Toray Industries Battery Film Developed for Lighter EV Batteries

Toray Industries Develops Advanced Battery Film Technology

Toray Industries Inc announced on July 29 that it has developed the Toray Industries Battery Film for anode current collectors in lithium-ion batteries used in electric vehicles and other applications. The technology enables conventional copper-foil current collectors to be replaced with film current collectors using a resin-film substrate. This development contributes to lighter battery systems, improved energy efficiency, and potentially extended driving range for electric vehicles through reduced battery weight and optimized material usage.

The newly developed current collector uses ultra-thin copper layers formed on a resin-film substrate, creating a lightweight alternative to traditional copper foil materials. The film-based collector is approximately 50% to 60% lighter than conventional copper-foil current collectors and could reduce battery cell weight by approximately 10%. Japan-based Toray estimates that the saved weight can be utilized to increase electrode active materials and electrolyte, potentially extending electric vehicle range by up to approximately 10% under specific conditions.

Battery cell evaluations confirmed that the new film current collector delivers performance comparable to conventional copper-foil current collectors. According to Toray, the developed material is the world’s first film for anode current collectors to satisfy all four key requirements required for current collector materials. The technology represents a significant step toward improving battery design by combining lower weight, competitive performance, and compatibility with future electrified mobility applications.

Toray has produced a standard 4.5-micron grade using mass-production equipment and has started supplying samples to customers. The company plans to commercialize the film initially for small- and medium-sized batteries used in mobile devices, drones, and eVTOL aircraft. The company is also evaluating applications for larger battery systems used in electric vehicles and energy storage systems, where lightweight materials can support improved performance and efficiency.

Frequently Asked Questions

What is the significance of Toray Industries Battery Film technology?
Toray Industries Battery Film technology introduces a lightweight anode current collector solution that replaces conventional copper foil with a resin-film substrate. The innovation reduces collector weight while maintaining comparable battery performance. It can help lower battery cell weight, improve energy efficiency, and potentially increase electric vehicle driving range. The technology may support future applications across electric vehicles, energy storage systems, drones, and advanced mobility platforms requiring lighter and more efficient battery designs.