Film heat exchanger coupling system and method

A method of manufacturing a heat exchanger array, the method comprising:

• generating a plurality of heat exchanger units that include:
• a first and second end;
• a first and second polymer sheet welded together at a plurality of edges to define a cavity between the first and second polymer sheets, the cavity being elongated extending between the first and second ends;
• an opposing first and second face defined respectively by the first and second polymer sheets;
• a first port at the first end of the heat exchanger unit defined by the first and second polymer sheets, the first port being an opening that extends between the first and second faces at the first end;
• and
• a second port at the second end of the heat exchanger unit defined by the first and second polymer sheets, the second port being an opening that extends between the first and second faces at the second end;
• stacking the plurality of heat exchanger units in an aligned configuration with the first ports of the plurality of heat exchanger units aligned;
• generating, with an adhesive, a first plurality of respective adhesive couplings between adjacent polymer sheets of adjacent heat exchanger units about adjacent first ports and without a coupling being generated between the first and second polymer sheets of a given heat exchanger unit;
• stacking the plurality of heat exchanger units in an aligned configuration with the second ports of the plurality of heat exchanger units aligned;
• and
• generating, with the adhesive, a second plurality of respective adhesive couplings between adjacent polymer sheets of adjacent heat exchanger units about adjacent second ports and without a coupling being generated between the first and second polymer sheets of a given heat exchanger unit,
• wherein the plurality of heat exchanger units are coupled as a unitary structure before generation of the first and second plurality of adhesive couplings;
• and
• wherein the stacking the plurality of heat exchanger units in an aligned configuration with the first ports of the plurality of heat exchanger units aligned comprises folding the unitary structure so that the plurality of heat exchanger units defined by the unitary structure are disposed in the aligned configuration with the first ports of the plurality of heat exchanger units aligned.

A method of manufacturing a heat exchanger array, the method comprising:

• stacking a plurality of heat exchanger units in an aligned configuration with respective first ports of the plurality of heat exchanger units aligned, the heat exchanger units of the plurality of heat exchanger units including:
• a first and second end;
• a first and second sheet coupled together to define a cavity between the first and second sheets;
• the first port at the first end of the heat exchanger unit defined by the first and second sheets;
• and
• a second port at the second end of the heat exchanger unit defined by the first and second sheets;
• and
• generating a first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports,
• wherein generating the first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports comprises applying an adhesive between the adjacent sheets of the adjacent heat exchanger units about the adjacent first ports,
• wherein the adhesive comprises at least one of a solvent adhesive, glue, double-sided tape and hot-melt adhesive, and
• wherein the solvent adhesive comprises at least one of Cyclohexane, Methylene dichloride, Ethylene dichloride, Acetone, n-Hexanol, 1,2 Dichloroethane, and Methyl benzene.

A method of manufacturing a heat exchanger array, the method comprising:

• stacking a plurality of heat exchanger units in an aligned configuration with respective first ports of the plurality of heat exchanger units aligned, the heat exchanger units of the plurality of heat exchanger units including:
• a first and second end;
• a first and second sheet coupled together to define a cavity between the first and second sheets;
• the first port at the first end of the heat exchanger unit defined by the first and second sheets;
• and
• a second port at the second end of the heat exchanger unit defined by the first and second sheets;
• and
• generating a first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports,
• wherein the plurality of heat exchanger units are coupled as a unitary structure before generation of the first plurality of couplings;
• and
• wherein the stacking the plurality of heat exchanger units in an aligned configuration with the first ports of the plurality of heat exchanger units aligned comprises folding the unitary structure so that the plurality of heat exchanger units defined by the unitary structure are disposed in the aligned configuration with the first ports of the plurality of heat exchanger units aligned.

A method of manufacturing a heat exchanger array, the method comprising:

• stacking a plurality of heat exchanger units in an aligned configuration with respective first ports of the plurality of heat exchanger units aligned, the heat exchanger units of the plurality of heat exchanger units including:
• a first and second end;
• a first and second sheet coupled together to define a cavity between the first and second sheets;
• the first port at the first end of the heat exchanger unit defined by the first and second sheets;
• and
• a second port at the second end of the heat exchanger unit defined by the first and second sheets;
• and
• generating a first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports,
• wherein the first and second sheets of the heat exchanger units are each defined by a multilayer laminate that comprises:
• a metallic layer having a first and second side;
• a sealant layer on the first side of the metallic layer;
• and
• a protective layer on the second side of the metallic layer to protect the metallic.