Apparatus for cooling liquid and collection assembly therefor

A liquid collection assembly positionable between a fill material and a fan of a cooling tower for collecting liquid gravitating through the fill material while allowing air to pass up to the fill material. The liquid collection assembly includes a plurality of trough assemblies supported in a spaced apart, vertically overlapping relationship to provide a uniform path for rising air, to capture the down flowing liquid, to provide a barrier between the liquid distribution system and the fan, and to carry the liquid into the at least one gutter. The trough assemblies are supported by a first end plate and a second end plate through which trough assemblies extend.

BACKGROUND

Conventional types of industrial cooling towers include counterflow towers wherein water or other liquid falls or is sprayed downward in the tower counter to air moving upwardly in the tower. Such systems are used for many applications including water air scrubbers, dust collection equipment, air cooling towers, evaporative coolers, fluid coolers or closed loop cooling towers, evaporative condensers or the like. Typically, such industrial cooling towers are large and permanent installations which include large bottom sumps to collect the falling water.

Some relatively small towers for such purposes have been built which are transportable, for various applications, such as small rooftop towers. For example, U.S. Pat. Nos. 5,227,095 and 5,487,531, issued to Harold D. Curtis, disclose individual modular towers of a size that can be readily transported, prefabricated at a factory, and then easily assembled at a field site to provide the capacity required by the particular water/liquid cooling or treatment project at the site. The systems disclosed in the Curtis patents have a fan or fans for supplying air to the tower in the bottom of the tower below the fill, evaporative cooling media, or liquid cooling coils. The fans force air directly upward in the tower. These systems are referred to generally as direct forced draft counter flow cooling towers.

Each system uses a large water or liquid collection basin, sump or reservoir to collect and contain the circulating water for the system. These basins or sumps are typically large because they must contain enough liquid to charge the system, including all associated piping. Because the process liquid (often, but not always, water) in these systems will scrub the air and collect airborne particles, such particles will settle out in the basins, sumps or reservoirs which then have to be periodically cleaned and the large volume of liquid in the system dumped, cleaned or disposed of. Such basins, sumps and reservoirs become internal sediment basins. Such basins are maintenance intense and require workers to enter and work in a confined space to perform cleaning. Simultaneously the large volume of liquid itself may require water or chemical treatment rather than disposal, further adding to costs. The volume of liquid in such systems greatly increases the weight of the system and increases rooftop loading.

Besides the issues of sedimentation, liquid volume and disposal, proposed tower systems have not adequately addressed the problem of air diffusion by their respective liquid collection systems. Generally, cooling tower (or other forms of towers like fluid coolers) efficiency is determined by how well the up flowing air is mixed with the down coming liquid. The fans in such systems are round and the air is not evenly distributed across the tower media or elements since the fans deliver no balanced air flow. Collection systems generally include a plurality of collection troughs. Sometimes, the troughs have sloping plate member, which overlap with adjacent plate members.

These collection troughs are typically supported in the tower housing by transverse support members or plates which block or limit air dispersion through them and prevent lateral dispersion of air between them. The collection troughs are also closely spaced to reduce water falling past the collection troughs and onto the fans. The close spacing can cause significant pressure drops and thus inefficient air flow. To further reduce water reaching the fans, a damper is sometimes implemented. The damper is a plate positioned between adjacent collection troughs to block water from falling onto the fans when the fans are in an off condition. A problem encountered with dampers is they are positioned at the bottom of the collection troughs and thus susceptible to freezing, which leads to the damper becoming stuck in either the open or closed position.

SUMMARY OF THE INVENTIVE CONCEPTS

In accordance with an aspect of the inventive concepts low profile, transportable cooling towers and/or fluid coolers/closed loop cooling towers are disclosed which include a liquid collection assembly located above one or more fans in the base of the tower housing. The liquid collection assembly is positioned below the fill media in the tower or heat transfer coils of a fluid cooler. It collects the liquid flowing through the fill or heat transfer coils and directs the same to an internal gutter, from which the liquid may be removed and recirculated.

In accordance with a further aspect of the inventive concepts, a liquid collection assembly is provided that includes a plurality of trough assemblies supported in a spaced apart, vertically overlapping relationship to provide a uniform path for rising air, to capture the down flowing liquid, to provide a barrier between the liquid distribution system and the fan, and to carry the liquid into the at least one gutter.

In one embodiment, the trough assemblies comprise a trough, a liquid diverter plate, and a damper. The trough has a liquid receiving channel, a first side, a second side, a first end, a second end, and upper end, and a lower end. The liquid diverter plate has a first end, a second end, a proximal end, a distal end, an upper surface, and a lower surface. The liquid diverter plate is a separate piece from the trough, and the proximal end of the liquid diverter plate is attached to the second side of the trough with the liquid diverter plate extending upwardly and laterally away from the trough so liquid flowing onto to the upper surface flows into the trough. The distal end is positioned vertically above an adjacent one of the troughs. The damper plate extends from the second side of the trough and is movable between a closed position wherein the damper extends between the second side of the trough and the first side of the adjacent trough to cover the space between the trough and the adjacent trough and an open position wherein the damper is spaced from the adjacent trough.

The liquid collection assembly can be utilized in equipment such as water air scrubbers, dust collection equipment, cooling towers, evaporative coolers, fluid coolers, evaporative condensers and any equipment that utilizes water or any liquid fluid for scrubbing, cleaning, or evaporative cooling. Although the liquid collection assembly is described for use with low profile transportable cooling towers and/or fluid coolers, the liquid collection assembly can be used with any systems, including those having conventional bottom sumps and basins.

Besides collecting the down coming liquid, the liquid collection assembly provides a low-pressure means for the air to flow vertically up between the surface elements of the liquid collection assembly and into the cooling media or fluid cooler coil system. The trough and the liquid diverter plates are strategically configured and spaced to direct and defuse the up flowing air to enhance even airflow through the liquid collection assembly and the fill media or heat exchanger. The structure of the troughs and the liquid diverter plates, and the void of internal support structures, allow air to disperse uniformly. This creates an efficient air to liquid mixture, improving thermal performance of the heat exchanger or cooling tower. In addition, previously proposed liquid collectors have a significant pressure drop across the collector panels. The inventive concepts described herein will reduce the pressure drop as compared to the existing technology. This will further increase thermal performance of the heat exchanger or cooling tower. The liquid collection assembly can be produced much more economically than the present technology.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Before explaining at least one embodiment of the inventive concepts disclosed, it is to be understood that the inventive concepts are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies in this description or illustrated in the drawings. The inventive concepts disclosed are capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed is for description only and should not be regarded as limiting the inventive concepts disclosed and claimed herein.

Referring to the drawings, and more particularly toFIG.1, a cooling tower module10constructed in accordance with the inventive concepts disclosed herein is shown. The cooling tower module10includes a housing assembly12, drift eliminators14, liquid distribution assemblies16, fill media18, liquid collection assemblies20, and fan assemblies22for drawing air through the bottom of the housing assembly12and blowing it through the liquid collection assemblies20, the fill media18, the drift eliminators14, and out the top of the housing assembly12countercurrent to the water distributed from liquid distribution assemblies16.

Any number of cooling tower modules can be combined to form a cooling tower of desired capacity. In one embodiment, the cooling tower module10may be formed to a size of 6 ft. by 12 ft. by 11 ft. Each module can include two sub-modules. The sub-modules may be arranged in a side-by-side relationship and each sub-module may include a drift eliminator14, a liquid distribution assembly16, a fill media18, a liquid collection assembly20, and a fan assembly22. The sub-modules may have a size of 6 ft. by 6 ft. by 11 ft. with each sub-module having a cooling capacity of 100 tons.

The housing assembly12includes a frame24supporting vertical side walls26and end walls28. One of the side walls26has been partially cutaway to illustrate the interior of the cooling tower module10. The frame24includes a plurality of lower horizontal beams30, a plurality of vertical beams32, and a plurality of upper horizontal beams34connected together to form a generally rectangular-shaped support frame. The beams34may be fabricated of any suitable material, including metal or pultruded fiberglass. When the cooling tower module10is combined with another cooling tower module10, the adjacent side walls can be omitted so the cooling tower modules10openly communicate with one another.

The frame24may be supported by four legs (not shown) at the corners of the frame24. The legs may be telescopically connected to the vertical beams32.

The housing assembly12further includes a liquid collection basin42. The liquid collection basin42is formed to collect water from the liquid collection assembly20as described below. The liquid collection basin42may include a first gutter44extending along an interior side of one of the longitudinal lower horizontal beams30and a second gutter (not shown)6extending along an interior side of the other longitudinal lower horizontal beam30. The first gutter44and the second gutter may be fluidly connected with a connecting gutter48. The first gutter44, the second gutter, and the connecting gutter48cooperate to form a first fan receiving space50and a second fan receiving space52. One of the first and the second gutters is provided with a liquid outlet54. In one embodiment, the liquid outlet54has a flange.

In one embodiment, the liquid distribution assembly16includes a liquid distribution header55and a plurality of lateral feeder conduits56. The liquid distribution header55and the lateral feeder conduits56may be made of any suitable material such as PVC, RFP, copper, stainless steel, aluminum, and resins, for example.

The liquid distribution assembly16further has a plurality of nozzle assemblies58connected to the lateral feeder conduits56and are in fluid communication with the lateral feed conduits56. The nozzle assemblies58function to discharge water therethrough to obtain a uniform distribution of water over the fill media18. The nozzle assemblies58may be any suitable nozzle assemblies. For example, a suitable nozzle assembly is disclosed in U.S. Publication No. 2017/0297043, which is hereby expressly incorporated herein by reference.

The drift eliminators14are mounted in the open top of the housing assembly12to intercept, trap, and collect mist blown through the housing assembly12to prevent the mist from escaping to the atmosphere. Drift eliminators are well known in the art and need not be described.

The fill material18may be any suitable fill media. In one embodiment, the fill material may be formed from a plurality of layers. For example, the fill material18may be corrugated plastic fill material. Like the drift eliminators, the fill media is well known in the art and need not be described.

Referring now toFIGS.1-12the liquid collection assembly20is positioned within the housing assembly12below the fill media18for collecting liquid that passes from the liquid distribution assembly16and through the fill media18. As illustrated inFIGS.1and3A-3C, the liquid collection assembly20may include a plurality of liquid collection assemblies20installed and removed in sections. In another version, the liquid collection assembly20may be formed as a single unit. Each of the liquid collection assemblies20includes a plurality of trough assemblies60supported in a spaced apart, vertically overlapping relationship to provide a path or plenum for rising air and to capture the down flowing liquid, to provide a barrier between the liquid distribution system, and the fan, and to carry the liquid into the at least one gutter.

Referring toFIGS.4-7, the trough assemblies60comprise a trough62, a liquid diverter plate64, and a damper plate66. The trough62has a liquid receiving channel68, a first side70, a second side72, a first end74, a second end76, and upper end78, and a lower end80. The troughs62are elongated members that form channels into which liquid falls. The troughs62are angled so gravity is utilized to carry the liquid into one of the gutters44or46. While the troughs62are shown to have a V-shaped bottom, the troughs62may be formed to have other shapes. For example, the bottom of the troughs62may be U-shaped.

In one embodiment, the trough62is bent along the upper end78of the second side72to form a hinge chamber82, which will be described more below. The trough62may have a bend84along the upper end78of the first side70to increase structural integrity.

The liquid diverter plate64has a first end86, a second end88, a proximal end90, a distal end92, an upper surface94, and a lower surface96. In one embodiment, the liquid diverter plate64is a separate piece from the trough62, and the proximal end90of the liquid diverter plate64is attached to the second side72of the trough62with the liquid diverter plate64extending upwardly and laterally away from the trough62so liquid flowing onto to the upper surface94flows into the liquid receiving channel68of the trough. It will be appreciated that in another embodiment, the liquid diverter plate64can be formed as a single piece with the trough62. The distal end92is positioned vertically above an adjacent one of the troughs62. The distal end92of the liquid diverter plate64has an inverted U-shape bend98to provide structural rigidity and to cause liquid dripping from the liquid diverter plate64to drop rather than travel along the lower surface96of the liquid diverter plate64. An intermediate portion of the liquid diverter plate64has a bend99. The proximal end90of the liquid diverter plate64is configured to be attached to the second side72of the trough62with suitable fasteners or adhesive, and the proximal end90of the liquid diverter plate64may have a bend99a(FIG.7) to increase structural integrity. The liquid diverter plate64cooperates with the trough62to further define a hinge trough100(FIG.5) extending the length of the trough assembly60.

The damper plate66extends from the second side72of the trough62and is movable between a closed position (FIG.8A) wherein the damper plate66extends between the second side72of the trough62and the first side70of the adjacent trough62to cover the space between the trough62and the adjacent trough62and an open position (FIG.8B) wherein the damper plate66is spaced from the adjacent trough62.

The damper plate66extends from the upper end78of the trough62. The damper plate66has a proximal end102and a distal end104. In one embodiment, the proximal end102is hinged to the second side72of the trough62. By way of example, the proximal end102has a bend forming a hinge member108positioned in the hinge chamber82. The hinge member108is insertable into the hinge chamber82and configured to hook in the hinge chamber82.

The damper plate66has a longitudinal bend110so the damper plate66has an inverted V shape that conforms to the contour of the liquid diverter plate64when the damper plate66is in the open position. In the closed position, the inverted V shape allows a portion of liquid falling onto an upper side112of the damper plate66to flow into the adjacent trough62and another portion of liquid falling onto the upper side112of the damper plate66to flow into the hinge trough100, which is in fluid communication with the gutter44. The inverted V shape further reduces the radius of travel of the damper plate66between the closed position and the open position.

The liquid collection assembly20further has a first end plate120(FIGS.2and9) attached to the first end74of the trough62and the first end86of the liquid diverter plate64; and a second end plate122(FIGS.2and10) through which the second end76of the trough62and the second end88of the liquid diverter plate64extend. The first end plate120is provided with a series of trough brackets124and liquid diverter plate brackets126. The first end74of the troughs62are supported by the trough brackets124and the first end86of the liquid diverter plates64are supported by the liquid diverter plate brackets126. The first end74of the troughs62and the first end86of the liquid diverter plates64are fluidically sealed relative to the first end plate120with a suitable sealant and may be secured to the trough brackets and the liquid diverter plate brackets126with fasteners, such as rivets.

The second end plate122has a plurality of openings128corresponding to the profile of the liquid receiving channels of the troughs and the liquid diverter plates64. The troughs62and the liquid diverter plates64are secured to the second end plate122with suitable fasteners and/or fluid sealant or adhesive so liquid flowing along the liquid receiving channels68and the hinge trough100passes through the second end plate122and into the gutter44.

The liquid collection assembly20is supported by the structure forming the first gutter44and the second gutter. As shown inFIGS.3A-3C, the liquid collection basin42may be provided with parallel tracks130for slidingly supporting the liquid collection assembly20.

With further reference toFIGS.3A-3C, the edges of the end walls120and122may be configured to mate with an end wall of an adjacent liquid collection assembly when abutted with one another to form a fluid tight seal. In one embodiment, opposing edges of the end walls120and122may be provided with a tongue and groove structure (not shown) to permit adjacent sections to mate with one another.

Desirably, the trough assemblies60require no intermediate supports, which would interfere with the flow of air and liquid through the cooling tower module. Nevertheless, supports may be used. By way of example, the supports may be in the form of cross supports132(FIG.11), and spacers134(FIG.12). The cross supports132are spaced apart from one another and engage to the distal ends92of each of the liquid diverter plates64so as not to be positioned in the air path. The spacers134are U-shaped members positioned vertically in the troughs62, and thus not in the air path, to provided support for the troughs62, as needed.

The liquid collection assembly20defines a vertical flow passage with the trough assemblies60supported within the flow passage to allow air to pass from the fan assembly22and through the flow passage and to collect liquid falling into the flow passage and to direct the collected water to the gutter44.

The trough62, the liquid diverter plate64, the damper plate66, first and second end plates120and122, the cross supports132, and the spacers134may be fabricated of a metal or sufficiently rigid plastic or fiberglass material.

FIGS.8A and8Bare schematic illustrations of the array of the trough assemblies60. The air flowing from the fan assembly22encounters the lower end of the troughs62and passes through the gaps or plenums between the troughs62and the liquid diverter plates64. In addition, the air flowing from the fan assembly22causes the damper plates66to move to the open position.

One of the advantageous of the inventive concepts disclosed herein is the increase and uniformity of the gaps between the trough assemblies60relative to the volume of the troughs62. This enhances more efficient air to liquid mixtures which increases performance of the system. In addition, the uniformity of the gaps reduces the pressure drop from the lower end to the upper end of the liquid collection assembly20. The reduced pressure drop also increases thermal performance of the cooling tower. An additional advantage is that there is a lower pressure drop because of the void of support structures in the gaps thus increasing the length of the flow space between adjacent ones of the trough assemblies60. In one embedment of the liquid collection assembly20, the effective width opening between adjacent trough assemblies60may be approximately four inches.

In one embodiment, the troughs62have a width of about 2.5 inches and spaced from the adjacent trough62about 8 inches. This provides a gap of about 5.5 inches between each trough62. In one embodiment, the liquid diverter plates64are configured to have a spacing of about 4.25 inches between each adjacent liquid diverter plate64and the upper end78of the adjacent trough62.

While the trough assemblies60are illustrated as being uniformly laterally spaced from one another, uniform spacing of the trough assemblies60is not mandatory. Depending upon the application or the specific shape of the housing, it is within the scope of the inventive concepts to vary the spacing between the trough assemblies60to direct air flow to specific areas. In addition, varying the size of the openings between adjacent surfaces will affect the air velocity between the adjacent surfaces. By varying the gap between them, air distribution may be better balanced throughout the system. However, the trough assemblies60should remain overlapped, so liquid cannot escape to the fans.

FIG.13illustrates another embodiment of a liquid collection assembly20aconstructed in accordance with the inventive concepts disclosed herein. The liquid collection assembly20ais substantially similar to the liquid collection assembly20, except as described herein below. The liquid collection assembly20amay include a plurality of liquid collection assemblies20ainstalled and removed in sections. In another version, the liquid collection assembly20amay be formed as a single unit. Each of the liquid collection assemblies20aincludes a plurality of trough assemblies60asupported in a spaced apart, vertically overlapping relationship to provide a path or plenum for rising air and to capture the down flowing liquid, to provide a barrier between the liquid distribution system, and the fan, and to carry the liquid into the at least one gutter.

Referring toFIGS.14and16, the trough assembly60ais substantially similar to the trough assembly60, except as described herein below. In one embodiment, the trough assemblies60acomprise a trough62a, a liquid diverter plate64a, and a damper plate66a.

The trough62ahas a liquid receiving channel68a, a first side70a, a second side72a, a first end74a, a second end76a, an upper end78a, a lower end80a. In one embodiment, the first side70aand the second side72amay have a bend84aalong the upper end78ato increase structural integrity. The first side70aof the trough62ais substantially symmetrical with the second side72aof the trough62awith the upper end78aof the first side70aand the upper end78aof the second side72aextending an equal vertical distance from the lower end80a.

The liquid diverter plate64ahas a first end86a, a second end88a, a proximal end90a, a distal end92a, an upper surface94a, and a lower surface96a. In one embodiment, the liquid diverter plate64ais a separate component from the trough62awith the proximal end90abeing spaced from the upper end78of the trough62ato define a gap. The proximal end90aof the liquid diverter plate64amay be laterally positioned between the first side70aand the second side72aof the trough62awith the liquid diverter plate64aextending upwardly and laterally away from the trough62aso liquid flowing onto to the upper surface94aflows into the liquid receiving channel68of the trough. The distal end92ais positioned vertically above an adjacent one of the troughs62a. An intermediate portion of the liquid diverter plate64amay have one or more longitudinal bends99a. As an alternative to using brackets, the liquid diverter plate64afurther includes a series of liquid diverter plate tabs136aextending perpendicular to the upper surface94aalong the first end86aand the second end88a.

The damper plate66a, as shown inFIG.15, has a first end103a, a second end105a, a proximal end102a, a distal end104a, an upper surface112a, and a lower surface114a. The damper plate66aextends laterally away from the second side of the trough and is rotatable about an axis of rotation115abetween a closed position (FIG.17A) and an open position (FIG.17B). In the closed position the damper plate66aextends between the second side72aof the trough62aand the trough62aof the adjacent one of the trough assemblies60ato cover the space between the trough62aand the adjacent trough62awith the proximal end102aof the damper plate66apositioned adjacent the second side72aof the trough62aand the distal end104apositioned adjacent the adjacent trough62a. Any liquid flowing onto the upper surface112aof the damper plate66aflows into the liquid receiving channel68of the trough62aor the adjacent trough62awhile the damper plate66ais in the closed position. In the open position, the distal end104aof the damper plate66ais spaced from the adjacent trough62aallowing air to flow upwardly between the trough62aand the adjacent trough62a.

The axis of rotation115ais spaced from the proximal end102aof the damper plate66atoward the distal end104aof the damper plate66a. A first portion116aof the damper plate66aextends between the proximal end102aof the damper plate66aand the axis of rotation115aand a second portion117aof the damper plate66aextends between the axis of rotation115aand the distal end104aof the damper plate66a. The first portion116aprovides a counterbalance force to the second portion117ato assist in moving the damper plate66afrom the closed position to the open position. The counterbalance force provided by the first portion116aof the damper plate66ais insufficient to cause the damper plate66ato rotate to the open position when the fan assembly22is not operating. As upward air flow contacts the lower surface114aof the damper plate66a, the counterbalance force is sufficient to assist the damper plate66ato rotate and remain in the open position when the fan assembly22is operating. The counterbalance force may be sufficient to reduce the amount of air flow required to cause the damper plate66ato rotate and remain in the open position.

In one embodiment, the axis of rotation115ais substantially vertically aligned with the second side72aof the trough62a. The first portion116amay extend through the gap defined by the space between the proximal end90aof the liquid diverter plate64aand the upper end78aof the trough62a. The first portion116aof the damper plate66amay move within the gap as the damper plate66amoves between the closed position and the open position. The damper plate66acovers the gap when the damper plate66ais in open position. In one embodiment, the first portion116aextends above the trough62awith the proximal end102aof the damper plate66abeing laterally positioned between the first side70aand the second side72a, such that any liquid flowing onto the upper surface112aof the first portion116aof the damper plate66aflows into the liquid receiving channel68aof the trough62aregardless of whether the damper plate66ais in the closed position or the open position.

In one embodiment, the damper plate66amay be pivotally coupled to the trough62awith the axis of rotation115abeing substantially near the upper end78aof the second side72aof the trough62a. In another embodiment, the damper plate66amay be pivotally coupled to the liquid diverter plate64awith the axis of rotation115abeing substantially near the proximal end90aof the liquid diverter plate64a.

The liquid collection assembly20afurther has a first end plate120aattached to the first end86aof the liquid diverter plate64aand through which the first end74aof the trough62aextend; and a second end plate122aattached the second end88aof the liquid diverter plate64aand through which the second end76aof the trough62aextend. The series of liquid diverter plate tabs136aextending from the first end86aand the second end88aof the liquid diverter plate64amay be secured to first end plate120aand the second end plate122awith fasteners, such as rivets. The liquid diverter plate64amay be fluidically sealed relative to the first end plate120aand the second end plate122athe with a suitable sealant.

The first end plate120aand the second end plate122ahave a plurality of openings128acorresponding to the profile of the liquid receiving channels68aof the troughs62a. The troughs62aare secured to the first end plate120aand the second end plate122awith suitable fasteners and/or fluid sealant or adhesive so liquid flowing along the liquid receiving channels68apasses through the first end plate120aor the second end plate122aand into the gutter44.

In one embodiment, the damper plate66amay include a set of pins118adefining the axis of rotation115aand extending from the first end103aand the second end105aand extending through the first end plate120aand the second end plate122a, respectively, such that the damper plate is pivotally coupled to the first end plate120aand the second end plate122a. The first end103aand the second end105amay be substantially near the first end plate120aand the second end plate122awithout causing interference of the damper plate66afrom freely moving between the closed position and the open position.

The proximal end102amay have a bend to increase the structural integrity of the damper plate66aand increasing the counterbalance force that is provided by the first portion116aof the damper plate66a. In one embodiment, additional weight may be added to the first portion116aof the damper plate66afurther increasing the counterbalance force and reducing the amount of air flow required to cause the damper plate66ato move to the open position.

The damper plate66amay have one or more longitudinal bends110acausing at least a portion of the damper plate66ato conform to the contour of the liquid diverter plate64awhen the damper plate66ais in the open position. In the closed position, the shape of the damper plate66acauses liquid falling onto an upper surface112aof the damper plate66ato flow into either the trough62aor the adjacent trough62a. The shape further reduces the radius of travel of the damper plate66abetween the closed position and the open position.

FIG.18illustrates another embodiment of a liquid collection assembly20bconstructed in accordance with the inventive concepts disclosed herein. The liquid collection assembly20bis substantially similar to the liquid collection assembly20and liquid collection assembly20a, except as described herein below. The liquid collection assembly20bmay include a plurality of liquid collection assemblies20binstalled and removed in sections. In another version, the liquid collection assembly20bmay be formed as a single unit. Each of the liquid collection assemblies20bincludes a plurality of trough assemblies60bsupported in a spaced apart, vertically overlapping relationship to provide a path or plenum for rising air and to capture the down flowing liquid, to provide a barrier between the liquid distribution system, and the fan, and to carry the liquid into the at least one gutter.

Referring toFIGS.19and21, the trough assembly60bis substantially similar to the trough assembly60and the trough assembly60a, except as described herein below. The trough assemblies60bcomprise a trough62b, a liquid diverter plate64b, and a damper plate66b.

The trough62bhas a liquid receiving channel68b, a first side70b, a second side72b, a first end74b, a second end76b, an upper end78b, a lower end80b. In one embodiment, the first side70band the second side72bmay have a bend84aalong the upper end78bto increase structural integrity. The trough62bfurther includes a series of trough tabs138bextending perpendicular to the first side70band the second side72balong the first end74bof the trough62b. The first side70bof the trough62bis substantially symmetrical with the second side72bof the trough62b; however, the second side72bis shorter between the upper end78band the lower end80bthan the first side70bof the trough62b, such that the upper end78of the second side72bis lower than the upper end of78bof the first side70b. Moreover, the upper end78bof the second side72bis lower than the upper end78bof the first side70bof the adjacent one of the troughs62b.

The liquid diverter plate64bis substantially similar to the liquid diverter plate64a, except as described herein below. The liquid diverter plate64bhas a first end86b, a second end88b, a proximal end90b, a distal end92b, an upper surface94b, and a lower surface96b. The liquid diverter plate64bis a separate component from the trough62bwith the proximal end90bbeing spaced from the second side72bof the trough62bto define a gap. The proximal end90bof the liquid diverter plate64bis laterally positioned between the first side70band the second side72bof the trough62b. The proximal end90bof the liquid diverter plate64bis vertically positioned below the upper end78bof the first side70band substantially vertically aligned with the upper end78bof the second side72bextending upwardly and laterally away from the trough62bso liquid flowing onto to the upper surface94bflows into the liquid receiving channel68bof the trough. The distal end92bis positioned vertically above an adjacent one of the troughs62b. An intermediate portion of the liquid diverter plate64bmay have one or more longitudinal bends99a. The liquid diverter plate64bfurther includes a series of liquid diverter plate tabs136bextending perpendicular to the upper surface94balong the first end86band the second end88bof the liquid diverter plate64b.

The damper plate66b, as shown inFIGS.19-21, has a first end103b, a second end105b, a proximal end102b, a distal end104b, an upper surface112b, and a lower surface114b. The damper plate66bis rotatable about an axis of rotation115bbetween a closed position (FIG.22A) and an open position (FIG.22B).

The axis of rotation115bis spaced from the proximal end102bof the damper plate66atoward the distal end104bof the damper plate66b. A first portion116bof the damper plate66bextends between the proximal end102bof the damper plate66band the axis of rotation115band a second portion117bof the damper plate66bextends between the axis of rotation115band the distal end104bof the damper plate66b. The first portion116bprovides a counterbalance force to the second portion117bto assist in moving the damper plate66afrom the closed position to the open position. The counterbalance force provided by the first portion116bof the damper plate66bis insufficient to cause the damper plate66bto rotate to the open position when the fan assembly22is not operating. As upward air flow contacts the lower surface114bof the damper plate66b, the counterbalance force is sufficient to assist the damper plate66bto rotate and remain in the open position when the fan assembly22is operating. The counterbalance force may be sufficient to reduce the amount of air flow required to cause the damper plate66bto rotate and remain in the open position. In one embodiment, as shown inFIG.20, the first portion116bis coiled by a series of overlapping bends between the proximal end102band the axis of rotation115bto increase the counterbalance force provided by the first portion116band reduce the length of the first portion116bto fit within the liquid receiving channel68bof the trough62b.

The axis of rotation115bmay be positioned in the liquid receiving channel68with the axis of rotation115bbeing vertically positioned slightly below the upper end78bof the second side72bof the trough62band laterally positioned adjacent the second side72bof the trough62b. The first portion116bmay extend from the axis of rotation115bdownwardly and laterally within the liquid receiving channel68band may move within the liquid receiving channel68aas the damper plate66amoves between the closed position and the open position. The second portion117bmay extend through the gap defined by the space between the proximal end90bof the liquid diverter plate64band the upper end78bof the trough62b. The second portion117bof the damper plate66amay move within the gap as the damper plate66amoves between the closed position and the open position. The damper plate66bcovers the gap when the damper plate66ais in open position. In one embodiment, the first portion116bextends below the liquid diverter plate64bwith the proximal end102bof the damper plate66bbeing laterally positioned between the first side70band the second side72b, such that any liquid flowing onto the upper surface112bof the first portion116bof the damper plate66bflows into the liquid receiving channel68bof the trough62bwhen the damper plate66ais in the closed position. The axis of rotation115bbeing positioned lower than the first side70bof the trough62bof the adjacent one of the trough assemblies60ballows a smaller angle of rotation for the damper plate66bbetween the close position and the open position. Hence, the arc length of the distal end104bof the damper plate66bwill be shorter resulting is a faster transition between the close position and the open position and requiring less force to move the damper plate66bto the open position.

Referring now toFIGS.22A and22b, In the closed position the damper plate66bextends between the second side72bof the trough62band the trough62bof the adjacent one of the trough assemblies60bto cover the space between the trough62band the adjacent trough62bwith the proximal end102bof the damper plate66bpositioned within the trough62band the distal end104bpositioned adjacent the adjacent trough62b. Any liquid flowing onto the upper surface112bof the damper plate66bflows into the liquid receiving channel68bof the trough62bor the adjacent trough62bwhile the damper plate66bis in the closed position. In the open position, the distal end104bof the damper plate66bis spaced from the adjacent trough62ballowing air to flow upwardly between the trough62band the adjacent trough62b. The position of the axis of rotation115brelative to the liquid diverter plate64bmay further allow the second portion117bof the damper plate66bto better conform to contour of the lower surface96bof the liquid diverter plate64bwhen in the open position.

In one embodiment, the damper plate66bmay be pivotally coupled to the trough62bwith the axis of rotation115bbeing substantially near the upper end78bof the second side72bof the trough62b. In another embodiment, the damper plate66bmay be pivotally coupled to the liquid diverter plate64bwith the axis of rotation115bbeing substantially near the proximal end90bof the liquid diverter plate64b.

The liquid collection assembly20bfurther has a first end plate120battached to the first ends86bof the liquid diverter plates64band the first ends74aof the troughs62a; and a second end plate122battached the second ends88bof the liquid diverter plates64band through which the second ends76bof the troughs62bextend. The series of liquid diverter plate tabs136bextending from the first ends86aand the second ends88aof the liquid diverter plates64band the series of trough tabs138bextending from the first ends74amay be secured to first end plate120band the second end plate122bwith fasteners, such as rivets. The liquid diverter plates64bare fluidically sealed relative to the first end plate120band the second end plate122bthe with a suitable sealant.

The second end plate122bhas a plurality of openings128bcorresponding to the profile of the liquid receiving channels68bof the troughs62b. The second end76bof the troughs62aare secured to and the second end plate122bwith suitable fasteners and/or fluid sealant or adhesive so liquid flowing along the liquid receiving channels68bpasses through the second end plate122band into the gutter44.

Although the inventive concepts have been illustrated and described in connection with compact, transportable cooling towers, the inventive concepts disclosed herein are equally adapted to use in fluid coolers. In fluid coolers liquid is passed countercurrent across a coil (i.e., heat exchanger) carrying a liquid to be cooled. Also, although the liquid collection assembly20has been illustrated and described in connection with compact, transportable cooling towers with bottom fan assemblies, the liquid collection assembly20may be used in more conventional systems having conventional liquid sumps or basins below the liquid cooler or fill media.

The inventive concepts disclosed provide several major improvements. The liquid collection assembly20collects the down coming liquid, but also directs and diffuses the up flowing air so that all the fill media gets substantially equal air flow across the entire surface of the heat exchanger or fill media. This enhances more efficient air to liquid mixtures which increases performance of the system. In addition, the design of the liquid collection assemblies reduces the pressure drop across the surface elements, as compared to existing technology. The reduced pressure drop also increases thermal performance of the cooling tower. The liquid collection assembly20is relatively simple and economical to manufacture.

From the above description, it is clear that the inventive concepts disclosed herein are well adapted to carry out the objects and to attain the advantages mentioned herein, as well as those inherent in the invention. While exemplary embodiments of the inventive concepts have been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the inventive concepts disclosed.