Flexible graphite as battery anode and current collector

In making graphite-based electrodes and current collectors, there is significant simplification if a flexible graphite process is used. The lithium intercalation capacity of Grafoil®1 flexible graphite sheet and its powder was evaluated using electrochemical charge–discharge cycling in half-cell configuration (coin cell with Li anode and graphite cathode). The sheet form was used with and without a copper current collector. Excellent electrical conductivity of the monolithic material with very low interface resistance helps as current collector and electrode. The comparatively low capacity of Grafoil® sheet is thought to be due to diffusion limitation of the structure, especially in the light of the very high capacity of its powder form. The highly irreversible capacity of the powdered material may be due to unfunctionalized graphitic structures or impurities present in the powder. Impedance response for the first intercalation–deintercalation was different than responses taken after several cycles. The presence of a second impedance arc suggests structural modification is taking place in the graphite anode, possibly through formation of a porous structure as a result of graphite expansion.