Patent ID: 8869398

Claim:
A method for manufacturing a heat exchanger, comprising: a. joining a first conductive sheet to a second conductive sheet to define a plurality of separate volumes in a blank envelope; b. creating an aperture in each separate volume in the blank envelope; c. heating the blank envelope; d. pressurizing each separate volume through the apertures; e. hot plastic forming the blank envelope into a formed envelope; f. creating a fluid channel through opposite ends of each separate volume; g. 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; and h. connecting adjacent fluid channels of adjacent formed envelopes to allow a different fluid to flow through each separate volume concurrently.