A hot water storage tank unit characterized by the above.

2. A hot water storage tank unit including a hot water storage tank for storing water and a foam insulation member covering the periphery of the hot water storage tank, The foam insulation member is composed of a plurality of divided insulation members, and has a plurality of burrs formed on the opposite side of the hot water storage tank along the dividing surfaces of the divided insulation members, The plurality of burrs are cut off while leaving their root portions, Among the plurality of burrs, the width of the burrs at the portions where the foam insulation member is thicker is larger than that at the portions where the foam insulation member is thin. A hot water storage tank unit characterized by the above.

3. 3. The hot water storage tank unit according to claim 1, wherein the width of the burrs is greater than the spacing between the burrs at some locations.

4. The plurality of burrs are provided so as to extend in a direction parallel to the dividing surface. The hot water storage tank unit according to any one of claims 1 to 3, characterized in that

5. The divided heat insulating member is composed of an upper heat insulating member covering the upper part of the hot water storage tank, a lower heat insulating member covering the lower part of the hot water storage tank, a front body heat insulating member provided in contact with the upper heat insulating member and the lower heat insulating member and covering the front side of the body side of the hot water storage tank, and a rear body heat insulating member provided in contact with the upper heat insulating member, the lower heat insulating member and the front body heat insulating member and covering the rear side of the body side of the hot water storage tank. The hot water storage tank unit according to any one of claims 1 to 4, characterized in that

6. The upper insulation member, the forward insulation member, and the aft insulation member are made of rigid polyurethane foam. The hot water storage tank unit according to claim 5,

7. The lower heat insulating member is made of polystyrene foam. The hot water storage tank unit according to claim 5 or 6, characterized in that:

8. The plurality of burrs are provided so that adjacent burrs are spaced at equal intervals. The hot water storage tank unit according to any one of claims 5 to 7, characterized in that

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