Abstract: An process for producing multiple porous graphene particulates for a lithium battery anode, the process comprising: (a) preparing a graphene dispersion having multiple anode material particles, multiple sheets of a starting graphene material, and a blowing agent dispersed in a liquid medium, wherein the blowing agent-to-graphene material weight ratio is from 0.01/1.0 to 1.0/1.0; (b) dispensing, forming and drying the graphene dispersion into multiple droplets containing therein graphene sheets, particles of the anode active material, and the blowing agent; and (c) heat treating the droplets at a 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 or to activate the blowing agent for producing the multiple porous graphene particulates.

Abstract: Provided is an alkali metal-sulfur battery, comprising: (a) an anode; (b) a cathode having (i) a cathode active material slurry comprising a cathode active material dispersed in an electrolyte and (ii) a conductive porous structure acting as a 3D cathode current collector having at least 70% by volume of pores and wherein cathode active material slurry is disposed in pores of the conductive porous structure, wherein the cathode active material is selected from sulfur, lithium polysulfide, sodium polysulfide, sulfur-polymer composite, sulfur-carbon composite, sulfur-graphene composite, or a combination thereof; and (c) a separator disposed between the anode and the cathode; wherein the cathode thickness-to-cathode current collector thickness ratio is from 0.8/1 to 1/0.8, and/or the cathode active material constitutes an electrode active material loading greater than 15 mg/cm2, and the 3D porous cathode current collector has a thickness no less than 200 ?m (preferably thicker than 500 ?m).

Abstract: Provided is filtration member for use in a filtration device, said filtration member comprising a layer of woven or nonwoven fabric having two primary surfaces and a layer of chemically functionalized graphite flakes deposited on at least one of the two primary surfaces or embedded in the layer of woven or nonwoven fabric, wherein said graphite flakes comprise chemical function contain 1%-50% by weight of a non-carbon element selected from O, N, H, F, Cl, Br, I, or a combination thereof. Also provided is a face mask comprising: (a) a mask body configured to cover at least wearer's mouth and nose; and (b) a fastener to hold the mask in place on the wearer's face; wherein the mask body includes (i) an air-permeable outer layer, (ii) an inner layer located on a wearer's side when the mask is worn, and (iii) the filtration member comprising graphite flakes.

Abstract: Provided is a powder mass of multiple porous graphene balls, wherein at least one of the porous graphene balls comprises multiple graphene sheets having a catalyst, in a form of nanoparticles or coating having a diameter or thickness from 0.3 nm to 10 nm, bonded to or supported by graphene sheet surfaces, wherein the porous graphene balls have a density from 0.01 to 1.7 g/cm3 (preferably and typically from 0.1 to 1.5 g/cm3), and a specific surface area from 50 to 3,000 m2/g (preferably and typically from 200 to 2,630 m2/g). A method of producing such porous graphene balls is provided as well. Also provided is a gas storage device containing the invented powder mass as a gas-absorbing, gas-adsorbing, gas-capturing, or gas-storing medium to store a gas species therein.

Abstract: Provided is a surface-stabilized anode active material particulate (for use in a lithium battery), comprising: (a) one or a plurality of prelithiated or un-prelithiated anode active material particles (with or without a coating of carbon, graphene, or ion-conducting polymer); (b) a protecting polymer layer that wraps around, embraces or encapsulates the one or plurality of anode active material particles, wherein the protecting polymer layer has a thickness from 0.

Abstract: Provided is an face mask comprising: (a) a mask body configured to cover at least wearer's mouth and nose; and (b) a fastener to hold the mask in place on the wearer; wherein the mask body includes (i) an air-permeable outer layer preferably comprising a hydrophobic material (e.g. water-repelling fibers), (ii) an inner layer located on a wearer's side when the mask is worn, and (iii) a graphene layer disposed in the mask body, wherein the graphene layer comprises a plurality of discrete 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. The graphene layer may be disposed between the outer layer and the inner layer or embedded (totally or partially) in the outer layer or the inner layer.

Abstract: Provided is an face mask comprising: (a) a mask body configured to cover at least wearer's mouth and nose; and (b) a fastener to hold the mask in place on the wearer; wherein the mask body includes (i) an air-permeable outer layer preferably comprising a hydrophobic material (e.g. water-repelling fibers), (ii) an inner layer located on a wearer's side when the mask is worn, and (iii) a graphene foam layer disposed in the mask body between the outer layer and the inner layer or embedded (totally or partially) in the outer layer or the inner layer. The foam pore wall graphene surfaces may be deposited with an antiviral or anti-bacteria compound.

Abstract: Provided is a battery charging system, comprising (a) at least one charging circuit to charge at least one rechargeable battery cell; and (b) a heating device to provide heat that is transported through a heat spreader element, implemented fully outside the battery cell, to heat up the battery cell to a desired temperature Tc before or during battery charging. The system may further comprise (c) a cooling device in thermal contact with the heat spreader element configured to enable transporting internal heat of the battery cell through the heat spreader element to the cooling device when the battery cell is discharged. Charging the battery at Tc enables completion of the charging of the battery in less than 15 minutes, typically less than 10 minutes, and more typically less than 5 minutes without adversely impacting the battery structure and performance. Also provided is a battery module or pack working with such a system.

Abstract: Provided is a cooling system for a battery module or pack comprising one or a plurality of battery cells, the system comprising a graphitic heat spreader element configured to be in thermal communication with the battery cells; and a cooling mechanism or device in thermal communication with the graphitic heat spreader element and configured to transport heat generated from the battery cells through the graphitic heat spreader element to the cooling mechanism or device when the battery cell is discharged. The graphitic heat spreader element may comprise a graphitic film selected from a flexible graphite sheet or an artificial graphite film obtained from carbonization and graphitization of a carbon precursor film.

Abstract: Provided is a composite particulate for use in a lithium battery cathode, the composite particulate comprising one or a plurality of particles of a cathode active material encapsulated by or embedded in an electrically and/or ionically conducting polymer gel network, wherein the cathode active material is selected from the group of lithium nickel cobalt metal oxides having a general formula LixNiyCozMwO2, where M is selected from the group consisting of aluminum (Al), titanium (Ti), tungsten (W), chromium (Cr), molybdenum (Mo), magnesium (Mg), beryllium (Be), calcium (Ca), tantalum (Ta), silicon (Si), and combinations thereof and x ranges from 0 to 1.2, the sum of y+z+w ranges from 0.8 to 1.2, w ranges from 0 to 0.5, y and z are both greater than zero, and the ratio z/y ranges from 0 to 0.5.

Abstract: Provided is a battery module cooling system, comprising a graphene heat spreader element (preferably in the form of a film, sheet, layer, belt, band, etc.) configured to abut at least one of the battery cells; and a cooling means in thermal communication with the heat spreader element and configured to transport heat generated from the battery cell(s) through the heat spreader element to the cooling means when the battery cells are discharged. Also provided is a method of operating a battery cooling system, comprising: (a) bringing a graphene heat spreader element in thermal contact with a plurality of battery cells in a module and receiving heat therefrom; and (b) directing the heat to transport through the graphene heat spreader element to a cooling means which acts to remove the heat and keep the battery below a desired temperature.

Abstract: Provided is a cathode active material for a lithium-ion battery, wherein the cathode active material is selected from the group of lithium nickel cobalt metal oxides having a general formula LixNiyCozMwO2, where M is selected from the group consisting of beryllium (Be), calcium (Ca), and combinations thereof with aluminum (Al), titanium (Ti), tungsten (W), chromium (Cr), molybdenum (Mo), magnesium (Mg), tantalum (Ta), and silicon (Si), and x ranges from 0 to 1.2, the sum of y+z+w ranges from 0.8 to 1.2, w range from 0 to 0.5, y and z are both greater than zero, and the ratio z/y ranges from 0 to 0.5. Preferably, M is selected from metal elements comprising combined Be and Mg, combined Ca and Mg, combined Ca and Be, or combined Be, Mg, and Ca.

Abstract: Provided is a graphene-embraced particulate (a secondary particle) for use as a lithium-ion battery cathode active material. The particulate comprises a core of one or a plurality of particles of a cathode active material embraced or encapsulated by a shell comprising multiple graphene sheets, wherein the cathode active material is selected from the group of lithium cobalt metal oxides having a general formula of LixNiyCozMwO2, M is selected from the group consisting of aluminum (Al), titanium (Ti), tungsten (W), chromium (Cr), molybdenum (Mo), magnesium (Mg), beryllium (Be), calcium (Ca), tantalum (Ta), silicon (Si), and combinations thereof, and x ranges from 0 to 1.2, the sum of y+z+w ranges from 0.8 to 1.2, w range from 0 to 0.5, y and z are both greater than zero, and the ratio z/y ranges from 0 to 0.5.

Abstract: Provided is a rechargeable alkali metal-sulfur cell comprising an anode active material layer, an electrolyte, and a cathode active material layer comprising multiple particulates, wherein at least one of the particulates comprises one or a plurality of sulfur-containing material particles being embraced or encapsulated by a thin layer of a conductive sulfonated elastomer composite having from 0.01% to 50% by weight of a conductive reinforcement material dispersed in a sulfonated elastomeric matrix material, wherein the conductive reinforcement material is selected from graphene sheets, carbon nanotubes, carbon nanofibers, metal nanowires, conductive polymer fibers, or a combination thereof and the composite has a recoverable tensile strain from 2% to 500%, a lithium ion conductivity from 10?7 S/cm to 5×10?2 S/cm, and a thickness from 0.5 nm to 10 ?m. This battery exhibits an excellent combination of high sulfur content, high sulfur utilization efficiency, high energy density, and long cycle life.

Abstract: A process for producing a supercapacitor cell, comprising (a) Assembling a porous cell framework composed of a first conductive foam structure, a second conductive foam structure, and a porous separator, wherein the first and/or second conductive foam structure has a thickness no less than 200 ?m and at least 80% by volume of pores; (b) Preparing a first suspension of an anode active material dispersed in a liquid electrolyte and a second suspension of a cathode active material (e.g. graphene sheets) dispersed in a liquid electrolyte; and (c) Injecting the first suspension into pores of the first conductive foam structure to form an anode and injecting second suspension into pores of the second conductive foam structure to form a cathode, wherein the anode active material or the cathode active material constitutes an electrode active material loading >10 mg/cm2, preferably >15 mg/cm2, more preferably >20 mg/cm2.

Abstract: Provided is a bi-polar electrode for a battery, the electrode comprising: (a) a current collector comprising a conductive material foil (e.g. metal foil) having a thickness from 10 nm to 100 ?m and two opposed, parallel primary surfaces, wherein one or both of the primary surfaces is coated with a layer of exfoliated graphite or expanded graphite material having a thickness from 10 nm to 50 ?m; and (b) a negative electrode layer and a positive electrode layer respectively disposed on the two sides of the current collector, each in physical contact with the layer of exfoliated graphite or expanded graphite material or directly with a primary surface of the conductive material foil (if not coated with a exfoliated or expanded graphite layer). Also provided is a battery comprising multiple (e.g. 2-300) bipolar electrodes internally connected in series. There can be multiple bi-polar electrodes that are connected in parallel.

Abstract: Provided is a process for producing a graphene-based supercapacitor electrode from a supply of coke or coal powder, comprising: (a) exposing this powder to a supercritical fluid for a period of time in a pressure vessel to enable penetration of the supercritical fluid into internal structure of the coke or coal; wherein the powder is selected from petroleum coke, coal-derived coke, meso-phase coke, synthetic coke, leonardite, anthracite, lignite coal, bituminous coal, or natural coal mineral powder, or a combination thereof; (b) rapidly depressurizing the supercritical fluid at a fluid release rate sufficient for effecting exfoliation and separation of the coke or coal powder to produce isolated graphene sheets, which are dispersed in a liquid medium to produce a graphene suspension; and (c) shaping and drying the graphene suspension to form the supercapacitor electrode having a specific surface area greater than 200 m2/g.

Abstract: Provided is a composite particulate for use in a lithium-ion battery anode. The composite particulate comprises one or a plurality of nanowires of an anode active material (e.g. Si, Ge, Sn, SiOx, SnO2, etc., where 0.1?x?1.9), having a diameter or thickness from 0.5 nm to 500 nm, encapsulated by or embedded in an electrically and/or ionically conducting polymer gel network. The polymer gel network may further comprise graphene sheets and/or other conductive additives (e.g. carbon nanotubes, CNT) dispersed therein. Also provided is a process for producing multiple composite particulates herein described.

Abstract: Lacrosse heads are provided that include a polymer and graphene. The graphene increases the durability of the lacrosse heads, while having limited impact on the stiffness and flexibility of the lacrosse heads. Also provided is equipment for other contact sports that include graphene to increase durability.

Abstract: Provided is an anode for a lithium battery or sodium battery, the anode comprising multiple porous graphene composite balls, wherein the porous graphene composite ball comprises a plurality of graphene sheets and an ion-conducting material, at a graphene-to-ion-conducting material weight ratio from 2/98 to 98/2, forming into the ball having a diameter from 100 nm to 20 ?m and a pore or multiple pores having a pore volume fraction from 10% to 99.9% based on the total porous graphene composite ball volume.