Frame for an evaporative cooler

A frame for an evaporative cooler includes a bottom channel including a bottom panel and two bottom-side panels, a top channel including a top panel and two top-side panels, and a pair of side channels disposed between, and engaged with, each of the bottom channel and the top channel. The side channels may include a vertical side panel, a flanged bottom, a flanged top, and a pair of flanged sides, where the flanged bottom is engaged with the bottom panel, the flanged top is engaged with the top panel, and each of the pair of flanged sides is engaged with a bottom-side panel of the bottom channel and a top-side panel of the top channel.

FIELD

The present disclosure generally relates to devices, systems, and methods for a frame, e.g., for evaporative coolers and pre-coolers.

BACKGROUND

Evaporative coolers are often used to cool buildings or to augment the cooling of buildings and processes in dry and moderately dry climates. In commercial applications, evaporative pre-coolers are increasingly used to improve the efficiency of vapor-compression cooling systems through their placement upstream of the condensing coil(s). Newer, more cost-effective evaporative coolers may use “rigid media” instead of (the more traditional) woven wood fiber evaporative media. The rigid media may be produced as rectangular blocks built up from glued, cross-corrugated sheets of treated paper. The media blocks are typically 12″ to 24″ wide, by 4″ to 12″ thick, by 36″ to 84″ high. In use, airflow may proceed through the thickness of the media block in a repeated “up and down” path, directed by opposed corrugations. Media blocks may be easily cut to desired dimensions for a particular cooler.

Evaporative cooling may be accomplished as water distributed on top of the media blocks flows gravitationally downward to wet the media. Air flowing on its extended course through the media may pick up moisture such that, in typical operation, the airstream is nearly saturated when it exits the media.

The media blocks may be arranged side-by-side and may be held in position in a frame, e.g., sheet metal or plastic frames. In most aspects, the media blocks should be held relatively securely in position for optimal performance and durability. If the media blocks are out of position, they may allow air and/or water to stray from its intended path and degrade performance. Also, wind or seismic forces should generally not be able to dislodge the media blocks from the enclosure. However, the media blocks may need to be removed and re-installed for routine service and occasional replacement. Typical evaporative cooler enclosures, and pre-cooler frames, may be designed with media removal from the top, as seen for example in U.S. Pat. No. 7,021,078, which is hereby incorporated by reference in its entirety. In this design, the media housing tilts out, the top (with its water feed system) is removed, and the media can then be lifted out for cleaning or replacement.

There remains a need for improved frames, e.g., for evaporative coolers and pre-coolers.

SUMMARY

In an aspect, a frame for an evaporative cooler includes a bottom channel including a bottom panel and two bottom-side panels, a top channel including a top panel and two top-side panels, and a pair of side channels disposed between, and engaged with, each of the bottom channel and the top channel. The side channels may include a vertical side panel, a flanged bottom, a flanged top, and a pair of flanged sides, where the flanged bottom is engaged with the bottom panel, the flanged top is engaged with the top panel, and each of the pair of flanged sides is engaged with a bottom-side panel of the bottom channel and a top-side panel of the top channel.

These and other features, aspects, and advantages of the present teachings will become better understood with reference to the following description, examples, and appended claims.

DETAILED DESCRIPTION

The embodiments will now be described more fully hereinafter with reference to the accompanying figures, in which preferred embodiments are shown. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated embodiments are provided so that this disclosure will convey the scope to those skilled in the art.

Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. The words “about,” “approximately” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Similarly, words of approximation such as “about,” “approximately,” or “substantially” when used in reference to physical characteristics, should be understood to contemplate a range of deviations that would be appreciated by one of ordinary skill in the art to operate satisfactorily for a corresponding use, function, purpose, or the like. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described embodiments. Where ranges of values are provided, they are also intended to include each value within the range as if set forth individually, unless expressly stated to the contrary. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the embodiments.

The present teachings may generally include devices, systems, and methods for a frame, e.g., for evaporative coolers and pre-coolers. In this manner, the present teachings may generally respond to a need for lower-cost, more easily serviced rigid-media evaporative cooler frames that are also lighter in weight and facilitate relatively easy shipping and handling.

That is, in evaporative coolers, media blocks may be arranged side-by-side, where they are held in position in frames, e.g., made from metal or plastic. The frames may be made from bottom, top, and side channels that are joined at the corners thereof. The bottom channels may be deeper, and may be configured to make watertight joints with the side channels so that they essentially can become reservoirs. In many designs, water that has drained from the blocks is collected in the reservoir, where it is then recirculated upward by a pump. In these designs, the blocks may be supported on a screen above the bottom of the reservoir, and a refill mechanism may be used to replenish the reservoir, e.g., to replace evaporated water. In other designs, incoming water flow from a pressurized source is carefully controlled to keep the media wet without an appreciable amount that drains from the bottom. In these designs, a pump, a screen, or a deep reservoir may not be required, but control of evaporative effectiveness and water quality can be more difficult.

In the art of pre-coolers, stainless steel may be a frame material of choice because of its strength and durability, and because it may not require any additional coatings. Also, frame corners may be continuously welded for strength and watertight performance. However, beyond the aforementioned, there may be little advancements regarding ways to join corner frames of rigid media evaporative pre-coolers. A way to understand limitations in the art is to review available product lines. Some examples include the Munters EPCC design shown online at https://www.munters.com/globalassets/inriver/resources/airt-epcc-productsheet-eng.pdf, as well as the Cool Edge (http://cooledge-precoolers.com/photos.htm) and HydEvap (http://www.haveacoolday.com/products/hydrevap-precoolers/hydrevap-literature) products, where each of the foregoing disclosures is hereby incorporated by reference in its entirety.

Thus, existing rectangular stainless-steel assemblies may have a very clean look, with inward-turned channels for all frame members, and welded corners. They may be fabricated of high quality materials and typically can be expected to outlast the rooftop units to which they are attached. However, they may have liabilities that can significantly limit their success in the marketplace—maintainability, high cost, manufacturing, and handling—where each of these liabilities is discussed below.

Maintainability—like other “open water” systems, evaporative cooling systems often require considerable maintenance. Regular removal, cleaning, and re-insertion of the media blocks are typically essential to effective long-term performance. With their inward-bent side frame members, pre-coolers in the art often complicate media removal and insertion. The inward-bent side channels may also compromise performance by reducing airflow along the outside edges of the media array.

High Cost—pre-cooling economics are tenuous in many climates. Welded corners and simple channels often require relatively thick stainless steel for adequate strength, and considerable labor may be required to weld and polish the joints. Welding stainless steel thinner than 16-gauge into watertight corners can be slow and challenging. Stainless steel has obvious durability advantages but at a high cost, especially when 18-gauge or thicker stainless steel is used. Large plastic frames with fused corners can be more economical, but may lack the strength, durability, and marketability of stainless-steel frames.

Streamlined Manufacturing—pre-coolers are typically custom-sized for specific heating, ventilation, and air-conditioning (HVAC) equipment, and so manufacturing should be easily adaptable to varying frame sizes. Tooling for holding frame members while corners are joined can be expensive, and smooth corners can limit opportunities for building alignment features into the frame members.

Handling Challenges—market opportunities for condenser and chiller pre-coolers may involve multiple units on large roofs, but the “smooth exterior ends” in the art can prevent easy attachment at either the top (e.g., for lifting onto trucks, trailers, and roofs) or the bottom (e.g., for interconnecting multiple units so they are stable during handling, lifting, and temporary storage in warehouses and on roofs).

The present teachings may generally respond to the aforementioned issues associated with frames in the art. Specifically, the present teachings may include a frame with a relatively simple framework that may provide advantages in strength, manufacturability, handling, and maintainability compared to other frames. For example, using side channels that have outward-turned edges and flanges, the present teachings may facilitate relatively economical spot-welding at frame corners, relatively easy media insertion and removal, relatively easy lifting from the top of the frame, and relatively easy holding to anchoring assemblies (e.g., plates and planks) at the bottom and/or top of the frame. Additional corner bends may further help align parts during manufacturing or setup, and can also increase strength (e.g., side channel strength) and allow for the use of a relatively thin material to reduce cost. Spot-welding, e.g., with caulk sealant, can also or instead eliminate challenges associated with continuous welding of relatively thin stainless steel.

The present teachings may thus include a relatively strong rigid media evaporative cooler frame that significantly advances the state-of-the-art. By way of example, some advantages of the present teachings may include: lower material costs; cost savings in manufacturing; relatively lighter weight and easier handling; relatively easy pairing of multiple units for stable storage and lifting; and relatively easy media removal from the front.

Thus, described herein are devices, systems, and methods for a frame for HVAC equipment such as an evaporative pre-cooler. It will be understood that while the exemplary embodiments herein may emphasize a frame for an evaporative pre-cooler, the principles of the present teachings may be adapted to a wide variety of HVAC equipment, and in particular, evaporative coolers and the like. Thus, any reference herein to an evaporative pre-cooler is intended to refer to any and all such a variety of HVAC equipment, and thus terms such as “evaporative pre-cooler,” “evaporative cooler,” “cooler,” and the like are intended to refer to any and all such a variety of HVAC equipment, unless a different meaning is explicitly stated or otherwise clear from the context.

FIG. 1is a perspective view of a frame100for an evaporative cooler101(e.g., an evaporative pre-cooler), in accordance with a representative embodiment. The frame100may include a plurality of features that facilitate relatively easy assembly (and disassembly, if necessary), relatively efficient use of materials and engagement features, relatively easy transport, relatively easy stacking or grouping with other frames100, enhanced strength, and so on.FIG. 1shows the frame100with a cutaway of rigid media102and a bottom support104for the rigid media102, which may include a screen or the like to facilitate a fluid pathway between the area of the rigid media102and a fluid reservoir116(e.g., having a sump, a drain, or the like). The view inFIG. 1emphasizes various features of the present teachings, e.g., including out-turned edges of various components that can allow for relatively easy spot-welding of the frame100from the outside, and can establish mating tabs that can be used to align, hold, and lift the frame100and the evaporative cooler101, generally. Thus, it will be understood that a variety of the aforementioned out-turned edges of various components of the frame100may be emphasized in the drawings for clarity. In other words, thicknesses are shown for many of these out-turned edges and the like for clarity, where, in actual use, such out-turned edges and the like may simply be formed of bent or folded sheet metal. That is, the various components or channels of the frame100may be formed of a single piece of material (e.g., sheet metal) that is manipulated into a desired shape for configuring the frame100, including the formation of the aforementioned out-turned edges and the like. In other aspects, the out-turned edges and the like are welded or otherwise adjoined to a separate piece of material for forming a component or channel of the frame100.

In general, the frame100may include a plurality of pieces (generally referred to herein as “channels”) that fit together to form the structure and shape of the frame100. That is, these pieces may be referred to herein as “channels” because they may fit together to support blocks of rigid media102of the evaporative cooler101, where each piece forms or defines a channel supporting one or more of the surfaces of the blocks of rigid media102by containing at least a portion of the surface within a cutout, void, or other mechanical engagement. In this manner, the frame100may include a bottom channel110, a top channel130, and a pair of side channels150.

As best shown inFIG. 2, the bottom channel110may include a bottom panel112that generally forms a base of the frame100, and thus the bottom panel112may also form a base for the evaporative cooler101. The bottom channel110may further include two bottom-side panels114extending upward from the bottom panel112thus forming sides of the bottom channel110, or sides of the frame100(i.e., the front side106and back side of the frame100) at a bottom portion thereof.

Turning back toFIG. 1(and as also shown inFIG. 3), the top channel130may include a top panel132that generally forms a top of the frame100, and thus the top panel132may also form a top for the evaporative cooler101. The top channel130may further include two top-side panels134extending downward from the top panel132thus forming sides of the top channel130, or sides of the frame100(i.e., the front side106and back side of the frame100) at a top portion thereof.

The bottom channel110and the top channel130may be connected via one or more side channels150generally disposed at the ends108(or sides, as referred to herein) of the frame100. For example, and as shown inFIG. 1, the frame100may include a pair of side channels150disposed between, and engaged with, each of the bottom channel110and the top channel130to form the frame100of the evaporative cooler101. It will be understood that the bottom channel110may define a reservoir116, or the bottom channel110may form a portion of the reservoir116of an evaporative cooler101. Stated otherwise, in certain aspects, the bottom channel110is structurally configured to serve as a liquid reservoir116for the evaporative cooler101.

The side channels150may each include a vertical side panel152with flanged features protruding at the perimeter of the vertical side panel152. For example, the vertical side panel152may include a flanged bottom154and a flanged top156disposed opposite one another and each extending outward from the vertical side panel152. The flanged bottom154of each side channel150may be engaged with the bottom panel112at an end108of the frame100(which may coincide with the distal end of the bottom panel112as well). Similarly, the flanged top156of each side channel150may be engaged with the top panel132at an end108of the frame100(which may coincide with the distal end of the top panel132as well).

The vertical side panel152may also or instead include a pair of flanged sides (a flanged first side160and a flanged second side162) disposed opposite one another and each extending outward from the vertical side panel152. Each of the pair of flanged sides of the side channels150may be engaged with a bottom-side panel114of the bottom channel110and a top-side panel134of the top channel130.

Thus, as described and shown herein, the assembled evaporative cooler101may generally include a frame100that is four-sided and substantially rectangular. The frame100may be made from a bottom channel110, a top channel130, and side channels150, e.g., with the channels joined together (e.g., at the corners using spot welds170or the like). The spot welds170may be spaced about two-inches apart, except for closer spacing at the corners, e.g., the top corners, but other spacing is also or instead possible. As discussed above,FIG. 1also shows cutaways of the rigid media102and a bottom support104(e.g., a screened plate) that supports the rigid media102, e.g., along the top edges of the bottom channel110. These components are shown for completeness but may not be a focus of the present teachings.

Turning back to the bottom channel110, a top portion118thereof may include a splash ledge120. More specifically, in certain implementations, a top portion118of each of the two bottom-side panels114of the bottom channel110may include the splash ledge120. The splash ledge120may include an inclined surface122, which is structurally configured to direct liquid toward the bottom panel112, e.g., to catch drips off of the evaporative rigid media102and return any captured droplets back to a fluid reservoir116. The splash ledge120may include downturned edges124at a terminal portion thereof. The splash ledge120may also or instead be structurally configured (e.g., sized and shaped) to support an edge of the bottom support104(or a portion thereof) that holds the rigid media102in place in the evaporative cooler101.

Turning back to the flanged portions of the side channels150, in general, the flanged portions may be structurally configured to mate or engage with portions of another channel, e.g., the bottom channel110, the top channel130, or both. For instance, in certain implementations, and as best shown inFIGS. 2 and 3, each of the pair of flanged sides (e.g., the flanged first side160and the flanged second side162) may include an outward-turned edge264serving as a “positioning stop” for, and/or enveloping, at least a portion of one or more of the bottom-side panels114(seeFIG. 2) and the top-side panels134(seeFIG. 3). These features (e.g., the outward-turned edges264and the like) may also add strength and can be particularly valuable for positioning the adjoining channels (the bottom channel110, the top channel130, and the side channel150) during assembly, as will be further discussed.

As shown in each ofFIGS. 1-3, the frame100may include one or more alignment features, e.g., in addition to flanged portions, which can similarly act as alignment features for the frame100. For example, such alignment features may be included on one or more of the flanged portions, and the portions of the frame100cooperating with the flanged portions. By way of example, the frame100may include a plurality of holes on cooperating components that align with each other to form an alignment aid for assembly/disassembly. Also, or instead, these holes may be structurally configured to serve as a guide for locating a spot weld170. These holes may also or instead be used otherwise in assembly, mounting, and lifting of the frame100or evaporative cooler101.

As such, the frame100may include one or more first holes171on each of the flanged bottom154and the flanged top156of the pair of side channels150. The first holes171may be used as guidance for joining the pair of side channels150to each of the bottom panel112and the top panel132—e.g., for locating spot weld170placement for attaching these components to form the frame100. Further, the frame100may include one or more second holes172, which may be structurally configured for alignment with one or more cooperating first holes171. For example, the frame100may include one or more second holes172disposed on one or more of the bottom panel112and the top panel132, e.g., where each of the second holes172aligns with a cooperating first hole171on the side channel150for aligning the side channel150with one or more of the bottom panel112and the top panel132.

Turning back toFIG. 1, the frame100may further include a seal180formed between two or more components of the frame100. For example, the frame100may include a seal180between the bottom channel110and the pair of side channels150. The seal180may be waterproof, which may be especially advantageous when the bottom channel110forms or contains a reservoir116as described herein. By way of example, the seal180may be comprised of one or more of a caulk sealant and a continuous compressible strip. This seal180may be disposed continuously along joints formed by engagement of the bottom channel110and the side channels150. A seal180may also or instead be disposed between the top channel130and the pair of side channels150, e.g., in the same or similar manner as a seal180between the bottom channel110and the pair of side channels150. Thus, in certain implementations, a seal180(e.g., a caulk sealant) may be applied substantially continuously along the inner vertical and bottom horizontal joints between the bottom channel110and the side channels150, where this lower portion of the frame100may serve as a water reservoir116. In this manner, water pressure in the reservoir116may impose outward pressure on the seal180, which may force the seal180(or sealant) tightly into spot-welded joints, thereby providing an effective and permanent (waterproof) seal180.

FIG. 2is an exploded view showing a bottom portion of a frame100for an evaporative cooler101, in accordance with a representative embodiment—the frame100may be the same or similar to that shown inFIG. 1. In particular,FIG. 2shows an exploded perspective view that depicts how the out-turned side channels150may facilitate spot-welding, sealing, and holding of the frame100—e.g., utilizing one or more of the flanged bottom154, the flanged first side160, and the flanged second side162.

As shown in the figure, the bottom channel110may have a relatively simple, substantially linear shape with a horizontal bottom panel112that terminates with a bottom leading edge213. Further, each bottom-side panel114may similarly terminate with bottom-side leading edges215. As discussed herein, the bottom channel110may also include one or more splash ledges120, e.g., a front splash ledge with a downturned edge124and back splash ledge with a downturned edge124. The front and back splash ledges120may be the same, or they may be slightly different—e.g., one or more of the splash ledges120may be specifically configured for collecting drips or retaining a bottom support104as shown inFIG. 1, or both. In certain aspects, each splash ledge120includes an inclined surface122and a downturned edge124. That is, a surface of the splash ledges120may angle slightly upward from its juncture with the bottom-side panel114, e.g., which can facilitate the return of captured water droplets into the bottom channel110, which may form a reservoir116as described herein.

FIG. 2shows a side channel150above the bottom channel110, where the side channel150is ready for insertion and coupling with the bottom channel110. As described herein, the side channel150may have a vertical side panel152with a flanged first side160and a flanged second side162projecting therefrom. As shown in the figure, one or more of the flanged first side160and the flanged second side162may include an outward-turned edge264that is structurally configured for enveloping at least a portion of the bottom-side leading edges215of the bottom-side panels114. The outward-turned edges264may also or instead function as strengthening folds. In certain aspects, the outward-turned edges264are substantially aligned with the vertical side panel152(i.e., a plane intersecting the vertical side panel152). In other aspects, the outward-turned edges264may include a U-shaped or a hook-shaped feature to aid in enveloping at least a portion of the bottom-side leading edges215of the bottom-side panels114. Such a U-shaped or hook-shaped feature may also or instead be included on the flanged bottom154, the flanged top156, or another portion of the frame100.

In addition to (or instead of) stiffening the flanged first side160and the flanged second side162, the outward-turned edges264may serve a valuable function during assembly. For example, as the precisely-made mating parts are placed together for coupling via spot-welding or the like, the outward-turned edges264may serve as stops for the bottom-side leading edges215and/or the bottom leading edge213. By way of further example, pushing the bottom-side leading edges215relatively tightly against the outward-turned edges264and then spot-welding these portions may ensure a desired predetermined alignment, e.g., where substantially right-angle joints between the bottom channel110and the side channels150are ensured. These right-angle bottom joints may be made before the top corner joints, and may assure a substantially “squared” frame100due to the length of contact between the bottom-side leading edges215and the outward-turned edges264.

At a bottom portion thereof, the side channel150may also or instead include a flanged bottom154as discussed herein. The flanged bottom154may have a width approximately equal to the width of flanged sides (e.g., the flanged first side160and the flanged second side162). The flanged bottom154may include first holes171as discussed herein, e.g., which may be configured to align with second holes172on the bottom panel112. Stated otherwise, the bottom channel110may include second holes172that are precisely located to mate with the first holes171in the out-bent flanged bottom154of the side channel150. Inserting close-fit cylinders, dowels, or the like through the aligned holes may also or instead contribute to accurate assembly of the frame100. Moreover, bolts, screws, pins, or the like may also or instead be inserted into the aligned holes during assembly of the frame100.

After full insertion of the side channel150into the bottom channel110, or when these components are otherwise engaged, spot-welds or the like may be made, e.g., at approximately two-inch intervals around the U-shaped joint between the bottom channel110and the flanged first side160, the flanged second side162, and the flanged bottom154of the side channel150. Next, a seal180(seeFIG. 1) may be formed using a caulk sealant or the like that may be applied from the inside to make the U-shaped joints substantially watertight. During and after subsequent pre-cooler assembly steps, the aligned holes can be used to secure the base of the frame100to wood struts or the like for handling and storage as will be further discussed below with respect toFIG. 4.

FIG. 3shows an exploded view of a top portion of a frame100for an evaporative pre-cooler101, in accordance with a representative embodiment, where the frame100may be the same or similar to that shown inFIGS. 1 and 2. In particular,FIG. 3shows similar details for the top corners of the frame100asFIG. 2shows for the bottom corners of the frame100.

As shown inFIG. 3, the top channel130may include a top panel132that is aligned substantially along a horizontal plane. The top channel130may further include top-side panels134that extend from the top panel132. The top-side panels134may include downward folds disposed at both the front and the back of the top channel130. The top channel130may terminate in a top leading edge333, which may be structurally configured for mating with the flanged top156of the side channel150. For example, the top leading edge333may include a plurality of second holes172configured to align with first holes171disposed on the side channel150.

As further shown in the figure, the top of the side channel150may include a flanged top156, which defines a horizontal flange having a width approximately equal to the width of flanged sides of the side channel150(the flanged first side160and the flanged second side162). The flanged top156may include the first holes171, which may be structurally configured to align with the second holes172disposed on the top channel130, i.e., the top leading edge333of the top panel132.

In assembly, the outer ends of the top-side panels134(which may be formed of downward folds of material from the top panel132) may fit tightly against the flanged sides of the side channel150, and the top leading edge333of the top panel132may align with the outer edge of the flanged top156of the side channel150. The edges of the top-side panels134of the top channel130may then contact the outward-turned edges264of the flanged sides of the side channel150(e.g., the outward-turned edges264of the flanged first side160and the flanged second side162) for spot welding or the like. By way of example, spot-welds that join the top-side panels134and the flanged sides of the side channel150may be relatively closely-spaced because of the limited contact area, and spot welds joining the top leading edge333of the top channel130with the flanged top156of the side channel150may be spaced similarly to those used at the bottom corners described above with reference toFIG. 2.

After assembly of the frame100, the alignment holes may be used to secure the top of the frame100to wood struts or the like for temporary handling and storage, as will be further discussed with respect toFIG. 4. Also, having a “top overhang” may provide a relatively strong corner location, e.g., where lift angles can be placed under such a corner such that a crane or the like can lift one or more units onto a roof without the need of a sling under the bottom of the frame100, as further discussed with reference toFIG. 4.

FIG. 4is a perspective view of a plurality of frames100for evaporative pre-coolers101configured for transport, in accordance with a representative embodiment. The frames100may be the same or similar to any of those described herein. Specifically,FIG. 4shows two frames100secured together for being lifted from above. As shown in the figure, the frames100may be placed front-to-front in order to protect the visible side of the evaporative media from damage during storage and handling. Temporarily securing two or more units together may have the following advantages: achieves a more stable configuration that is less vulnerable to falling over under forces of wind or impact, both in storage and on roofs, before final attachment to HVAC equipment; reduces handling costs as lifting equipment performs fewer operations by handling multiple units at once; and facilitates stacking of completed units to increase storage density.

FIG. 4also shows how alignment holes471may be used to secure two or more frames100to a single, shared bottom strut490, which may simply be a piece of wood such as a 2″×4″ piece of wood. Lag bolts492or similar may be driven through the alignment holes471and into the into the bottom strut490, with the two units spaced relatively close together or touching. At the top, a similar, single, shared top strut491, which may simply be a piece of wood such as a 2″×4″ piece of wood, may be placed across the multiple units with lag bolts492or the like driven upward through alignment holes471and into the top strut491.

The multiple frames100joined at their top and bottom ends by a top strut491and a bottom strut490, respectively, may then be lifted, e.g., in one of two ways, depending on the type of lift. For example, for movement inside a shop or the like, a forklift or the like may be used with forks inserted in the gap at the floor created by elevating the frames100upward by the thickness of the bottom struts490. When the units arrive on a truck or trailer at a building site, where typically they must be lifted for attachment to HVAC equipment on a roof, time can be saved by gripping the multiple unit array under overhanging top edges494. This strategy may be much faster, both for attachment and release, compared to slinging lift straps under the bottoms of the units.FIG. 4shows a lift apparatus496, which may include support fingers or the like that extend under the top corners of the frames100. The lift apparatus496may cooperate with a lift pipe498or the like, which can be prepared with various hole sets for different lengths of frames100. Screw eyes499or the like may be inserted into the holes in the lift pipe498, which can then be attached to a lift line500, such as a crane's cable, a pulley system, or the like.

In certain aspects, the lift apparatus496may include a component with inward turned edges (e.g., to form a hook-like structure) that can be inserted under an overhang component of the frame100. This can be disposed in a location in-between frames100as shown in the figure, or in a location at or near the lag bolts492. Also, the lift apparatus496may be disposed outside of a perimeter of the frames100, e.g., to allow for stacking or the like. In some aspects, the lift apparatus496may include angles with in-turned edges that are welded to a steel plate or the like, where the plate slides along the lift pipe498and can be ultimately restrained against outward movement (which could allow a rig to drop the load) by the screw eyes499or the like engaged with the lift pipe498. One end of this plate may be fixed on the lift pipe498with its inward angles slid under one end of the frame100, while another plate is temporarily slid out so its inward angles can drop downward—then the plate slides inward so the angles are under an overhang of the frame100, where the screw eyes499or the like are dropped into the holes on the lift pipe498to prevent outward movement of the plate. The frame(s)100may then be ready for lifting or other transport.

Thus, in general, described throughout this disclosure are frames for evaporative coolers and pre-coolers. As such, one aspect includes an evaporative pre-cooler including one or more blocks of rigid media, a plate engaging and supporting a bottom end of each of the blocks of rigid media, and a frame containing the blocks of rigid media and the plate. The frame may include a bottom channel including a bottom panel and two bottom-side panels extending upward from the bottom panel, a top channel including a top panel and two top-side panels extending downward from the top panel, and a pair of side channels disposed between, and engaged with, each of the bottom channel and the top channel to form the frame. The side channels may each include a vertical side panel, a flanged bottom and a flanged top disposed opposite one another and each extending outward from the vertical side panel, and a pair of flanged sides disposed opposite one another and each extending outward from the vertical side panel. The flanged bottom of each side channel may be engaged with the bottom panel at an end thereof, the flanged top of each side channel may be engaged with the top panel at an end thereof, and each of the pair of flanged sides of the side channels may be engaged with a bottom-side panel of the bottom channel and a top-side panel of the top channel.

Implementations may include one or more of the following features. The plate may be disposed, at least in part, between the two bottom-side panels. A top portion of each of the two bottom-side panels of the bottom channel may include a splash ledge, where the plate is engaged with the splash ledge of each of the two bottom-side panels. Each splash ledge may include an inclined surface structurally configured to direct liquid toward a bottom surface of the plate. The plate may include one or more perforations providing a fluid path for the liquid to travel from the bottom surface of the plate to the bottom panel of the bottom channel.

In another aspect, the present teachings may include an evaporative cooler framework designed to hold one or more side-by-side blocks of rigid evaporative media, where the framework includes four enclosing channels. The framework may include a bottom channel with a horizontal bottom plane and side planes extending upward from the bottom plane, a top channel with a horizontal top plane and side planes extending downward from the top plane, and mirror-image side channels with orthogonal side, top, and bottom planes extending outward from their vertical center planes. The side channels may make close-tolerance fits inside the ends of the top and bottom channels. The four channels of the framework may be permanently joined by spot-welds along their mating planes at each corner. The joints between the bottom channel and side channels may be sealed by a non-welded means.

Implementations may include one or more of the following features. The sealing means may include caulk that is applied from the interior. The sealing means may include a continuous compressible strip. The sealing means may also be applied between the top channel and side channels. The bottom channel may include low-inwardly-sloping outward-bent planes from its top edges that capture stray moisture droplets from the evaporative media. A perforated horizontal screen may be supported on, and secured to, the inward edges of the outward-bent planes, e.g., to support the evaporative media, stiffen the framework, and allow water to drain downward below the media. The horizontal mating planes at each corner may have aligned holes.

Unless the context clearly requires otherwise, throughout the description, the words “comprise,” “comprising,” “include,” “including,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in a sense of “including, but not limited to.” Additionally, the words “herein,” “hereunder,” “above,” “below,” and words of similar import refer to this application as a whole and not to any particular portions of this application.

It will be appreciated that the devices, systems, and methods described above are set forth by way of example and not of limitation. For example, regarding the methods provided above, absent an explicit indication to the contrary, the disclosed steps may be modified, supplemented, omitted, and/or re-ordered without departing from the scope of this disclosure. Numerous variations, additions, omissions, and other modifications will be apparent to one of ordinary skill in the art. In addition, the order or presentation of method steps in the description and drawings above is not intended to require this order of performing the recited steps unless a particular order is expressly required or otherwise clear from the context.