Abstract: A gasket or other sealing member containing intercalated graphite exhibits improved strength and safety properties and simplified manufacture. Such a gasket may be formed by filling a mold of the appropriate shape with intercalated graphite powder and applying sufficient pressure and heat to produce a coherent mass. The properties of an intercalated graphite gasket may be further improved by incorporating metal reinforcement, metal powders, organic polymers ceramic powders or even exfoliated graphite into the intercalated graphite gasket.

Abstract: An electric motor brush or other electrical contact fabricated with intercalated graphite exhibits improved electrical conductivity, strength and performance when compared with electrical brushes made with non-intercalated graphite or with carbon. Such contacts may be formed by filling a mold of the appropriate shape with intercalated graphite powder and applying sufficient pressure and heat to produce a coherent mass. The ability of intercalated graphite powder to be compacted in such a fashion leads to economic methods of manufacturing electrical contacts. The properties of these contacts may be further improved by the incorporation of metal powder, organic polymers or ceramic powders into the intercalated graphite prior to pressing.

Abstract: A bearing or other support member containing intercalated graphite exhibits many of the properties of a metal (ie: conductivity, luster, ductility) while enhancing the lubricating properties of pure graphite. The bearings are made by pressing an intercalated graphite powder either alone or mixed with metal powders, organic polymers or ceramic powders into the desired shape. This results in a bearing that has low friction properties, improved load bearing characteristics, higher operating temperatures and a reduced cost of manufacture.

Abstract: Members, such as bearings, gaskets, electrical conductors and the like, as well as containing coatings, made from graphite intercalated with a metal halide exhibit superior stability except when used or stored in an extremely humid atmosphere. In a humid atmosphere these members and coatings tend to swell, crack and develop a corrosion layer over time. In accordance with the present invention, however, members and coatings made from intercalated graphite mixed with from 2 vol. % to about 30 vol. % of a metal powder do not exhibit this environmental instability.

Abstract: An electrically conductive composition is disclosed which comprises a graphite intercalation compound of graphite, a Bronsted acid such as hydrogen fluoride, chloride, or bromide, nitric, nitrous, sulfuric or perchloric acid, and a metal halide selected from boron trihalide, a pentahalide of a metal from Group V of the Periodic Table, a tetrahalide of a metal from Group IV of the Periodic Table and mixtures thereof.