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.