Method for manufacturing a vacuum storage device for warm water and compression tool for executing the method
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Solution Overview
Problem
Existing methods for producing vacuum storage devices, such as those described in DE 10 2017 209 782 A1, DE 10 2013 016 705 A1, and DE 20 2010 013 137 U1, are inefficient due to the time-consuming process of connecting and disconnecting lines for filling and evacuation, and maintaining the vacuum, which complicates industrial-scale production.
Innovation Solution
The method involves using pressing jaws aligned parallel to each other and a crimping tool with a pivoting movement to deform pipe elements, creating a gas-tight seal without the need for permanent valve elements, allowing for efficient vacuum maintenance and reducing manufacturing costs by using commercially available crimping tools with adjustable V-shaped press jaws to prevent pipe jacket tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional connecting and disconnecting lines are used for filling and evacuation, then the vacuum storage device can be manufactured, but the manufacturing process becomes time-consuming and inefficient
Solution Approach 1:
The patent extracts the valve elements from the vacuum storage device structure, eliminating the need for permanent valve components. Instead, temporary valve elements are introduced only during the filling and evacuation processes, then removed afterward. This extraction approach eliminates the time-consuming connection and disconnection of permanent valves while maintaining the necessary process functionality.
Solution Approach 2:
The patent implements preliminary action by pre-positioning temporary valve elements in the filling and evacuation lines before the actual processes begin. These temporary valves are already in place and ready for immediate use, eliminating the need for on-site assembly or complex connection procedures during manufacturing, thus reducing production time.
2Reliability
If permanent valve elements are used to maintain vacuum, then vacuum integrity is ensured, but manufacturing costs increase and installation space is required
Solution Approach 1:
The patent removes permanent valve elements from the vacuum storage device design. Instead, temporary valve elements are used during manufacturing processes and then removed, leaving no permanent valve components in the final product. This maintains vacuum integrity through alternative means (sealed closures) while eliminating the complexity and space requirements of permanent valves.
Solution Approach 2:
The patent employs temporary, disposable valve elements for the filling and evacuation processes. These inexpensive, short-lived components perform their function during manufacturing and are then discarded, replaced by simple sealed closures in the final product. This approach reduces manufacturing costs and device complexity compared to permanent valve solutions.
3Ease of operation
If crimping jaws with pivoting movement are used, then the crimping tool can be applied laterally to the pipe section, but the pipe wall may tear due to non-parallel deformation
Solution Approach 1:
The patent segments the crimping action into two distinct phases: first, a lateral positioning phase that brings the crimping tool into contact with the pipe element, and second, a parallel compression phase that applies the actual crimping force. This segmentation allows the tool to be applied laterally for ease of operation while ensuring the final deforming force is applied parallel to the pipe axis to prevent tearing and ensure gas-tight sealing.
Solution Approach 2:
The patent implements a dynamic crimping process where the crimping jaws transition from a lateral approach position to a parallel compression position. The tool is initially positioned laterally for easy access, then the crimping force is applied in a controlled manner to ensure parallel deformation. This dynamic approach combines the ease of lateral application with the precision of parallel crimping.
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 approach enables efficient industrial-scale production of vacuum storage devices by maintaining vacuum integrity and reducing manufacturing costs, while ensuring the pipe jacket is not damaged, thus facilitating the production of reliable and cost-effective vacuum storage devices for hot water.
Implementation Method 1
a) squeezing at least one pipe element (5), through which the insulating material is filled or air is extracted, so tightly that the vacuum is maintained. This is achieved by maintaining a compression force.
Implementation Method 2
The compression force can be higher at the beginning of the squeezing process to allow for plastic deformation and then decrease.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a method for manufacturing a vacuum storage tank for hot water, comprising at least the following steps: - Filling an intermediate jacket space in a double-jacketed storage tank (2) with an insulating material that can be introduced as a fluid via a filling line (3) opening into the intermediate jacket space; - Sealing the filling line (3); - Evacuating the intermediate jacket space via a vacuum suction line (4); - Sealing the vacuum suction line (4); wherein the filling line (4) and/or the vacuum suction line (3) are each connected via at least one shut-off valve (3.1, 3.2, 4.1, 4.2) to a pipe element (5) that opens into the intermediate jacket space, and wherein the pipe element (5) is compressed at a pinch point (5.1) after the intermediate jacket space has been filled and evacuated, and the compression is maintained. The pipe element (5) is cut off at a shear point (5.2) while the crush is maintained and sealed fluid-tight so that the crush at the crush point (5.1) becomes relaxed.