Process for graphene-mediated metallization of polymer films

A process for producing a surface-metalized polymer film, said process comprising:

• (A) preparing a graphene dispersion comprising multiple graphene sheets and an optional conducive filler dispersed in a first liquid medium, which is an adhesive monomer or oligomer, or comprises a liquid adhesive monomer, oligomer or polymer dissolved in a liquid solvent;
• (B) feeding a continuous polymer film from a feeder roller or spool into a graphene deposition zone, wherein said graphene dispersion is sprayed, painted, coated, cast, or printed to deposit said graphene sheets and optional conductive filler to a surface of the polymer film for forming a graphene-coated polymer film;
• (C) moving said graphene-coated polymer film into a metallization chamber which accommodates a plating solution therein for plating a layer of a desired metal onto said graphene-coated polymer film to obtain a surface-metalized polymer film;
• and
• (D) operating a winding roller to collect said surface-metalized polymer film;
• wherein said 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 25% 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, doped graphene, chemically functionalized graphene, or a combination thereof.