Heat exchanger system having manifolds structurally integrated with a duct

A heat exchanger system comprising

• a gas turbine engine comprising a gas-flow duct having a duct wall with a duct wall outer surface and a duct wall inner surface;
• a heat exchanger partial shell joined to the duct wall inner surface, so that the heat exchanger partial shell and a shell portion of the duct wall inner surface constitute a heat exchanger, wherein the heat exchanger is joined to the duct wall inner surface with a plurality of mechanical fasteners;
• a heat exchanger inlet manifold at an inlet location along the duct wall and comprising an elongated nonplanar inlet sheet of material having two inlet-manifold side margins, wherein each inlet-manifold side margin is joined to the duct wall outer surface, so that the elongated nonplanar inlet sheet and an inlet-manifold portion of the duct wall outer surface define the inlet manifold, wherein the inlet sheet of material is made of a metal, and wherein the inlet sheet of material is welded to the duct wall outer surface;
• a heat exchanger inlet opening extending through the duct wall between the inlet manifold and the heat exchanger;
• a heat exchanger outlet manifold at an outlet location along the duct wall and comprising an elongated nonplanar outlet sheet of material having two outlet-manifold side margins, wherein each outlet-manifold side margin is joined to the duct wall outer surface, so that the elongated nonplanar outlet sheet and an outlet-manifold portion of the duct wall outer surface define the outlet manifold, wherein the outlet sheet of material is made of a metal, and wherein the outlet sheet of material is welded to the duct wall outer surface;
• and
• a heat exchanger outlet opening extending through the duct wall between the outlet manifold and the heat exchanger.

A heat exchanger system comprising

• a duct having a duct wall with a duct wall outer surface and a duct wall inner surface;
• a heat exchanger partial shell hermetically joined to the duct wall inner surface, so that the heat exchanger partial shell and a shell portion of the duct wall inner surface constitute a heat exchanger;
• a heat exchanger inlet manifold defined by a nonplanar inlet sheet of material hermetically joined to the duct wall outer surface, and an inlet-manifold portion of the duct wall outer surface;
• a heat exchanger inlet opening extending through the duct wall between the inlet manifold and the heat exchanger;
• a heat exchanger outlet manifold defined by a nonplanar outlet sheet of material hermetically joined to the duct wall outer surface, and an outlet-manifold portion of the duct wall outer surface;
• and
• a heat exchanger outlet opening extending through the duct wall between the outlet manifold and the heat exchanger.