Abstract:
A cooling tower is provided for industrial process cooling as well as air conditioning systems. The cooling tower includes a base that has a bottom for supporting the base on a substrate and a plurality of support posts extending away from the bottom. The main body includes a top wall with at least one fan aperture and a plurality of side walls extending downwardly from the top wall. The side walls are dimensioned and configured to telescope onto upper ends of the support posts. Thus, areas beneath the main body and between the support posts define inlets for accommodating airflow generated by the cooling fan mounted in the top wall.

Description:
This application is a continuation-in-part of U.S. patent application Ser. No. 09/379,152, filed Aug. 23, 1999, now U.S. Pat. No. 6,250,610, issued Jun. 26, 2001. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The subject invention relates to cooling towers for air conditioning systems and industrial process cooling. 
     2. Description of the Prior Art 
     Air conditioning systems for large buildings employ cooling towers for carrying out a portion of the heat exchange that is essential to the cooling process. Industrial processes (e.g., chemical production, metals industry, plastics industry, food processing, etc.) generate heat that must be disposed of, often by use of cooling towers. The cooling tower is a housing that channelizes air in proximity to a heat exchange fluid. For example, a heat exchange fluid may be circulated through the cooling tower, and at least one fan may be mounted on the cooling tower to generate a flow of cooling air in proximity to the heat exchange fluid. Heat is transferred from the heat exchange fluid to the air, largely through the evaporation of a small percentage of fluid which substantially lowers the temperature of the primary heat exchange fluid. The cooled heat exchange fluid can then return to the process to perform a heat exchange function for either industrial process equipment or commercial air conditioning system. 
     The efficiency of an air conditioning system depends, in part, upon the heat exchange carried out in the cooling tower. Large buildings require large cooling towers, and in many instances an array of large cooling towers. Industrial processes depend on cooling towers to prolong the life of other equipment as well as produce top quality production. 
     The majority of prior art cooling towers are assembled from a plurality of pieces of sheet metal that are mounted to a metallic support frame. These prior art cooling towers typically are manufactured at a location remote from the installation site, and then are shipped to the installation site in a substantially assembled form. These large metallic prior art cooling towers are fairly heavy, and therefore require extensive structural support and greater transportation costs. Furthermore, the size and weight of prior art cooling towers complicates the hoisting and installation of the cooling tower onto the roof of the building. Costs of prior art cooling towers also are adversely affected by the labor intensive process for manufacturing and assembling the various metallic components of the prior cooling tower. 
     In addition to the cost penalties, the metallic sheet material used in prior art cooling towers generates significant vibration related noise due to the rotation of the fans and due to the flow of air through the cooling tower. Noise pollution often requires noise abatement measures that complicate the installation process and that further add to costs. 
     Prior art metallic cooling towers also are subject to corrosion or rust. Thus, prior art cooling towers have a relatively short life. Corrosion and rust problems can be avoided or deferred by employing corrosion or rust resistant alloys. However, these metallic materials further add significantly to the cost of the prior art cooling tower. 
     The prior art includes two types of cooling towers made with plastics. The first type of prior art plastic cooling tower is fabricated from a plurality of fiberglass reinforced polyester (FRP) panels that are fastened together. These plastic towers gain strength through the supplemental glass fiber in the plastic. FRP towers are generally more costly than the galvanized metal towers. Additionally these prior art towers have to be caulked at the seams, require many fasteners to hold the tower together and can develop leaks at the many joints. 
     The other type of prior art plastic towers are vertically oriented unitary cylinders. These towers can be very tall, with heights up to 19 feet. The ratio of the height to the cross-sectional area limits the cooling capability of the tower since cross-sectional are is more determinant of cooling capacity. The excessive height of these towers requires these prior art towers to be shipped with the axis of the cylinder oriented horizontally, which complicates off-loading and installation. These units have also been limited to one fan assembly per cylindrical unit. 
     In view of the above, it is an object of the subject invention to provide a cooling tower that is lighter weight and more durable than prior art cooling towers. 
     It is another object of the subject invention to provide a cooling tower that substantially avoids complex and costly assembly of components. 
     It is an additional object of the subject invention to provide a cooling tower that produces low levels of vibration related noise. 
     It is also an object to provide a unitary molded plastic tower that is not cylindrical and allows a much higher ratio of cross-sectional area to overall height. 
     It is also an object to provide a cooling tower that can be shipped fully assembled and upright to ease off-loading and installation. 
     Still a further object of the subject invention is to provide a substantially corrosion resistant cooling tower. 
     SUMMARY OF THE INVENTION 
     The subject invention is directed to a cooling tower that is made substantially from plastic. More particularly, a major portion of the cooling tower is defined by a tower shell that is unitarily molded from a suitable plastic, such as polyethylene. The unitarily molded tower shell may be formed by rotational molding. The tower shell may be molded to include air inlet louvers that are unitarily molded with the body of the tower shell. Additionally, short cylindrical flanges may be molded at the top of the tower shell for accommodating fans and necessary support housings for the fans. Apertures may be molded into the tower shell or may subsequently be cut into the tower shell for accommodating fluid pipes and/or conduits for electric cables. Separate fittings may then be mounted to these molded or cut apertures to accommodate connections with pipes or conduits. These separate fittings may be plastic or metal depending upon specifications of the heat exchange system. 
     The tower shell preferably is elongated and of polygonal cross-sectional shape, such as an octagonal cross-sectional shape. Thus, the cooling tower may include substantially parallel top and bottom surfaces that are aligned or alignable substantially horizontally. The tower shell may further include at least one vertically aligned or alignable side wall that is unitarily formed to extend continuously around the periphery of the tower shell. Angled connecting walls extend between the side walls and the respective top and bottom walls. 
     Tower shells in accordance with the subject invention may be of different respective lengths to accommodate different cooling demands. However, all of the tower shells may be of substantially constant longitudinal cross-sectional size and shape. Thus, a larger tower shell may differ from a smaller tower shell primarily by the length and by the number of cooling fans accommodated along the length. This use of a uniform cross-sectional shape for all tower shells enables the tower shells to be manufactured in the same or similar rotational molds. The molds may be rotatable about a horizontal axis and may be adapted to adjust the length of the mold by merely repositioning end wall portions of the mold. 
     The polygonal cross-section of tower shells in accordance with the subject invention enables a uniform width and depth for the fill material that performs the mass transfer function within the tower shell. Additionally, the tapered bottom portion of the polygonal tower shell defines a concave water sump at the bottom of the tower, while the tapered top section achieves an efficient exit air flow. 
     The tower also has several strengthening posts designed to provide structural stability where needed. These posts are a corrugated shape that provides more strength than a straight wall. Additional strength is created by conical ends that help support fan systems on the top of the tower. 
     Strength also is achieved by the rotational molding. In particular, the rotational molding of a structure as large as the subject cooling towers results in greater thicknesses at locations where surfaces meet at an angle. These greater thicknesses effectively define unitary fillets that add to the strength and vibration resistance. The fillets are particularly helpful at the peripheries of the top and bottom walls at the louvers, at the reinforcing flanges and where the fan-mounting flanges meet the top wall. Thus, the subject cooling towers avoid the complex assembling inefficiencies of the prior art and simultaneously enhance strength and efficiency at critical locations. 
     An alternate cooling tower employs the above-described rotational molding techniques, but is formed from two separately molded parts that can be assembled to one another. More particularly, the alternate cooling tower includes a base unitarily rotationally molded from a plastic material, such as polyethylene, and a main body unitarily rotationally molded from a plastic material, such as polyethylene. The base preferably includes a bottom wall, a side wall enclosure extending up from the bottom wall and an upwardly concave sump wall connecting upper ends of the side wall enclosure. The sump wall is spaced from the bottom wall in most locations to provide a double wall construction. However support ribs may extend between the bottom wall and the sump wall at selected locations. The base further includes a plurality of support posts projecting unitarily upwardly from the side wall. Each support post preferably is hollow and has a selected cross-sectional shape to achieve sufficient rigidity in the presence of loads applied thereto by the main body and the fans and to support external loads due to vibrations and wind. The posts are spaced from one another to define air inlets between the respective posts. Portions of each post remote from the side and bottom walls of the base or sump define outwardly and upwardly facing steps for supporting the main body. 
     The main body of the cooling tower in accordance with the second embodiment includes a top wall and a side wall enclosure extending downwardly from the top wall. The top wall preferably includes upper and lower panels and at least one fan support opening. The fan support opening preferably is characterized by a substantially cylindrical flange extending between the panels of the top wall. Fans can be mounted to the flange substantially as described with respect to the first embodiment. The side wall enclosure of the main body also may have inner and outer panels and a bottom edge remote from the top wall. The side wall enclosure is dimensioned to telescope over the top ends of the posts so that the bottom edge of the side wall enclosure can be supported on the steps at the top ends of the posts. Additionally, recesses may be molded between the inner and outer panels of the side walls adjacent the bottom edge for receiving portions of the posts that extend upwardly from the steps. 
     The side wall enclosure of the main body is further molded to include a plurality of reinforcing ribs or channels. The reinforcing ribs or channels are defined by a plurality of intersecting side wall panels that meet at selected angles. The rotational molding creates unitarily fillets similar to the fillets described with respect to the first embodiment. The fillets have a greater thickness of plastic material. Therefore the fillets provide reinforcement against vibration and enhanced structural rigidity. The reinforcing ribs or channels preferably are disposed to align with the support posts of the base. 
     The cooling tower of the second embodiment is assembled by positioning a fill material on the top of the posts. The fill material may be any conventional material used for cooling towers, and preferably is a high efficiency spiral wound PVC formed to include a plurality of corrugations that define complex flow channels. The main body then is telescoped onto the upper ends of the posts so that the bottom edge of the side wall enclosure of the main body is supported on the outwardly and upwardly facing steps defined on the respective posts. The portions of the posts spaced inwardly and upwardly from the steps slide into engagement with the recesses formed in the bottom edges of the side wall enclosure on the main body. Bolts or other fastening means can be directed through the side wall enclosure of the main body and into portions of the posts upwardly from the steps to securely fasten the main body to the base or sump portion of the cooling tower. 
     The double-panel construction and the recesses and support channels unitarily molded into the base and main body provide resistance against loads applied to the cooling tower, such as wind loads and vibration loads attributable to the rotation of the fans and the airflow created by the fans. The load resistance attributable to the recesses in the base and the channels in the main body is enhanced by the fillets created by the rotational molding process employed for both the base and the main body of the cooling tower. The cooling tower also provides a large inlet area between the posts for an inflow of air. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a two-fan cooling tower in accordance with the subject invention. 
     FIG. 2 is a front elevational view of the cooling tower shown in FIG.  1 . 
     FIG. 3 is an end elevational view of the cooling tower of FIGS. 1 and 2. 
     FIG. 4 is a top plan view of a three-fan cooling tower in accordance with the subject invention. 
     FIG. 5 is a front elevational view of the three-fan cooling tower shown in FIG.  4 . 
     FIG. 6 is a cross-sectional view taken along line  6 — 6  in FIG.  1 . 
     FIG. 7 is a perspective view of an alternate cooling tower in accordance with the subject invention. 
     FIG. 8 is a perspective view of the base for the cooling tower of FIG.  7 . 
     FIG. 8A is a cross-sectional view taken along line  8 A— 8 A in FIG.  8 . 
     FIG. 9 is a perspective view of the main body of the cooling tower shown in FIG.  7 . 
     FIG. 10 is a perspective view similar to FIG. 7 but showing the fill material and fans incorporated into the cooling tower. 
     FIG. 11 is an end elevational view of the cooling tower shown in FIG.  10 . 
     FIG. 11A is a cross-sectional view taken along line  11 A— 11 A in FIG.  11 . 
     FIG. 12 is a side elevational view of the cooling tower shown in FIG.  10 . 
     FIG. 13 is a perspective view of an assembly of the cooling towers shown in FIG.  10 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A two-fan cooling tower in accordance with the subject invention is identified generally by the numeral  10  in FIGS. 1-3. The cooling tower  10  includes a tower shell  12  that is unitarily molded from polyethylene in a rotational mold. The tower shell  12  is molded to include a substantially vertically aligned side wall  14  extending continuously about the tower shell  12 . The side wall  14  includes planar parallel front and rear sections  16  and  18  that extend between semi-cylindrical end sections  20  and  22 . 
     The tower shell  12  further includes the tapered top connecting wall  24  extending unitarily from the side wall  14 . The top connecting wall  24  includes planar front and rear sections  26  and  28  respectively which extend unitarily from the planar front and rear side wall section  16  and  18  respectively. Additionally, the tapered top connecting wall  24  further includes conically generated end sections  30  and  32  respectively which extend upwardly and inwardly from the semi-cylindrical sections  20  and  22  respectively of the side wall  14 . 
     The tower shell  12  further includes a tapered bottom connecting wall  34  extending unitarily downwardly and inwardly from the side wall  14 . More particularly, the tapered bottom connecting wall  34  includes front and rear panels  36  and  38  that extend from the planar front and rear sections  16  and  18  respectively of the side wall  14 . The tapered bottom connecting wall  34  further includes planar bottom end panels  40  and  42  that extend angularly inwardly from opposite ends of the tower shell  12 . Upper ends of the end panels  40  and  42  are connected to the side wall  14  by substantially horizontal chordal support panels  44  and  46  respectively. Triangular corner panels  48 ,  50 ,  52  and  54  extend between the front and rear panels  36  and  38  and the end panels  40  and  42  of the tapered bottom connecting wall  34 . More particularly, the triangular corner panel  48  extends between the front panel  36  and the end panel  40 . The triangular corner panel  50  extends between the rear panel  38  and the end panel  40 . The triangular corner panel  52  extends between the front panel  36  and the end panel  46 , while the triangular corner panel  54  extends between the rear panel  38  and the end panel  42 . Upper ends of the lower corner panels  48 - 54  are connected to lower portions of the side wall  14  by horizontal chordal support panels  58 - 64 . The chordal support panels  44 ,  46  and  58 - 64  provide necessary structural support for the tower shell  12  and also support the PVC fill  66  disposed in the tower shell. The front and rear lower panels  36  and  38  and the triangular lower corner panels  48 - 54  all are molded to include louvers  68  for accommodating an upward air flow. 
     The tower shell  12  further includes a planar bottom wall  70  of substantially rectangular configuration extending unitarily between the lower edges of the front and rear panels  36  and  38  and the end panels  40  and  42 . The tower is mounted on a support platform  100  constructed of steel or fiberglass reinforced plastic (FRP) that uniformly supports the planar bottom  70  of the tower. This support platform also has support legs  101  that protrude perpendicular to the bottom of the tower to provide additional support for the side walls  14 . End support enclosures  72  and  74  extend unitarily downwardly from the lower end panels  40  and  42  and terminate in substantially coplanar relationship with the bottom wall  70 . Portions of the end enclosure  74  are provided with circular apertures  78  extending therethrough for accommodating fittings to deliver electrical conduits and pipes to the cooling tower  10 . Strengthening posts  105  are molded corrugations placed several places in the tower to provide enhanced strength over a straight wall. 
     The tower shell  12  further includes a substantially oval top wall  84  which extends unitarily between and joins upper end regions of the tapered upper wall  24 . The top wall  84  is molded to include first and second circular fan openings  86  and  88  respectively. 
     As shown most clearly in FIG. 2, the tower shell  12  assumes a substantially octagonal profile when viewed from the front and from the rear. Additionally, as shown in FIG. 3, the tower shell  12  assumes a substantially octagonal profile and cross-section when viewed from the left or right ends. 
     As noted above, the tower shell  12  is used with fittings at apertures  78  in the end enclosure  74 . Still further, a coated steel fan ring  92  may be mounted to each of the fan apertures  86  and  88  in the top wall  84 . Fans  94  along with the appropriate hardware and motors then are mounted to the fan rings  92  for generating an upward flow of air through the louvers  68  and out of the fan apertures  86  and  88 . 
     The tower shell  12  is unitarily formed in a rotational mold that rotates about an axis extending from left to right in FIG.  1 . The mold may be elongated to provide a larger tower shell as shown in FIGS. 4 and 5 respectively. More particularly, FIGS. 4 and 5 show a tower shell  112  that is structurally and functionally similar to the tower shell  12  shown in FIGS. 1-3. Additionally, the end view of the tower shell  12  shown in FIG. 3 is substantially identical to the end view for the tower shell  112 . However, the tower shell  112  differs by being sufficiently elongated to accommodate a third fan. Furthermore, additional supports are provided at the tapered lower front and rear panels, on planar portions of the side panels and on the elongated planar portions of the upper panel. The tower shell  12  shown in FIGS. 1-3 defines an overall length of approximately 15 feet. In contrast, the tower shell  112  shown in FIGS. 4 and 5 to define an overall length of almost 22 feet. 
     The rotational molding results in greater thickness at locations where walls, panels, flanges and/or posts meet at an angle. For example this greater thickness defines a unitary fillet  102  as illustrated in FIG. 6 where the oval top wall  84  intersects the planar front section  26  of the tapered top connecting wall  24 . The fillets define a thickness approximately twice the thickness of other locations. For example, the nominal plastic thickness at most locations on the tower shell  12  is approximately 0.375 inch. However the unitary fillets define thicknesses of about 0.750 inch. Comparable fillets exist at other intersecting surfaces. In particular, unitary fillets exist at the strengthening posts  105 , at the louvers  68 , and at the fan apertures  86  and  88 . These unitary fillets add to strength and vibration resistance. 
     An alternate cooling tower in accordance with the subject invention is identified generally by the numeral  200  in FIGS.  7  and  10 - 12 . The cooling tower  200  includes a base  202  and a main body  204 . Additionally, the cooling tower  200  is used with a fill material  206  and a plurality of fans  208  as shown in FIGS. 10-12. 
     The base  202  is unitarily rotationally molded from a plastic material and is shown most clearly in FIG.  8 . More particularly, the base  202  includes opposed substantially parallel end walls  210  and opposed substantially parallel side walls  212 . The end walls  210  each of are double-panel construction with an outer panel  214  and an inner panel  216 . The outer and inner panels  214  and  216  of each end wall  210  are substantially parallel to one another and are spaced apart. Top walls  218  extend angularly between the outer and inner panels  214  and  216  to define the tops of the respective end walls  210 . The end walls  210  each include a bottom edge  220 . The bottoms edges  220  are substantially parallel, and hence define a plane. The end walls  210  are further characterized by two rectangular mounting channels  222  that extend inwardly from the outer panels  214  and continuously between the end walls  210  as shown in FIGS. 11 and 12. The rectangular channels  222  are dimensioned to nest over I-beams for securely positioning and supporting the base  202  relative to a substrate. 
     The side walls  212  extend unitarily between the outer panels  214  of the end walls  210 . The side walls  212  include bottom edges  224  that are parallel to one another and that lie in the plane defined by the bottom edges  220  of the end walls  210 . The side walls  212  are further characterized by support channels  226  that extend inwardly and upwardly from the bottom edges  224 . The walls defining the support channels  226  contribute to support of loads applied to the base  202 . It is important, that the respective support channels  226  are defined by surfaces that intersect the panels of the side walls  212 . Mere openings in the side walls  212  would not perform the reinforcing function of the intersecting surfaces defined by the channels  226 . Furthermore, the walls of the support channels  226  join the walls of the mounting channels  222  and enable a transfer of loads to the walls of the mounting channel  222  and to the I-beams engaged in the mounting channels  222 . 
     The base  202  also has a bottom wall  227  that is aligned orthogonal to the end walls  210  and the side walls  212 . The bottom wall  227  is joined unitarily with the bottom edges  220  of the outer panels  214  of the end walls  210  and with the bottom edges  224  of the side walls  212 . Additionally, the bottom wall  227  joins unitarily with bottom edges of the walls that define the channels  222  and  226 . 
     The base  202  further includes a concave sump wall  228  that extends unitarily between upper ends of the side walls  212  and between the inner panels  216  of the opposed end walls  210 . The sump wall  228  is spaced upwardly from the bottom wall  227  and is formed by a plurality of planar surfaces that intersect along lines of intersection that extend parallel to the side walls  212 . Thus, the sump wall  228  is substantially symmetrical about an axis extending perpendicularly between the end walls  210 . Additionally panels of the sump wall  228  closest to the side walls  212  effectively function as inner panels of the side walls  212 . 
     Hollow rectangular end support posts  230  extend unitarily upwardly from the end walls  210 . Similarly, hollow rectangular side support posts  232  extend unitarily upwardly from the side walls  212  at locations aligned with the support channels  226 . Hollow rectangular corner support posts  234  extend upwardly at the corner intersections of the end walls  210  with the respective side walls  212 . The support posts  230 - 234  each include an upwardly facing step  236 . The steps  236  lie in a common plane substantially parallel to the plane defined by the bottom wall  227 . The support posts  230 - 234  further include inner supports  238  that extend upwardly from the respective steps  236  and substantially perpendicular to the plane defines by the steps  236 . 
     The main body  204 , as shown in FIG. 9, also is unitarily rotationally molded from a plastic material, such as polyethylene. The main body includes a top wall  240 , opposed end walls  242  and opposed side walls  244  each of which is a double-panel construction. The end walls  242  are substantially parallel to one another and extend unitarily downwardly from the top wall  240 . Similarly, the side walls  244  are substantially parallel to one another and extend unitarily downward from the top wall  240  and unitarily and orthogonally between the end walls  242 . 
     The top wall  240  is characterized by two convex outer panels  246  disposed respectively in proximity to the end walls  242 . The convex outer panels  246  are characterized by fan mounting apertures  247  and cylindrical flanges  248  that extend down from the convex outer panels  246  at the apertures  248 . Fans can be mounted to the flanges  248  in the fan mounting apertures  247  substantially as shown in FIGS. 10-12 and as described with respect to the first embodiment. The convex outer panels  246  are separated from one another by a transverse support channel  249  that contributes to the rigidity of the top wall  240 . Additionally, inner panels  250  extend unitarily from the lower edges of the respective flanges  248  to the side walls  244 , the nearer end wall  242  and the support channel  249 . Inverted V-shaped ribs  251  extend between the inner and outer panels  246  and  250  of the top wall  240 . Additionally, the inverted V-shaped ribs  251  extend substantially radially from the cylindrical flanges  248 . 
     The end walls  242  have inner panels, outer panels  252  and bottom connecting panels  253 . Similarly, the side walls  244  have inner panels, outer panels  254  and bottom connecting panels  255 . The bottom connecting panels  253  and  255  define a common plane that extends orthogonal to the respective end walls  242  and side walls  244 . The double panel construction of the end walls  242  and side walls  244  contributes to strength and rigidity. 
     The end walls  242  and side walls  244  are characterized by support-receiving recesses  257  that extend upwardly into the bottom connecting panels  253  and  255  of the respective end walls  242  and side walls  244 . The support-receiving recesses  257  are disposed and dimensioned to receive the inner supports  238  of the posts  230 - 234  on the base  202 . Thus, portions of the bottom connecting panels  253  and  255  outwardly from the support receiving recesses  257  can be received on the steps  236  of the posts  230 - 234 . 
     The end walls  242  and side walls  244  are further characterized by a plurality of vertical reinforcement channels  258 . The reinforcement channels  258  are defined by a plurality of intersecting surfaces so that support fillets are defined at the intersections substantially as described with respect to the first embodiment, and as shown in FIG.  6 . The reinforcement channels  258  are disposed to align with the posts  230 - 234  of the base  202 . 
     The base  202  and the main body  204  of the cooling tower  200  can be assembled to one another as shown in FIG.  7  and  10 - 12  by merely telescoping the lower end of the main body  204  on to the upper ends of the posts  230 - 234  of the base  202 . As a result, the inner supports  238  of the respective posts  230 - 234  are received in the support receiving recesses  257  adjacent the bottom connecting panels  253  and  255  of the main body  204 . Additionally, portions of the bottom connecting panels  253  and  255  in proximity to the support-receiving recesses  257  are supported on the steps  236  of the posts  230 - 234 . As a result, the main body  204  is accurately positioned at a specified height relative to base  202  and is prevented from shifting in longitudinal or transverse directions. The base  202  and the main body  204  can be securely held in their assembled condition by passing bolts or other such fastening means through portions of the end walls  242  and side walls  244  that align respectively with the support receiving recesses  257 . Thus, the bolts will engage both the side walls  244  or end walls  242  and the associated inner supports  238  engaged in the support receiving recesses  257 . 
     The fill material  206  shown in FIGS. 10-12 can be supported on the top ends of the posts  230 - 234  before or after mounting the main body  204  on the base  202  as described above. The fans  208  then can be mounted to the fan mounting apertures  248  substantially as described with respect to the first embodiment. The spaces between the posts  230 - 234  and immediately below the main body  204  define air inlets for accommodating the flow of air generated by the fans  208  and may be partly closed by louver panels, as shown. The large inlet area achieved with the cooling tower  200  leads to efficient cooling. 
     The mounting channels  222  in the base  202  provide a very rigid structure that can be supported on two I-beams without a separate steel skid, as had been required in the prior art. The intersecting surfaces defined throughout base  202  and the main body  204 , including the hollow support posts  230 - 234  are characterized by increased-thickness fillets that further enhance rigidity and strength of these portions of the cooling tower  200 . Further the alignment of the reinforcement channels  258 , with the support posts  232  and with the support channels  226  lead to exceptional strength and load transfer to the I-beams nested in the channels  222 . 
     FIGS. 7-12 illustrate with a unitary base  202  and a unitary main body  204 . FIG. 13 illustrates an option where a plurality of such cooling towers  202  can be assembled together to define a cooling tower assembly with an unlimited number of cooling fans.