Carbon Nanofiber Mats: Breaking the Limits of Traditional Carbon Materials

Problem

Pylontech (China) in energy storage, filtration, and advanced composite materials relying on conventional carbon fabrics, carbon black additives, or metal meshes encountered multiple performance bottlenecks:

Limited electrical conductivity uniformity
Insufficient surface area for electrochemical reactions
Poor flexibility at low basis weight
Trade-offs between porosity, mechanical strength, and thickness

In lithium-ion batteries, supercapacitors, fuel cells, EMI shielding, and industrial filtration, these constraints resulted in:

Lower energy density and rate capability
Higher material loading and system weight
Reduced durability under mechanical deformation and thermal cycling

Solution

Carbon Nanofiber Mat was introduced by Toray Industries as a nonwoven network of nanoscale carbon fibers, typically produced through electrospinning followed by high-temperature carbonization. This structure delivered:

High specific surface area with interconnected porous pathways
Excellent electrical conductivity with uniform current distribution
Low density and high flexibility, even at ultra-thin thickness
Superior mechanical integrity compared with conventional carbon films
Outstanding chemical and thermal stability

The nanoscale fiber architecture enabled simultaneous optimization of conductivity, strength, and porosity, overcoming the inherent limitations of traditional carbon materials.

Result

After adopting carbon nanofiber mat materials, Pylontech (China) achieved measurable improvements:

15-35% improvement in electrode charge/discharge efficiency
20-40% increase in active material utilization
Enhanced cycle life in batteries and supercapacitors
Reduced system weight without compromising structural stability

Overall, carbon nanofiber mats enabled lighter, stronger, and higher-performance functional systems across energy, electronics, and industrial applications.

QY Research has recently published a comprehensive market study on Carbon Nanofiber Mat. Key findings are summarized below.

Core Market Data

Global market size: USD 1.4 billion
CAGR (2024-2030): 14.8%
Average price: USD 100 per m2
Annual production: 14 million m2
Gross margin: 44%
Production capacity: 19 million m2

List of Main Players

Toray (TYO: 3402, Japan)
Teijin (TYO: 3401, Japan)
Kuraray (TYO: 3405, Japan)
Ahlstrom (HEL: ALSTR, Finland)
Hexcel (NYSE: HXL, USA)
Toyobo (TYO: 3101, Japan)
Resonac (TYO: 4004, Japan)
SGL Carbon (ETR: SGL, Germany)
Jiangsu Cnano Technology (SSE STAR: 688050, China)
Zhongke Electric (SZSE: 300035, China)
Materic (Private, USA)
NanoAmor (Private, USA)
MK Nano (Private, Canada)
Elmarco (Private, Czech)
Fiberio (Private, USA)
Finetex (Private, South Korea)
Nanoval (Private, Germany)
Johns Manville (Private, USA)
Sinofibers Technology (Private, China)
Nanocomp Technologies (Private, USA)
Applied Nanotech (Private, USA)
Inovenso (Private, Turkey)

1. By Fiber Diameter

Ultra-fine (Below 100 nm): Sensors and high-end electrochemical electrodes
Standard (100-300 nm): Batteries, supercapacitors, EMI shielding
Coarse (Above 300 nm): Filtration and composite reinforcement

2. By Manufacturing Process

Electrospun Carbon Nanofiber Mat
Vapor-Grown Carbon Nanofiber Mat

3. By Application

Lithium-Ion & Sodium-Ion Battery Electrodes
Supercapacitors
Fuel Cell Gas Diffusion Layers
EMI Shielding & Thermal Management
Industrial Filtration Media
Advanced Composite Reinforcement

Case Study for Bidding

Time: April 2024
Supplier: Toray Industries
Buyer: Pylontech (China)
Product: Electrospun Carbon Nanofiber Mat (High Conductivity Grade)
Quantity: 520,000 m2
Contract Value: USD 31.8 million
Delivery Timeline: Q4 2024

Detailed Application Scenario

The buyer integrated carbon nanofiber mats as conductive reinforcement layers in high-power lithium-ion battery electrodes. The mat's interconnected fiber network enabled rapid electron transport and improved electrolyte infiltration.

Compared with conventional carbon-coated foils, the carbon nanofiber mat delivered:

Lower internal resistance
More uniform current distribution
Reduced electrode degradation during fast charging

This resulted in higher power density, extended cycle life, and improved thermal stability, demonstrating the critical role of carbon nanofiber mats in next-generation energy storage and advanced functional material systems.

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This release was published on openPR.