Abstract: A method of forming impressions in a flexible graphite sheet is provided. More particularly, the inventive method involves contacting a flexible graphite sheet with an forming element capable of oscillating against the flexible graphite sheet, whereby the oscillations in the element are such that a plurality of impressions are formed in the flexible graphite sheet.

Abstract: Methods are provided for manufacturing bipolar graphite articles (110). First and second components (112, 114) are formed from flexible graphite material. The first component (112) may have a protrusion (122) formed thereon, and the second component (114) may have a recess (128) formed therein which is complementary to the protrusion (122) of the first component (112). The first and second components (112, 114) are assembled so that the protrusion (122) of the first component (112 ) is received in the recess (128) of the second component (114). 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 (114), or both the components, may have flat surfaces which engage the other component.

Abstract: Seal ring for engine exhaust systems in the form of a composite of flexible graphite and metal mesh with the metal mesh being positioned close to the bearing surface of the seal ring whereby audible emanations from the seal ring during use are avoided.

Abstract: Method and assembly for reinforcing flexible graphite by fusion bonding a film of thermoplastic polymer to the flexible graphite to form a laminiated product. One side of the thermoplastic polymer is raised to its softening temperature to cause it to bond to the flexible graphite while the opposite side thereof is maintained at a temperature below its softening point.

Abstract: A flexible graphite laminate of flexible graphite and a core material bonded through an intermediate coating of an epoxy resin composite comprising an epoxy resin having a glass transition temperature after cure of below 120.degree. C. and particles of a thermoplastic agent dispersed in the epoxy resin and having a crystalline or partially crystalline structure and a melting temperature of between 120.degree. C. and 200.degree. C.

Abstract: A process for forming pinhole free ultra-thin flexible sheet material from natural graphite comprising treating low ash natural graphite particles with an oxidizing agent to intercalate the graphite, introducing the particles after they are dried to less than 2% by weight water into a furnace preheated to at least 2000.degree. F. to cause rapid expansion to a specific volume of at least 800 cc/gm and compressing the expanded graphite to below 8 mils in thickness with a density of less than 1.3 g/cc.

Abstract: A composite sheet suitable for manufacturing thermally insulating gaskets for use between an aluminum head and steel muffler of an internal combustion engine, comprising a thermally insulating refractory fiber layer disposed between a metal layer and a flexible graphite layer.

Abstract: A method for intercalating graphite flakes which requires less intercalation solution and avoids a washing step, thus producing economy in material and production costs, and avoiding production of contaminated waste water which requires costly disposal steps.

Abstract: A high strength, high coefficient of thermal expansion fine-grained isotropic graphite article produced from 30% to 70% of attritor milled gilsonite coke or other high CTE carbon filler particles and minor amounts of a binder such a coal tar pitch and petroleum pitch, the article being formed by warm isostatic molding at a temperature of between 50.degree. C. and 70.degree. C. under a pressure between 100 and 1000 psi for a time between 1 and 10 minutes. The particle size of the fillers ranges up to 150 microns.