US Patent 7784528 Heat exchanger system having manifolds structurally integrated with a duct

A heat exchanger system includes a duct having a duct wall with a duct wall outer surface and a duct wall inner surface; and a heat exchanger partial shell hermetically joined to the duct wall inner surface. The heat exchanger partial shell and a shell portion of the duct wall inner surface constitute a heat exchanger. A heat exchanger inlet manifold is defined by a nonplanar inlet sheet of material hermetically joined to the duct wall outer surface. A heat exchanger outlet manifold is defined by a nonplanar outlet sheet of material hermetically joined to the duct wall outer surface. A heat exchanger inlet opening extends through the duct wall between the inlet manifold and the heat exchanger, and a heat exchanger outlet opening extends through the duct wall between the outlet manifold and the heat exchanger.