An evaporative cooling pad and a method of manufacturing an evaporative cooling pad

Abstract

The disclosure relates to an evaporative cooling pad (1) comprising: a first set (2) of corrugated sheets (4); a second set (6) of corrugated sheets (4), wherein the sheets (4) of the first set (2) are disposed alternatively in a stack with the sheets (4) of the second set (6) to form the pad (1); elongated flutes (8) of said corrugated sheets (4) of the first and second sets (2,6) form passageways (10) extending from a first side (12) to a second side (14) of the pad (1); wherein the flutes (8) of a corrugated sheet of the first set (2) are adapted to at least face the flutes (8) of an adjacently arranged corrugated sheet of the second set (6). At least one fixating element (16) is arranged to penetrate at least one of the corrugated sheets (4) in the stack of corrugated sheets (4) for attaching the corrugated sheets (4) to each other. The disclosure further relates to a method of manufacturing an evaporative cooling pad (1).

Description

[0001] An evaporative cooling pad and a method of manufacturing an evaporative cooling pad

[0002] Technical field

[0003] The present invention relates to an evaporative cooling pad and a method of manufacturing an evaporative cooling pad. More specifically, the disclosure relates to an evaporative cooling pad comprising a first set of corrugated sheets; a second set of corrugated sheets, wherein the sheets of the first set are disposed alternatively in a stack with the sheets of the second set to form the pad; elongated flutes of said corrugated sheets of the first and second sets form passageways extending from a first side to a second side of the pad; wherein the flutes of a corrugated sheet of the first set are adapted to at least face the flutes of an adjacently arranged corrugated sheet of the second set. The present invention also relates to a method of manufacturing an evaporative cooling pad.

[0004] Background art

[0005] Air treatment units, such as evaporative humidifiers and cooler apparatuses, may be used to humidify and cool different types of spaces in buildings. The space may be a space within a building.

[0006] Electric equipment within a building may generate heat, which increases the temperature within the building. Increased temperature may decrease the performance of the equipment. Electric equipment may also be sensitive to static electricity. If the humidity in a space within the building falls below a certain level, static electricity may be generated. A correct humidity and temperature within the space is therefore important the performance of the electric equipment. Alternatively, the space to be humidified and cooled may be a space within a building for holding animals. A correct humidity and temperature within the space is important in order for the animals to feel well and stay healthy.

[0007] Evaporative humidifiers and cooler apparatuses comprises an organic or inorganic noncombustible or combustible cooling and humidification media, also known as an evaporative media, which is a component configured to be exposed to a fluid. The fluid, such as water, is supplied to the top of the evaporative media via a fluid distribution element. The water flows down the evaporative media, which comprises a number of corrugated sheets. As warm and dry air passes through the evaporative media, it evaporates a proportion of the water and thus produces cold, humidified air. The rest of the water is drained to a fluid tray or water gutter.

[0008] The warm and dry air may be directed through the evaporative media by means of a forced air flow, which is generated by a fan. The air passes through channels or passageways in the pads, which passageways are created by the corrugated sheets. Alternatively, the air may pass through the channels or passageways by natural features or convection. The flutes of the sheets may be arranged in parallel. Alternatively, the flutes of the sheets may crossing adjacent sheets wherein said crossed flutes defining the passageways penetrating from side to side of the pad. The flutes of the corrugated sheets bearing against one another so that the sheets touch where the wave peaks and wave troughs of their respective flutes cross.

[0009] Document JP2016188748A discloses an example of a humidifier comprising humidifying materials stacked in a block shape. Flat plates and corrugated plates of the humidifying materials may be joined by heat welding, adhesives, double-sided adhesive tapes or staples.

[0010] Joining the humidifying materials in a humidifier by adhesives, tapes or heat welding may result in an increased pressure drop in the dehumidifier. Further, the joined areas by adhesive, tape or heat welding may reduce the ability of the humidifying materials in a humidifier to take up fluid, which results in a reduced performance of the humidifier. Joining the humidifying materials by staples may reduce the life span of the humidifier.

[0011] Despite known solutions in the field, it would be desirable to develop an evaporative cooling pad and a method of manufacturing an evaporative cooling pad, which overcome or alleviate at least some of the drawbacks of the prior art.

[0012] It is an object of the present invention to mitigate, alleviate or eliminate one or more of the above-identified deficiencies and disadvantages in the prior art and solve at least the above mentioned problem.

[0013] A further objective of the present invention is to achieve an evaporative cooling pad which increases the performance and life span of a humidifier. A further objective of the present invention is to achieve an evaporative cooling pad which is robust and perform effective cooling and humidifying.

[0014] A further objective of the present invention is achieve an evaporative cooling pad, which may be assembled on site in a short period of time.

[0015] These objectives are achieved by the evaporative cooling pad initially defined, further comprising the features that at least one fixating element is arranged to penetrate at least one of the corrugated sheets in the stack of corrugated sheets for attaching the corrugated sheets to each other. These objects are also been achieved by the method of manufacturing an evaporative cooling pad. Due to the at least one fixating element, which is arranged to attach the corrugated sheets to each other, the evaporative cooling pad will effectively take up fluid and release the fluid in order to humidify and cool an ambient space in a building. Due to absence of glue, staples and tape, the performance and life span of the pad increases. The penetration of the at least one fixating element will form a robust assembly of the pad, which results in an effective cooling and humidity performance of the pad. Due to the penetration of the at least one fixating element, the pad can be assembled on site in a short period of time. The fixating element may be a mechanical entity. The mechanical entity may be a single piece or a combination of pieces. The corrugated sheets are configured to be attached to each other by the single piece or the combination of pieces.

[0016] The evaporative cooling pad may be arranged in an air treatment unit, such as an evaporative humidifier and cooler apparatus. The air treatment unit may be used to humidify and cool different types of spaces in buildings. The evaporative cooling pad may be an evaporative media or a cooling and humidification media. The evaporative cooling pad is configured to be exposed to a fluid and to evaporate the fluid to which it is exposed. The evaporative cooling pad may be arranged in cassettes, which are supported by a rigid frame of the air treatment unit. The air treatment unit comprises a fluid distribution element, which is configured to distribute the fluid to the evaporative cooling pad. A tray or water gutter is arranged to collect fluid downstream of the evaporative cooling pad. The fluid distributed by the fluid distribution element is collected from the tray. A first fluid pump may be connected to the fluid distribution element, wherein the first fluid pump is configured to deliver fluid to the fluid distribution element. The first fluid pump is arranged at a fluid pipe arranged between the tray and the fluid distribution element. The first fluid pump may suck the fluid from the tray and deliver the fluid to the fluid distribution element. A fluid conduit may be arranged between the tray and a fluid reservoir, for conveying a make-up fluid from the fluid reservoir to the tray. The make-up fluid may be fresh water from a community network pipe system. A second fluid pump may be arranged in the fluid conduit. The fluid conduit may be arranged between the fluid reservoir and the fluid distribution element, for conveying a makeup fluid from the fluid reservoir to the fluid distribution element. A fan is configured to generate an air flow through the evaporative cooling pad. As the warm and dry air flow passes through the evaporative cooling pad, a proportion of the water is evaporated and thus produces cold, humidified air.

[0017] The evaporative cooling pad is configured to receive and evaporate the fluid. The evaporative cooling pad comprises a number of corrugated sheets connected to each other, so that passageways are formed between the corrugated sheets. The passageways penetrates from a first side to a second side of the evaporative cooling pad. The air flow created by the fan is configured to flow in the passageways through the evaporative cooling pad. The first side of the evaporative cooling pad may be configured as the first surface of the evaporative cooling pad. The second side of the evaporative cooling pad may be configured as the second surface of the evaporative cooling pad. The first set of corrugated sheets comprises wave peaks and wave troughs having specific shapes, amplitudes, wave heights and wave lengths. The second set of corrugated sheets comprises wave peaks and wave troughs having specific shapes, amplitudes, wave heights and wave lengths. The shape, amplitudes, wave heights and wave lengths of the first set of corrugated sheets may be different from the shape, amplitudes, wave heights and wave lengths of the second set of corrugated sheets.

[0018] The basic principle behind evaporative air cooling is the process of evaporation of a liquid cooling medium, typically water. When water evaporates, it absorbs heat, and as a result, the surrounding air becomes cooler. An evaporative air treatment unit, or evaporative air cooler, uses this principle to cool the air by blowing it over a wet cooling pad or through a series of wet cooling pads. As the air passes over the wet pad, the water evaporates, which cools and humidifies the air. The cooled air can then be circulated into the space to be cooled. However, it is to be noted that while the present disclosure is mainly related to cooling and humidifying of air, the pad of the present invention could as well be used in other applications where heat and mass transfer based on evaporation is involved, for example in chemical engineering processes. Hence, in such applications, the terms "cooling" and "humidification" as used in the context of the present disclosure may then be replaced by, or referred to as "heat transfer" and "mass transfer", respectively. Accordingly, in such applications the component herein referred to as a "cooling pad", may then rather be referred to as a "heat transfer pad" or a "mass transfer pad", etc.

[0019] The sheets of the first set may be disposed alternatively in a stack with the sheets of the second set to form the pad. This means that every other sheet in the stack may belong to the first set of sheets and that the other sheets belong to the second set of sheets. In other words, the first and second sets of corrugated sheets may be alternately arranged in the stack. Thus, the sheets of the first set can be disposed alternately in a stack with the sheets of the second set to form the pad. Further, the corrugated sheets of the first set may be disposed alternatively with or to the corrugated sheets of the second set, so that the flutes of the first set crossing the flutes of the second set. Thus, the flutes of the first set may have an alternative direction than the flutes of the second set in the stack.

[0020] The corrugated sheets of the first and second sets may comprise openings, which are configured to be penetrated by the at least one fixating element. The openings may be arranged in the corrugated sheets before the at least one fixating element is penetrated in the openings. The openings may have a shape which is adapted to the shape of the fixating elements. The openings may have a size which is adapted to the size of the fixating elements.

[0021] The flutes of a corrugated sheet of the first set may be adapted to be in a contacting relationship with the flutes of an adjacently arranged corrugated sheet of the second set. The corrugated sheets may bear against each other. The at least one fixating element may be configured to hold the corrugated sheets in the contacting relationship.

[0022] A frame may be arranged to at least partly surround the pad. The pad may be attached to the frame. The frame may be configured to fixate the shape of the pad. The evaporative cooling pad may be arranged in a cassette, which is supported by a rigid frame of the air treatment unit.

[0023] The flutes of the corrugated sheets each may have a half-hexagonal shape, such that the passageways formed between two adjacent corrugated sheets have a hexagonal shape, wherein the passageways with a hexagonal shape may be arranged in parallel to each other. The hexagonal shape of the passageways will increase the cooling efficiency and the humidity performance of the pad. Due to the half-hexagonal shape of the flutes of the corrugated sheets, the pad can easily be assembled on site in a short period of time.

[0024] The flutes of the corrugated sheets each may have a sinusoidal shape, and wherein the sheets of the first set may be disposed alternatively with the sheets of the second set, with the flutes of the first set crossing the flutes of the second set. The the at least one fixating element may fixate the corrugated sheets in a position with the flutes of the first set crossing the flutes of the second set. This will result in that the first and second set corrugated sheets will touch each other where at least one of the wave peaks and wave troughs of their respective flutes cross. Thus, the sheets of the first set may be disposed alternately with the sheets of the second set, with the flutes of the first set crossing the flutes of the second set.

[0025] The corrugated sheets of the first and second sets may comprise an impregnation substance. The sheets may be treated with an impregnation substance that increase the life span of the pads and also reduces the need of maintenance of the pads. The impregnation substance may bond the sheets together by curing the impregnation substance at positions were the sheets have contact with each other.

[0026] The at least one fixating element may comprise an elongated rod, which may be configured to puncture the corrugated sheets of the first and second sets. The rod may have a sharp point in at least one end. The rods are made of a material which is harder than the material of the corrugated sheets. The rod may puncture the corrugated sheets at a suitable position. The rod may puncture the corrugated sheets in a suitable direction in relation to the direction of the stack of corrugated sheets. The rod may alternatively be configured to penetrate pre-prepared openings in the corrugated sheets. The rod may be a skewer, spike, stick or a needle. The rod may have a rough surface, such as a wood texture. The rough surface increases the friction between the rod and the corrugated sheets. Due to the friction between the rod and the corrugated sheets, the respective corrugated sheets in the stack of corrugated sheets can remain in a fixed position in relation to each other. The rod may be made of wood. The rod may however be made of steel or plastic. In order to increase the friction between a rod made of steel or plastic, the surface of the rod may be provided with a rough surface or with projections, such as barbs.

[0027] The rod may comprise at least one weakened snap point. After the rod has been inserted in the stack of corrugated sheets, a part of the rod may protrude from the pad of corrugated sheets. At least a part of the rod, which protrudes from the pad may be snapped of at the weakened snap point. Due to the at least one weakened snap point, the pad can easily be assembled on site in a short period of time.

[0028] The at least one fixating element may comprise a lock element protruding from the corrugated sheets of the first and second sets, wherein the lock element may be arranged at contact points between the corrugated sheets. The lock element may be a protruding element attached to the corrugated sheet. The lock element may be an integrated piece of the corrugated sheet. The lock element may have shape, which hook into an adjacent corrugated sheet, so that the adjacent corrugated sheets are attached to each other by the lock element,

[0029] The lock element may comprise a flap, which emanates from the openings, and wherein the flap of one corrugated sheet may be configured to be folded into an opening of an adjacent corrugated sheet in the stack of corrugated sheets, so that the flap connects the adjacent sheets to each other. The connection of the sheets using the flaps result in evaporative cooling pad, which may be assembled on site in a short period of time. Further, the flaps may keep the openings clear as passageways for the fluid passing the pad. The flaps may have a shape that hook into an opening of an adjacent corrugated sheet when the sheets abuts against each other.

[0030] The flap may emanate from a semi-punched opening. The semi-punched opening may create a flap which correspond the shape of the semi-punched opening. This flap has a shape, which effectively hook into a semi-opening of an adjacent corrugated sheet The method of manufacturing an evaporative cooling pad according to the present invention, comprises the steps of: providing a first set of corrugated sheets, providing a second set of corrugated sheets, wherein the method comprises the further steps of: punching an opening with a remaining foldable flap in the provided sheets of the first and second sets, and folding the foldable flaps for locking the sheets to each other.

[0031] The step of folding the foldable flaps for locking the sheets to each other is preceded by the steps of disposing one of the punched sheets above the other punched sheet, and displacing the punched sheets towards each other so that the flaps of the punched sheets above the other punched sheet enter the openings of the other punched sheet.

[0032] The step of punching an opening with a foldable flap in the provided sheets, may comprise punching a semi-punched opening with a foldable flap in the provided sheets

[0033] The step of disposing one of the sheets above the other sheet may comprise identifying the positions of the openings in the sheets by an optical device, comprising an optical sensor connected to a control unit, which is configured to receive sensed images of the sheets from the optical sensor for identifying the positions of the openings and positioning one of the sheets above the other sheet based on the identified positions of the openings by the control unit such that the openings are aligned. Alternatively, or in combination with identifying the positions of the openings in the sheets by an optical device, the positions of trough and peak connection points of the sheets may be identified by an optical device to determine where to create the opening and foldable flap.

[0034] The step of punching an opening with a foldable flap in the provided sheets is preceded by the steps of: positioning one of the sheets above the other sheet; identifying positions of trough and peak connection points of the sheets by an optical device comprising an optical sensor connected to a control unit, which is configured to receive sensed images of the sheets from the optical sensor for identifying the positions of the trough and peak connection points, and determining where to create openings and foldable flaps in the sheets based on the identified positions of the trough and peak connection points by the control unit.

[0035] The method may comprise the further steps of applying an impregnation substance to the sheets, and curing the impregnation substance for bonding the sheets together by the impregnation substance at positions were the sheets have contact with each other. The joined areas by the impregnation substance may have ability for the sheets to take up fluid.

[0036] The method may comprise the further step of: bonding the adjacent sheets together by spot welding at positions were the sheets have contact with each other. The joined areas by the spot welds may have ability for the sheets to take up fluid.

[0037] The present disclosure will become apparent from the detailed description given below.

[0038] Brief of the

[0039] The above objects, as well as additional objects, features and advantages of the present disclosure, will be more fully appreciated by reference to the following illustrative and non-limiting detailed description of example embodiments of the present disclosure, when taken in conjunction with the accompanying drawings.

[0040] Fig. 1 schematically illustrates a front view of an evaporative cooling pad according to an example;

[0041] Fig. 2a schematically illustrates a section view along line I - I in fig. 1;

[0042] Fig. 2b schematically illustrates a section view along line II - II in fig. 1;

[0043] Fig. 2c schematically illustrates a section view of a pad 1 according to an example;

[0044] Fig. 3 schematically illustrates a view in perspective of corrugated sheets according to an example;

[0045] Fig. 4 schematically illustrates a front view of an evaporative cooling pad according to an example;

[0046] Fig. 5 schematically illustrates a front view of an evaporative cooling pad according to an example;

[0047] Fig. 6 schematically illustrates a front view of an evaporative cooling pad according to an example;

[0048] Fig. 7 schematically illustrates a view wherein corrugated sheets are packed together; Fig. 8 schematically illustrates a section view along line III - III in fig. 6;

[0049] Fig. 9 schematically illustrates a section view along line IV - IV in fig. 8; and

[0050] Fig. 10 shows a flowchart of a method according to an example.

[0051] Detailed description

[0052] The present disclosure will now be described with reference to the accompanying drawings, in which preferred example embodiments of the disclosure are shown. The disclosure may, however, be embodied in other forms and should not be construed as limited to the herein disclosed embodiments. The disclosed embodiments are provided to fully convey the scope of the disclosure to the skilled person.

[0053] Figure 1 schematically illustrates a front view of an evaporative cooling pad 1 according to an example. The evaporative cooling pad 1 is arranged in an air treatment unit 3. The air treatment unit 3 may be comprised in a cooling system 5. The evaporative cooling pad 1 is configured to be exposed to a fluid 7. The evaporative cooling pad 1 is configured to evaporate the fluid 7 to which it is exposed. The evaporative cooling pad 1 is also known as an evaporative media or a cooling and humidification media. The evaporative cooling pad 1 may be arranged in cassettes or frames 18 (fig. 4) of the air treatment unit 1.

[0054] The evaporative cooling pad 1 is configured to receive and evaporate the fluid 7. A fluid distribution element 9 is configured to distribute the fluid 7 to the evaporative cooling pad 1. A tray 11 or water gutter is arranged to collect fluid 7 downstream of the evaporative cooling pad 1. The fluid 7 distributed by the fluid distribution element 9 is collected from the tray 11. A first fluid pump 13 is be connected to the fluid distribution element 9, wherein the first fluid pump 13 is configured to deliver fluid 7 to the fluid distribution element 9. The first fluid pump 13 is arranged at a fluid pipe arranged between the tray 11 and the fluid distribution element 9. The first fluid pump 13 may suck the fluid 7 from the tray 11 and deliver the fluid 7 to the fluid distribution element 9. Vertically directed arrows 15 represent the direction of fluid 7 through the fluid distribution element 9, the evaporative cooling pad 1 and further to the fluid tray 11. A fluid conduit 40 is arranged between the tray 11 and a fluid reservoir 42, for conveying a make-up fluid 44 from the fluid reservoir 42 to the tray 11. A second fluid pump 46 is arranged in the fluid conduit 40. Fig. 2a schematically illustrates a section view along line I - I in fig. 1. The evaporative cooling pad 1 comprising a first set 2 of corrugated sheets 4 and a second set 6 of corrugated sheets 4 having flutes 8 defined in an angle in relation to a line 21 extending from the first side 12 to the second side 14 of the pad 1. The corrugated sheets 4 of the first set 2 being disposed alternatively with the sheets 4 of the second set 6 , with the flutes 8 of the first set 2 crossing the flutes 8 of the second set 6. The crossed flutes 8 defining passageways 10 penetrating from a first side 12 to a second side 14 of the pad 1. In fig. 2a the surface of a corrugated sheet 4 of the first set 2 is exposed. In fig. 2a the flutes 8 of the sheets 4 of the first set 2 are directed in an angle a in relation to a line extending from the first side 12 to the second side 14 of the pad 1. A fan 17 is configured to generate an air flow 19 through the evaporative cooling pad 1.

[0055] Fig. 2b schematically illustrates a section view along line II - II in Fig. 1. In fig. 2b the surface of a sheet 4 of the second set 6 is exposed. In fig. 2b the flutes 8 of the sheets 4 of the second set 6 are directed in an angle |3 in relation to the line 21 extending from the first side 12 to the second side 14 of the pad 1.

[0056] Fig. 2c schematically illustrates a section view of a pad 1, similar to the sections in in figures 2a and 2b in which the surface of a sheet 4 of the first set 2 or second set 6 is exposed. In fig. 2c the flutes 8 of the corrugated sheets 4 of the first set 2 and the second set 6 are directed in parallel in relation to the line 21 extending from the first side 12 to the second side 14 of the pad 1.

[0057] Fig. 3 schematically illustrates a view in perspective of corrugated sheets 4 stackable to an evaporative cooling pad 1. A first set 2 of corrugated sheets 4 and a second set 6 of corrugated sheets 4 are configured to be disposed alternatively in a stack to form the pad 1. Elongated flutes 8 of the corrugated sheets 4 of the first and second sets 2, 6 form passageways 10 extending from a first side 12 to a second side 14 of the shaped pad 1. The flutes 8 of a corrugated sheet 4 of the first set 2 are adapted to at least face the flutes 8 of an adjacently arranged corrugated sheet 4 of the second set 6. The corrugated sheets 4 of the first and second sets 2, 4 comprise an impregnation substance 32.

[0058] Fig. 4 schematically illustrates in a front view an example of an evaporative cooling pad

[0059] 1. The flutes 8 of the corrugated sheets 4 are directed in parallel to each other and configured to bear against one another so that the corrugated sheets 4 touch where wave peaks pl and wave troughs tl of their respective flutes 8 are positioned. The first and second sets 2, 6 of corrugated sheets 4 are connected to each other at contact areas between wave peaks pl and wave troughs tl. Fixating elements 16 are arranged to attach the corrugated sheets to each other. In fig. 4 the fixating elements 16 are rods, which are configured to puncture the corrugated sheets 4 of the first and second sets 2, 6. Alternatively, the corrugated sheets 4 of the first and second sets 2,6 comprises openings 26, and the rods 16 are configured to penetrate the openings 26 of the corrugated sheets 4 of the first and second sets 2,6. At least one end of the rods 16 may be provided with a sharp point. The rods 16 extend in a direction which is parallel with the stacked direction of the layers of the corrugated sheets 4. The rods 16 may have a rough surface, such as a wood texture. Further, the rods 16 may comprise at least one weakened snap point 22, where the rods 16 can be snapped off to a suitable length. The rod 16 may be a skewer, spike, stick or a needle. A frame 18 is arranged to at least partly surround the pad 1.

[0060] Fig. 5 schematically illustrates in a front view an example of an evaporative cooling pad 1. According to this example the rods 16 extend in a direction with an angle 6 in relation to the stacked direction of the layers of the corrugated sheets 4. In figures 4 and 5 the flutes 8 of the corrugated sheets 4 each has a sinusoidal shape, and wherein the sheets 4 of the first set 2 are disposed alternatively with the sheets 4 of the second set 6, with the flutes 8 of the first set 2 arranged in parallel with the flutes 8 of the second set 6. It is also possible to dispose the sheets 4 of the first set 2 alternatively with the sheets 4 of the second set 6, with the flutes 8 of the first set 2 crossing the flutes 8 of the second set 6.

[0061] Fig. 6 schematically illustrates in a front view an example of an evaporative cooling pad 1. In fig. 6 the flutes 8 of the corrugated sheets 4 each has a half-hexagonal shape, such that the passageways 10 formed between two adjacent corrugated sheets 4 have a hexagonal shape, wherein the passageways 10 with a hexagonal shape are arranged in parallel to each other. In figures 4 - 6 the flutes 8 of a corrugated sheet 4 of the first set 2 are adapted to be in a contacting relationship with the flutes 8 of an adjacently arranged corrugated sheet 4 of the second set 6. However, it is possible to arrange the flutes 8 of a corrugated sheet 4 of the first set 2 at a distance to the flutes 8 of an adjacently arranged corrugated sheet 4 of the second set 6, so that there is a gap between the adjacently arranged corrugated sheets 4. In fig. 6 two different examples of fixating elements 16 are arranged to attach the corrugated sheets 4 to each other.

[0062] Fig. 7 schematically illustrates a view wherein corrugated sheets 4 of the first and second sets 2, 6 are packed together in order to reduce space when storing and transporting the corrugated sheets 4 to different locations before stacked together to a pad 1. In this packed configuration, the wave peaks pl of an underlying corrugated sheet 4 are accommodated from the underside in wave peaks p2 of an overlying corrugated sheet 4. Thus in this packed configuration, less space is required for storing and transporting comparing to a configuration when the corrugated sheets 4 are connected to form passageways 10 extending from the first side 12 to the second side 14 of the pad 1, shown in fig. 6.

[0063] Fig. 8 schematically illustrates a section view along line III - III in fig. 6. According to this example, the fixating element 16 comprising a lock element 24 (see fig. 9) protruding from the corrugated sheets 4 of the first and second sets 2, 6. The lock element 24 is arranged at contact points between the corrugated sheets 4. The lock element 24 comprises a flap 28 (see fig. 9), which emanates from a semi-punched opening 26.

[0064] Fig. 9 schematically illustrates a section view along line IV - IV in fig. 8. The flap 28 of one corrugated sheet 4 is configured to be folded into an opening 26 of an adjacent corrugated sheet 4 in the stack of corrugated sheets 4, so that the flap 28 connects the adjacent sheets to each other. An optical device 30 comprising an optical sensor 54 is connected to a control unit 56, which is configured to receive sensed images of the sheets 4 from the optical sensor 54 for identifying positions of trough 50 and peak 52 connection points of the sheets 4, and / or for identifying positions of the openings 26 in the sheets 4 so that one of the sheets 4 may be positioned above the other sheet 4 such that the openings 26 are aligned.

[0065] Fig. 10 shows a flowchart of a method of manufacturing an evaporative cooling pad disclosed in figures 1 - 9. The method comprises the steps of providing slOl a first set 2 of corrugated sheets 4, providing sl02 a second set 6 of corrugated sheets 4, wherein the method comprises the further steps of: punching sl03 an opening 26 with a remaining foldable flap 28 in the provided sheets 4 of the first and second sets 2,6, and folding sl04 the foldable flaps 28 for locking the sheets 4 to each other. The step of folding sl04 the foldable flaps 28 for locking the sheets 4 to each other is preceded by the steps of: disposing sl05 one of the punched sheets 4 above the other punched sheet 4, and displacing sl06 the punched sheets 4 towards each other so that the flaps 28 of the punched sheets 4 above the other punched sheet 4 enter the openings 26 of the other punched sheet 4.

[0066] The step of punching sl03 an opening 26 with a foldable flap 28 in the provided sheets 4, comprises punching a semi-punched opening 26 with a foldable flap 28 in the provided sheets 4. The step of disposing sl05 one of the sheets 4 above the other sheet 4 comprises identifying the positions of the openings 26 in the sheets 4 by an optical device 30 comprising an optical sensor 54 connected to a control unit 56, which is configured to receive sensed images of the sheets 4 from the optical sensor 54 for identifying the positions of the openings 26, and positioning one of the sheets 4 above the other sheet 4 based on the identified positions of the openings 26 by the control unit 56 such that the openings 26 are aligned.. The step of punching sl03 an opening 26 with a foldable flap 28 in the provided sheets 4 is preceded by the steps of: positioning 107 one of the sheets 4 above the other sheet 4; identifying 108 positions of trough 50 and peak 52 connection points of the sheets 4 by an optical device 30, comprising an optical sensor 54 connected to a control unit 56, which is configured to receive sensed images of the sheets 4 from the optical sensor 54 for identifying the positions of the trough 50 and peak 52 connection points, and determining 109 where to create openings 26 and foldable flaps 28 in the sheets 4 based on the identified positions of the trough 50 and peak 52 connection points by the control unit 56. The method comprises the further steps of applying sllO an impregnation substance 32 to the sheets 4, and curing sill the impregnation substance 32 for bonding the sheets 4 together by the impregnation substance 32 at positions were the sheets 4 have contact with each other. Further, the method comprises the further step bonding sll2 the adjacent sheets 4 together by spot welding at positions were the sheets 4 have contact with each other.

Claims

AMENDED CLAIMS received by the International Bureau on 23 January 2025 (23.01 .2025)1. An evaporative cooling pad (1) comprising: a first set (2) of corrugated sheets (4);5 a second set (6) of corrugated sheets (4), wherein the sheets (4) of the first set(2) are disposed alternatively in a stack with the sheets (4) of the second set (6) to form the pad (1); elongated flutes (8) of said corrugated sheets (4) of the first and second sets (2,6) form passageways (10) extending from a first side (12) to a second side (14) of the pad (1);10 wherein the flutes (8) of a corrugated sheet of the first set (2) are adapted to at least face the flutes (8) of an adjacently arranged corrugated sheet of the second set (6), wherein at least one fixating element (16) is arranged to penetrate at least one of the corrugated sheets (4) in the stack of corrugated sheets (4) for attaching the corrugated sheets (4) to each other, wherein the corrugated sheets (4) of the first and second sets (2, 6) comprises openings (26),15 which are configured to be penetrated by the fixating element (16), wherein the at least one fixating element (16) comprising a lock element (24) protruding from the corrugated sheets (4) of the first and second sets (2, 6), and wherein the lock element (24) is arranged at contact points between the corrugated sheets (4), characterized in that the lock element (24) comprises a flap (28), which emanates from the20 openings (26), and wherein the flap (28) of one corrugated sheet (4) is configured to be folded into an opening (26) of an adjacent corrugated sheet (4) in the stack of corrugated sheets (4), so that the flap (28) connects the adjacent sheets to each other.

2. The pad (1) according to claim, wherein the flutes (8) of a corrugated sheet of the first set25 (2) are adapted to be in a contacting relationship with the flutes (8) of an adjacently arranged corrugated sheet of the second set (6).

3. The pad (1) according to any one of the preceding claims, wherein a frame (18) is arranged to at least partly surround the pad (1).30AMENDED SHEET (ARTICLE 19)204. The pad (1) according to any one of the preceding claims, wherein the flutes (8) of the corrugated sheets (4) each has a half-hexagonal shape, such that the passageways (10) formed between two adjacent corrugated sheets (4) have a hexagonal shape, wherein the passageways (10) with a hexagonal shape are arranged in parallel to each other.

55. The pad (1) according to any one of the claims 1 and 3, wherein the flutes (8) of the corrugated sheets (4) each has a sinusoidal shape, and wherein the sheets (4) of the first set(2) are disposed alternatively with the sheets (4) of the second set (6), with the flutes (8) of the first set (2) crossing the flutes (8) of the second set (6).

106. The pad (1) according to any one of the preceding claims, wherein the corrugated sheets (4) of the first and second sets (2, 6) comprises an impregnation substance (32).

7. The pad (1) according to any one of the preceding claims, wherein the at least one fixating15 element (16) comprises an elongated rod, which is configured to puncture the corrugated sheets (4) of the first and second sets (2, 6).

8. The pad (1) according to claim 7, wherein the rod has a rough surface, such as a wood texture.

209. The pad (1) according to any one of claims 7 and 8, wherein the rod comprises at least one weakened snap point (22).

10. The pad (1) according to any one of the preceding claims, wherein the flap (28) emanates25 from a semi-punched opening (26).

11. A method of manufacturing an evaporative cooling pad (1) according to any one of the preceding claims, characterized by the steps of:30 providing (slOl) a first set (2) of corrugated sheets (4), providing (s!02) a second set (6) of corrugated sheets (4), wherein the method comprises the further steps of:AMENDED SHEET (ARTICLE 19)21 punching (slO3) an opening (26) with a remaining foldable flap (28) in the provided sheets (4) of the first and second sets (2, 6), and folding (sl04) the foldable flaps (28) for locking the sheets (4) to each other.5 12. The method according to claim 11, whereby the step of folding (s!04) the foldable flaps(28) for locking the sheets (4) to each other is preceded by the steps of: disposing (sl05) one of the punched sheets (4) above the other punched sheet(4), and displacing (sl06) the punched sheets (4) towards each other so that the flaps10 (28) of the punched sheets (4) above the other punched sheet (4) enter the openings (26) of the other punched sheet (4).

13. The method according to any one of the claims 11 and 12, whereby the step of punching(sl03) an opening (26) with a foldable flap (28) in the provided sheets (4), comprises punching15 a semi-punched opening (26) with a foldable flap (28) in the provided sheets (4)14. The method according to claim 12, whereby the step of disposing (s!05) one of the sheets(4) above the other sheet (4) comprises identifying the positions of the openings (26) in the sheets (4) by an optical20 device (30), comprising an optical sensor connected to a control unit, which is configured to receive sensed images of the sheets (4) from the optical sensor for identifying the positions of the openings (26), and positioning one of the sheets (4) above the other sheet (4) based on the identified positions of the openings (26) by the control unit such that the openings (26) are aligned.2515. The method according to claim 11, whereby the step of punching (s!03) an opening (26) with a foldable flap (28) in the provided sheets (4) is preceded by the steps of: positioning (107) one of the sheets (4) above the other sheet (4); identifying (108) positions of trough (50) and peak (52) connection points of the30 sheets (4) by an optical device (30), comprising an optical sensor connected to a control unit, which is configured to receive sensed images of the sheets (4) from the optical sensor for identifying the positions of the trough (50) and peak (52) connection points, andAMENDED SHEET (ARTICLE 19)22 determining (109) where to create openings (26) and foldable flaps (28) in the sheets (4) based on the identified positions of the trough (50) and peak (52) connection points by the control unit.5 16. The method according to any one of the claims 11 - 13, whereby the method comprises the further steps of: applying (sllO) an impregnation substance (32) to the sheets (4), and curing (sill) the impregnation substance (32) for bonding the sheets (4) together by the impregnation substance (32) at positions were the sheets (4) have contact10 with each other.

17. The method according to any one of the claims 11 - 16, whereby the method comprises the further step of: bonding (s112) the adjacent sheets (4) together by spot welding at positions15 were the sheets (4) have contact with each other.AMENDED SHEET (ARTICLE 19)

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