Fill Support Grid Hanger Integrally Formed Blocks

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Solution Overview

Problem

Existing cooling tower fill support grid securing methods are inefficient, prone to flexing, and require additional structural members, which can complicate installation and stability.

Innovation Solution

A fill support grid hanger with an elongated rail and integrally formed blocks that contact horizontal structural members to prevent flexing, combined with three-dimensional surface features and bores for secure attachment, ensuring stable and direct mounting without intervening spacer bars.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fill support grid securing methods using flanges and nails or screws are used, then the grid can be attached to horizontal structural members, but the attachment is prone to flexing and requires additional structural members like spacer bars

Engineering Contradiction:

Improveattachment stabilityVSAvoidstructural member requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the flange and support blocks into a single integrated hanger component. The hanger includes a flange for attachment to the horizontal structural member and blocks that extend downward to contact and support the fill support grid, eliminating the need for separate spacer bars and reducing the number of parts required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hanger is divided into distinct functional segments: the flange portion for attachment to the structural member, the blocks for supporting the fill grid, and the integrally formed connection between them. This segmentation allows each part to perform its specific function optimally while being part of a unified component.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If spacer bars are used to secure the fill support grid, then the grid can be mounted between structural members, but installation becomes more complicated and time-consuming

Engineering Contradiction:

Improveinstallation simplicityVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The invention extracts and eliminates the intermediary spacer bar from the assembly process. The hanger directly attaches to the horizontal structural member and directly supports the fill grid, removing the intermediate component that complicated installation and increased time requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If the rail is allowed to flex toward and away from the horizontal structural member, then the installation may be simpler, but the structural integrity and stability are compromised

Engineering Contradiction:

Improvestructural integrityVSAvoidflex restraint mechanism

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The blocks are positioned at specific locations along the rail to provide localized support and prevent flexing at critical points. The blocks extend downward from the rail to contact the fill support grid, providing distributed support that maintains structural integrity without requiring the entire rail to be overly rigid or complex.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11585614B2Fill support assembly

Publication Date: 2023.02.21 EVAPCO INC

AI summary

A fill support grid hanger for hanging a full support grid from a horizontal structural member that obviates the need for an intervening spacer bar. The hanger features a flange at the top, a plurality of blocks in the back to stabilize the hanger on the horizontal structural member, and three-dimensional features on the front side to receive and prevent lateral movement of two or more different types of fill support grids.