Abstract: Provided is a multivalent metal-ion battery comprising an anode, a cathode, and an electrolyte in ionic contact with the anode and the cathode to support reversible deposition and dissolution of a multivalent metal, selected from Ni, Zn, Be, Mg, Ca, Ba, La, Ti, Ta, Zr, Nb, Mn, V, Co, Fe, Cd, Cr, Ga, In, or a combination thereof, at the anode, wherein the anode contains the multivalent metal or its alloy as an anode active material and the cathode comprises a cathode active layer of a graphite or carbon material having expanded inter-graphene planar spaces with an inter-planar spacing d002 from 0.43 nm to 2.0 nm as measured by X-ray diffraction. Such a metal-ion battery delivers a high energy density, high power density, and long cycle life.

Abstract: A method of producing isolated graphene sheets directly from a graphitic material, comprising: a) mixing multiple particles of a graphitic material and multiple particles of a solid carrier material to form a mixture in an impacting chamber of an energy impacting apparatus; b) operating the impacting apparatus for peeling off graphene sheets from the graphitic material and transferring these graphene sheets to surfaces of solid carrier material particles to produce graphene-coated solid particles inside the impacting chamber; c) separating the graphene sheets from the solid carrier material particle surfaces to recover isolated graphene sheets. The method enables production of graphene sheets directly from a graphitic material without going through a chemical intercalation or oxidation procedure. The process is fast (hours as opposed to days of conventional processes), has low or no water usage, environmentally benign, cost effective, and highly scalable.

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: Provided is a method of producing isolated graphene sheets directly from a carbon/graphite precursor. The method comprises: (a) providing a mass of halogenated aromatic molecules selected from halogenated petroleum heavy oil or pitch, coal tar pitch, polynuclear hydrocarbon, or a combination thereof; (b) heat treating this mass at a first temperature of 25 to 300° C. in the presence of a catalyst and optionally at a second temperature of 300-3,200° C. to form graphene domains dispersed in a disordered matrix of carbon or hydrocarbon molecules, and (c) separating and isolating the planes of hexagonal carbon atoms or fused aromatic rings to recover graphene sheets from the disordered matrix.

Abstract: Provided is particulate of an anode active material for a lithium battery, comprising one or a plurality of anode 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 anode active material layer for a lithium battery. This layer comprises multiple particulates of an anode active material, wherein at least a particulate is composed of one or a plurality of particles of an anode active material being encapsulated by a thin layer of graphene/elastomer composite having from 0.01% to 50% by weight of graphene sheets dispersed in an elastomeric matrix material, wherein the encapsulating shell (the thin layer of composite) has a thickness from 1 nm to 10 ?m and the graphene/elastomer composite has a lithium ion conductivity from 10?7 S/cm to 10?2 S/cm and an electrical conductivity from 10?7 S/cm to 100 S/cm when measured at room temperature. The anode active material is preferably selected from Si, Ge, Sn, SnO2, SiOx, Co3O4, Mn3O4, etc., which has a specific capacity of lithium storage greater than 372 mAh/g (the theoretical lithium storage limit of graphite).

Abstract: A hybrid solid electrolyte particulate for use in a rechargeable lithium battery cell, wherein said particulate comprises one or more than one inorganic solid electrolyte particles encapsulated by a shell of conducting polymer electrolyte wherein (i) the hybrid solid electrolyte particulate has a lithium-ion conductivity from 10?6 S/cm to 5×10?2 S/cm and both the inorganic solid electrolyte and the conducting polymer electrolyte individually have a lithium-ion conductivity no less than 10?6 S/cm; (ii) the conducting polymer electrolyte has an electron conductivity no less than 10?6 S/cm; and (iii) the conducting polymer electrolyte-to-inorganic solid electrolyte ratio is from 1/100 to 100/1 or the conducting polymer electrolyte shell has a thickness from 1 nm to 10 ?m. Also provided is a lithium-ion or lithium metal cell containing multiple hybrid solid electrolyte particulates in the anode and/or the cathode. Processes for producing hybrid solid electrolyte particulates are also disclosed.

Abstract: A hybrid solid electrolyte particulate for use in a rechargeable lithium battery cell, wherein said particulate comprises one or more than one inorganic solid electrolyte particles encapsulated by a shell of elastic polymer electrolyte wherein (i) the hybrid solid electrolyte particulate has a lithium-ion conductivity from 10?6 S/cm to 5×10?2 S/cm and both the inorganic solid electrolyte and the elastic polymer electrolyte individually have a lithium-ion conductivity no less than 10?6 S/cm; (ii) the elastic polymer electrolyte-to-inorganic solid electrolyte ratio is from 1/100 to 100/1 or the elastic polymer electrolyte shell has a thickness from 1 nm to 10 ?m; and (iii) the elastic polymer electrolyte has a recoverable elastic tensile strain from 5% to 1,000%. Also provided is a lithium-ion or lithium metal cell containing multiple hybrid solid electrolyte particulates in the anode, cathode and/or the separator. Processes for producing hybrid solid electrolyte particulates are also disclosed.

Abstract: A hybrid solid electrolyte particulate (or multiple particulates) for use in a rechargeable lithium battery cell, wherein the particulate comprises one or more than one inorganic solid electrolyte particles encapsulated by a shell of polymer electrolyte wherein the hybrid solid electrolyte particulate has a lithium-ion conductivity from 10?6 S/cm to 5×10?2 S/cm and both the inorganic solid electrolyte and the polymer electrolyte individually have a lithium-ion conductivity no less than 1031 6 S/cm. Also provided is a lithium-ion or lithium metal cell containing multiple hybrid solid electrolyte particulates in the anode, cathode and/or the separator. Processes for producing hybrid solid electrolyte particulates are also disclosed.

Abstract: An electrochemical battery cell comprising an anode having a primary anode active material, a cathode, and an ion-conducting electrolyte, wherein the cell has an initial output voltage, Vi, measured at 10% depth of discharge (DoD), selected from a range from 0.3 volts to 0.8 volts, and a final output voltage Vf measured at a DoD no greater than 90%, wherein a voltage variation, (Vi?Vf)/Vi, is no greater than ±10% and the specific capacity between Vi and Vf is no less than 100 mAh/g or 200 mAh/cm3 based on the cathode active material weight or volume, and wherein the primary anode active material is selected from lithium (Li), sodium (Na), potassium (K), magnesium (Mg), aluminum (Al), zinc (Zn), titanium (Ti), manganese (Mn), iron (Fe), vanadium (V), cobalt (Co), nickel (Ni), a mixture thereof, an alloy thereof, or a combination thereof.

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 process for producing a graphene/Si nanowire hybrid material, comprising: (a) dispersing catalyst metal-coated Si particles, graphene sheets, and an optional blowing agent in a liquid medium to form a graphene/Si dispersion; (b) dispensing and depositing the dispersion onto a supporting substrate to form a wet layer and removing the liquid medium from the wet layer to form a dried layer of graphene/Si mixture material; (c) exposing the dried layer to a high temperature environment, from 300° C. to 2,000° C., to induce volatile gas molecules from graphene sheets or to activate the blowing agent for producing the graphene foam and to enable a catalyst metal-catalyzed growth of multiple Si nanowires emanated from Si particles as a feed material in pores of the foam to form a layer of the hybrid material; and (d) operating a mechanical breaking means to produce the Si nanowire/graphene hybrid material in a powder mass form.

Abstract: Provided is a lithium secondary battery comprising a cathode, an anode, and an electrolyte or separator-electrolyte assembly disposed between the cathode and the anode, wherein the anode comprises: (a) An anode current collector, initially having no lithium or lithium alloy as an anode active material when the battery is made and prior to a charge or discharge operation; and (b) a thin layer of a high-elasticity polymer in ionic contact with the electrolyte and having a recoverable tensile strain from 2% to 700%, a lithium ion conductivity no less than 10?8 S/cm, and a thickness from 0.5 nm to 100 ?m. Preferably, the high-elasticity polymer contains a cross-linked network of polymer chains having an ether linkage, nitrile-derived linkage, benzo peroxide-derived linkage, ethylene oxide linkage, propylene oxide linkage, vinyl alcohol linkage, cyano-resin linkage, triacrylate monomer-derived linkage, tetraacrylate monomer-derived linkage, or a combination thereof in the cross-linked network of polymer chains.

Abstract: Provided is a metal matrix nanocomposite comprising: (a) a metal or metal alloy as a matrix material; and (b) multiple graphene sheets that are dispersed in said matrix material, wherein said multiple graphene sheets are substantially aligned to be parallel to one another and are in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from pristine graphene, 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 chemically functionalized graphene is not graphene oxide. The metal matrix exhibits a combination of exceptional tensile strength, modulus, thermal conductivity, and/or electrical conductivity.

Abstract: Disclosed herein is a composite particulate comprising a plurality of active material particles; and a single graphene sheet or a plurality of graphene sheets surrounds the plurality of active material particles and a surface of the composite particulate, wherein a single graphene sheet or a plurality of graphene sheets provides an electron-conducting path.

Abstract: Provided is a method of producing multiple isolated hollow graphene balls, comprising: (a) mixing multiple particles of a graphitic material and multiple particles of a solid polymer carrier material to form a mixture in an impacting chamber of an energy impacting apparatus; (b) operating the energy impacting apparatus to peel off graphene sheets from the graphitic material and transferring the graphene sheets to surfaces of solid polymer carrier material particles to produce graphene-coated polymer particles; (c) recovering the graphene-coated polymer particles from the impacting chamber; and (d) suspending the graphene-encapsulated polymer particles in a gaseous medium to keep the particles separated from each other while concurrently pyrolyzing the particles to thermally convert polymer into pores and carbon, wherein at least one of the graphene balls comprises a hollow core enclosed by a shell composed of graphene sheets bonded together by carbon.

Abstract: The disclosure provides a multi-layer prelithiated anode including (a) a conducting substrate having a first primary surface and a second primary surface; (b) a first layer of lithium metal deposited onto the first primary surface of the conducting substrate; (c) a first graphitic layer that substantially covers the first lithium metal layer; and (d) a first anode active layer deposited on a primary surface of the first graphitic layer. The first anode active layer includes an anode active material. Also provided are a lithium battery including such a prelithiated anode and a method of producing such an anode.

Abstract: Provided is method of producing graphene directly from a pulp, paper, or paper product, the method comprising a procedure of subjecting the pulp, paper, or paper product (preferably containing post-consumer, reclaimed, or recycled product) to a graphitization treatment at a graphitization temperature in the range of 1,500° C. to 3,400° C. (preferably >2,500° C.) in a substantially non-oxidizing environment for a length of time sufficient for converting the product to a graphene material product. Preferably and typically, the method does not involve the use of an externally added undesirable chemical (other than those paper chemicals already present in the paper product) or catalyst. The method is environmentally benign, ecologically friendly, and highly scalable.

Abstract: A method of producing a graphene suspension, comprising: (a) mixing multiple particles of a graphitic material and multiple particles of a solid carrier material to form a mixture in an impacting chamber of an energy impacting apparatus; (b) operating the energy impacting apparatus with a frequency and an intensity for a length of time sufficient for peeling off graphene sheets from the graphitic material and transferring the graphene sheets to surfaces of the carrier material particles to produce graphene-coated carrier particles inside the impacting chamber; and (c) dispersing the graphene-coated carrier particles in a liquid medium and separating the graphene sheets from the carrier material particles using ultrasonication or mechanical shearing means and removing the carrier material from the liquid medium to produce the graphene suspension. The process is fast (1-4 hours as opposed to 5-120 hours of conventional processes), environmentally benign, cost effective, and highly scalable.

Abstract: A method of producing graphene sheets from coke or coal powder, comprising: (a) forming an intercalated coke or coal compound by electrochemical intercalation conducted in an intercalation reactor, which contains (i) a liquid solution electrolyte comprising an intercalating agent; (ii) a working electrode that contains the powder in ionic contact with the liquid electrolyte, wherein the coke or coal powder is selected from petroleum coke, coal-derived coke, meso-phase coke, synthetic coke, leonardite, lignite coal, or natural coal mineral powder; and (iii) a counter electrode in ionic contact with the electrolyte, and wherein a current is imposed upon the working electrode and the counter electrode for effecting electrochemical intercalation of the intercalating agent into the powder; and (b) exfoliating and separating graphene planes from the intercalated coke or coal compound using an ultrasonication, thermal shock exposure, mechanical shearing treatment, or a combination thereof to produce isolated graphen