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Tesla’s 1 million-mile battery takes a step forward with new electrode patent

Tesla Gigafactory 1, where Model 3 battery cells are produced. (Photo: Tesla)

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A newly released patent from Tesla has teased what appears to be a step towards Elon Musk’s one-million-mile battery target. The patent describes a new lithiation process for battery cells, which has the potential to improve the quality of cells and possibly even save on costs.

Tesla has submitted a patent titled “Method for Synthesizing Nickel-Cobalt-Aluminum Electrodes.” The document outlines a new electrode synthesizing method that could be used for battery cell production. The proposed application defines an efficient heating process for Nickel-Cobalt-Aluminum (NCA) electrodes. According to the document, previous heating methods at times cause the formation of a lithium substrate known as L15AIO4, which is an impurity. Lowering the amount of lithium within a battery reduces the presence of the contamination, but also leads to “materials with inferior electrochemical properties.”

As noted in the patent, batteries would heat to a temperature high enough to allow for single crystal growth. The revised ratio of lithium to other metals would limit the formation of impurities during the first heating process. Then, the battery would be heated a second time at a temperature lower than the first heating cycle. Researchers involved in the patent noted that this process helped develop an impurity-free single crystal NCA that allowed battery cells to achieve over 4,000 charge cycles.

Lithiation measurements at different temperatures. (Credit: Tesla/U.S. Patent Office)

The patent outlines the heating process:

“Methods disclosed herein include a first lithiation step, wherein a lithium and an other metal component are present in a first lithium/other metal ratio of less than 1.0 and are sintered at a temperature between 800 and 950°C for a time period between 1 and 24 hours to obtain a first lithiated material. The method further includes a second lithiation step, wherein a lithium and a other metal component are present in a second lithium/other metal ratio and further wherein the first lithiated electrode material is sintered with additional LiOHTLO at between 650 and 760°C for a time period between 1 and 24 hours to obtain a second lithiated material.”

In summary, the use of NCA electrodes in batteries would allow for single-crystal materials to present themselves without impurities. The lack of contaminants could lead to an increased lifespan of the cells altogether, helping Tesla take a giant leap forward in its quest to produce a one-million-mile battery for its vehicles.

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Interestingly enough, one of the listed names on the patent is battery expert and researcher Jeff Dahn, who has worked with Tesla in the past. Tesla summoned the help of Dahn, who leads a team of researchers at Canada’s Dalhousie University, to help the electric car maker improve its batteries. Dahn’s research has helped Tesla’s development of high-quality battery cells by inventing new electrode combinations, like the one described in this patent, and electrolyte solutions aimed at further increasing battery life.

Tesla’s batteries are always in a state of improvement, and over the years, the cells that the company utilizes for its vehicles and energy storage systems have gotten more energy-dense. Economies of scale that is made possible with facilities such as Gigafactory Nevada have also gone a long way towards helping Tesla near the $100 per kWh mark, a level that is widely considered the point where electric vehicles could achieve price parity with their internal combustion-powered counterparts.

Apart from its battery patents, Tesla has also been busy acquiring several battery companies. Among these are Maxwell Technologies and Hibar Systems, both of which were developing technologies that would allow for better battery quality and more efficient production costs. Relatively simple developments such as those described in Tesla’s recent patent help this cause too, especially since every little bit of optimization helps.

Tesla’s development of its battery technology could lead to its vehicles lasting 20 to 30 years, far longer than petrol-powered cars. It appears the company is planning to create a product line that could stay with owners for extended periods with relatively no annual maintenance. And that, together with price parity, can very well be the catalyst for society’s acceleration towards sustainability.

The full text of Tesla’s “Method for Synthesizing Nickel-Cobalt-Aluminum Electrodes” patent could be accessed in the document below.

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METHOD FOR SYNTHESIZING NIC… by Joey Klender on Scribd

Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Tesla watchers spot mysterious castings at Fremont Factory

The castings seem to be quite new, as they do not seem to match any of the castings that are currently being used for the Model Y.

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Credit: @metgodinwilderness7130/YouTube

A recent flyover of the Fremont Factory has triggered speculations about Tesla’s ongoing initiatives that are yet to be unveiled publicly. This was hinted at by the sighting of some apparent vehicle castings around the factory that have never really been observed before.

A Fremont Factory flyover

In a recent update, drone operator Met God in Wilderness, who has been chronicling the progress and developments of the Fremont Factory for years, shared some footage from his August 14, 2025 flyover. Based on the video, the Fremont Factory seemed very much alive. Vehicles were being pumped out of the factory, and a rather interestingly covered car could be seen going around the test track.

What is quite fascinating about the footage from the Fremont Factory is the fact that the vehicles that were moving from the production line to the outbound logistics lot are not driven manually anymore. As per Tesla in previous updates, vehicles produced at the Fremont Factory navigate to the outbound logistics lot on their own using Unsupervised FSD

Mysterious castings

Perhaps most interestingly, the drone operator also managed to capture some footage of some castings that were being gathered just outside one of the facility’s sprung structures. These castings seem to be quite new, as they do not seem to match any of the castings that are currently being used for the Model Y. This has brought speculations suggesting that the new components, which seem smaller than standard Model Y megacasts, may be for a different, perhaps more compact, vehicle. 

As per Tesla in its second quarter earnings call, the company actually started the initial production of more affordable models sometime in June. These vehicles, as per Elon Musk, will be made available for consumers in the fourth quarter. “Given that we started in North America and that our goal is to maximize production with higher rates by the end of Q3, we’re going to keep pushing hard on our current models to avoid complexity… We’ll be running with the more affordable models available for everyone in Q4,” Musk said.

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Watch the recent drone footage of the Fremont Factory in the video below.

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Investor's Corner

Shareholder group urges Nasdaq probe into Elon Musk’s Tesla 2025 CEO Interim Award

The SOC Investment Group represents pension funds tied to more than two million union members, many of whom hold shares in TSLA.

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Credit: xAI/X

An investment group is urging Nasdaq to investigate Tesla (NASDAQ:TSLA) over its recent $29 billion equity award for CEO Elon Musk. 

The SOC Investment Group, which represents pension funds tied to more than two million union members—many of whom hold shares in TSLA—sent a letter to the exchange citing “serious concerns” that the package sidestepped shareholder approval and violated compensation rules.

Concerns over Tesla’s 2025 CEO Interim Award

In its August 19 letter to Nasdaq enforcement chief Erik Wittman, SOC alleged that Tesla’s board improperly granted Musk a “2025 CEO Interim Award” under the company’s 2019 Equity Incentive Plan. That plan, the group noted, explicitly excluded Musk when it was approved by shareholders. SOC argued that the new equity grant effectively expanded the plan to cover Musk, a material change that should have required a shareholder vote under Nasdaq rules.

The $29 billion package was designed to replace Musk’s overturned $56 billion award from 2018, which the Delaware Chancery Court struck down, prompting Tesla to file an appeal to the Delaware Supreme Court. The interim award contains restrictions: Musk must remain in a leadership role until August 2027, and vested shares cannot be sold until 2030, as per a Yahoo Finance report.

Even so, critics such as SOC have argued that the plan does not have of performance targets, calling it a “fog-the-mirror” award. This means that “If you’re around and have enough breath left in you to fog the mirror, you get them,” stated Brian Dunn, the director of the Institute for Comprehension Studies at Cornell University.

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SOC’s Tesla concerns beyond Elon Musk

SOC’s concerns extend beyond the mechanics of Musk’s pay. The group has long questioned the independence of Tesla’s board, opposing the reelection of directors such as Kimbal Musk and James Murdoch. It has also urged regulators to review Tesla’s governance practices, including past proposals to shrink the board. 

SOC has also joined initiatives calling for Tesla to adopt comprehensive labor rights policies, including noninterference with worker organizing and compliance with global labor standards. The investment group has also been involved in webinars and resolutions highlighting the risks related to Tesla’s approach to unions, as well as labor issues across several countries.

Tesla has not yet publicly responded to SOC’s latest letter, nor to requests for comment.

The SOC’s letter can be viewed below.

Nasdaq+Letter Tsla Socig Final by Simon Alvarez

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Tesla Model Y L has two distinct features for luxurious comfort

This is not to say the other interior additions are not factors in the Model Y becoming a more luxurious and premium vehicle, but the two mentioned in this article are particularly pertinent in that conversation.

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Credit: Tesla

Tesla’s new Model Y L has two distinct features that are geared toward giving occupants a taste of luxury with guaranteed comfort.

These two features should definitely be part of the company’s future lineup, and they could prove to be massive upgrades to the Model Y’s interior, which is certainly premium but is missing some things that truly tailor to a “luxury” feel of an automobile.

This is not to say the other interior additions are not factors in the Model Y becoming a more luxurious and premium vehicle, but the two mentioned in this article are particularly pertinent in that conversation.

Tesla Model Y L might not come to the U.S., and it’s a missed opportunity

Power-Adjustable Thigh Supports

In the front seats of the Model Y L, there are power-adjustable thigh supports that will enable some additional comfort on the legs:

Most might think that these thigh supports are simply a feature that makes the ride more comfortable, which is true. However, they have benefits for the ride and after you exit the car.

Providing proper lift on the legs and thighs can be beneficial for people with back problems or posture issues. The lower back takes an increased amount of stress during long car rides, especially as the legs are fixed in the chosen seating position.

Tesla Model Y L officially launched: price, features, and more

Adding some support to the thighs can help reduce pressure on the lower back and hips, and distribute weight more evenly, taking stress off pressure points.

It can also contribute to better spinal alignment. They also have safety benefits, as some riders could have an improved seatbelt position thanks to the thighs being in this position.

Second-Row Mechanical Armrest

Tesla also added mechanical, one-touch armrests to the Model Y L’s second row, a nice and premium touch for the riders in the middle of the vehicle:

Add the additional space the Model Y L provides to riders, and it already gets more comfortable. However, the addition of the mechanical armrests gives a good option of comfort for those who are seated in the second row.

They can also be retracted with the touch of a button, allowing for those in the third row to exit the vehicle easily.

One con to the mechanical portion of these armrests is that it is another moving part, and, of course, that puts it at risk of having issues.

However, it is certainly more premium than a manual armrest, and the flashy carbuyers will appreciate this small but mighty addition.

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