US4477399A — Method and apparatus for manufacturing a foam ins…

Claim 1

Independent Claim 109 words

A method of manufacturing a water heater having an internal tank, an intermediate layer of expanded foam and an outer shell spaced from said internal tank by said intermediate layer, comprising positioning the outer shell about said internal tank to at least partially form a cavity for said insulative material, closing said partially formed cavity adjacent one end thereof by inflating an inflatable device between said shell and tank to define a boundary for said insulative material, placing an expandable foam material into said cavity defined by said internal tank, said inflatable device and said outer shell, waiting for said form material to expand and form said intermediate layer,

Claim 2

Independent Claim 109 words

A method of manufacturing a water heater having an internal tank, an intermediate layer of expanded foam and an outer shell spaced from said internal tank by said intermediate layer, comprising positioning the outer shell about said internal tank to at least partially form a cavity for said insulative material, closing said partially formed cavity adjacent one end thereof by inflating an inflatable device between said shell and tank to define a boundary for said insulative material, placing an expandable foam material into said cavity defined by said internal tank, said inflatable device and said outer shell, waiting for said form material to expand and form said intermediate layer,

Claim 3

Dependent Claim 43 words

deflating said inflatable device and inspecting the area of said tank and outer shell adjacent the boundary previously formed by said inflatable device to assure said intermediate layer has been retained by said inflatable device during the expansion of said expandable foam material.

Claim 4

Dependent Claim 43 words

deflating said inflatable device and inspecting the area of said tank and outer shell adjacent the boundary previously formed by said inflatable device to assure said intermediate layer has been retained by said inflatable device during the expansion of said expandable foam material.

Claim 5

Dependent Claim 17 words

A method of manufacture as claimed in claim 1 including inflating said inflatable device with compressed air.

Claim 6

Dependent Claim 20 words

A method of manufacture as claimed in claim 1 including removing said inflatable device after expansion of said foam material.

Claim 7

Dependent Claim 109 words

A method as claimed in claim 1 wherein said internal tank has a top, bottom and sidewall portions and said outer shell for surrounding said internal tank has an open bottom with top and sidewall portions, the sidewall portions of said shell having a base portion for extending below the bottom of said internal tank, positioning the bottom of said internal tank above the base portion of said outer shell to provide a space beneath said inner tank for a fuel-burner arrangement, and inflating said device about the periphery of said internal tank bottom between said tank and said outer shell to define a lower boundary for said cavity.

Claim 8

Dependent Claim 30 words

A method as claimed in claim 4 including orienting said water heater with its bottom lowermost and injecting such expandable foam insulative material through the top of said outer shell.

Claim 9

Dependent Claim 74 words

A method as claimed in claim 1 for insulating an electric water heater having said interior tank with top, bottom and sidewall portions, said outer shell for surrounding said interior tank having top, bottom and sidewall portions and said outer shell sidewalls having an opening to accommodate an electric heater for said tank, inflating said inflatable device between said tank and said shell around the opening perimeter to define a boundary for said cavity.

Claim 10

Dependent Claim 29 words

A method of claim 1, 4 or 6, sealing portions of said outer shell through which components of said inner tank extend prior to injecting such expanding foam material.

Claim 11

Dependent Claim 28 words

A method of claim 1, 4 or 6, using a mixed urethane composition as said insulative material, injecting such mixed urethane composition as a liquid into said cavity.

Claim 12

Dependent Claim 35 words

A method of claim 1, 4 or 6, using a mixed urethane composition as the foam material, pre-heating said inner tank wall portions and injecting such mixed urethane composition as a liquid into said cavity.

Claim 13

Dependent Claim 34 words

A method of claim 1, 4 or 6, injecting a predetermined amount of expanding foam insulative material such that when foamed, the entire cavity between said inner tank and said outer shell is filled.

Claim 14

Dependent Claim 36 words

A method of claim 1, 4 or 6, adapted for insulating a cylindrical water heater, locating said outer shell concentric with said inner tank to define an annular cavity along the side of said water heater.

Claim 15

Independent Claim 148 words

An apparatus for use in insulating water heaters of the type having an inner tank and an outer shell spaced from such inner tank by an intermediate layer of insulative material, said apparatus comprising means for locating supporting such inner tank, means for locating and supporting such outer shell in a manner to be spaced from such inner tank which in combination with said means for locating and supporting such inner tank positions such inner tank within such outer shell intermediate the length thereof, an inflatable tube for securement about such inner tank intermediate the length thereof and interior to such outer shell, said tube when inflated sealingly engaging such outer shell and inner tank and closing the space therebetween to allow forming of such insulative layer by inserting a fluid post-foaming material in the space between such outer shell and such inner tank above said inflated tube.

Claim 16

Independent Claim 148 words

An apparatus for use in insulating water heaters of the type having an inner tank and an outer shell spaced from such inner tank by an intermediate layer of insulative material, said apparatus comprising means for locating supporting such inner tank, means for locating and supporting such outer shell in a manner to be spaced from such inner tank which in combination with said means for locating and supporting such inner tank positions such inner tank within such outer shell intermediate the length thereof, an inflatable tube for securement about such inner tank intermediate the length thereof and interior to such outer shell, said tube when inflated sealingly engaging such outer shell and inner tank and closing the space therebetween to allow forming of such insulative layer by inserting a fluid post-foaming material in the space between such outer shell and such inner tank above said inflated tube.

Claim 17

Dependent Claim 34 words

An apparatus as claimed in claim 12 wherein said means for locating and supporting such inner tank also locates said outer shell to define the space between such outer shell and such inner tank.

Claim 18

Dependent Claim 39 words

An apparatus as claimed in claim 13 wherein said means for locating and supporting such inner tank is a raised platform, said platform being of a shape to position such outer shell with said platform interior to such shell.

Claim 19

Dependent Claim 33 words

An apparatus as claimed in claim 14 wherein said platform presents an area for supporting said tube at a position intermediate the length of such inner tank located and positioned by said platform.

Claim 20

Dependent Claim 121 words

Apparatus for use in insulating a fuel-fired water heater having an inner tank and an outer shell spaced from such inner tank to provide a cavity into which a fluid post-foaming insulative material is introduced to insulate such inner tank, said apparatus comprising means for locating such inner tank bottom inwardly of such outer shell base portion to provide space beneath such inner tank for a fuel burner arrangement and an inflatable tube for insertion in the cavity defined between such inner tank base portion and such outer shell, said tube when inflated with fluid sealing off such cavity at the lower end of said water heater and said tube being deflatable after foamed insulative material has set in such cavity.

Claim 21

Dependent Claim 121 words

Apparatus for use in insulating a fuel-fired water heater having an inner tank and an outer shell spaced from such inner tank to provide a cavity into which a fluid post-foaming insulative material is introduced to insulate such inner tank, said apparatus comprising means for locating such inner tank bottom inwardly of such outer shell base portion to provide space beneath such inner tank for a fuel burner arrangement and an inflatable tube for insertion in the cavity defined between such inner tank base portion and such outer shell, said tube when inflated with fluid sealing off such cavity at the lower end of said water heater and said tube being deflatable after foamed insulative material has set in such cavity.

Claim 22

Dependent Claim 31 words

Apparatus of claim 16, wherein said tube has a valve for holding pressurized fluid in the inflated tube and for releasing such pressurized fluid when deflation of said tube is desired.

Claim 23

Dependent Claim 21 words

Apparatus of claim 16, wherein said locating means is adapted to concentrically locate such outer shell relative to such inner tank.

Claim 24

Dependent Claim 15 words

Apparatus of claim 18, wherein said locating means is adapted to support such inner tank.

Claim 25

Dependent Claim 58 words

Apparatus of claim 16, wherein said apparatus is used for insulating a water heater having a cylindrical inner tank and corresponding cylindrical outer shell, said locating means having a support on which such inner tank rests and a circular portion for contacting the interior of said outer shell thereby locating such outer shell concentric with such inner tank.

Claim 26

Dependent Claim 33 words

Apparatus of claim 20, wherein said support is adapted to elevate such inner tank upwardly relative to such outer shell to provide a space beneath the inner tank for a fluid burner arrangement.

Claim 27

Dependent Claim 18 words

Apparatus of claim 16, wherein said tube has its surface adapted to release from set foamed insulative material.

Claim 28

Dependent Claim 15 words

Apparatus of claim 22, wherein said tube has its surface treated with a release agent.

Claim 29

Dependent Claim 10 words

Apparatus of claim 16, wherein said tube consists of polyethylene.

Claim 30

Dependent Claim 32 words

Apparatus of claim 21, wherein said support is a plate having feet depending therefrom, said feet being of a height to locate such inner tank upwardly of such outer shell base portion.

Claim 31

Dependent Claim 13 words

Apparatus of claim 16, wherein said tube has a cylindrical or torus shape.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-10-16	1988-04-16	1988-10-16	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-10-16	1992-04-16	1992-10-16	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-10-16	1996-04-16	1996-10-16	$7700.00	Window Closed / Lapsed

Method and apparatus for manufacturing a foam insulated water heater

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