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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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xAI’s Grokipedia goes live, gets praise from Wikipedia co-founder

xAI’s latest creation, Grokipedia, has gone live, and even if it’s only at Version 0.1, it is already receiving positive reviews from some users.

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Credit: xAI/X

xAI’s latest creation, Grokipedia, has gone live, and even if it’s only at Version 0.1, it is already receiving positive reviews from some users. These include Larry Sanger, the co-founder of Wikipedia, the world’s largest online encyclopedia, which has become quite controversial in recent years over accusations of bias.

Grokipedia launches

Immediately after Grokipedia went live, the AI-powered Wikipedia alternative was tested by numerous users. So far, a good number of testers have responded positively to the online encyclopedia, with many observing that Grokipedia does tend to be more neutral than Wikipedia. This was particularly evident in controversial topics, from alternative medicine to events like Gamergate.

Among these users was Larry Sanger, who noted that while Grokipedia still has a lot of areas of improvement, it is already very promising. “My initial impression, looking at my own article and poking around here and there, is that Grokipedia is very OK. The jury’s still out as to whether it’s actually better than Wikipedia. But at this point I would have to say “maybe!” He wrote in a post on X. 

Musk responded to Sanger’s comments, stating that the Wikipedia co-founder’s observations are “accurate.” The xAI founder also noted in a separate X post that even in its V0.1 form, Grokipedia is already better than Wikipedia. 

Why Grokipedia exists 

During an interview on the Tucker Carlson Show, Sanger point out that Wikipedia has become a far cry from his initial vision for the online encyclopedia, and a lot of this was because of the its “Reliable sources/Perennial sources” page, which categories publications and sources into tiers of credibility. Sanger noted that the list leaned heavily left, with conservative publications getting effectively blacklisted in favor of their more liberal.

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Musk responded to Sanger’s comments by stating that Grokipedia will be created as a step towards xAI’s broader goal of “understanding the Universe.” He added that Grokipedia, which will use xAI’s Grok, would provide broader sourcing and a freer exchange of information compared to Wikipedia’s current system. 

One month after Elon Musk’s comments, Grokipedia has gone live in its V0.1 form.

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Tesla Fremont Factory celebrates 15 years of electric vehicle production

Since opening in 2010, the Fremont Factory has produced all four “S3XY” models while creating tens of thousands of jobs.

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Credit: Tesla

Tesla is marking the 15-year anniversary of its Fremont Factory in California, the first automotive mass-manufacturing plant acquired by the electric car maker. 

Since opening in 2010, the Fremont Factory has produced all four “S3XY” models while creating tens of thousands of jobs and investing billions of dollars in the region.

Celebrating 15 years of EV production

The Fremont Factory’s milestone was celebrated by the official Tesla Manufacturing account on X, which posted a photo of several Teslas forming a “15” in front of the facility’s iconic white facade. As per the electric vehicle maker, the Fremont Factory has now produced 3.6 million vehicles so far, and it has also created over 20,000 jobs in the state. 

“15 years ago, we opened Fremont factory. Today, the Fremont team is producing all 4 S3XY models, totaling 3.6M vehicles made so far. 20k+ California jobs created w/ billions of dollars invested,” the official Tesla Manufacturing account on X wrote in its post.

The Fremont Factory’s transformation

Tesla acquired the Fremont Factory from the defunct NUMMI joint venture between General Motors and Toyota in May 2010 for $42 million. The facility had produced more than 8 million vehicles under GM and Toyota over 26 years. Following its acquisition, Tesla retooled the 5.3-million-square-foot plant to support the production of the Model S sedan.

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Over the past 15 years, the factory has evolved into Tesla’s primary North American production hub, assembling the Model S, 3, X, and Y. Annual output has exceeded 550,000 vehicles, including nearly 560,000 produced in 2023 alone. Expectations are high that other products, such as the next-generation Roadster and Optimus, might be produced in the Fremont Factory as well.

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Tesla posts job opening for next-generation Roadster production

Elon Musk teased a major demonstration at the Tesla Design Studio in Hawthorne, scheduled for the end of the year.

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Tesla-profile-Roadster-2-2
Image used with permission for Teslarati. (Credit: Tom Cross)

Tesla has opened its first job listing specifically for the next-generation Roadster, hinting at some substantial progress on the company’s long-awaited flagship all-electric supercar. 

The company is looking for a Manufacturing Engineer to support the development and launch of new battery manufacturing equipment, which would likely be pivotal to the Roaster, considering its teased performance and range.

Tesla’s next-generation Roadster batteries

As per Tesla’s Careers website, the Roadster Manufacturing Engineer’s tasks would include ideating equipment concepts, developing specifications, validating processes, and addressing production bottlenecks. Tesla emphasized that the position involves collaboration across domestic and international sites, supporting equipment factory acceptance tests and assisting operations teams, with expected travel under 50 percent. 

“In this role, you will take large-scale manufacturing systems for new battery products and architectures from the early concept development stage through equipment launch, optimization, and handover to local operations teams. Battery development is at the heart of our company, and this is an exciting opportunity to work directly on the central challenges for the all-new Roadster product architecture while still in its early development stages,” the job listing noted.

The opening marks one of the first public hiring efforts explicitly tied to the next-gen Roadster, suggesting that the vehicle’s development might be approaching its initial manufacturing phase. The fact that the new Roadster’s first job opening is related to its battery is interesting, as the vehicle was unveiled with a range of 620 miles way back in late 2018. Though at the time, Elon Musk also noted that the Roadster would be fitted with a 200 kWh battery, twice the size of the batteries used in the Model S and Model X. 

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Musk teases “most epic demo ever” and fuels Roadster speculation

Back in July, Elon Musk teased a major demonstration at the Tesla Design Studio in Hawthorne, California, scheduled for the end of the year. Musk shared on X that he had just visited the studio, calling the upcoming event the “most epic demo ever by one of year. Ever.”

The statement immediately prompted speculations that Tesla may finally be ready to reveal the production version of the next-generation Roadster. Originally unveiled alongside the Semi in 2018, the Roadster has remained under wraps while the company scaled production of other models. Since its unveiling, however, the Roadster’s rollout has been pushed back in favor of the original Model Y, the refreshed Model S and X, the Cybertruck, the refreshed Model 3, the Semi, and the new Model Y.

At the time of its unveiling, the next-generation Roadster was teased to be nothing short of a monster, with a 0-60 mph time of 1.99 seconds and a top speed of over 250 mph. Elon Musk also teased that the next-generation Roadster would have a range of 620 miles per charge. Later, the CEO noted that the Roadster should be able to achieve a 0-60 mph launch of less than 1 second, thanks to the vehicle’s SpaceX package. Musk has also noted recently that the next-generation Roadster would be “beyond a car.”

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