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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 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:

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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

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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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Tesla’s NHTSA probe is already on its way to being resolved

The problem the NHTSA had with Tesla’s reporting is already on its way to being resolved, as the agency and the company have been in communication.

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tesla showroom
Credit: Tesla

Tesla is being probed by the National Highway Traffic Safety Administration (NHTSA) for not reporting accidents in a timely manner, the agency said on Thursday.

It is already well on its way to being resolved, the agency said.

The agency’s Office of Defects Investigation (ODI) identified numerous instances in which Tesla reported crashes that “occurred several months or more before the dates of the reports.”

The Standing General Order in place by the agency requires crash reports to be submitted within five days of Tesla receiving the notice of an accident.

The investigation states Tesla submitted crashes in one of two ways:

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“Many of the reports were submitted as part of a single batch, while others were submitted on a rolling basis.”

The problem the NHTSA had with Tesla’s reporting is already on its way to being resolved, as the agency and the company have been in communication.

Tesla has already been in contact with the agency’s ODI and stated that the timing of the reports was an issue with its data collection. The issue has been resolved, Tesla told them.

The NHTSA said the initiation of the probe against Tesla is a “standard process for reviewing compliance with legal requirements, to evaluate the cause of potential delays in reporting, the scope of any such delays, and the mitigations that Tesla has developed to address them.”

It is the latest NHTSA probe into Tesla, as it has also been investigating the company for accidents during Full Self-Driving operation in reduced visibility conditions.

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The agency also sought information on the rollout of Robotaxi a few months ago, and how Tesla planned to handle low-visibility conditions in its driverless ride-hailing service.

The NHTSA was interested in knowing how Tesla planned to assess the ability of FSD’s engineering controls, whether any other similar FSD crashes had occurred in low visibility, and if modifications to FSD software would impact its performance in these conditions.

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Tesla rolls out minor but significant improvement to Robotaxi service

As per Tesla, Robotaxis will now arrive at their pickup locations with their doors locked.

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Credit: @AdanGuajardo/X

Tesla has rolled out a minor but significant improvement to its Robotaxi service. The update was shared by the Tesla community on social media platforms such as X. 

New Robotaxi App update

As observed by the electric vehicle community on social media, Tesla has started rolling out the Robotaxi App’s Version 25.8.5 (6074) to users. The update seems to be quite minor, though Tesla mentioned something quite notable the update’s “What to Test” section.

As per Tesla, Robotaxis will now arrive at their pickup locations with their doors locked. Customers would not need to unlock the Robotaxis manually, however, as the vehicles would automatically unlock as they approach the car. “You ride now arrives locked and will automatically unlock as you walk up. Just ensure your app has Bluetooth access enabled,” Tesla wrote.

While this update is minor, it does improve the safety of the vehicles themselves. It also provides another layer of convenience for users of the driverless ride-hailing service. The fact that Tesla is already refining the Robotaxi App’s features this early bodes well for the program. It suggests, if any, that the service will already be fairly refined when it starts being opened to more users.

Robotaxi praised for its safety

Tesla is following a deliberate and cautious rollout strategy for its Robotaxi rollout, though early reviews of the system have been quite positive. Some reviewers have also dubbed Tesla’s Robotaxi service as a safer alternative to more conventional ride-hailing services such as Uber.

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This was highlighted by auto reviewer Scotty Reiss in a post on A Girl’s Guide to Cars.

“I like the personal safety factor. No driver to threaten or harass you. You control the locking and unlocking of the car. You can change the pickup location at any time. The car will wait for you. You can call the support desk if you need help. You can change your destination if the drop-off area seems sketchy. All of it together makes me feel safer getting a car home from the airport at midnight or into the city after dark, and I definitely feel safer having my daughters take a self-driving rideshare when they go out to meet friends for dinner,” Reiss wrote in her post.

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