Cooling tank, water purifier having same, and cooling tank manufacturing method

Provided is a cooling tank comprising a tank body in which a water accommodation space is formed, a foaming case for encompassing the outer peripheral surface of the tank body, and a foam insulating material formed by a foaming agent flowing into the foaming space between the outer peripheral surface of the tank body and the foaming case, and then foaming, wherein the foam insulating material is integrated with the tank body and the case through foaming, and the case has an air outlet through which air of the foaming space is discharged during a foaming process.

CROSS-REFERENCE OF RELATED APPLICATIONS AND PRIORITY

The Present Application is a national stage application of International Application No. PCT/KR2020/017592 filed on Dec. 4, 2020 which claims priority to Korean Patent Application Nos. 10-2019-0161061 filed Dec. 5, 2019 and 10-2019-0161063 filed Dec. 5, 2019, the disclosure of which are incorporated by reference as if fully set forth herein.

TECHNICAL FIELD

The present disclosure relates to a cooling tank for a water purifier, a water purifier including the same, and a method for manufacturing the cooling tank, and more particularly, to a cooling tank in which a foamed thermal insulating material is formed by injecting a foaming agent between a foaming case and a tank body, a water purifier including the same, and a method for manufacturing the cooling tank.

BACKGROUND ART

Water purifiers may have devices for filtering harmful elements such as foreign substances, heavy metals, or the like contained in water, and water ionizers, water softeners, and the like may also belong to water purifiers in a broad sense. Such water purifiers may be configured to provide hot water and/or cold water, and for this purpose, a heating device and/or a cooling device (a cold water generator) may be provided therein.

Such a cold water generator may also use a tank cooling method generating cold water with directly cooling water contained in a cold water tank by an evaporation tube (evaporator), or an ice-condensed cooling method discharging cold water through a cold water pipe by installing an evaporation tube (evaporator) through which a refrigerant flows and the cold water pipe through which purified water flows, in an ice-condensed tank, cooling an ice-condensed solution accommodated in the ice-condensed tank by the evaporation tube (evaporator), and thermally exchanging the cooled ice-condensed solution or ice with the purified water flowing through the cold water pipe. To this end, the evaporation tube (evaporator) may be connected to a compressor, a condenser, and an expansion valve to constitute a cooling cycle.

Meanwhile, a cooling tank provided in the cold water generator for accommodating cold water (purified water or an ice-condensed solution) may exchange heat with an external source, to increase a temperature of water contained therein, such that dew condensation may occur (generated condensed water) on a surface of the tank body with a low temperature. In particular, when dew condensation occurs, mold may easily grow on the surface of the tank body due to mold spores in the air, which often causes discomfort to users.

In order to secure such cold retaining performance and/or anti-dew condensation performance, a thermal insulating material (a cold retaining material) may be installed on a surface of the tank body in many cases. Such a thermal insulating material has been manufactured separately as expandable polystyrene (EPS), Styrofoam, or the like to have a shape corresponding to a shape of the surface of the tank body, and used in a manner attached to the surface of the cooling tank.

However, since such an EPS insulating material may be separately manufactured and attached to the tank body, a gap into which external air penetrates may be formed between the cooling tank and the EPS insulating material. Therefore, when the EPS insulating material is used, not only thermal insulation performance (cold retaining performance) may not be sufficient, but also dew condensation may occur (generated condensed water) on the surface of the tank body, and external air can penetrate into these condensed regions, to create an environment in which mold may easily grow.

In order to solve problems regarding the EPS insulating material, a nude foaming method in which a foamed thermal insulating material is directly formed on a surface of a tank body has recently been used. Korean Patent Publication No. 2017-0022775 proposes a nude foaming method in which a polyurethane foamed thermal insulating material is formed on an external peripheral surface of a cold water tank assembly by inserting the cold water tank assembly into a foaming jig and then performing a foaming process.

However, in such a nude foaming process, there may be problems that, since a foamed thermal insulating material is formed between a surface of the foaming jig (or a vinyl provided on the surface of the foaming jig) and the cold water tank assembly, a foamed surface may not be clean, and since a large amount of foaming powder particles may be generated in post-processing operations such as a process of grinding or deburring the foamed surface, a process of removing the vinyl, or the like, the foam powder particles, which may be impurities, may remain in the tank. In particular, in this nude foaming process, since the foamed thermal insulating material is directly exposed to ambient air, air may move through fine pores formed in the foamed thermal insulating material. Furthermore, the foamed thermal insulating material formed by the nude foaming process may have problems in that not only may mold grow in the pores therein, but it may also be difficult to remove the mold generated in the pores. In particular, the mold may continue to spread into the foamed thermal insulating material through the pores of the foamed thermal insulating material, causing user discomfort as well as sanitary issues.

PRIOR ART LITERATURE(S)

SUMMARY OF INVENTION

Technical Problem

An aspect of the present disclosure is to solve at least some of the problems of the prior art as described above, and to provide a cooling tank securing sufficient dew condensation performance and thermal insulation performance, a water purifier including the same, and a method of manufacturing the cooling tank.

Another aspect of the present disclosure is to provide a cooling tank minimizing a non-foamed region, a water purifier including the same, and a method of manufacturing the cooling tank.

Another aspect of the present disclosure is to facilitate manufacturing of a cooling tank, a water purifier including the same, and a method of manufacturing the cooling tank.

Another aspect of the present disclosure is to provide a cooling tank shielding a tank body and a foamed thermal insulating material from contact with external air, a water purifier including the same, and a method of manufacturing the cooling tank.

Another aspect of the present disclosure is to provide a cooling tank of which it is easy to clean an external surface and remove dew condensation (generated condensed water), a water purifier including the same, and a method of manufacturing the cooling tank.

Solution to Problem

According to an aspect of the present disclosure, a cooling tank includes a tank body in which a water accommodation space is formed; a foaming case surrounding an external peripheral surface of the tank body; and a foamed thermal insulating material formed by a foaming process after a foaming agent is introduced into a foaming space between the external peripheral surface of the tank body and the foaming case, wherein the foamed thermal insulating material is integrated with the tank body and the foaming case by the foaming process, and an air outlet through which air in the foaming space is discharged during the foaming process is formed in the foaming case.

In addition, an injection port injecting the foaming agent may be formed in the foaming case.

Further, the injection port may be formed adjacent to one side of the foaming case, and the air outlet may include a main outlet formed to oppose the injection port and adjacent to the other side of the foaming case. A diameter of the main outlet may have a value of 4 to 15 mm.

In addition, the air outlet may further include a corner outlet located at a corner of the foaming case. In this case, a diameter of the corner outlet may have a value of 0.5 to 1.5 mm.

Further, the foaming case discharges the air through the main outlet, and a shielding film member shielding leakage of the foamed thermal insulating material may be installed at the main outlet.

In addition, the foaming case may have a divided structure.

Further, the foaming case may have a downward inclination, inclined toward a center from an external side of a lower surface.

In addition, the foamed thermal insulating material may have a density of 0.065 to 0.085 g/cm3after curing is completed.

Further, the tank body may have a tank edge portion corresponding to an open region, and the foaming case may have a case edge portion corresponding to the tank edge portion, wherein the tank edge portion and the case edge portion may be insertedly fastened to each other.

In this case, the tank edge portion may have protruding portions protruding toward the case edge portion, and the case edge portion may have a receiving portion formed between protruding portions of the case edge portion to be insertedly fastened to the protruding portions of the tank edge portion.

Further, the tank body may have a water flow port protruding toward the foaming case to enable flow of water accommodated in the water accommodation space, and a sealing member attached to the foaming case to seal the foaming space from an external space may be installed on an external surface of the water flow port.

In this case, the water flow port may have a stepped structure in which a first stepped portion, a second stepped portion, and an end portion, having gradually smaller diameters in an external side direction of the tank body, are sequentially formed, and the foaming case may have a through-hole through which an end portion of the water flow port is exposed externally, a seating surface formed around the through-hole and corresponding to the second stepped portion, and a seating bump protruding toward the tank body to correspond to the first stepped portion around the seating surface. Further, the sealing member may be provided between the first stepped portion and the seating bump.

In addition, the tank body may have a bump protruding from the tank body toward the foaming case, and a sealing member attached to the foaming case to seal the foaming space from an external space may be installed on an external surface of the bump.

In this case, the bump may have a stepped structure, in which a first stepped portion, a second stepped portion, and an end portion, having gradually smaller diameters in an external side direction of the tank body, are sequentially formed, the foaming case may have a through-hole through which an end portion of the bump is exposed externally, a seating surface formed around the through-hole and corresponding to the second stepped portion, and a seating bump protruding toward the tank body to correspond to the first stepped portion around the seating surface, and the sealing member may be provided between the first stepped portion and the seating bump.

According to another aspect of the present disclosure, a cooling tank assembly includes the cooling tank of any one of claims1to7; and a tank cover covering an open upper surface of the cooling tank, wherein at least a portion of a tube member and a sensor is coupled to the tank cover.

According to another aspect of the present disclosure, a water purifier includes a filter unit filtering incoming raw water to generate purified water; a cold water generator generating cold water with a cooling tank assembly including the cooling tank of any one of claims1to7and a tank cover covering an upper surface of the cooling tank; and an extracting unit supplying the cold water generated by the cold water generator to a user.

According to another aspect of the present disclosure, a method for manufacturing a cooling tank, includes a seating operation of seating a foaming assembly in which a tank body in which a water accommodation space is formed and a foaming case surrounding an external peripheral surface of the tank body are assembled, on a foaming jig; an injection operation of injecting a foaming agent into a foaming space formed between the external peripheral surface of the tank body of the foaming assembly and an internal surface of the foaming case through an injection port formed in the foaming case; an upper surface closing operation of closing an upper surface of the foaming jig; and a foaming-curing operation of foaming and curing the foaming agent to form a foamed thermal insulating material in the foaming space, wherein the foamed thermal insulating material is integrated with the tank body and the foaming case by the foaming-curing operation, and the foaming-curing operation is configured to discharge air present in the foaming space through an air outlet formed in the foaming case.

Advantageous Effects of Invention

According to an aspect of the present disclosure having such a configuration, it is possible to obtain effects of securing sufficient dew condensation performance and thermal insulation performance.

In addition, according to an aspect of the present disclosure, there may be an effect of minimizing a non-foamed region.

Moreover, according to an aspect of the present disclosure, it is possible to obtain an effect of being easy to manufacture a cooling tank.

In addition, according to an aspect of the present disclosure, there may be an effect of shielding a tank body and a foamed thermal insulating material from contact with external air.

Moreover, according to an aspect of the present disclosure, it is possible to obtain effects of being easy to clean an external surface and remove dew condensation (generated condensed water).

BEST MODE FOR INVENTION

Hereinafter, preferred embodiments of the present disclosure will be described with reference to the accompanying drawings. However, an embodiment of the present disclosure may be modified in various other forms, and the scope of the present disclosure is not limited to embodiments described below. In addition, embodiments of the present disclosure may be provided to explain the present disclosure more completely to those of ordinary skill in the art. Shapes and sizes of elements in the drawings may be exaggerated for clarity.

In addition, in the present specification, singular expressions may include plural expressions unless the context clearly dictates otherwise, and the same reference characters may refer to the same element or corresponding element throughout the specification.

Hereinafter, various embodiments of the present disclosure will be described with reference to the drawings.

First, a cooling tank assembly200including a cooling tank100according to an embodiment of the present disclosure will be described with reference toFIGS.1to4.

FIG.1is a perspective view of a cooling tank assembly200according to an embodiment of the present disclosure,FIG.2is a perspective view illustrating the cooling tank assembly200ofFIG.1from below from the rear,FIG.3is an exploded perspective view of the cooling tank assembly200ofFIG.1, andFIG.4is an exploded perspective view of a cover assembly201of the cooling tank assembly200ofFIG.3.

Referring toFIGS.1to4, a cooling tank assembly200according to an embodiment of the present disclosure may be configured to include a cooling tank100, a cover assembly201, and a cover thermal insulating material250.

As illustrated inFIG.3, the cooling tank100may be configured to include a tank body110in which a water accommodation space S1is formed, a foaming case130, and a foamed thermal insulating material150, and a detailed description of the cooling tank100will be described later with reference toFIGS.1to3andFIGS.5to11.

The cover assembly201may be configured to include a tank cover210located on the tank body110and combined with the tank body110, and a cold water pipe220, an evaporation pipe230, and a stirring unit240, coupled to the tank cover210. In addition, a temperature sensor ST measuring a temperature of water accommodated in the water accommodation space S1and a water level sensor SL measuring a water level of the water may be installed in the tank cover210.

A plurality of openings215may be formed in a cover body211to install various components such as the cold water pipe220, the evaporation pipe230, the stirring unit240, the temperature sensor ST, the water level sensor SL, or the like. Various components may be introduced into the water accommodation space S1of the tank body110through the openings215. In addition, for the fastening of the tank cover210and the tank body110, a plurality of places may be screwed through a fastening port (H1inFIG.4) of the tank cover210and a fastening port (H2inFIG.5) of the tank body110. In addition, a gasket (not illustrated) may be provided between the tank cover210and the tank body110to seal the tank cover210and the tank body110.

The evaporation tube230may flow a refrigerant to cool an ice-condensed liquid accommodated in the water accommodation space S1of the tank body110, and may be connected to a compressor, a condenser, and an expansion valve, not illustrated, to constitute a cooling cycle (a cooling system). In the evaporation tube230, an upper side thereof may be supported by the tank cover210, and a lower side thereof may be supported by an evaporation tube support groove (118inFIG.6) formed in the water accommodation space S1of the tank body110. In addition, the evaporation tube230needs to sufficiently secure a flow path length to exchange with the ice-condensed liquid sufficiently thermally. For this purpose, the evaporation tube230may have a spiral shape. In addition, the refrigerant flowing through the evaporation tube230may be connected to the cooling system through a connection member235sealed to an end portion of the evaporation tube230.

Also, the cold water pipe220may be disposed on an outside of the evaporation pipe230in the water accommodation space S1, and may have a shape surrounding the evaporation pipe230. Like the evaporation pipe230, the cold water pipe220needs to sufficiently secure a flow path length to exchange with the ice-condensed liquid sufficiently thermally. For this purpose, the cold water pipe220may also have a spiral shape. In addition, one side of the cold water pipe220may be connected to a filter unit (310inFIG.17), and purified water filtered by the filter unit310may flow through an internal space of the cold water pipe220. Therefore, the purified water flowing through the internal space of the cold water pipe220may be cooled by thermal exchange with an ice-condensed liquid or an ice-condensed ice cooled by the evaporation pipe230, and may be discharged as cold water. Moreover, an upper side of the cold water pipe220may be connected to the tank cover210, and a lower side of the cold water pipe220may be supported by a cold water pipe support groove (119inFIG.6) formed in the water accommodation space S1of the tank body110.

In addition, the other side of the cold water pipe220may be connected to an extraction unit (330inFIG.17) through a pipe connection member (FT) and a pipe (not illustrated) coupled thereto. Therefore, the cold water discharged from the cold water pipe220may be provided to a user through the extraction unit330.

Moreover, the stirring unit240may be configured to equalize a temperature of an ice-condensed liquid accommodated in the water accommodation space S1of the tank body110, to efficiently perform thermal exchange between the purified water flowing through the cold water pipe220and the ice-condensed liquid. The stirring unit240may be configured to include a motor241providing a rotational driving force, stirring blades243rotating by the driving force of the motor241, and a circulation guide member245disposed to surround the stirring blades243on the upper side of the evaporation tube230and to guide circulation of the ice-condensed liquid to facilitate the circulation of the ice-condensed liquid, when the stirring blades243are rotated. For example, when the stirring blades243are rotated, the ice-condensed liquid may move to a lower side of the water accommodation space S1, may move in a radial-outward direction in the water accommodation space S1, may rise through a space between the cold water pipe220and an internal surface of the tank body110, and may move in a radial-inward direction, to have a circulation path flowing into the stirring blades243through the circulation guide member245.

In addition, a support groove245afor supporting the upper side of the evaporation tube230may be formed on a lower surface of the circulation guide member245. Therefore, the upper side of the evaporation tube230may be supported by the support groove245a, and the lower side of the evaporation tube230may be supported by the evaporation tube support groove (118inFIG.6) formed in the water accommodation space S1of the tank body110. Therefore, the evaporation tube230may be stably supported.

An ice-condensed cooling method may be used in various forms in water purifiers, and Korea Patent Publication No. 2019-0119444 filed by the present applicant also discloses a cold water manufacturing apparatus including the same internal structure as the present disclosure. Therefore, a detailed description thereof will be omitted, and will be replaced with the description of Korea Patent Publication No. 2019-0119444.

In addition, the cover thermal insulating material250may be coupled to the tank cover210of the cover assembly201, to insulate a portion of the tank cover210. In addition, to connect various components such as the cold water pipe220, the evaporation pipe230, the stirring unit240, the temperature sensor ST, the water level sensor SL, and the like, installed in the tank cover210, externally, a plurality of openings251may be formed in the cover thermal insulating material250to correspond to externally exposed positions of the components, as illustrated inFIGS.1to3.

Since various components may be installed in the cover assembly201, an external shape of the cover assembly201may have a complicated shape. Therefore, a shape of the cover thermal insulating material250should also have a complicated shape. Therefore, the cover thermal insulating material250may be separately manufactured as expandable polystyrene (styrofoam) or the like to facilitate manufacturing of a complicated shape, and may be configured to be attached to the external surface of the cover assembly201.

In this case, as will be described later, cold water may be accommodated in the tank body110located in a lower portion of the cooling tank assembly200, and the tank cover210may be coupled to an upper portion of the tank body110and may serve only to seal the upper portion of the tank body110. For example, since, with respect to a temperature of water according to a position of the tank body110, a temperature of a lower portion of the tank body110may be low, and a temperature of an upper portion of the tank body110may be relatively higher than that of the lower portion due to a difference in density of water according to a temperature, cold retaining (heat insulating) performance and anti-dew condensation performance, required for the tank cover210coupled to the upper portion of the tank body110may be relatively lower than a portion of the tank body110. In consideration thereof point, the cover thermal insulating material250may be formed of EPS. A cover thermal insulating material250according to an embodiment of the present disclosure is not limited to EPS. To realize higher cold retaining (heat insulating) performance and higher anti-dew condensation performance, a foaming space S2may be formed between the foaming case and the tank cover210, in a similar manner to a cooling tank100to be described later, and a foaming agent (FA inFIG.14) may be injected into the foaming space S2, to configure a foamed thermal insulating material corresponding to the tank cover210.

With respect to a cooling tank assembly200according to an embodiment of the present disclosure, the ice-condensed cooling method illustrated inFIGS.1to4has been described, but a cooling tank assembly200according to an embodiment of the present disclosure is not limited to the ice-condensed cooling method as described above, and may be configured as a tank cooling method in which water contained in a cold water tank may be directly cooled by an evaporation tube (an evaporator)230to generate cold water.

Next, a cooling tank100according to an embodiment of the present disclosure will be described with reference toFIGS.1to3and5to11.

FIG.5is a perspective view illustrating a cooling tank100in the cooling tank assembly200ofFIG.3,FIG.6is a cross-sectional view ofFIG.5, taken along line I-I′,FIG.7is an exploded perspective view illustrating a foam assembly101provided in the cooling tank100ofFIG.5from below,FIG.8is an exploded perspective view illustrating an internal space of a foaming case130of the foaming assembly101ofFIG.7from above,FIG.9is a bottom view of the foaming case130ofFIG.7, andFIGS.10A and10Bare bottom views illustrating a modified example of the foaming case130ofFIG.9, andFIGS.11A and11Bare perspective views illustrating a modified example of the foaming case130ofFIG.9.

Referring toFIGS.1to3, and5to11, a cooling tank100according to an embodiment of the present disclosure may be configured to include a tank body110, a foaming case130and a foamed thermal insulating material150. In addition, the tank body110and the foaming case130may be coupled to each other to form a foaming assembly101, before a foaming agent FA is injected.

The tank body110may have a structure combined with a tank cover210, as described above, and a water accommodation space S1may be formed therein. In an ice-condensed cooling method, an ice-condensed liquid may be accommodated in the water accommodation space S1, and in a tank cooling method in which water contained in the cooling tank100is directly cooled by an evaporation tube (an evaporator)230to generate cold water, purified water may be accommodated in the water accommodation space S1.

In addition, at least one water flow port111through which water accommodated in the water accommodation space S1flows into a lower portion of the tank body110may be formed. On a side surface of the tank body110, to install the tank body110in a housing (not illustrated) of a water purifier, a bump115for coupling the tank body110to a frame (not illustrated) or the like with a bolt (a screw), may be formed. A configuration of the bump115is not limited to fastening of the tank body110, and may be used for other purposes.

Moreover, the foaming case130may be installed to accommodate the tank body110therein and to surround an external peripheral surface of the tank body110. Between an external surface of the tank body110and an internal surface of the foaming case130, a foaming space S2in which the foaming agent (FA inFIG.14) is foamed may be formed. In addition, to accommodate the tank body110in the foaming case130, the foaming case130may have a structure to be divided into a first case131and a second case135.

A bonding member (T inFIG.13) may be bonded to a division portion138divided into the first case131and the second case135, to insert the foaming assembly101, coupled to the tank body110and the foaming case130while maintaining the assembled state as described below, into a foaming jig. Since deformation of an external surface of the foaming case130may be limited by the foaming jig, the bonding member T may be sufficient to provide a bonding force such that the foaming case130is prevented from being divided, in a process of inserting the foaming assembly101into the foaming jig. Therefore, the bonding member T may be formed of tape attached to the division portion138between the first case131and the second case135, but the present disclosure is not limited thereto. For example, the bonding member T may be formed of an adhesive applied to the division portion138, and an insertedly-fastening member that enables physical coupling between the first case131and the second case135may be used. Also, various other modifications thereof are possible.

In addition, a configuration in which the first case131and the second case135overlap is possible, such that the foaming agent FA does not leak from the division portion138externally during a foaming process.

In addition, the foamed thermal insulating material150may be formed by introducing and foaming the foaming agent FA into a foaming space between the external peripheral surface of the tank body110and the foaming case130. Therefore, the foamed thermal insulating material150may be integrated with the tank body110and the foaming case130by the foaming process.

In this case, the foaming agent FA may be a foaming liquid capable of forming a urethane (polyurethane) foam. The urethane (polyurethane) foam may use polyurethane, obtained by reaction of an isocyanate compound with glycol, as a material, and may refer to a foamed product usually formed by mixing carbon dioxide, generated by reaction of isocyanate and water as a crosslinking agent, and a volatile solvent such as Freon as the foaming agent FA. The urethane foam may have various levels of hardness such as super soft, soft, semi-hard, hard, or the like, depending on a type of glycol, a raw material to be used. When the foaming agent FA used in the present disclosure forms a urethane foam, various changes is possible in composition and manufacturing method of the urethane foam. In addition, the foamed thermal insulating material150provided in the cooling tank100of the present disclosure is not limited to urethane foam, and various types of known foaming agents may be used, when the tank body110is accommodated in the foaming case and uniform foaming is effected between the foaming case and the external surface of the tank body110.

An injection port136for injection of the foaming agent FA, and an air outlet AE through which air in the foaming space S2is discharged during the foaming process may be formed in the foaming case130. In this case, the injection port136may be formed adjacent to one side of the foaming case130, and may be formed to have a size necessary for an injection operation. The injection port136may be completely cut to form a through-hole, but may be partially cut to form a cutout137, as illustrated inFIG.10B. As illustrated inFIG.10B, the cutout137may be folded in an injection direction, when the foaming agent FA is injected, and the cutout137may move in an opposite direction (in an outward direction) to have a structure in which the injection port136is closed.

Moreover, the air outlet AE may include a main outlet AE1opposing the injection port136and formed adjacent to the other side of the foaming case130. When the main outlet AE1is installed in a direction, opposite to the injection port136, a large amount of air may be discharged through the main outlet AE1. Therefore, foaming toward the main outlet AE1may be smoothly performed. In addition, the main outlet AE1may be installed adjacent to a complicated shape of the foaming case130. For example, as illustrated inFIG.9, the main outlet AE1may be installed eccentrically toward the water flow port111from a central portion, rather than the central portion of the foaming case130, such that air is discharged from a portion adjacent to the water flow port111to effectuate sufficient foaming around the water flow port111having a complex shape. As illustrated inFIG.10A, the main outlet AE1may be also located in the central portion, corresponding to the injection port136disposed in the central portion of the foaming case130.

In addition, since the main outlet AE1has a relatively large size, among the air outlets AE, a shielding film member MB may be used to block the main outlet AE1. In this case, the shielding film member MB may be formed of a material preventing leakage of the foaming agent FA during the foaming process, and allowing air to be discharged. As an example of the shielding film member MB, a non-woven fabric or a mesh network having a small gap may be used. The material of the shielding film member MB may not be limited thereto, and various materials and types of members may be used as long as it is possible to discharge air and prevent leakage of the foaming agent FA. In addition, the shielding film member MB may be attached to an internal surface of the foaming case130. Since the foaming case130may be supported by the foaming jig during the foaming process, the shielding film member MB may be attached to an external surface of the foaming case130.

Since a foaming pressure of the foaming agent FA may be very high during the foaming process, to sufficiently resist the main outlet AE1and/or the shielding film member MB against leakage of the foaming agent FA, it is preferable that the main outlet AE1may be provided as a plurality of main outlets AE1having small sizes, as illustrated inFIGS.9,10A, and the like. As such, to easily discharge air, the main outlet AE1may have a diameter of approximately 4 mm to 15 mm, more preferably 4 to 10 mm. Also, the number of the main outlets AE1may be three or more. However, as illustrated inFIG.10(b), the main discharge port AE1may have a slot shape formed to be long and thin.

The air outlet AE may further include a corner outlet AE2located at a corner of the foaming case130. When only the main outlet AE1is provided in the foaming case130, air flow may be low at the corner of the foaming case130, and thus, a non-foamed region (an unfilled region) may be likely to occur in a corner portion. In consideration thereof point, it is possible to install the corner outlet AE2in the corner of the foaming case130. According to the inventor's experiment, it can be confirmed that, foaming of the corner portion may be sufficiently effectuated when installing the corner outlet AE2in a region, adjacent to the corner (a vertex) of the foaming case130, as compared to installing a plurality of outlets in the corner portion.

When the corner outlet AE2is formed to be large, the foaming agent FA may leak through the corner outlet AE2during the foaming process. Therefore, it may be necessary to install the shielding film member MB at the corner outlet AE2as well. To block the corner outlet AE2formed at each corner, it may be cumbersome to install the plurality of shielding film members MB. In consideration thereof, the corner outlet AE2may have a diameter of about 1 mm, preferably a range between 0.3 to 2.0 mm, more preferably a range between 0.5 and 1.5 mm, such that air is discharged but leakage of a foamed foaming agent FA is prevented. In addition, each of the corner outlets AE2may be formed at each corner.

Since the corner outlet AE2may be formed on a curved surface of the corner, it may not be easy to form the corner outlet AE2by punching using a mold. In consideration thereof point, as illustrated inFIG.11B, the corner outlet AE2may be also located in a planar region, adjacent to the corner. In addition, inFIGS.11A and11B, a radius of curvature of the corner portion may increase to smoothly effectuate foaming of the foaming agent FA in the corner portion. As inFIG.11B, even when the corner outlet AE2is located in the planar region, adjacent to the corner, an unfilled (non-foamed) region may not occur in the corner of the foaming case130.

Moreover, since the foaming case130may be formed of a plastic material such as PE or PP, it may be easy to form the foaming case130and the foaming case130may have a smooth surface. Therefore, a surface of the foaming case130may be easily cleaned. For example, even when dew condensation (generated condensed water) occurs on the surface of the foaming case130or there are contaminants such as mold or the like, cleaning thereof may be easily effectuated, and the contaminants may be prevented from moving into the foamed thermal insulating material150located in the foaming case130.

In addition, as illustrated inFIG.6, the foaming case130may have a downward inclined slope in a direction toward a center from an external side of a lower surface145, and, even when condensed water occurs on the surface of the foaming case130, may be configured to gather and move downwardly the condensed water around the center of the lower surface145, to reduce a residual portion of the condensed water on the surface of the foaming case130.

Referring toFIGS.6to8, sealing may be made between a coupling portion of the foaming case130and the tank body110. Through this sealing structure, it is possible not only to prevent the foaming agent FA from leaking externally during the foaming process of the foaming agent FA, but also to completely block the external surface of the foaming case130and the foamed thermal insulating material150, after curing of the foaming agent FA is completed to form the foamed thermal insulating material150.

The tank body110may include a tank edge portion120corresponding to an open region, and the foaming case130may include a case edge portion140corresponding to the tank edge portion120. In this case, it may be necessary to prevent leakage of the foaming agent FA at a boundary between the tank edge portion120and the case edge portion140. To prevent the leakage of the foaming agent FA at the boundary between the tank edge portion120and the case edge portion140, the tank edge portion120and the case edge portion140may have a structure in which they are insertedly fastened to each other. Specifically, as illustrated inFIG.6, the tank edge portion120may include a protruding portion121protruding toward the case edge portion140, and the case edge portion140may include a receiving portion141formed between protruding portions142, such that the protruding portion121is insertedly fastened therebetween. For example, upper and lower surfaces of the protruding portion121of the tank edge portion120may be in contact with an internal side surface of the receiving portion141formed by the protruding portions142of the case edge portion140, to form a ‘U’-shaped contact structure between the tank edge portion120and the case edge portion140. A protruding portion142located on an upper portion of the receiving portion141may form a ‘U’-shaped contact structure between the protruding portion142and the tank edge portion120by contacting upper and lower surfaces of the protruding portion142with an internal side surface of a recessed portion122of the tank edge portion120. In addition, a protruding portion142located on a lower portion of the receiving portion141may have a structure contacting a stepped portion123of the tank edge portion120. As such, it is possible to reliably prevent leakage of the foaming agent FA in a foaming operation through the contact structure between the tank edge portion120and the case edge portion140, having a multistepped zigzag shape, as well as to block flow of external air through the boundary between the tank edge portion120and the case edge portion140as much as possible, in a state in which curing of the foaming agent FA is completed. For a better sealing structure, a sealing member to be described later may be additionally installed between the protruding portion121and the receiving portion141or between the protruding portion142and the recessed portion122.

Moreover, the tank body110may include a water flow port111protruding toward the foaming case130to enable flow of water accommodated in the water accommodation space S1. A sealing member OR in close contact with the foaming case130may be installed on an external surface of the water flow port111to seal the foaming space S2from an external space. In addition, to form a multistepped contact structure between the water flow port111and the foaming case130, the water flow port111may have a stepped structure in which a first stepped portion111a, a second stepped portion111b, and an end portion111c, having gradually smaller diameters in an external side direction of the tank body110, are sequentially formed. In response to this, a through-hole132may be formed in the foaming case130to expose the end portion111cof the water flow port111externally. A seating surface134corresponding to the second stepped portion111bmay be formed around the through-hole132. A seating bump133protruding toward the tank body110to correspond to the first stepped portion111amay be provided around the seating surface134. In this case, the sealing member OR may be inserted between the first stepped portion111aand the seating bump133, to realize sealing between the water flow port111and the foaming case130.

In addition, the tank body110may include a bump115protruding from the tank body110toward the foaming case130, and may fasten the tank body110to a frame (not illustrated) in a housing (not illustrated) through the bump115. In this case, a sealing member OR in close contact with the foaming case130may be installed on an external surface of the bump115to seal the foaming space S2from an external space. In addition, to form a multistepped contact structure between the bump115and the foaming case130, the bump115may have a stepped structure in which a first stepped portion115a, a second stepped portion115b, and an end portion115c, having gradually smaller diameters in an external side direction of the tank body110, are sequentially formed. In response to this, a through-hole132may be formed in the foaming case130to expose the end portion115cof the bump115externally. A seating surface134corresponding to the second stepped portion115bmay be formed around the through-hole132. A seating bump133protruding toward the tank body110to correspond to the first stepped portion115amay be provided around the seating surface134. In this case, the sealing member OR may be inserted between the first stepped portion115aand the seating bump133, to realize sealing between the bump115and the foaming case130.

A foamed thermal insulating material150may be formed by foaming the foaming agent FA injected into a space between the foaming case130and the tank body110. It could be seen by the present inventors that a difference in performance depends on an injection amount of the foaming agent FA.

[Table 1] illustrates results of tests obtained by performing the tests including, to form a polyurethane foam, using a material mixed with BILLYOL (RF-334T) and ECO FOAM-A in a certain ratio (1:1.1) as an example of a foaming agent FA, and using a urethane high pressure foaming machine (not illustrated), while changing injection time (sec) of the foaming agent FA. A temperature of a foaming jig was maintained at 40° C., and a foaming-curing time period was given by 20 minutes to achieve complete curing.

In [Table 1], a weight was measured by cutting a size of a specimen for a foamed thermal insulating material150into 50 mm*50 mm*17 mm for each of the tests, and a density was a value calculated from the measured weight and a volume of the specimen.

In addition, to measure thermal insulation performance and anti-condensation performance, measurements were made after leaving the specimen under dew condensation conditions in summer in a room having a temperature of 35° C. and a relative humidity of 93%.

A remaining ice amount (g) for measuring the thermal insulation performance was a result of measuring an amount of ice remaining after 1.5 days after adding 2000 g of ice. A dew condensation amount (g) for measuring the anti-condensation performance was a result of measuring an amount of dew remaining after 1 day after continuously adding ice water (measurement results mainly from side surfaces thereof).

In addition, foaming quality was visually determined to see whether a non-foamed region had occurred. Moreover, EPS in far right boxes of [Table 1] was a result of measurement using EPS including the same shape and volume as the foamed thermal insulating material150.

As illustrated in [Table 1], the remaining ice amount (g) was showed to tend to decrease, as a density of the foamed thermal insulating material150in which curing was completed increases. In this case, it can be seen that amounts of pores in the foamed thermal insulating material150are not large, and heat transfer, similar to conduction, was performed, in a similar manner to plastics, to reduce a cooling effect (a thermal insulation effect), when the density of the foamed thermal insulating material150was high. It can be confirmed that thermal insulation performance in using a foaming case130was superior to thermal insulation performance in using EPS.

In addition, as illustrated in [Table 1], the dew condensation amount (g) was showed to tend to increase, as a density of the foamed thermal insulating material150in which curing was completed increases, and was believed that this was because amounts of pores in the foamed thermal insulating material150are not large, like the thermal insulation performance, when the density of the foamed thermal insulating material150was high.

As illustrated in [Table 1], when the density of the foamed thermal insulating material150was low (Comparative Example 1 and Comparative Example 2), a foaming amount and a foaming pressure were not sufficient. In these cases, foaming was not occurred in some regions.

As such, when the density of the foamed thermal insulating material150was less than 0.065 g/cm3(Comparative Example 1 and Comparative Example 2), thermal insulation performance and anti-condensation performance were excellent, but there was a non-foamed region. In the non-foamed region, dew condensation may occur in an internal region of the foaming case130, and contamination such as mold or the like may occur due to such dew condensation (generated condensed water). When the density of the foamed thermal insulating material150was greater than 0.085 g/cm3(Comparative Example 3), it can be seen that thermal insulation performance and anti-condensation performance were deteriorated.

Therefore, the density of the foamed thermal insulating material150may be in a range of 0.065 to 0.085 g/cm3, comprehensively considering the thermal insulation performance, the anti-condensation performance, and the foaming quality (Inventive Examples 1 to 3).

[Method of Manufacturing Cooling Tank100(S100)]

Next, a method (S100) of manufacturing a cooling tank100according to an aspect of the present disclosure will be described with reference toFIGS.12to17.

FIG.12is a flowchart illustrating a method (S100) of manufacturing a cooling tank100according to an embodiment of the present disclosure,FIG.13is a perspective view illustrating a state of the foaming assembly101ofFIG.12in a preparation operation (S110) of the foam assembly101,FIG.14is a perspective view illustrating a state of the foaming assembly101ofFIG.12in an injection operation (S150) of injecting a foaming agent,FIG.15is a perspective view illustrating a state of the foaming assembly101ofFIG.12in an injection port closing operation (S160), andFIG.16is a perspective view of a cooling tank100manufactured by completing a foaming-curing operation (S180) of the foaming agent ofFIG.12.

As illustrated inFIG.12, a method of manufacturing a cooling tank100according to an embodiment of the present disclosure may be configured to include a seating operation (S130) of seating a foaming assembly101on a foaming jig, a partial closing operation (S140) of closing front, rear, left, and right sides of the foaming jig, an injection operation (S150) of injecting a foaming agent FA, an upper surface closing operation (S170) of closing an upper surface of the foaming jig, and a foaming-curing operation (S180) in which the foaming agent FA is foamed and cured, and may further include at least a portion of a preparation operation (S110) of preparing the foaming assembly101, an opening operation (S120) of opening a foaming jig (not illustrated), an injection port (136) closing operation (S160) of closing an injection port136, or a post-processing operation (S190) of post-processing and/or inspecting a cured cooling tank100.

A preparation operation (S110) of preparing the foaming assembly101may be performed by coupling a tank body110and a foaming case130to form a foaming space S2between the tank body110and the foaming case130, as illustrated in FIG.7. In this case, protruding portions111and115provided in the tank body110, for example, a water flow port111and a bump115may have an end portion exposed from an external surface of the foaming case130, through a through-hole132provided in the foaming case130. In addition, the water flow port111and the bump115may be seated on a seating surface134and a seating bump133formed around the seating surface134in the foaming case130. To seal between the tank body110and the foaming case130, a sealing member OR may be installed on an external peripheral surface on which a step difference between the water flow port111and the bump115is formed. The sealing member OR may be formed as an O-ring, as illustrated inFIG.6. In addition, the sealing member OR may be installed between a first stepped portion (111aand115a) and the seating bump133, not only to prevent the foaming agent FA from leaking externally when the foaming agent FA is foamed, as will be described later, but also to completely block an external surface of the foaming case130and a foamed thermal insulating material150, after curing of the foaming agent FA is completed to form the foamed thermal insulating material150.

The preparation operation (S110) of preparing the foaming assembly101may include shielding a main outlet AE1having a relatively large size, among air outlets AE using a shielding film member MB. In this case, the shielding film member MB may be formed of a material preventing leakage of the foaming agent FA and allows air to be discharged, and a nonwoven fabric may be used as an example thereof. The material of the shielding film member MB is not limited thereto, and various materials and types of members may be used as long as it is possible to discharge air and prevent leakage of the foaming agent FA. In addition, the shielding film member MB may be attached to an internal surface of the foaming case130, but since the foaming case130may be supported by the foaming jig during a foaming process, the shielding film member MB may be attached to the external surface of the foaming case130.

The foaming case130may have a structure to be divided into a first case131and a second case135to accommodate the tank body110therein. Therefore, an operation of bonding a bonding member T to a division portion138corresponding to an interface between the first case131and the second case135may be included, not to divide the first case131and the second case135.

In the foaming-curing operation (S180) to be described later, since deformation of the external surface of the foaming case130may be limited by the foaming jig, the bonding member T may be sufficient to provide a bonding force preventing the foaming case130from being separated from each other, in a process of inserting the foaming assembly101into the foaming jig. Therefore, the bonding member T may be formed of a tape attached to the division portion138between the first case131and the second case135, but the present disclosure is not limited thereto. For example, the bonding member T may be composed of an adhesive applied to the division portion138, and an insertedly-fastening member that enables physical coupling between the first case131and the second case135may be used. Also, various other modifications thereof are possible.

Next, the opening operation (S120) of opening a foaming jig may open a space into which the foaming assembly101is inserted to seat the foaming assembly101on the foaming jig. In this case, the foaming jig may have a structure to be divided in plural, to have an internal surface corresponding to an external shape of the foaming assembly101. A shape of the foaming jig and the number of portions of the foaming jig to be divided may be changed, depending on a shape of the foaming assembly101. For example, when the foaming assembly101has a cylindrical shape, a shape by which a peripheral surface and upper and lower surfaces of the cylindrical shape are supported, and a divided structure thereof may be included. For convenience of description, a case in which a foaming assembly101has a hexahedral shape and a foaming jig has a six-sided support structure corresponding thereto will be described below. As illustrated inFIG.13, when the foaming assembly101has a hexahedral shape, the foaming jig may have a divided structure supporting six, i.e., front, rear, left, right, upper, lower surfaces of the foaming assembly101. Therefore, in the opening operation (S120), an upper surface of the foaming jig may be opened and front, rear, left, and right surfaces of the foaming jig may be at least partially spaced apart from the foaming assembly101, such that the foaming assembly101is easily inserted into the foaming jig. In this case, the front, rear, left, and right surfaces of the foaming jig may rotate with respect to a lower portion thereof, and an upper portion thereof may be opened to spread in an outward direction, but the present disclosure is not limited thereto. A structure in which the front, rear, left, and right surfaces of the foaming jig collectively move in the outward direction with respect to the foaming assembly101may be included.

In the seating operation (S130) of seating a foaming assembly101on a foaming jig, the foaming assembly101may be seated on the foaming jig through an open upper surface of the foaming jig.

When the foaming assembly101is seated on the foaming jig, the partial closing operation (S140) of closing a portion of the foaming jig may be performed. In the partial closing operation (S140), the front, rear, left, and right surfaces of a foaming jig opened in the opening operation (S120) may be in contact with external peripheral surfaces of the foaming assembly101on front, rear, left, and right sides, to support the external peripheral surfaces of the foaming assembly101. Therefore, deformation of the foam assembly101may be prevented during foaming of the foaming agent FA in the foaming-curing operation (S180) to be described later.

Thereafter, the injection operation (S150) of injecting a foaming agent FA into the foaming assembly101may be performed. In the injection operation (S150), the foaming agent FA may be injected through the injection port136of the foaming case130, as illustrated inFIG.14. In this case, the foaming agent FA may be a foaming liquid capable of forming a urethane (polyurethane) foam. The urethane (polyurethane) foam may use polyurethane, obtained by reaction of an isocyanate compound with glycol, as a material, and may refer to a foamed product usually formed by mixing carbon dioxide, generated by reaction of isocyanate and water as a crosslinking agent, and a volatile solvent such as Freon as the foaming agent FA. The urethane foam may have various hardness such as super soft, soft, semi-hard, hard, or the like, depending on a type of glycol, a raw material to be used. In addition, as a foam molding method, a one-shot method and a prepolymer process may be used. Among them, the prepolymer method may be a method of reacting a portion of glycol with diisocyanate in advance to prepare a prepolymer (partial polymerization agent), mixing and foaming remaining portions of glycol, foaming agent FA, catalyst, and the like thereinto, and may be suitable for use as the foamed thermal insulating material150because foaming thereof is evenly performed. When the foaming agent FA used in the present disclosure forms a urethane foam, composition and manufacturing method of the urethane foam are not limited to the above. In addition, the foamed thermal insulating material150provided in the cooling tank100of the present disclosure is not limited to urethane foam, and various types of known foaming agents FA may be used, when the tank body110is accommodated in the foaming case and foaming is effected between the foaming case and the external surface of the tank body110.

The injection operation (S150) may be performed during a foaming agent (FA) input time period (e.g., a value selected from 1.3 to 1.7 seconds) preset in consideration of input speed and pressure of the foaming agent FA, such that a predetermined amount of the foaming agent FA in response to the foaming space S2is injected into the foaming space S2. In this manner, the foaming agent FA may be injected according to a certain condition, such that the foamed thermal insulating material150has a certain quality (e.g., a constant density). In particular, when the density of the foamed thermal insulating material150is in a range of 0.065 to 0.085 g/cm3after curing is completed, a non-foamed region does not occur and thermal insulation performance and dew condensation performance may be sufficiently secured. Therefore, an injection amount of the foaming agent FA and injection time of the foaming agent FA corresponding thereto may be set such that the density becomes of 0.065 to 0.085 g/cm3.

The injection operation (S150) may be performed using a urethane high-pressure foaming machine (not illustrated), and as an example of the foaming agent FA, a material mixed with BILLYOL (RF-334T) and ECO FOAM-A in a certain ratio (for example, 1:1.1 to 1.2) may be used.

When the injection of the foaming agent FA is completed, the injection port (136) closing operation (S160) of closing an injection port136may be additionally performed. When the injection of the foaming agent FA into the foaming space S2starts, foaming of the foaming agent FA may be performed in the foaming space S2. To prevent the foaming agent FA from being exposed externally through the injection port136, an operation of closing the injection port136may be performed. The injection port (136) closing operation (S160) may be performed by closing a portion of the injection port136of the foaming case130with a shielding film member (BM inFIG.15), and a tape may be used as an example of the shielding film member BM, to easily perform an operation. The shielding film member BM is not limited thereto, and various materials and shapes may be changed, as long as the injection port136is easily closed. As illustrated inFIG.10B, when a cutout137, partially cut, is formed in the injection port136, the cutout137may be folded in an injection direction when the foaming agent FA is injected, and may have a structure in which the cutout137moves in the opposite direction to close the injection port136during a foaming process of the foaming agent FA. In addition, as will be described later, after the injection of the foaming agent FA is completed, an upper surface of the foaming jig may be closed such that the injection port136is in a closed state by the foaming jig. Therefore, the injection port (136) closing operation (S160) may be selectively performed.

In this manner, after the injection operation (S150) is completed, or after the injection operation (S150) and the injection port (136) closing operation (S160) are completed, the upper surface closing operation (S170) of closing the upper surface of the foaming jig may be performed.

Moreover, after the upper surface closing operation (S170), the foaming-curing operation (S180) in which the foaming agent FA is foamed and cured may be performed.

When injection of the foaming agent FA into the foaming space S2starts, foaming of the foaming agent FA may be performed in the foaming space S2. Therefore, as illustrated by the arrow inFIG.15, air in the foaming space S2may be discharged externally through the air outlet AE. In this case, a position of the air outlet AE may be set to prevent a non-foamed space from being formed by the foaming agent FA completely filling the foaming space S2in the foaming-curing operation S180. In particular, since a corner outlet AE2may be formed in a portion corresponding to a corner of the foaming case130, complete foaming may be performed up to a corner portion of the foaming case130. In this case, the corner outlet AE2may have a diameter of about 1 mm, preferably 0.3 to 2.0 mm, more preferably 0.5 to 1.5 mm.

In addition, since the main outlet AE1may be installed in a direction opposite to the injection port136, to discharge a large amount of air through the main outlet AE1, foaming toward the main outlet AE1may be smoothly performed.

This foaming-curing operation (S180) may be performed for a preset time period (e.g., 20 minutes±2 minutes) such that the foaming agent FA is completely foamed and the foamed foam is cured.

To ensure smooth foaming, the foaming jig may be maintained at a preset temperature (e.g., 40° C.±5° C.). To this end, the foaming jig may be configured to be maintained at the preset temperature from the opening operation (S120), until a subsequent process is performed.

Moreover, when the foaming-curing operation (S180) is completed, manufacturing of the cooling tank100may be completed, as illustrated inFIG.16. Thereafter, a post-processing operation (S190) of post-processing and/or inspecting a cured cooling tank100may be performed. In the post-processing operation, the inspection operation of inspecting appearance of the cooling tank100, an operation of removing burring that may partially occur during foaming, a grinding or deburring operation and an air cleaning operation, and a packaging operation, and the like may be performed.

Since the foaming case130includes the injection port136and the air outlet AE, a post-processing operation of sealing the injection port136and the air outlet AE through a filling material formed of a material such as silicone, hot melt, and the like, may be performed, to prevent the foamed thermal insulating material150from contacting external air through this space.

As described above, in a method for manufacturing a cooling tank100according to the present disclosure, quality problems of a foam powder flowing into a tank internal space may be minimized by inserting a foaming agent FA into a foaming space S2formed between a foaming case130and a tank body110using the foaming case130to perform foaming, and maximally shielding leakage of a foaming liquid, and problems of mold or bacteria propagating in the foamed thermal insulating material150may be prevented by completely shielding a foamed thermal insulating material150from an external space through the foaming case130. In addition, it is possible to sufficiently secure thermal insulation performance and anti-condensation performance through the foamed thermal insulating material150.

As illustrated inFIG.17, a water purifier300may include a filter unit310filtering incoming raw water to generate purified water, a cold water generator320cooling the purified water filtered in the filter unit310to generate cold water, and an extracting unit330extracting the cold water cooled by the cold water generator320.

The filter unit310may include a plurality of filters, as known to filter and purify raw water.

In addition, the cold water generator320may be configured to include a cooling tank assembly200having the cooling tank100, mentioned above, and the tank cover210, mentioned above. In addition, the cold water tank assembly200may be configured by a tank cooling method generating cold water with directly cooling water contained in a cold water tank by an evaporation tube (an evaporator)230as well as an ice-condensed cooling method illustrated inFIGS.1to4.

Moreover, the extracting unit330may be configured to include a cock member or a faucet, to supply cold water to a user.

DESCRIPTION OF REFERENCE CHARACTERS