Method and blank for the manufacture of high efficiency open volumed packing bodies

A method and manufacturing blank for the production of high performance substantially symmetrical open volumed packing bodies is disclosed comprising the steps of forming a blank from sheet material, the blank comprising a plurality of generally identical plates interconnected in linear series by ribbon members coupling adjacent plates and defining a median strip, shaping the plates into troughs having longitudinal axes oriented perpendicularly to the median strip, and bending the median strip to bring the longitudinal axes into close proximity with one another to form an open volumed packing body having a central core defined by the aligned bores.

FIELD OF THE INVENTION 
The present invention relates, in a broad aspect, to a method for 
manufacturing packing bodies for use in packed column or tower chemical 
processing operations. More particularly, the present invention is 
directed to a method and manufacturing blank for the production of high 
efficiency, high performance, substantially symmetrical, open volumed 
packing bodies. 
BACKGROUND OF THE INVENTION 
Packing bodies for use in chemical processing operations such as 
absorption, desorption, extraction, scrubbing, heat exchange and the like 
are well-known in the art. Typically, relatively large numbers of 
substantially identical packing bodies are loaded into processing columns 
or towers in a random or dumped manner. It is also known in the art to 
fill processing columns with structured packing materials comprising 
ordered arrays of substantially identical packing bodies. In both 
applications, the function of the packing bodies is to enhance fluid 
contact and interaction between opposing streams of fluid within the 
packed column or tower to enhance the efficiency and rate of the chemical 
process involved. The packing bodies accomplish this by providing large 
areas of wettable surface and by disrupting fluid flow within the column 
to form large numbers of individual droplets and fine streams thereby 
promoting the mixing of the various reaction streams. 
Recently, high efficiency, high performance packing bodies have been 
developed which provide a substantially uniform distribution of open 
cellular units throughout their internal volume and external surface area. 
These high efficiency packing bodies provide maximal wettable surface area 
with a minimal restriction to fluid flow and are relatively insensitive to 
orientation within packed columns. As a result, the packing bodies can be 
dump loaded into processing columns or towers without fear of obstructing 
fluid flow and larger volumes of fluid can be passed through physically 
smaller columns at increased rates, thereby substantially increasing 
process efficiency and reducing costs. 
Unfortunately, the uniform geometric configuration of these improved, high 
efficiency packing bodies makes it difficult if not impossible to produce 
such packing bodies in an economical manner. Prior art manufacturing 
techniques include casting, injection molding, and extrusion processes. 
All of these techniques have the drawback of eliminating a certain degree 
of the uniform radial symmetry within the ideal packing bodies in order to 
allow the packing body to be extruded from a die or released from a mold. 
While it is possible to cast complex structures such as these utilizing a 
lost wax or similar technique, this is a prohibitively expensive and time 
consuming process. Exotic multi-piece injection molds also can be utilized 
to produce substantially uniform packing bodies. However, these too are 
prohibitively expensive. 
Even more significantly, a number of high temperature or chemically active 
processing systems require the utilization of metal packing bodies within 
the processing column or tower. To date, it has not been possible to 
produce a high efficiency, high performance, generally symmetrical, open 
volumed packing body from metal. Most prior art metal packing bodies have 
been formed from rolled metal blanks which have been punched or stamped 
prior to rolling. The rolled packing bodies are generally spherical or 
tubular in shape and may include internal projections to enhance their 
efficiency. However, their performance falls far short of that of ideal 
high efficiency packing bodies. 
Accordingly, it is a principal object of the present invention to provide a 
method and associated blank for manufacturing high efficiency, high 
performance, substantially uniform and symmetrical, open volumed packing 
bodies from a wide variety of materials including metals, plastics and 
ceramics. 
It is a further object of the present invention to provide a method and 
blank for manufacturing high efficiency, substantially uniform and 
symmetrical, open volumed packing bodies utilizing inexpensive mass 
production techniques that do not directly involve expensive casting, 
molding, or extrusion processes. 
SUMMARY OF THE INVENTION 
These and other objectives are achieved by the present invention which 
provides a method for manufacturing high performance, symmetrical, open 
volumed packing bodies having uniform geometrical configurations from a 
wide variety of materials. The method of the present invention is suitable 
for manufacturing open volumed objects having a wide variety of shapes and 
geometries including highly complex and efficient packing body 
configurations utilizing simple and economical sheet materials and 
manufacturing techniques. 
In accordance with the present invention, substantially symmetrical open 
volumed column packing bodies are produced from a blank of sheet material. 
This generally planar blank of sheet material is formed as a plurality of 
generally identical plates which are interconnected in a linear series by 
one or more ribbon members coupling adjacent plates. This linear series of 
interconnected plates can be formed by cutting or stamping the desired 
sections from a single piece of sheet material or individual plates can be 
threaded together in series by one or more ribbon members coupling the 
generally outer periphery of adjacent plates. Either configuration is 
preferred and in both configurations the ribbon member defines a median 
strip linking the plates in a linear series. 
During or after formation of the blank, each plate is shaped into a trough 
having its longitudinal axis oriented perpendicularly to the median strip. 
Shaping takes place through stamping, folding, or bending each plate in 
the same direction along each plate's longitudinal axis such that all 
longitudinal axes so formed are generally co-planar and parallel. 
The shaped troughs can be arcuate or angular in cross section or 
combinations of both configurations. Angular troughs are contemplated as 
being either acute or obtuse depending upon the number of plates in the 
blank and the ultimate configuration of the packing body being produced. 
Additionally, the surface of each plate can be provided with projecting 
fingers or arches as well as crenellations and additional folds to 
increase the wettable surface area and number of drip formation points. 
Preferably, for ease of manufacturing, such additional surface features 
will be arranged generally parallel with the longitudinal axis of each 
plate though other arrangements are contemplated as being within the scope 
of the present invention. 
Following the formation of the blank of substantially identical trough 
shaped plates interconnected by the ribbon member median strip, the ribbon 
members of the median strip are bent to bring the longitudinal axes of the 
trough shaped plates into close proximity with one another in 
substantially parallel alignment. The resulting configuration defines a 
packing body having an open internal configuration with a central, 
longitudinal core defined by the aligned axes of the plates and an outer, 
generally equatorial segmented median strip defined by the bent ribbon 
members. The general outer configuration of the packing body is defined by 
the initial shape of the plates. For example, circular plates will produce 
a spherical packing body whereas polygonal plates will produce a 
polyhedral packing body. 
Those skilled in the art will appreciate that any number of plates may be 
linked in series to produce packing bodies having varying densities. 
Similarly, an almost infinite variety of packing body shapes can be 
construted utilizing the method of the present invention by designing the 
appropriate shaped plates in the initial starting blank. 
It is also contemplated as being within the scope of the present invention 
to form the starting blank as a linear series of interconnected trough 
shaped plates rather than forming and shaping the blank in two separate 
operations. This method is suitable for both integral, one-piece blanks or 
multi-piece blanks stitched together with a flat ribbon member or members. 
However, where it is contemplated that the plates will incorporate 
projecting fingers or arcuate members, separate forming and shaping steps 
may be preferred. 
The manufacturing blank can be formed of any suitable material or 
combination of materials including metals and plastics. For example, a 
one-piece linear series of plates can be stamped from sheet metal stock or 
plastic. Similarly, individual metal plates may be interconnected in 
series by one or more flat metal ribbon members. Alternatively, individual 
metal plates may be linked by a plastic ribbon member or vice versa. 
In a preferred exemplary embodiment of the present invention each plate of 
the manufacturing blank is provided with a plurality of uniformly 
distributed open cellular units defined by concentric arcuate members 
interconnected by radially extending struts. Alternatively, each plate may 
be formed of open mesh materials such as metal screen. It is also 
contemplated as being within the scope of the present invention for each 
plate to be solid and non-perforated. 
A further understanding of the present invention will be provided to those 
skilled in the art from the following detailed description and the 
associated drawings which first will be described briefly.

DETAILED DESCRIPTION 
Referring more particularly to the drawings, FIGS. 1 through 4 illustrate 
an exemplary embodiment of a manufacturing blank and high performance, 
substantially symmetrical open volume packing body formed in accordance 
with the teachings of the present invention. Blank 10, comprises a 
plurality of generally identical plates 12, 14, and 16 which are 
interconnected in a linear series by ribbon members 30 and 32. Blank 10 is 
formed from sheet material using any known sheet manufacturing process 
including stamping, punching, and cutting operations. These manufacturing 
techniques of blank 10 are preferred however, in those situations where 
the material forming the blank 10 is not adaptable to such manufacturing 
techniques it is also contemplated as being within the scope of the 
present invention to cast blank 10 in sheet form. For example, while it is 
preferred that blank 10 is formed from metal or plastic, some chemical 
processing applications may require unique ceramic materials or reinforced 
plastics which are not readily suitable to punching or stamping 
operations. 
It should be noted that while blanks 12, 14, and 16 are each shown provided 
with a plurality of holes 28, holes are not essential to the present 
invention. Similarly, it is not essential to the present invention to have 
all plates of blank 10 exactly identical. Accordingly, some plates may be 
provided with holes 28 and others may be solid. Similarly, varying numbers 
of holes may be provided in different plates or some plates may be sized 
or shaped slightly different from the other plates in the blank. However, 
the generally identical plates 12, 14, and 16 of blank 10 are preferred as 
this both simplifies manufacturing and provides a desired degree of 
symmetry to the open volumed packing body formed in accordance with the 
present invention. 
Ribbon members 30 and 32 couple adjacent plates in a linear series to form 
blank 10 and define a median strip linking the linear series of the 
plates. An additional ribbon ribbon member 34 may be provided as shown on 
plate 16 in FIGS. 1 and 2, if desired. Similarly, an additional member 
(not shown) corresponding to ribbon member 34 may be provided on plate 12. 
These additional ribbon members are not essential to the practice of the 
present invention, but are desireable as they complete the median strip 
ultimately formed in the open volumed packing body. 
Referring to FIG. 2, blank 10 is shown in side view to illustrate the 
trough shapes formed in plates 12, 14, and 16 with their respective 
longitudinal axes 36, 38 and 40 aligned generally perpendicularly to the 
median strip defined by ribbon members 30, 32, and 34. This shaping of 
plates 12, 14, and 16 can be accomplished during the original formation 
process through bending or folding blank 10 or by shaping the plates after 
formation of the blank. For example, in the first instance where blank 10 
is stamped from sheet stock, it is possible to produce blank 10 with the 
appropriate trough shaped plates 12, 14, and 16. Either method is 
preferred. In FIG. 2, the troughs of plates 12, 14, and 16 are shown as 
being angular in cross section. It is also contemplated as being within 
the scope of the present invention to form arcuate or curved troughs as 
well as combinations of both configurations. For example, as long as the 
longitudinal axes 36, 38 and 40 are preserved, it is possible to add 
additional folds or crenellations to the surfaces of each plate to enhance 
both strength, rigidity and surface area. 
To manufacture the high efficiency packing body, the method of the present 
invention takes the formed and shaped blank 10 and bends the ribbon 
members 30, 32, and 34 of the median strip to bring longitudinal axes 36, 
38 and 40 into close proximity with one another in substantially parallel 
alignment as shown in FIGS. 3 and 4. Though ribbon members 30, 32, and 34 
are shown in FIGS. 3 and 4 as bent in an arcuate fashion, this is not 
essential to practice the present invention. Those skilled in the art will 
appreciate that as long as the ribbon members are dimensioned 
appropriately to allow sufficient material for spanning the distance 
between plates 12, 14, and 16 in the ultimate folded or bent 
configuration, it is possible to bend ribbon members 30, 32, and 34 in a 
wide variety of configurations. Such configurations would include angles 
or multiple angles and crenellations as well as straight sections. These 
configurations are not shown in FIGS. 3 and 4. 
Accordingly, by forming blank 10 with its plurality of plates 12, 14, and 
16 interconnected by ribbon members 30, 32, and 34 and shaping plates 12, 
14, and 16 into troughs with axes 36, 38 and 40 it is possible to bend the 
median strip defined by ribbon members 30, 32, and 34 to produce a 
substantially symmetrical open volumed packing body as shown in FIG. 4. 
The packing body has an outer configuration defined by the shape of plates 
12, 14, and 16 and an inner core defined by their respective axes 36, 38, 
and 40. Holes 28 are uniformly distributed throughout the interior volume 
of the packing body formed by blank 10 making the packing body relatively 
insensitive to fluid flow orientation within a packed column. 
The number of plates forming the blank of the present invention can be 
altered to suit the degree of packing body density desired. For example, 
two identical plates can be utilized to form a packing body having minimal 
internal density. Conversely, a virtually unlimited number of plates may 
be incorporated into the blank to form packing bodies having significantly 
higher densities. Thus, by varying the number of plates and the number of 
holes within each plate, it is possible to make extremely high efficiency, 
high performance packing bodies having complex geometries that are 
virtually impossible to make using known prior art techniques. Moreover, 
the method of the present invention makes it possible to construct such 
complex structures from metal and other materials without compromising the 
symmetry of the final packing body. Thus, the present invention makes it 
possible to construct high efficiency metal packing bodies in an 
inexpensive manner using conventional sheet material manufacturing 
techniques such as stamping, punching, and bending. Further economy in 
construction is achieved by utilizing a single manufacturing blank that 
does not require fasteners to maintain its ultimate shape. As a result, 
the method of the present invention is particularly well suited to 
automated production techniques having a minimal number of steps. 
The ultimate external configuration of the packing body formed in 
accordance with the teachings of the present invention is detemined by the 
original shape of the plates forming the manufacturing blank. FIGS. 5 
through 10 are illustrative of exemplary alternative embodiments of the 
present invention illustrating this variable feature. For example, in FIG. 
5 plate 18 is formed with a plurality of concentric arcuate members 42 and 
44 interconnected by a plurality of radially extending struts 46 defining 
a plurality of uniformly distributed open cellular units 48. Ribbon 
members 50 and 52 are shown extending from plate 18 in partial section to 
define the median strip linking adjacent plates (not shown) in linear 
series. This preferred exemplary plate configuration provides an extremely 
high degree of internal symmetry making the packing body particularly 
insensitive to fluid flow orientation within a packed column or tower. 
Moreover, the open cellular construction provides a maximal amount of 
wettable surface area and drip formation points at the intersections of 
the arcuate members and struts. Those skilled in the art will appreciate 
that any number of arcuate members and struts may be utilized to provide a 
plate construction having a practically unlimited number of open cellular 
units. Moreover, though circular plates have been discussed in these 
examples, it is also possible to construct the plates with angular or 
polygonal configurations to produce packing bodies of varying shapes. 
Along these lines, FIG. 6 illustrates an additional alternative embodiment 
of the present invention wherein plate 20 is formed as a rectangular 
polygon provided with a plurality of holes 54 relatively evenly 
distributed throughout its planar extent. Ribbon members 56 and 58 are 
shown extending from plate 20 in partial section to define the median 
strip linking adjacent plates (not shown) in linear series. 
Similarly, FIG. 7 shows an additional alternative embodiment of blank 10 
wherein plate 22 is constructed in a triangular polygonal configuration. 
Also shown in FIG. 7 is a further modification of the blank of the present 
invention wherein multiple ribbon members 60, 62, 64, and 66 are shown 
extending from plate 22 in partial section. Ribbon members 60 through 66 
define the theoretical median strip linking the interconnected plates (not 
shown) in linear series of this alternative embodiment. The resultant 
packing body formed by a manufacturing blank comprising a plurality of 
identical plates 22 will be generally conical in its outer configuration. 
The provision of additional ribbon members 64 and 66 functions to provide 
additional wettable surface area and drip formation points as well as an 
external stabilizing meridian strip about the outer periphery of the 
packing body so formed. 
Those skilled in the art will appreciate that the ribbon members utilized 
to practice the method of the present invention can be provided with 
holes, projecting fingers or arches (not shown), or slots of their own 
(not shown) to increase surface area. Moreover, as shown in FIG. 7, 
multiple ribbon members coupling adjacent plates in the linear series of 
the manufacturing blank can also be provided to further enhance the 
performance of the packing body. 
Turning now to FIG. 8, an additional alternative embodiment of the present 
invention is illustrated in which the manufacturing blank is constructed 
in a nonintegral fashion from individual plates threaded on a continuous 
ribbon member. Thus, representative plate 24 is shown threaded on ribbon 
member 68 through slots 70 and 72. Plate 24 is shown as a polygonal plate 
of open wire mesh. The mesh of plate 24 can be constructed of metal, 
fiberglass, plastic, or other suitable material and provides a high degree 
of wettable surface area and drip formation points. Moreover, this 
non-unitary construction eliminates waste material produced from 
conventional stamping and cutting techniques by enabling the blank to be 
constructed from easily manufactured substantially identical plates which 
can be constructed from appropriately sized raw materials with minimal 
waste. Similar economies are achieved by utilizing a mass produced ribbon 
68 which can be cut to the appropriate length and threaded through the 
appropriate number of plates to form a blank having the desired 
configuration and ultimate density. 
To increase the efficiency of the packing body produced in accordance with 
the method of the present invention, it is also contemplated to provide 
the manufacturing blank with a plurality of projecting fingers or 
projecting arcuate strips to increase the number of drip formation points. 
FIGS. 9 and 10 show an alternative plate 26 having extending ribbon 
members 74 and 76 defining the theoretical median strip and punched out 
arcuate strips 78 and 80 and projecting fingers 82 and 84. Those skilled 
in the art will appreciate that projecting arcs 78 and 80 and projecting 
fingers 82 and 84 can be stamped or punched out of sheet material during 
the initial forming step of the present invention. Preferably, embodiments 
of the present invention having plates incorporating projecting arcs and 
fingers will be formed from sheet material with the projecting arcs and 
fingers prior to shaping of the plates into troughs. However, this is not 
essential to practice the method of the present invention as it is also 
possible to form a blank having the appropriate trough shaped 
configuration with projecting arcs and fingers. It should be appreciated 
that all of these alternative embodiments discussed can also be provided 
with a variety of holes having various configurations and locations as 
desired. 
Those skilled in the art will appreciate that the folded configuration of 
the packing bodies formed in accordance with the teachings of the present 
invention impart a degree of structural rigidity that is sufficient to 
withstand the rigors of loading and operation in packed columns or towers. 
Additional strength can be provided through additional folds or ribbon 
members as well as selecting starting materials having the appropriate 
strengths or thickness to provide the desired degree of rigidity. 
Typically, a metal blank having an approximate thickness of 0.5 mm. is 
suitable for most metal packing applications. This material is quite rigid 
yet is easily manipulated with conventional sheet metal forming techniques 
to perform the method of the present invention. 
A certain degree of interlocking and meshing of the packing bodies is to be 
expected when loaded into a packed column or tower. However, because of 
the complete absence of cupped or occluded surfaces within the packing 
bodies themselves and as a result of the substantially symmetrical 
configuration of the internal structures of the packing bodies, such 
interlocking will not have a significant effect on column performance. 
Additionally, interlocking can be reduced through the provision of 
additional ribbon members interconnecting the adjacent plates in the 
manufacturing blank. As shown in FIG. 4, ribbon members 30, 32, and 34 
define a generally equatorial median strip preventing interlocking between 
plates 12, 14, and 16. Additional median strips as shown in FIG. 7 provide 
an enhanced degree of interlocking resistance and also provide additional 
structural rigidity. 
The cross sectional shape of the angular troughs illustrated in FIG. 2 will 
vary from acute to obtuse angles depending upon the number of plates in 
the blank and the ultimate density of the packing body configurtion 
produced. Packing bodies having a minimal number of plates will utilize 
obtuse angles in the plates; whereas packing bodies comprising a 
relatively large number of interconnected plates will utilize acute angle 
troughs. The same is true for troughs having an arcuate configuration. 
Having thus described exemplary embodiments of the method and manufacturing 
blank of the present invention, it should now be apparent to those skilled 
in the art that various modifications, adaptations, and equivalent 
constructions and steps may be made in view thereof which still fall 
within the scope and spirit of the present invention. For example, 
different forming techniques may be utilized to produce the manufacturing 
blank and a wide variety of projections may be substituted for the 
projecting arcs and fingers disclosed. Accordingly, the scope of the 
present invention is defined and limited only by the following claims.