Abstract: Composite electrode/current collectors for capacitors, e.g., a flow-through capacitor or electric double layer capacitor are disclosed. Also disclosed are methods for making a composite electrode/current collectors and capacitors having at least one composite electrode/current collector.

Abstract: The invention provides to thermal management devices constructed from flexible graphite. In one embodiment, the thermal management device includes a wick structure inside a shell. In certain preferred embodiments, the wick structure is composed of a mass of expanded graphite. In a another embodiment, the shell of the-device includes flexible graphite and an optional wick structure. In certain preferred embodiments, the flexible graphite shell is fluid impermeable. The invention further includes methods of making the aforementioned thermal management devices.

Abstract: A flexible graphite sheet having a hydrophobic binder and a carbonaceous material adhered thereto is disclosed. The flexible graphite sheet may be used as an electrode or a gas diffusion layer in a fuel cell, such as a proton exchange membrane fuel cell. Fuel cells having such a flexible graphite sheet and methods for making such flexible graphite sheets are also disclosed.

Abstract: Adhesive-backed graphite foil rings (62,64) are suited to forming a seal between a metal gasket plate (12) and adjacent pipe flanges (40, 42). To form the rings, a thin layer of adhesive (74) is applied in the form of a coating to a flexible graphite sheet (70). A release liner (80) may be applied over the adhesive layer. The rings (62,64) are cut from the adhesive coated flexible graphite sheet. In one method, the rings are die cut while leaving the release liner intact. After removal of extraneous material, a plurality of the rings remain attached to the release liner and can be peeled away from the liner as needed. In another method, a central cut-out portion (102) from a large adhesive-backed ring is later used to form a smaller adhesive-backed ring.

Abstract: The invention relates to power packs, which comprises a plurality of fuel cells and a reactant supply element. In one embodiment, the power pack comprises a reactant supply element for a reactant comprising one of a fuel or an oxidant; and a plurality of cylindrical fuel cells. The reactant supply element is aligned with the plurality to be capable to deliver the reactant to more than one fuel cell of the plurality. In a second embodiment, the power pack comprises a reactant supply element for a reactant comprising a fuel and a plurality of fuel cells attached to the reactant supply element. At least two of the plurality are removably attached to the reactant supply element, and the power pack comprises a passive oxidant supply.

Abstract: The invention relates to power packs, which comprises a plurality of fuel cells and a reactant supply element. In one embodiment, the power pack comprises a reactant supply element for a reactant comprising one of a fuel or an oxidant; and a plurality of cylindrical fuel cells. The reactant supply element is aligned with the plurality to be capable to deliver the reactant to more than one fuel cell of the plurality. In a second embodiment, the power pack comprises a reactant supply element for a reactant comprising a fuel and a plurality of fuel cells attached to the reactant supply element. At least two of the plurality are removably attached to the reactant supply element, and the power pack comprises a passive oxidant supply.

Abstract: The invention relates to expanded graphite and methods of making the graphite and products that can be made from the graphite made from the inventive process. The invention includes the step of introducing a fluid into at least one of a plurality of interstices of graphite flake, wherein the fluid comprises at least one of a sub-critical point fluid, a near critical point fluid, or a supercritical fluid. The graphite flake is also intercalated with an intercalant and optionally an oxidizing agent. The invention may further include novel techniques of exfoliating the graphite. The invention may be practiced to make nano-sized graphite particles and also graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites.

Abstract: The invention may be practiced to make graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites. One method of making the graphite aforementioned composites includes introducing an intercalant into at least one interstice of at least one flake of natural graphite. The method also includes introducing a fluid into the at least one interstices of the flake. Preferably, the fluid comprises at least one of a sub-critical fluid, near critical point fluid, or a supercritical fluid. Furthermore the method includes blending the flake with a polymer, thereby forming a graphite-polymeric composite.

Abstract: The invention relates to tubular fuel cells and methods of making such fuel cells. The inventive fuel cells include at least one fluid permeable structure having a plurality of perforations or channels. The perforations allow fluids, e.g., hydrogen or oxygen, to flow through the structure. The inventive methods include forming at least one perforated structure and forming the perforated structure into a tubular fuel cell or at least a potential component of a tubular fuel cell.

Abstract: A heat sink apparatus is constructed from alternating longer and shorter sheets of graphite material sandwiched together such that the longer sheets extend beyond the shorter sheets to define fins. The directions of higher thermal conductivity of the anisotropic graphite material are oriented in the plane of the sheet. The longer and shorter sheets have base ends aligned together to define a generally planar base surface for engaging an electronic device to be cooled.

Abstract: Partially expanded graphite flake having a specific volume of no more than about 50 cm3/g, more preferably, about 10-25 cm3/g has excellent sheet forming properties and is readily moldable to form molded products, such as gaskets. The partially expanded graphite flake may be produced by a low temperature process, in which the flakes are first intercalated with an intercalation solution, then subjected to a low temperature exfoliation of below about 500° C. In an alternative process, the flakes are intercalated with no more than about 40 pph of an intercalation solution (less if the particles are not subjected to a subsequent washing step) and then exfoliated at conventional exfoliation temperatures of about 800° C.

Abstract: The invention relates to tubular fuel cells and methods of making such fuel cells. The inventive fuel cells include at least one fluid permeable structure having a plurality of perforations or channels. The perforations allow fluids, e.g., hydrogen or oxygen, to flow through the structure. The inventive methods include forming at least one perforated structure and forming the perforated structure into a tubular fuel cell or at least a potential component of a tubular fuel cell.

Abstract: A composite heat sink apparatus includes a metal base which has a thermal conductivity of at least about 200 W/m° K. The metal base is preferably constructed either of copper of aluminum. The heat sink apparatus further includes a plurality of fins attached to the base, the fins being constructed of anisotropic graphite material having a direction of relatively high thermal conductivity perpendicular to the base.

Abstract: Apparatus and methods are provided for the embossing of a sheet of flexible graphite material between a pair of embossing rollers. The embossing rollers include a primary embossing roller and a backup roller. The primary embossing roller has an embossing pattern defined thereon. One or both of the rollers include a raised stabilization area adjacent a periphery of the embossing pattern. The raised stabilization area preferably has a roughened outer surface for better gripping the sheet of flexible graphite material. The raised stabilization areas apply a stabilizing force to the sheet adjacent the periphery of the embossing pattern, thereby limiting egress of the material laterally away from the embossing pattern. The roughened surfaces increase the grip of the raised areas upon the sheet, thus aiding in pulling the sheet between the rollers and also aiding in the application of lateral stabilization forces to the sheet.

Abstract: Fluid permeable graphite article in the form of a glassy carbon coated perforated flexible graphite sheet useful as an electrode and electrically conductive backing material in flow-through type electrical capacitors.

Abstract: Flexible graphite sheets having enhanced surface area prepared from materials comprising expanded graphite particles and activated carbon particles on phenol resin. The sheets with enhanced surface area are useful in the formation of articles adapted for use in supercapacitors.

Abstract: A method enables preparation of a stock or starting material having improved catalytic properties. These materials will be useful in the formation of articles adapted for use in electrochemical fuel cells.

Abstract: Graphite sheets having enhanced surface area are prepared from flexible graphite sheets to which an activated carbon precursor has been added, followed by activation of the precursor. The sheets with enhanced surface area are useful in the formation of articles adapted for use in supercapacitors.

Abstract: Components for use in electrochemical double-layer capacitors utilize at least one layer of a flexible graphite sheet material in an electrode or current collector or utilize a tanged metal layer in a current collector.

Abstract: An anode for a lithium-ion battery is presented as well as a process for producing an anode for a lithium-ion battery. The anode is formed from a generally continuous sheet of particles of exfoliated graphite having a thickness of no more than about 350 microns, itself or in a laminate with a metallic substrate. The process involves laminating particles of exfoliated graphite to a metallic substrate, such that the particles of exfoliated graphite form a generally continuous sheet of graphite having a thickness of no more than about 350 microns. The inventive anode reduces or eliminates capacity fading due to contact loss and has superior permeability to lithium.