Upcycling Spent Graphite from Li-ion Batteries into Cu/Expanded Graphite Composites as high-performance electromagnetic wave absorbers.

With the widespread adoption of lithium-ion batteries and modern electronic components in both daily life and industrial production, there is a growing focus on the high-value recycling of spent lithium-ion batteries and the development of absorbents with high electromagnetic wave absorption capabilities. Efficiently regenerating recycling graphite from spent batteries through low-cost methods and utilizing it to prepare high-performance electromagnetic wave absorbing materials holds significant importance in addressing both the utilization of waste graphite and electromagnetic pollution issues simultaneously. This work presents a method to transform spent graphite into expanded graphite with a three-dimensional conductive structure using an enhanced Hummer's treatment and thermal reduction process. Subsequently, Cu/EG composite materials were efficiently prepared through straightforward mechanical ball milling and calcination. The unique honeycomb-like porous structure of expanded graphite facilitates the reflection and scattering of electromagnetic waves, electron transfer, and defect polarization. Additionally, the incorporation of copper nanoparticles improves the conduction loss and enhances interface polarization, allowing for precise tuning of the composite material's absorption performance. The results demonstrate that Cu/EG composite materials exhibit excellent electromagnetic wave absorption performance. The Cu/EG(1:3) sample exhibits effective absorption in the C, X, and Ku bands, achieving a minimum reflection loss (RL_min) of -54 dB and a maximum effective absorption bandwidth (EAB_max) of 5.28 GHz. This performance is attained with a thickness of just 2.2 mm and a filler content of only 15 wt.%.