Patent ID: 6851171

Claim:
A method of fabricating a multi-channel device, the method comprising the steps of: (a) fabricating a partial laminate, the fabrication of the partial laminate comprising the steps of: (i) providing a base web, the base web having a first edge and a second edge, the second edge opposite from, and substantially parallel to, the first edge, and a first surface; (ii) providing a first edge web; (iii) providing a second edge web; (iv) optionally providing one or more additional webs; (v) aligning the first edge web with the first edge of the base web; (vi) contacting the first edge web with the first surface of the base web; (vii) aligning the second edge web with the second edge of the base web; (viii) contacting the second edge web with the first surface of the base web; (ix) aligning any optional additional webs between the first edge web and the second edge web; (x) contacting any optional additional webs with the first surface of the base web; (xi) securing the edge webs and any optional additional webs to the first surface of the base web, thus defining one or more open partial laminate channels, the one or more open partial laminate channels running substantially parallel to at least the first base web edge; (b) separating the partial laminate into a plurality of subassemblies, each subassembly comprising a base, a first edge strip, a second edge strip, and optionally one or more additional strips, the base, the first edge strip, the second edge strip, and any optional additional strips defining one or more subassembly open channels, each subassembly base having a first edge, the first subassembly base edge being substantially orthogonal to the one or more subassembly open channels, and a second edge, the second subassembly base edge opposite from and substantially parallel to the first subassembly base edge; (c) placing one or more additional subassemblies together with a first subassembly to form a partial stack, such that the base of each additional subassembly cooperates with an adjacent subassembly to form one or more closed channels, wherein the one or more channels of at least one subassembly are substantially orthogonal to the one or more channels of at least one other subassembly; (d) terminating the partial stack with a final plate, the final plate having a first edge and a second edge, the final plate second edge opposite from and substantially parallel to the final plate first edge, wherein the final plate cooperates with an adjacent additional subassembly to define one or more closed channels; (e) securing the first edge of at least one additional subassembly to the first edge strip of an adjacent subassembly; (f) securing the second edge of the at least one additional subassembly to the second edge strip of the adjacent subassembly; (g) securing the final plate first edge to the first edge strip of the adjacent subassembly; and (h) securing the final plate second edge to the second edge strip of the adjacent subassembly.