Insulated fluid storage unit and method of making

Abstract

A hot water storage unit includes an outer decorative shell with a hardened foam insulation within a cavity therebetween. A prefabricated bottom wall is secured between the opposed sidewalls of the tank and shell. The bottom wall is secured just above the temperature sensing and drain connectors of the storage tank with the top connections protected by a fiberglass covers. A top shell cover includes an air foam insulation injection hole. The bottom wall is a stable supporting body member having an outer sealing portion which is integrally formed with the body member or which is a separate element affixed to the body member to form an extension of the body member. The outer sealing portion has sufficient compression or deflection to produce a seal in response to positioning the shell about the tank. The insulation is introduced as a liquid which expands to form the insulation, with the bottom wall preventing the liquid insulation from passing downwardly of the dam. The bottom wall is shown as a single piece styrofoam body member slightly smaller than the width of the cavity with an outer polyurethane seal element secured to the outer wall of the body member. The styrofoam element or body member has radial slits to permit wrapping about the tank and has abutting ends, and is attached to the tank by an adhesive.