Production of thin graphite sheets for a high electrical conductivity film by the mechanical delamination of ternary graphite intercalation compounds

Herein we propose a production scheme for conductive films composed of thin graphite sheets with high crystallinity and polymeric resin. The crystalline graphite sheets were successfully produced from natural graphite powder by solution-phase synthesis of graphite intercalation compounds (GICs), following a wet planetary-ball milling under mild conditions. The shear forces in the milling pot lead to a peeling of graphite flakes. Taking into consideration the interlayer bonding force, the delamination should be preferentially done from the expanded GICs interlayer rather than intrinsic graphite one. Some composite films derived from the phenolic resin and flaky graphite sheets displayed much higher electrical conductivities compared to the film from the feed graphite particles. We also demonstrate the stage structure of synthetic GICs affected the film conductivity. The composite films made from exfoliated products of ground (around stage IV) GICs exhibited high electrical conductivity with a small amount of the graphite sheets.