Active microchannel fluid processing unit and method of making

An active microchannel fluid processing unit, comprising:

• (a) at least one first sub-assembly;
• wherein said at least one first sub-assembly has at least a first inlet and a first outlet;
• wherein the at least one first sub-assembly comprises at least one first inner sheet in alternating contact with at least one first outer sheet, said at least first one inner sheet having a first major surface in contact with said at least one first outer sheet and a second major surface in contact with an outer sheet or an end block wherein said first major surface and said second major surface are separated by a thickness, and said at least first one inner sheet having at least one solid margin, said at least one solid margin defining at least one edge of at least one slot through said thickness;
• wherein said at least one inner sheet is adjacent said at least one outer sheet,
• wherein said at least one outer sheet has at least one opening positioned within said solid margin,
• wherein said solid margin sealably spaces said at least one outer sheet,
• wherein said at least one outer sheet defines at least one longitudinal wall of a flow channel having a length parallel to a sheet length,
• wherein said first assembly comprises a first flow path, such that, during operation, a fluid can enter through said at least one opening into at least one slot to flow in a direction parallel to the length of said flow channel and exit through another opening that is located on either said at least one outer sheet having said at least one opening or on a second outer thin sheet disposed on an opposite side of said inner sheet;
• wherein said at least one outer sheet and said at least one inner sheet form a first stack;
• and
• (b) at least one second sub-assembly;
• said at least one second sub-assembly comprising at least a second inlet, a second outlet and a second flow path;
• wherein said second flow path is separate from said first flow path;
• wherein said second flow path is within said first stack or is in a second stack;
• wherein said second stack, if present, comprises at least one second inner sheet in alternating contact with a second at least one outer sheet;
• wherein said at least one first sub-assembly is capable of performing at least a first unit operation and said at least one second sub-assembly is capable of performing at least a second unit operation.