Synthetic media pads for an evaporative cooler and method for evaporative cooling

Abstract

Synthetic media pads configured to be arranged in a stack of an evaporative cooler for a gas turbine, wherein the synthetic media pads include high density synthetic media pads and low density synthetic media pads. The sides of the pads may have surface patterns, such as grooves and ridges, to provide support for the pads.

What is claimed is: 
     
         1 . An evaporative cooler configured for a device, the cooler comprising a stack of synthetic media pads, wherein the stack is configured to be mounted in an inlet chamber having an inlet open to atmospheric air and an outlet coupled to an air inlet to the device, wherein the synthetic media pads include high density synthetic media pads and low density synthetic media pads. 
     
     
         2 . The evaporative cooler of  claim 1  wherein the synthetic media pads are formed of polyester or glass fibers, and the high density synthetic media pads have a density of fibers greater than a density of fibers in the low density synthetic media pads. 
     
     
         3 . The evaporative cooler of  claim 2  wherein the density of the high density synthetic media pads is at least twice the density of the low density synthetic media pads. 
     
     
         4 . The evaporative cooler of  claim 1  wherein the high density synthetic media pads alternate in the stack with the low density synthetic media pads. 
     
     
         5 . The evaporative cooler of  claim 1  wherein the synthetic media pads each are formed of polyester or glass fibers. 
     
     
         6 . The evaporative cooler of  claim 1  wherein the low density synthetic media pads include sides, and a surface pattern on the sides includes parallel ridges and grooves. 
     
     
         7 . The evaporative cooler of  claim 6  wherein the parallel ridges each peak in a rear half of the stack and slope downward from the peak towards a front face of the stack. 
     
     
         8 . The evaporative cooler of  claim 6  wherein the parallel ridges are wavy between a front face and a rear face of the stack. 
     
     
         9 . The evaporative cooler of  claim 6  the high density synthetic media pads includes sides, and a surface pattern on the sides includes parallel ridges and grooves. 
     
     
         10 . The evaporative cooler of  claim 1  wherein the synthetic media pads are arranged in the stack such that front edges of the media pads are aligned with a front face of the stack and rear edges of the media pads are aligned with a rear face of the stack. 
     
     
         11 . The evaporative cooler of  claim 1  wherein a front surface of the stack covers an entirety of an air flow passage in the inlet chamber. 
     
     
         12 . Synthetic media pads configured to be arranged in a stack for an evaporative cooler mounted in an air inlet chamber for a gas turbine, wherein the synthetic media pads include high density synthetic media pads and low density synthetic media pads. 
     
     
         13 . The synthetic media pads of  claim 12  wherein the synthetic media pads are formed of polyester or glass fibers, and the high density synthetic media pads have a density of fibers at least fifty percent denser than a density of fibers in the low density synthetic media pads. 
     
     
         14 . The synthetic media pads of  claim 12  wherein the synthetic media pads each are formed of polyester or glass fibers. 
     
     
         15 . The synthetic media pads of  claim 12  wherein the low density synthetic media pads include sides, and a surface pattern on the sides includes parallel ridges and grooves. 
     
     
         16 . The synthetic media pads of  claim 15  wherein the parallel ridges each peak in a rear half of the stack and slope downward from the peak towards a front face of the stack. 
     
     
         17 . The synthetic media pads of  claim 15  wherein the parallel ridges are wavy between a front face and a rear face of the stack. 
     
     
         18 . A method to form a stack of synthetic media pads for an evaporative cooler, the method comprising:
 arranging in the stack high density synthetic media pads of synthetic fibers, wherein a density of fibers in the high density media pads is above a first threshold density;   arranging in the stack low density synthetic media pads of synthetic fibers, wherein a density of fibers in the low density media pads is below a second threshold density which is lower than the first threshold density, and   positioning the stack in the evaporative cooler such that a front surface of the stack faces air drawn into an inlet chamber and a rear surface faces an air passage leading to an inlet to a gas turbine.   
     
     
         19 . The method of  claim 18  further comprising applying heat to sides of the low density synthetic media pads to deform the fibers at the sides to form a surface pattern on the sides including parallel ridges and grooves. 
     
     
         20 . The method of  claim 19  further comprising applying heat to sides of the high density synthetic media pads to deform the fibers at the sides to form a surface pattern on the sides including parallel ridges and grooves.