Filling sheets and related filling packaging components

Abstract

A filling package includes a first filling sheet, the first filling sheet defining an air inlet edge, an exhaust edge, and an air flow axis extending between the air inlet edge and the exhaust edge. The first filling sheet defines a first corrugated section, the first corrugated section having a first inlet end, a first outlet end, and a first peak extending between the first inlet end and the first outlet end. The second filling sheet defines a second corrugated section, the second corrugated section having a second inlet end, a second outlet end, and a second peak extending between the second inlet end and the second outlet end. The first peak extends relative to the second peak so that a first corrugated portion defined by the first corrugated section and the second corrugated section has a cross-sectional shape that varies between the first inlet end and the second inlet end and the first outlet end and the second outlet end.

Description

[0001] This application is a divisional application of the patent application with application number 201980078287.0, application date November 27, 2019, and invention name “Filling sheets and related filling packaging components”. Background Art

[0002] The cooling tower market has been steadily moving toward efficient and cost-effective fill media. Fill media, fillers, filler packing, or baffles are typically constructed of an assembly of polymer sheets that form flow channels or corrugations between connected or generally parallel arranged sheets through which air and water flow in the cooling tower. Fill media increases the surface area exposure of the flowing water and air of the cooling tower, thereby driving significant contact and interaction between the air and water in the cooling tower, and thus increasing heat transfer. This interaction primarily achieves the cooling effect of the water through mass transfer between the air and water, but there may be some significant heat transfer. Since fill media is a critical component of cooling towers, entities strive to have cost-effective products with high tower performance to remain competitive in the cooling tower and fill markets.

[0003] In general, fill media costs can be reduced by creating a fill media product with adequate thermal performance for a given cooling tower application that consists of fewer individual sheets that make up the fill media assembly. The reduction in sheets per unit of fill volume saves material and reduces molding and assembly time for the fill package, thereby reducing overall product cost.

[0004] The performance of a cooling tower is generally measured by the amount of water that the tower can cool to a specified operating temperature under specified design conditions. Most of this cooling occurs in the fill media where water flowing through the fill media mixes with the air flowing through the fill media. The primary form of heat transfer from the water to the surrounding air is through evaporation. A small amount of water evaporates from the bulk of the water in the tower. This evaporating mass of water carries an amount of energy equal to the heat from the evaporation of the bulk of the water, causing the remaining water to cool. It is generally understood that having a larger surface area within the fill media increases the rate of evaporation. Therefore, a fill having a larger surface area per unit volume is generally more efficient at cooling water flowing through the fill media or fill packing than a fill media or fill packing having a smaller surface area per unit volume.

[0005] The evaporation of water into the air is limited by the moisture carrying capacity of the air. As the air becomes more saturated with water vapor, the evaporation rate decreases. This means that in order to maintain a high evaporation rate or degree of evaporation, a high mass flow rate of air through the tower and the filling medium is required. In cooling towers, this is usually done with the help of fans or by forcing air through the filling medium or filling package, although natural ventilation systems generate airflow based on the difference in air density inside and outside the tower. Due to the forced air flow through the space or channel inside the filling medium or filling package, the air driven by the fan in a typical tower is subject to resistance to its movement. As the air flows from the inlet side of the filling medium to the outlet side of the filling medium, the resistance can be characterized by the pressure drop over the entire filling medium obtained. Compared with a more moderate pressure drop, overcoming the relatively large pressure drop in the filling medium usually requires the use of a more powerful fan. The work of an effective filling package is to achieve a specified cooling effect at the smallest possible pressure drop. In other words, the preferred package has high thermal performance and low pressure drop values ​​between the air inlet side and the air outlet side.

[0006] Filling media or filler packaging is usually composed of a component of corrugated sheets connected to form a filling medium or filler packaging. The larger main wrinkles in the corrugated sheet are called "corrugated" or macrostructure. The corrugations in the sheet increase the surface area of ​​the sheet on which water can form a film, thereby increasing the surface area of ​​water exposed to the air flowing through the folds or corrugations. The corrugations also form a channel for air, and the air flows through the filling package along the corrugations from the air inlet end to the outlet end of the filling medium or filler packaging. For example, the corrugations at an angle of thirty degrees (30 °) to the straight flow direction between the air inlet end and the outlet end (the straight flow direction can usually be the vertical direction / axis of the filling medium or filler packaging in the cross-corrugated filling package) will cause the air to flow roughly in the same direction as the corrugations or roughly along and through the corrugations under the guidance of the corrugations. This means that the geometry of the corrugations affects the way air flows through the package. This feature of the corrugation can not only be used to direct air to where it is needed, but also to increase the mixing of the airflow within the corrugation and the filler package, thereby avoiding air stratification or cross-flow.

[0007] Microstructures are often added to the fluting to further increase the surface area of ​​the fill media or filler packaging over which the water can form a film to interact with the air flowing through the fluting. The microstructures in the fluting also keep the water film flowing down the fluting in a constant flux or changing state so that the water film closely exposed to the flowing air is constantly changing to improve heat transfer. The continuous mixing of the water film created by the microstructure increases the cooling rate of the liquid film, similar to how stirring hot coffee cools the coffee down faster than without stirring. The microstructures also serve to maintain the distribution of water on the surface to provide benefits to all available surface area provided by the geometry of the fluting and macrostructure.

[0008] However, incorporating corrugations and microstructures into the corrugations of a fill package may result in the undesirable effect of increasing resistance to airflow, thereby increasing the pressure drop between the inlet or air intake end and the outlet end of the fill package. It is desirable to design, develop and deploy fill sheets assembled into fill packages that improve thermal efficiency and limit pressure drop under typical operating conditions of cooling towers. The preferred present invention addresses the shortcomings of prior art fill sheets and related fill package assemblies by arranging the fill sheets relative to each other in the fill package to improve heat transfer between water flowing through the fill package and air flowing along the corrugations. Summary of the invention

[0009] Briefly, a filling package includes a first filling sheet, the first filling sheet defining an air intake edge, an exhaust edge, and an airflow axis extending between the air intake edge and the exhaust edge. The first filling sheet defines a first corrugated section having a first inlet end and a first outlet end. The first corrugated section also includes a first peak and a first valley and a second valley extending between the first inlet end and the first outlet end. The second filling sheet defines a second corrugated section, the second corrugated section having a second inlet end, a second outlet end, and a second peak extending between the second inlet end and the second outlet end. The first inlet end is positioned near the second inlet end, and the first outlet end is positioned near the second outlet end. The first peak, the second peak, the first valley, and the second valley define a first corrugated airflow section. The cross-sectional shape of the first corrugated airflow section continuously changes along the first corrugated airflow section. For any given corrugation, the cross-sectional shape of the first corrugated airflow section is generally composed of an area of ​​a plane drawn substantially perpendicular to the airflow axis between a pair of adjacent or stacked filling sheets, defined by the first sheet corrugated macrostructure folds and the corrugation line connecting two corrugated valleys. In a preferred embodiment, the peak of the second filler sheet extends into the adjacent fluted airflow section and continuously changes position relative to the peak of the first filler sheet along its length to continuously change the cross-sectional shape in the fluted airflow section between multiple rows of spacers or connectors at the inlet and outlet ends of the fluted section. The first peak extends relative to the second peak so that the fluted airflow section changes continuously in all fluted sections between the first and second inlet ends and the first and second outlet ends or between connector or spacer locations throughout the fluted path.

[0010] On the other hand, a preferred embodiment of the present invention relates to a filler sheet for cooling a medium flowing out of the sheet. The filler sheet includes a top edge and a plurality of protrusions. The plurality of protrusions include a first peak protrusion proximate to a top edge having a first base. An upper platform is defined near the first base. The upper platform defines an upper sheet plane. A plurality of corrugations extend from the top edge of the filler sheet toward a bottom edge. A longitudinal axis extends through the top edge and the bottom edge, and a transverse axis extends substantially perpendicular to the longitudinal axis and parallel to the upper sheet plane. The plurality of corrugations include a first corrugation having a first top corrugation end proximate to the first peak protrusion. A microstructure consisting of bands is formed on the corrugation. The microstructure defines a microstructure peak between the top edge and the bottom edge on the first corrugation. The upper platform and the microstructure peak define an upper offset distance.

[0011] On the other hand, a preferred embodiment of the present invention relates to a filler sheet for insertion into a cooling tower to cool a cooling medium flowing out of the sheet. The filler sheet includes an air inlet edge, an exhaust edge positioned opposite the air inlet edge, and a plurality of corrugations extending from the air inlet edge toward the exhaust edge. The air flow axis extends through the top edge and the bottom edge, and the transverse axis extends substantially perpendicular to the air flow axis. The plurality of corrugations include a first corrugated section. The first corrugated section includes a first arc extending at a first side of the air flow axis and a second arc extending at a second opposite side of the air flow axis. The filler sheet also includes a plurality of spacer rows. The spacer rows include an air inlet spacer row and an intermediate spacer row. The air inlet spacer row is positioned at the air inlet edge, and the intermediate spacer row is positioned between the first arc and the second arc. The filler sheet also includes a microstructure formed on the plurality of corrugations. The microstructure defines a microstructure angle relative to the transverse axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The foregoing summary, as well as the following detailed description of the preferred invention, will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the invention, the drawings show presently preferred embodiments. However, it should be understood that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0013] Figure 1 is a front elevational view of a filling sheet according to a first preferred embodiment of the present invention;

[0014] Figure 1A is along Figure 1 The line 1A-1A is intercepted Figure 1 A cross-sectional view of a filling sheet;

[0015] Figure 2 is a front elevational view of a filling sheet according to a second preferred embodiment of the present invention;

[0016] Figure 2A is along Figure 2 The line 2A-2A is intercepted Figure 2 A cross-sectional view of a filling sheet;

[0017] Figure 3 yes Figure 2 A top plan view of a filling portion or a filling package;

[0018] Figure 3A yes Figure 3 a side elevation view of a filled portion or a filled packaging;

[0019] Figure 3B is from Figure 2 The shape of the adjacent corrugated peak pairs of two filling sheet filling portions or filling material packaging taken in shape 3B is represented by a front elevation view;

[0020] Figure 3C yes Figure 3B A front elevational representation of the shape of a single pair of corrugated peaks of two fill sheet fill sections or a fill package;

[0021] Figure 4 Yes Figure 2 A front elevation view of a filling package of two filling sheets of a second preferred embodiment;

[0022] Figure 4A is along Figure 4 The line 4A intercepts the limit at Figure 4 A cross-sectional view of a first corrugated airflow region between a first filling sheet and a second filling sheet of a filling package;

[0023] Figure 4B is along Figure 4 The line 4B intercepts the limit at Figure 4 A cross-sectional view of a first corrugated airflow region between a first filling sheet and a second filling sheet of a filling package;

[0024] Figure 4C is along Fig. 9 The line 4C intercepts the limit at Figure 4 A cross-sectional view of a first corrugated airflow region between a first filling sheet and a second filling sheet of a filling package;

[0025] Figure 5 is a front perspective view of a two-piece filling package according to a third preferred embodiment of the present invention;

[0026] Figure 5A is along Figure 5 The line 5A-5A is intercepted Figure 5 A cross-sectional view of a filling package;

[0027] Figure 6is a front perspective view of a nine-piece filling package according to a third preferred embodiment of the present invention;

[0028] Figure 7 is based on Figure 5 A front elevational view of a filling package of a filling sheet of a third preferred embodiment;

[0029] Fig. 7A is from Figure 7 The shape of 7A is taken from Figure 7 A front elevation view representation of the orientation of the peaks of the first filling sheet and the second filling sheet of the filling package;

[0030] Figure 7B is from Figure 7 The shape of 7B is intercepted Figure 7 A front elevation view representation of the orientation of the peaks of the first filling sheet and the second filling sheet of the filling package;

[0031] Figure 7C is along Figure 7 The line 7C-7C is intercepted Figure 7 A cross-sectional view of a filling package;

[0032] Fig.7D is along Figure 7 The line 7D-7D intercepts Figure 7 A cross-sectional view of a filling package;

[0033] Fig. 7E yes Figure 7 An enlarged front elevation view of a second flute of a first filling sheet of a filling package;

[0034] Figure 8 yes Figure 5 A portion of a top perspective view of a filling package of a third preferred embodiment of the present invention;

[0035] Fig. 8A is from Figure 8 The shape of 8A is cut inside Figure 8 an enlarged top perspective view of a portion of a filler package;

[0036] Fig. 9 yes Figure 5 A replacement portion of a top perspective view of a refill package of a third preferred embodiment of FIG. 1; and

[0037] Fig.9A is from Fig. 9 The shape of 9A is intercepted Fig. 9 An enlarged top perspective view of a portion of a filler package. DETAILED DESCRIPTION

[0038] In the following description, certain terms are used only for convenience and not for limitation. Unless explicitly stated herein, the terms "a / an" and "the" are not limited to one element, but should be interpreted as meaning "at least one". The words "right", "left", "bottom" and "top" represent directions in the referenced drawings. The words "inwardly" or "proximally" and "outwardly" or "distally" refer to directions toward and away from the geometric center or orientation of the device and instrument and its related parts, respectively. The terms include the words listed above, their derivatives and words with similar meanings.

[0039] It should also be understood that the terms "about", "approximately", "substantially" and the like used herein when referring to dimensions or characteristics of components of the present invention indicate that the dimensions / characteristics described are not strict boundaries or parameters and do not exclude minor variations thereof that are functionally the same or similar, as will be understood by those of ordinary skill in the art. At a minimum, such references including numerical parameters will include variations using mathematical and industrial principles accepted in the art (e.g., rounding, measurement results or other systematic errors, manufacturing tolerances, etc.) that will not cause the least significant digit to change.

[0040] refer to Figure 1 , Figure 1A , Figure 3 and Figure 3A A first preferred embodiment of the present invention is directed to a fill sheet, generally designated 10, comprised of a relatively thin polymeric material for assembly into a fill medium or fill package, generally designated 50', for a cooling tower. Assembly of the first preferred fill sheet 10 into a fill medium or fill package is not shown in the accompanying drawings, but similar to the second preferred fill medium or fill package 50', the first preferred fill sheet 10 is generally assembled into a fill medium or fill package, as will be apparent to one of ordinary skill in the art based on a review of the present disclosure. The fill sheet 10 preferably defines a plurality of flutes or pleats 12 comprising a portion of the macrostructure of the first preferred fill sheet 10, the plurality of flutes or pleats 12 comprising a first sheet flute 12a, a second sheet flute 12b, a third sheet flute 12c, a fourth sheet flute 12d, a fifth sheet flute 12e, and a sixth sheet flute 12f, preferably extending from an exhaust edge 14 to an intake edge 16 of the fill sheet 10. In the first preferred embodiment, the sheet flutes 12 are interrupted by rows of spacers 17 that extend across the filler sheet 10 generally perpendicularly relative to the air flow axis 34 extending between the exhaust and intake edges 14, 16. The rows of spacers 17 provide platforms 19 where adjacent filler sheets 10 meet or are spaced apart from each other in an assembled installed configuration, as will be described in more detail below.

[0041] The sheet flutes 12a, 12b, 12c, 12d, 12e, 12f have substantially the same or similar configuration within the fill medium or fill package and are generally referred to herein as flutes 12. In the first preferred embodiment, there are preferably six (6) sheet flutes 12 per foot on each side of the fill sheet 10, but the fill sheet 10 is not limited thereto. The fill sheet 10 is not limited to including six (6) sheet flutes 12, and may include more or fewer sheet flutes 12 depending on the preferred size and shape of the fill sheet 10, the size of the cooling tower, the designer's preference, and other relevant factors. The first preferred fill sheet 10 and the fill medium or fill package consisting of a plurality of assembled or installed fill sheets 10 are configured and designed for use in a counterflow cooling tower, wherein air flows along the sheet flutes 12 in an airflow direction 30 from the air intake edge 16 toward the exhaust edge 14, and water flows under the action of gravity in a water flow direction 32 from the exhaust edge 14 toward the air intake edge 16. The fill sheet 10 and fill package, including the features thereof described herein, are not limited to use in counterflow cooling towers or in counterflow applications, and may be used in crossflow cooling towers or other related flow applications.

[0042] refer to Figures 2 to 4C In the second preferred embodiment, the fill sheet 10' and associated fill medium or fill package 50' have similar configurations and functions as the first preferred fill sheet 10 and fill package, and the same reference numerals are used to identify the same or similar features, with a prime (') being used to distinguish the second preferred embodiment from the first preferred embodiment. The second preferred fill sheet 10' and fill medium or fill package 50' are designed and configured for use in a counterflow cooling tower, but include an additional row of spacers 17, and are shown without the microstructures 20 thereon, but when compared to the first preferred fill sheet 10, the second preferred fill sheet 10' is similarly designed and constructed, and may include the microstructures 20 thereon, as shown. Figure 2A The fill sheet 10' and fill medium or fill package 50' of the second preferred embodiment, including the features thereof described herein, are not limited to use in counterflow cooling towers, and may be used in crossflow cooling towers or other related flow applications.

[0043] refer to Figures 1 to 4C, the first preferred filling sheet 10 and the second preferred filling sheet 10' are assembled into a filling medium or filling package 50' by positioning the rows of spacers 17, 17' adjacent to each other, such as by hanging the sheets 10, 10' adjacent to each other, gluing the matching rows of spacers 17, 17' together, engaging connectors 18, 18' along the rows of spacers 17, 17' of adjacent filling sheets 10, 10' to secure and lock the adjacent sheets 10, 10' together, or otherwise positioning the filling sheets 10, 10' to define a filling medium or filling package 50'. The filling sheets 10, 10' are not limited to including connectors 18, 18', which are preferably pressed together to attach the filling sheets 10, 10' together, and may include glue bosses, spacers, alignment features, snap-fit ​​connectors, or other spacers or connectors capable of positioning the filling sheets 10, 10' relative to each other to define a filling package 50'. For example, the filler sheets 10, 10' may include blunt spacers (see Figure 2 The blunt spacers are not connected to each other, but space the filling sheets 10, 10' relative to each other or glue them together in the overall configuration of the filling package 50' to define the filling medium or filling package 50'. Figure 3 , Figure 3A and Figures 4 to 4C A preferred filling medium or filling package 50' is disclosed having a first filling sheet 10a' and a second filling sheet 10b'. The filling medium or filling package 50' can be constructed from nearly any number of filling sheets 10, 10' to produce a filling medium or filling package 50' having a variety of sizes.

[0044] The fluting geometry of the fluting 12, 12' comprises a fluting profile having varying heights along a path formed by a series of connected tangent arcs, each of which has a midpoint extending horizontally less than one-half (1 / 2) of the fluting period from the end of the arc. All arc endpoints of the fluting path of the fluting 12, 12' are vertically aligned and provide locations for spacer rows 17, 17', spacers and / or connectors 18, 18' between adjacent filler sheets 10, 10'. When the filling sheets 10, 10' are assembled into a filling medium or a filling package 50', the arcs on each adjacent, upper / lower filling sheet 10, 10' of the filling medium or the filling package 50' are bent in opposite directions from the spacer rows 17, 17' or the connectors 18, 18', thereby forming separations between the peaks 36c, 36c' of the flutes 12, 12' between the spacer rows 17, 17' or the connectors 18, 18', thereby allowing the flute height of the filling sheets 10, 10' to increase toward the center of the arc. For example, the first sheet flutes 12a, 12a' and the second sheet flutes 12b, 12b' of the first filling sheet 10a, 10a' include first peaks 36c, 36c' and second peaks 38c, 38c', which have an increased height along the first peaks 36c, 36c' and the second peaks 38c, 38c' between the spacer rows 17, 17' (see Figure 3B and Figure 3C ).

[0045] The geometry of the assembled preferred sheet flutes 12, 12' described above forms a filling medium or filling package 50' that mixes air between the airflow inlet ends 36a, 36a', the airflow outlet ends 36b, 36b', the flute peaks 36c, 36c', and the opposing valleys 36d, 36d', 36e, 36e' associated with the flute peaks 36c, 36c', within the flute airflow sections 40' defined by each of the sheet flutes 12, 12'. In the first and second preferred embodiments, the airflow inlet ends 36a, 36a' and the airflow outlet ends 36b, 36b' of the flute airflow sections 40' are positioned at the spacer rows 17, 17' and each pair of filling sheets 12, 12' in the filling medium or filling package 50' includes a plurality of flute airflow sections 40' associated with each of the sheet flutes 12, 12'. The configuration of the sheet flutes 12, 12' and their assembly into the fill medium and filler package 50' to define the fluted airflow section 40' mixes the flowing air and cooling fluid, preferably water, by continuously changing the cross-sectional shape within the fluted airflow section 40' and by the water film on the filler sheet 10, 10' interacting with the air as the air flows through the fluted airflow section 40'. In addition, the small alternating horizontal offsets of the arcs of the sheet flutes 12, 12' allow the flute height at the peaks 36c, 36c', 38c, 38c' to increase away from the ends of the arcs near the spacer rows 17, 17' and connectors 18, 18' of the first and second preferred embodiments. The offset of the arcs of the sheet flutes 12, 12' increases the surface area and thermal performance of the filler sheet 10, 10' while still maintaining the nearly vertical geometry of the sheet flutes 12, 12' with minimal contact points, which is ideal for low fouling fill designs. Due to the difference in partial pressure between the air in contact with the fluid surface area and the saturated state, mass transfer occurs within the corrugated airflow portion 40' and the sheet corrugations 12, 12', such as between the first sheet corrugation 12a, 12a' and the second sheet corrugation 12b, 12b' of the fill medium or filler package 50'. Due to the preferred geometry of the sheet corrugations 12, 12', the filler sheets 10, 10' and the filler package 50', as the air flows through the plurality of corrugated airflow portions 40', the less saturated air from the bulk airflow freshens the air in contact with the fluid surface area on the filler sheets 10, 10. Due to the velocity of the gas flowing in the airflow direction 30, 30' (up to 800 feet per minute), the airflow through the sheet corrugations 12, 12' is likely to be turbulent, but stratification of moist air may still exist within the corrugations 12, 12'.

[0046] Based on the distance traveled by the air in the filling medium or filling package 50' and the air flow rate, the air is usually in the filling package 50' between the air inlet edge 16' and the exhaust edge 14' for about one-half second (1 / 2 second). The continuous change in the shape of the cross-section of the preferred corrugated airflow portion 40' of the assembled sheet fluting 12, 12' and the cross-section along the corrugated portion 40' destroys the boundary layer of flowing air or stratification that may exist in the airflow. When the air flows through the continuously changing cross-sectional shape of the corrugated portion 40', the slight change in the directional flow of the air affects the mass transfer by regenerating the boundary layer and improving the mixing with the bulk phase. As the fluid travels downward along the surface of the filling sheet 10, 10' through the continuously changing corrugated airflow portion 40', at least a portion of the air flowing through the corrugated airflow portion 40' passes over the peaks 36c, 36c', 38c, 38c' of the corrugated 12, 12' and enters the adjacent corrugated airflow portion 40'.

[0047] refer to Figure 2 , Figure 3B and Figures 3C to 4C , a simplified representation of the shape and configuration of first peaks 36c' and second peaks 38c' of first sheet flutes 12a' and second sheet flutes 12b' of first and second filler sheets 10a', 10b' in a filler package 50' shows a tangent point where the peaks 36c', 38c' generally overlap one another along the air flow axis 34'. This configuration promotes mixing of the air in the sheet flutes 12' and fluted portions 40' by not only promoting air along a single sheet flute 12' from the air inlet edge 16' to the air outlet edge 14', but also by promoting air to flow over the peaks 36c', 38c' and into adjacent sheet flutes 12' or fluted portions 40', thereby further promoting mixing of air at the surface of the filler sheet 10' within the filler medium or filler package 50'.

[0048] refer to Figures 1 to 4C , the filling sheet 10, 10' also preferably includes microstructures 20, 20' incorporated thereon to primarily disrupt the water film as it flows through the filling package 50', aiding in the distribution of water on the filling sheet 10, 10' within the sheet flutes 12, 12' and the fluted airflow portion 40' and increasing the total surface area exposure of the water film on the microstructures 20, 20' to air flowing through the filling package 50'. Figure 2A , the second preferred embodiment Figures 2 to 4CThe filler sheets 10, 10' and filler medium or filler package 50' do not show microstructures 20, 20' on the surface of the filler sheets 10, 10', but the first preferred filler sheet and the second preferred filler sheet 10, 10' include microstructures 20, 20' and for simplicity, the microstructures 20, 20' are not shown in these views. The most common type of microstructures 20, 20' can be described as bands or small wrinkles cut out of larger cycles of the filler sheets 10, 10' and sheet corrugations 12, 12' (or macrostructures). In the preferred filler medium and filler package 50', the microstructures 20, 20' are preferably composed of arcuate, trapezoidal or sinusoidal bands of microstructures 20, 20', which are formed in directions at angles that are independent of the path or direction of the sheet corrugations 12, 12' of the macrostructure, such as Figure 1 and Figure 1A Typically, the preferred microstructures 20, 20' are designed and configured independently of the macrostructures, corrugations or sheet flutes 12, 12' of the preferred filler sheets 10, 10', because the microstructures 20, 20' of the first and second preferred embodiments have a V-shaped or herringbone shape, which is opposite to the typical microstructures of the prior art, extending at a microstructure angle Δ relative to the sheet flutes 12, 12', which extend generally perpendicular to the flutes of the filler sheet or perpendicular to the airflow axis 34.

[0049] The microstructures 20, 20' of the first and second preferred filler sheets 10, 10' consist of corrugated bands formed into the sheet flutes 12, 12' or filler sheets 10, 10' at a microstructure angle Δ. The microstructure angle Δ is preferably independent of the direction of travel or path of the sheet flutes 12, 12' between the air inlet edge 16, 16' and the air outlet edge 14, 14' to redistribute the water film within and between the sheet flutes 12, 12' by creating water flow in the direction of the microcorrugations of the microstructures 20, 20'. This configuration of microstructures 20, 20' provides benefits over known microstructure orientations because less aggressive (shorter) microstructures are required to distribute water across the preferred filler sheets 10, 10', resulting in lower pressure drop and better fouling resistance. The first preferred microstructure 20 and the second preferred microstructure 20' substantially define a V-shaped or herringbone design between the upper portion 11a, 11a' and the lower portion 11b, 11b' of the filler sheet 10, 10'. In a preferred embodiment, the microstructure angle Δ is approximately thirty degrees (30°), but is not limited thereto and may be larger or smaller, such as between fifteen and forty-five degrees (15°-45°), depending on design preferences, requirements and other factors. Preferably, the microstructure angle Δ is measured between a transverse axis 22, 22' defined on the upper portion 11a, 11a' and the lower portion 11b, 11b' and the longitudinal path of the microstructure 20, 20'. The transverse axis 22, 22' is preferably perpendicular to the airflow axis 34, 34'.

[0050] The first preferred filler sheet 10 and the second preferred filler sheet 10' define a sheet plane 24, 24' that is preferably defined by a platform 19, 19' from which the protrusions 18, 18' may or may not extend generally at the spacer rows 17, 17'. In the first preferred embodiment and the second preferred embodiment, at least a portion of the sheet flutes 12, 12' between adjacent spacer rows 17' extend beyond the sheet plane 24, 24' at a peak 36c, 36c', 38c, 38c' of the sheet flutes 12, 12' away from a center portion of the filler sheet 10, 10' by an offset distance D, D'. The sheet flutes 12, 12' also preferably have a flute cycle C of approximately one and one-half to four inches (11 / 2-4") or three and eight-tenths centimeters to ten centimeters (3.8-10 cm). F , C F ', but these specific corrugated cycles C F , C F The microstructures 20, 20' are not limited thereto and may be otherwise sized and configured. The microstructures 20, 20' preferably have a microstructure height H of approximately four hundredths to one tenth of an inch (0.04-0.1") or one to two and a half millimeters (1-2.5 mm). M , H M ', but is not limited thereto and may be otherwise sized and configured. The filler sheets 10, 10' in the filler package 50' are preferably spaced apart or define a sheet spacing H of approximately three quarters of an inch to one and two tenths of an inch (3 / 4-1.2") or one and nine tenths to three centimeters (1.9-3 cm). S ', but is not limited thereto and may be sized and configured in other ways.

[0051] refer to Figures 5 to 9AIn the third preferred embodiment, the fill sheet 10" and the associated filler package 50' have similar configuration and function as the first preferred fill sheet 10 and the second preferred fill sheet 10' and filler package 50', and the same figure marks are used to identify the same or similar features, wherein a double prime symbol (") is used to distinguish the third preferred embodiment from the first preferred embodiment and the second preferred embodiment. The third preferred fill sheet 10" and the fill medium or filler package 50" are designed and configured for a cross-flow cooling tower, wherein air flows along the sheet corrugations 12" and within the corrugated airflow portion 40" in an airflow direction 30" from the air intake edge 16" toward the exhaust edge 14", and water flows from the top edge 60 of the fill sheet 10" to and out of the bottom edge 62 of the fill sheet 10" in a water flow direction 32" under the action of gravity. The fill sheet 10" and fill medium or fill package 50" of the third preferred embodiment, including the features thereof described herein, are generally not limited to use in crossflow cooling towers or in crossflow applications, and may be used in counterflow cooling towers or other related flow applications.

[0052] refer to Figures 1 to 9AThe filler medium or filler package 50" of the third preferred embodiment is used for insertion into a cooling tower to cool a cooling medium, preferably water, flowing through the filler package 50", wherein the third preferred filler package 50" is designed so that the water flow direction 32" is approximately perpendicular to the air flow direction 30". In contrast, the filler package 50' of the second preferred embodiment is also used for insertion into a cooling tower and is designed so that the water flow direction 32' is approximately parallel to and opposite to the air flow direction 30'. In the first preferred embodiment and the second preferred embodiment, the first filler sheet 10a, 10a' defines a first corrugation 12a, 12a', a second corrugation 12b, 12b', a third corrugation 12c, 12c', a fourth corrugation 12d, 12d', a fifth corrugation 12d', a fifth corrugation 12c', a fifth corrugation 12d ... In the third preferred embodiment, the first filling sheet 10a" defines the first flute 12a", the second flute 12b", the third flute 12c", the fourth flute 12d", the fifth flute 12e", the sixth flute 12f", the seventh flute 12g", the eighth flute 12h", the ninth flute 12i", the tenth flute 12j", the eleventh flute 12k" and the twelfth flute, but the number of sheet flutes 12, 12', 12" of the first preferred embodiment, the second preferred embodiment and the third preferred embodiment is not limited, and depending on the size, configuration, application, designer's preference and related factors, the filling sheets 10, 10', 10" may include various numbers of sheet flutes 12, 12', 12". By continuously changing the cross-sectional shape of the fluted airflow sections 40', 40" along the sheet flutes 12, 12', 12", the air within the fluted airflow sections 40', 40" is continuously mixed, thereby aiding thermal performance.

[0053] Figure 5 , Figure 5A and Figures 7 to 9A The third preferred filling package 50" includes a first filling sheet 10a" and a second filling sheet 10b", but may also include additional filling sheets, such as a third filling sheet 10c", a fourth filling sheet 10d", a fifth filling sheet 10e", a sixth filling sheet 10f", a seventh filling sheet 10g", an eighth filling sheet 10h", and a ninth filling sheet 10i", as shown in FIG. Figure 6 As shown, however, the filler package 50" may include as few as a first filler sheet 10a" and a second filler sheet 10b" and less than or greater than Figure 6The nine filling sheets 10c", 10d", 10e", 10f", 10g"', 10h", 10i". The first filling sheet 10a" defines an air inlet edge 16", an exhaust edge 14", and an air flow axis 34" extending between the air inlet edge 16" and the exhaust edge 14". The first filling sheet 10a" defines a first corrugated section 36", and the first corrugated section 36" has a first inlet end 36a"', a first outlet end 36b" and a first peak 36c" extending between the first inlet end 36a" and the first outlet end 36b". In the third preferred embodiment, the first peak 36c" extends substantially parallel to the air flow axis 34", but is not limited thereto. The first peak 36c" may extend at an angle relative to the air flow axis 34" or in a curved or arched manner.

[0054] The third preferred filling package 50" also includes a second filling sheet 10b", which defines a second corrugated section 38", which has a second inlet end 38a", a second outlet end 38b", and a second peak 38c", extending between the second inlet end 38a", and the second outlet end 38b". The first peak 36c" extends relative to the second peak 38c"', so that the first corrugated airflow portion 40" defined by the first and second corrugated sections 36", 38" has a cross-sectional shape that continuously changes between the first inlet end 36a", and the second inlet end 38a"' and the first outlet end 36b", and the second outlet end 38b". In the third preferred embodiment, the second peak 38c" extends at a certain angle relative to the airflow direction 30" and intersects with the first peak 36c", such as in the first and second corrugated sections 36", 38". Fig. 7AContinuously changing or modifying the cross-sectional shape of the first fluted portion 40" increases boundary mixing between water flowing along the surfaces of the first filling sheet 10a" and the second filling sheet 10b" and air flowing through the first fluted airflow portion 40". The change in cross-sectional shape improves mixing or surface exposure of air as it flows through the first corrugated airflow portion 40". In the third preferred embodiment, the first inlet end 36a" and the second inlet end 38a" and the first outlet end 36b" and the second outlet end 38b" are aligned along the airflow axis 34" and define a first corrugated portion length L1". In the third preferred embodiment, the first corrugated portion length L1" is approximately four to six inches (4-6") or ten to fifteen centimeters (10-15 cm), but is not limited thereto and may be larger or shorter depending on the designer and configuration purposes. The first peak 36c" and the second peak 38c" are not limited to extending approximately linearly within the first corrugated section 36" and the second corrugated section 38" as long as the extension of the first peak 36c" and the second peak 38c" results in a continuous change in the cross-sectional shape of the corrugated portion 40" in the first corrugated section 36" and the second corrugated section 38"' of the filling package 50", between the first filling sheet 10a"' and the second filling sheet 10b".

[0055] In the third preferred embodiment, the second peak 38c" is at a first flute portion angle θ ( Fig. 7A ) extends so that the shape of the cross-section of the first corrugated portion 40" varies between the first inlet end 36a" and the second inlet end 38a" and the first outlet end 36b" and the second outlet end 38b". In a third preferred embodiment, the first corrugated portion angle θ is approximately two to five degrees (2°-5°), but is not limited thereto, and may be larger or smaller or have a different configuration, such as a curved, undulating or other shape that helps modify the cross-section of the first corrugated portion 40". The cross-section preferably changes gradually and consistently between the first inlet end 36a" and the second inlet end 38a" and the first outlet end 36b" and the second outlet end 38b" of the first corrugated portion 40", but is not limited thereto, and may change in various ways, such as inconsistently and at various rates along the airflow direction 30", to facilitate boundary mixing of air and water during operation to improve heat transfer between air and water in the filler package 50".

[0056] refer to Figures 1 to 4CIn the first preferred embodiment and the second preferred embodiment, the first peaks 36c, 36c', the second peaks 38c' and the lower peaks 38c' of the first flutes 12a, 12a' of the first sheet 10a, 10a' extend in an arc between the air inlet edge 16, 16' and the exhaust edge 14, 14'. The arcuate first peaks 36c, 36c', the second peaks 38c' and the lower peaks 38c' similarly result in a continuously varying cross-sectional shape along the length of the first fluted portion 40' between the air inlet edge 16, 16' and the exhaust edge 14, 14' of the preferred embodiment. The continuously varying cross-sectional shape in the fluted portion 40' facilitates enhanced boundary mixing and heat transfer between water and air in the filling medium or filling package 50' of the first preferred embodiment and the second preferred embodiment. The first preferred filling sheet 10 results in a filling medium having two back-to-back fluted portions separated by a row of spacers 17 between the air inlet edge 16 and the exhaust edge 14. Specifically, each of the flutes 12 of the fill sheet 10 in the fill media of the first preferred embodiment defines a fluted portion 40 between the inlet spacer row 17a and the intermediate spacer row 17b, and another fluted portion 40 between the intermediate spacer row 17b and the exhaust spacer row 17c. Similarly, the second preferred fill sheet 10' results in a fill media 50' having four back-to-back fluted portions 40' separated by the spacer row 17' between the inlet edge 16' and the exhaust edge 14'. Specifically, each of the corrugations 12' of the filling sheet 10' in the filling medium 50' of the second preferred embodiment defines a corrugated portion 40' between the air intake spacer row 17a' and the first intermediate spacer row 17b', defines a corrugated portion 40' between the first intermediate spacer row 17b' and the second or central intermediate spacer row 17b', defines a corrugated portion 40' between the second or central intermediate spacer row 17b' and the third intermediate spacer row 17b', and defines a corrugated portion between the third intermediate spacer row 17b' and the exhaust spacer row 17c'. The filling medium 50' of the first preferred embodiment and the second preferred embodiment is not limited to including continuous back-to-back corrugated portions 40' between the air inlet edges 16, 16' and the exhaust edges 14, 14', and may include a few single corrugated portions 40' located almost anywhere on the filling medium 50', a plurality of corrugated portions 40' that do not extend to the air inlet edges 16, 16' and the exhaust edges 14, 14' and are completely between the air inlet edges 16, 16' and the exhaust edges 14, 14', or a filling medium 50' that includes almost complete coverage of the filling medium 50' between the spacer rows 17, 17'.

[0057] refer to Figures 7 to 7B, the second peak 38c" of the second filling sheet 10b" of the third preferred embodiment is positioned at a first side of the first peak 36c" of the first filling sheet 10a" close to the first inlet end 36a" and the second inlet end 38a" and the second peak 38c"' is positioned at a second side of the first peak 36c" close to the first outlet end 36b"' and the second outlet end 38b". Therefore, the second peak 38c" intersects with the first peak 36c" as it extends from the second inlet end 38a" to the second outlet end 38b" of the first corrugated portion 40", to facilitate a continuous change in the cross-sectional shape of the first corrugated portion 40".

[0058] refer to Figures 5 to 9A In the third preferred embodiment, the first fluted section 36" of the first filling sheet 10a" and the second fluted section 38" of the second filling sheet 10b" define a first fluted airflow portion 40" positioned between the first filling sheet 10a" and the second filling sheet 10b" and the exemplary first fluted airflow portion 40" is Figure 5A , Figure 7C and Fig.7D The first flute 12a" of the third preferred embodiment is also associated with a second flute airflow portion 42a" extending from the air inlet edge 16" to the air outlet edge 14", a third flute airflow portion 42b", a fourth flute airflow portion 42c", a fifth flute airflow portion 42d", and a sixth flute airflow portion 42e". The plurality of corrugated portions 40", 42a", 42b", 42c", 42d", 42e" preferably include alternating peaks 36c", 38c", which are substantially parallel to the airflow axis 34" and inclined at a first corrugated portion angle θ relative to the airflow axis 34", such that the cross-section of the corrugated portion 40"' in the identification section between the first filling sheet 10a" and the second filling sheet 10b" continuously changes between the air intake edge 16" and the exhaust edge 14". Based on designer preference or specific preferred functions, these corrugated portions 40" are not limited to six corrugated portions 40", 42a", 42b", 42c", 42d", 42e" having a constant and uniformly varying cross-section and may have portions with no variation in cross-section or that vary in various inconsistent ways.

[0059] refer to Figure 5 , Figure 5A and Figures 7 to 7DThe first corrugated section 36" preferably also includes a first valley 36d" at a first side of the first peak 36c" and a second valley 36e" at a second side of the first peak 36c", or is further defined by the first valley 36d" and the second valley 36e" relative to the airflow direction 30" and the airflow axis 34". Similarly, the second corrugated section 38" preferably also includes a third valley 38d" at a first side of the second peak 38c" and a fourth valley 38e" at a second side of the second peak 38c", or is further defined by the third valley 38d" and the fourth valley 38e" relative to the airflow direction 30" or the airflow axis 34". In a third preferred embodiment, the first and second corrugated sections 36", 38" have a right-angle channel shape, wherein the first peak 36c" and the second peak 38c" are curved or have chamfers. The first corrugated segment 36' and the second corrugated segment 38' are not so limited and may have alternative shapes, such as the curved first corrugated segments 36, 36' and the second corrugated segments 38, 38' of the first preferred embodiment and the second preferred embodiment, which also form an arc or curve in the microstructure height direction of the first preferred filling sheet 10a, 10a' and the second preferred filling sheet 10b, 10b', or may be otherwise designed and configured to continuously change the cross-sectional shape of the multiple corrugations 12, 12' and the corrugated airflow portion 40' as air flows through the filling package 50' during operation to increase boundary mixing of air and water in the filling medium or filling package 50' during operation.

[0060] refer to Figure 3 , Figure 3A and Figure 5 As shown, the second preferred filling medium or filling package 50' and the third preferred filling medium or filling package 50"' and the filling sheet 10', 10" have an air flow length L defined between the air intake edge 16', 16" and the exhaust edge 14', 14". A ', L A In a preferred embodiment, the airflow length L A ', L A " is approximately twenty-four to fifty-six inches (24-56") or sixty-one to one hundred and forty centimeters (61-140cm), but is not limited thereto. Airflow length L A ', L A” can be larger or smaller, depending on the requirements of the cooling tower, the designer's preferences, performance requirements or other design factors. In addition, the fill medium or filler packages 50', 50" can be stacked or adjacent to each other so that the first filler package 50', 50" is positioned with its exhaust edge 14', 14" adjacent to the intake edge 16', 16" of the second filler package 50', 50" so that air flows through the two packages 50', 50" in the air flow direction 30, 30', 30" and water flows through the packages 50', 50" in the water flow direction 32, 32', 32".

[0061] refer to Figures 1 to 4C In operation, the first preferred fill package and the second preferred fill package 50' are preferably inserted into a counterflow cooling tower so that air flows from the air intake edge 16, 16' along the plurality of corrugations 12, 12' to the exhaust edge 14, 14', and water or other cooling fluid flows from the exhaust edge 14, 14' to the air intake edge 16, 16' in the water flow direction 32, 32' under the action of gravity. The curved or arcuate shape of the corrugated airflow portion 40' between the plurality of corrugations 12, 12' and the fill sheets 10, 10' causes the air flowing through the plurality of corrugated airflow portion 40' to change direction and mix along the interface with the fill medium or the water film on the surface of the plurality of fill sheets 10, 10' in the fill package 50'. The mixing of the air flowing through the plurality of fluted airflow sections 40' prevents the water-saturated air from remaining in contact with the water film, so that the dry air is exposed to the water film, rather than remaining in the center of the plurality of fluted airflow sections 40' without being in direct contact with the water film, as might occur in a constant cross-section flute (not shown) of the prior art that does not continuously change from one end to the other. The air flowing through the plurality of fluted airflow sections 40' has a typical flow velocity range of about three hundred to eight hundred feet per minute (300-800 ft / min) or one hundred fifty to four hundred centimeters per second (150-400 cm / sec), an average velocity of about seven hundred feet per minute (700 ft / min) or one hundred forty inches per second (140 in / sec) or three hundred fifty-six centimeters per second (356 cm / sec), so that any given portion of the air remains in the filler package 50' for only a portion of a second. It is preferred that all portions of the airflow be exposed to the water film on the surface of the filling sheet 10, 10' in a relatively rapid manner to maximize heat transfer between the air and the water or cooling medium flowing through the filling package 50'. The varying cross-sectional shapes of the plurality of corrugated airflow portions 40' of the first preferred embodiment and the second preferred embodiment facilitate mixing of the air flowing through the plurality of corrugated airflow portions 40' to maximize the relatively rapid exposure of all air to the surface of the water film.

[0062] refer to Figures 5 to 9A, in operation, the third preferred filler package 50" is preferably inserted into a crossflow cooling tower so that air flows in the air flow direction 30" from the air intake edge 16" along the multiple corrugated airflow sections 40" to the exhaust edge 14" and water flows from the top edge 60 to the bottom edge 62 in the water flow direction 32" under the action of gravity. The third preferred filler package 50" is generally not limited to use in crossflow cooling towers or in crossflow applications, and can be used in counterflow cooling towers or other related flow applications. The displacement of the peaks 36c", 38c" of the corrugated segments 36", 38" that cause the cross-section of the corrugated airflow section 40" to continuously change causes the air flowing through the fill medium or filler package 50" to change direction and mix along the interface with the water film on the surface of the multiple corrugated airflow sections 40". The mixing of air flowing through the plurality of flutes 12" and the flute airflow portion 40" prevents water-saturated air from remaining in contact with the water film, allowing dry air to be exposed to the water film, rather than dry air remaining centrally within the flute airflow portion 40' without direct contact with the water film, as might occur in prior art constant cross-section flutes (not shown).

[0063] In a third preferred embodiment, the peaks 36c", 38c" are alternately oriented at a first corrugation portion angle θ such that they are oriented downwardly toward the air inlet edge 16". This downward orientation of the peaks 36c", 38c" pushes the water or other cooling medium toward the air inlet edge 16" by resisting the force of the airflow that pushes the flowing water or cooling medium toward the exhaust edge 14". Therefore, the orientation of the peaks 36c", 38c" also resists the accumulation or blockage of water or cooling medium at the exhaust edge 14", which may occur in the absence of the described orientation of the peaks 36c", 38c" or other water or cooling medium anti-accumulation features.

[0064] refer to Figure 7, the fourth flute 12d", the eighth flute 12h" and the twelfth flute 12l" of the third preferred filling sheet 10" are composed of graduated flutes 12d", 12h", 12l" that do not include peaks 36c", 38c", and the peaks 36c", 38c" change orientation relative to each other to change the cross-sectional shape of the graduated flutes 12d", 12h", 12l". The graduated flutes 12d", 12h", 12l" are used for graduated filling sheets 10", which are manufactured in a continuous thermoforming process so that the first filling sheet 10a", the second filling sheet 10b", and the additional filling sheets 10c", 10d", 10e", 10f", 10g", 10h", 10i" are properly aligned when assembled into a filling medium or filling package 50", so that the multiple flutes 12" have a consistent and continuously changing cross-sectional shape between the air intake edge 16" and the exhaust edge 14". In general, the filler sheets 10" are preferably assembled by rotating the filler sheets 10" one hundred eighty degrees (180°) relative to each successive filler sheet 10" in the stack of the filler package 50" to arrange the alternatingly oriented peaks 36c", 38c". of adjacent filler sheets 10" in the preferred filler package 50". The filler sheets 10" are not limited to including indexing corrugations 12d", 12h", 12l", but for the reasons described herein, indexing corrugations 12d", 12h", 12l" are preferred. Alternatively, the filler sheets 10" can be designed to have a different configuration for every other filler sheet 10" added to the filler package 50" assembly to facilitate the alternatingly oriented peaks 36c", 38c" of the third preferred embodiment without the indexing corrugations 12d", 12h", 12l". In this alternative configuration, the filler sheets are not rotated, but different filler sheets are alternately stacked to define the fill medium.

[0065] refer to Figures 1 to 9A, a filler sheet 10" of the third preferred embodiment is shown having a relatively flat or planar surface defining a plurality of corrugations 12", but is not limited thereto. The filler sheet 10" may include microstructures, such as the microstructures 20, 20' of the first preferred embodiment or the second preferred embodiment, or other surface features that increase the surface area of ​​the filler sheet 10, 10', 10" to additionally expose a water film or other cooling medium to the airflow. In addition, the filler sheets 10, 10', 10" can be combined with edge features, such as baffles, dewatering devices and other features, which are not shown for clarity but can be attached to the filler sheets 10, 10', 10" and the filler medium or filler package 50', 50" or integrated into the filler sheets 10, 10', 10" and the filler medium or filler package 50', 50" in some embodiments. The filler sheets 10, 10', 10" are also preferably designed for limited pressure drop of airflow while maximizing heat transfer between air flowing through the filler medium or filler package 50', 50" and water or cooling medium flowing through the filler medium or filler package 50', 50". In a third preferred embodiment, the filler sheets 10" in the filler package 50" are spaced apart from one another at a spacing distance S of approximately nineteen millimeters (19 mm) or approximately three-quarters of an inch (3 / 4"), but are not limited thereto and may have a larger or smaller spacing distance S for various applications, functions, and designer preferences.

[0066] refer to Figures 8 to 9A , the third preferred filler package 50" is shown as an assembly of two filler sheets 10", including a first filler sheet 10a" and a second filler sheet 10b", wherein the second filler sheet 10b" is shown as extending a short distance beyond the first filler sheet 10a" to illustrate the orientation of the first peak 36c" and the second peak 38c" relative to each other. The third preferred filler package 50" is preferably not designed so that the second filler sheet 10b" extends beyond the first filler sheet 10a" at the vent edge 14" when adjacent filler sheets 10" preferably terminate in close proximity or proximity to each other in the preferred filler package 50".

[0067] refer to Figures 4 to 4C, the second preferred filler package 50' is configured as a counterflow filler package 50', wherein air flows from the air inlet edge 16' to the exhaust edge 14' in an air flow direction 30' that is approximately parallel to the air flow axis 34' and water flows from the exhaust edge 14' to the air inlet edge 16' in a water flow direction 32' under the action of gravity. The filler sheet 10' of the second preferred filler package 50' may include a connector 18', which is preferably composed of a spacer or platform connector 18 having a substantially planar platform 19', and the connector 18 can extend from the platform 19'. The connector 18' can be bonded, fixed to be glued together or positioned adjacent to each other to define the filler package 50'. The filler sheet 10' of the second preferred embodiment includes an arcuate, wavy or sinusoidal sheet corrugation 12' extending between the air inlet edge 16' and the exhaust edge 14' to guide air through the filler package 50'.

[0068] refer to FIG. 4A to FIG. 4C , a representative cross section of a filled package 50' in three identified areas of a first corrugated section 36' and a second corrugated section 38' or along a corrugated airflow section 40' shows a change in at least a portion of the corrugated airflow section 40' between the first filling sheet 10a' and the second filling sheet 10b' that facilitates mixing between the flowing air and water near the surfaces of the first filling sheet 10a' and the second filling sheet 10b' within the corrugated airflow section 40". The second peak 38c' of the second corrugated section 38' is laterally displaced relative to the first peak 36c' of the first corrugated section 36', thereby causing the air to flow between the first inlet end 36a' and the second inlet end 36a'. The cross-sectional shape and air flow characteristics of the corrugated airflow portion 40' are continuously changed in the airflow direction 30' by flowing between the outlet end 38a' and the first outlet end 36b' and the second outlet end 38b'. Similarly, adjacent corrugated airflow portions 40' in the filling package 50' have a changing cross-sectional shape that promotes the flow of air between adjacent corrugated airflow portions 40' over and under the peaks 36c', 38c' and valleys 36d', 36e', 38d', 38e' of the corrugated segments 36', 38'. Although the changing cross-sectional shape of the corrugated airflow portions 40' in the first corrugated segment 36' and the second corrugated segment 38' is FIG. 4A to FIG. 4C , but preferably, each of the corrugated airflow sections 40' of the first sheet corrugation 12a', the second sheet corrugation 12b', the third sheet corrugation 12c', the fourth sheet corrugation 12d', the fifth sheet corrugation 12e' and the sixth sheet corrugation 12f' of each of the filling sheets 10' in the second preferred filling package 50' has a similarly varying cross-section and configuration.

[0069] refer to Figures 1 to 4CIn the first preferred embodiment and the second preferred embodiment, the filling sheet 12, 12' includes a corrugated section 36, 36' extending between a first inlet end 36a, 36a' and a first outlet end 36b, 36b' and defines a first corrugated airflow portion 40' when assembled into the filling medium 50'. The filling medium 50' includes a plurality of corrugated sections 36, 36' and a corrugated airflow portion 40' defined by the sheet corrugations 12, 12' of adjacent filling sheets 10, 10'. The first corrugated sections 36, 36' preferably define a first corrugated section length L between adjacent spacer rows 17, 17'. F , L F In the first preferred embodiment and the second preferred embodiment, the length L of the first corrugated section is F , L F ' is about four to eight inches (4-8"), but the first corrugated section 36, 36' is not limited thereto and can be longer, such as 8 to 12 inches (8-12") or shorter, such as 1 to 4 inches (1-4"), depending on the design and function of the filling sheet 10, 10'. In the first preferred embodiment and the second preferred embodiment, the corrugated section 36, 36' is defined between the spacer rows 17, 17', such as between the air intake spacer row 17a, 17a' and the middle spacer row 17c, 17c', between the exhaust spacer row 17b, 17b' and the middle spacer row 17c, 17c', or between two adjacent middle spacer rows 17c'. In the first preferred embodiment and the second preferred embodiment, the corrugated section 36, 36' is an arcuate , and in each successive corrugated segment 36, 36' on opposite sides of the spacer rows 17, 17', extend to opposite sides of the airflow axis 34, 34'. For example, in a first preferred embodiment, the corrugated segments 36 in the lower portion 11b extend to a first side of the airflow axis 34, and the corrugated segments 36 in the upper portion 11a are arcuate or extend to a second, opposite side of the airflow axis 34. In a second preferred embodiment, the corrugated segments 36' in the upper portion 11a' and the lower portion 11b' are configured similarly to the first preferred filling sheet 10, but the second preferred filling sheet 10' includes a central intermediate spacer row 17c', wherein adjacent or successive corrugated segments 36' extend to the same side of the airflow axis 34' at opposite sides of the central intermediate spacer row 17c'. Reference Figure 6 The first corrugated section 36" also defines the length L of the first corrugated section. F ”.

[0070] refer to Figures 1 to 4In the first and second preferred embodiments, the sheet flutes 12, 12' of the flute segments 36, 36' have flute peaks 36c, 36c'. The flute peaks 36c, 36c' of the first and second preferred embodiments are arcuate and define flute vectors 13, 13' consisting of lines extending at tangents to the flute peaks 36c, 36c'. The flute vectors 13, 13' in the first and second preferred embodiments vary continuously between the inlet end 36a, 36a' and the outlet end 36b, 36b' of the flute segments 36, 36' or the flute airflow portion 40'. The flute vectors 13, 13' are independent of the microstructure angles Δ, Δ' because the microstructure angles Δ, Δ' are not perpendicular to the direction of extension of the sheet flutes 12, 12' or the flute vectors 13, 13'. In prior art filled sheets, the microstructures are typically positioned perpendicular to the flute vectors of the flutes of the sheet. Additionally, in a preferred embodiment, the microstructure angles Δ, Δ' do not extend parallel to the fluting vectors 13, 13', such that there is always a bow angle defined between the microstructure angles Δ, Δ' and the fluting vectors 13, 13'. Additionally, in the first preferred embodiment and the second preferred embodiment, the first fluting vectors 13, 13' vary continuously between the inlet end 36a, 36a' and the outlet end 36b, 36b', such that the acute angle between the microstructure angles Δ, Δ' and the fluting vectors 13, 13' varies continuously along the fluting segments 36, 36' between the inlet end 36a, 36a' and the outlet end 36b, 36b'. Figures 5 to 9 In the third preferred embodiment, the sheet flutes 12" of the corrugated segment 36" have a corrugation vector 13" extending along or parallel to the corrugation peak 36c". Therefore, the corrugation vector 13" alternately extends approximately parallel to the airflow axis 34" and at a corrugation portion angle θ" relative to the airflow axis 34". Although the third preferred embodiment of the filled sheet 10" does not show microstructures thereon, similar to the first and second preferred embodiments, the microstructure angles of the microstructures positioned on the filled sheet 10" will be independent of the orientation of the corrugation vector 13". The third preferred embodiment of the filled sheet 10" may, for example, include microstructures 20, 20' having a V-shaped or herringbone configuration that are substantially the same as the first and second preferred embodiments, wherein the inflection line at the line is approximately centrally positioned between the spacer rows 17" and extends approximately parallel to the transverse axis 22".

[0071] Those skilled in the art will appreciate that changes may be made to the above 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 specific embodiments disclosed, but is intended to cover modifications within the spirit and scope of the present invention as defined by the present disclosure.

Claims

1. A filling sheet for inserting into a cooling tower to cool a cooling medium flowing out of the sheet, the filling sheet comprising: Intake edge; an exhaust edge positioned opposite the intake edge; a plurality of flutes extending from the air inlet edge toward the air outlet edge, an air flow axis extending through the air inlet edge and the air outlet edge and a transverse axis extending substantially perpendicular to the air flow axis, the filler sheet being oriented such that air flows along the plurality of flutes from the air inlet edge toward the air outlet edge and water flows from the air outlet edge toward the air inlet edge, the plurality of flutes comprising a first flute segment having a first peak, a first inlet end, a first outlet end and defining a first flute vector; as well as a microstructure formed on the plurality of flutes, the microstructure defining a microstructure angle relative to the transverse axis, the microstructure including the first peak between the first inlet end and the first outlet end on the first flute segment, the microstructure acting to redistribute water both within the plurality of flutes and between the plurality of flutes by generating water flow in the direction of microfolds of the microstructure, the microstructure angle being independent of the first flute vector.

2. The filling sheet according to claim 1, further comprising: A platform is defined between the intake edge and the exhaust edge, the platform defining a sheet plane, the platform and the microstructure peak defining an offset distance.

3. The filling sheet according to claim 1, wherein the microstructure angle is fifteen to forty-five degrees.

4. The fill sheet of claim 1, wherein the first flute has an arcuate shape between the first inlet end and the first outlet end.

5. The fill sheet of claim 1, wherein the plurality of flutes have alternating generally linear and angled shapes between the air intake edge and the air exhaust edge.

6. The fill sheet of claim 2, wherein the offset distance is 25 thousandths to one-half inch (0.025-0.5").

7. The filled sheet of claim 1, wherein the microstructures define a microstructure height, the microstructure height being between four hundredths and one tenth of an inch (0.04-0.1").

8. The filling sheet of claim 1, wherein the plurality of flutes include a first sheet flute, a second sheet flute, a third sheet flute, a fourth sheet flute, a fifth sheet flute, and a sixth sheet flute.

9. The filler sheet of claim 1, wherein the air intake edge, the air exhaust edge, the plurality of flutes, and the microstructure are comprised of an integrally formed polymeric material.

10. The fill sheet of claim 1, wherein the plurality of flutes define a flute period, the flute period being between one and one-half inches and four inches (1 1 / 2-4").

11. The filling sheet of claim 2, wherein a connector extends from the platform.

12. The filled sheet of claim 1, wherein the first peak is arcuate, the first fluting vector is tangential to the first peak, the first fluting segment includes a first inlet end and a first outlet end, and the first fluting vector varies between the first inlet end and the first outlet end.

13. The fill sheet of claim 1, wherein the first flute segment comprises a first inlet end, a first outlet end, and a first peak, the first peak extending substantially straight between the first inlet end and the first outlet end, the first flute vector extending parallel to the first peak.

14. A filling sheet for insertion into a cooling tower to cool a cooling medium flowing out of the sheet, the filling sheet comprising: Intake edge; an exhaust edge positioned opposite the intake edge; a plurality of flutes extending from the air inlet edge toward the air outlet edge, an air flow axis extending through the air inlet edge and the air outlet edge and a transverse axis extending substantially perpendicular to the air flow axis, the plurality of flutes comprising a first flute section extending between a first inlet end and a first outlet end, the first flute section comprising a first arc extending at a first side of the air flow axis and a second arc extending at a second, opposite side of the air flow axis; a plurality of spacer rows including a first spacer row and a second spacer row, the first spacer row being positioned closer to the intake edge than the second spacer row; as well as A microstructure is formed on the plurality of flutes, the microstructure defining a microstructure angle relative to the transverse axis.

15. The fill sheet of claim 14, wherein the plurality of spacer rows include a vent spacer row, the vent spacer row being positioned at the vent edge.

16. The fill sheet of claim 14, wherein the plurality of spacer rows define a plurality of platforms and a plurality of connectors.

17. The fill sheet of claim 14, wherein the first spacer row consists of an intake spacer row, and the second spacer row consists of an intermediate spacer row.

18. The fill sheet of claim 14, wherein the first row of spacers consists of an intermediate row of spacers and the second row of spacers consists of an exhaust row of spacers.

19. The filling sheet of claim 14, wherein the first spacer row consists of an intermediate spacer row, and the second spacer row consists of another intermediate spacer row.

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