Polymer film heat exchanger with integral fluid distribution manifolds and method

Abstract

A polymer film heat exchanger with integral fluid distribution manifolds. Methods of making polymer film heat exchangers.

The claimed invention is: 
     
         1 . A device comprising:
 a plurality of polymer films including a first film adjacent a second film and including a third film adjacent the second film, the plurality of polymer films in stacked alignment and having a stack axis normal to a plane of the plurality of polymer films, wherein the first film is bonded to the second film with a first bond having a first pattern configured to form a first channel between the first film and the second film, and further wherein the second film is bonded to the third film with a second bond having a second pattern configured to form a second channel between the second film and the third film, and further including a first pair of ports fluidly coupled to the first channel and including a second pair of ports fluidly coupled to the second channel, wherein the first pair of ports and the second pair of ports have port axes aligned substantially parallel with the stack axis.   
     
     
         2 . The device of  claim 1  wherein the third film is bonded to a fourth film with a third bond, the third bond having the first pattern and wherein the first channel is fluidly coupled to a region bound by the third film and the fourth film. 
     
     
         3 . The device of  claim 2  wherein the fourth film is bonded to a fifth film with a fourth bond, the fourth bond having the second pattern and wherein the second channel is fluidly coupled to a region bound by the fourth film and the fifth film. 
     
     
         4 . The device of  claim 1  wherein the first channel is bound by the first bond and wherein the second channel is bound by the second bond. 
     
     
         5 . The device of  claim 1  wherein the first pair of ports and the second pair of ports are on a common side of the plurality of polymer films. 
     
     
         6 . The device of  claim 1  wherein the polymer films of the plurality of polymer films have a substantially rectangular profile and wherein the first pair of ports includes a first input port and includes a first output port and wherein the first input port and the first output port are aligned on a common diagonal determined by the profile. 
     
     
         7 . The device of  claim 1  wherein at least one of the first bond and the second bond includes at least one of a thermal joint, a weld joint, and an adhesive joint. 
     
     
         8 . The device of  claim 1  wherein the first channel is fluidly isolated from the second channel. 
     
     
         9 . The device of  claim 1  further including a first reinforcement plate coupled to a first selected polymer film of the plurality of polymer films. 
     
     
         10 . The device of  claim 9  further including a second reinforcement plate coupled to a second selected polymer film of the plurality of polymer films. 
     
     
         11 . The device of  claim 10  further including at least one spacer coupled to the first reinforcement plate and coupled to the second reinforcement plate, wherein the at least one spacer is configured to retain the first reinforcement plate and the second reinforcement plate in fixed alignment and at a predetermined distance apart. 
     
     
         12 . The device of  claim 1  wherein the first film and the second film have a dimension in common. 
     
     
         13 . The device of  claim 1  wherein the first film, the second film, and the third film have an aperture in common. 
     
     
         14 . A method comprising:
 forming a first bond coupling a first film and a second film, the first bond having a first bond pattern, the first film and the second film in stacked alignment and having a first channel therebetween;   forming a second bond coupling the second film and a third film, the second bond having a second bond pattern, the second film and the third film in stacked alignment and having a second channel therebetween, the second channel fluidly independent of the first channel;   forming a first pair of ports in the first film, the first pair of ports in fluid communication with the first channel; and   forming a second pair of ports in the third film, the second pair of ports in fluid communication with the second channel.   
     
     
         15 . The method of  claim 14  further including forming a third bond coupling the third film and a fourth film, the third bond having the first bond pattern, the third film and the fourth film in stacked alignment and wherein the first channel is fluidly coupled to a region bound by the third film and the fourth film. 
     
     
         16 . The method of  claim 15  further including forming a fourth bond coupling the fourth film and a fifth film, the fourth bond having the second bond pattern, the fourth film and the fifth film in stacked alignment and wherein the second channel is fluidly coupled to a region bound by the fourth film and the fifth film. 
     
     
         17 . The method of  claim 14  wherein forming the first pair of ports and forming the second pair of ports includes forming on a common side of the films. 
     
     
         18 . The method of  claim 14  wherein the first film, the second film, and the third film have a substantially rectangular profile and wherein forming the first pair of ports includes forming a first input port and includes forming a first output port and wherein the first input port and the first output port are aligned on a common diagonal determined by the profile. 
     
     
         19 . The method of  claim 14  wherein at least one of forming the first bond and forming the second bond includes forming at least one of a thermal joint, a weld joint, and an adhesive joint. 
     
     
         20 . The method of  claim 14  further including affixing a first reinforcement plate to the first film. 
     
     
         21 . The method of  claim 20  further including affixing a second reinforcement plate coupled to a film. 
     
     
         22 . The method of  claim 21  further including providing at least one spacer coupled to the first reinforcement plate and coupled to the second reinforcement plate, wherein the at least one spacer is configured to retain the first reinforcement plate and the second reinforcement plate in fixed alignment and at a predetermined distance apart.