Corrugated sheet and novel packing

Abstract

The utility model relates to gas -liquid heat and mass transfer equipment technical field especially relates to a corrugated sheet and novel filling, including the air inlet area, mixed air area, heat exchange area and air outlet area that set gradually along the air flow direction, mixed air area is located between the air inlet area and heat exchange area for the even distribution of the air volume that enters, the heat exchange area forms the continuous zigzag corrugation that penetrates the upper and lower ends of sheet, for guiding the spray water to flow from top to bottom, the passage of air outlet area is structured as the circular arc curve structure that arcs upwards along the air outlet direction. This scheme has the advantages of improving the air distribution uniformity, reducing the outlet floating water, avoiding the installation error and optimizing the gas -liquid contact efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of gas-liquid heat and mass transfer equipment, and in particular to a corrugated plate and a novel packing material. Background Technology

[0002] Corrugated packing is widely used in gas-liquid heat and mass transfer equipment such as cooling towers and energy towers due to its advantages such as large specific surface area and high heat exchange efficiency. Traditional corrugated packing is usually composed of multiple parallel stacked corrugated plates. Air passes laterally through the air ducts between the plates, while the spray liquid flows vertically downward along the corrugated grooves to achieve countercurrent heat exchange.

[0003] However, existing technologies have the following significant drawbacks:

[0004] 1. Lateral water migration problem: Traditional corrugated plates use a uniform tooth height design. When air passes through laterally at high speed, the airflow generates shear force on the liquid film inside the corrugated grooves, causing the water to migrate along the air intake direction. This not only creates localized dry areas in the packing, reducing heat exchange efficiency, but also exacerbates the risk of scaling due to uneven liquid film distribution.

[0005] 2. Severe water drift at the outlet: Conventional air outlets use straight channels or simple sloping structures, causing water droplets carried by the air to escape directly at the outlet due to inertia (i.e., "water drift"), increasing water replenishment costs and potentially polluting the surrounding environment. Although adding a water collector can alleviate this, it additionally increases equipment resistance and maintenance costs.

[0006] 3. Homogeneous structure leads to installation errors: Most corrugated plates have symmetrical or nearly symmetrical air inlets and outlets (such as equal width and the same tilt angle). During on-site assembly, the air-liquid flow field distribution is easily disrupted due to incorrect orientation, resulting in performance degradation.

[0007] 4. Insufficient uniformity of air distribution: Traditional corrugated plates lack a dedicated air mixing structure, resulting in uneven airflow distribution before entering the heat exchange area, which affects the overall heat exchange efficiency.

[0008] 5. Limited corrugated structure: Existing corrugated plates typically use a single corrugation height in their heat exchange area, making it impossible to simultaneously optimize the gas-liquid contact area and flow resistance.

[0009] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0010] To address the aforementioned problems, the present invention aims to provide a corrugated plate and a novel packing material, which have the advantages of improving air distribution uniformity, reducing outlet drift, avoiding installation errors, and optimizing gas-liquid contact efficiency.

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] This application provides a corrugated plate, the technical solution of which is as follows: it includes an air inlet zone, an air mixing zone, a heat exchange zone and an air outlet zone arranged sequentially along the air flow direction;

[0013] ●The mixing zone is located between the air intake zone and the heat exchange zone, and is used to evenly distribute the incoming air volume;

[0014] • The heat exchange area has continuous tortuous corrugations running through the upper and lower ends of the plates to guide the spray water to flow from top to bottom;

[0015] ●The air outlet channel in the air outlet area is constructed as an arc-shaped upward curved structure along the air outlet direction.

[0016] Furthermore, this application also proposes that the width of the air outlet zone is greater than the width of the air inlet zone.

[0017] Furthermore, this application also proposes that the angle between the air intake channel and the horizontal line in the air intake zone ranges from 30° to 60°.

[0018] Furthermore, this application also proposes that the corrugations in the heat exchange region have a continuous, tortuous, zigzag structure.

[0019] Furthermore, this application also proposes that high-corrugation and low-corrugation are alternately arranged along the transverse direction within the heat exchange area.

[0020] Furthermore, this application also proposes that the tooth height difference between adjacent high corrugations and low corrugations is at least 1 mm.

[0021] Furthermore, this application also proposes that the corrugated plate has a non-corrugated transition zone at the junction of the air inlet zone, air mixing zone, heat exchange zone and air outlet zone.

[0022] Furthermore, this application also proposes that the mixing zone has continuous and tortuous corrugations that run through the upper and lower ends of the plate, and that the tooth height of the mixing zone corrugations is not higher than that of the high corrugations in the heat exchange zone.

[0023] Furthermore, this application also proposes a novel packing material comprising multiple corrugated plates stacked together, with a transverse air duct and a longitudinal spray liquid flow channel formed between adjacent corrugated plates; the corrugated plates are the aforementioned corrugated plates.

[0024] As can be seen from the above, the corrugated plate and novel packing provided in this application have the advantages of improving air distribution uniformity, reducing outlet drift, avoiding installation errors, and optimizing gas-liquid contact efficiency by setting a mixing zone to evenly distribute air volume, an arc-shaped outlet zone to reduce water drift, an asymmetrical structure to avoid installation errors, and alternating high and low temperature patterns to optimize gas-liquid contact. Attached Figure Description

[0025] Figure 1 This is a front view of a corrugated sheet provided in this application.

[0026] Figure 2 A schematic diagram of the bottom surface of a corrugated sheet provided in this application.

[0027] Figure 3 for Figure 2 Enlarged view of part A. Detailed Implementation

[0028] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0029] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0031] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0032] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0033] In existing technologies, corrugated packing is widely used in gas-liquid heat and mass transfer equipment such as cooling towers and energy towers. This packing forms transverse airflow channels and longitudinal liquid flow channels through multiple parallel stacked corrugated plates. Traditional corrugated packing, due to its uniform tooth height design, causes the liquid film to migrate laterally under the shearing action of airflow, creating localized dry areas and exacerbating the risk of scaling. The outlet uses a straight channel or a simple inclined surface structure, causing water droplets to escape due to inertia, resulting in water drift and requiring an additional water collector. A symmetrical design between the inlet and outlet can easily lead to incorrect installation orientation, disrupting the gas-liquid flow field distribution. To solve these problems, it was first observed that the lateral migration of water flow originates from the uneven shearing action of airflow on the liquid film, necessitating the installation of an air distribution equalization structure after the air inlet to balance the airflow distribution. Secondly, it was found that water drift is directly related to the airflow direction at the outlet, requiring modification of the flow channel morphology to promote water droplet separation. Finally, to address the issue of installation errors, an asymmetrical structural design is needed to prevent incorrect installation. Based on this, it is proposed to add a mixing zone between the air inlet zone and the heat exchange zone to optimize the airflow distribution, adopt a continuous tortuous corrugation to stabilize the water flow path, and achieve gas-liquid separation through an arc-shaped air outlet channel.

[0034] Example 1:

[0035] As shown in Figures 1-3, this embodiment relates to a corrugated plate, comprising an air inlet zone 1, a mixing zone 2, a heat exchange zone 3, and an air outlet zone 4 arranged sequentially along the airflow direction. The mixing zone 2 is located between the air inlet zone 1 and the heat exchange zone 3. The heat exchange zone 3 forms continuous tortuous corrugations 5 running through the upper and lower ends of the plate. The air outlet channel 6 of the air outlet zone 4 is constructed as an upward-curving arc structure along the air outlet direction. The mixing zone 2 refers to the transition area between the air inlet zone 1 and the heat exchange zone 3, which balances the airflow distribution through multi-directional deflection. The continuous tortuous corrugations 5 of the heat exchange zone 3 refer to a zigzag extension structure running through the upper and lower ends of the plate, reducing lateral migration by forming a stable longitudinal liquid flow path. The arc structure of the air outlet zone 4 refers to an upward-curving arc in the channel cross-section, which can be achieved using a gradually changing radius curved surface forming process. By changing the airflow direction, centrifugal force is generated, promoting water droplet separation.

[0036] Specifically, after air enters the air intake zone 1, it is evenly distributed to the heat exchange zone 3 under the multi-directional deflection effect of the mixing zone 2, avoiding shear damage to the liquid film caused by local high-speed airflow. The sprayed water forms a stable liquid film along the continuous tortuous ripples 5 of the heat exchange zone 3.

[0037] The alternating ripples guide the water flow vertically downwards. When air carrying water droplets enters the arc-shaped channel of the air outlet zone 4, the change in flow direction causes the water droplets to adhere to the inner wall of the channel due to centrifugal force. After accumulating, they flow back along the wall to the heat exchange zone 3, thereby reducing water drift. The asymmetrical structural design of the air inlet zone 1 and the air outlet zone 4 achieves error prevention installation through differentiated tilt angles or widths.

[0038] Compared to existing technologies, traditional corrugated plates lack a mixing zone 2, leading to uneven airflow distribution. The uniform-height corrugations cannot suppress lateral liquid film migration, and straight-channel outlets cannot effectively separate water droplets. This solution balances airflow distribution through a mixing zone 2, stabilizes the water flow path with continuous tortuous corrugations 5, and utilizes centrifugal force to achieve gas-liquid separation in an arc-shaped outlet channel 6. Simultaneously, the asymmetrical structure prevents installation errors. Through these technical solutions, this application effectively reduces the formation of dry zones caused by lateral liquid film migration, lowering the risk of heat exchange efficiency degradation. The arc-shaped outlet channel 6 significantly reduces water droplet escape, eliminating the need for a water collector to control water drift.

[0039] Furthermore, the width of the outlet zone 4 is greater than the width of the inlet zone 1. The width of the outlet zone 4 refers to the lateral dimension of the area at the end of the airflow direction. This can be achieved by extending the edges of the outlet zone 4 outwards, making its cross-sectional area larger than that of the inlet zone 1. The width of the inlet zone 1 refers to the lateral dimension of the air inlet end. This can be achieved by adjusting the tilt angle or straight extension length of the edges of the inlet zone 1, creating a narrower inlet structure. This asymmetrical structure created by the width difference provides a clear visual identification benchmark during assembly. Specifically, the width difference between the outlet zone 4 and the inlet zone 1 forms a recognizable shape feature at the edge of the plate. Operators can determine the installation direction by observing the difference in lateral extension length on both sides of the plate. In other words, the asymmetrical structural design of the inlet zone 1 and the outlet zone 4 eliminates the risk of incorrect installation direction and ensures a stable distribution of the gas-liquid flow field. Furthermore, the widened design of the air outlet zone 4 creates an outwardly expanding flow channel cross-section. When air flows through the heat exchange zone 3, the increased cross-sectional area of ​​the air outlet zone 4 reduces the flow velocity, thus weakening the inertial impact force of entrained water droplets. Through this technical solution, this application effectively eliminates the problem of confusing installation direction caused by structural symmetry, avoiding flow field turbulence and decreased heat exchange efficiency caused by reverse installation. The widened structure of the air outlet zone 4 maintains airflow stability while reducing drift water, achieving water conservation and pollution prevention without the need for an additional water collector.

[0040] Furthermore, the angle between the air intake channel 7 and the horizontal line within the air intake zone 1 ranges from 30° to 60°. This angle range refers to the inclination angle of the air intake channel 7 relative to the horizontal reference plane within the air intake zone 1. This can be achieved by molding or bending the corrugated sheet. This angle range is configured to ensure smooth airflow into the mixing zone 2 while creating a physical characteristic that differentiates it from the outlet zone 4. Specifically, the inclination angle of the air intake channel 7 is limited to 30°–60°, resulting in an asymmetrical geometry between the air intake zone 1 and the outlet zone 4. When the installation direction is correct, air enters the mixing zone 2 along the pre-set inclined channel, ensuring uniform airflow distribution.

[0041] like Figure 1 As shown, the corrugations in heat exchange zone 3 exhibit a continuous, zigzag structure. This continuous, zigzag structure refers to a serpentine channel formed by periodically reversing crests and troughs, which can be achieved by stamping alternating inclined corrugated units onto the surface of a metal sheet. This structure generates local turbulence by altering the fluid flow path, thereby weakening the shearing effect of the airflow on the liquid film. Specifically, the continuously zigzag corrugated units form alternating inclined fluid guide surfaces in the vertical direction, causing the sprayed water to flow downwards along a zigzag path under gravity. The inclined surface of each corrugated unit...

[0042] This causes the water flow to deflect, creating a continuous zigzag motion trajectory. This flow pattern generates velocity gradient differences between adjacent corrugated units, inducing eddy disturbances and thus disrupting the laminar boundary layer at the gas-liquid interface. The mirror-symmetric arrangement of the corrugated units further forms staggered fluid barriers, dividing the transverse airflow into multiple branches and reducing the unidirectional impact intensity of the airflow on the liquid film.

[0043] In the specific design, high corrugations 8 and low corrugations 9 are alternately arranged laterally within the heat exchange zone 3. The high corrugations 8 refer to raised structures with relatively high corrugation height, which can be formed on the plate using a stamping process. A height difference exists between the tooth tips of the high corrugations 8 and the adjacent low corrugations 9, with a tooth height difference of at least 1 mm between adjacent high corrugations 8 and low corrugations 9. This feature limits the lateral displacement of the liquid film under airflow shear by blocking the lateral migration path of the sprayed water. The low corrugations 9 refer to raised structures with relatively low corrugation height, which can be achieved by adjusting the depth of the stamping die. A height difference exists between the tooth tips of the low corrugations 9 and the adjacent high corrugations 8, with a tooth height difference of at least 1 mm between adjacent high corrugations 8 and low corrugations 9. This feature reduces the shear force on the liquid film by lowering the local airflow velocity, while maintaining the continuity of the longitudinal water flow channel. Specifically, the alternating arrangement of high corrugations 8 and low corrugations 9 in the heat exchange zone 3 forms an asymmetrical structure. When air flows through this area, the high corrugations 8 obstruct the lateral airflow. During longitudinal flow, the spray water is confined between adjacent high corrugations 8, making lateral movement difficult. Conversely, the low corrugation 9 area allows water to flow longitudinally while the turbulence created by the tooth height difference enhances the renewal of the liquid film surface. The alternating high and low corrugations create a concave-convex structure that causes the water flow to zigzag between longitudinal and lateral directions, extending the liquid film residence time and improving distribution uniformity. This solution alters the airflow distribution pattern through the alternating high and low corrugations, weakening the shear force, and simultaneously restricts the liquid film migration path through the physical barrier formed by the tooth height difference, solving the dry zone and scaling problems caused by lateral water migration in traditional structures. Through the above technical solution, this application effectively suppresses the lateral migration of spray water under the action of airflow, making the liquid film more uniformly distributed on the corrugated surface and reducing the decrease in heat exchange efficiency caused by local dry zones; at the same time, the turbulence effect enhances the liquid film surface renewal capacity, reducing the risk of scaling deposits on the corrugated surface.

[0044] like Figure 1 and 2As shown, non-corrugated transition zones 10 are provided at the junctions of the corrugated plate in the air inlet zone 1, the air mixing zone 2, the heat exchange zone 3, and the air outlet zone 4. The non-corrugated transition zone 10 refers to the straight or bent section of the non-corrugated structure formed at the junction. Specifically, this can be achieved by retaining a straight area during stamping, which eliminates abrupt changes between different corrugated structures. The junction refers to the boundary between the air inlet zone 1 and the air mixing zone 2, between the air mixing zone 2 and the heat exchange zone 3, and between the heat exchange zone 3 and the air outlet zone 4. Specifically, this can be achieved by forming a straight transition section through mold processing, which prevents direct overlap of corrugated structures in adjacent areas. In detail, after setting the non-corrugated transition zone 10 between the air inlet zone 1 and the air mixing zone 2, the airflow, after passing through the inclined channel of the air inlet zone 1, is buffered by the straight section before entering the air mixing zone 2, making the airflow velocity distribution more uniform. Between heat exchange zone 3 and air outlet zone 4, the non-corrugated transition zone 10 blocks the direct connection between the tortuous corrugations and the arc-shaped air outlet channel 6, allowing the airflow to adjust its direction within the straight section before entering the arc-shaped air outlet channel 6. Furthermore, the non-corrugated transition zones 10 at each junction form continuous, straight boundaries on the plate surface, allowing for precise positioning of each zone during stamping using mold positioning lines.

[0045] Precise alignment of the corrugated structure. This application uses a non-corrugated transition zone 10 to create physical isolation, ensuring that the corrugated structures in different areas do not interfere with each other. When the airflow passes through the straight section, the velocity gradient decreases, and the sprayed water re-establishes a stable liquid film within the straight section. At the same time, the straight boundary formed by the non-corrugated transition zone 10 can be quickly identified visually during assembly, avoiding incorrect plate orientation.

[0046] Furthermore, a continuous, tortuous corrugation 11 is formed within the mixing zone 2, penetrating the upper and lower ends of the plate, and the tooth height of the corrugation 11 is not higher than that of the high corrugation 8 in the heat exchange zone 3. The corrugation 11 refers to a corrugated structure located within the mixing zone 2, penetrating the upper and lower surfaces of the plate, and exhibiting a continuous, tortuous shape. Specifically, it can be implemented using a sine wave or sawtooth wave shape, and its continuous tortuous path guides the airflow to change direction multiple times. The tooth height limitation means that the vertical height between the crests and troughs of the corrugation 11 does not exceed the tooth height of the high corrugation 8 in the heat exchange zone 3. This can be achieved by adjusting the depth parameters of the corrugation forming mold. This limitation ensures that the corrugation 11 does not excessively obstruct the airflow into the heat exchange zone 3. In essence, the continuous tortuous structure of the corrugation 11 causes the airflow to undergo multiple turns before entering the heat exchange zone 3, dispersing the airflow impact energy and thus reducing the shearing effect on the liquid film. The tooth height of the corrugations 11 in the mixing zone is controlled to not exceed the level of the high corrugations 8 in the heat exchange zone, to avoid the generation of local vortices due to the sudden reduction of the cross-sectional area of ​​the airflow channel caused by excessively high corrugations. Through the path guidance and tooth height control of the corrugations 11 in the mixing zone, the airflow is more evenly distributed when entering the heat exchange zone 3, reducing the lateral migration of water flow caused by concentrated airflow impact, while maintaining the stability of the liquid film coverage of the corrugations in the heat exchange zone 3.

[0047] Example 2:

[0048] (Illustrated figure) This embodiment relates to a novel packing material, comprising multiple corrugated plates stacked together. The corrugated plates adopt the scheme described in Embodiment 1, with a transverse airflow channel and a longitudinal spray liquid flow channel formed between adjacent corrugated plates. The transverse airflow channel refers to the horizontal airflow path formed between adjacent corrugated plates, specifically achieved by arranging the corrugated structures on the surface of the plates in an alternating pattern, allowing air to flow laterally along the corrugated grooves. The longitudinal spray liquid flow channel refers to the vertical liquid flow path formed between adjacent corrugated plates, specifically guided by the continuous, tortuous corrugated structure on the surface of the plates, guiding the liquid to flow downwards. After the multiple corrugated plates are stacked, the transverse airflow channel allows air to flow horizontally, while the longitudinal spray liquid flow channel guides the spray liquid to flow vertically downwards, forming a counter-current gas-liquid contact.

[0049] Through the above technical solutions, this application effectively prevents the formation of dry areas caused by the lateral migration of water flow and reduces the risk of scaling; the arc-shaped air outlet structure reduces water drift and avoids the need for additional water collectors; the asymmetrical structure eliminates incorrect installation direction and ensures stable gas-liquid flow field; alternating corrugations and continuous tortuous paths enhance the uniformity of liquid film distribution and improve heat exchange efficiency.

[0050] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0051] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A corrugated sheet, characterized in that: It includes an air inlet zone (1), an air mixing zone (2), a heat exchange zone (3), and an air outlet zone (4) arranged sequentially along the air flow direction; - The mixing zone (2) is located between the air inlet zone (1) and the heat exchange zone (3) and is used to evenly distribute the incoming air volume; - The heat exchange area (3) is formed with continuous tortuous corrugations (5) that run through the upper and lower ends of the plate, which are used to guide the spray water to flow from top to bottom; - The air outlet channel (6) of the air outlet area (4) is constructed as an arc-shaped upward curved structure along the air outlet direction.

2. The corrugated sheet as described in claim 1, characterized in that: The width of the air outlet area (4) is greater than the width of the air inlet area (1).

3. The corrugated sheet as described in claim 1 or 2, characterized in that: The angle between the air intake channel (7) in the air intake zone (1) and the horizontal line is 30°–60°.

4. The corrugated sheet as described in claim 1, characterized in that: The corrugations in the heat exchange area (3) have a continuous, tortuous, zigzag structure.

5. The corrugated sheet as described in claim 1, characterized in that: The heat exchange zone (3) is alternately provided with high corrugations (8) and low corrugations (9) along the transverse direction.

6. The corrugated sheet as described in claim 5, characterized in that: The tooth height difference between adjacent high corrugations (8) and low corrugations (9) is at least 1 mm.

7. The corrugated sheet as described in claim 1, characterized in that: The corrugated plate has a non-corrugated transition zone (10) at the junction of the air inlet zone (1), the air mixing zone (2), the heat exchange zone (3) and the air outlet zone (4).

8. The corrugated sheet as described in claim 5 or 7, characterized in that: The mixing zone (2) has a continuous and tortuous mixing zone corrugation (11) that runs through the upper and lower ends of the plate, and the tooth height of the mixing zone corrugation (11) is not higher than the high corrugation (8) in the heat exchange zone (3).

9. A novel packing material, characterized in that: It includes multiple corrugated plates stacked together, with a transverse air duct and a longitudinal spray liquid flow channel formed between two adjacent corrugated plates; The corrugated sheet is the corrugated sheet according to any one of claims 1 to 8.

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