Abstract: Provided is a graphene-based coating suspension comprising multiple graphene sheets, thin film coating of an anti-corrosive pigment or sacrificial metal deposited on graphene sheets, and a binder resin dissolved or dispersed in a liquid medium, wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene material having 0.001% to 47% by weight of non-carbon elements wherein the non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof. The invention also provides a process for producing this coating suspension. Also provided is an object or structure coated at least in part with such a coating.

Abstract: Provided is a process for producing a graphene-based continuous or long fiber, comprising: (a) preparing a graphene dispersion having chemically functionalized graphene sheets dispersed in a fluid medium wherein the graphene sheets contain chemical functional groups attached thereto; (b) dispensing and depositing at least a continuous or long filament of the graphene dispersion onto a supporting substrate, wherein the dispensing and depositing procedure includes mechanical shear stress-induced alignment of the graphene sheets along a filament axis direction, and partially or completely removing the fluid medium to form a continuous or long fiber comprising aligned chemically functionally graphene sheets; and (c) using heat, electromagnetic waves, UV light, or high-energy radiation to induce chemical reactions or chemical bonding between chemical functional groups attached to adjacent chemically functionalized graphene sheets to form the continuous or long graphene fiber.

Abstract: Provided is a graphene-based aqueous coating suspension comprising multiple graphene sheets, particles of an anti-corrosive pigment or sacrificial metal, and a waterborne binder resin dissolved or dispersed in water, wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene material having 0.001% to 47% by weight of non-carbon elements wherein the non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein the coating suspension does not contain a silicate binder or microspheres dispersed therein. Also provided is an object or structure coated at least in part with such a coating.

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 meso-porous structure of a carbon, graphite, metal, or conductive polymer 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%).

Abstract: A method of producing a pre-selenized (selenium-preloaded) active cathode layer for a rechargeable alkali metal-selenium cell; the method comprising: (a) preparing an integral layer of mesoporous structure having pore sizes from 0.5 nm to 50 nm (preferably from 0.5 nm to 5 nm) and a specific surface area from 100 to 3,200 m2/g; (b) preparing an electrolyte comprising a solvent and a selenium 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 nanoscaled selenium particles or coating on the graphene surfaces. The selenium particles or coating have a thickness or diameter smaller than 20 nm (preferably <10 nm, more preferably <5 nm or even <3 nm) and preferably occupy a weight fraction of at least 70% (preferably >90% or even >95%).

Abstract: Provided is a pre-selenized cathode for an alkali metal-selenium cell, comprising (A) an integral layer of a mesoporous structure of a carbon, graphite, metal, or conductive polymer, wherein the mesoporous structure has mesoscaled pores with a pore size of 0.5-50 nm and a specific surface area from 100 to 3,200 m2/g and (b) nanoparticles or nanocoating of selenium or metal selenide having a diameter or thickness from 0.5 nm to 20 nm, wherein selenium or metal selenide resides in the mesoscaled pores and occupies an amount from 50% to 99% by weight based on the total weight of selenium or metal selenide and the integral layer of mesoporous structure combined.

Abstract: Provided is a rechargeable alkali metal-selenium cell comprising an anode active material layer, an electrolyte, and a cathode active material layer containing multiple particulates of a selenium-containing material selected from a selenium-carbon hybrid, selenium-graphite hybrid, selenium-graphene hybrid, conducting polymer-selenium hybrid, a metal selenide, a Se alloy or mixture with Sn, Sb, Bi, S, or Te, a selenium compound, or a combination thereof and wherein at least one of the particulates comprises one or a plurality of selenium-containing material particles being embraced or encapsulated by a thin layer of a high-elasticity polymer having a recoverable tensile strain no less than 5% when measured without an additive or reinforcement, a lithium ion conductivity no less than 10?7 S/cm at room temperature, and a thickness from 0.5 nm to 10 ?m This battery exhibits an excellent combination of high selenium content, high selenium utilization efficiency, high energy density, and long cycle life.

Abstract: Provided is a method of manufacturing a rechargeable alkali metal-selenium cell, comprising: (a) providing a cathode and an optional cathode current collector to support the cathode; (b) providing an alkali metal anode and an optional anode current collector to support said anode; and (c) providing an electrolyte in contact with the anode and the cathode and an optional separator electrically separating the anode and the cathode; wherein the cathode contains multiple particulates of a selenium-containing material wherein at least one of the particulates comprises one or a plurality of selenium-containing material particles being embraced or encapsulated by a thin layer of a high-elasticity polymer having a recoverable tensile strain from 5% to 1,000% when measured without an additive or reinforcement, a lithium ion conductivity no less than 10?7 S/cm at room temperature, and a thickness from 0.5 nm to 10 ?m.

Abstract: Provided is a method of manufacturing an alkali metal-selenium cell, comprising: (a) providing a cathode; (b) providing an alkali metal anode; and (c) combining the anode and the cathode and adding an electrolyte in ionic contact with the anode and the cathode to form the cell; wherein the cathode contains multiple particulates of a selenium-containing material selected from selenium, a selenium-carbon hybrid, selenium-graphite hybrid, selenium-graphene hybrid, conducting polymer-selenium hybrid, a metal selenide, a Se alloy or mixture with Sn, Sb, Bi, S, or Te, a selenium compound, or a combination thereof and wherein at least one of the particulates comprises one or a plurality of selenium-containing material particles being embraced or encapsulated by a thin layer of an elastomer having a recoverable tensile strain from 5% to 1000%, a lithium ion conductivity no less than 10?7 S/cm, and a thickness from 0.5 nm to 10 ?m.

Abstract: Provided is particulate for use in a lithium-selenium battery cathode, the particulate comprising one or a plurality of cathode active material particles (selected from Se, lithium polyselenide, sodium polyselenide, potassium polyselenide, a Se alloy or mixture with Sn, Sb, Bi, S, or Te, or a combination thereof) being embraced or encapsulated by a thin layer of a protecting polymer having a lithium ion conductivity from 10?8 S/cm to 5×10?2 S/cm and a thickness from 0.

Abstract: Provided is a rechargeable alkali metal-selenium cell comprising an anode active material layer, an electrolyte, and a cathode active material layer containing multiple particulates of a selenium-containing material selected from a selenium-carbon hybrid, selenium-graphite hybrid, selenium-graphene hybrid, conducting polymer-selenium hybrid, a metal selenide, a Se alloy or mixture with Sn, Sb, Bi, S, or Te, a selenium compound, or a combination thereof and wherein at least one of the particulates comprises one or a plurality of selenium-containing material particles being embraced or encapsulated by a thin layer of an elastomer having a recoverable tensile strain no less than 5% when measured without an additive or reinforcement, a lithium ion conductivity no less than 10?7 S/cm at room temperature, and a thickness from 0.5 nm to 10 ?m This battery exhibits an excellent combination of high selenium content, high selenium utilization efficiency, high energy density, and long cycle life.

Abstract: A process for producing graphene-enabled hybrid particulates for use as a cathode active material of an alkali metal battery, the process comprising: (a) preparing a mixture suspension of graphene sheets and a selenium material dispersed in a liquid medium; and (b) dispensing and forming the mixture suspension into hybrid particulates, wherein at least one of the hybrid particulates comprises a single or a plurality of graphene sheets and a plurality of fine selenium particles or coatings, having a diameter or thickness from 0.5 nm to 10 ?m, and the graphene sheets and the selenium particles or coatings are mutually bonded or agglomerated into the hybrid particulate containing an exterior graphene sheet or multiple exterior graphene sheets embracing the selenium particles or coatings, and wherein the graphene is in an amount from 0.01% to 30% by weight based on the total weight of graphene and selenium combined.

Abstract: A process for producing a graphene foam-protected selenium cathode layer, the process comprising: (A) preparing a layer of solid graphene foam having pores (or cells) and pore/cell walls containing graphene sheets and having a physical density from 0.001 g/cm3 to 1.5 g/cm3; and (B) infiltrating or impregnating selenium into the pores to obtain the graphene foam-protected selenium cathode layer; wherein the graphene sheets are selected from a pristine graphene or a non-pristine graphene material, having a content of non-carbon elements greater than 2% by weight, selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, or a combination thereof.

Abstract: A method of producing a pre-selenized (selenium-preloaded) active cathode layer for a rechargeable alkali metal-selenium cell; the method comprising: (a) Preparing an integral layer of porous graphitic structure having a specific surface area greater than 100 m2/g; (b) Preparing an electrolyte comprising a solvent and a selenium 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 nanoscaled selenium particles or coating on the graphene surfaces. The selenium 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%).

Abstract: A graphene-enabled hybrid particulate for use as a cathode active material of an alkali metal-selenium battery, wherein the hybrid particulate is composed of a single or a plurality of graphene sheets and one or a plurality of fine selenium particles or coatings, having a diameter or thickness from 0.5 nm to 10 ?m, and the graphene sheets and the selenium particles or coatings are mutually bonded or agglomerated into a hybrid particulate containing an exterior graphene sheet or multiple exterior graphene sheets embracing the selenium particles or coatings, and wherein the hybrid particulate has an electrical conductivity no less than 10?4 S/cm and the graphene amount is from 0.01% to 30% by weight based on the total weight of graphene and selenium combined. Typically and desirably, the hybrid particulate is substantially spherical or ellipsoidal in shape.

Abstract: A graphene foam-protected selenium cathode layer for an alkali metal-selenium cell, comprising: (a) a sheet or a roll of solid graphene foam composed of multiple pores and pore walls containing graphene sheets, wherein the graphene sheets contain a pristine graphene material having less than 0.01% by weight of non-carbon elements or a non-pristine graphene material having 0.01% to 20% by weight of non-carbon elements, wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, chemically functionalized graphene, or a combination thereof, wherein the graphene sheets are interconnected or chemically merged together without an adhesive resin; and (b) selenium coating or particles residing in the pores or bonded to the pore walls of the solid graphene foam.

Abstract: A metal-bonded graphene foam product, comprising: (A) a sheet or roll of solid graphene foam, having a sheet plane and a sheet thickness direction, composed of multiple pores (cells) and pore walls, wherein said pore walls contain a pristine graphene material having less than 0.01% by weight of non-carbon elements or a non-pristine graphene material having 0.01% to 20% by weight of non-carbon elements, wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, chemically functionalized graphene, or a combination thereof; and (B) a metal that fills in the is bonded to graphene sheets, wherein the metal-bonded graphene foam product has a thickness-direction thermal conductivity from 10 W/mK to 800 W/mK or a thickness-direction electrical conductivity from 40 S/cm to 3,200 S/cm.

Abstract: A surface-enabled, metal ion-exchanging battery device comprising a cathode, an anode, a porous separator, and a metal ion-containing electrolyte, wherein the metal ion is selected from (A) non-Li alkali metals; (B) alkaline-earth metals; (C) transition metals; (D) other metals such as aluminum (Al); or (E) a combination thereof; and wherein at least one of the electrodes contains therein a metal ion source prior to the first charge or discharge cycle of the device and at least the cathode comprises a functional material or nanostructured material having a metal ion-capturing functional group or metal ion-storing surface in direct contact with said electrolyte, and wherein the operation of the battery device does not involve the introduction of oxygen from outside the device and does not involve the formation of a metal oxide, metal sulfide, metal selenide, metal telluride, metal hydroxide, or metal-halogen compound.

Abstract: A process for producing a metal-bonded graphene foam product, comprising: (a) preparing a graphene dispersion having multiple graphene sheets dispersed in a liquid medium, which contains an optional blowing agent having a blowing agent-to-graphene weight ratio from 0/1.0 to 1.0/1.0; (b) dispensing and depositing the graphene dispersion onto a surface of a supporting substrate to form a wet graphene layer; (c) removing the liquid medium from the wet graphene layer; (d) heat-treating the dried layer of graphene at a first heat treatment temperature selected from 80° C. to 3,200° C. at a desired heating rate sufficient to induce volatile gas molecules from the non-carbon elements of graphene sheets or to activate the blowing agent for producing a sheet or roll of solid graphene foam having multiple pores and pore walls containing graphene sheets; and (e) impregnating or infiltrating a metal into the pores to form the metal-bonded graphene foam.

Abstract: Provided is a method of producing isolated graphene sheets from a supply of coke or coal powder containing therein domains of hexagonal carbon atoms and/or hexagonal carbon atomic interlayers. The method comprises: (a) dispersing particles of the coke or coal powder in a liquid medium containing therein an optional surfactant or dispersing agent to produce a suspension or slurry, wherein the coke or coal powder is selected from petroleum coke, coal-derived coke, mesophase coke, synthetic coke, leonardite, anthracite, lignite coal, bituminous coal, or natural coal mineral powder, or a combination thereof; and (b) exposing the suspension or slurry to ultrasonication at an energy level for a sufficient length of time to produce the isolated graphene sheets.