Flexible graphite article and method of manufacture
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.
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.