Hot-water supply unit and method for manufacturing the same
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Solution Overview
Problem
Hot-water supply units with heating mechanisms arranged above the tank face challenges in reducing the number of parts while maintaining structural integrity and avoiding increased weight, particularly due to the need for robust support structures for heavy components.
Innovation Solution
A configuration where the thermal insulator connects the tank and support plate, stabilizing the main frame, eliminating the need for a thicker tank or extensive frames, by using a foam filler like urethane to create a column-like structure that supports the entire unit, with the support plate doubling as a drainage member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tank is made thicker or extensive frames are employed to support the heating mechanism, then the structural integrity and support capability are improved, but the weight and number of parts increase
Solution Approach 1:
The thermal insulator is merged with the support function by connecting it to both the tank and the support plate. This integration allows the insulator to serve dual purposes: thermal insulation and structural support, thereby reducing the need for additional support structures and decreasing the overall weight of the unit.
Solution Approach 2:
The support plate is designed to perform multiple functions: it supports the main frame and heating mechanism, serves as a drainage member with its convex shape, and works in conjunction with the thermal insulator to provide structural stability. This multi-functionality reduces the number of separate components needed.
2Stability of the object's composition
If the tank is made thicker or extensive frames are employed to support the heating mechanism, then the structural integrity is improved, but the number of parts increases
Solution Approach 1:
The thermal insulator is merged with the support function by connecting it to both the tank and the support plate. This integration allows the insulator to serve dual purposes: thermal insulation and structural support, thereby reducing the need for additional support structures and decreasing the overall weight of the unit.
Solution Approach 2:
The support plate is designed to perform multiple functions: it supports the main frame and heating mechanism, serves as a drainage member with its convex shape, and works in conjunction with the thermal insulator to provide structural stability. This multi-functionality reduces the number of separate components needed.
3Device complexity
If thermal insulator is used to connect tank and support plate, then the number of parts is reduced, but the stability must be ensured
Solution Approach 1:
The convex shape of the support plate corresponds to the curved surface of the tank, creating a stable geometric relationship between components. This curved interface enhances the reliability of the connection between the support plate and tank while reducing the need for additional fastening parts.
Solution Approach 2:
The thermal insulator connects dissimilar materials (tank and support plate) while providing both thermal insulation and mechanical support. This composite approach allows the system to achieve both insulation and structural stability with a single component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces the number of parts and weight of the hot-water supply unit without compromising stability, allowing for efficient thermal insulation and support of the heating mechanism, while also serving as a drainage member.
Implementation Method 1
using a foam filler like urethane to create a column-like structure that supports the entire unit
Implementation Method 2
The tank needs thermal insulation to improve heat efficiency of the unit
Data Source
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AI summary
Provided is a hot-water supply unit (100), comprising: a heating mechanism (710) configured to heat up heating medium; a tank (300) configured to store water heated up by the heating medium; a water pipe (720) connected with the tank; thermal insulator (400) adhering to and substantially surrounding the tank; a main frame (600) supporting the heating mechanism and the water pipe to be at a position above the tank and the thermal insulator; a support plate (500) disposed between the thermal insulator and the main frame; and a housing (200) accommodating the heating mechanism, the tank, the at least one water pipe, the thermal insulator, the main frame and the support plate, wherein: the thermal insulator connects the tank and the support plate; and the main frame is fixed to the support plate to be supported by the support plate.