Corrugated sheet packing and method of making

A packing is constructed for an apparatus for mixing or for exchange processes. The packing includes at least two zig-zag layers each of which has a number of parallel rows of substantially rectangular deflecting surfaces with alternating gaps in the inclined flanks. Bridges connect the rows of deflecting surfaces and are disposed in the troughs and at the apices of the corrugated layer. The packing can be produced by simple stamping and bending steps.

This invention relates to a packing made of corrugated sheet material and a 
process of making the packing. 
Heretofore, various types of packings have been known for use in mass 
transfer, direct heat exchange and mixing. For example, various types of 
packings have been used in static mixers such as described in U.S. Pat. 
No. 4,062,524 and 4,220,416. The function of the packings in these mixers 
is to provide a homogeneous mixing of two or more cocurrent flows, that 
is, to insure good mixing of the end product over the whole flow 
cross-section at all quantity and viscosity ratios of the components 
required to be mixed. 
When used in mass transfer processes, particularly for rectification, the 
packings are flowed through in countercurrent by the phases concerned in 
the mass transfer. In this case, the various surfaces of the packings 
serve as support surfaces for a liquid phase which trickles down as a film 
under gravity and with which, in the case of a gas-liquid process, a gas 
phase filling up the various gaps in the packing in counter-current to the 
liquid phase is brought into surface contact or with which, in the case of 
extraction columns, a second liquid phase is brought into surface contact. 
However, the various packings have been constructed in manners which are 
very expensive, particularly in view of the wide range of diameters 
required for such packings. For example, U.S. Pat. No. 4,062,524 describes 
packings which are formed of comb-like plates which are pushed together in 
the shape of a cross. U.S. Pat. No. 4,220,416 describes packings which 
consist of joined-together discrete elements in the form of "Spanish 
riders". In each case, the packings require special stamping tools for 
each diameter. 
Accordingly, it is an object of the invention to provide a packing which is 
simple and inexpensive to produce for any required diameter. 
It is another object of the invention to provide a packing element which 
can be made in a relatively simple manner for use in constructing a 
packing. 
Briefly, the invention provides a packing which is comprised of a plurality 
of layers which define crossing deflecting surfaces which are disposed at 
an inclination to a given flow direction therethrough. Each layer is of 
zig-zag shape defining a plurality of flanks with alternating troughs and 
apices. In addition, each layer has a plurality of contiguous longitudinal 
rows of alternating deflecting surfaces and gaps as well as a plurality of 
longitudinal bridges connecting the rows of deflecting surfaces and gaps. 
The deflecting surfaces and gaps are disposed in the flanks of the shaped 
packing while the bridges are alternately disposed in the troughs and 
apices of the layer. 
In forming a packing, at least two of the layers are disposed one above the 
other to define crossing flow channels. 
The packing may comprise a number of groups of two or more layers which are 
disposed one on another, for example being placed adjacent to one another 
in segment-wise relation. Further, the contour of the packing or of the 
various layers can be adapted to the inner periphery of an apparatus in 
which the packing is used. 
If the base material used for the packing is sheet metal, the gaps are 
conveniently stamped out. However, if the base material is plastics, each 
layer can be produced by injection molding. 
The invention also provides a flat one-piece bendable body for making a 
packing layer which is formed with longitudinal rows of alternating 
deflecting surfaces and gaps as well as a plurality of longitudinally 
disposed bridges which interconnect the rows. The body is dimensioned so 
as to be shaped into a corrugated layer having a zig-zag shape defining a 
plurality of inclined flanks in which the rows of deflecting surfaces and 
gaps are disposed and alternating troughs and apices connecting the flanks 
in which the bridges are disposed.

Referring to FIG. 1, a flat one-piece body 1 made of sheet metal is 
provided with a plurality of longitudinal rows 2 of alternating gaps 3 and 
deflecting surfaces 4. In addition, the body 1 is provided with a 
plurality of longitudinally disposed bridges 5 which interconnect the rows 
2 of deflecting surfaces 4. As indicated, the deflecting surfaces 4 of 
each row 2 are of the same transverse width as the gaps 3 in the row 2. In 
addition, each deflecting surface 4 and gap 3 is of rectangular shape. 
Alternatively, the gaps 3 can be of other shapes, for example, the corners 
of the gaps 3 can be beveled so that the connecting bridges are formed 
between the deflecting surfaces 4. 
As indicated in FIG. 1, the deflecting surfaces 4 of adjacent rows 2 are 
offset from one another by the width of one deflecting surface 4 and are 
interconnected at both ends by the connecting bridges 5. 
Referring to FIGS. 3 and 4, the flat body 1 is shaped into a corrugated 
layer such that the rows 2 of deflecting surfaces 4 and gaps 5 are 
disposed in and across the inclined flanks of the layer while the 
connecting bridges 5 are disposed at alternating troughs and apices of the 
corrugated layer. As indicated, each bridge 5 is located between a gap 3 
and a deflecting surface 4 of adjacent longitudinal rows 2. 
Referring to FIG. 5, in order to form a packing a plurality of the 
corrugated layers, for example, four layers, are so assembled in tiered 
relation that continuous crossing channels 6 are formed. As shown, each 
layer 1 is disposed relative to an adjacent layer 1 so as to position the 
deflecting surfaces 4 of the respective layers in the planes of the 
deflecting surfaces 4 of the adjacent layer 1 to define the crossing flow 
channels therebetween. Alternatively, the deflecting surfaces 4 can be 
disposed in the planes of the gaps 3 of the adjacent packing to define 
non-continuous flow channels. 
In order to hold the layers together in a unit, the various layers can be 
joined together along the connecting bridges 5, for example by welding. 
When the packing is placed, for example in a column, the deflecting 
surfaces 4 of each layer 1 are disposed at an inclination to a given flow 
direction through the packing. In addition, the packing is shaped to the 
contour of the column or other enclosure in which the packing is to be 
mounted. 
Of note, the layers 1 for the packing can be made of any other suitable 
material. For example, the layers 1 can be made of plastics, in which case 
the corrugated layers can be injection molded. 
The invention thus provides a packing which can be made of relatively 
simple parts in a simple expeditious manner. The packings which are formed 
can be used for mixing two or more cocurrent flows or for placing two or 
more media in contact in a countercurrent relation.