Polymer film heat exchanger sealing 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 an 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;
• 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;
• a first welding element disposed about the first port between the first and second polymer sheets within the cavity;
• and
• a second welding element disposed about the second port between the first and second polymer sheets within the cavity;
• stacking the plurality of heat exchanger units in an aligned configuration with the first ports of the plurality of heat exchanger units aligned;
• generating heat in the first welding elements at the same time and at a temperature sufficient to generate a first plurality of respective welds between adjacent polymer sheets of adjacent heat exchanger units about adjacent first ports and without a weld 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 heat in the second welding elements at the same time and at a temperature sufficient to generate a second plurality of respective welds between adjacent polymer sheets of adjacent heat exchanger units about adjacent second ports and without a weld being generated between the first and second polymer sheets of a given heat exchanger unit.