Method for Producing Substrate Having Catalyst Compositions on Surfaces of Opposite Sides

2:

• The method of claim 1 in which a surface to be coated by a physical deposition process is cleaned by an ion-gun in an oxygen atmosphere and in an argon atmosphere prior to deposition.

3:

• The method of claim 1 wherein the substrate is supported upon a substantially rigid heat sink conforming to the shape of the substrate during the thermal spraying of the one surface.

4:

• The method of claim 1 in which the thermal spraying of the one surface precedes the physical deposition of a metal composition on the surface opposite the one surface.

5:

• The method of claim 1 in which coating the opposite surface of the substrate by a physical deposition process comprises an electron beam vapor deposition of a noble metal composition.

6:

• The method of claim 1 in which coating the opposite surface of the substrate by a physical deposition process comprises plasma sputtering a noble metal composition.

8:

• The method of claim 7 for making a micro channel catalytic device further comprising the step of squeezing the substrate laterally such that the preformed folds of the substrate narrow from their apexes to form the micro channels.

9:

• The method of claim 7 in which the pre-forming of the substrate with longitudinal folds comprises stamping the folds into a sheet material.

10:

• The method of claim 7 in which the preformed substrate is supported during the step of thermal spraying in contact with a substantially rigid heat sink having an upper surface with a shape corresponding to the supported side of the pre-folded substrate.

11:

• The method of claim 7 further including brazing the apexes of the folds on each side of the substrate to a plate to form enclosed channels defined by the apexes of the folds.

12:

• The method of claim 1 or claim 7 in which the one surface is grit-blasted prior to thermal spraying.

13:

• The method of claim 1 or claim 7 in which the physical deposition of a noble metal on the surface is performed subsequent to the thermal spraying of the one surface.

14:

• A micro component micro channel catalytic heat exchange device produced in accordance with claim 1 or claim 7.

15:

• The method of claim 1 or claim 7 wherein the catalyst on the one surface is thermally sprayed and the catalyst on the opposite surface is deposited by a physical deposition process.