Integral evaporator and defrost heater system

Abstract

A heat exchanger system having a fluid passage operable to fluidly communicate a first fluid and a heat transfer surface extending from the fluid passage for transferring heat between the first fluid and a second fluid. The system can further include a heating element operably coupled to and selectively applying thermal energy to at least one of the fluid passage and the heat transfer surface.

1 . A heat exchanger system comprising:
 a fluid passage operable to fluidly communicate a first fluid;   a heat transfer surface extending from said fluid passage for transferring heat between said first fluid and a second fluid; and   a heating element operably coupled to and selectively applying thermal energy to at least one of said fluid passage and said heat transfer surface.   
     
     
         2 . The heat exchanger system according to  claim 1  wherein said fluid passage and said heat transfer surface are formed from a single sheet of material, said single sheet of material having opposing ends and being formed to define said fluid passage, said heat transfer surface, and a sealed area whereby said opposing ends are joined. 
     
     
         3 . The heat exchanger system according to  claim 2  wherein said sealed area is welded by laser, ultrasonics, or electric arc, or brazed. 
     
     
         4 . The heat exchanger system according to  claim 2 , wherein said heating element is sheathed using said single sheet of material. 
     
     
         5 . The heat exchanger system according to  claim 1  wherein said fluid passage and said heat transfer surface are a unitarily-formed extrusion. 
     
     
         6 . The heat exchanger system according to  claim 5  wherein said heating element is encapsulated within said unitarily-formed extrusion. 
     
     
         7 . The heat exchanger system according to  claim 1 , further comprising:
 a heater element passage formed with at least one of said fluid passage and said heat transfer surface, said heater element passage being sized to permit subsequent insertion of said heating element therein.   
     
     
         8 . The heat exchanger system according to  claim 7  wherein said heating element passage is fluidly separate from said fluid passage. 
     
     
         9 . The heat exchanger system according to  claim 1  wherein said heating element is mechanically coupled to at least one of said fluid passage and said heat transfer surface. 
     
     
         10 . The heat exchanger system according to  claim 1  wherein said heating element comprises varying thermal energy output along its length for localized heating. 
     
     
         11 . The heat exchanger system according to  claim 1  wherein said heat transfer surface comprises a wave-like shape. 
     
     
         12 . The heat exchanger system according to  claim 1  wherein said heat transfer surface comprises a plurality of spines. 
     
     
         13 . The heat exchanger system according to  claim 1  wherein said heat transfer surface is angled in a direction of flow of said second fluid. 
     
     
         14 . The heat exchanger system according to  claim 1  wherein said fluid passage comprises a round cross-sectional shape. 
     
     
         15 . The heat exchanger system according to  claim 1  wherein said fluid passage comprises an oval cross-sectional shape. 
     
     
         16 . The heat exchanger system according to  claim 1  wherein said fluid passage comprises an airfoil cross-sectional shape. 
     
     
         17 . The heat exchanger system according to  claim 1  wherein at least one of said fluid passage and said heat transfer surface is made of aluminum. 
     
     
         18 . The heat exchanger system according to  claim 1  wherein said fluid passage and said heat transfer surface are each made of different material. 
     
     
         19 . The heat exchanger system according to  claim 1  wherein said fluid passage, said heat transfer surface, and said heating element collectively form an arcuate shape along at least a portion thereof. 
     
     
         20 . A heat exchanger system comprising:
 a first passage operable to fluidly communicate a first fluid;   a first heat transfer surface extending from said first passage for transferring heat between said first fluid and a second fluid;   a first heating element operably coupled to and selectively applying thermal energy to at least one of said first passage and said first heat transfer surface;   a second passage operable to fluidly communicate said first fluid;   a second heat transfer surface extending from said second passage for transferring heat between said first fluid and a second fluid; and   a connecting passage fluidly coupling said first passage and said second passage for communication of said first fluid.   
     
     
         21 . The heat exchanger system according to  claim 20  wherein at least said first passage and said second passage together forming an arcuate shape along at least a portion thereof. 
     
     
         22 . The heat exchanger system according to  claim 20  wherein at least said first passage and said first heat transfer surface are a unitarily-formed extrusion. 
     
     
         23 . The heat exchanger system according to  claim 20 , further comprising:
 a second heating element operably coupled to at least one of said second passage and said second heat transfer surface.   
     
     
         24 . The heat exchanger system according to  claim 20  wherein said first passage and said first heat transfer surface are formed from a single sheet of material, said single sheet of material having opposing ends and being formed to define said first passage, said first heat transfer surface, and a sealed area whereby said opposing ends are joined. 
     
     
         25 . The heat exchanger system according to  claim 20  wherein said connecting passage fluidly couples said first passage and said second passage in parallel.