Abstract: Provided is a solid state electrolyte composition for a rechargeable lithium battery. The electrolyte composition comprises a lithium ion-conducting polymer matrix or binder and lithium ion-conducting inorganic species that is dispersed in or chemically bonded by the polymer matrix or binder, wherein the lithium ion-conducting inorganic species is selected from Li2CO3, Li2O, Li2C2O4, LiOH, LiX, ROCO2Li, HCOLi, ROLi, (ROCO2Li)2, (CH2OCO2Li)2, Li2S, LixSOy, or a combination thereof, wherein X=F, Cl, I, or Br, R=a hydrocarbon group, 0<x?1, 1?y?4; and wherein the polymer matrix or binder is in an amount from 1% to 99% by volume of the electrolyte composition. Also provided are a process for producing this solid state electrolyte and a lithium secondary battery containing such a solid state electrolyte.

Abstract: Provided is a method of producing isolated graphene sheets, comprising: (a) providing a reacting slurry containing a mixture of particles of a graphite or carbon material and an intercalant and/or an oxidizing agent; (b) providing one or a plurality of flow channels to accommodate the reacting slurry, wherein at least one of the flow channels has an internal wall surface and a volume and an internal wall-to-volume ratio of from 10 to 4,000; (c) moving the reacting slurry continuously or intermittently through at least one or a plurality of flow channels, enabling reactions between the graphite or carbon particles and the intercalant and/or oxidant to occur substantially inside the flow channels to form a graphite intercalation compound (GIC) or oxidized graphite (e.g. graphite oxide) or oxidized carbon material as a precursor material; and (d) converting the precursor material to isolated graphene sheets.

Abstract: Provided is particulate of a cathode active material for a lithium battery, comprising one or a plurality of cathode active material particles being embraced or encapsulated by a thin layer of a high-elasticity polymer having a recoverable tensile strain no less than 5%, a lithium ion conductivity no less than 10?6 S/cm at room temperature, and a thickness from 0.5 nm to 10 ?m, wherein the polymer contains an ultrahigh molecular weight (UHMW) polymer having a molecular weight from 0.5×106 to 9×106 grams/mole. The UHMW polymer is preferably selected from polyacrylonitrile, polyethylene oxide, polypropylene oxide, polyethylene glycol, polyvinyl alcohol, polyacrylamide, poly(methyl methacrylate), poly(methyl ether acrylate), a copolymer thereof, a sulfonated derivative thereof, a chemical derivative thereof, or a combination thereof.

Abstract: Provided is an alkali metal-sulfur cell comprising: (a) a quasi-solid cathode containing about 30% to about 95% by volume of a cathode active material (a sulfur-containing material), about 5% to about 40% by volume of a first electrolyte containing an alkali salt dissolved in a solvent and an ion-conducting polymer dissolved, dispersed in or impregnated by a solvent, and about 0.01% to about 30% by volume of a conductive additive wherein the conductive additive, containing conductive filaments, forms a 3D network of electron-conducting pathways such that the quasi-solid electrode has an electrical conductivity from about 10?6 S/cm to about 300 S/cm; (b) an anode; and (c) an ion-conducting membrane or porous separator disposed between the anode and the quasi-solid cathode; wherein the quasi-solid cathode has a thickness from 200 ?m to 100 cm and a cathode active material having an active material mass loading greater than 10 mg/cm2.

Abstract: Provided is a surface-metalized polymer article comprising a polymer component having a surface, a first layer of multiple functionalized graphene sheets having a first chemical functional group, multiple functionalized carbon nanotubes having a second chemical group functional group, or a combination of both, which are coated on the polymer component surface, and a second layer of a plated metal deposited on the first layer, wherein the multiple functionalized graphene sheets contain single-layer or few-layer graphene sheets and/or the multiple functionalized carbon nanotubes contain single-walled or multiwalled carbon nanotubes, and wherein the multiple functionalized graphene sheets or functionalized carbon nanotubes are bonded to the polymer component surface with or without an adhesive resin.

Abstract: Provided is a laminated graphitic layer as an elastic heat spreader, the layer comprising: (A) a plurality of graphitic or graphene films prepared from (i) graphitization of a polymer film or pitch film, (ii) aggregation or bonding of graphene sheets, or (iii) a combination of (i) and (ii), wherein the graphitic or graphene film has a thermal conductivity of at least 200 W/mK, an electrical conductivity no less than 3,000 S/cm, and a physical density from 1.5 to 2.25 g/cm3; and (B) a conducting polymer network adhesive that bonds together the graphitic or graphene films to form the laminated graphitic layer; wherein the conductive polymer network adhesive is in an amount from 0.001% to 30% by weight and wherein the laminated graphitic layer preferably has a fully recoverable tensile elastic strain from 1% to 50% and an in-plane thermal conductivity from 100 W/mK to 1,750 W/mK.

Abstract: A process for producing an integrated layer (10 nm to 500 ?m) of highly oriented halogenated graphene sheets, comprising: (a) preparing a graphene oxide (GO) dispersion having GO sheets dispersed in a fluid medium; (b) dispensing and depositing a layer of GO dispersion onto a surface of a supporting substrate under a shear stress condition that induces orientation of GO sheets to form a wet layer of GO on the supporting substrate; (c) introducing a halogenating agent into the wet layer of graphene oxide and effecting a chemical reaction between the halogenating agent and GO sheets to form a wet layer of halogenated graphene, C6ZxOy, wherein Z is a halogen element selected from F, Cl, Br, I, or a combination thereof, x=0.01 to 6.0, y=0 to 5.0, and x+y?6.0; and (d) removing the fluid medium.

Abstract: A method of producing a powder mass for a lithium battery, the method comprising: (a) providing a solution containing a sulfonated elastomer dissolved in a solvent or a precursor in a liquid form or dissolved in a solvent; (b) dispersing a plurality of particles of a cathode active material in the solution to form a slurry; and (c) dispensing the slurry and removing the solvent and/or polymerizing/curing the precursor to form the powder mass, wherein the powder mass comprises multiple particulates and at least a particulate comprises one or a plurality of particles of a cathode active material being encapsulated by a thin layer of sulfonated elastomer having a thickness from 1 nm to 10 ?m, a fully recoverable tensile strain from 2% to 800%, and a lithium ion conductivity from 10?7 S/cm to 5×10?2 S/cm at room temperature.

Abstract: The disclosure provides multi-functional composite particulates for a lithium battery, wherein at least one of the composite particulates has a diameter from 100 nm to 50 ?m and comprises a polymer electrolyte matrix comprising a lithium salt dissolved or dispersed in the polymer electrolyte matrix and one or a plurality of primary particles of an anode active material that are encapsulated by, embedded in, dispersed in, or bonded by the polymer electrolyte having a lithium ion conductivity from 10?8 to 5×10?2 S/cm, wherein the primary particles have a diameter or thickness from 0.5 nm to 20 ?m and occupy a weight fraction from 5% to 98% based on the total weight of the composite particulate. Also provided is a method of producing such composite particulates, an anode electrode comprising these particulates, and a lithium cell.

Abstract: Provided is a lithium secondary battery containing an anode, a cathode, a porous separator/electrolyte element disposed between the anode and the cathode, and a cathode-protecting layer bonded or adhered to the cathode, wherein the cathode-protecting layer comprises a lithium ion-conducting polymer matrix or binder and inorganic material particles that are dispersed in or chemically bonded by the polymer matrix or binder and wherein the cathode-protecting layer has a thickness from 10 nm to 100 ?m and the polymer matrix or binder has a lithium-ion conductivity from 10?8 S/cm to 5×10?2 S/cm. Additionally or alternatively, there can be a similarly configured anode-protecting layer adhered to the anode. Such an electrode-protecting layer prevents massive internal shorting from occurring even when the porous separator gets melted, contracted, or collapsed under extreme temperature conditions induced by, for instance, dendrite or nail penetration.

Abstract: Provided is an anode particulate or a solid mass of particulates for a lithium battery, the particulate comprising a graphite matrix and a single or a plurality of carbon foam-protected primary particles of an anode active material embedded or dispersed in the graphite matrix, wherein the primary particles of anode active material have a volume Va, the carbon foam contains pores having a pore volume Vp, and the volume ratio Vp/Va is from 0.3/1.0 to 5.0/1.0 and wherein the carbon foam is physically or chemically connected to both the graphite matrix and the primary particles of the anode active material. The carbon foam is preferably reinforced with a high-strength material.

Abstract: The invention provides multiple anode particulates for a lithium battery. At least one of the particulates comprises a core and a thin encapsulating layer encapsulating the core, wherein the core comprises a single or a plurality of porous primary particles of an anode active material (having a pore volume Vpp and a solid volume Va) dispersed or embedded in a porous carbon matrix (a carbon foam matrix) having a pore volume Vp, and the thin encapsulating layer comprises graphene sheets and has a thickness from 1 nm to 10 ?m, an electric conductivity from 10?6 S/cm to 20,000 S/cm and a lithium ion conductivity from 10?8 S/cm to 5×10?2 S/cm and wherein the volume ratio Vp/Va is from 0.1/1.0 to 10/1.0 or the total pore-to-solid ratio (Vp+Vpp)/Va is from 0.3/1.0 to 20/1.0.

Abstract: A dual electroplating cell comprising: (a) an electrolyte component containing therein ions of a first metal; (b) a porous cathode current collector having surface areas to capture and store metal ions directly thereon, wherein the cathode current collector has a specific surface area greater than 100 m2/g that is in direct contact with said electrolyte; (c) a porous anode current collector having surface areas to capture and store metal ions thereon, wherein the anode current collector has a specific surface area greater than 100 m2/g that is in direct contact with the electrolyte; (d) a porous separator disposed between the anode and the cathode; and (e) an ion source of the first metal disposed in the anode current collector or the cathode current collector and in electronic contact therewith to obtain an open circuit voltage (OCV) from 0.3 volts to 3.5 volts when the cell is made.

Abstract: Provided is a lithium metal secondary battery comprising a cathode, an anode, and a non-solid state electrolyte without a porous separator disposed between the cathode and the anode, wherein the anode comprises: (a) an anode active material layer containing a layer of lithium or lithium alloy, in a form of a foil, coating, or multiple particles aggregated together, as an anode active material; and (b) an anode-protecting layer in physical contact with the anode active material layer, having a thickness from 1 nm to 100 ?m and comprising an elastomer having a fully recoverable tensile elastic strain from 2% to 1,000% and a lithium ion conductivity from 10?8 S/cm to 5×10?2 S/cm when measure at room temperature; wherein the lithium metal secondary battery does not include a lithium-sulfur battery or a lithium-selenium battery.

Abstract: Provided is a humic acid-based coating suspension comprising humic acid, particles of an anti-corrosive pigment or sacrificial metal, and a binder resin dissolved or dispersed in a liquid medium, wherein the humic acid has a weight fraction from 0.1% to 50% based on the total coating suspension weight excluding the liquid medium. Also provided is an object or structure coated at least in part with such a coating.

Abstract: Provided is a method of producing a graphitic film, comprising: (a) providing a suspension of aromatic molecules selected from petroleum heavy oil or pitch, coal tar pitch, a polynuclear hydrocarbon, a halogenated variant thereof, or a combination thereof, dispersed or dissolved in a liquid medium; (b) dispensing and depositing the suspension onto a surface of a supporting substrate to form a wet layer of aromatic molecules, wherein the procedure includes subjecting the suspension to an orientation-inducing stress or strain; (c) partially or completely removing the liquid medium; and (d) heat treating the resulting dried layer at a first temperature selected from 25° C. to 3,200° C. so that the aromatic molecules are merged or fused into larger aromatic molecules to form the graphitic film having graphene domains or graphite crystals, wherein the larger aromatic molecules or graphene planes in the graphene domains or graphite crystals are substantially parallel to each other.

Abstract: Provided is a process for producing a polymer composite film, comprising the steps of: (a) mixing a phthalocyanine compound with a polymer or its precursor and a liquid to form a slurry and forming the slurry into a wet film on a solid substrate, wherein the polymer is preferably selected from the group consisting of polyimide, polyamide, polyoxadiazole, polybenzoxazole, polybenzobisoxazole, polythiazole, polybenzothiazole, polybenzobisthiazole, poly(p-phenylene vinylene), polybenzimidazole, polybenzobisimidazole, and combinations thereof; and (b) removing the liquid from the wet film and, in some embodiments, converting the precursor to the polymer to form the polymer composite film comprising from 0.1% to 50% by weight of the phthalocyanine compound dispersed in the polymer.

Abstract: A rechargeable lithium cell comprising a cathode, an anode, an optional ion-permeable membrane disposed between the anode and the cathode, a non-flammable salt-retained liquefied gas electrolyte in contact with the cathode and the anode, wherein the electrolyte contains a lithium salt dissolved in or mixed with a liquefied gas solvent having a lithium salt concentration greater than 1.0 M so that the electrolyte exhibits a vapor pressure less than 1 kPa when measured at 20° C., a vapor pressure less than 60% of the vapor pressure of the liquefied gas solvent alone, a flash point at least 20 degrees Celsius higher than a flash point of the liquefied gas solvent alone, a flash point higher than 150° C.

Abstract: Provided is a method of producing an integral 3D humic acid-carbon hybrid foam, comprising: (A) forming a solid shape of humic acid-polymer particle mixture; and (B) pyrolyzing the solid shape of humic acid-polymer particle mixture to thermally reduce humic acid into reduced humic acid sheets and thermally convert polymer into pores and carbon or graphite that bonds the reduced humic acid sheets to form the integral 3D humic acid-carbon hybrid foam.

Abstract: A method of producing a pre-sulfurized active cathode layer for a rechargeable alkali metal-sulfur cell; the method comprising: (a) Preparing an integral layer of porous graphene structure having a specific surface area greater than 100 m2/g; (b) Preparing an electrolyte comprising a solvent and a sulfur source; (c) Preparing an anode; and (d) Bringing the integral layer and the anode in ionic contact with the electrolyte and imposing an electric current between the anode and the integral layer (serving as a cathode) to electrochemically deposit nano-scaled sulfur particles or coating on the graphene surfaces. The sulfur particles or coating have a thickness or diameter smaller than 20 nm (preferably <10 nm, more preferably <5 nm or even <3 nm) and occupy a weight fraction of at least 70% (preferably >90% or even >95%).