Flexible graphite article and method of manufacture

• US 7,470,468 B2
• Filed: 12/01/2004
• Issued: 12/30/2008
• Est. Priority Date: 04/07/1999
• Status: Expired due to Fees

• Current Assignee: NeoGraf Solutions, LLC
• Original Assignee: Graftech International Holdings Inc (Graftech International Limited)
• Inventors: Capp, Joseph Paul, Warddrip, Michael Lee, Weber, Thomas William, Mercuri, Robert Angelo
• Primary Examiner(s): Hendricks; Keith D.
• Assistant Examiner(s): MILLER, DANIEL H
• Application Number:
  US11/001,698
• Publication Number:
  US 20050202245A1
• Time in Patent Office: 1,490 Days
• Field of Search: 428/408, 165/185, 429/34, 264/104, 264/134, 264/105, 264/136, 423/447.1, 423/447.3
• US Class Current: 428/408
• CPC Class Codes: C04B 14/022 Carbon
• CPC Class Codes: C04B 30/00 Compositions for artificial stone, not containing binders
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A flexible graphite sheet exhibiting enhanced isotropy is provided. In addition, an apparatus, system and method for continuously producing a resin-impregnated flexible graphite sheet is also provided.

Claims

1. A method for forming a graphite plate sealed with a resin sealant, said method comprising:

a. providing a graphite sheet having opposed planar surfaces defining an interior portion therebetween, said sheet being formed from exfoliated graphite particles to provide said interior with pores and defining a graphite density of said sheet;

b. providing a curable resin sealant;

c. contacting said resin sealant with at least one of said planar surfaces, allowing said resin sealant to communicate through said pores;

d. compressing said sheet to form a graphite plate having graphite density after compression, wherein said graphite density is greater after compression than before compression; and

e. curing said resin sealant contained within said pores to seal said plate.

2. The method of claim 1 wherein said graphite density before compression is from about 0.08 to about 0.8 g/cc.

3. The method of claim 1 wherein said graphite density before compression is from about 0.08 to 0.5 g/cc.

4. The method of claim 1 wherein said graphite density after compression is from about 1.0 to 2.2 g/cc.

5. The method of claim 1 wherein compressing further includes forming a pattern in at least one of said planar surfaces.

6. The method of claim 5 wherein said plate is a fluid-flow plate of a fuel cell and further wherein said pattern is a continuous fluid-flow channel.