Composite Hanger Grid for Cooling Tower Splash Bars

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Solution Overview

Problem

Current splash bar support systems in cooling towers face issues such as corrosion, structural limitations, and complex installation processes due to the use of wire mesh grids and plastic injection molded grids, which lead to premature failure and increased installation time.

Innovation Solution

A composite hanger grid system with vertically aligned horizontal beams and suspension members that form a grid of windows, allowing splash bars to be supported perpendicularly, with elongated slots and locking structures on the splash bars for secure retention within the grid, facilitating easier installation and enhanced structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If wire mesh grids with spot welded connections are used to support splash bars, then the grid provides structural support, but the spot welded connections become the point of failure due to limited structural capacity and corrosion

Engineering Contradiction:

Improvestructural capacityVSAvoidfailure resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The grid is divided into vertical members and horizontal members that are separate components rather than being spot welded together. This segmentation eliminates the weak spot welded joints while maintaining structural integrity through alternative connection methods using deformations on vertical members to engage horizontal members.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grid combines different material properties by using corrosion-resistant vertical members (such as stainless steel or coated wire) with horizontal members that can be wood or other materials. This composite approach allows each component to be optimized for its specific function while resisting the corrosive cooling tower environment.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If plastic injection molded grids are used to support splash bars, then the grid provides integrated connection methods, but the grids fail at high stress areas near the top where accumulated load exceeds material strength

Engineering Contradiction:

Improveintegrated connectionVSAvoidload bearing capacity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The grid is divided into separate vertical and horizontal members that can be assembled after manufacturing. This allows each component to be manufactured independently with optimized properties, avoiding the stress concentration issues in integrated plastic grids while maintaining ease of assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection mechanism uses deformations on vertical members that can be adjusted to different positions along the member length. This allows optimization of the connection points to distribute loads more evenly and avoid high stress concentrations at fixed locations.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If splash bars are retained using external clips or opposing clips, then the splash bars are held in place, but the installation process becomes complex and time-consuming

Engineering Contradiction:

Improveretention securityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The retention function is merged into the horizontal members themselves through integrally formed features such as locking portions and extensions. This eliminates the need for separate external clips while maintaining secure retention, thereby simplifying the installation process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The horizontal members have self-retaining features that automatically secure the splash bars without requiring additional components or complex installation procedures. The locking portions and extensions work together to provide automatic retention once the splash bars are positioned.

Inventive Principle:

Principle #25Self-service

4Stability of the object's composition

If the horizontal beams are supported at fixed locations on suspension members, then the grid structure is stable, but the system lacks adaptability to different cooling tower configurations

Engineering Contradiction:

Improvestructural stabilityVSAvoidconfiguration flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The support locations of horizontal beams on vertical members are made adjustable rather than fixed. Deformations can be positioned at different locations along the vertical members, allowing the grid configuration to be dynamically adapted to different cooling tower dimensions and requirements while maintaining structural stability.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS9546830B2Composite hanger grid and components, splash bar, assembly thereof and method of assembly

Publication Date: 2017.01.17 BRENTWOOD IND INC

AI summary

A composite hanger grid for supporting splash bars in a cooling tower uses separate vertical suspension members and horizontal beams by which all of the operational loads imposed on the splash bars are transferred to the horizontal beams, which then transfer the load to the vertical suspension members. Since all of the horizontal beams are independent of each other and separate components from the vertical suspension members, the horizontal beams will be loaded equally throughout the entire hanger grid. Also disclosed are components of the composite hanger grid, splash bars adapted for use with specific embodiments of the composite hanger grid, assemblies of the composite hanger grid with its supported splash bars, a method of assembling a composite hanger grid and a method of assembling an evaporative cooler fill assembly, including hanger grids and splash bars, in a cooling tower.