Patent ID: 8357427

Claim:
A method of manufacturing a partially catalyst-coated metal-substrate monolith, comprising the steps of: obtaining a multipath monolith substrate that is the product of a process comprising: obtaining one or more metal foils; texturing at least one of the foils to form corrugations; and folding, stacking, or rolling the foils to form them into a layered structure having open space between the foil layers and an overall monolith shape, the monolith shape having two opposing open ends along which edges of the foils are exposed and a perimeter closing the volume between the open ends; closing off the open ends of the monolith by pressing pads against them, the pads contacting the edges of the foils including contact on edge locations that are not on the perimeter; injecting material through one or more ports in the pads into space within the monolith, the space accessing a portion of the interior of the monolith limited to from about 10 percent to about 90 percent of the open space between layers, the remaining open space within the monolith being inaccessible from the one or more ports; contacting monolith surfaces bounding the accessed open space with the injected material while not contacting any of the monolith surfaces bounding the inaccessible open space with injected material; and selectively coating a portion of the monolith with a catalyst composition, the selectivity being defined by either selection to the surfaces contacted by the injected material or by exclusion from the surfaces contacted by the injected material; wherein the one or more ports are no more than ten, and the material is not injected into the remaining open space within the monolith that is inaccessible from the one or more ports; wherein the multipath monolith comprises flow paths defined by the corrugations and wherein the flow paths are interconnected.