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Tesla explores safer battery production with novel DCM recovery system patent

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In what appears to be yet another step towards its goal of operating the safest car factory in the industry, Tesla has been granted a patent that could pave the way for a safer process in battery production. Published today, the electric car maker’s recent patent describes a system to treat and recycle Dichloromethane (DCM), which is among the materials used in the production of electric car batteries.

DCM is utilized in a variety of industrial processes, particularly in chemical plastic welding, wherein softened plastic pieces or surfaces are welded together. The material is also used to soften plastic sheets for stretching or shaping, and as a solvent to remove unwanted compounds. In Tesla’s case, DCM is among the materials used in the forming of a separator base film for an electric car’s battery system. While DCM is invaluable in manufacturing, though, the material carries some health risks.

Dichloromethane is the least toxic among the simple chlorohydrocarbons, but its high volatility makes it an inhalation hazard nonetheless. Prolonged skin contact with DCM could also result in the material dissolving some of the skin’s fatty tissues, causing irritation or chemical burns. With these risks in mind, the manufacturing industry employs ways to recover DCM. Tesla notes that current systems for DCM treatment and recovery are capital intensive, particularly since the process involves expensive components such as activated carbon beds, condensers, steam boilers and distribution systems, density separation vessels, and waste water treatment systems.

Tesla’s diagrams outlining its Dichloromethane recovery system. [Credit: US Patent Office]

Tesla describes conventional DCM treatment systems as follows:

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“The DCM itself may then be removed through a heating and/or evaporation process with the exhaust collected. This exhaust containing DCM is then combined with the exhaust from other tools and systems used in the manufacturing process. The combined exhaust may then be fed to a recovery plant to recover DCM. In the recovery plant, the waste exhaust stream is typically treated with activated carbon. This scrubbing process requires high capital expenditure (many expensive components), high operating cost (extensive steam and cooling water consumption which accounts for >20% of total process cost), large footprint requirements, and large amounts of waste water that need to be processed. In order to address these cost and environmental-remediation issues, an improved process for the removal of DCM from exhaust streams is needed.”

Tesla’s take on DCM treatment and recovery utilizes a wet scrubber and a density separator vessel as key components of the system. The wet scrubber in Tesla’s patent has a scrubbing chamber, where water is utilized to scrub the waste exhaust stream containing the DCM. Tesla notes that the wet scrubber could adopt a variety of designs to remove DCM from the waste exhaust stream, including a venturi scrubber design, a condensation scrubber design, an impingement-plate scrubber design, or a packed bed tower design, among others.

Tesla’s use of a density separator vessel is described in the following section from the patent.

“The density separator vessel has an inlet to receive the liquid water and DCM mixture, an outlet to expel DCM, and an outlet to expel waste water. The DCM may be routed back to the industrial process for reuse and/or collected for later use. The waste water may be routed back to the wet scrubber, as shown along (the) waste water return loop. Waste water may also or alternately be routed to waste water treatment system for processing for subsequent treatment by (the) waste water treatment system.

“Typically, a large portion of the waste water is returned to the wet scrubber via (the) waste water return loop and a small portion of the waste water is treated by the waste water treatment system. Even though the waste water may contain small amounts of DCM, the waste water will still retain its ability to scrub the exhaust containing DCM. An advantage of the wet scrubber over the activated carbon beds is that all or most of the water used by the wet scrubber is the waste water from the density separator vessel, resulting in substantial savings of water and energy, and resultantly, substantial cost savings.”

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Tesla states that compared to more traditional exhaust treatment systems, the DCM treatment and recovery model outlined in its patent effectively eliminates the use of steam and cooling, while also reducing the amount of throughput needed by a waste water system. With these efficiencies in mind, Tesla notes that it could reduce capital expenditures and operating costs “for the same amount of DCM processed processing.” The increased simplicity of the system and reduced airflow rates are expected to help the company get more savings in both capital expenditures and operating costs as well.

More than a way to optimize its operations, Tesla’s recent patent is also a notable way for the company to keep its battery production lines safer for its employees. Such a system would definitely be invaluable for the company, particularly as Tesla is now preparing the Model 3 for a global rollout. With the Model 3 ramp ever-expanding, and with high-volume vehicles like the Model Y and possibly the Tesla pickup truck in the pipeline, optimizations such as a better DCM treatment and recovery system are all but necessary.

Tesla’s recently published patent on its DCM treatment system could be accessed here.

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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Investor's Corner

Tesla Board member and Airbnb co-founder loads up on TSLA ahead of robotaxi launch

Tesla CEO Elon Musk gave a nod of appreciation for the Tesla Board member’s purchase.

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(Credit: Tesla)

Tesla Board member and Airbnb Co-Founder Joe Gebbia has loaded up on TSLA stock (NASDAQ:TSLA). The Board member’s purchase comes just over a month before Tesla is expected to launch an initial robotaxi service in Austin, Texas.

Tesla CEO Elon Musk gave a nod of appreciation for the Tesla Board member in a post on social media.

The TSLA Purchase

As could be seen in a Form 4 submitted to the United States Securities and Exchange Commission (SEC) on Monday, Gebbia purchased about $1.02 million worth of TSLA stock. This was comprised of 4,000 TSLA shares at an average price of $256.308 per share.

Interestingly enough, Gebbia’s purchase represents the first time an insider has purchased TSLA stock in about five years. CEO Elon Musk, in response to a post on social media platform X about the Tesla Board member’s TSLA purchase, gave a nod of appreciation for Gebbia. “Joe rocks,” Musk wrote in his post on X.

Gebbia has served on Tesla’s Board as an independent director since 2022, and he is also a known friend of Elon Musk. He even joined the Trump Administration’s Department of Government Efficiency (DOGE) to help the government optimize its processes.

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Just a Few Weeks Before Robotaxi

The timing of Gebbia’s TSLA stock purchase is quite interesting as the company is expected to launch a dedicated roboatxi service this June in Austin. A recent report from Insider, citing sources reportedly familiar with the matter, claimed that Tesla currently has 300 test operators driving robotaxis around Austin city streets. The publication’s sources also noted that Tesla has an internal deadline of June 1 for the robotaxi service’s rollout, but even a launch near the end of the month would be impressive.

During the Q1 2025 earnings call, Elon Musk explained that the robotaxi service that would be launched in June will feature autonomous rides in Model Y units. He also noted that the robotaxi service would see an expansion to other cities by the end of 2025. “The Teslas that will be fully autonomous in June in Austin are probably Model Ys. So, that is currently on track to be able to do paid rides fully autonomously in Austin in June and then to be in many other cities in the US by the end of this year,” Musk stated. 

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Tesla hints at ‘Model 2’ & next-gen EV designs

Tesla’s Q1 2025 update confirms new models this year, with production tied to existing factory lines. Could it be time for the Model 2 debut?

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(Credit: Tesla)

During its Q1 2025 earnings call, Tesla executives hinted at the much-rumored “Model 2” and other next-gen EV designs.

Tesla slightly addressed whether or not it will be pushing forward with the debut of new models later this year in its latest earnings call. The company’s product development executive, Lars Moravy, shared some details about Tesla’s design process and the upcoming affordable models.

“We’re still planning to release models this year. As with all launches, we’re working through, like, the last minute issues that pop up. We’re knocking them down one by one. At this point, I would say that the ramp might be a little slower than we had hoped initially…But there’s nothing that’s blocking us from starting production within the next, within the timeline laid out in the opening remarks.

“And I will say it’s important to emphasize that, as we’ve said all along, the full utilization of our factories is the primary goal for these new products. And so the flexibility of what we can do within the form factor and, you know, the design of it is really limited to what we can do on our existing lines rather than building new ones. But we’ve been targeting the low cost of ownership. Monthly payment is the biggest differentiator for our vehicles, and that’s why we’re focused on bringing these new models with the, you know, the lowest price, to the market, within the constraints I just highlighted.”

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In January, Tesla’s Chief Financial Officer Vaibhav Taneja teased several new product introductions for this year. There is at least one product that most Tesla supporters and investors are hoping to see: the company’s affordable vehicles, which have been dubbed by the EV community as the “Model 2” or “Model Q.”

Before Tesla’s Robotaxi event last year, many speculated that the company would also unveil its affordable next-gen vehicle. Gene Munster from Deepwater had expected Tesla to release a stripped-down version of the Model 3 as its affordable vehicle during the Robotaxi event. In the end, Tesla unveiled its Robotaxi vehicle and its Robovan design.

It’s been a while since the Robotaxi event, and Tesla has kept mum about its affordable vehicle. Considering its Q1 2025 performance, TSLA investors look forward to catalysts that could boost the stock.

The “Model 2” has been labeled a potential catalyst for Tesla. As such, TSLA investors and supporters have been itching for news about the new affordable vehicle. The main questions surrounding the “Model 2” revolve around its design and price. Based on Moravy’s statement, the “Model 2’s” design will heavily depend on Tesla’s current assembly lines and supply chain structures.

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Tesla regains Piper Sandler’s confidence with Robotaxi plans & Q1 Results

Piper Sandler says Tesla delivered the best-case scenario for bulls. $TSLA has catalysts ahead to silence the bears.

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tesla-model-y-delivery
(Credit: Tesla)

Tesla gained Piper Sandler analyst Alexander Potter’s confidence following its Q1 2025 earnings call. Piper Sandler reaffirmed its Overweight rating and $400 TSLA price target, signaling optimism for the company’s robotaxi and affordable vehicle launches expected this year. The firm’s stance reflects Tesla’s resilience amid market challenges.

Despite expectations of weak Q1 financials, Tesla’s stock edged up in after-hours trading, defying skepticism. Piper Sandler’s Alexander Potter noted that the results met the hopes of Tesla supporters, particularly as the company held firm on its timelines. Potter emphasized that anticipation for robotaxi details and new vehicle launches should keep critics at bay, supporting the $400 target.

“In our preview last week, we predicted that (at best) Q1 would be a non-event. With the stock trading up slightly in the after-hours session, it appears our best-case scenario has materialized. Considering generally weak Q1 financials, we think this is the best result that TSLA bulls could’ve reasonably hoped for.

“In our view, the most important Q1 takeaway is this: Tesla didn’t hedge expectations re: launching Robotaxis or lower-priced vehicles in 1H25. With <2 months until the end of June, investors can look forward to some interesting catalysts in the weeks ahead. In our view, this alone should be enough to keep the bears at bay, at least until we have a better idea re: the details of Tesla’s new products, as well as the scale/scope of the Robotaxi launch,” wrote Potter.

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Wedbush Securities’ Dan Ives, a longtime TSLA bull, echoed Potter’s optimism for Tesla. Ives raised his price target for Tesla stock from $315 to $350 with a BUY rating. His Tesla upgrade came after Elon Musk’s announcement during the Q1 earnings call that he would reduce his involvement with DOGE, signaling a sharper focus on Tesla.

Tesla’s steady Q1 performance and unwavering commitment to its 2025 roadmap, including the Robotaxi launch and lower-priced models, bolster investor confidence. Piper Sandler’s analysis underscores Tesla’s ability to navigate a competitive electric vehicle market while advancing its technological edge. The upcoming Robotaxi launch and affordable vehicle introductions are pivotal, with analysts expecting these initiatives to drive stock value through 2025.

As Tesla prepares for these milestones, its stock movement reflects market trust in Musk’s vision. With Piper Sandler and Wedbush reaffirming bullish outlooks, Tesla’s strategic moves will remain under close scrutiny, positioning the company to capitalize on its innovation pipeline in a dynamic industry landscape.

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