Liquid collector

Abstract

In one aspect, the liquid collector has a forward lower edge, a connecting wall extending downward from the forward edge, a first layback wall connected to the connecting wall and extending upward and rearward from the connecting wall, and an intermediate upper edge of the layback wall rearward and above the forward lower edge. The liquid collector further includes an air diverter wall extending rearward from the first layback wall below the intermediate upper edge, a second layback wall extending above and rearward from the air diverter wall, and a rear upper edge of the second layback wall rearward of the intermediate upper edge and above the forward lower edge.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS)

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 414,236, filed October 7, 2022, the entire contents of which are incorporated herein by reference.

[0002]

[0002] This disclosure relates to heat exchangers that use liquids, and more particularly to heat exchangers that distribute the liquid to a heat exchange medium and have a liquid collector that collects the liquid after it contacts the heat exchange medium. [Background technology]

[0003]

[0003] Some heat exchange systems include a heat exchanger, such as an indirect or direct heat exchanger, a coil-type or plate-type heat exchanger, with a heat exchange medium such as a filter, a fan that generates air movement across the heat exchange medium, and a system that distributes a liquid (e.g., water) across the heat exchange medium. The indirect heat exchanger, such as a coil-type, plate-type or pillow-type heat exchanger, contains a first fluid (e.g., working fluid) therein, and a second fluid (e.g., air) flows across the outer surface of the indirect heat exchanger, absorbing heat indirectly through the walls of the indirect heat exchanger.

[0004]

[0004] Cooling towers are an example of heat exchange systems, including parallel-flow, cross-flow, and counter-flow configurations. A counter-flow cooling tower with an indirect heat exchanger directs airflow in a first direction (e.g., generally upward) through the indirect heat exchanger via a cooling tower fan and has a liquid distribution system that distributes a liquid (e.g., water) to the indirect heat exchanger in an opposite second direction (e.g., generally downward). The water may contain, for example, one or more chemicals to inhibit microbial growth and / or one or more chemicals (e.g., glycol) to inhibit freezing.

[0005]

[0005] Some counterflow cooling towers have water collectors that collect the water falling from the indirect heat exchanger and direct the collected water to the cooling tower sump. The water collectors are spaced apart to form openings between them that allow air to move around the water collectors and come into contact with the indirect heat exchanger. Summary of the Invention

[0006]

[0006] In one aspect of the present disclosure, a liquid collector is provided for collecting falling liquid while allowing air to flow around it. The liquid collector includes a forward lower edge, a connecting wall extending downward from the forward edge, and a first layback wall connected to the connecting wall and extending upward and rearward away from the connecting wall. The first layback wall has a first inclined surface that receives liquid and directs the liquid toward the connecting wall. The liquid collector further includes an intermediate upper edge of the layback wall rearward and above the forward lower edge, an air diverter wall extending rearward from the first layback wall below the intermediate upper edge, and a second layback wall extending above and rearward of the air diverter wall. The second layback wall has a second inclined surface that receives liquid and directs the liquid toward the air diverter wall. The liquid collector also has a rear upper edge of a second layback wall that is rearward of the intermediate upper edge and above the front lower edge. The first and second layback walls direct airflow along the front and rear sides of the liquid collector while limiting deflections of the airflow, thereby reducing air pressure drop across the liquid collector and improving the efficiency of the heat exchange device using the liquid collector.

[0007]

[0007] The present disclosure also provides a heat exchange apparatus including a heat exchanger, a liquid distribution system configured to distribute liquid to the heat exchanger, and a pair of spaced-apart rails. The heat exchange apparatus further includes a plurality of liquid collectors for collecting at least a portion of the liquid distributed to the heat exchanger, and a liquid collector mount configured to facilitate arranging the liquid collectors side by side along the rails. The liquid collector mount has a coupling configured to engage with the liquid collectors arranged along the rails and prevent their movement. In this manner, the liquid collectors can be easily installed in the heat exchange apparatus by arranging the liquid collectors side by side along the rails and engaging the coupling of the mount. Similarly, the liquid collectors can be easily removed for cleaning or replacement by disengaging the coupling of the mount and moving the liquid collectors away from each other along the rails.

[0008] In another aspect of the present disclosure, a method for assembling a liquid collector array, such as a liquid collector array in a cooling tower, is provided. The method includes placing a mount for a first liquid collector on a rail of the liquid collector array and moving the first liquid collector along the rail to a first installation position. The first liquid collector is tilted while in the first installation position to cause liquid in at least one groove of the first liquid collector to drain from the first liquid collector. The method further includes placing a mount for a second liquid collector on the rail of the liquid collector array and moving the second liquid collector along the rail to a second installation position adjacent to the first liquid collector. The second liquid collector is tilted while in the second installation position to cause liquid in at least one groove of the second liquid collector to drain from the second liquid collector. This method thereby provides an intuitive and straightforward approach to assembling a liquid collector array and may be performed without removing the rail from a supporting structure, such as an internal frame of a cooling tower.

[0009] The present disclosure also provides a heat exchange device including a housing having a first outer wall and a second outer wall opposite the first outer wall, a heat exchanger within the housing, a fan operable to generate airflow relative to the heat exchanger, and a liquid distribution system that distributes liquid to the heat exchanger. The heat exchange device further includes a first liquid collector array including a plurality of first liquid collectors having grooves for collecting liquid falling from the heat exchanger and first gaps between the first liquid collectors that allow air movement between the first liquid collectors. The first liquid collectors of the first liquid collector array are configured to direct air from the first gaps away from the first wall in a first direction toward the heat exchanger. The heat exchange device further includes a second liquid collector array including a plurality of second liquid collectors having grooves for collecting liquid falling from the heat exchanger and gaps between the second liquid collectors that allow air movement between the second liquid collectors. The second liquid collectors of the second liquid collector array are configured to direct air from the second gap in a second direction intersecting the first direction, away from the second outer wall and toward the heat exchanger. The first and second liquid collector arrays increase the efficiency of heat transfer from the heat exchanger by directing air in a direction away from the first and second outer walls of the housing and toward the heat exchanger.

[0010]

[0010] In yet another aspect of the present disclosure, there is provided a heat exchange apparatus including a housing, a heat exchanger within the housing, a fan operable to contact air with the heat exchanger, and a sump for liquid within the housing. The heat exchange apparatus further includes a liquid distribution system operable to direct liquid from the sump to the heat exchanger, and a liquid distribution system pump within the housing. Because the pump is within the housing, it is protected from weather, improving durability and allowing a technician to service the pump even when it is raining outside the housing. Furthermore, because the pump is within the housing, it fits within the footprint of the heat exchange apparatus, providing a more compact shape for the heat exchange apparatus during transportation and / or installation. [Brief explanation of the drawings]

[0011] [Figure 1]

[0011] FIG. 1 is a perspective view of a heat exchanger apparatus including an upper heat exchanger subassembly and a lower liquid collector and fan subassembly. [Figure 2]

[0012] 2 is a cross-sectional view taken along line 2-2 of FIG. 1, showing the liquid distribution system, indirect heat exchanger, liquid collector assembly, and sump of the heat exchange apparatus of FIG. 1. [Figure 3]

[0013] FIG. 2 is a perspective view of the liquid collector-fan subassembly of FIG. 1 showing first and second liquid collector arrays directing collected liquid into channels in the liquid collector-fan subassembly below. [Figure 4]

[0014] FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3, showing liquid flowing along one of the liquid collectors into a groove, down through the gap between the inner and outer walls, and into the sump. [Figure 5]

[0015] 3 is an elevational view of the nested liquid collectors of the liquid collection assembly of FIG. 2, showing the primary grooves above and secondary grooves below each liquid collector. [Figure 6]

[0016] FIG. 6 is an elevation view of one of the liquid collectors of FIG. 5 showing a drip edge at the lower end of the upper primary groove and a recess upstream of the drip edge that forms an air buffer to direct air flow around the drip edge. [Figure 7]

[0017] 6 is an image of a finite element analysis performed on the liquid collector of FIG. 5, showing the path of air flow through the liquid collector. [Figure 8]

[0018] 8 is an image of a finite element analysis performed on a prior art liquid collector showing that the air exits the prior art liquid collector at a much greater angle to vertical than the airflow exiting the liquid collector of FIG. [Figure 9-10]

[0019] 9 is a table comparing the airflow characteristics and liquid collector shapes of FIGS. 7 and 8. FIG. [Figure 11]

[0020] FIG. 3 is a schematic diagram of the cooling tower of FIG. 2 showing first and second liquid collector arrays directing airflow away from the sidewall of the heat exchange subassembly. [Figure 12]

[0021] FIG. 4 is a perspective view of a portion of the liquid collector-fan subassembly of FIG. 3 with one of the liquid collector arrays removed to show a removable panel on the interior wall that directs liquid into the sump. [Figure 13]

[0022] FIG. 13 is a view similar to FIG. 12 with the fan and both liquid collector arrays removed to show the sump, the internal pump compartment, and the pump that pumps collected liquid from the sump to the liquid distribution system. [Figure 14]

[0023] FIG. 4 is a top view of the lower portion of the liquid collector-fan subassembly of FIG. 3 with the liquid collector array removed to show the fan area, the passageway, and the sump area on the opposite side of the passageway from the fan area. [Figure 15]

[0024] FIG. 1 is a perspective view of a liquid collector assembly including a liquid collector, a closed end cap, and an open end cap. [Figure 16]

[0025] FIG. 16 is a cross-sectional view of the liquid collector assembly of FIG. 15 taken along line 16-16 with the closed end cap removed to show the cross-sectional profile of the liquid collector. [Figure 17-23]

[0026] 16A and 16B are perspective views of a process for installing the liquid collector assembly of FIG. 15 into a liquid collector array. [Figure 24]

[0027] FIG. 10 is a perspective view of another lower liquid collector and fan subassembly. [Figure 25]

[0028] FIG. 25 is a cross-sectional view taken along line 25-25 of FIG. 24, showing the liquid collector array above the sump of the lower liquid collector-fan subassembly. [Figure 26]

[0029] 26 is a cross-sectional view taken along line 26-26 of FIG. 24, showing the sidewall of the drain that directs collected liquid from the grooves of the lower liquid collector-fan subassembly to the sump. [Figure 27]

[0030] 27 is a cross-sectional view of a portion of the lower liquid collector-fan subassembly taken along line 27-27 of FIG. 24, showing an end trough that collects liquid not collected by an adjacent liquid collector assembly. [Figure 28]

[0031] FIG. 28 is a cross-sectional view of a portion of the lower liquid collector-fan subassembly taken along line 28-28 of FIG. 24, showing an intermediate deflector that deflects liquid to either liquid collector array. [Figure 29A]

[0032] 25 is a perspective view of one of the liquid collector arrays of FIG. 24, showing longitudinally spaced rails that support opposite ends of the liquid collector assemblies of the liquid collector array. [Figure 29B]

[0033] FIG. 29B is a cross-sectional view taken along line 29B-29B of FIG. 29A, showing the end caps of adjacent liquid collector assemblies stacked on top of each other and supported by rails, with the central portions of the liquid collector assemblies omitted for clarity. [Figure 30]

[0034] 29A is a perspective view similar to FIG. 29A, but with all but one of the liquid collector assemblies removed, showing an opening in one of the rails that facilitates continuous advancement of the liquid collector assembly into position between the rails. [Figure 31]

[0035] FIG. 29B is a perspective view of the liquid collector assembly of FIG. 29A, showing the open end cap of the liquid collector assembly, which allows liquid collected in the primary and secondary grooves of the liquid collector assembly to exit the liquid collector assembly and be collected in the grooves of the liquid collector and fan assembly below. [Figure 32]

[0036] FIG. 32 is a side view of the open end cap of FIG. 31 , showing a central opening in the open cap for receiving the body of the liquid collector assembly and a notch in the open end cap that engages with the edge of the body of the liquid collector assembly to secure the body to the central opening. DETAILED DESCRIPTION OF THE INVENTION

[0012]

[0037] Referring to FIG. 1 , a heat exchange apparatus, such as a cooling tower 10, is provided that receives heated working fluid at an inlet 11 and supplies cooled working fluid at an outlet 14. The cooling tower 10 includes an upper heat exchange subassembly 16 and a lower liquid collector and fan subassembly 18. The heat exchange subassembly 16 has an air outlet 20 that allows air that has contacted an indirect heat exchanger 22 to exit the cooling tower 10, as shown in FIG. 2 . The liquid collector and fan subassembly 18 has an air inlet 24, such as one or more air inlets, and an airflow generator, such as one or more fans 26, that draw air into the cooling tower 10. The fan 26 includes an electric motor that rotates a fan member having blades to move air from the air inlet 24 to the air outlet 20.

[0013]

[0038] Referring to FIG. 2 , cooling tower 10 includes a liquid distribution system 30 having a pump 32 for pumping collected liquid from a sump 34 of cooling tower 10 through pipes 35 and into a distribution header 36 of liquid distribution system 30. Distribution header 36 has one or more outlets, such as spray nozzles 38 or orifices, for distributing liquid droplets to indirect heat exchanger 22. In one embodiment, indirect heat exchanger 22 includes a coil 40 having an inlet header 42 that receives working fluid from inlet 12, an outlet header 44 that directs the collected working fluid to outlet 14, and a serpentine tube 46 connecting inlet header 42 and outlet header 44. Serpentine tube 46 includes a flow path 48 and a return end 50 connecting the flow paths. Liquid from spray nozzles 38 travels generally downward in direction 52 across serpentine tube 46 and enters a liquid collector device 54. Liquid collector device 54 collects the liquid and recirculates it away from fan 26 for redirection to distribution header 36. The liquid collector device 54 includes a first liquid collector array 56 and a second liquid collector array 58 that capture falling liquid.

[0014]

[0039] The liquid distributed to the indirect heat exchanger 22 evaporates as it moves over the coils 40, absorbing heat from the indirect heat exchanger 22. The air flowing over the coils 40 and the liquid moving across the coils 40 remove heat from the working fluid passing inside the indirect heat exchanger 22. The cooling tower 10 may operate in a dry mode or a wet mode. In a dry mode, the pump 32 does not pump liquid to the distribution header 36, and heat is removed from the working fluid by the movement of air over the coils 40. In a wet mode, the pump 32 pumps liquid to the distribution header 36, and heat is removed from the working fluid as described above. In some embodiments, the cooling tower 10 may operate in a wet-only mode, in which the fan 26 is not operated and the pump 32 operates such that heat is primarily removed from the working fluid in the coils 40 by the liquid moving over the coils 40.

[0015]

[0040] Referring to FIG. 3, the liquid collector and fan subassembly 18 is shown with the heat exchange subassembly 16 removed, revealing the first and second liquid collector arrays 56, 58. A portion of the exterior wall 62 of the housing 64 of the cooling tower 10 has also been removed, revealing the grooves 60 of the liquid collector and fan subassembly 18. The first and second liquid collector arrays 56, 58 are angled to direct collected liquid into the grooves 60 near the exterior wall 62 of the housing 64. The first and second liquid collector arrays 56, 58 are generally mirror images of each other about the center of the cooling tower 10, and each of the first and second liquid collector arrays 56, 58 directs airflow toward the airflow exiting the other of the first and second liquid collector arrays 56, 58.

[0016]

[0041] Referring to FIG. 4, each of the first and second liquid collector arrays 56, 58 includes two or more liquid collectors, such as a liquid collector assembly 70. The liquid collectors discussed herein may be, for example, a single member or a collection of components. Each liquid collector assembly 70 includes a liquid collector body 72 and mounts, such as a closed end cap 74 and an open end cap 76, at opposite ends of the liquid collector body 72. Referring to FIG. 5, each liquid collector body 72 includes a first collection channel, such as a primary groove 150, and a secondary collection channel, such as a secondary groove 152, for receiving liquid 154 falling downward from the coil 40. Additionally, the liquid collectors 72 are laterally spaced apart from one another to form openings 153 that allow air 210 to move upward through the first and second liquid collector arrays 56, 58.

[0017]

[0042] Returning to FIG. 4 , each liquid collector body 72 has a raised portion 80 and a lowered portion 82 so that liquid falling from the coil 40 is collected in the liquid collector body 72 and travels in direction 86 into the groove 60. The groove 60 has an outlet 90 that introduces liquid into a gap 92 between the outer wall 62 and an inner wall 96. The inner wall 96 has an upper end 100 in the groove 60 and a lower end 102 below an upper portion 104 of the sump 34. The sump 34 has an inner wall 106 and a bottom wall 108. The lower end 102 of the inner wall 96 has a lowermost end 110 separated by a gap 112 from the bottom wall 108 of the sump 34. Liquid travels from the liquid collector body 72 in direction 114, through the groove 60, and into the gap 92. The liquid travels downward 120 along the gap 92 under the influence of gravity, and then travels in direction 122 through the gap 112 into the sump 34. As the collected liquid enters the sump 34 at the lower end 130 of the sump 34 , the collected liquid creates turbulence within the sump 34 , limiting the settling of particles within the sump 34 .

[0018]

[0043] 1, 3, and 4, the liquid collector and fan subassembly 18 has doors 140, 142 and a walkway 144 extending therebetween. The walkway 144 allows maintenance personnel to walk through a maintenance area 146 (see FIG. 14) between the fan 26 and the sump 34 to perform maintenance and / or cleaning of the fan 26 and the sump 34. A maintenance personnel may easily clean the sump 34 when the pump 32 is off by opening a drain 151 (see FIG. 14), draining the sump 34, and scrubbing or otherwise cleaning the interior surface of the sump 34. Furthermore, because the sump 34 is entirely on one side of the walkway 14 opposite the fan 26, the sump 34 is in an easily accessible area inside the cooling tower 10, rather than being spread out underneath the fan as in some conventional cooling towers where the sump extends across the entire footprint of the cooling tower.

[0019]

[0044] 5, the liquid collectors 72 of the first liquid collector array 58 include liquid collectors 72A, 72B, 72C, and 72D. The liquid collectors 72 are elongated and have a uniform cross-section perpendicular to their length throughout the liquid collector body 72. The liquid collectors 72 may be manufactured, for example, by extruding metal, plastic, and / or composite materials into the desired cross-section. The length of the liquid collectors 72 may be selected to suit a particular embodiment, such as from 3 feet to 24 feet.

[0020]

[0045] 5 have a similar configuration, and liquid collector bodies 72A and 72B will be described. Liquid collector body 72B includes primary grooves 150 and secondary grooves 152. The liquid collector bodies 72 are nested such that the primary grooves 150 of one liquid collector body 72A overlap the secondary grooves 152 of the adjacent liquid collector body 72B in a first direction 115 (e.g., vertically). Liquid collector body 72A is spaced from liquid collector body 72B in a second direction 117 (e.g., horizontally) to form openings 153 between the liquid collectors 72 through which air 210 can move.

[0021]

[0046] The primary grooves 150 of each liquid collector body 72 capture a majority of the liquid 154 collected by each liquid collector body 72, for example, approximately 60% of the liquid 154. The remaining liquid 154 falls into the gap 157 between the liquid collectors 72A and 72B and lands on a liquid impact surface 160. The liquid impact surface 160 has an upper surface portion 161 that extends at an angle 163 (see FIG. 6) of approximately 19 degrees to approximately 22 degrees, for example, approximately 21 degrees, from the vertical. The inclination of the angle 163 of the liquid impact surface upper portion 161 reduces splashing from the liquid impact surface 160. Furthermore, the inclination of the liquid impact surface portion 161, the vertical turn portion 240 (see FIG. 6) of the liquid collector body 72B, and the vertical turn portion 242 of the adjacent liquid collector body 72A direct airflow from the gap 157 in a substantially vertically upward direction.

[0022]

[0047] 5, substantially all of the liquid entering secondary groove 152 does so by smoothly flowing down the liquid impingement surface. During operation of cooling tower 10, some liquid will inevitably accumulate on surface 167. The liquid travels downward along surface 167 until it reaches a drip-off, such as drip edge 200 of liquid collector body 72B. The liquid then falls from drip edge 200 into secondary groove 152.

[0023]

[0048] The liquid collector body 72B has a lip 164 to retain liquid in the secondary groove 152. Liquid that travels over the lip 164 may be captured in the tertiary groove 166, and liquid that travels down the opposite side of the liquid collector body 72B may be collected in the tertiary groove 170. Although the amount of liquid that reaches the tertiary grooves 166, 170 may be very small, such as a few drops over the course of a day's operation, in some embodiments it may be beneficial to utilize the tertiary grooves 166, 170 to further inhibit liquid from falling through the liquid collector assembly 54.

[0024]

[0049] 5, the liquid collector body 72B includes an air diverter 168 and a primary channel wall 180 that rises from the air diverter 168 and has a surface portion 180A that receives the falling liquid. The liquid collector body 72B has a secondary channel wall 182 that rises from the air diverter 168 on the opposite side of the primary channel 150, and a lower secondary channel wall 184 that extends downward from the air diverter 168. The lower secondary channel wall 184 includes a lower surface portion 184A of the impact surface 160. The angle between the liquid impact surface lower portion 184A and the liquid impact surface upper portion 161 is less than 180 degrees.

[0025]

[0050] 6, the liquid collector body 72A has a front lower edge 169, a connecting wall 171, and a first layback wall 173 extending above and rearward from the connecting wall 173. The liquid collector body 72A further includes an intermediate edge 175 of the first layback wall 173, an air diverter wall 177, a second layback wall 181 extending above and rearward from the air diverter wall 177, and a rear upper edge 179 of the second layback wall 181.

[0026]

[0051] Continuing to refer to Figure 6, air diverter 168 includes a lower straight wall portion 190, an upper straight wall portion 192, and a junction 195 therebetween. The angles and dimensions shown in Figure 6 are exemplary for the embodiment of Figure 6 and may be ± about 5 degrees for angles and ± about 0.1 inches for dimensions. For example, lower straight wall portion 190 may form an angle 193A from vertical that ranges from about 100 degrees to about 110 degrees, e.g., about 105 degrees.

[0027]

[0052] The lower straight wall 190 of the air diverter 168 redirects airflow along the lower secondary channel wall 184 of the liquid collector body 72B toward the upper secondary channel wall 182 of the adjacent liquid collector body 72C. The air diverter 168 further includes an air pocket forming portion, such as a curved portion 194 having a recess 196 immediately upstream of the drip edge 200, that is exposed to the air flow path 210 between the liquid collectors 72.

[0028]

[0053] 6 and 7, the recess 196 on the lower side of the air diverter 168 creates a low-velocity portion 202 of air flow between the liquid collectors 72, which acts as an air buffer upstream of the drip edge 200. An air flow path 210 passes through a lower opening 212 between the liquid collectors 72B, 72C and exits through an upper exit opening 214 between the liquid collectors 72B, 72C. The air flow path 210 has a high-velocity zone 216 created by the inflow of air into the lower opening 212 and the redirection of the air by the air diverter 168. The air buffer 202 directs the high-velocity zone 216 away from the drip edge 200. Liquid dripping from the drip edge 200 may then generally be forced by the high-velocity zone 216 toward the liquid impact surface 160 of the liquid collector body 72B. This inhibits liquid from flowing over the upper edge 220 of the lip 164 and keeps liquid moving along the surface 167 of the primary groove wall 180 into the secondary groove 152 .

[0029]

[0054] The straight wall 190 and recess 196 of the air diverter 168 provide additional benefits. For example, the straight wall 190 and recess 196 redirect the air flow path 210 before the air reaches the drip edge 200, reducing the air-side pressure drop, improving air flow, and limiting liquid waves on the liquid impingement surface 160 caused by air moving across the liquid impingement surface 160.

[0030]

[0055] 5 and 6, the upper secondary channel walls 182 and primary channel walls 180 include substantially vertical turns 240, 242 to promote airflow upward toward the indirect heat exchanger 22. With reference to FIG. 7, the liquid collector 72 discharges air in a direction 251 at an angle 253 relative to the vertical. The angle 253 ranges from about 5 degrees to about 15 degrees, e.g., about 8 degrees (see row 276 of the table in FIG. 9). Directing the airflow exiting the liquid collector 72 substantially vertically reduces the air pressure drop across the liquid collector 72 and improves airflow. Additionally, directing the airflow exiting the liquid collector 72 substantially vertically also uniforms the airflow through the indirect heat exchanger 22, improving the thermal performance of the indirect heat exchanger 22.

[0031]

[0056] Referring to FIG. 8, a finite element analysis of a prior art liquid collector is shown. The prior art liquid collector includes a liquid collector 250 with a primary collection channel 252 and a secondary collection channel 254. The primary collection channel 252 includes a turning wall 256 that imparts a large change of direction to air 258 entering an opening 260 between the liquid collectors 250. The liquid collector 250 includes a liquid impingement wall 262 that not only introduces liquid into the primary collection channel 252 but also turns the air flow 258 outward from an outlet 264 between the liquid collectors 250 at an angle 266 that may be approximately 56 degrees (see row 274 in FIG. 9). With reference to FIGS. 9 and 10, tables 270 and 272 are shown comparing the values ​​of the reference air collector in row 274, which corresponds to the air collector 250 shown in FIG. 8, with the prototype in row 276, which corresponds to the liquid collector body 72 shown in FIG. 5.

[0032]

[0057] 2 and 11 , the first and second liquid collector arrays 56, 58 direct airflow in intersecting directions 300, 302 toward the coils 40 and out the openings between the liquid collectors 72. Furthermore, by orienting the outlets 214 to direct the airflow toward each other, the airflow is directed away from the walls 304, 306 of the heat exchange subassembly 16. In this manner, the first and second liquid collector arrays 56, 58 direct the airflow from the first and second liquid collector arrays 56, 58 toward the coils 40, increasing the efficiency of heat transfer from the coils 40.

[0033]

[0058] With reference to FIG. 12, the liquid collector fan subassembly 18 is shown with the liquid collector array 58 removed to show that the interior wall 96 is made up of panels 350, 352, 354, 356, 358, 360 that are removable for cleaning.

[0034]

[0059] 13, the liquid collector fan subassembly 18 is shown with portions removed to avoid obscuring the view of the pump 34 and the internal pump compartment 360 of the subassembly 18. The pump 34 resides within the housing 64 of the cooling tower 10, which may protect the pump 34 from environmental elements such as rain, snowflakes, etc., thereby increasing the durability of the pump 34. The internal pump compartment 360 is defined in part by walls 362, 364 of the sump 34 and a wall 366 of the housing 64. The pump 370 has an inlet 380 for drawing liquid into the pump 370 and an outlet 382 for introducing evaporated fluid into the pipes 35 (see FIG. 2) for passage to the distribution header 36.

[0035]

[0060] 15 and 16, a liquid collector assembly 400 is shown that includes a liquid collector body 402, a mounting portion such as a closed end cap 404, and an opposing mounting portion such as an open end cap 406. The open end cap 406 has openings 408, 410 that align with the primary grooves 412 and secondary grooves 414 of the liquid collector 408 and allow liquid to flow from the primary grooves 412 and secondary grooves 414 into groove 60 (see, for example, FIG. 4). As shown in FIG. 16, the liquid collector 408 is identical to the liquid collector body 72 described above, except that the liquid collector 408 does not include the tertiary grooves 166, 170. The liquid collector assembly 400 may be used in place of the liquid collector body 72.

[0036]

[0061] 17 through 22, a process for assembling a liquid collector array 450 (see FIG. 23) is shown. The liquid collector array 450 is similar to the first and second liquid collector arrays 56, 58, and the following process may be used to assemble the first and second liquid collector arrays 56, 58. The liquid collector array 450 includes rails 452, 454 for supporting both ends of the liquid collector assembly 400. Referring momentarily to FIGS. 2 and 4, the process of assembling or disassembling the liquid collector trays of the cooling tower 10 may be performed by a maintenance worker standing in the walkway 144 below the liquid collectors 72.

[0037]

[0062] 17 and 18 , the first liquid collector assembly 400A advances, moving the closed end cap 404 upward through the opening 456 in the rail 452 and moving the open end cap 406 upward through the opening 470 in the rail 454. The first liquid collector assembly 400A then moves in the direction 458, sliding the closed end cap 404 into the channel 460 defined between the upper and lower flanges 462, 464 of the rail 452 and sliding the end cap 406 along the upper flange 472 of the rail 454 until the open end cap 406 engages a stop 474 on the liquid collector array 450. The stop 474 may have a shape that interlocks with or joins with the side of the end cap 406.

[0038]

[0063] 19 and 20, a similar process is repeated for liquid collector assembly 400B, advancing liquid collector assembly 400B along rails 452, 454 until liquid collector assembly 400B contacts and seats against liquid collector assembly 400A. Referring to FIG. 15, open end cap 406 has a lower recess 480 that receives a protrusion 482 on an adjacent liquid collector assembly 400. Similarly, open end cap 406 has an upper protrusion 481 that extends into a recess 483 on an adjacent liquid collector assembly 400. Closed end cap 404 may have a similar peripheral shape to open end cap 406.

[0039]

[0064] 20, the liquid collector assembly 400B is slid in direction 458 until the closed end cap 404 of assembly 400B contacts and seats against the corresponding closed end cap 404 of assembly 400A, and the open end cap 406 of liquid collector assembly 400B contacts and seats against the open end cap 406 of liquid collector assembly 400A. In this manner, the open end caps 404 and closed end caps 406 of adjacent liquid collector assemblies 400 form an interlocking engagement that securely maintains the orientation of the liquid collector bodies 402 once the liquid collector array 450 is assembled.

[0040]

[0065] 21 and 22, multiple liquid collection assemblies 400 are lined up on rails 452, 454 until they reach openings 456, 470 in rails 452, 454. A maintenance worker then advances liquid collector assembly 400D upward through openings 456, 470 and moves liquid collector assembly 400D in a direction 486 opposite direction 458 to position assembly 400D at ends 488, 490 of rails 452, 454. The procedure of loading liquid collection assemblies 400 in direction 486 is repeated to fill empty portions 491 of rails 452, 454.

[0041]

[0066] 23 and 24, a maintenance technician advances the liquid collectors 400E, 400F upward into the openings 470, 456 in the rails 452, 454, secures the end caps 404, 406 of the liquid collector assemblies 400E, 400F with the adjacent assemblies 400G, 400H, and deflates the liquid collector array 450. In one embodiment, the maintenance technician connects plates to the rails 452, 454 to cover the openings 470, 456 and secure the liquid collector assemblies 400 to the rails 452, 454. To remove the liquid collectors 400, such as for replacement or cleaning, the process of FIGS. 17-23 is reversed.

[0042]

[0067] 24, there is shown a lower liquid collector and fan subassembly 500 that is similar in many respects to the lower liquid collector and fan subassembly 18 discussed above, with the differences emphasized. The lower liquid collector and fan subassembly 500 may be used in conjunction with the upper heat exchange subassembly 16 described above, or with another upper heat exchange subassembly disposed above the lower liquid collector and fan subassembly 500. The lower liquid collector and fan subassembly 500 includes an air inlet 502 with a fan 504 that draws air into an exterior structure, such as a housing 506, and directs the air through an opening 508 in a generally upward direction 510 toward an upper heat exchange subassembly disposed above the lower liquid collector and fan subassembly 500.

[0043]

[0068] Liquid, such as water, falls in a generally downward direction 512 into opening 508 and onto liquid collector arrays 520, 522. Lower liquid collector-fan subassembly 500 has a central deflector 526 that directs liquid falling onto it into one of liquid collector arrays 520, 522. Lower liquid collector-fan subassembly 500 also has end troughs 530, 532 (see FIG. 27) and grooves 540 that cooperate with liquid collector arrays 520, 522 to capture any liquid falling from heat exchangers (such as coil 40, see FIG. 2) above lower liquid collector-fan subassembly 500.

[0044]

[0069] 24 and 31 , the liquid collector arrays 520, 522 include liquid collectors 549 and liquid collector assemblies 550 that are angled to direct collected liquid toward the grooves 540. Each liquid collector assembly 550 includes a body 552 having a primary groove 554 and a secondary groove 556. The body 552 may be made of a metal material, such as stainless steel, a plastic material, or a composite material, as some examples. The liquid collector assemblies 550 include mounts, such as a closed end cap 560 and an open end cap 562, at opposite ends 550B of the body 552. The open end cap 562 has an opening 564 that allows liquid to drain from the primary grooves 554 and secondary grooves 556 in a lateral direction 558 and flow into the grooves 540. The closed end cap 560 covers the primary grooves 554 and secondary grooves 556 and prevents liquid from flowing out of the primary grooves 554 and secondary grooves 556 in a direction opposite to the lateral direction 558. The closed end cap 560 and the open end cap 562 may be made of a metal, plastic, or composite material that provides sufficient rigidity to maintain the body 552 in place within the liquid collector arrays 520, 522.

[0045]

[0070] 25, lower liquid collector and fan subassembly 500 includes a pump 570 and a sump 572 within a housing 506. Housing 506 includes an outer wall 574 that defines a portion of groove 540. With reference to FIGS. 25 and 26, lower liquid collector and fan subassembly 500 includes a drain 580 with an opening 582 that opens into groove 540 and allows liquid within groove 540 to drain generally in direction 584 into sump 572. Drain 580 includes side walls 590, 592 and an inner wall 594 spaced inwardly from outer wall 574. In this manner, inner wall 594, side walls 590, 592, and a portion of outer wall 574 form a rectangular passageway that allows liquid collected in groove 540 to drain into sump 572 under the influence of gravity. The lower liquid collector and fan subassembly 500 also includes a door 596 that allows access to a passageway 598 between the fan 504 and the sump 572. The passageway 598 is kept dry during wet operation of the heat exchanger above the lower liquid collector and fan subassembly 500 because the liquid collector arrays 520, 522 collect liquid that drops from the heat exchanger.

[0046]

[0071] 24 and 27, the housing 506 includes an outer wall 600 to which a trough 532 is attached. The trough 532 has an upper wall 602 that extends across a lower wall 604 of the trough 532. The upper wall 602 and the outer wall 600 define an upper opening 606 therebetween that receives liquid falling in a direction 608 from an upper heat exchange subassembly that is above the lower liquid collector-fan subassembly 500. The liquid collector array 522 includes an outer end liquid collector body 552A with primary grooves 554A and secondary grooves 556A. The trough 532 is above the secondary grooves 556A and vertically overlaps the secondary grooves 556A to capture liquid falling to the outer wall 600. The trough 532 has a drip edge 610, and liquid traveling along a surface 612 of the trough 532 is directed into the secondary grooves 556 of the liquid collector 552A. Trough 530 has a similar configuration and operation to trough 532 and cooperates with liquid collector array 520 to collect falling liquid in a similar manner as trough 532 cooperates with liquid collector array 522 .

[0047]

[0072] 28, liquid collector array 522 includes inner end liquid collector body 552B having primary grooves 554B and secondary grooves 556B. Similarly, liquid collector assembly 526 includes inner end liquid collector body 552C with primary grooves 554C and secondary grooves 556C. Central deflector 526 has an upper surface 630 and first and second portions, such as liquid-guiding walls 632, 634, that direct liquid falling on upper surface 630 into either inner end liquid collector body 552C or inner end liquid collector body 552B.

[0048]

[0073] 29A, a liquid collector array 552 is shown, which is similar to liquid collector array 520. Liquid collector array 522 includes laterally spaced apart rails 640, 642 that support ends 644, 646 of liquid collector assemblies 550 of liquid collector array 522. Liquid collector assembly 550 includes an outer end liquid collector assembly 550A that includes outer end liquid collector body 552A described above.

[0049]

[0074] 30, all of the liquid collector assemblies 550 except for the outer end liquid collector assembly 550A have been removed. The rail 640 includes a channel 650 that receives the closed end cap 560, and the rail 642 includes an upper rail 652 and a lower rail 654 with an opening 656 therebetween for receiving the open end cap 562. The rails 640, 642 include lower walls 660, 662 that support the undersides of the closed end cap 560 and the open end cap 562. The lower rail 654 has an opening 670 that allows a user to install or remove the liquid collector assembly 550 from beneath the rails 640, 642 without removing the rails 640, 642. This allows a user to clean or replace the liquid collector assembly 550 as needed in the passageway 598.

[0050]

[0075] To position each of the liquid collector assemblies 550 along the rails 640, 642, the liquid collector assemblies 550 are positioned below the rails 640, 642 so that the open end cap 560 of the liquid collector assembly 550 is below the opening 670 of the rail 642. The user then lifts the liquid collector assembly 570 in an upward direction 672 until the closed end cap 560 and the open end cap 562 are vertically higher than the lower walls 660, 662. The user then moves the liquid collector assembly 550 laterally 676 to position the closed end cap 560 of the liquid collector assembly 550 on the lower wall 660 of the rail 640. The liquid collector assembly 550 is then moved vertically 678 until it contacts either a stop 680 of the rail 640 or another liquid collector assembly 550. To position the liquid collector assemblies 550 at the opposite end 682 of the rails 640, 642, a similar process is performed, except that the liquid collector assemblies 550 move in direction 684 after traveling upward through the openings 670. In one embodiment, the liquid collector assemblies 522 include a plate or other support that connects to the lower rail 654 once all of the liquid collector assemblies 550 are positioned on the rails 640, 642, as shown in FIG. 29A . The plate or support prevents the liquid collector assemblies 550, which are aligned with the openings 670, from disengaging from the lower rail 654.

[0051]

[0076] 32, the open end cap 562 includes a body 700 that may be made of, by way of example, a plastic material. The body 700 includes one or more openings 702 with primary groove openings 704 for accommodating the primary grooves 554 of the liquid collector body 552 and secondary groove openings 706 for accommodating the secondary grooves 556 of the liquid collector body 552. The body 700 includes notches 710, 712, 714, 716 that receive edges 720, 722, 726 (see FIG. 27) and edge 728 of the liquid collector body 552. The edges 722, 726 may be tips of upwardly facing barbs on the liquid collector body 552.

[0052]

[0077] Notch-to-edge engagement engages the open end cap 562 with the liquid collector 552. The open end cap 562 includes one or more detents that releasably couple with an adjacent open end cap once the liquid collector assembly 550 is attached to the rails 640, 642. In one embodiment, the open end cap 562 includes upper and lower detents 740, 742 (see FIG. 31 ) and upper and lower recesses 744, 746 that engage with corresponding recesses and detents on an adjacent open end cap 562.

[0053]

[0078] 32 , the body 700 of the open end cap 562 has a front upper recess 760, a front lower protrusion 762, a rear upper protrusion 764, and a rear lower recess 766. When the liquid collector assemblies 550 are installed side by side along the rails 640, 642, the front upper recess 760 of the first liquid collector assembly 550 receives the rear upper protrusion 764 of the second liquid collector assembly 550 that is in front of the first liquid collector assembly 550, and the front lower protrusion 762 of the first liquid collector assembly 550 extends into the rear lower recess 766 of the second liquid collector assembly 550.

[0054]

[0079] 29A and 29B, when the liquid collector assemblies 550 are placed on the rails 640, 642, the rear upper protrusions 764 of the opening caps 562 of the front liquid collector assembly 550A are stacked on the front lower protrusions 762 of the rear liquid collector assembly 550B on the rails 642. Similarly, the closing caps 560A, 560D of the liquid collector assemblies 550A, 550B are stacked on the rails 640.

[0055]

[0080] 29B, the rail 640 has a C-shaped cross-section including a bottom wall portion 660 for supporting the liquid collector assembly 550, a vertical wall portion 770, and a horizontal wall portion 772. The rail 640 further includes retainer portions 774, 776 that limit lateral movement of the closure cap 560 on the rail 640. The upper rail 652 and the lower rail 654 similarly include retainer portions 780, 782 that resist lateral movement of the opening cap 562 on the rail 642.

[0056]

[0081] The use of singular terms such as "a," "an," etc. is intended to encompass both the singular and the plural unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms. The phrase "at least one of," as used herein, is intended to be construed in a disjunctive sense. For example, the phrase "at least one of A and B" is intended to encompass A, B, or both A and B.

[0057]

[0082] While specific embodiments of the present invention have been shown and described, it will be understood that many variations and modifications will occur to those skilled in the art, and the present invention is intended to encompass all such variations and modifications within the scope of the appended claims. For example, the liquid collector described above may be used in different types of heat exchangers, such as to collect working fluid dripping from the packing sheet of a direct heat exchanger in a cooling tower. As yet another example, the liquid collector described herein may be used in a direct air carbon capture system to collect carbon capture solvent sprayed onto a carbon capture medium, such as packing.

Claims

1. A liquid collector that collects falling liquid and allows air to flow around it, a front lower edge; a connecting wall portion extending downward from the front edge portion; a first layback wall portion connected to the connecting wall portion and extending upward and rearward away from the connecting wall portion, the first layback wall portion having a first inclined surface that receives liquid and directs the liquid toward the connecting wall portion; an intermediate upper edge of the layback wall portion rearward and above the forward lower edge; an air diverter wall portion extending rearward from the first layback wall portion to below the intermediate upper edge portion; a second layback wall extending above and rearward of the air diverter wall, the second layback wall having a second inclined surface for receiving liquid and directing the liquid toward the air diverter wall; a rear upper edge of the second layback wall portion rearward of the intermediate upper edge and above the front lower edge; A liquid collector comprising:

2. a joint between the air diverter wall and the second layback wall, The liquid collector of claim 1 , wherein the interface includes a bottom drip edge.

3. The liquid collector of claim 2 , wherein the air diverter wall includes a recess forward of the lower drip edge.

4. a lower drip edge intermediate the air diverter wall and the second layback wall; 2. The liquid collector of claim 1, wherein the air diverter wall includes a curved portion forward of the lower drip edge.

5. the second layback wall, the air diverter wall, and the first layback wall define at least a portion of a primary channel of the liquid collector; The liquid collector of claim 1 , wherein the connecting wall and the first layback wall define at least a portion of a secondary groove of the liquid collector.

6. the first layback wall portion includes an upper straight wall portion located below the intermediate upper edge portion and a lower straight wall portion extending intersecting the upper straight wall portion, a joint portion connecting the upper straight wall portion and the lower straight wall portion; The liquid collector of claim 1 , wherein the air diverter wall extends rearwardly from the junction.

7. the first layback wall portion includes an upper wall portion connecting the intermediate upper edge portion and the air diverter wall portion, The liquid collector of claim 1 , wherein the top wall portion of the first layback wall portion and the second layback wall portion extend parallel to each other.

8. The liquid collector of claim 1 , wherein one or more of the front lower edge, the middle upper edge, and the rear upper edge are part of a barb.

9. 2. The liquid collector of claim 1, wherein the liquid collector has a length and a cross-section perpendicular to the length that is uniform over at least a majority of the length of the liquid collector.

10. The liquid collector is a main body including the front lower edge portion, the connecting wall portion, the first layback wall portion, the intermediate upper edge portion, the air diverter wall portion, the second layback wall portion, and the rear upper edge portion; the body having opposed ends; an open end cap connected to one end of the liquid collector; 10. The liquid collector of claim 1, wherein a closed end cap is connected to the other end of the liquid collector.

11. Further comprising a lower front wall portion and a lower rear wall portion, 2. The liquid collector of claim 1, wherein the lower front wall and the lower rear wall project below the connecting wall to form a tertiary groove in the liquid collector.

12. A heat exchanger; a liquid distribution system configured to distribute liquid to the heat exchanger; a pair of spaced apart rails; a plurality of liquid collectors for collecting at least a portion of the liquid distributed to the heat exchanger; a mount for the liquid collector configured to facilitate aligning the liquid collector along the rail; and a coupling portion of the mount for the liquid collector configured to engage with the liquid collector disposed along the rail and prevent movement of the liquid collector; A heat exchange device comprising:

13. 13. The heat exchange device of claim 12, wherein the coupling portions of the mounts include front and rear engagement surfaces of each mount that engage corresponding rear and front engagement surfaces of adjacent mounts when the liquid collectors are positioned side by side along the rail.

14. The heat exchange device of claim 12 , wherein the coupling portions of the mounts include a front lower protrusion, a front upper recess, a rear lower recess, and a rear upper protrusion of each mount.

15. The heat exchange device of claim 12 , wherein the mount includes a flat that slides along the rail.

16. The heat exchange device of claim 12 , wherein the coupling portion of the mount includes a recess and a detent that engages the recess for releasably engaging the mount.

17. the rails each include a lower support for supporting the mount of the liquid collector; 13. The heat exchange device of claim 12, wherein at least one of the rails has a through opening in the lower support sized to facilitate advancement of one of the mounts of each liquid collector through the through opening in the lower support.

18. the rails each including a first end and a second end and a length therebetween; one of the rails having a through opening intermediate the first end and the second end sized to allow the liquid collector mount to be advanced therethrough; the through opening is at a first distance from the first end of the one rail that allows a first plurality of the liquid collectors to be disposed on the one rail between the first end and the through opening; 13. The heat exchange device of claim 12, wherein the through opening is at a second distance from the second end of the one rail that allows a plurality of second liquid collectors to be positioned on the one rail between the second end and the through opening.

19. 20. The heat exchange device of claim 18, wherein the first distance is greater than the second distance to allow a majority of the liquid collectors of the plurality of liquid collectors to be positioned between the through opening and the first end of the one rail.

20. the liquid collectors each include a liquid collector body having a primary groove and a secondary groove for collecting the fluid; 13. The heat exchange device of claim 12, wherein the liquid collectors each include an open end cap connected to the liquid collector array that allows fluid in the primary grooves and the secondary grooves to drain from the liquid collector.

21. The heat exchange device of claim 12 , wherein at least one of the rails has a stop that limits movement of the liquid collector along the rail.

22. Each of the liquid collectors is a front lower edge; a connecting wall portion extending downward from the front edge portion; a first layback wall portion connected to the connecting wall portion and extending upward and rearward from the connecting wall portion, the first layback wall portion having a first inclined surface that receives liquid and directs the liquid toward the connecting wall portion; an intermediate upper edge of the layback wall portion rearward and above the forward lower edge; an air diverter wall portion extending rearward from the layback wall portion below the intermediate upper edge portion; a second layback wall extending above and rearward of the air diverter wall, the second layback wall having a second inclined surface for receiving liquid and directing the liquid toward the air diverter wall; The heat exchange device of claim 12 , comprising:

23. the heat exchange device includes an enclosed space; the heat exchanger is located within the enclosed space; the liquid distribution system includes a liquid outlet within the enclosed space above the heat exchanger; The heat exchange apparatus of claim 12 , wherein the liquid distribution system includes a pump within the enclosed space below the liquid collector.

24. 1. A method of assembling a liquid collector array, comprising: placing a first liquid collector mount on the rail of the liquid collector array, the first liquid collector mount having at least one groove for collecting falling liquid; moving the first liquid collector along the rail to a first installation position, and tilting the first liquid collector in the first installation position to drain the liquid in the at least one groove of the first liquid collector from the first liquid collector; placing a second liquid collector mount on the rail of the liquid collector array, the second liquid collector mount having at least one groove for collecting falling liquid; moving the second liquid collector along the rail to a second installation position adjacent to the first liquid collector, and tilting the second liquid collector in the second installation position to drain the liquid in the at least one groove of the second liquid collector from the second liquid collector; A method comprising:

25. 25. The method of claim 24, wherein placing the mounts of the first liquid collector on the rails includes advancing one of the mounts of the first liquid collector through an opening in one of the rails.

26. the one of the rails has a length; 26. The method of claim 25, wherein advancing the one of the mounts of the first liquid collector through the opening in the one rail comprises advancing the one mount through the opening in a direction transverse to the length of the one rail.

27. 26. The method of claim 25, wherein placing the mounts of the second liquid collector on the rails includes advancing one of the mounts of the second liquid collector through the opening in the one rail.

28. moving the first and second liquid collectors along the rails includes moving the first and second liquid collectors along the rails in a first direction; The method further comprises:

25. The method of claim 24, including moving a third liquid collector along the rail in a second direction opposite the first direction.

29. placing the mounts of the first liquid collector on the rails includes advancing one of the mounts of the first liquid collector through an opening in one of the rails; The method further comprises: placing a first mount of a third liquid collector on the other rail and a second mount of the third liquid collector above the opening in the one rail; connecting a support to the one rail below the second mount of the third liquid collector to close the opening in the one rail; 25. The method of claim 24, comprising:

30. 25. The method of claim 24, wherein moving the first liquid collector along the rail to the first installation position comprises moving the first liquid collector in a first direction until the first liquid collector abuts a stop on the rail that limits further movement of the first liquid collector in the first direction.

31. 25. The method of claim 24, wherein moving the second liquid collector along the rail includes inserting a front protrusion of the mount of the second liquid collector into a rear opening of the mount of the first liquid collector.

32. 25. The method of claim 24, further comprising placing a plurality of liquid collector mounts on the rail to fill the rail with liquid collectors, and securing the first liquid collector, the second liquid collector, and the plurality of liquid collectors to the rail.

33. 25. The method of claim 24, wherein moving the second liquid collector along the rail includes stacking portions of the mounts of the first and second liquid collectors.

34. a housing having a first outer wall and a second outer wall opposite the first outer wall; a heat exchanger within the housing; a fan operable to generate airflow over the heat exchanger; a liquid distribution system for distributing liquid to the heat exchanger; a first liquid collector array including a plurality of first liquid collectors having grooves for collecting liquid falling from the heat exchanger and first gaps between the first liquid collectors for allowing air movement between the first liquid collectors, the first liquid collectors being configured to direct air from the first gaps away from the first wall in a first direction towards the heat exchanger; a second liquid collector array including a plurality of second liquid collectors having grooves for collecting liquid falling from the heat exchanger and gaps between the second liquid collectors for allowing air movement between the second liquid collectors, the second liquid collectors being configured to direct air from the second gaps in a second direction intersecting the first direction, away from the second outer wall and towards the heat exchanger; A heat exchange device comprising:

35. the first liquid collector is configured to direct air from the first gap at an angle relative to normal to the first direction; 35. The heat exchange device of claim 34, wherein the second liquid collector is configured to direct air from the second gap in the second direction at the angle relative to normal.

36. The first and second liquid collectors each include: a secondary groove having a first layback wall; a primary groove having a second layback wall; the first layback wall and the second layback wall of the first liquid collector are oriented to extend along the first direction; 35. The heat exchange device of claim 34, wherein the first layback wall and the second layback wall of the second liquid collector are oriented to extend along the second direction.

37. 35. The heat exchange device of claim 34, wherein the first and second liquid collectors each include an upper primary groove and a lower secondary groove having a pair of spaced-apart parallel walls oriented in the first or second direction.

38. Each liquid collector is a front lower edge; a connecting wall portion extending downward from the front edge portion; a first layback wall portion connected to the connecting wall portion and extending upward and rearward away from the connecting wall portion, the first layback wall portion having a first inclined surface that receives liquid and directs the liquid toward the connecting wall portion; an intermediate upper edge of the layback wall portion rearward and above the forward lower edge; an air diverter wall portion extending rearward from the layback wall portion below the intermediate upper edge portion; a second layback wall extending above and rearward of the air diverter wall, the second layback wall having a second inclined surface for receiving liquid and directing the liquid toward the air diverter wall; 35. The heat exchange device of claim 34, comprising:

39. a first end groove intermediate the first liquid collector array and the first outer wall for collecting liquid falling adjacent the first outer wall; a second end groove intermediate the second liquid collector array and the second outer wall for collecting liquid falling adjacent the second outer wall; 35. The heat exchange device of claim 34, further comprising:

40. 35. The heat exchange device of claim 34, further comprising an intermediate deflector intermediate the first and second liquid collector arrays for receiving fluid falling from the heat exchanger, the intermediate deflector having a first portion configured to direct the falling liquid toward the first liquid collector array and a second portion configured to direct the falling liquid toward the second liquid collector array.

41. the first liquid collector array includes a first pair of rails supporting the first liquid collectors, the first pair of rails having at least one opening to facilitate loading of the first liquid collectors onto the first pair of rails; 35. The heat exchange device of claim 34, wherein the second liquid collector array includes a second pair of rails supporting the second liquid collectors, the second pair of rails having at least one opening to facilitate loading of the second liquid collectors onto the first pair of rails.

42. Housing and a heat exchanger within the housing; a fan operable to direct air into contact with the heat exchanger; a sump for liquid within said housing; a liquid distribution system operable to direct the liquid from the sump to the heat exchanger; a pump of the liquid distribution system within the housing; A heat exchange device comprising:

43. the housing includes a floor and an exterior wall extending from the floor; 43. The heat exchange device of claim 42, wherein the pump resides in a pocket at least partially formed by the floor, the outer wall, and the sump.

44. the housing includes a floor and an exterior wall extending from the floor; the sump includes a wall spaced apart from and extending parallel to the outer wall; 43. The heat exchange apparatus of claim 42, wherein the pump is between the wall of the sump and the outer wall of the housing.

45. the liquid distribution system includes a tube for receiving liquid from the pump; 43. The heat exchange device of claim 42, wherein a portion of the tube is inside the housing and a portion of the tube is outside the housing.

46. a plurality of liquid collectors for collecting at least a portion of the liquid from the heat exchanger; 43. The heat exchange apparatus of claim 42, wherein the liquid collector is above the pump to limit liquid contact with the pump.

47. a groove above the sump into which the liquid collector directs collected liquid; a drain configured to direct liquid from the groove to the sump; 46. ​​A heat exchange device further comprising:

48. The housing comprises: Doors and a passageway within the housing; the sump and pump on one side of the passage; the fan on an opposite side of the passage from the sump and pump; 43. The heat exchange device of claim 42, comprising:

Images