Application Analysis of Insulation Material of Solar Water Heater

Currently, polyurethane rigid foam holds a unique position as an insulation material due to its exceptionally low thermal conductivity and ease of molding. However, as a reaction-molded polymer, it is prone to mold shrinkage—where the final volume of the foam is smaller than the maximum volume during the molding process. This shrinkage is one of its most significant drawbacks.

Mold shrinkage often leads to a reduction in the final foam volume compared to the filled cavity, resulting in issues like foam and shell separation. These problems can severely affect the product's appearance, insulation performance, and overall lifespan. To mitigate this, many applications use high-density filling or molding techniques to maintain structural integrity.

However, in the case of Changsha and Hunan solar water heaters, traditional molding methods are not feasible due to their complex design—thin shells, intricate nozzles, and delicate inner linings. High-density foaming increases production costs, and even with high-density free-foam filling, defects such as foam separation from the outer casing, deformation of the tank, and damage to the heat collection nozzle still occur. These issues lead to numerous manufacturing defects and quality concerns.

Through extensive research and analysis, it has become clear that reducing the shrinkage rate during foam molding without increasing the density is crucial for improving the performance of these solar water heaters. Based on this understanding, a new formulation and material selection strategy were developed. Pilot tests on some production lines have shown promising results, with reduced foam-shell separation and significantly lower casing deformation. This approach enhances both the safety and reliability of the products.

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