Abstract: A porous metal structure having a continuous metal phase intermingled with a continuous tortuous porous phase. The continuous tortuous porous phase can be made to terminate at a surface of the porous metal structure with elongated pores. The porous metal structure can be made to have a bulk density divided by the density of the metal of from, for example, 0.99 to 0.01. Such structures can be made by electrodepositing a metal in the interstitial spaces of a polymer foam and by electroforming a metal in the interstitial spaces of a stretched porous structure of sintered polymer beads.

Abstract: A filter for removing soot from the exhaust gases from a diesel engine. The filter incorporates two elements. The first element is a flow-through filter element incorporating a porous metal substrate formed by electrodepositing a metal such as nickel in the interstitial spaces of a packed array of electrically nonconductive particles of a material and then removing the material of the particles to produce the porous metal substrate. The second element is a hollow body having an inlet port and an outlet port, the filter element being positioned in and sealed to the hollow body so that diesel exhaust gases directed into the inlet port of the hollow body flow through the porous metal substrate from the inlet side of the porous metal substrate to the outlet side of the porous metal substrate and then out the outlet port of the hollow body. The bulk density of the porous metal substrate is less than 40% of the density of the metal of the substrate.

Abstract: A method for making the anode (or the cathode) of a nickel-metal hydride battery by electrodepositing a metal in the interstitial spaces a bed of metal-hydride active material particles (or electrodepositing a metal in the interstitial spaces of a bed of nickel hydroxide particles). Alternatively, the anode (or cathode) can be made by pressing metal-hydride active material particles (or nickel hydroxide particles) into a cellular metal substrate formed by electrodepositing a metal in the interstitial spaces of a bed of particles. Or, the anode (or cathode) can be made by flowing a suspension of metal-hydride active material particles (or nickel hydroxide particles) through a cellular metal substrate formed by electrodepositing a metal in the interstitial spaces of a bed of particles.

Abstract: The invention relates to an improvement in an electrolytic cell having an anode positioned within an anode chamber and an oxidizing gas depolarized cathode positioned within a cathode chamber adapted to contain a catholyte, said cathode chamber spaced apart from the anode chamber by a cation-permeable partition. The improved cell comprises the cathode having a cellular metal structure comprising a continuous interconnected network of electrolytically deposited metal defining therebetween a plurality of substantially convex and substantially electrically nonconductive cellular compartments. The arrangement of the compartments is adapted to permit passage of the oxidizing gas to the catholyte. The cellular metal structure is further characterized in that the deposited metal interfaces the cellular compartments within the cellular metal structure.

Abstract: A cellular metal structure comprising a continuous interconnected network of electrolytically deposited metal defining a plurality of substantially convex cellular compartments therebetween is disclosed. The metal structure is produced by positioning a cellular array of substantially convex and substantially electrically nonconductive particles having a plurality of interstitial spaces therebetween between the anode and cathode of an electrolytic cell. The array is at least partially immersed in an aqueous solution of an electrolyte suitable for the electrolytic deposition of the metal. A direct current potential is applied between the anode and cathode to electrolytically deposit a continuous interconnected network of metal in the interstitial spaces defined between the cellular array of substantially convex particles.