Fill sheets and related fill pack assemblies

A fill sheet for insertion into a cooling tower to cool a cooling medium flowing over the sheet, the fill sheet comprising:

• an air intake edge;
• an air exit edge positioned opposite the air intake edge
• a plurality of flutes extending from the air intake edge toward the air exit edge, an airflow axis extending through the air intake edge and the air exit edge and a lateral axis extending substantially perpendicular to the airflow axis, the fill sheet oriented such that air flows along the plurality of flutes from the air intake edge toward the air exit edge and water flows from the air exit edge toward the air intake edge, the plurality of flutes including a first flute section having a first peak, a first inlet end, a first outlet end and defining a first flute vector, the first flute vector comprised of a line extending at a tangent to the first peak, the first flute vector constantly changing between the first inlet end and the first outlet end;
• and
• microstructure formed on the plurality of flutes, the microstructure defining a microstructure angle relative to the lateral axis, the microstructure angle being constant in the first flute section, the microstructure extends across the first peak between the first inlet end and the first outlet end on the first flute section, the microstructure serves to redistribute the water both within and between the plurality of flutes by generating water flow in a direction of micro-corrugations of the microstructure, the microstructure angle being independent of the first flute vector.

A fill sheet for insertion into a cooling tower to cool a cooling medium flowing over the sheet, the fill sheet comprising:

• an air intake edge;
• an air exit edge positioned opposite the air intake edge
• a plurality of flutes extending from the air intake edge toward the air exit edge, an airflow axis extending through the air intake edge and the air exit edge and a lateral axis extending substantially perpendicular to the airflow axis, the plurality of flutes including a first flute section extending between a first inlet end and a first outlet end, the first flute section including a first arc extending at a first side of the airflow axis and a second arc extending at a second opposite side of the airflow axis;
• a plurality of spacer rows, including a first spacer row and a second spacer row, the first spacer row positioned closer to the air intake edge than the second spacer row;
• and
• microstructure formed on the plurality of flutes, the microstructure defining a microstructure angle relative to the lateral axis.