Water heater and method for manufacturing water heater

Abstract

A water heater (1A) comprises: a first heat insulation member which has a cylindrical shape having a first recess recessed from a cylindrical surface, and which houses a tank for storing hot water inside a cylinder; a panel (40) to which an electrical component (60) connected to a heating device for supplying heated hot water to the tank is attached, and which is disposed in the first recess; and a first fixing member which is insert-molded in the first recess and fixes the panel (40).

Description

Water heater and method for manufacturing the same

[0001] The present disclosure relates to a water heater and a method for manufacturing the same.

[0002] Some water heaters have electrical components, such as a control device for controlling a heating device, attached to the side of a hot water storage tank.

[0003] For example, Patent Document 1 discloses a water heater in which a box containing electrical components is attached to a housing that contains a hot water storage tank and a heating device placed on the tank.

[0004] Furthermore, Patent Document 2 discloses a water heater in which electrical components are arranged in the gap between a corner of a housing that houses a hot water storage tank and the tank.

[0005] European Patent No. 3462106

[0006] The water heater described in Patent Document 1 requires a frame to attach the box to the housing, resulting in an increase in the number of parts. Similarly, the water heater described in Patent Document 2 also requires metal fittings to secure the electrical components and a frame to secure the metal fittings to the housing, since electrical components are placed in the corners of the housing. This results in an increase in the number of parts.

[0007] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a water heater that can be equipped with electrical components using a small number of parts, and a method for manufacturing a water heater.

[0008] To achieve the above object, the water heater according to the present disclosure includes a first insulating member, a panel, and a first fixing member. The first insulating member has a cylindrical shape with a first recess recessed from the cylindrical surface, and houses a tank for storing hot water inside the cylinder. The panel is mounted with electrical equipment connected to a heating device that supplies heated hot water to the tank, and is positioned in the first recess. The first fixing member is insert-molded into the first recess and fixes the panel.

[0009] According to the configuration of the present disclosure, the first insulating member has a cylindrical shape with a first recess recessed from the cylindrical surface. The first fixing member is insert-molded into the first recess to fix the panel. Because the panel is fixed to the first insulating member via the first fixing member, no additional member is required to fix the panel to the housing. As a result, the water heater can be equipped with electrical components using a small number of parts.

[0010] a perspective view of a water heater according to embodiment 1 of the present disclosure, viewed from diagonally above the front; a front view showing the internal structure of a housing provided in a water heater according to embodiment 1 of the present disclosure; a top view of a hot water storage unit provided in a water heater according to embodiment 1 of the present disclosure; a perspective view showing the outer peripheral portion of an insulating member provided in a water heater according to embodiment 1 of the present disclosure when the housing and panel are removed; a perspective view of a fixing bracket provided in a water heater according to embodiment 1 of the present disclosure; a perspective view showing the appearance of a panel provided in a water heater according to embodiment 1 of the present disclosure when the housing is removed; a perspective view of a panel and a top surface portion of an insulating member provided in a water heater according to embodiment 1 of the present disclosure, viewed from diagonally below; an enlarged view of an upper portion of a panel and a top surface portion of an insulating member provided in a water heater according to embodiment 2 of the present disclosure; an enlarged view of a lower portion of a panel provided in a water heater according to embodiment 2 of the present disclosure; a front view showing the appearance of a water heater panel according to embodiment 3 of the present disclosure when the housing is removed; a perspective view of the top surface of a panel and an insulating member provided in a water heater according to embodiment 3 of the present disclosure, viewed diagonally from below; a front view showing the appearance of a panel provided in a water heater according to embodiment 4 of the present disclosure when the housing is removed; a cross-sectional view of an insulating member showing a groove provided in the insulating member provided in a water heater according to embodiment 4 of the present disclosure; a perspective view of a modified water heater according to embodiment 1 of the present disclosure; a perspective view of a modified water heater according to embodiment 1 of the present disclosure when the housing is removed from the modified water heater according to embodiment 1 of the present disclosure; a perspective view of a first modified fixing bracket provided in a water heater according to embodiment 1 of the present disclosure; a perspective view of a second modified fixing bracket provided in a water heater according to embodiment 1 of the present disclosure; a perspective view of a third modified fixing bracket provided in a water heater according to embodiment 1 of the present disclosure;

[0011] A water heater and a method for manufacturing a water heater according to an embodiment of the present disclosure will be described in detail below with reference to the drawings. In the drawings, identical or equivalent parts are designated by the same reference numerals. In the illustrated Cartesian coordinate system XYZ, when the cylindrical axis of the water heater's cylindrical tank is oriented vertically, the vertical direction is the Z-axis, and the horizontal plane perpendicular to the vertical direction is the XY-plane. This coordinate system will be referenced as appropriate below.

[0012] (Embodiment 1) The water heater according to embodiment 1 is a water heater in which a heating unit equipped with a heating device is disposed on a hot water storage unit equipped with a hot water storage tank and a heat insulating member. In this water heater, in order to reduce the number of parts, a panel equipped with multiple electrical components for operating the heating device is directly attached to a recess in the heat insulating member of the hot water storage unit. First, the overall configuration of the water heater equipped with the hot water storage unit and the heating unit will be described with reference to Figures 1 to 3.

[0013] Fig. 1 is a perspective view of a water heater 1A according to embodiment 1, seen from diagonally above the front. Fig. 2 is a front view showing the internal structure of a housing 10 provided in the water heater 1A. Fig. 3 is a top view of a hot water storage unit 30 provided in the water heater 1A.

[0014] 2 shows the water heater 1A with the front panel 11, right side panel 12, and left side panel 13 of the housing 10 shown in Fig. 1 removed. For ease of understanding, Fig. 3 shows the hot water storage unit 30 with the top surface 323 shown in Fig. 2 removed from the heat insulating member 32A.

[0015] As shown in Fig. 1, the water heater 1A includes a rectangular parallelepiped housing 10. As shown in Fig. 2, the water heater 1A includes a heating unit 20 housed in an upper region of the internal space of the housing 10, and a hot water storage unit 30 housed in a lower region of the internal space of the housing 10.

[0016] The heating unit 20 is a unit having a circuit for heating the hot water stored in the hot water storage unit 30. In detail, although not shown, the heating unit 20 includes a heat exchanger and heater for heating the hot water, and a pump and electromagnetic three-way valve for circulating the hot water between the hot water storage unit 30 and the heating unit 20. In the heating unit 20, devices such as the heat exchanger, heater, pump, and electromagnetic three-way valve are connected by piping, electrical wires, etc. to form a circuit for heating the hot water. In addition, the circuit of the heating unit 20 is provided with sensors such as a flow meter, a thermometer, and a pressure gauge to monitor the operating status of each device. The heating unit 20 heats the hot water and supplies the heated hot water to the hot water storage unit 30 through the operation of each of the above devices.

[0017] In contrast, the hot water storage unit 30 is a unit that stores and keeps warm the hot water heated by the heating unit 20. In detail, the hot water storage unit 30 includes a tank 31 shown in FIG. 3 that stores the hot water, and a heat insulating member 32A that keeps the tank 31 warm.

[0018] The tank 31 has a cylindrical shape. The tank 31 is connected to the heating unit 20, a water pipe, etc. by piping, and stores hot water supplied from them. The outer periphery of the tank 31 is covered with a heat insulating member 32A, which keeps the hot water inside warm.

[0019] 3, the heat insulating member 32A has a first side surface portion 321 that covers the outer periphery of the tank 31 from the right end of the front surface to just before the left end of the rear surface, and a second side surface portion 322 that covers the outer periphery of the tank 31 from the left end of the rear surface to just before the right end of the front surface. The heat insulating member 32A forms a cylindrical shape by combining the first side surface portion 321 and the second side surface portion 322. The heat insulating member 32A houses the tank 31 in its internal space and also covers the outer periphery of the tank 31.

[0020] Here, the term "cylinder" refers to a round tube when describing the shape of the heat insulating member 32A. In this case, the cylinder may have an open bottom and an open top, or the bottom and the open top may be closed by a flat plate portion, a curved surface portion, or the like.

[0021] 2, the heat insulating member 32A has a top surface portion 323 that covers the top of the tank 31 and a bottom surface portion 324 that covers the bottom of the tank 31. In addition to the top surface portion 323 and the bottom surface portion 324, the heat insulating member 32A has the first side surface portion 321 and the second side surface portion 322 described above, thereby covering the entire tank 31 and suppressing heat radiation from the tank 31.

[0022] The first side surface 321, the second side surface 322, the top surface 323, and the bottom surface 324 of the heat insulating member 32A are each formed from foamed plastic, such as expanded polystyrene, thereby making it difficult for heat from the tank 31 to be transferred to the outside, thereby improving the heat retention of the tank 31.

[0023] Since the insulating member 32A is made of such foamed plastic, it has a certain degree of rigidity and is strong enough not to undergo plastic deformation even when a certain degree of compressive force is applied. In the water heater 1A, since the insulating member 32A has such characteristics, the top surface 323 of the insulating member 32A is used as a member to support the heating unit 20.

[0024] Specifically, a frame structure 21, which is made up of a plurality of elongated steel plates that are L-shaped or U-shaped in cross section and assembled into a rectangular parallelepiped shape, is placed on the top surface 323 of the heat insulating member 32A. In this way, the frame structure 21 is attached to the top surface 323. The various devices and piping of the heating unit 20 are attached to the frame structure 21. With this configuration, the heating unit 20 is provided on the top surface 323. As a result, in the water heater 1A, the heating unit 20 is disposed on the tank 31 with a small number of parts.

[0025] In such a water heater 1A, a panel on which a plurality of electrical components are mounted may be attached to the side of the tank 31.

[0026] Here, the multiple electrical components refer to components for operating the heating unit 20. The electrical components are, for example, components for controlling each device of the heating unit 20 based on the output of each sensor of the heating unit 20, components for supplying power from an external power source to each device, etc. Also, the panel refers to a board or box on which the multiple electrical components are attached, and the panel is, for example, a component called a control panel or a distribution board.

[0027] However, when attaching such a panel to the side of the tank 31, new parts such as a frame and mounting brackets are required to attach the panel to the housing 10, which may result in an increase in the number of parts.

[0028] Therefore, in the water heater 1A, in order to adopt a simple configuration and reduce the number of parts, a panel is attached directly to the above-mentioned heat insulating member 32A. Next, the structure for attaching the panel will be described in detail with reference to Figures 4 to 7.

[0029] Fig. 4 is a perspective view showing the outer peripheral portion of heat insulating member 32A included in water heater 1A when housing 10 and panel 40 are removed. Fig. 5 is a perspective view of fixing bracket 50 included in water heater 1A. Fig. 6 is a perspective view showing the appearance of panel 40 included in water heater 1A when housing 10 is removed. Fig. 7 is a perspective view of panel 40 and top surface portion 323 of heat insulating member 32A viewed obliquely from below.

[0030] 4 shows the water heater 1A from the front and from above, with the housing 10 and the panel 40 removed. The same is true for FIG.

[0031] As shown in FIG. 4, the second side surface portion 322 of the heat insulating member 32A has a flat surface portion 325A having a shape obtained by cutting out a cylindrical surface, and a plurality of fixing metal fittings 50 provided on the flat surface portion 325A.

[0032] The outer peripheral surface of the second side surface portion 322 is formed into a cylindrical surface shape. The flat surface portion 325A is formed into a flat surface parallel to the cylindrical axis of the cylindrical surface. As a result, the second side surface portion 322 has a shape in which a portion of the cylindrical surface is cut out by the flat surface portion 325A. As a result, the second side surface portion 322 is recessed from the cylindrical surface at the location of the flat surface portion 325A. The second side surface portion 322 utilizes this recessed space to save space in the water heater 1A. Specifically, a fixing bracket 50 is attached to the flat surface portion 325A to attach a panel 40 to this recessed space.

[0033] As shown in Fig. 5, the fixing bracket 50 is formed from a metal plate bent into a hat-shaped cross section. Specifically, the fixing bracket 50 has a first plate-shaped portion 51 bent into an angular U-shape in cross section, and second plate-shaped portions 52 bent at acute angles on each side of the first plate-shaped portion 51. The second plate-shaped portion 52 is insert-molded into the flat portion 325A of the heat insulating member 32A, so that the fixing bracket 50 is attached to the flat portion 325A with the plate surface of the first plate-shaped portion 51 exposed, as shown in Fig. 4. As a result, the fixing bracket 50 is firmly fixed to the flat portion 325A with a simple configuration.

[0034] As shown in Fig. 5, a plurality of screw holes 53 are formed in the first plate-shaped portion 51 of the fixing bracket 50. Fastening members, such as bolts, are fastened into these screw holes 53, thereby attaching the panel 40 to the flat surface portion 325A of the heat insulating member 32A, as shown in Fig. 6.

[0035] The panel 40 has a rectangular plate shape. Electrical components 60, such as a control device that controls the pump and heater provided in the heating unit 20, a three-way electromagnetic valve provided in the heating unit 20, a terminal block to which sensors such as a flow meter, a thermometer, and a pressure gauge are connected, and contactors, are attached to a surface portion of the panel 40. The panel 40 is attached to the flat surface portion 325A of the heat insulating member 32A with the surface portion on which the electrical components 60 are attached facing outward.

[0036] Such panel 40 is fixed by fixing bracket 50 that is insert-molded into the above-mentioned flat portion 325A. By providing such a configuration, water heater 1A can arrange electrical components 60 with a small number of parts.

[0037] The upper end of the flat surface portion 325A of the heat insulating member 32A is positioned so that it abuts the upper end of the second side surface portion 322. A top surface portion 323 is disposed above the upper end of the second side surface portion 322. The top surface portion 323 has a cylindrical portion 327 to which a rectangular plate portion 328, whose diameter is larger than that of the cylindrical portion 327, is attached, as shown in FIG. 7 . To support the frame structure 21 of the heating unit 20, which is made up of steel plates assembled into a rectangular parallelepiped shape, the top surface portion 323 has a cylindrical portion 327 to which a rectangular plate portion 328, whose diameter is larger than that of the cylindrical portion 327, is attached, as shown in FIG. 7 . As a result, the rectangular plate portion 328 of the top surface portion 323 overhangs the flat surface portion 325A, i.e., the panel 40. This allows the top surface portion 323 to overhang the panel 40, preventing condensation adhering to the equipment, piping, etc. of the heating unit 20 from flowing into the panel. In other words, the rectangular plate portion 328 of the top surface portion 323 functions as a canopy, preventing water from seeping into the electrical equipment 60 of the panel 40.

[0038] Furthermore, the panel 40 is located below the protruding top surface portion 323. As a result, the water heater 1A is space-saving. Furthermore, as described above, the panel 40 is provided on the flat surface portion 325A, which is formed by cutting out the cylindrical surface of the heat insulating member 32A. This positions the panel 40 inside the cylindrical surface of the heat insulating member 32A. As a result, the water heater 1A is even more space-saving.

[0039] Such a water heater 1A is manufactured by the following steps: (1) The bottom surface 324 of the insulating member 32A is placed on the bottom panel 13 of the housing 10. (2) The tank 31 is placed on the bottom surface 324. (3) The first side surface 321 and the second side surface 322 of the insulating member 32A are attached to the side surfaces of the tank 31, and the side surfaces of the tank 31 are covered with the first side surface 321 and the second side surface 322. (4) The top surface 323 of the insulating member 32A, on which the heating unit 20 is placed, is placed on the first side surface 321 and the second side surface 322, thereby attaching the top surface 323 to the first side surface 321 and the second side surface 322. (5) A panel 40, to which electrical equipment 60 connected to the heating unit 20 is attached, is placed on the flat surface portion 325A, and the panel 40 is fixed to the flat surface portion 325A with fixing brackets 50. (6) By the above steps (2) to (4), the housing 10 is attached to the tank 31 covered with the heat insulating member 32A. By these steps, the water heater 1A described above, in which electrical equipment 60 is attached, can be manufactured with a small number of parts.

[0040] The first side surface portion 321 and the second side surface portion 322 of the heat insulating member 32A described above are an example of a first heat insulating member as defined in the present disclosure. The top surface portion 323 of the heat insulating member 32A is an example of a second heat insulating member as defined in the present disclosure. The flat surface portion 325A is an example of a first recess as defined in the present disclosure, as can be seen from its shape recessed from a cylindrical surface. The heating unit 20 is an example of a heating device as defined in the present disclosure. The fixing bracket 50 is an example of a first fixing member as defined in the present disclosure. The top surface portion 323 and the bottom surface portion 324 of the heat insulating member 32A are an example of a second heat insulating member and a third heat insulating member as defined in the present disclosure. The foamed plastic that is the material of the heat insulating member 32A is an example of a resin material as defined in the present disclosure.

[0041] As described above, in the water heater 1A according to the first embodiment, the second side surface 322 of the heat insulating member 32A has a flat surface 325A recessed from the cylindrical surface, and the fastening bracket 50 is insert-molded into the flat surface 325A to secure the panel 40. Therefore, no additional components, such as a frame or mounting bracket, are required to secure the panel 40 to the housing 10. As a result, the water heater 1A can be equipped with electrical equipment 60 using a small number of parts. Furthermore, since the panel 40 is placed on the flat surface 325A recessed from the cylindrical surface of the second side surface 322, space is saved.

[0042] The top surface 323 of the heat insulating member 32A has a rectangular plate portion 328 that protrudes above the panel 40, making it difficult for water to penetrate into the panel 40 and the electrical equipment 60. For example, when condensation occurs on the equipment, piping, etc. of the heating unit 20, the water can be prevented from penetrating into the panel 40 and the electrical equipment 60.

[0043] (Embodiment 2) In embodiment 1, panel 40 is fixed by passing fastening members through through holes (not shown) and fastening the fastening members to screw holes 53 of fixing brackets 50. However, panel 40 is not limited to this. A structure for adjusting the position of panel 40 may be provided. Furthermore, water heater 1A may be provided with a structure for determining the position of panel 40.

[0044] In the water heater 1B according to the second embodiment, a long hole is provided in the panel 40. Furthermore, a wall surface for determining the position of the panel 40 is provided in the heat insulating member 32A.

[0045] A water heater 1B according to a second embodiment will be described below with reference to Figures 8 and 9. In the second embodiment, the configuration different from the first embodiment will be mainly described.

[0046] 8 is an enlarged view of the upper part of the panel 40 and the top surface 323 of the heat insulating member 32B. FIG. 9 is an enlarged view of the lower part of the panel 40.

[0047] As shown in FIG. 8 , the upper end portion of the panel 40 of the water heater 1B is provided with a plurality of elongated holes 41. The number of elongated holes 41 is the same as the number of screw holes 53. The long axes of the elongated holes 41 are oriented in the vertical direction. A bolt 42 is passed through each of the elongated holes 41 and attached to the screw holes 53 of the flat portion 325B described in the first embodiment, thereby fixing the panel 40 to the flat portion 325B. Because the long axes of the elongated holes 41 are oriented in the vertical direction, an operator can adjust the position of the panel 40 to a desired vertical position by tightening the bolts 42 while moving the panel 40 in the vertical direction. In this way, the elongated holes 41 facilitate the installation of the panel 40 and the adjustment of the position of the panel 40.

[0048] 8 and 9, the flat surface portion 325B of the heat insulating member 32B is formed in a rectangular shape with its short side oriented horizontally and its long side oriented vertically, similar to the case shown in Fig. 4. The length in the long side direction is shorter than the length in the vertical direction of the second side surface portion 322 of the heat insulating member 32B. As a result, as shown in Fig. 9, an inner wall surface 326 that extends horizontally and faces upward is provided between the lower part of the flat surface portion 325B and the circumferential surface of the second side surface portion 322.

[0049] The panel 40 is formed in a rectangular shape that is slightly smaller than the flat portion 325B of the heat insulating member 32B. Like the flat portion 325B, the panel 40 has its short side oriented horizontally and its long side oriented vertically. In contrast, the inner wall surface 326 is spaced from the screw hole 53 of the fastening bracket 50 by a distance obtained by dividing the distance from the top surface of the panel 40 to the center of the elongated hole 41 by the longitudinal length of the panel 40. As a result, by placing the panel 40 on the inner wall surface 326, the vertical position of the elongated hole 41 of the panel 40 can be determined.

[0050] When attaching the panel 40, the lower end of the panel 40 oriented in this manner is placed on the inner wall surface 326, thereby positioning the panel 40 in the up-down direction. Furthermore, the inner wall surface 326 supports the lower end of the panel 40 during attachment, thereby facilitating the attachment work of the panel 40 by fastening the bolts 42. As a result, the inner wall surface 326 makes it easy to assemble the panel 40 to the heat insulating member 32B.

[0051] As described above, in water heater 1B according to embodiment 2, flat portion 325B has inner wall surface 326 extending horizontally at the bottom. When installing panel 40 in water heater 1B, panel 40 can be easily positioned and installed in the vertical direction by abutting the lower end of panel 40 against inner wall surface 326. Furthermore, in water heater 1B, panel 40 is supported by inner wall surface 326, so that panel 40 is less likely to shift position.

[0052] Further, the panel 40 is provided with a long hole 41. Therefore, in the water heater 1B, the position of the panel 40 can be easily adjusted when the panel 40 is attached to the fixing bracket 50. As a result, the water heater 1B can be easily assembled.

[0053] Third Embodiment In the first and second embodiments, the flat surface portions 325A, 325B are formed only on the second side surface portions 322 of the heat insulating members 32A, 32B. However, the heat insulating members 32A, 32B are not limited to this. Other configurations of the heat insulating members 32A, 32B may include recesses recessed from the cylindrical surfaces of the heat insulating members 32A, 32B that are connected to the flat surface portions 325A, 325B.

[0054] In water heater 1C according to the third embodiment, another flat surface portion connected to flat surface portion 325C is formed on top surface portion 323 of heat insulating member 32C.

[0055] 10 to 12, a water heater 1C according to the third embodiment will be described below. In the third embodiment, the configuration different from the first and second embodiments will be mainly described.

[0056] Fig. 10 is a front view showing the outer peripheral portion of heat insulating member 32C included in water heater 1C according to embodiment 3 when housing 10 and panel 40 are removed. Fig. 11 is a front view showing the appearance of panel 40 included in water heater 1C when housing 10 is removed. Fig. 12 is a perspective view of panel 40 and top surface portion 323 of heat insulating member 32C viewed obliquely from below.

[0057] As shown in FIG. 10, in the heat insulating member 32C, a flat surface portion 325C is provided on the second side surface portion 322, and another flat surface portion 329 is provided on the top surface portion 323.

[0058] The flat surface 325C on the second side surface portion 322 is formed in the shape of a large rectangle with its longitudinal axis facing up and down. The flat surface 325C is shorter in the up and down direction than the flat surface 325A described in the first embodiment, and as a result, is formed biased toward the upper region of the second side surface portion 322. As in the first embodiment, the flat surface 325C is a plane parallel to the cylindrical axis of the second side surface portion 322, and as a result, is recessed from the cylindrical surface of the second side surface portion 322.

[0059] In contrast, the flat surface portion 329 on the top surface portion 323 is formed in the shape of a small rectangle whose longitudinal length is the same as the lateral length of the flat surface portion 325C. The flat surface portion 329 is provided on the flat surface portion 325C of the second side surface portion 322 with its longitudinal direction oriented horizontally. As a result, the flat surface portion 329 is adjacent to the flat surface portion 325C of the second side surface portion 322 in the vertical direction. Furthermore, the flat surface portion 329 is provided on the same plane as the flat surface portion 325C of the second side surface portion 322. Therefore, the flat surface portion 329 forms an integral flat portion that is continuous with the flat surface portion 325C of the second side surface portion 322.

[0060] To secure the panel 40 to the integral flat surface portion 325C and flat surface portion 329, metal fixtures 50 are insert-molded in the lower region of the flat surface portion 325C of the second side surface portion 322. Metal fixtures 50 are also insert-molded in the upper region of the flat surface portion 329. By securing the panel 40 to these metal fixtures 50, the panel 40 is secured to the integral flat surface portion 325C and flat surface portion 329 formed from the second side surface portion 322 to the top surface portion 323, as shown in FIG. 11 . This arrangement of the panel 40 prevents the top surface portion 323 from shifting relative to the second side surface portion 322. It also determines the position of the top surface portion 323 relative to the second side surface portion 322.

[0061] In the first embodiment, it is described that the top surface portion 323 has a shape in which a rectangular plate portion 328 is provided on a cylindrical portion 327, and in the third embodiment, the top surface portion 323 has the same shape. The flat portion 329 is formed by cutting out the cylindrical portion 327 of the top surface portion 323. As a result, the rectangular plate portion 328 of the top surface portion 323 protrudes above the panel 40, as shown in FIG. 12 .

[0062] In the water heater 1C, it is sometimes the case that someone who does not fully understand how to use it wires the water heater 1C, resulting in incorrect wiring. In such a case, if the electrical components 60 heat up and become too hot, there is a risk of a fire. In order to prevent the fire from spreading in such a case, a canopy portion 45 is provided that extends from the panel 40 along the rectangular plate portion 328 of the top surface portion 323.

[0063] The canopy portion 45 is made of a metal or ceramic material, extends horizontally from the upper end of the panel 40, and covers the underside of the rectangular plate portion 328 of the top surface portion 323. This prevents the fire from spreading to the top surface portion 323 and the heating unit 20 in the unlikely event of a fire.

[0064] The top surface 323 of the heat insulating member 32C is an example of a second heat insulating member as defined in the present disclosure. The flat surface 329 is an example of a second recess as defined in the present disclosure. The fixing metal fitting 50 insert-molded into the flat surface 329 is an example of a second fixing member as defined in the present disclosure.

[0065] As described above, in the water heater 1C according to the third embodiment, the flat surface 329 formed on the top surface 323 of the heat insulating member 32C is formed on and continuous with the flat surface 325C of the second side surface 322. Therefore, by installing the panel 40 across the flat surface 329 and the flat surface 325C, it is possible to prevent misalignment between the top surface 323 and the second side surface 322 of the heat insulating member 32C. Furthermore, determining the positions of the top surface 323 and the second side surface 322 facilitates assembly of the water heater 1C.

[0066] In addition, the water heater 1C is provided with a canopy 45 made of a metal or ceramic material that extends along the underside of the top surface 323. This makes it possible to prevent the fire from spreading even if the panel 40 accidentally catches fire.

[0067] Fourth Embodiment In the first to third embodiments, the panel 40 is attached to the flat portions 325A-325C formed on the side surfaces of the heat insulating members 32A-32C. Other configurations may be combined with these flat portions 325A-325C.

[0068] In the water heater 1D according to the fourth embodiment, the flat portion 325D is connected to a groove for wiring.

[0069] A water heater 1D according to embodiment 4 will be described below with reference to Figures 13 and 14. In embodiment 4, the description will focus on configurations that differ from embodiments 1 to 3.

[0070] Fig. 13 is a front view showing the appearance of panel 40 included in water heater 1D according to embodiment 4 when housing 10 is removed. Fig. 14 is a cross-sectional view of heat insulating member 32D included in water heater 1D, showing groove 33 provided in heat insulating member 32D.

[0071] As shown in FIG. 13, a first side surface portion 321 and a second side surface portion 322 of the heat insulating member 32D are provided with a plurality of grooves 33 through which wires extending from the heating unit 20 are passed.

[0072] Each of the grooves 33 extends from a flat surface portion 325D formed on the second side surface portion 322 of the heat insulating member 32D toward the top surface portion 323 of the heat insulating member 32D.

[0073] More specifically, each groove 33 has a first groove portion 331 extending horizontally from the flat surface portion 325D and a second groove portion 332 extending vertically, specifically upward, from the first groove portion 331 and further extending to a wiring through-hole (not shown) in the top surface portion 323. Cables extending from devices of the heating unit 20, such as a pump, heater, electromagnetic three-way valve, and sensors such as a flow meter, thermometer, and pressure gauge, including electrical wires such as communication lines and power lines, are passed through the first groove portion 331 and the second groove portion 332 of each groove 33. This allows each groove 33 to connect the devices of the heating unit 20 to the electrical components 60 of the panel 40 via cables.

[0074] Furthermore, each groove 33 has a shape recessed from the outer peripheral surface of the first side surface portion 321 and the second side surface portion 322 of the heat insulating member 32D, similar to the flat surface portion 325D on which the panel 40 is installed. Specifically, as shown in FIG. 14 , each groove 33 has a triangular or rectangular recessed shape in cross section. To improve drainage, each groove 33 desirably has a lower inner wall that becomes lower toward the outside, as shown in FIG. 13 . For example, the first groove portion 331 may be triangular in cross section, with the lower inner wall sloping downward. Because each groove 33 has a recessed shape from the outer peripheral surface of the heat insulating member 32D, the water heater 1D achieves space saving.

[0075] Furthermore, as described above, each groove 33 has a first groove portion 331 extending horizontally and a second groove portion 332 extending vertically. Therefore, even if water generated by condensation on the equipment and piping of the heating unit 20 flows down the cables and seeps into each groove 33, the water will remain inside the first groove portion 331 extending horizontally. As a result, each groove 33 prevents water from seeping into the flat portion 325D on which the panel 40 is installed.

[0076] As described above, in the water heater 1D according to the fourth embodiment, the outer peripheral surface of the heat insulating member 32D is provided with a groove 33 having a first groove portion 331 extending horizontally and a second groove portion 332 extending vertically from the first groove portion 331, through which a cable connected to the electrical equipment 60 of the panel 40 is passed. Even if water enters the groove 33, the water remains in the first groove portion 331 extending horizontally, and therefore the water is less likely to travel to the panel 40 and reach the electrical equipment 60. In other words, the groove 33 can prevent water from entering the flat portion 325D on which the panel 40 is installed.

[0077] Furthermore, similar to the flat surface portion 325D, the groove 33 has a shape recessed from the outer peripheral surface of the heat insulating member 32D. Therefore, the groove 33 can realize space saving of the water heater 1D.

[0078] Although the water heater 1A-1D and the method for manufacturing the water heater 1A-1D according to the embodiment of the present disclosure have been described above, the water heater 1A-1D is not limited to this.

[0079] For example, in the water heater 1A-1D according to embodiment 1-4, the panel 40 is installed in the flat portion 325A-325D formed by cutting out the outer peripheral surface of the heat insulating member 32D. However, the water heater 1A-1D is not limited to this. In the water heater 1A-1D, the panel 40 can be installed in any recessed portion recessed from the cylindrical surface of the heat insulating member 32D. This configuration allows for space-saving in the water heater 1A-1D. Furthermore, by ensuring space for installing the panel 40 and insert-molding the fixing bracket 50 into the recessed portion, the panel 40 can be fixed with a small number of parts.

[0080] For example, the flat surfaces 325A-325D may be replaced with a rectangular parallelepiped recessed from the outer peripheral surface of the heat insulating members 32A-32D, or a plate-like recessed from the outer peripheral surface of the heat insulating members 32A-32D. Also, the flat surfaces 325A-325D may be replaced with a recessed portion having an uneven bottom.

[0081] In addition, in the embodiments 1-4, the water heaters 1A-1D are housed in the rectangular parallelepiped housing 10, but the shape of the housing 10 is not limited to this. In the water heaters 1A-1D, the shape of the housing 10 is arbitrary.

[0082] Fig. 15 is a perspective view of a modified example of water heater 1A according to embodiment 1. Fig. 16 is a perspective view of a modified example of water heater 1A according to embodiment 1 when housing 10 is removed from the modified example of water heater 1A.

[0083] As shown in Fig. 15, the housing 10 may have a cylindrical shape. In this case, the heating unit 20 may be attached directly to a top surface 323 of the heat insulating member 32A that can be accommodated in the cylindrical space of the housing 10, rather than being housed in a rectangular parallelepiped frame structure 21, as shown in Fig. 16.

[0084] 16, the top surface 323 may have a disk shape that can be accommodated in the cylindrical space of the housing 10, and the disk surface, i.e., the upper surface, of the top surface 323 may have recesses and projections that allow the undersides of the devices and piping of the heating unit 20 to fit into them. The undersides of the devices and piping of the heating unit 20 may fit into the recesses and projections of the top surface 323, thereby attaching the heating unit 20 to the top surface 323. In this way, the heating unit 20 may be accommodated in the cylindrical housing 10, as shown in FIG.

[0085] Furthermore, in embodiments 1-4, the fixing bracket 50 has a hat-shaped cross section. However, the fixing bracket 50 is not limited to this. The fixing bracket 50 may be any shape as long as it is insert-molded into the flat surfaces 325A-325D and secures the panel 40. The shape of the fixing bracket 50 is arbitrary as long as it satisfies this condition.

[0086] 17 to 20 are perspective views of first to fourth modified examples of the fixing bracket 50 included in the water heater 1A according to the first embodiment.

[0087] The fixing bracket 50 may have a U-shaped cross section as shown in Fig. 17. In this case, the bottom of the U-shaped cross section and two of the two side sections may be insert-molded into the flat sections 325A-325D.

[0088] Furthermore, as shown in Figure 18, the fixing bracket 50 may have a hat-shaped cross section, with a first plate-shaped portion 51 bent into an angular U-shape in cross section, and a second plate-shaped portion 52 folded back vertically on each side of the first plate-shaped portion 51.

[0089] Furthermore, as shown in FIG. 19 , the fixing bracket 50 may have at least one elongated hole 54 extending in the longitudinal direction of the second plate-shaped portion 52 formed in the base of each of the second plate-shaped portions 52 described with reference to FIG. 18 . A plurality of elongated holes 54 may be arranged in the longitudinal direction of each of the bases of the second plate-shaped portion 52. In such a configuration, the elongated holes 54 may be insert-molded when each of the second plate-shaped portions 52 is insert-molded into the flat portion 325A. This configuration can further increase the bonding strength of the fixing bracket 50 to the flat portion 325A. In other words, this configuration can further increase the pull-out resistance of the fixing bracket 50.

[0090] 20 , the fixing bracket 50 may have a shape in which a flat first plate-shaped portion 51 and a second plate-shaped portion 52 that is smaller than the first plate-shaped portion 51 are connected by a cylinder 55 with their plate surfaces parallel to each other. In this case, the second plate-shaped portion 52 may be insert-molded. With this configuration, the installation space for the fixing bracket 50 can be reduced.

[0091] Although the heat exchangers 1A-1D according to embodiments 1-4 are provided with a plurality of fasteners 50, specifically two fasteners 50, the number of fasteners 50 is arbitrary. The heat exchangers 1A-1D may be provided with only one fastener 50, or may be provided with three or more fasteners 50.

[0092] The present disclosure allows various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to explain the present disclosure and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and the meaning of the disclosure equivalent thereto are considered to be within the scope of the present disclosure.

[0093] This application is based on Japanese Patent Application No. 2023-111107, filed on July 6, 2023. The entire specification, claims, and drawings of Japanese Patent Application No. 2023-111107 are incorporated herein by reference.

[0094] 1A-1D water heater, 10 housing, 11 front panel, 12 right side panel, 13 left side panel, 20 heating unit, 21 frame structure, 30 hot water storage unit, 31 tank, 32A-32D heat insulating member, 33 groove, 40 panel, 41 elongated hole, 42 bolt, 45 eaves portion, 50 fixing bracket, 51 first plate-shaped portion, 52 second plate-shaped portion, 53 screw hole, 54 elongated hole, 55 cylinder, 60 electrical equipment, 321 first side portion, 322 second side portion, 323 top surface portion, 324 bottom surface portion, 325A-325D flat portion, 326 inner wall surface, 327 cylinder portion, 328 rectangular plate portion, 329 flat portion, 331 first groove portion, 332 second groove portion.

Claims

1. a first insulating member having a cylindrical shape with a first recess recessed from a cylindrical surface, the first insulating member accommodating a tank for storing hot water inside the cylinder; a second insulating member that covers the first insulating member and the tank from above; a panel on which electrical equipment connected to a heating device for supplying heated hot water to the tank is attached and which is disposed in the first recess; Equipped with the second heat insulating member has a recessed outer circumferential surface and a second recess disposed above the first recess and continuous with the first recess; the panel is disposed within the first recess and the second recess; At least one of the first recess and the second recess is insert-molded and has a fixing member that fixes the panel. Water heater.

2. The first recess has a shape obtained by cutting out the cylindrical surface along a plane parallel to the cylindrical axis. The water heater according to claim 1.

3. the first recess has the fixing member and a horizontally extending inner wall surface on a lower side; The panel is fixed to the fixing member in a state where it is placed on the inner wall surface. The water heater according to claim 1 or 2.

4. The first recess has the fixing member, The panel has a long hole for fastening to the fixing member with a fastening member. The water heater according to claim 1 or 2.

5. The first recess has the fixing member, The fixing member has a first plate-shaped portion that fixes the panel, and a second plate-shaped portion that supports the first plate-shaped portion and is insert-molded into the first recess. The water heater according to claim 1 or 2.

6. The second insulating member protrudes above the panel. The water heater according to claim 1 or 2.

7. the first recess is provided in contact with an upper end of the first heat insulating member, The second heat insulating member overhangs the first recess. The water heater according to claim 6.

8. The panel has an eave portion that covers the lower surface of the second heat insulating member. The water heater according to claim 6.

9. the first heat insulating member and the second heat insulating member are formed of a resin material, The eaves portion is formed of a metal material or a ceramic material. The water heater according to claim 8.

10. the first heat insulating member has a first groove portion extending horizontally from the first recess portion and a second groove portion extending vertically from the first groove portion to the second heat insulating member, A cable connecting the electrical component and the heating device is passed through the first groove and the second groove. The water heater according to claim 6.

11. a step of disposing a tank for storing hot water inside a first insulating member having a cylindrical shape with a first recess recessed from a cylindrical surface; a step of covering the first heat insulating member and the tank from above with a second heat insulating member having a second recess with a recessed outer circumferential surface, and disposing the second recess on the first recess so that the second recess is continuous with the first recess; a step of placing a panel having electrical equipment attached thereto, the electrical equipment being connected to a heating device for supplying heated hot water to the tank, inside the first recess and the second recess; Equipped with At least one of the first recess and the second recess has an insert-molded fixing member, In the step of arranging the panel, the panel is fixed to the at least one recess by the fixing member.

12. the first heat insulating member has a first side surface portion covering a part of the side surface portion of the tank and a second side surface portion covering another part of the side surface portion of the tank, The water heater includes a second insulating member that covers the tank from above, a third insulating member that covers a lower portion of the tank, and a housing that surrounds the first insulating member, the second insulating member, and the third insulating member, In the step of placing the tank inside the first insulating member, placing the tank on the third heat insulating member, attaching the first side surface portion and the second side surface portion to a side surface portion of the tank, and further attaching the second heat insulating member on which the heating device is placed to the first heat insulating member by placing the second heat insulating member on the first side surface portion and the second side surface portion; the method further includes, after the step of placing the tank inside the first heat insulating member, a step of attaching the housing to the first heat insulating member, the second heat insulating member, and the third heat insulating member. A method for manufacturing the water heater according to claim 11.