Abstract: A vacuum formable film fill sheet for crossflow water cooling towers is disclosed having a repeating chevron pattern defining a series of zig-zag, serpentine, spaced ridges on opposed faces of the sheet with the ridges on one face of the sheet defining the grooves on the opposite face thereof and vice versa. The formed sheets are located in upright, horizontally spaced relationship between the overlying hot water distribution basin of the tower and the cold water basin thereof for generally horizontal flow of air past films of water flowing downwardly over the fill sheets. The angularity of the straight ridge sections of the chevron pattern with respect to one another, the vertical height of each repeat pattern, the transverse angularity of the ridges and the spacing between adjacent sheets has been unexpectedly found to provide significantly improved results as compared with prior chevron pattern fill sheets.

Abstract: An improved, self-positioning, synthetic resin, multiple-sheet fill structure for cooling towers is provided which preferably includes upright, thin fill sheets having elongated, outwardly extending, hollow, cooperable indexing units thereon; the respective indexing units are strategically located and arranged such that opposed units on adjacent sheets are transversely disposed relative to one another and telescopically interengage with two point contact. This construction minimizes sheet warpage while increasing the load and deflection resistance of the fill structure. Preferably, the indexing units are of outwardly tapered configuration and present arcuate, opposed end segments separated by recess-defining walls; inwardly extending bottom walls connected to the recess-defining walls serve as spaced abutment surfaces extending into the hollow regions defined by the units for engaging the associated units on adjacent fill sheets.