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Tesla patent points to battery cell improvements with clever deformation detection process

Tesla's 2170 battery cells. (Credit: Tesla)

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A recent patent published late August has revealed that Tesla is working on a monitoring system and apparatus that will allow the electric car maker to detect deformations in battery cells in a more effective manner. 

Tesla’s patent application, titled “Apparatus and Method for Detection of Deformation in Battery Cells,” notes that battery cycle life is among the most crucial parameters to ensure optimal performance in machines such as electric vehicles and energy storage devices. Over the course of their lifetime, battery cells will be subjected to multiple charge and discharge cycles, at times in vastly varying conditions and environments.  

As noted by the company in its patent application, there are instances when cells operate in an environment where the ambient temperature may intermittently surge to levels above the stable thermal temperature for normal operations. Cells could also be subjected to high charge and discharge rates and large periodic loads, which could result in significant heating, among other reactions. 

Subjected to these factors, battery cells could experience several effects, such as the thickening of electrodes or the volume expansion of electrochemically active materials within the cell itself. These expansions could ultimately result in cells experiencing deformation, which could, in turn, result in both reversible and irreversible mechanical strain, as well as the potential degradation of the battery’s electrodes. 

An illustration depicting Tesla’s apparatus and method for detecting deformations in battery cells. (Credit: US Patent Office)

These battery cell deformations are traditionally monitored using strain gauges or optical gauges that exclusively detect and evaluate deformations at single points in a cell. Tesla noted that this system has space for improvements, since optical evaluations might not provide the correct status of deformation across the entire surface of a battery. This could result in strain and deformation measurements that are inaccurate. 

With these factors in mind, Tesla has come up with a deformation detection apparatus that enables the contactless detection of deformations and/or swelling of the battery across the entire surface of the cell itself. Tesla describes the deformation detection apparatus as follows. 

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“A deformation detection apparatus includes a cell movement-control assembly to handle a linear motion and a rotational motion of a battery cell, a body that supports the cell movement-control assembly, a digital micrometer, and control circuitry. The control circuitry controls a displacement of the battery cell between a first position and a second position along a longitudinal axis through a scanning region of the digital micrometer and a plurality of rotational positions of the battery cell at a plurality of charge states and a plurality of discharge states. The control circuitry measures a plurality of outer diameter values of the battery cell for a plurality of linear positions and a plurality of rotational positions along the longitudinal axis of the battery cell and determines a change in a geometrical shape (deformation and/or strain) of the battery cell for the plurality of linear positions and the plurality of rotational positions.”

An illustration depicting Tesla’s apparatus and method for detecting deformations in battery cells. (Credit: US Patent Office)

According to the electric car maker, the battery cell deformation monitoring process outlined in its patent will provide advantages over traditional monitoring methods. 

“The disclosed apparatus, such as the apparatus 100 and method of determination of deformations in the battery cell 112 advantageously provides a contactless solution for deformation detection in the battery cells, as compared to conventional contact-based solutions. Further, instead of measuring the plurality of outer diameter values/strain values at a specific point in time, the disclosed apparatus 100 advantageously facilitates measurement of the plurality of outer diameter values/strain values at a plurality of points on the battery cell 112. The apparatus 100 enables detection of localized/non-localized deformation regions on the battery cell 112, which may exhibit signs of deformation at different charge/discharge states at different points in time.”

Tesla’s recently published patent application for its new battery cell deformation detection apparatus could be accessed in full here

The implications of Tesla’s recent patent are notable. By adopting its deformation detection system, the company would be able to evaluate the quality of its cells and their operating limits more effectively. This could open the doors to improvements in the company’s batteries, which could, in turn, result in even more range and performance for Tesla’s electric vehicles. 

Tesla holds a notable lead among automakers in terms of battery technology, as exhibited by the company’s electric vehicles’ vastly superior range compared to the competition. This is represented by Tesla’s recent “Raven” update to the 100 kWh Model X, which allowed the SUV to travel 325 miles in one charge. This is notably impressive, considering that the Audi e-tron, a smaller, lighter vehicle equipped with a 95 kWh battery pack (5% smaller than the Model X), is only EPA-rated for 204 miles per charge (38% less range than Tesla’s larger, heavier vehicle). A report from German business newspaper Wirtschaftswoche has also determined that Tesla’s batteries for the Model 3 have over four times less cobalt compared to the batteries utilized by Volkswagen today.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Tesla makes big change to encourage Full Self-Driving purchases

Tesla Full Self-Driving was recently proven to be about ten times safer than a human driver in terms of accident frequency.

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Credit: Whole Mars Blog | X

Tesla has made a big change to its Online Design Studio, hoping to encourage car buyers to purchase Full Self-Driving with their vehicles.

Now, when you look at ordering a car on Tesla’s website, the portion of the page that formerly showed a render of Full Self-Driving capabilities has been replaced by a compilation of the suite’s performance in a variety of challenging scenarios.

It’s a great way to show off FSD’s impressive ability to work through road conditions that can even stump human drivers.

The move is much better than what the page previously illustrated. Now, people can see the true capabilities of the FSD suite and what it could do to change their perspective on how vehicles can be. Instead of a vessel of transportation, FSD turns cars into a semi-autonomous mode of travel.

Tesla Full Self-Driving is statistically very safe, logging about ten times the number of miles between accidents as human drivers, based on recent data the company released.

Tesla Q2 2025 vehicle safety report proves FSD makes driving almost 10X safer

It is available for purchase in two different ways: an outright purchase for $8,000 or in a monthly subscription for $99. This enables the software to essentially do a vast majority of the legwork of driving. Drivers must keep their eyes on the road and be prepared to take over if an intervention is needed.

However, FSD has been proven to be a very accurate and safe way to travel. Tesla recently released a video of a drive from the Bay Area to Los Angeles, a nearly seven-hour trip, under FSD without a single intervention ever needed:

Tesla flexes its most impressive and longest Full Self-Driving demo yet

From a personal perspective, Tesla Full Self-Driving is a great way to travel because it truly takes a lot of the stress out of driving. In the past, I’ve used it during weekend Demo Drives to navigate around my town to see if it could handle some of the tougher traffic in my area. It became such an amazing and convenient alternative that when I went back to my car, I truly missed the advantage of having it.

I took a Tesla Model Y weekend-long Demo Drive – Here’s what I learned

However, I am picking up my Tesla Model Y this coming weekend and will enjoy it for the free three months before subscribing to the monthly program.

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Tesla offers new feature to save battery and reduce phantom drain

While in Low Power Mode, your vehicle continues to use energy for standby functions, screen activity, and Tesla app interactions. In cold weather, available energy may drop more quickly.”

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Credit: Tesla

Tesla is offering a new feature to help owners save battery and reduce phantom drain, an issue that some have complained of with their cars.

While Teslas are some of the most efficient EVs on the market, they utilize energy and battery life when they’re parked to keep certain features, like Sentry Mode, Summon Standby, and others, active in preparation for potential events that occur.

Keeping these features ready to perform utilizes energy, and if your car is parked at an airport where it could be sitting stagnant for a few days, the battery percentage could start to dwindle pretty significantly.

Because of this, Tesla is rolling out a new feature called “Low Power Mode,” which will automatically disable a handful of settings to combat battery dwindling and phantom battery drain.

Tesla writes in the release notes for the feature:

“When Low Power Mode is enabled, your vehicle will conserve energy by automatically disabling the following features:

    • Sentry Mode
    • Summon Standby
    • Outlets
    • Keep Accessory Power On
    • Keep Climate On and Camp Mode
    • Scheduled Preconditioning
    • Cabin Overheat Protection

While charging with Low Power Mode enabled:

    • Sentry Mode and accessory power will remain available
    • Keep Climate On and Camp Mode are only available when Supercharging

While in Low Power Mode, your vehicle continues to use energy for standby functions, screen activity, and Tesla app interactions. In cold weather, available energy may drop more quickly.”

This feature seemed to be a reaction to a past issue that an owner had as their Cybertruck continued to utilize energy even though the pickup was parked at an airport and the owner was in Japan. The Cybertruck had utilized a lot of energy to keep standby functions active, which left the owner in an interesting spot when they returned.

CEO Elon Musk stepped in, and it seems this feature might have been a reaction to that situation. This is an ideal thing to use if you’re looking to conserve your battery’s state of charge.

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Tesla is bringing back something it took from the Model 3…for a price

“Modify your Model 3 by replacing the turn signal buttons on your steering wheel with turn signal stalks. This modification is included in the purchase price and is installed by a Tesla Service Center.”

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Credit: Tesla

Tesla is bringing back the Model 3’s turn signal stalk in China after removing the part with the refresh of the all-electric sedan early last year.

However, it is going to cost you.

In 2024, Tesla launched the Model 3 “Highland,” a refreshed version of the vehicle that included several large-scale changes. One of the most noticeable was the lack of a turn signal stalk, something the company chose to remove and instead implement turn signal buttons on the steering wheel.

The buttons were met with mixed reviews, as some drivers complained that it was too difficult to get used to them. Others had no problem with the change, noting that it was slightly more convenient for them or that they enjoyed the minimalistic look.

Now, Tesla is offering Model 3 owners in China the opportunity to replace the stalk for a price of ¥ 2,499, or about $350:

“Modify your Model 3 by replacing the turn signal buttons on your steering wheel with turn signal stalks. This modification is included in the purchase price and is installed by a Tesla Service Center.”

Tesla notes on its website that the service is available for Model 3 vehicles without stalks manufactured after February 7, 2025. Any car without a stalk that was manufactured before that date will have the service available to them in the future.

Installation can be performed at a Service Center or by the owner. However, Tesla notes that it is not responsible for any damages resulting from self-installation and recommends that the part be put in by an employee.

The cockpit of the Tesla lineup has been under intense scrutiny by the company in recent years. After a few changes to things like the stalk, steering wheel shape, and others, Tesla has usually given drivers the chance to have things reverted back to their preferences if they want.

They did this for the Model S and Model X a few years ago after implementing the yoke steering wheel.

Tesla Steering Wheel Retrofits have started, and it’s easy to get rid of your yoke

The stalk was not supposed to be removed from the Model 3 and Model Y, but Tesla chose to do so with the refresh last year.

It seems the minimalization of the cockpit, overall, is a move that prepares drivers for autonomy, as eventually, Teslas will be void of pedals, steering wheels, and any other apparatus that are used to control the car.

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