A monolithic porous ceramic filler

Abstract

The present invention discloses a monolithic porous ceramic filler, which relates to a porous ceramic material prepared from industrial waste slag as raw material. The present invention is formed by combining multiple porous ceramic plates, wherein two adjacent porous ceramic plates are connected by supporting fixtures and extend along a first direction. The components formed by extending along the first direction are repeatedly arranged along a second direction, wherein a ventilation duct is formed between two adjacent components, and the ventilation duct is used for air and water to pass between the porous ceramic plates. The present invention abandons the model of previous patents in the same series that relied on plastic fixing frames or plastic belt racks for connection and fixation, and uses non-mechanical components to connect and fix the porous ceramic plates, making the filler a monolithic structure without plastic parts.

Description

Technical Field

[0001] The present invention relates to a porous ceramic material prepared with industrial waste residue as raw material, in particular to an integral porous ceramic filler used as a heat exchange filler core of evaporative cooling air conditioning equipment, specifically an integral porous ceramic filler. Background Art

[0002] Evaporative cooling air conditioners operate based on the principle of heat transfer through evaporative cooling. As air passes through a film of water, the enthalpy-humidity difference between the air on the film surface and the moving air causes water to diffuse from the film surface into the air, a process known as evaporation. During this process, the water vapor absorbs a significant amount of latent heat, lowering the temperature of both the air and water. The filler in an evaporative cooling air conditioner is the site of heat transfer generated by the water vapor.

[0003] Evaporative cooling pads, also known as wet curtains, are core components of evaporative cooling systems, and their performance directly impacts the unit's performance. Physical properties such as thickness, specific surface area, and material are highly correlated with the unit's evaporative cooling efficiency and other performance characteristics. Pads must possess the following characteristics: a large specific surface area for high water absorption capacity; corrosion resistance to prevent bacterial growth; good wet stiffness to prevent collapse in prolonged water contact; flame retardancy to minimize fires caused by electrical failures; and environmental friendliness and non-toxicity. Commonly used pads are paper curtains and PVC (polyvinyl chloride) curtains. Paper curtains are currently the most widely used due to their large specific surface area, high water absorption capacity, ease of production, and low cost. However, they have poor wet stiffness, antibacterial and mildew resistance, and flame retardancy, posing health and safety risks. PVC curtains are easy to produce, low-cost, flame-retardant, and mildew-resistant, but they also have poor water absorption, resulting in low cooling efficiency.

[0004] To overcome the aforementioned shortcomings of paper and PVC curtains, we use porous ceramic sheets as an alternative material, further processing them into porous ceramic fillers. The densely distributed macropores on the porous ceramic surface allow for strong water absorption. Furthermore, due to its inorganic nature, it is also flame-retardant, mildew-resistant, and has a long lifespan. Combining the advantages of both paper fiber and PVC, porous ceramic fillers are the optimal choice for heat exchange fillers in evaporative cooling air conditioning units.

[0005] Researchers have long explored the industrialization of porous ceramic packing, assembling individual porous ceramic plates into modules using a fixed frame. Patents have been filed for these technologies, such as "A Through-Type Porous Ceramic Wet Curtain" (CN 104197445 B) and "A Laminated Porous Ceramic Wet Curtain" (CN 204084701 U). In 2019, researchers further explored simplifying the large fixed frame into a simple and flexible belt-type mounting bracket, and filed a patent for "A Belt-Type Porous Ceramic Packing (CN201921413554.9)," significantly simplifying the product's production process. However, both the frame and the belt bracket are plastic components, relying on them to secure and connect the porous ceramic plates. Over time, these components can age and break, causing the ceramic plates to fall apart.

[0006] In order to further improve the performance of porous ceramic fillers and optimize the production process, in 2021, researchers explored completely abandoning the dependence of porous ceramics on frames or belt racks, and optimized the product into an integral porous ceramic filler without frame or frame connection. Summary of the Invention

[0007] In response to the deficiencies in the prior art, the present invention provides an integral porous ceramic filler, abandoning the previous model of the same series of patents that relied on a plastic fixing frame or a plastic belt frame for connection and fixation, and connecting and fixing the porous ceramic plates with non-mechanical components, so that the filler becomes an integral structure without plastic parts. In terms of performance, the integral porous ceramic filler does not require plastic parts, which prevents the filler from falling apart due to plastic aging during use, thereby increasing its service life; the ceramic sheets are seamlessly connected in pairs to prevent the ceramic sheets from shaking and colliding during operation, reducing the chance of filler breakage. In terms of production technology, the connection and installation of plastic parts are eliminated, thereby reducing the cost of raw materials and equipment, and making it easier to achieve automated production.

[0008] To achieve the above-mentioned purpose, the present invention provides an integral porous ceramic filler, which is formed by combining a plurality of porous ceramic blocks, wherein the porous ceramic blocks include a plurality of porous ceramic plates, and adjacent two porous ceramic plates are connected by an adhesive and extend along a first direction, wherein, in the porous ceramic blocks, the side of one porous ceramic plate is seamlessly connected to the plane of the other porous ceramic plate and extends along the first direction, the porous ceramic blocks are repeatedly arranged along the second direction, and also include supporting and fixing members of inorganic materials, the two ends of the supporting and fixing members are respectively connected to the porous ceramic blocks, and a ventilation duct is formed between the adjacent two porous ceramic blocks, and the ventilation duct is used for air and water to pass between the porous ceramic blocks.

[0009] The integral porous ceramic filler as described above, further, the angle between two adjacent porous ceramic plates is greater than 0 o Less than 180 o , so that the porous ceramic plate presents a curved shape.

[0010] The above-mentioned integral porous ceramic filler, further, the porous ceramic plate has a regular shape, and the regular shape is a rectangular or square sheet cut from the foamed ceramic block.

[0011] The above-mentioned integral porous ceramic filler, further, the thickness of the sheet body is 1-15 mm.

[0012] As for the above-mentioned integral porous ceramic filler, further, the component extending along the first direction is a whole piece of unconnected rectangular or square porous ceramic plate.

[0013] The integral porous ceramic filler as described above, further, the porous ceramic blocks are supported, fixed and connected by supporting and fixing members of inorganic materials to form a plurality of regularly arranged and spaced three-dimensional structures.

[0014] The integral porous ceramic filler as described above, further, the porous ceramic blocks are supported, fixed and connected by supporting and fixing members of inorganic materials to form a plurality of regularly arranged and spaced three-dimensional structures.

[0015] The integral porous ceramic filler as described above is further provided with a polymer or metal outer frame on the outside of the filler to protect the filler and prevent it from being damaged due to collision during transportation and use.

[0016] The integral porous ceramic filler as described above, further, the first direction and the second direction are perpendicular.

[0017] Compared with the prior art, the present invention has the following advantages: 1. Abandoning the previous generation's method of using shaping tape to clamp, fix and connect porous ceramic plates, an adhesive is used to bond the molecular structures of dispersed porous ceramic plates, so that the ceramic plates are seamlessly connected, stronger and more stable, and the filler is prevented from shaking when the wind blows.

[0018] 2. The seamless connection between the porous ceramic plates leaves no gaps between the plates in the horizontal direction, thus limiting the air flow to the surface of the porous ceramic plates, allowing for more complete contact with the surface water film for heat exchange and improving heat exchange efficiency.

[0019] 3. By removing plastic parts such as the frame and the belt rack, the porous ceramic plates can be prevented from falling apart due to plastic aging and breakage, thereby increasing the service life of the filler.

[0020] 4. By removing the frame and the belt rack, the use of fillers and the production process are reduced, which reduces production costs, makes it easier to realize automatic production, and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0022] Figure 1 This is a schematic diagram of the structure of a porous ceramic plate, where the angle between two adjacent porous ceramic plates is 90 o ;

[0023] Figure 2 The multiple porous ceramic plates (i.e. Figure 1 ) Schematic diagram of the structure of the combined integral porous ceramic packing; wherein 101, porous ceramic plate, 102, supporting fixture, 103, ventilation duct, 104, porous ceramic plate;

[0024] Figure 3 This is a schematic structural diagram of a monolithic porous ceramic filler composed of multiple large, integral porous ceramic blocks in Example 2;

[0025] Among them, 201 is a porous ceramic plate, 202 is a supporting fixture, and 203 is a ventilation duct.

[0026] Figure 4 Schematic diagram of the structure of a belt-type porous ceramic filler of a comparative example;

[0027] Among them, 301, porous ceramic plate, 302, shaping belt, 303, buckle, 304, porous ceramic plate, 305, ventilation duct. DETAILED DESCRIPTION

[0028] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0029] Example:

[0030] It should be noted that the terms "first", "second", etc. in the description and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof in the embodiments of the present invention are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0031] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as limiting the present invention.

[0032] In the description of the present invention, "plurality" means at least two, such as two or three, unless otherwise specifically defined. Furthermore, unless otherwise specified or defined, the terms "mounted," "connected," and "connected" should be understood broadly, meaning, for example, fixed, removable, or integral; mechanical or electrical; direct or indirect through an intermediary; and internal communication between two components. Those skilled in the art will understand the specific meanings of these terms in the present invention.

[0033] See also Figures 1 to 4 , Figure 1 This is a schematic diagram of the structure of a porous ceramic plate, where the angle between two adjacent porous ceramic plates is 90 o ; Figure 2 This is a schematic structural diagram of a monolithic porous ceramic filler composed of multiple porous ceramic plates in Example 1; Figure 3 This is a schematic structural diagram of a monolithic porous ceramic filler composed of multiple large, integral porous ceramic blocks in Example 2; Figure 4 It is a structural schematic diagram of a belt-type porous ceramic filler of a comparative example.

[0034] The present invention provides an integral porous ceramic filler, which is formed by combining multiple porous ceramic blocks, and is characterized in that the porous ceramic blocks include multiple porous ceramic plates, and two adjacent porous ceramic plates are connected by an adhesive and extend along a first direction, wherein, in the porous ceramic blocks, the side of one porous ceramic plate is seamlessly connected to the plane of another porous ceramic plate and extends along the first direction, and the porous ceramic blocks are repeatedly arranged along the second direction, and also include supporting and fixing members of inorganic materials, the two ends of the supporting and fixing members are respectively connected to the porous ceramic blocks, and a ventilation duct is formed between the two adjacent porous ceramic blocks, and the ventilation duct is used for air and water to pass between the porous ceramic blocks.

[0035] As an optional embodiment, in some embodiments, the angle between two adjacent porous ceramic plates is greater than 0. o Less than 180 o , so that the porous ceramic plate presents a curved shape.

[0036] As an optional implementation, in some embodiments, the porous ceramic plate has a regular shape, and the regular shape is a rectangular or square sheet cut from a foamed ceramic block.

[0037] As an optional implementation, in some embodiments, the thickness of the sheet is 1-15 mm.

[0038] As an optional implementation, in some embodiments, the porous ceramic blocks are supported, fixed and connected by supporting and fixing members made of inorganic materials to form a plurality of regularly arranged and spaced three-dimensional structures.

[0039] As an optional implementation, in some embodiments, a polymer or metal frame is provided on the outside of the filler to protect the filler and prevent it from being damaged due to collision during transportation and use.

[0040] As an optional implementation manner, in some embodiments, the first direction and the second direction are perpendicular.

[0041] Example 1:

[0042] like Figure 2 The integral porous ceramic filler shown is formed by combining multiple rectangular or square hole ceramic plates 101. The porous ceramic plates 101 are supported by supporting fixing members 102 to form ventilation ducts 103 to facilitate heat exchange between air, water and steam on the porous ceramic surface.

[0043] The porous ceramic plate 101 includes a porous ceramic plate 104 and a supporting fixture 102. The porous ceramic plates are connected to each other by an adhesive to form a porous ceramic plate. The angle between the two porous ceramic plates is 90 o .

[0044] The two ends of the supporting fixture 102 are respectively connected to two porous ceramic plates 101, so that the multiple porous ceramic plates 101 form a regularly arranged integral three-dimensional structure with spaced channels.

[0045] Example 2:

[0046] Refer to Example 1, the difference is that a whole piece of straight porous ceramic plate without splicing is used instead of 90 o Curved porous ceramic plate. Figure 3 The integral porous ceramic filler shown is formed by combining multiple I-shaped porous ceramic plates 201. The porous ceramic plates 201 are connected by supporting fixings 202 to form ventilation ducts 203 to facilitate heat exchange between air, water and steam on the porous ceramic surface.

[0047] Comparative Example:

[0048] like Figure 4 The "belt-type porous ceramic filler" shown (see CN201921413554.9) is formed by a combination of multiple rectangular or square porous ceramic plates 301. The porous ceramic plates 301 are supported by buckles 303 to form ventilation ducts 305 to facilitate heat exchange between air, water and steam on the porous ceramic surface. The porous ceramic plates 301 include porous ceramic plates 304 and shaping belts 302. The shaping belts 302 are used to fix a plurality of porous ceramic plates 304 together to form porous ceramic plates arranged in a corrugated shape. The shaping belt forms an angle of 120 between two adjacent porous ceramic plates. o The shaping belt 302 is provided with buckles 303, and the porous ceramic plates 301 are connected in pairs through the buckles to form a three-dimensional porous ceramic filler.

[0049] The performance of the porous ceramic packing in Examples 1 and 2, along with that in the comparative example, was tested. The results showed that in Examples 1 and 2, the porous ceramic plates were seamlessly bonded with adhesive, eliminating plastic components such as sizing tape and clips. This resulted in a more complete connection. During use, the absence of gaps between the porous ceramic plates allowed air to flow evenly along the ceramic surface, improving heat exchange efficiency by 10%.

[0050] Compared to the comparative example, the removal of the belt frame in Examples 1 and 2 further reduces the obstruction of the ventilation duct caused by the thickness of the belt frame (approximately 3 mm), thereby reducing wind resistance of the filler by 10% and lowering system fan energy consumption. Furthermore, the elimination of the customization, positioning, and connection of the belt frame facilitates automated production, reduces production costs, and improves production efficiency.

[0051] In the description of this specification, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

[0052] The above embodiments are intended only to illustrate the technical concepts and features of the present invention. Their purpose is to enable those skilled in the art to understand the contents of the present invention and implement them accordingly. They are not intended to limit the scope of protection of the present invention. Any equivalent changes or modifications made based on the essence of the present invention are intended to be covered by the scope of protection of the present invention.

Claims

1. A monolithic porous ceramic packing, formed by combining multiple porous ceramic blocks, characterized in that: The porous ceramic plate comprises a plurality of porous ceramic plates, and two adjacent porous ceramic plates are connected by an adhesive and extend along a first direction. In the porous ceramic plate, the side of one porous ceramic plate is seamlessly connected to the plane of another porous ceramic plate and extends along the first direction. The plates are repeatedly arranged along the second direction and further comprise supporting and fixing members of inorganic materials. The two ends of the supporting and fixing members are respectively connected to the porous ceramic plates. A ventilation duct is formed between two adjacent porous ceramic plates, and the ventilation duct is used for air and water to pass between the porous ceramic plates.

2. The monolithic porous ceramic filler according to claim 1, characterized in that: The angle between two adjacent porous ceramic plates is greater than 0 o Less than 180 o , so that the porous ceramic plate presents a curved shape.

3. The monolithic porous ceramic filler according to claim 1, characterized in that: The porous ceramic plate has a regular shape, which is a rectangular or square sheet cut from a foamed ceramic block.

4. The monolithic porous ceramic filler according to claim 3, characterized in that: The thickness of the sheet is 1-15 mm.

5. The monolithic porous ceramic filler according to claim 1, characterized in that: The porous ceramic plates are supported, fixed and connected by supporting and fixing members made of inorganic materials to form a plurality of regularly arranged and spaced three-dimensional structures.

6. The monolithic porous ceramic filler according to claim 1, characterized in that: A polymer or metal outer frame is provided on the outside of the filler to protect the filler and prevent it from being damaged due to collision during transportation and use.

7. The monolithic porous ceramic filler according to any one of claims 1 to 6, characterized in that: The first direction and the second direction are perpendicular.

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