Abstract: A method of manufacturing an electrode for an electrochemical fuel cell is disclosed, comprising providing a sheet of compressed mass of expanded graphite particles having a plurality of perforations defined by walls of the expanded graphite particles, and the perforations passing through the sheet between first and second opposed surfaces of the sheet; coating the sheet with a thermosettable organic resin, said coating step comprising filling a portion of said perforations with the thermosettable organic resin; curing and baking the sheet, and reopening a portion of the filled perforations during the curing and baking step; activating the thermosettable organic resin to form a high surface area carbon on the walls of the perforations; and loading a catalyst onto the high surface area carbon.

Abstract: Methods are provided for manufacturing bipolar graphite articles. First and second components are formed from flexible graphite material. The first component may have a protrusion formed thereon, and the second component may have a recess formed therein which is complementary to the protrusion of the first component. The first and second components are assembled so that the protrusion of the first component is received in the recess of the second component. Preferably, the components are made from uncured resin impregnated graphite material. The assembled components are then pressed together and heated to cure the resin so as to bond the components together. Alternatively the second component, or both the components, may have flat surfaces which engage the other component.

Abstract: The present invention relates to a flexible graphite sheet having increased isotropic properties. More particularly, the present invention relates to a flexible graphite sheet formed from particles of expanded natural graphite formed from graphite flake sized no more than about 30% by weight +80 mesh prior to expansion. The resulting sheet of flexible graphite exhibits improved conductive and fluid sealing properties.

Abstract: A method enables preparation of a stock or starting material having improved thermal and/or electrical properties along with a desired set of other properties. These materials will be useful in the formation of articles adapted for use in electrochemical fuel cells and supercapacitors.

Abstract: An method for producing a material useful for forming a component for an electrochemical fuel cell is provided. More particularly, the component is formed of a sheet of a compressed mass of expanded graphite particles. The component is treated with a water resistant additive sufficient to provide utility as a component in an electrochemical fuel cell. Preferably, the water resistant additive is a fluoropolymer material. More preferably, the water resistant additive is a polytetrafluoroethylene material. The treatment preferably occurs by coating and/or impregnating the water resistant material in the sheet of graphite particles.

Abstract: An improved method enables preparation of articles for a variety of applications, including embossing or otherwise shaping to form a variety of articles. A plurality of thin, preferably resin-impregnated, flexible graphite sheets are arranged to form zones in a composite material having a graded density or other characteristic. Variation of properties between zones in the stock material formed is useful for achieving a desired set of properties in the formation of articles such as those useful in electrochemical fuel cells and double-layer capacitors.

Abstract: Methods are provided for manufacturing bipolar graphite articles. First and second components are formed from flexible graphite material. The first component has a protrusion formed thereon, and the second component has a recess formed therein which is complementary to the protrusion of the first component. The first and second components are assembled so that the protrusion of the first component is received in the recess of the second component. Preferably, the components are made from uncured resin impregnated graphite material. The assembled components are then pressed together and heated to cure the resin so as to bond the components together.

Abstract: A method of manufacturing material suitable for the construction of a component of a fuel cell, such as a flow field plate or electrode, is provided. Uncured resin impregnated flexible graphite sheet is ground into particles. Without re-expanding the particles, and without adding further resin to the particles, the particles are molded into the form of the desired material. The material is then cured. Additives may be mixed with the particles to improve the properties of the material.

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: A catalyst support material useful in a membrane electrode assembly is presented. The support catalyst material is elongate electrically anisotropic particles of flexible graphite, and the membrane electrode assembly includes a pair of electrodes, an ion exchange membrane having opposed surfaces positioned between the electrodes and a catalyst material on the inventive support, at least a portion of an opposed surface of the ion exchange membrane being adjacent the catalyst which is supported on the elongate electrically anisotropic particles of flexible graphite sheet.

Abstract: An electrode for an electrochemical fuel cell is provided. More particularly, an electrode formed of a sheet of a compressed mass of expanded graphite particles having a plurality of transverse fluid channels passing through the sheet between first and second opposed surfaces of the sheet, is provided. The electrode is treated with a water resistant additive sufficient to provide utility as a cathode in an electrochemical fuel cell.

Abstract: The invention presented is a graphite article having predetermined anisotropic characteristics, as well as a process for preparing the article. More particularly, the article is prepared by a process involving determining the desired anisotropic characteristics for a finished flexible graphite article; intercalating and then exfoliating flakes of graphite to form exfoliated graphite particles; forming a substrate graphite article by compressing the exfoliated graphite particles into a coherent article formed of graphene layers; and producing a controlled directional alignment of the graphene layers in the substrate graphite article to provide a finished graphite article having the desired anisotropic ratio.

Abstract: A membrane electrode assembly is provided. More particularly, an assembly is provided which includes a pair of electrodes and an ion exchange membrane having opposed major surfaces positioned between the electrodes, at least one of the electrodes being formed of a sheet of a compressed mass of expanded graphite particles having a plurality of transverse fluid channels passing through the sheet between first and second opposed surfaces of the sheet, one of opposed surfaces abutting the ion exchange membrane. At least one of the surfaces of the ion exchange membrane has a catalyst metal selectively loaded thereon.

Abstract: The invention presented is a graphite article having predetermined anisotropic characteristics, as well as a process for preparing the article. More particularly, the article is prepared by a process involving determining the desired anisotropic characteristics for a finished flexible graphite article; intercalating and then exfoliating flakes of graphite to form exfoliated graphite particles; forming a substrate graphite article by compressing the exfoliated graphite particles into a coherent article formed of graphene layers; and producing a controlled directional alignment of the graphene layers in the substrate graphite article to provide a finished graphite article having the desired anisotropic ratio.

Abstract: A graphite article useful in producing a membrane electrode assembly comprising a pair of electrodes and an ion exchange membrane positioned between the electrodes is presented. At least one of the electrodes is formed of a sheet of a compressed mass of expanded graphite particles having a plurality of transverse fluid channels passing through the sheet between first and second opposed surfaces of the sheet, one of opposed surfaces abutting the ion exchange membrane when used in a membrane electrode assembly. At least some of the fluid channels are interconnected to enable flow of fluid therebetween.

Abstract: A membrane electrode assembly is provided comprising a pair of electrodes and an ion exchange membrane positioned between the electrodes, at least one of the electrodes being formed of a sheet of a compressed mass of expanded graphite particles having a plurality of transverse fluid channels passing through the sheet between first and second opposed surfaces of the sheet, one of opposed surfaces abutting said ion exchange membrane, said transverse fluid channels being formed by mechanically impacting an opposed surface of the sheet to displace graphite within the sheet at predetermined locations.

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: Fluid permeable graphite article in the form of a perforated flexible graphite sheet having increased electrical and thermal conductivity transverse to the surfaces of the sheet.

Abstract: A thermal insulating device, and process for making it, are presented. The inventive thermal insulating device is formed of a cylindrically shaped shell comprising multiple layers of a continuous spiral wound anisotropic flexible graphite sheet, the layers of spiral wound graphite sheet being separated by and bonded to a cured resin.

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.