System for manufacturing a heat exchanger

Abstract

A method for manufacturing a heat exchanger includes joining a first conductive sheet to a second conductive sheet to define a plurality of separate volumes in a blank envelope, creating an aperture in each separate volume in the blank envelope, and heating the blank envelope. The method further includes pressurizing each separate volume through the apertures, hot plastic forming the blank envelope into a formed envelope, and assembling a plurality of formed envelopes into a heat exchanger core, wherein the heat exchanger core includes a fluid passage outside of the formed envelopes, wherein the fluid passage is defined by adjacent formed envelopes, and wherein the fluid passage extends across a dimension of the heat exchanger core.

What is claimed is: 
     
         1 . A system for manufacturing a heat exchanger, comprising:
 means for joining a first conductive sheet to a second conductive sheet to define a plurality of separate volumes in a blank envelope;   means for hot plastic forming the blank envelope into a formed envelope; and   means for assembling a plurality of the formed envelopes into a heat exchanger core to allow a different fluid to flow through each separate volume, wherein the heat exchanger core includes a fluid passage outside of the formed envelopes, wherein the fluid passage is defined by adjacent formed envelopes, and wherein the fluid passage extends across a dimension of the heat exchanger core.   
     
     
         2 . The system as in  claim 1 , wherein the means for joining a first conductive sheet to a second conductive sheet to define a plurality of separate volumes in a blank envelope defines a first volume in each blank envelope substantially surrounded by a second volume in each blank envelope. 
     
     
         3 . The system as in  claim 1 , wherein the means for hot plastic forming the blank envelope into a formed envelope creates an aperture in each separate volume in the blank envelope. 
     
     
         4 . The system as in  claim 3 , wherein the means for hot plastic forming the blank envelope into a formed envelope injects a gas through each aperture and into each volume. 
     
     
         5 . The system as in  claim 1 , wherein the means for assembling a plurality of the formed envelopes into a heat exchanger core aligns adjacent volumes in each formed envelope parallel to flow through the fluid passage. 
     
     
         6 . The system as in  claim 1 , wherein the means for assembling a plurality of the formed envelopes into a heat exchanger core creates a fluid channel through opposite ends of each separate volume. 
     
     
         7 . A system for manufacturing a heat exchanger, comprising:
 at least one of a friction stir welder, a fusion welder, or a laser welder that joins a first conductive sheet to a second conductive sheet to define a plurality of separate volumes in a blank envelope;   at least one of a supply of inert gas, a press, a heater, or a die that hot plastic forms the blank envelope into a formed envelope; and   at least one of a cutting tool or a welding machine that assemble a plurality of the formed envelopes into a heat exchanger core to allow a different fluid to flow through each separate volume, wherein the heat exchanger core includes a fluid passage outside of the formed envelopes, wherein the fluid passage is defined by adjacent formed envelopes, and wherein the fluid passage extends across a dimension of the heat exchanger core.   
     
     
         8 . The system as in  claim 7 , wherein the least one of a friction stir welder, a fusion welder, or a laser welder defines a first volume in each blank envelope substantially surrounded by a second volume in each blank envelope. 
     
     
         9 . The system as in  claim 7 , wherein the at least one of a supply of inert gas, a press, a heater, or a die creates an aperture in each separate volume in the blank envelope. 
     
     
         10 . The system as in  claim 9 , wherein the at least one of a supply of inert gas, a press, a heater, or a die injects a gas through each aperture and into each volume. 
     
     
         11 . The system as in  claim 7 , wherein the at least one of a cutting tool or a welding machine aligns adjacent volumes in each formed envelope parallel to flow through the fluid passage. 
     
     
         12 . The system as in  claim 7 , wherein the at least one of a cutting tool or a welding machine creates a fluid channel through opposite ends of each separate volume. 
     
     
         13 . A system for manufacturing a heat exchanger, comprising:
 a laser welder that joins a first conductive sheet to a second conductive sheet to define a plurality of separate volumes in a blank envelope;   a press that hot plastic forms the blank envelope into a formed envelope; and   a welding machine that assembles a plurality of the formed envelopes into a heat exchanger core to allow a different fluid to flow through each separate volume, wherein the heat exchanger core includes a fluid passage outside of the formed envelopes, wherein the fluid passage is defined by adjacent formed envelopes, and wherein the fluid passage extends across a dimension of the heat exchanger core.   
     
     
         14 . The system as in  claim 13 , wherein the laser welder defines a first volume in each blank envelope substantially surrounded by a second volume in each blank envelope. 
     
     
         15 . The system as in  claim 13 , wherein the press creates an aperture in each separate volume in the blank envelope. 
     
     
         16 . The system as in  claim 15 , wherein the press injects a gas through each aperture and into each volume. 
     
     
         17 . The system as in  claim 13 , wherein the welding machine aligns adjacent volumes in each formed envelope parallel to flow through the fluid passage. 
     
     
         18 . The system as in  claim 13 , wherein the welding machine creates a fluid channel through opposite ends of each separate volume.