回複：If I dont'tell USCIS he is not in US, just file AP for him, w

I understand this is not right, but really have no other choose.I heard about expedite process, is he physically required to attend the interview?

-What kind of interview you are talking about? You can not file the I-131 for AP for him. Even if USCIS approve the AP mistakenly, he can not use it because USCIS will find it sooner or later adn thus, the consequence may be serious. Also, because the CBP has his record that he was not admitted to enter US due to AP expiration last time and that means he is in China when the new AP application is filed.

My next Q is about visa, except H1, will other visa be OK forhim to come back and stay until 485 approved?

-Only H4 visa may be practical besides H1 visa if you can get the H1 status.