Abstract: A polymer matrix composite containing graphene sheets homogeneously dispersed in a polymer matrix wherein the polymer matrix composite exhibits a percolation threshold from 0.0001% to 0.1% by volume of graphene sheets to form a 3D network of interconnected graphene sheets or network of electron-conducting pathways.

Abstract: Provided is a process for manufacturing 2D inorganic compound platelets, the process comprising (a) preparing a first stock containing a 3D layered inorganic compound material dispersed in a liquid medium, (h) injecting the first stock into a continuous reactor having a vortex flow, (c) operating the continuous reactor to form a reaction product suspension containing 2D inorganic compound platelets dispersed in the liquid medium, and (d) separating and recovering said 2D inorganic compound platelets from said product suspension. The product suspension may be directed to flow back to the continuous director for further processing for at least another pass through the reactor, prior to step (d). The continuous reactor is preferably a Couette-Taylor reactor.

Abstract: Provided is an elastic heat spreader film comprising: a) a graphitic film prepared from graphitization of a polymer film or pitch film, wherein the graphitic film has graphitic crystals parallel to one another and parallel to a film plane, having an inter-graphene spacing less than 0.34 nm, and wherein the graphitic film alone, after compression, has a thermal conductivity at least 600 W/mK, an electrical conductivity no less than 4,000 S/cm, and a physical density greater than 1.7 g/cm3; and b) an elastomer or rubber that permeates into the graphitic film from at least a surface of the film; wherein the elastomer or rubber is in an amount from 0.001% to 30% by weight based on the total heat spreader film weight. The elastic heat spreader film has a fully recoverable tensile elastic strain from 2% to 100% and an in-plane thermal conductivity from 100 W/mK to 1,750 W/mK.

Abstract: Provided is a elastic heat spreader film comprising: (a) an elastomer or rubber as a binder material or a matrix material; and (b) multiple graphene sheets that are bonded by the binder material or dispersed in the matrix material, wherein the multiple graphene sheets are substantially aligned to be parallel to one another and wherein the elastomer or rubber is in an amount from 0.001% to 20% by weight based on the total heat spreader film weight; 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 elastic heat spreader film has a fully recoverable tensile elastic strain from 2% to 100% and an in-plane thermal conductivity from 200 W/mK to 1,750 W/mK.

Abstract: Provided is a process for producing an elastic heat spreader film, the process comprising: (a) providing a layer of an aggregate or cluster of multiple graphene sheets; (b) impregnating an elastomer or rubber into the aggregate or cluster as a binder material or a matrix material to produce an impregnated aggregate or cluster, wherein the multiple graphene sheets are bonded by the binder material or dispersed in the matrix material and the elastomer or rubber is in an amount from 0.001% to 20% by weight based on the total heat spreader film weight; and (c) compressing the impregnated aggregate or cluster to produce the heat spreader film wherein the multiple graphene sheets are substantially aligned to be parallel to one another and wherein the elastic heat spreader film has a fully recoverable tensile elastic strain from 2% to 100% and an in-plane thermal conductivity from 200 W/mK to 1,750 W/mK.

Abstract: A process for producing a nanographene platelet-reinforced composite material having nanographene platelets or sheets (NGPs) as a first reinforcement phase dispersed in a matrix material and the first reinforcement phase occupies a weight fraction of 1-90% based on the total composite weight. Preferably, these NGPs, alone or in combination with a second reinforcement phase, are bonded by an adhesive and constitute a continuous 3-D network of electron- and phonon-conducting paths.

Abstract: Provided is a method of producing graphene directly from a non-intercalated and non-oxidized graphitic material, comprising: (a) dispersing the graphitic material in a liquid solution to form a suspension, wherein the graphitic material has never been previously exposed to chemical intercalation or oxidation; and (b) subjecting the suspension to microwave or radio frequency irradiation with a frequency and an intensity for a length of time sufficient for producing graphene; wherein the liquid solution contains a metal salt dissolved in water, organic solvent, ionic liquid solvent, or a combination thereof. The method is fast (minutes as opposed to hours or days of conventional processes), environmentally benign, and highly scalable.

Abstract: Provided is a process for producing a graphene foam laminate for use as a sealing material, the process comprising (a) providing a layer of graphene foam; and (b) laminating the layer of graphene foam with one layer of permeation-resistant polymer to form a two-layer laminate or with two layers of permeation-resistant polymer to form a three-layer laminate wherein the graphene foam layer is sandwiched between the two permeation-resistant polymer layers. The two permeation-resistant polymer layers can be the same or different in composition. The product is a new, novel, unexpected, and patently distinct class of highly conducting, elastic, thermally stable, and strong sealing materials.

Abstract: Provided is an anode particulate for a lithium battery, the particulate comprising a polymer foam material having pores and a single or a plurality of primary particles of an anode active material embedded in or in contact with said polymer foam material, wherein said primary particles of anode active material have a total solid volume Va, and said pores have a total pore volume Vp, and the volume ratio Vp/Va is from 0.1/1.0 to 10/1.

Abstract: Provided is a method of producing multiple particulates, the method comprising: (a) dispersing multiple primary particles of an anode active material, having a particle size from 2 nm to 20 ?m, and particles of a polymer foam material, having a particle size from 50 nm to 20 ?m, and an optional adhesive or binder in a liquid medium to form a slurry; and (b) shaping the slurry and removing the liquid medium to form the multiple particulates having a diameter from 100 nm to 50 ?m; wherein at least one of the multiple particulates comprises a polymer foam material having pores and a single or a plurality of the primary particles embedded in or in contact with the polymer foam material, wherein the primary particles have a total solid volume Va, and the pores have a total pore volume Vp, and the volume ratio Vp/Va is from 0.1/1.0 to 10/1.

Abstract: Provided is a method of producing graphene from a microwave-expandable un-exfoliated graphite or graphitic carbon, comprising: (a) feeding a powder of the microwave-expandable material onto a non-metallic solid substrate, wherein the powder is in a ribbon shape having a first ribbon width and a first ribbon thickness; (b) moving the ribbon-shape powder into a microwave applicator chamber containing a microwave power zone having a microwave application width (no less than the first ribbon width) and a microwave penetration depth (no less than the first ribbon thickness) so that the entire ribbon-shape powder receives and absorbs microwave power with a sufficient power level for a sufficient length of time to exfoliate and separate the powder for producing graphene sheets; and (c) moving the graphene sheets out of the microwave chamber, cooling the graphene sheets, and collecting the graphene sheets in a collector container or for a subsequent use.

Abstract: Provided is a vapor-based heat transfer apparatus (e.g. a vapor chamber or a heat pipe), comprising: a hollow structure having a hollow chamber enclosed inside a sealed envelope or container made of a thermally conductive material, a wick structure in contact with one or a plurality of walls of the hollow structure, and a working liquid within the hollow structure and in contact with the wick structure, wherein the wick structure comprises a graphene material.

Abstract: Provided is a vapor-based heat transfer apparatus (e.g. a vapor chamber or a heat pipe), comprising: a hollow structure having a hollow chamber enclosed inside a sealed envelope or container made of a thermally conductive material, a wick structure in contact with one or a plurality of walls of the hollow structure, and a working liquid within the hollow structure and in contact with the wick structure, wherein the wick structure comprises a graphene material and the hollow structure walls comprise an evaporator wall having a first surface plane and a condenser wall having a second surface plane, wherein multiple sheets of the graphene material in the wick structure are aligned to be substantially parallel to one another and perpendicular to at least one of the first surface plane and the second surface plane. Also provided is a process for producing this apparatus.

Abstract: Provided is a vapor-based heat transfer apparatus (e.g. a vapor chamber or a heat pipe), comprising: a hollow structure having a hollow chamber enclosed inside a sealed envelope or container made of a thermally conductive material, a wick structure in contact with one or a plurality of walls of the hollow structure (interior wall of the hollow chamber), and a working liquid within the hollow chamber and in contact with the wick structure, wherein the wick structure comprises flakes of exfoliated graphite worms or expanded graphite. Preferably, these flakes are substantially parallel to one another and perpendicular to the hollow chamber wall surface (e.g. aligned parallel to the heat flow direction from the heat source).

Abstract: A continuous process for producing a surface-metalized polymer article, comprising: (a) continuously immersing a polymer article into a graphene dispersion comprising multiple graphene sheets dispersed in a liquid medium for a period of immersion time and then retreating the polymer article from the dispersion, enabling deposition of graphene sheets onto a surface of the polymer article to form a graphene-attached polymer article; (b) continuously moving the graphene-attached polymer article into a drying or heating zone to enable bonding of graphene sheets to said surface to form a graphene-covered polymer article; and (c) continuously moving the graphene-covered polymer article into a metallization zone where a layer of a metal is chemically, physically, electrochemically or electrolytically deposited onto a surface of the graphene-covered polymer article to form the surface-metalized polymer article. Step (a) may be preceded by a surface treatment of the polymer article.

Abstract: A polymer matrix composite containing graphene sheets homogeneously dispersed in a polymer matrix wherein the polymer matrix composite exhibits a percolation threshold from 0.0001% to 0.1% by volume of graphene sheets to form a 3D network of interconnected graphene sheets or network of electron-conducting pathways.

Abstract: Provided is a multi-layer graphitic laminate comprising at least two graphitic films or graphene layers and a layer of conductive adhesive disposed between the two graphitic films or graphene layers and bonded thereto, wherein the conductive adhesive layer comprises graphene sheets or expanded graphite flakes disperse in or bonded by an adhesive resin, and the graphene sheets or expanded graphite flakes occupy a weight fraction from 0.01% to 99% based on the total conductive adhesive weight.

Abstract: Provided is a process for producing a multi-layer graphitic laminate, the process comprising: (A) providing a plurality of graphitic films or graphene layers, wherein at least one of said graphene layers is selected from a sheet of graphene paper, graphene fabric, graphene film, graphene membrane, or graphene foam; and (B) laminating at least two of the graphitic films and graphene layers and a conductive adhesive layer disposed between the two graphitic films or graphene layers to form the multi-layer graphitic laminate, wherein the conductive adhesive layer comprises graphene sheets or expanded graphite flakes dispersed in or bonded by an adhesive resin and the graphene sheets or expanded graphite flakes occupy a weight fraction from 0.01% to 99% based on the total conductive adhesive weight.

Abstract: A unitary graphene-based integrated heat sink comprising a heat collection member (base) and at least one heat dissipation member (e.g. fins) integral to the baser, wherein the base is configured to be in thermal contact with a heat source, collects heat therefrom, and dissipates heat through the fins. The unitary graphene material is obtained from heat-treating a graphene oxide gel at a temperature higher than 100° C., 500° C., 1,250° C., or 2,000° C., and contains chemically bonded graphene molecules having inter-graphene distance of 0.3354-0.4 nm (preferably <0.337 nm). The unitary graphene material is a graphene single crystal, a poly-crystal with incomplete grain boundaries, or a poly-crystal having large grain sizes (e.g. >mm or cm), exhibiting a degree of graphitization preferably from 1% to 100% and a Mosaic spread value less than 0.7 (preferably no greater than 0.4). The finned heat sink may also be made from a filler-reinforced graphene matrix composite.

Abstract: A process for producing a thin film graphene oxide-bonded metal foil current collector for a battery or supercapacitor, comprising: (a) preparing a graphene oxide gel having graphene oxide (GO) molecules dissolved in a fluid medium; (b) depositing a layer of GO gel onto at least one of two primary surfaces of a metal foil to form a layer of wet graphene oxide gel, wherein the depositing procedure includes shear-induced thinning of the GO gel; (c) partially or completely removing said fluid medium from the deposited wet layer to form a dry film of GO having an inter-plane spacing d002 of 0.4 nm to 1.2 nm as determined by X-ray diffraction; and (d) heat treating the dry film of graphene oxide to form the thin film graphene oxide-bonded metal foil current collector at a heat treatment temperature from 80° C. to 2,500° C.