Microstructures for filling sheets

Abstract

A filling sheet for cooling a working fluid flowing through the filling sheet with a gas flowing through a film of the working fluid, the filling sheet comprising a microstructure. The microstructure includes a top ridge, a bottom ridge, and a sidewall connecting the top ridge and the bottom ridge. The top ridge and the bottom ridge define a longitudinal axis. The microstructure also includes rows of undulating peaks and valleys oriented at an acute microtexture angle relative to the longitudinal axis. The rows of undulating micro-texture peaks and valleys define a row axis. The rows of micro-texture peaks include alternating micro-texture tops and micro-texture basins, and the rows of micro-texture valleys include alternating micro-texture crowns and micro-texture bases.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 443,464, filed on February 6, 2023, entitled “Microstructures for Filler Sheets,” the entire contents of which are incorporated herein by reference in their entirety. Background Art

[0003] Fill sheets and fill packs are used in the cooling tower, mass transfer, and trickling filter markets, as well as in the oil / water separation, bio-columns, nitrification towers, mist eliminators, and related systems and markets. Fill sheets and fill packs have undergone minor changes to their general construction since their earliest designs and have become a commodity in these markets. Fundamental changes such as limited microtexture features and specialized glue bonding are relatively recent and generally minor changes to the fill sheet and fill pack product market.

[0004] For the cooling tower industry in particular, it would be advantageous to develop fill media products that have the ability to be modified to meet the application requirements of cooling towers, improve the cooling performance of existing towers, and reduce the required size of new cooling tower designs based on the improved fill properties. One way in which cooling tower performance can be characterized is by comparing the water flow rate that a tower can cool to a desired temperature given specific environmental and operating conditions. Fills that improve the overall performance of cooling towers by replacing the original fill would benefit fill manufacturers and tower owners. Additionally, improving fill properties to allow the design of cooling towers that are smaller than existing tower designs and have the same or improved performance would benefit fill manufacturers, tower designers, and tower owners.

[0005] A typical design for a packing stack consists of an assembly of multiple filler sheets with simple corrugated channels, called grooves, extending along the direction of air travel through the sheets and the stack. These grooves are designed to direct the bulk of the air flow from the stack's air inlet to its air outlet. To this end, the grooves typically extend from the stack's air inlet toward the stack's air outlet, with a path formed along the valleys of one or a series of grooves. A common configuration for grooves in a packing stack consists of grooves extending from the air inlet to the outlet at a constant angle, with alternating sheets having alternating corrugation angles. These grooves typically have dedicated contact points along the peaks and valleys of the grooves, also known as spacers, that separate adjacent sheets and provide rigidity to the stack. These packing products also have a feature known as "microstructure," which is designed to improve the heat and mass transfer properties of the packing by increasing the turbulence of the air flowing through the grooves, improving the mixing and distribution of the fluid film on the filler sheets, and providing a modest increase in the stack's surface area. A common type of microstructure used in cooling tower fill consists of linear channels cut into a sheet or fluted profile. These channels are typically smaller than fluted channels and either do not extend from the inlet to the outlet of the fill pack or extend at an acute angle of less than forty-five degrees (45°) relative to the air inlet face. This design increases airflow turbulence and fill surface area compared to existing fill sheet and fill pack designs, but is limited in its ability to distribute water across the sheet. The depth of the fill sheet's channels can be increased to improve the fill's ability to distribute water across the sheet, as well as increase turbulence and fill surface area. However, increasing the channel depth also reduces the overall tower performance beyond a certain point by increasing the pressure drop across the fill. This pressure drop limits the amount of airflow through the tower, thereby reducing the overall cooling provided by the tower. An alternative microstructure design, more common in fillers used in the mass transfer market, is a pattern of peaks and valleys formed by raised features. This design offers the advantage of improved water distribution as water flows around the raised features, but the increase in turbulence and surface area is limited when the flowing water fills a portion of the microstructure's valleys. Considering the limitations of current microstructure designs, there is a need to design a microstructure that maintains turbulence and increases the surface area of ​​the ribbon-type microstructure, while also providing improved water distribution.

[0006] There is a need to design, construct, and deploy filler sheets and associated filler packs that maintain turbulence and increase the surface area of ​​the ribbon-type microstructures, while also providing improved water distribution across the sheet for improved mass transfer. Preferred embodiments of filler sheets with preferred microstructures address the shortcomings of prior art media and packings by utilizing novel microstructural configurations on the filler sheet to balance increased turbulence with improved water distribution. Summary of the Invention

[0007] The filler sheet may comprise microstructured or micro-corrugated strips and raised / recessed textures or micro-texture features on the microstructured or micro-corrugated strips. The microstructure may be superimposed on the corrugated grooves of the filler sheet, wherein the groove / groove path extends from the gas inlet edge of the filler sheet to the gas outlet edge, and superimposed on the filler stack comprising the assembled filler sheets. The groove path may be angled or oriented in a cross-corrugated configuration. The microstructured or micro-corrugated strips may be oriented horizontally / perpendicularly to the direction of airflow or water flow. The microstructured or micro-corrugated strips may vary in height along the direction of airflow. The microstructured or micro-corrugated strips may be angled and configured in a herringbone arrangement. The microstructure may comprise a texture or micro-texture that is a continuous pattern of positive and negative dome features, microtexture peaks or microstructure peaks, and microtexture valleys or microstructure valleys. The positive and negative dome features or microtexture peaks and valleys may be hemispherical. The grooves on the filler sheet are designed and configured to direct the direction and path of airflow along the filler sheet and fill pack from the air inlet to the air outlet, while the microstructures are designed and configured to improve the heat transfer and mass transfer characteristics of the filler by increasing the turbulence of air flowing over the filler sheet and / or through the grooves, thereby improving the mixing and distribution of the fluid film on the filler sheet and providing a modest increase in the surface area of ​​the fill pack.

[0008] The raised / recessed texture or microtexture features of the microstructure may comprise a textured pattern of raised and recessed locations on the filler sheet. The microtexture features may comprise surface features of interconnected microtexture peaks and microtexture valleys. Interconnected positive and negative dome features or microtexture peaks and microtexture valleys may be present throughout the filler sheet and generally comprise microtexture features. The raised / recessed texture or microtexture may comprise a waveform comprising microtexture peaks and microtexture valleys that undulates along the sheet / microstructure strip or micro-corrugated strip in the direction of airflow. The microstructure may comprise a pattern / corrugation of peaks and valleys superimposed on a cross-sectional view of a groove profile that undulates along the length of the groove path. The microstructure may also comprise micro-corrugated strips that are combined with a pattern / corrugation of microtexture peaks and microtexture valleys or microtexture features formed on a relatively flat sheet that does not include a macrostructure or groove that directs a large amount of airflow from an air inlet to an air outlet in the direction of the groove. These relatively flat sheets generally allow air to flow directly from the air inlet end to the gas outlet end without being directed in a desired direction by the grooves because the flat sheets generally do not include grooves or large structures.

[0009] The filler sheet may include: micro-corrugated strips having bands or ridges of varying heights defined on the sheet, the bands or ridges being connected to one another by the conduit sides or sidewalls; a plurality of continuous elevated ridges / strips / portions extending along the entirety of at least one sidewall of the filler groove; and straight segments of the elevated strips that do not span the entire length from the gas inlet to the gas outlet. Micro-texture peaks and micro-texture valleys may be superimposed on these micro-corrugated strips to increase the surface area and film distribution or working fluid film distribution across the filler sheet by spreading the liquid film laterally across the filler sheet, thereby producing a uniform film thickness and reducing dry spots across the sheet. The micro-texture on the filler sheet facilitates an overall uniform distribution of the water film across the entire surface of the sheet to limit dry spots and overflow on the sheet surface during use, which improves heat transfer by exposing the working fluid or water to a uniform or improved distribution across the filler sheet.

[0010] In another aspect, a filler sheet for cooling a working fluid using gas on a film of the working fluid flowing over the surface of the filler sheet comprises a microstructure, the working fluid typically comprising water. The microstructure comprises micro-corrugations having a plurality of top ridges and bottom ridges forming micro-corrugated bands. The top ridges and bottom ridges define a longitudinal axis. The microstructure further comprises micro-texture features, which may comprise rows of wavy micro-texture peaks and micro-texture valleys oriented at acute micro-texture angles relative to the longitudinal axis. The rows of wavy micro-texture peaks and micro-texture valleys may define a row axis. The rows of micro-texture peaks comprise alternating micro-texture apexes and micro-texture basins, and the rows of micro-texture valleys comprise alternating micro-texture crests and micro-texture bases.

[0011] In another aspect, a preferred invention is directed to a microstructure of a filler sheet for increasing airflow turbulence and film distribution. The microstructure includes microcorrugations defined on the filler sheet and a plurality of microtexture features on the microcorrugations. The microcorrugations include a plurality of top ridges and a plurality of bottom ridges. The plurality of top ridges includes a first top ridge, and the plurality of bottom ridges includes a first bottom ridge. The first top ridge and the first bottom ridge define a first microcorrugation band. The first microcorrugation band extends from a first band end to a second band end. The first top ridge and the first bottom ridge define a band height. The plurality of microtexture features include a first microtexture apex and a first microtexture base, the first bottom ridge, the first sidewall, or the first top ridge on the first microcorrugation band. When the microtexture is superimposed on a substantially flat filler sheet or flat portion of the microcorrugation, the first microtexture apex can be the topmost portion on the first top ridge, and the first microtexture base can be the bottommost portion on the first top ridge, as the grooved features or shape of the microcorrugations can adjust which portions of the filler sheet are the topmost and bottommost portions of the sheet. The microtexture features are located on the microcorrugation bands. The first microtexture apex produces a local maximum in microstructure profile height as one travels along the length of the microcorrugated stripe between the first and second ends, and the first microtexture base produces a local minimum in microstructure profile height as one travels along the length of the microcorrugated stripe between the first and second ends.

[0012] In another aspect, a preferred invention is directed to a microstructure of a filler sheet for increasing airflow turbulence and film distribution. The microstructure comprises: a plurality of top ridges comprising a first top ridge, a plurality of bottom ridges comprising a first bottom ridge, a plurality of side walls comprising a first side wall, and a microtexture defined on the first top ridge. The first top ridge is connected to the first bottom ridge by a first side wall. The first top ridge and the first bottom ridge define a first micro-corrugated band. The first micro-corrugated band extends from a first band end to a second band end. The top ridge and the bottom ridge define a band height. The band height is approximately two hundredths to three tenths of an inch (0.02-0.30"). The microtexture comprises a first row of micro-texture peaks and a first row of micro-texture valleys. The first row of micro-texture peaks extends approximately parallel to the first row of micro-texture valleys.

[0013] In another aspect, a preferred invention is directed to a microstructure for a filler sheet for increasing airflow turbulence and film distribution. The microstructure comprises rows of microtexture peaks and rows of microtexture valleys, the rows of microtexture peaks comprising a first row of microtexture peaks, and the rows of microtexture valleys comprising a first row of microtexture valleys. The first row of microtexture peaks extends generally parallel to the first row of microtexture valleys. The first row of microtexture peaks comprises a first microtexture apex and a first microtexture basin, and the first row of microtexture valleys comprises a first microtexture crown and a first microtexture base. The first row of microtexture peaks is separated from the first row of microtexture valleys by a row width. The row width is between 5 and 25 percent of an inch.

[0014] On the other hand, a preferred embodiment is directed to a filler sheet for promoting mass transfer between a working fluid flowing through the filler sheet and a gas flowing through the working fluid. The filler sheet includes a mass transfer region defined between a working fluid inlet edge and a working fluid outlet edge and a microstructure formed in the mass transfer region. The microstructure includes a top ridge and a bottom ridge connected by a side wall. The top ridge and the bottom ridge define a longitudinal axis, a row of microtexture peaks and microtexture valleys oriented at acute microtexture angles relative to the longitudinal axis. The row of microtexture peaks and microtexture valleys defines a row axis. The row of microtexture peaks includes alternating microtexture apexes and microtexture basins, and the row of microtexture valleys includes alternating microtexture crowns and microtexture bases. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The foregoing summary of the invention, as well as the following detailed description of preferred embodiments of the filler sheet and filler pack, and the microstructure formed on the filler sheet of the present invention, will be better understood when read in conjunction with the accompanying drawings. For purposes of illustrating the microstructure of the filler sheet, preferred embodiments are shown in the accompanying drawings. However, it should be understood that the invention is not limited to the precise arrangements and instrumentalities shown. In the accompanying drawings:

[0016] Figure 1 is a side perspective view of a portion of a filler sheet according to a first preferred embodiment having a preferred microstructure thereon, wherein the portion of the filler sheet shows a cross-section having microcorrugations and superimposed microtexture, wherein the bands of the microcorrugations extend parallel to each other and the microtexture is arranged as a plurality of rows of peaks and valleys oriented at an angle relative to the bands of the microcorrugations;

[0017] Figure 2 yes Figure 1 a top perspective view of a portion of a filler sheet;

[0018] Figure 3 yes Figure 1 a front perspective view of a portion of a filler sheet;

[0019] Figure 4 yes Figure 1 an alternative front perspective view of a portion of a filler sheet of FIG, wherein the portion of the filler sheet is further simplified to illustrate the micro-corrugated bands and the micro-texture superimposed on the micro-corrugated bands;

[0020] Figure 4A It is from Figure 4 The circle 4A is intercepted Figure 4 An enlarged portion of the filler sheet;

[0021] Figure 5A is a top perspective view of a portion of a filler sheet having a preferred microstructure, specifically a portion of a macrostructured groove having a preferred microstructure;

[0022] Figure 5B yes Figure 5A an alternative top perspective view of a portion of a filler sheet;

[0023] Figure 5C yes Figure 5A Another alternative top perspective view of a portion of a filler sheet;

[0024] Figure 5D yes Figure 5A a side elevational view of a portion of the infill piece;

[0025] Figure 6A is a top perspective view of a portion of a filler sheet having a preferred microstructure of a herringbone or herringbone configuration;

[0026] Figure 6B yes Figure 6A an enlarged top perspective view of a portion of a filler sheet;

[0027] Figure 7A is a cross-sectional view of the microstructure of a filler sheet according to a preferred embodiment of the present invention along a row of microtexture peaks, showing alternating microtexture apexes and microstructure basins;

[0028] Figure 7B yes Figure 7A a top perspective partial cross-sectional view of the filler sheet taken along a line perpendicular to the longitudinal axis of the microstructure;

[0029] Figure 8A is a texture map of microtexture features including microtexture peaks and microtexture valleys or ridges according to a preferred embodiment of the present invention;

[0030] Figure 8B is a texture image of a micro-ripple band according to a preferred embodiment of the present invention;

[0031] Figure 8C is a texture map of combined micro-texture features, the combined micro-texture features include Figure 8A microtexture peaks and microtexture valleys or ridges and Figure 8B Micro-ripple bands;

[0032] Figure 8D is a texture map comprising alternative microtexture features of microtexture peaks and microtexture valleys or ridges according to a preferred embodiment of the present invention;

[0033] Figure 8E is a texture map of an alternative micro-ripple band according to a preferred embodiment of the present invention;

[0034] Figure 8FIt is a texture map of combined micro-texture features. The combined micro-texture features include Figure 8D microtexture peaks and microtexture valleys or ridges and Figure 8E Micro-ripple bands;

[0035] Figure 8G is an extended texture map including alternative microtexture features of microtexture peaks and microtexture valleys or ridges according to a preferred embodiment of the present invention;

[0036] Figure 8H is a texture map of an alternative micro-ripple band according to a preferred embodiment of the present invention;

[0037] Figure 8I is a texture map of combined micro-texture features, the combined micro-texture features include Figure 8G microtexture peaks and microtexture valleys or ridges and Figure 8H Micro-ripple bands;

[0038] Figure 9 is a topographical image of a portion of a filler sheet having a preferred microstructure according to another preferred embodiment of the present invention, the portion comprising a combined microtexture feature superimposed on a microcorrugation comprising a plurality of microcorrugation bands;

[0039] Figure 10 is a top plan view of a filling sheet having a preferred microstructure and exemplary grooves or macrostructures according to a preferred embodiment of the present invention;

[0040] Figure 10A yes Figure 10 Filler sheet along Figure 10 a cross-sectional view taken along line 10A-10A of FIG, wherein the top surface comprises a preferred microstructure cross-section and the bottom surface or portion is shown solid for clarity, but in a preferred embodiment will comprise a mirror image of the top surface having a sheet thickness;

[0041] Figure 11A is a cross-sectional view of a portion of a filler sheet showing a sinusoidal micro-corrugated strip according to a preferred embodiment of the present invention;

[0042] Figure 11B is a cross-sectional view of a portion of a filler sheet showing the flat top ridge and arcuate sidewalls of the micro-corrugated strip and the bottom ridge in accordance with a preferred embodiment of the present invention;

[0043] Figure 11C is a cross-sectional view of a portion of a filler sheet showing three layers of micro-corrugated tape according to a preferred embodiment of the present invention;

[0044] Figure 11D is a cross-sectional view of a portion of a filling sheet showing a planar micro-corrugated strip according to a preferred embodiment of the present invention;

[0045] Figure 11E is a cross-sectional view of a portion of a filling sheet showing a zigzag micro-corrugated band according to a preferred embodiment of the present invention;

[0046] Figure 12 is a top perspective view of a portion of a filler sheet showing dome-shaped microtexture or raised features according to a preferred embodiment of the present invention;

[0047] Figure 13 is a top perspective view of a portion of a filler sheet showing wavy microtexture or raised features according to a preferred embodiment of the present invention;

[0048] Figure 14 is a top perspective view of a portion of a filler sheet showing raised dome-shaped microtexture or raised features in accordance with a preferred embodiment of the present invention;

[0049] Figure 15 is a top perspective view of a portion of a filler sheet showing pyramidal microtexture or raised features according to a preferred embodiment of the present invention;

[0050] Figure 16 is a top perspective view of a portion of a filler sheet showing frusto-conical microtexture or raised features in accordance with a preferred embodiment of the present invention;

[0051] Figure 17 is a top perspective view of a portion of a filler sheet showing conical microtexture or raised features according to a preferred embodiment of the present invention;

[0052] Figure 18 is a top perspective view of a portion of a filler sheet showing domed microtexture or raised features of varying sizes in accordance with a preferred embodiment of the present invention;

[0053] Figure 19 is a cross-sectional view of a three-layer micro-corrugated strip portion of a preferred microstructure according to a preferred embodiment of the present invention;

[0054] Figure 20 yes Figure 19 A top perspective cross-sectional view of a portion of a preferred microstructure;

[0055] Figure 21 yes Figure 19 an enlarged cross-sectional view of a portion of a preferred microstructure;

[0056] Figure 22 yes Figure 21 A top perspective cross-sectional view of a portion of a preferred microstructure;

[0057] Figure 23is a front perspective cross-sectional view of a plurality of three-layer micro-corrugated strips of a preferred microstructure of the present invention; and

[0058] Figure 24 yes Figure 23 An enlarged front perspective cross-sectional view of a three-layer micro-corrugated ribbon. DETAILED DESCRIPTION

[0059] Certain terms are used in the following description for convenience only and are not limiting. Unless otherwise specified herein, the terms "a," "an," and "the" are not limited to one element, but should be understood to mean "at least one." The words "right," "left," "lower," and "upper" designate directions in the accompanying drawings to which reference is made. The words "inwardly" or "distal" and "outwardly" or "proximally" refer to directions toward and away from, respectively, the geometric center of the preferred filler sheet and related parts thereof. The terminology includes the words listed above, their derivatives, and words of similar meaning.

[0060] It should also be understood that the terms "about," "approximately," "generally," "substantially," and similar terms used herein, when referring to dimensions or characteristics of components of the preferred invention, indicate that the dimensions / characteristics are not strict boundaries or parameters and do not preclude minor variations that are functionally identical or similar, as will be understood by those of ordinary skill in the art. At a minimum, such references to numerical parameters include variations that do not alter the least significant digit using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.).

[0061] refer to Figures 1 to 4A 、 Figure 10 and Figure 10A A first preferred embodiment of the present invention is directed to a filler sheet, generally designated by the reference numeral 8, for facilitating mass transfer between a working fluid, typically comprising water, flowing through the filler sheet 8 and a gas, the gas flowing through a film of the working fluid on the filler sheet 8, preferably a thin film of the working fluid on the filler sheet 8. In a cooling tower, the working fluid typically comprises water and the gas typically comprises ambient air, but the working fluid and gas are not limited thereto and may include other fluids and gases for various mass transfer applications. For convenience and clarity, the working fluid and gas are referred to herein as "a" and "b" in conjunction with the reference numeral 8. Figures 1 to 4AA portion 10 of the filler sheet 8 is shown in FIG. The filler sheet 8 includes a mass transfer region 6 defined between a working fluid inlet edge 8a and a working fluid outlet edge 8b of the filler sheet 8. The mass transfer region 6 is also preferably positioned between a first side edge 7a and an opposing second side edge 7b. The filler sheet 8 is oriented so that the working fluid, typically water, flows from the inlet edge 8a through the mass transfer region 6 to the outlet edge 8b during operation, and preferably forms a film of the working fluid on the surface on both sides of the filler sheet 8 during operation. In a typical cooling tower construction, the filler sheet 8 is oriented vertically so that the inlet edge 8a is at the top portion of the cooling tower and the outlet edge 8b is at the bottom portion of the cooling tower so that gravity drives the water movement through the mass transfer region 6. The filler sheets 8 may also include assembly features 4, preferably mechanical assembly tabs, such as those described in U.S. Patent Nos. 6,544,628 or 11,333,180, which facilitate connecting multiple filler sheets 8 into filler packs, but are not limited thereto, and the filler sheets 8 may be designed and constructed without assembly features 4, such that the filler sheets 8 are not assembled into a pack or otherwise arranged relative to each other without the use of assembly features 4. For example, the filler sheets 8 may be suspended within the cooling tower in an orientation generally parallel to one another, but not connected to one another via assembly features 4.

[0062] The microstructures 12 are formed in the mass transfer region 6 of the filler sheet 8 and include features on the filler sheet 8 that increase gas flow turbulence, improve working fluid film distribution, and increase the surface area of ​​the filler sheet 8 and the surface area of ​​the water or cooling fluid film on the filler sheet 8, but are not grooves 20 or large structures that direct the bulk of the gas flow from the gas inlet edge 9a to the gas outlet edge 9b of the filler sheet 8. The microstructures 12 can have various designs, configurations, and / or orientations. For example, the microstructures 12 can be configured in a herringbone or herringbone configuration ( Figure 6A and Figure 6B ). The microstructure 12 of the first preferred embodiment includes a top ridge or upper platform 12a and a bottom ridge or lower platform 12b connected by a side wall 12c. The top ridge 12a defines a top ridge plane 14, and the bottom ridge 12b defines a bottom ridge plane 16. When the filler sheet 8 is generally flat or planar, each of the top ridges 12a is preferably positioned on the top ridge plane 14, and each of the bottom ridges 12b is preferably positioned on the bottom ridge plane 16, but is not limited to this, and may be positioned on different planes, or may be inclined and oriented in various shapes and configurations. The mass transfer region 6 of the filler sheet 8 preferably occupies most of the surface area of ​​the filler sheet 8 to enhance heat transfer between the working fluid and the gas, but the mass transfer region 6 may be interrupted by assembly features 4, reinforcement features or other features to increase the strength and rigidity of the filler sheet 8, or to facilitate connecting the filler sheet 8 into a filler stack.

[0063] Figure 10 The filler sheet 8 of the present invention includes a counter-flow filler sheet 8, wherein the cooling fluid or water flows from the working fluid inlet edge 8a toward the working fluid outlet edge 8b under the action of gravity and flows out, and the air is driven upward from the gas inlet edge 9a through the filler stack toward the gas outlet edge 9b and flows out. The filler sheet 8 of the present invention is not limited to a counter-flow filler sheet 8, and can include a cross-flow filler sheet 8 or almost any kind of filler sheet 8, as long as the microstructure 12 in the filler sheet can increase the air flow turbulence, improve the working fluid film distribution and fill surface area, so as to improve the performance of the filler sheet 8, and in addition, Figure 10 A preferred filler sheet 8 is shown having a plurality of grooves 20 to direct the gas flow from the gas inlet edge 9a toward and to the gas outlet edge 9b, but the filler sheet 8 is not limited thereto and may be designed and configured without the plurality of grooves 20 and / or other large structures.

[0064] The top ridges 12a and bottom ridges 12b can define a longitudinal axis 18 that extends generally parallel relative to the top ridges 12a and bottom ridges 12b and the sidewalls 12c as they extend through the mass transfer region 6. The top ridges 12a and bottom ridges 12b and the sidewalls 12c are not limited in this regard and can have curved, angled, or otherwise varied configurations as they extend through the mass transfer region 6. For example, the top ridges 12a and bottom ridges 12b and the sidewalls 12c can define a herringbone shape ( Figure 6A and Figure 6B ), when viewed in a cross-section generally perpendicular to the longitudinal axis 18, the top and bottom ridges 12a, 12b and the sidewalls 12c may have a sinusoidal wave type configuration.

[0065] refer to Figures 1 to 5D , Figure 11 and Figure 11A, the preferred filler sheet 8 of the preferred embodiment includes a gas inlet edge 9a and a gas outlet edge 9b. Gas, typically comprising ambient air, flows from the gas inlet edge 9a toward the gas outlet edge 9b during operation, or in a countercurrent orientation relative to the flow of the working fluid flowing from the working fluid inlet edge 8a to the working fluid outlet edge 8b under gravity. The gas flow direction is typically defined between the gas inlet edge 9a and the gas outlet edge 9b, and can alternatively be configured in a cross-flow arrangement or perpendicular to the working fluid inlet edge 8a and the working fluid outlet edge 8b. In the cross-flow arrangement, the gas inlet edge 9a is at a first side edge 7a of the filler sheet 8 and the gas outlet edge 9b is at an opposite second side edge 7b of the filler sheet 8. The filler sheet 8 may include a plurality of grooves 20 extending from the gas inlet edge 9a toward the gas outlet edge 9b in the mass transfer region 6, with the filler sheet 8 of a preferred embodiment shown in FIG11 as having eleven (11) grooves 20, including a first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth and eleventh grooves 20 extending from the gas inlet edge 9a toward the gas outlet edge 9b, and four (4) grooves 20 extending from the side of the filler sheet 8 toward the gas outlet edge 9b. The filler sheet 8 is not limited to including such an arrangement of grooves 20 or including any grooves 20. The gas flow, typically ambient air, preferably flows along the path of the plurality of grooves 20 and is typically oriented in the direction of gas flow, but the local gas flow through the plurality of grooves 20 can be, and typically is, angled relative to the direction of gas flow or has an arcuate or sinusoidal shape. A second preferred filler sheet (in 5A to 5D 11 ) includes a plurality of grooves 20 having groove peaks 20a and groove valleys 20b that guide gas from the gas inlet edge 9a to the gas outlet edge 9b. The plurality of grooves 20 of the second preferred embodiment define a generally sinusoidal cross-section taken perpendicular to the direction of the groove peaks 20a and the groove valleys 20b. The plurality of grooves 20 are not limited to having a generally sinusoidal cross-section and may have other shapes designed and configured to guide the gas flow from the gas inlet edge 9a toward the gas outlet edge 9b during operation. For example, in the first preferred filler sheet 8, the grooves 20 are oriented at an angle and extend generally parallel to each other, as shown in FIG11 , and have a generally trapezoidal shape or cross-section.

[0066] The plurality of grooves 20 define a groove height H f , the top ridge 12a and the bottom ridge 12b define the belt height H m In a preferred embodiment, the groove height H f Greater than belt height H m . At the groove height H f Greater than belt height H mIn the preferred embodiment, the plurality of grooves 20 can be described as the macrostructure of the filler sheet 8, and the microstructures 12 including the top and bottom ridges 12a, 12b, the sidewalls 12c, and the rows of associated microtexture peaks 12d and microtexture valleys 12e (described in further detail below) are the microstructures of the filler sheet 8. The groove height H f Can be about four-tenths to one-tenth, two-tenths of an inch (0.4-1.2") (10.2-30mm), with a height H m It can be about two hundredths to three tenths of an inch (0.02-0.30") (0.51-7.6mm), but the groove height H f and belt height H m It is not so limited and may be otherwise sized and configured for alternative applications and functions based on designer preferences and / or operational requirements and specifications.

[0067] The plurality of grooves 20 of the filler sheet 8 can extend from the gas inlet edge 9a toward the gas outlet edge 9b or to the gas outlet edge to direct or guide the gas, typically ambient air, from the gas inlet edge 9a toward the gas outlet edge 9b. The filler sheet 8 defines a sheet axis 38 that extends generally perpendicularly relative to the gas inlet edge 9a and the gas outlet edge 9b and generally parallel relative to the cooling fluid or water or fluid flow direction 3. The plurality of grooves 20 can define a groove axis 20c that extends generally parallel to the direction of the plurality of grooves 20. The plurality of grooves 20 extend generally parallel and in the same direction from the gas inlet edge 9a and the working fluid outlet edge 8b to the gas outlet edge 9b and the working fluid inlet edge 8a in the counterflow filler sheet 8 of FIG. 11 , but are not limited thereto, and the plurality of grooves 20 can change direction between the gas inlet edge 9a and the gas outlet edge 9b, can extend along an arcuate path, or can otherwise extend across the filler sheet 8. The plurality of grooves 20 may extend generally perpendicularly relative to the sheet axis 38 or may be formed at an acute groove angle Δ defined between the groove axis 20c and the sheet axis 38. f extend.

[0068] Reference 5A to 5D , shows a portion of the mass transfer region 6 of a filler sheet 8, and in particular, a portion of a filler sheet 8 having grooves 20. Micro-corrugated stripes 13 extend through the grooves 20 such that the micro-corrugated stripes 13 are oriented generally perpendicular to the groove axis 20 c of the grooves 20. The micro-corrugated stripes 13 are not limited to being oriented generally perpendicular to the groove axis 20 and may extend at an angle relative to the groove axis 20 c or perpendicular to the groove axis 20. In this preferred embodiment, micro-texture features including rows of micro-texture peaks 12 d and rows of micro-texture valleys 12 e are superimposed on the micro-corrugated stripes 13.

[0069] Reference Figures 1 to 5D, Figure 11 and Figure 11A , preferably the top ridge 12a defines a top ridge width W t , the bottom ridge 12b defines the bottom ridge width W b . Top ridge width W t and bottom ridge width W b The lengths along the top ridge 12a and the bottom ridge 12b are substantially uniform, but are not limited thereto and may vary or change along the lengths of the top ridge 12a and the bottom ridge 12b. t and bottom ridge width W b The width of the top ridges 12a and the bottom ridges 12b is substantially equal and consistent, but is not limited thereto, and may vary between portions of the top ridges 12a and the bottom ridges 12b, may vary in different portions of the mass transfer region 6, or may be designed and constructed in other ways based on designer preference, functional requirements of the filler sheet 8, or operating environment. In a preferred embodiment, the top ridge width W t Greater than belt height H m , bottom ridge width W b Greater than belt height H m , but is not limited thereto and may be designed and configured in other ways based on designer preference or operational requirements. Top ridge width W t and bottom ridge width W b may alternatively be substantially equal to or less than the belt height H m .

[0070] refer to Figure 4 and Figure 4A The top ridge 12a includes a first top ridge 12a1, the bottom ridge 12b includes a first bottom ridge 12b1, and the sidewall 12c includes a first sidewall 12c1. The first upper sidewall angle Δ u is defined by the first top ridge 12a1 and the first sidewall 12c1, and the first lower sidewall angle Δ l Defined by the first bottom ridge 12b1 and the first sidewall 12c1. The first upper sidewall angle Δ u and the first lower sidewall angle Δ l is defined between sidewall axis 22 and vertical axis 24 associated with first top ridge 12a1, first bottom ridge and first sidewall 12c1, respectively, and likewise associated with each of the plurality of top ridges 12a, plurality of bottom ridges 12b and sidewall 12c. In a preferred embodiment, upper sidewall angle Δ u and the lower side wall angle Δ l Preferably, it is about thirty to sixty degrees (30-60°), more preferably forty-five degrees (45°).

[0071] refer to Figures 1 to 6B 、 Figure 9 、 Figures 11A to 11E and Figures 19 to 24 , the plurality of top ridges 12a include a first top ridge 12a1, the plurality of bottom ridges 12b include a first bottom ridge 12b1, and the plurality of side walls 12c include a first side wall 12c1. The first top ridge 12a1 is connected to the first bottom ridge 12b1 by the first side wall 12c1. The first top ridge 12a1 and the first bottom ridge 12b1 define a first micro-corrugated strip 131 extending from a first strip end 13a1 to a second strip end 13a2. The first micro-corrugated strip 131 also preferably includes at least a first side wall 12c1 connecting the first top ridge 12a1 to the first bottom ridge 12b1. The filler sheet 8 preferably includes a plurality of micro-corrugated strips 13, which include a plurality of top ridges 12a, a bottom ridge 12b and a connecting side wall 12c. As a non-limiting example, Figure 1 The portion of the mass transfer region 6 shown in FIG includes first, second and third micro-corrugated strips 131, 132, 133 having first, second and third top ridges 12a1, 12a2, 12a3 and first, second and third bottom ridges 12b1, 12b2, 12b3 and first, second and third side walls 12c1, 12c2, 12c2. The second micro-corrugated strip 132 extends from the first strip end 13b1 to the second strip end 13b2, and the third micro-corrugated strip 133 extends from the first strip end 13c1 to the second strip end 13c2. In addition, Figure 2 、 Figure 4 、 Figure 9 、 Figure 11A and Figure 11B The portion of the mass transfer region 6 shown also includes a fourth micro-corrugated strip 134 having a fourth top ridge 12a4, a fourth bottom ridge 12b4, and a fourth sidewall 12c4 extending from a first strip end 13d1 to a second strip end 13d2. The filler sheet 8 is not limited to including any particular number of micro-corrugated strips 13, including top and bottom ridges 12a, 12b, and sidewalls 12c, and may include virtually any number of micro-corrugated strips 13 desired by a designer or user depending on design configuration, filler sheet configuration, operating conditions, or other factors.

[0072] Reference Figure 11C and Figures 19 to 24The first micro-corrugated strip 131 may include a first intermediate ridge 12f1 and a first intermediate sidewall 12g1. In this configuration, the first micro-corrugated strip 131 includes a first top ridge 12a1, a first sidewall 12c1, a first intermediate ridge 12f1, a first intermediate sidewall 12g1, and a first bottom ridge 12b1, thereby defining a substantially three-layered first micro-corrugated strip 131. The first micro-corrugated strip 131 is not limited to having this three-layer construction and may include additional layers or intermediate ridges 12f, or may not include intermediate ridges 12f. This three-layer first micro-corrugated strip 131 provides additional first intermediate ridges 12f1 for water or cooling medium to flow in the mass transfer zone 6 and form a thin film for heat transfer. This three-layer first micro-corrugated strip 131 also preferably includes rows of micro-texture peaks 12d and micro-texture valleys 12e stacked thereon, but is not limited thereto and may include alternative micro-textures.

[0073] In a preferred embodiment, the first micro-corrugation bands 131 extend perpendicularly relative to the direction 3 of fluid or water flow through the filler sheet 8, and the micro-corrugation bands 13 can each extend generally perpendicular to the direction 3 of fluid flow. The micro-corrugation bands 13 are not limited to extending generally perpendicular to the direction 3 of fluid flow and can extend at an angle relative to the direction 3 of fluid flow or in a variety of orientations relative to the direction 3 of fluid flow, such as in a herringbone or herringbone configuration. The first micro-corrugation bands 131, as well as the micro-corrugation bands 13, can generally extend at an acute micro-corrugation band angle relative to the direction 3 of fluid flow through the filler sheet 8.

[0074] refer to Figures 1 to 6B and Figures 11A to 11E The microstructure may further include a second micro-corrugated strip 132 having a second top ridge 12a2, a second bottom ridge 12b2, and a second sidewall 12c2. The second micro-corrugated strip 132 extends from a third strip end or first strip end 13b1 of the second micro-corrugated strip 132 to a fourth strip end or second strip end 13b2 of the second micro-corrugated strip 132. The microstructure may further include a third micro-corrugated strip 132 having a third top ridge 12a3, a third bottom ridge 12b3, and a third sidewall 12c3. e The third micro-corrugated strip 133 extends from the fifth strip end portion or the first strip end portion 13c1 of the third micro-corrugated strip 133 to the third micro-corrugated strip 133. eThe sixth belt end or the second belt end 13c2. The first, second and third micro-corrugated belts 131, 132, 133 may extend generally parallel to each other and to the longitudinal axis 18 defined by the first, second and / or third micro-corrugated belts 131, 132, 133. The first, second and third micro-corrugated belts 131, 132, 133 and the fourth or more micro-corrugated belts 134 are not limited to extending generally linearly between the first and second belt ends 13a1, 13a2, 13b1, 13b2, 13c1, 13c2, 13d1, 13d2 and may extend in a bow, zigzag, sinusoidal or other pattern depending on designer or user preferences, the working environment, operational requirements or other factors related to the associated filler sheet 8 or cooling tower. In addition, the micro-corrugated belts 131, 132, 133, 134 are not limited to being positioned side by side, but may be configured in other ways, such as in a herringbone configuration (see Figure 6A and Figure 6B As a non-limiting example, the first micro-corrugated strips 131 may be oriented in a herringbone configuration relative to the third micro-corrugated strips 133 .

[0075] Reference Figures 11A to 11E The micro-corrugated strips 131, 132, 133, 134 may have various cross-sectional configurations. As non-limiting examples, the cross-sectional shapes of the micro-corrugated strips 131, 132, 133, 134 may include: a sinusoidal waveform ( Figure 11A ); alternating relatively flat top ridges 12a1, 12a2, 12a3, 12a4 and bottom ridges 12b1, 12b2, 12b3, 12b4 with curved sidewalls 12c1, 12c2, 12c3, 12c4 ( Figure 11B ); a three-layer design having relatively flat upper, lower and middle ridges 12a1, 12a2, 12a3, 12a4, 12b1, 12b2, 12b3, 12b4, 12f1 and angled side walls 12c1, 12c2, 12c3, 12c4, 12g1 ( Figure 11C ); having generally flat top and bottom ridges 12a1, 12a2, 12a3, 12a4, 12b1, 12b2, 12b3, 12b4, 12f1 and angled sidewalls 12c1, 12c2, 12c3, 12c4, 12g1 ( Figure 11D ); and a sawtooth shape ( having pointed top and bottom ridges 12a1, 12a2, 12a3, 12a4, 12b1, 12b2, 12b3, 12b4, 12f1 and angled sidewalls 12c1, 12c2, 12c3, 12c4, 12g1 Figure 11E). The first top ridge 12a1 and the first bottom ridge 12b1 can have an arcuate cross-sectional shape, wherein the first top ridge 12a1 is curved toward a first direction and the first bottom ridge 12b1 is curved opposite to the first direction. The micro-corrugated bands 131, 132, 133, 134 are not limited to these shapes and can take on virtually any shape that is configured to increase airflow turbulence and film distribution, withstand normal operating conditions of the filler sheet 8, and take on the general size and shape of the preferred microstructure 12. Any of the various shapes of micro-corrugated bands 13, 131, 132, 133, 134 can also include rows of micro-texture peaks 12d and micro-texture valleys 12e thereon to further increase airflow turbulence and film distribution of the filler sheet 8. Multiple rows of micro-texture peaks 12d and micro-texture valleys 12e can extend across the first micro-corrugated band 13, 131, as well as across any additional micro-corrugated bands 132, 133, 134 on the filler sheet 8.

[0076] Reference Figures 1 to 4A 、 Figure 9 、 Figures 11A to 11E and Figures 19 to 24 , the first top ridge 12a1 may define a first top ridge width W t1 , and the first bottom ridge 12b1 may define a first bottom ridge width W b1 The first top ridge width W t1 With the first bottom ridge width W b1 is substantially the same as, but not limited to, and the first top ridge width W t1 and the first bottom ridge width W b1 The second top ridge 12b2 may define a second top ridge width W t2 , and the second bottom ridge 12b2 may define a second bottom ridge width W b2 , where the second top ridge width W t2 and bottom ridge width W b2 Basically the same, but likewise not limited thereto.

[0077] refer to Figure 4A and Figure 11D , the first top ridge 12a1 defines a first upper sidewall angle Δ relative to the first sidewall 12c1 u , and the first bottom ridge 12b1 defines a first lower sidewall angle Δ relative to the first sidewall 12c1 l The first upper sidewall angle Δ u and the first lower sidewall angle Δ l The first upper sidewall angle Δ is approximately thirty to sixty degrees (30-60°), but is not limited thereto and may have a smaller or larger angle or may not be limited to a specific angle, such as when the sidewall 12c is curved or arched or the top ridge 12a and the bottom ridge 12b are not substantially planar or flat.u and the first lower sidewall angle Δ l can be basically equal ( Figure 4A and Figure 11D ), but is not limited thereto.

[0078] refer to Figures 1 to 5D and Figures 12 to 18 , the microstructure 12 also includes rows of microtexture peaks 12d and microtexture valleys 12e, which may be arranged at an acute microtexture angle Δ relative to the longitudinal axis 18. m Orientation. The rows of microtexture peaks 12d and microtexture valleys 12e define a row axis 26. The rows of microtexture peaks 12d and microtexture valleys 12e preferably extend generally parallel to the row axis 26 in the mass transfer region 6, but are not limited thereto and may have a curved, bowed, sinusoidal, or other shape extending across the filler sheet 8 in the mass transfer region 6. The rows of microtexture peaks 12d and microtexture valleys 12e preferably define a row width W between adjacent ones of the rows of microtexture peaks 12d and microtexture valleys 12e. r , the row width is measured on the top ridge plane 14 or the bottom ridge plane 16 which is generally parallel to the sheet plane of the filler sheet 8. The row width W r The top ridge width W is approximately 5 to 25 percent of an inch (0.05-0.25") (1.2-6.25 mm), but is not limited thereto and may be otherwise sized and configured based on designer preference, filler sheet performance requirements, or other performance criteria. In a preferred embodiment, the top ridge width W is approximately 5 to 25 percent of an inch (0.05-0.25") (1.2-6.25 mm). t and bottom ridge width W b Preferably larger than the row width W r .

[0079] The row of microtexture peaks 12d comprises a first row of microtexture peaks 12d1, and the row of microtexture valleys 12e comprises a first row of microtexture valleys 12e1. The microstructure 12 may also include columns of microtexture peaks 12h comprising a first row of microtexture peaks 12h1, and columns of microtexture valleys 12j comprising a first row of microtexture valleys 12j1. The rows of microtexture peaks 12d and microtexture valleys 12e are preferably oriented substantially parallel to one another and substantially symmetrically across the sheet axis 38 relative to the columns of microtexture peaks 12h and microtexture valleys 12j, but this orientation is not limited thereto. The rows of microtexture peaks 12d and microtexture valleys 12e and the columns of microtexture peaks 12h and microtexture valleys 12j may be oriented at an acute angle, in a zigzag pattern, in an arcuate pattern, or in other directions relative to one another, depending on designer preference, filler sheet requirements, or other factors associated with the filler sheet 8. Alternatively, the filler sheet 8 may be designed and constructed without the columns of microtexture peaks 12h and the columns of microtexture valleys 12j.

[0080] Reference Figures 1 to 6B and Figures 12 to 18The rows of microtexture peaks 12d include alternating microtexture apexes 28 and microtexture basins 30, and the microtexture valleys 12e include alternating microtexture crowns 32 and microtexture bases 34. The multiple rows of microtexture peaks 12d and microtexture valleys 12e extend across the filler sheet 8 in a wavy, undulating, or sinusoidal pattern along the rows in the mass transfer region 6, and have relatively smooth arcuate surfaces between the multiple rows of microtexture peaks 12d and microtexture valleys 12e, defining a relatively smooth curved or arcuate surface. In the mass transfer region 6, the microtexture apexes 28 and microtexture crowns 32 are generally aligned perpendicular to the rows of microtexture peaks 12d and microtexture valleys 12e, and the microtexture basins 30 and microtexture bases 34 are generally aligned perpendicular to the rows of microtexture peaks 12d and microtexture valleys 12e, but are not limited thereto and may be aligned and spaced apart in other manners. The alternating microtexture apexes 28 and microtexture basins 30, as well as the microtexture crowns 32 and microtexture bases 34, form a generally saddle shape between pairs of microtexture apexes 28 and the intervening microtexture basins 30 and associated microtexture bases 34 adjacent the microtexture basins 30. The columns of microtexture peaks 12h and columns of microtexture valleys 12j are comprised of the microtexture apexes 28, basins 30, crowns 32, and bases 34 of the rows of microtexture peaks 12d and microtexture valleys 12e, as described herein and shown in the accompanying drawings.

[0081] The microtexture apex 28 of the row of microtexture peaks 12d is preferably defined as the topmost portion of the dome shape or the top of the ridge of the microstructure 12, and the microtexture base 34 is preferably defined as the bottommost portion of the inverted dome shape or the inverted ridge of the microstructure 12. The microstructure 12 of the preferred embodiment has a combination of rows of microtexture peaks 12d and microtexture valleys 12e with top and bottom ridges 12a, 12b and interconnected sidewalls 12c.

[0082] In a preferred embodiment, the filler sheet 8 is used to cool a working fluid using a gas, which comprises water and flows through the filler sheet 8, and the gas comprises ambient air and flows through a film of water on the filler sheet 8. The ambient air is preferably forced to flow through the filler sheet 8 by driving a fan. The microstructure preferably defines a mass transfer region 6 on the filler sheet 8, and the filler sheet 8 may have a generally flat or planar configuration, or may include a plurality of grooves 20 that direct the flow of air through the filler sheet 8 from the gas inlet edge 9a towards the gas outlet edge 9b. A plurality of filler sheets 8 are preferably positioned adjacent to each other or connected to each other in a fill pack, wherein water flows under gravity through the fill pack from the working fluid inlet edge 8a to the working fluid outlet edge 8b, and air flows in the opposite direction from the working fluid outlet edge 8b to the working fluid inlet edge 8a or generally parallel to the fluid flow direction 3.

[0083] The gas flow direction may define the gas inlet edge 9a, the gas outlet edge 9b and the opposite side ends or edges of the filler sheet 8. The mass transfer region 6 is preferably defined between the gas inlet edge 9a and the gas outlet edge 9b and the opposite side ends. The microstructure 12 is defined in the mass transfer region 6. The microstructure 12 includes a microstructure with a small texture acute angle Δ m The rows of oriented undulating microtexture peaks 12d and microtexture valleys 12e define a row axis 26, and the microstructure 12 includes alternating microtexture apices 28 and microtexture basins 30, as well as microtexture crowns 32 and microtexture bases 34, which extend along or generally parallel to the row axis 26, respectively.

[0084] Reference Figures 1 to 3 and Figures 12 to 18 , first row of microtexture peaks 12d1 extends generally parallel relative to first row of microtexture valleys 12e1, which are generally parallel to row axis 26. First row of microtexture peaks 12d1 includes a first microtexture apex 281 and a first microtexture basin 301, and first row of microtexture valleys 12e1 includes a first microtexture crown 321 and a first microtexture base 341. First microtexture apex 281 is preferably along the tall portion of first row of microtexture peaks 12d1 between first microtexture basin 301 and second microtexture basin 302, and first microtexture basin 301 is preferably along the short portion of first row of microtexture peaks 12d1 between first microtexture apex 281 and second microtexture basin 302. The first microtexture crown 321 is preferably along the high portion of the first row of microtexture valleys 12e1 between the first microtexture base 341 and the second microtexture base 342, and the first microtexture base 341 is preferably along the low portion of the first row of microtexture valleys 12e1 between the first microtexture crown 321 and the second microtexture crown 322. Figure 1The portion of the filler sheet 10 also includes second, third, fourth, fifth, sixth, seventh, and eighth rows of microtexture peaks 12d2, 12d3, 12d4, 12d5, 12d6, 12d7 and second, third, fourth, fifth, sixth, and seventh rows of microtexture valleys 12e2, 12e3, 12e4, 12e5, 12e6, 12e7 extending across the mass transfer region 6. The filler sheet 8 is not limited to including any particular number of rows of microtexture peaks 12d and / or microtexture valleys 12e and may include nearly any number of rows of microtexture peaks 12d and microtexture valleys 12e, depending on the size, shape, configuration, and other factors of the filler sheet 8. The first, second, third, fourth, fifth, sixth, seventh and eighth rows of microtexture peaks 12d2, 12d3, 12d4, 12d5, 12d6, 12d7 and the first, second, third, fourth, fifth, sixth, seventh and eighth rows of microtexture valleys 12e2, 12e3, 12e4, 12e5, 12e6, 12e7 preferably extend parallel to each other and to the row axis 26, but are not limited thereto, and may have orientations and shapes similar to the first row of microtexture peaks 12d1 and microtexture valleys 12e1 described above.

[0085] The microtextured apex 28, bowl 30, crown 32, and base 34 can have various shapes, sizes, and designs configured and designed to increase airflow turbulence and working fluid film distribution in the filler sheet 8, particularly in the mass transfer region 8. The first microtextured apex 281 and the second microtextured apex 282 can have a dome shape, and the first microtextured base 341 and the second microtextured base 342 can have an inverted dome shape ( Figure 12 and Figure 18 The first microtexture vertex 281 and the second microtexture vertex 282 may have a pyramid shape ( Figure 15 ). The first microtexture apex 281 and the second microtexture apex 282 may have a truncated cone shape, and the first microtexture base 341 and the second microtexture base 342 may have an inverted truncated cone shape ( Figure 16 ). The first microtexture apex 281 and the second microtexture apex 282 may have a conical shape, and the first microtexture base 341 and the second microtexture base 342 may have an inverted conical shape ( Figure 17 The apex 28, the basin 30, the crown 32 and the base 34 may form a relatively continuous wavy or arcuate raised structure ( Figures 1 to 3 and Figure 13 The rows of microtexture peaks 12d may be defined by microtexture apexes 28 having domed or other protruding or raised shapes with relatively flat microtexture basins 30 therebetween, and rows of relatively flat microtexture valleys 12e ( Figure 14). In addition, the dimensions of the apexes 28, bowls 30, crowns 32, and bases 34 of the rows of microtexture peaks 12d and microtexture valleys 12e need not be uniform ( Figure 18 ), but the general size and shape of each of the apex 28, basin 30, crown 32 and base 34 in the mass transfer region 6 can be uniform.

[0086] Reference Figure 4 and Figure 4A , the filler sheet 8 preferably has a sheet thickness T of about 8 to 15 thousandths of an inch (0.008 to 0.015") (0.203 to 0.381 mm) (8 to 15 mils) that is generally uniform throughout the mass transfer zone 8. The apexes 28, bowls 30, crowns 32, and bases 34 of the rows of microtexture peaks 12d and microtexture valleys 12e preferably maintain this generally uniform sheet thickness T, as mirror images of the features on the opposite side of the filler sheet 8. The filler sheet 8 and mass transfer zone 6 are not limited to having this uniform sheet thickness T, and may have variations in the thickness of the filler sheet 8 in different areas to achieve stiffness and strength, but in a preferred embodiment the microstructures 12 preferably have a relatively uniform sheet thickness T.

[0087] refer to Figure 7A and Figure 7B The second preferred filler sheet 208 has similar features to the first preferred filler sheet 8, and like reference numerals are used to denote similar or identical features, with the prefix "2" being used to distinguish features of the second preferred embodiment from those of the first preferred embodiment. The second preferred filler sheet 208 includes microstructures 212 in the mass transfer region 206 of the filler sheet 8. Figure 7A and Figure 7B For clarity, a one-sided view of the filler sheet 208 is shown, but the filler sheet 208 has a consistent thickness, wherein the opposite side of the filler sheet 208 is the top surface or Figure 7A and Figure 7B A mirror image of the surface shown in .

[0088] The second preferred filler sheet 208 includes a microstructure 212 having a top ridge 212a, a bottom ridge 212b, a row of microtexture peaks 212d, and a row of microtexture valleys 212e. The row of microtexture peaks 212d includes alternating microtexture apexes 228 and microtexture valleys 230, and a row axis 226. The top ridge 212a and the bottom ridge 212b also define a longitudinal axis 218. Figure 7A and Figure 7B The cross-section of shows a filler sheet 8 with an exaggerated thickness and, for clarity, without corresponding microstructures on the bottom side of the filler sheet 208, but a second preferred filler sheet 208 preferably has a relatively small and consistent thickness, wherein the corresponding microstructures 212 on the bottom side of the filler sheet 208 are a mirror image of the top side microstructures.

[0089] refer to Figures 1 to 6B 、 Figures 8A to 10 and Figures 11A to 24 The preferred microstructure 12 includes a microcorrugation comprising a first top ridge 12a1, a first bottom ridge 12b1, and a first sidewall 12c1, as well as a plurality of microtexture features on the microcorrugation, including a first microtexture vertex 281 and a first microtexture base 341 on the first top ridge 12a1. The first microtexture vertex 281 and the first microtexture base 341 are not limited to being located on the first top ridge 12a1 and can be located on the first bottom ridge 12b1, the first sidewall 12c1, or on the filler sheet 8 or mass transfer region 6 to increase airflow turbulence, improve working fluid film distribution, and increase filler surface area. The microtexture features include at least the first microtexture vertex 281 and the first microtexture base 341 on the filler sheet 8 or mass transfer region 6, but preferably also include rows of microtexture peaks 12d and rows of microtexture valleys 12e distributed across the microcorrugation, including the plurality of top ridges 12a, the plurality of bottom ridges 12b, and the plurality of sidewalls 12c.

[0090] The plurality of microtexture features preferably includes a row of microtexture peaks 12d and a row of microtexture valleys 12e defining a row axis 26. The plurality of top ridges 12a and bottom ridges 12b or the first top ridge 12a1 and the first bottom ridge 12b1 define a longitudinal axis 18. The row axis 26 and the longitudinal axis 18 define an acute microtexture angle Δ m Furthermore, in a preferred embodiment, the first row of microtexture peaks 12d1 and the row axis 26 define an acute water angle Δ with respect to the liquid or water flow direction 3 of the filler sheet 8. w The first row of microtexture peaks 12d1 and the row axis 26 are not limited to defining an acute water angle Δ with respect to the liquid or water flow direction 3. w and can be oriented on the filler sheet 8 to be substantially parallel or perpendicular to each other.

[0091] The cross-sections of the first row of microtexture peaks 12d1 and the first row of microtexture valleys 12e1 have a sinusoidal shape. The cross-sections of the first row of microtexture peaks 12d1 and the first row of microtexture valleys 12e1 are not limited to having a sinusoidal shape and may have alternative shapes, such as a pyramidal shape, an arcuate shape, a wave shape, a wave shape interrupted by a flat surface, a truncated cone shape, a truncated cone shape interrupted by a flat surface, and other shapes that perform the preferred functions of the microtexture peaks 12d and microtexture valleys 12e and withstand normal operating conditions of the microtexture peaks 12d and microtexture valleys 12e.

[0092] The microtextured feature preferably comprises a microtextured grid comprised of microtextured apexes 28 and microtextured bases 34. The microtextured apexes 28 include first and second microtextured apexes 281 and 282, and the microtextured bases 34 include first and second bases 341 and 342. The microtextured grid also preferably comprises microtextured basins 30, including first and second microtextured basins 301 and 302, and microtextured crowns 32, including first and second microtextured crowns 321 and 322. The microtextured apexes 28 are preferably the topmost portion of the grid, while the microtextured bases 34 are preferably the bottommost features in the grid, wherein, if the grid is formed on a flat substrate, the microtextured basins 30 and microtextured crowns 32 are positioned relative height between the microtextured apexes 29 and the microtextured bases 34.

[0093] Those skilled in the art will appreciate that changes may be made to the above-described embodiments without departing from the broad inventive concept of the present invention. Therefore, it should be understood that the present invention is not limited to the particular embodiments disclosed, but is intended to cover modifications within the spirit and scope of the present invention as defined by this specification.

Claims

1. A microstructure for a filler sheet, the filler sheet being used to increase airflow turbulence and working fluid film distribution, the microstructure comprising: a micro-corrugation defined on the filler sheet, the micro-corrugation comprising a plurality of top ridges and a plurality of bottom ridges, the plurality of top ridges comprising a first top ridge and the plurality of bottom ridges comprising a first bottom ridge, the first top ridge and the first bottom ridge defining a first micro-corrugation strip, the first micro-corrugation strip extending from a first strip end to a second strip end, the first top ridge and the first bottom ridge defining a strip height; as well as A plurality of microtexture features on the microcorrugation include a first microtexture peak and a first microtexture base on the first microcorrugation band.

2. The microstructure according to claim 1, wherein The plurality of microtexture features define rows of microtexture peaks and microtexture valleys, the rows of microtexture peaks and microtexture valleys defining a row axis, the plurality of top ridges and the plurality of bottom ridges defining a longitudinal axis, the row axis and the longitudinal axis defining an acute microtexture angle.

3. The microstructure according to claim 2, wherein: The row of microtexture peaks includes a first row of microtexture peaks and a first row of microtexture valleys, the first row of microtexture peaks defining an acute water angle relative to a direction of fluid flow of the filler sheet.

4. The microstructure according to claim 3, wherein: The first row of microtexture peaks extends substantially parallel to the first row of microtexture valleys.

5. The microstructure according to claim 3, wherein A cross-section of the first row of microtexture peaks has a sinusoidal shape, and a cross-section of the first row of microtexture valleys has a sinusoidal shape. The microstructure according to claim 1 , wherein: The plurality of microtexture features includes a microtexture grid of microtexture apexes including the first microtexture apexes and a microtexture base including the first microtexture base.

7. The microstructure according to claim 6, wherein: The microtextured grid includes a microtextured basin and a microtextured crown.

8. The microstructure according to claim 1, wherein The shape of the first microtexture apex is selected from the group consisting of a dome, a bowed protrusion, a pyramid, a truncated cone, and a cone.

9. The microstructure according to claim 1, wherein The first micro-corrugated strip extends perpendicularly relative to a direction of fluid flow through the filler sheet.

10. The microstructure according to claim 1, wherein The first micro-corrugated strip extends at an acute strip angle relative to a direction of fluid flow through the filler sheet.

11. The microstructure according to claim 1, wherein The micro-corrugations are arranged in a herringbone shape.

12. The microstructure according to claim 1, wherein The first top ridge and the first bottom ridge are connected by a first sidewall.

13. The microstructure according to claim 1, wherein The first top ridge and the first bottom ridge are connected by a first side wall and a first middle ridge.

14. The microstructure according to claim 1, wherein The micro-corrugations have a cross-sectional shape selected from the group consisting of a sine wave, alternating flat and curved portions, planar top and bottom ridges, planar sidewalls, and a zigzag shape.

15. The microstructure of claim 1, wherein the band height is approximately two hundredths to three tenths of an inch (0.02-0.3").

16. The microstructure according to claim 1, wherein The first microtexture apex is the topmost point on the first top ridge, and the first microtexture base is the bottommost point on the first top ridge.

17. A microstructure for a filler sheet, the filler sheet being used to increase airflow turbulence and working fluid film distribution, the microstructure comprising: a plurality of top ridges, the plurality of top ridges including a first top ridge; a plurality of bottom ridges, the plurality of bottom ridges including a first bottom ridge; a plurality of sidewalls, the plurality of sidewalls including a first sidewall, a first top ridge connected to the first bottom ridge by the first sidewall, the first top ridge and the first bottom ridge defining a first micro-corrugated strip, the first micro-corrugated strip extending from a first strip end to a second strip end, the top ridge and the bottom ridge defining a strip height, the strip height being approximately two hundredths of an inch to three tenths of an inch; as well as A microtexture is defined on the first top ridge, the microtexture comprising a first row of microtexture peaks and a first row of microtexture valleys, the first row of microtexture peaks extending generally parallel to the first row of microtexture valleys.

18. The microstructure according to claim 17, wherein The first micro-corrugated strip includes a first intermediate ridge and a first intermediate sidewall.

19. The microstructure according to claim 17, further comprising: a second micro-corrugated strip, the second micro-corrugated strip comprising a second top ridge, a second bottom ridge, and a second sidewall, the second micro-corrugated strip extending from a third strip end to a fourth strip end, the first strip and the second strip extending generally parallel to a longitudinal axis defined by the first micro-corrugated strip and the second micro-corrugated strip.

20. The microstructure according to claim 19, further comprising: A third micro-corrugated strip includes a third top ridge, a third bottom ridge, and a third sidewall, the third micro-corrugated strip extending from the fifth strip end to the sixth strip end, the first micro-corrugated strip being oriented in a herringbone configuration relative to the third micro-corrugated strip.

21. The microstructure according to claim 17, wherein The first top ridge and the first bottom ridge have an arcuate cross-sectional shape.

22. The microstructure according to claim 21, wherein The first top ridge is arcuate toward a first direction, and the first bottom ridge is arcuate opposite to the first direction.

23. The microstructure according to claim 17, wherein The first top ridge defines a first top ridge width, and the first bottom ridge defines a first bottom ridge width, the first top ridge width being substantially the same as the first bottom ridge width.

24. The microstructure according to claim 17, wherein The first top ridge defines a first upper sidewall angle relative to the first sidewall, and the first bottom ridge defines a first lower sidewall angle relative to the first sidewall, the first upper sidewall angle and the first lower sidewall angle being approximately thirty to sixty degrees.

25. The microstructure according to claim 24, wherein The first upper sidewall angle and the first lower sidewall angle are substantially equal.

26. The microstructure according to claim 17, further comprising: rows of microtextured peaks; as well as A row of microtextured valleys extends across the first micro-corrugated strip.

27. A microstructure for a filler sheet, the filler sheet being used to increase airflow turbulence and working fluid film distribution, the microstructure comprising: a row of microtexture peaks comprising a first row of microtexture peaks; as well as and a row of microtexture valleys comprising a first row of microtexture valleys, the first row of microtexture peaks extending generally parallel relative to the first row of microtexture valleys, the first row of microtexture peaks comprising a first microtexture apex and a first microtexture basin, and the first row of microtexture valleys comprising a first microtexture crown and a first microtexture base, the first row of microtexture peaks being separated from the first row of microtexture valleys by a row width that is between five percent of an inch and twenty-five percent of an inch.

28. The microstructure according to claim 27, wherein The first microtexture apex has a dome shape, and the first microtexture base has an inverted dome shape.

29. The microstructure according to claim 27, wherein The first microtexture apex has a pyramid shape.

30. The microstructure according to claim 27, wherein The first microtexture apex has a frusto-conical shape, and the first microtexture base has an inverted frusto-conical shape.

31. The microstructure according to claim 27, wherein The first microtexture apex has a cone shape, and the first microtexture base has an inverted cone shape.

32. The microstructure according to claim 27, further comprising: a plurality of top ridges including a first top ridge; a plurality of bottom ridges including a first bottom ridge; as well as A plurality of sidewalls includes a first sidewall, the first top ridge being connected to the first bottom ridge by the first sidewall.

33. The microstructure according to claim 32, wherein The first top ridge and the first bottom ridge define a first micro-corrugated strip extending from a first strip end to a second strip end, the top ridge and the bottom ridge defining a micro-corrugation height that is approximately two hundredths of an inch to three tenths of an inch.

34. The microstructure according to claim 33, wherein The first micro-corrugated strip includes a first intermediate ridge and a first intermediate sidewall.

35. The microstructure according to claim 34, wherein The first micro-corrugated strip has a substantially sinusoidal cross-section.

36. The microstructure according to claim 32, wherein The first top ridge and the first bottom ridge have a substantially flat cross-section.

37. The microstructure according to claim 32, wherein The first top ridge and the first bottom ridge have a generally arcuate cross-section.

38. The microstructure according to claim 36, wherein The first top ridge defines a first top ridge width, and the first bottom ridge defines a first bottom ridge width, the first top ridge width being substantially the same as the first bottom ridge width.

39. The microstructure according to claim 27, further comprising: a column of microtexture peaks comprising a first column of microtexture peaks; as well as A column of microtexture valleys including a first column of microtexture valleys.

40. The microstructure according to claim 39, wherein The rows of microtexture peaks and the rows of microtexture valleys are oriented generally perpendicularly with respect to the columns of microtexture peaks and the columns of microtexture valleys.

41. A filler sheet for promoting mass transfer between a working fluid flowing through the filler sheet and a gas flowing over the working fluid, the filler sheet comprising: a mass transfer region defined between a working fluid inlet edge and a working fluid outlet edge; as well as a microstructure formed in the mass transfer region, the microstructure comprising top and bottom ridges connected by a sidewall, the top and bottom ridges defining a longitudinal axis, rows of microtexture peaks and microtexture valleys oriented at an acute microtexture angle relative to the longitudinal axis, the rows of microtexture peaks and microtexture valleys defining a row axis, the rows of microtexture peaks comprising alternating microtexture apices and microtexture basins, and the rows of microtexture valleys comprising alternating microtexture crowns and microtexture bases.

42. The filler sheet according to claim 41, further comprising: A plurality of grooves extend in the mass transfer region from a gas inlet edge toward a gas outlet edge, the plurality of grooves defining a groove height, the top ridge and the bottom ridge defining a band height, the groove height being greater than the band height.

43. The filling piece according to claim 42, wherein The plurality of grooves extend from the gas inlet edge toward the gas outlet edge.

44. The filling sheet according to claim 42, wherein The plurality of grooves extend at acute groove angles relative to the sheet axis.

45. The filling sheet according to claim 41, further comprising: A gas inlet edge and a gas outlet edge, wherein gas flows from the gas inlet edge to the gas outlet edge and defines a gas flow direction.

46. ​​The filling sheet according to claim 41, wherein The microstructures are arranged in a herringbone or herringbone configuration.

47. The filling sheet according to claim 41, wherein The microtexture apex is defined at a topmost portion of the dome shape, and the microtexture base is defined at a bottommost portion of the inverted dome shape.

48. The filling sheet according to claim 41, wherein The top ridge defines a top ridge width, and the bottom ridge defines a bottom ridge width, defining a band height therebetween, the top ridge width being greater than the band height, and the bottom ridge width being greater than the band height.

49. The filling sheet according to claim 41, wherein The top ridge includes a first top ridge, the bottom ridge includes a first bottom ridge, and the sidewall includes a first sidewall, a first upper sidewall angle defined by the first top ridge and the first sidewall, and a first lower sidewall angle defined by the first bottom ridge and the first sidewall.

50. The filling sheet according to claim 49, wherein The first upper sidewall angle is approximately thirty to sixty degrees, and the first lower sidewall angle is approximately thirty to sixty degrees.

51. The filling sheet according to claim 41, wherein The rows of microtexture peaks and valleys define a row width, the top ridges define a top ridge width, and the bottom ridges define a bottom ridge width, the top ridge width being greater than the row width and the bottom ridge width being greater than the row width.

52. The filling piece according to claim 51, wherein The top ridge width is approximately equal to the bottom ridge width.

53. A filler sheet for cooling a working fluid on the filler sheet by utilizing gas flowing through a film of the working fluid, the filler sheet comprising: a working fluid inlet edge, a working fluid outlet edge, and an edge on the opposite side; a mass transfer region defined between the working fluid inlet edge and the working fluid outlet edge and the edge of the opposite side; as well as a microstructure defined in the mass transfer region, the microstructure comprising a top ridge, a bottom ridge, and a sidewall connecting the top ridge and the bottom ridge, the top ridge and the bottom ridge defining a longitudinal axis, the microstructure further comprising rows of microtexture peaks and microtexture valleys oriented at an acute angle relative to the longitudinal axis, the rows of microtexture peaks and microtexture valleys defining a row axis, the rows of microtexture peaks comprising alternating microtexture apices and microtexture basins, and the rows of microtexture valleys comprising alternating microtexture crowns and microtexture bases.

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