Bonded Sheet Pairs for Heat Exchange Fill Packs

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Solution Overview

Problem

Existing fill pack construction methods for heat exchange towers are labor-intensive, costly, and pose environmental and safety concerns due to the use of solvents, while also lacking rigidity and reliability in large-scale installations.

Innovation Solution

The method involves forming integrally bonded sheet pairs using RF welding or other bonding methods, which are then assembled into a fill pack, providing increased rigidity and ease of handling, and can be mechanically attached for stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sheets are merely adjacent each other without bonding, then assembly is simple and quick, but the fill pack lacks rigidity and sheets may fall out

Engineering Contradiction:

Improveassembly speedVSAvoidsheet stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The fill pack is divided into modular units where sheets are bonded in pairs to form stable segments. These segmented bonded pairs are then assembled together, providing both rapid assembly through modularity and reliable sheet stability through bonding at critical points.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Adjacent sheets are merged into bonded pairs by applying bonding material at contact points. This merging creates a stable unit that prevents sheets from falling out while maintaining assembly efficiency through the pairing approach.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If bonding material is applied to all contact points, then sheet stability is maximized, but labor and material costs increase

Engineering Contradiction:

Improvesheet stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Bonding material is applied selectively at specific contact points where sheets touch, rather than uniformly across all surfaces. This localized bonding approach provides sufficient sheet stability at critical locations while reducing material consumption and manufacturing complexity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of bonding all possible contact points (excessive action), the invention applies bonding material to a sufficient subset of contact points (partial action) that achieves the required sheet stability without unnecessary material usage or labor.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If solvents are used to bond sheets, then bonding effectiveness is improved, but environmental and safety issues arise

Engineering Contradiction:

Improvebonding strengthVSAvoidenvironmental contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention replaces harmful solvent-based bonding with alternative bonding methods that eliminate environmental contamination and safety hazards. The bonding mechanism is converted from a chemical process with harmful byproducts to a cleaner process that achieves equivalent bonding strength without harm.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention substitutes the chemical bonding mechanism (solvent-based adhesion) with an alternative bonding approach that does not rely on volatile chemicals. This replacement eliminates the harmful environmental and safety factors associated with solvent evaporation and exposure while maintaining effective bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Volume of stationary object

If large volumes of fill pack material are required, then heat exchange capacity is improved, but handling and installation become difficult

Engineering Contradiction:

Improvefill pack volumeVSAvoidhandling ease

Core Design Contradiction:

Volume of stationary objectVSEase of operation

Solution Approach 1:

The large fill pack volume is achieved through the assembly of multiple bonded sheet pairs arranged in modular sections. This segmentation allows the large overall structure to be handled as manageable units during installation, with each bonded pair serving as a stable component of the larger assembly.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces labor and chemical usage, enhances rigidity and handling ease, and ensures reliable bonding in large-scale fill packs for heat exchange applications.

Implementation Method 1

the radio frequency (RF) welds the sheets together from opposite sides of the bonded sheet pair

Methodology Applied

Scientific EffectRF welding: Dielectric Heating

Data Source

PatentUS8771457B2Fill pack assembly and method with bonded sheet pairs

Publication Date: 2014.07.08 SPX COOLING TECHNOLOGIES INC

AI summary

A fill pack assembly and method for assembling a fill pack from individual sheets utilizes integrally bonded sheet pairs. Each sheet pair is a pair of two individual adjacent fill sheets which have been bonded together via any suitable bonding method. A plurality of the thus formed sheet pairs can then be attached together to form an entire fill pack or portion of a fill pack. Such fill packs are useful in heat exchange devices such as industrial cooling towers.