Fill pack assembly and method with bonded sheet pairs

Abstract

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.

What is claimed is: 
     
         1 . A method of assembling a fill pack from individual fill sheets, comprising:
 integrally bonding two individual adjacent fill sheets, wherein each sheet has a perimeter and an internal contact point, wherein said internal contact point is one of a peak or a valley disposed within said perimeter and wherein each respective internal contact point engages the other contact point during assembly, to each other to form a first bonded sheet pair;   repeating the step of integrally bonding two individual adjacent fill sheets to each other to form a second bonded sheet pair;   attaching said first and said second bonded sheet pair pairs to each other, wherein the step of attaching the first and second bonded sheet pairs together comprises holding them together using a mounting tube having a first end and a second end which passes through apertures in the first and second bonded sheet pairs; and a first cap attached to said first end and a second cap attached to said second end.   
     
     
         2 . The method of  claim 1 , further comprising repeating the steps of integrally bonding two individual adjacent fill sheets, and repeating the steps of attaching bonded sheet pairs to each other. 
     
     
         3 . The method of  claim 1 , wherein the step of bonding two individual sheets together to form a bonded sheet pair comprises twin sheet vacuum forming 
     
     
         4 . The method of  claim 1 , wherein said step of integrally bonding two individual sheets comprises placing the two individual adjacent fill sheets between a pair of electrodes and radio frequency (RF) welding the individual sheets along the perimeter at the internal contact points. 
     
     
         5 . A method of assembling a fill pack from individual fill sheets, comprising:
 integrally bonding two individual adjacent fill sheets, wherein each sheet has a perimeter and an internal contact point, wherein said internal contact point is one of a peak or a valley disposed within said perimeter and wherein each respective internal contact point engages the other contact point during assembly, to each other to form a first bonded sheet pair;   repeating the step of integrally bonding two individual adjacent fill sheets to each other to form a second bonded sheet pair; and   attaching said first and said second bonded sheet pair pairs to each other, wherein the step of attaching two or more bonded sheet pairs together comprises inserting at least one mounting pin through the bonded sheet pairs.   
     
     
         6 . The method of  claim 5 , further comprising repeating the steps of integrally bonding two individual adjacent fill sheets, and repeating the steps of attaching bonded sheet pairs to each other. 
     
     
         7 . The method of  claim 5 , wherein the step of bonding two individual sheets together to form a bonded sheet pair comprises twin sheet vacuum forming. 
     
     
         8 . The method of  claim 5 , wherein said step of integrally bonding two individual sheets comprises placing the two individual adjacent fill sheets between a pair of electrodes and radio frequency (RF) welding the individual sheets along the perimeter at the internal contact points. 
     
     
         9 . A method of assembling a fill pack from individual fill sheets, comprising:
 integrally bonding two individual adjacent fill sheets, wherein each sheet has a perimeter and an internal contact point, wherein said internal contact point is one of a peak or a valley disposed within said perimeter and wherein each respective internal contact point engages the other contact point during assembly, to each other to form a first bonded sheet pair;   repeating the step of integrally bonding two individual adjacent fill sheets to each other to form a second bonded sheet pair; and   attaching said first and said second bonded sheet pair pairs to each other, wherein the step of attaching two or more bonded sheet pairs together comprises restraining the bonded sheet pairs within a restraining frame.   
     
     
         10 . The method of  claim 9 , further comprising repeating the steps of integrally bonding two individual adjacent fill sheets, and repeating the steps of attaching bonded sheet pairs to each other. 
     
     
         11 . The method of  claim 9 , wherein the step of bonding two individual sheets together to form a bonded sheet pair comprises twin sheet vacuum forming. 
     
     
         12 . The method of  claim 9 , wherein said step of integrally bonding two individual sheets comprises placing the two individual adjacent fill sheets between a pair of electrodes and radio frequency (RF) welding the individual sheets along the perimeter at the internal contact points. 
     
     
         13 . A fill pack for use in an environmental heat exchange assembly, comprising:
 a plurality of bonded sheet pairs each comprising a first sheet and a second sheet bonded to each other, wherein the first and second sheet pairs are bonded together via radio frequency (RF) welding;   a mounting tube having a first end and a second which passes through apertures in the plurality of bonded sheet pairs; and   a first cap attached to said first end and a second cap attached to said second end.   
     
     
         14 . A fill pack for use in an environmental heat exchange assembly, comprising:
 a plurality of bonded sheet pairs each comprising a first sheet and a second sheet bonded to each other, wherein the first and second sheet pairs are bonded together via radio frequency (RF) welding; and   at least one mounting pin inserted through the sheet pairs.