Overview
Expanded graphite is produced by treating natural or synthetic graphite with intercalation agents (e.g., sulfuric acid) followed by rapid heating, causing the graphite layers to 'exfoliate' into a low-density, accordion-like structure. This process increases surface area up to 400 m²/g while retaining graphite's inherent conductivity. Unlike conventional graphite, expanded graphite exhibits exceptional compressibility and resilience, making it ideal for sealing applications. Its development in the 1960s addressed leakage issues in industrial equipment, with modern variants now enabling advanced energy storage and composite materials.
Physical and Chemical Properties
The material's defining characteristic is its expansion ratio, typically ranging from 100:1 to 300:1 by volume. This creates a network of interconnected pores that provide unique mechanical flexibility – compressed density can reach 1.0–1.8 g/cm³ while remaining 70–90% recoverable after decompression. Thermally, it maintains graphite's anisotropic conductivity (150–400 W/mK in-plane), but its out-of-plane conductivity drops to 5–20 W/mK due to disrupted layer alignment. Chemically inert, it resists most acids (except strong oxidizers) and operates stably from -200°C to 450°C in oxidizing environments, or up to 3,000°C in inert atmospheres.
Main Applications
Over 60% of expanded graphite is used in sealing products, particularly high-temperature gaskets for chemical reactors and power plants. Its conformability ensures leak-proof joints even on uneven surfaces. In electronics, it serves as EMI shielding and thermal interface materials for 5G devices, often blended with polymers. The energy sector utilizes it in lithium-ion battery anodes (enhancing cycle life by 15–20%) and hydrogen storage composites. As a flame retardant, its intumescent properties enable self-extinguishing coatings for construction materials. Emerging uses include oil spill cleanup and flexible graphite foil for fuel cells.
Safety and Storage
While non-toxic, airborne expanded graphite dust poses inhalation risks (PEL 15 mg/m³ for particulates). NFPA classifies it as combustible when finely divided (dust explosion class St-1). Static electricity during handling requires grounding equipment. Storage should avoid humidity above 60% RH to prevent oxidation. Bulk bags must be kept away from strong oxidizers (nitrates, peroxides). Firefighting requires Class D extinguishers for bulk material; water sprays can be used for contained fires but may spread loose particles.
B2B Procurement Guide
Key specifications include expansion volume (ml/g, tested per ISO 9459), sulfur content (critical for semiconductor applications), and particle size distribution (affects compressibility). For gasket production, verify recovery rate (>85% after 25% compression) and creep resistance. Suppliers typically offer technical grades (80–150 ml/g, $10–20/kg) and premium grades (200–300 ml/g, $30–50/kg) with customized surface treatments. MOQs range from 500 kg for standard grades to 50 kg for battery-grade material. Lead times vary from 2 weeks (stock) to 8 weeks (custom expansion ratios).
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