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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 owners propose interesting theory about Apple CarPlay and EV tax credit

“100%. It’s needed for sales because for many prospective buyers, CarPlay is a nonnegotiable must-have. If they knew how good the Tesla UI is, they wouldn’t think they need CarPlay,” one owner said.

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Credit: Tesla Raj/YouTube

Tesla is reportedly bracing for the integration of Apple’s well-known iOS automotive platform, CarPlay, into its vehicles after the company had avoided it for years.

However, now that it’s here, owners are more than clear that they do not want it, and they have their theories about why it’s on its way. Some believe it might have to do with the EV tax credit, or rather, the loss of it.

Owners are more interested in why Tesla is doing this now, especially considering that so many have been outspoken about the fact that they would not use it in favor of the company’s user interface (UI), which is extremely well done.

After Bloomberg reported that Tesla was working on Apple CarPlay integration, the reactions immediately started pouring in. From my perspective, having used both Apple CarPlay in two previous vehicles and going to Tesla’s in-house UI in my Model Y, both platforms definitely have their advantages.

However, Tesla’s UI just works with its vehicles, as it is intuitive and well-engineered for its cars specifically. Apple CarPlay was always good, but it was buggy at times, which could be attributed to the vehicle and not the software, and not as user-friendly, but that is subjective.

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Nevertheless, upon the release of Bloomberg’s report, people immediately challenged the need for it:

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Some fans proposed an interesting point: What if Tesla is using CarPlay as a counter to losing the $7,500 EV tax credit? Perhaps it is an interesting way to attract customers who have not owned a Tesla before but are more interested in having a vehicle equipped with CarPlay?

“100%. It’s needed for sales because for many prospective buyers, CarPlay is a nonnegotiable must-have. If they knew how good the Tesla UI is, they wouldn’t think they need CarPlay,” one owner said.

Tesla has made a handful of moves to attract people to its cars after losing the tax credit. This could be a small but potentially mighty strategy that will pull some carbuyers to Tesla, especially now that the Apple CarPlay box is checked.

@teslarati :rotating_light: This is why you need to use off-peak rates at Tesla Superchargers! #tesla #evcharging #fyp ♬ Blue Moon – Muspace Lofi

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Ron Baron states Tesla and SpaceX are lifetime investments

Baron, one of Tesla’s longest-standing bulls, reiterated that his personal stake in the company remains fully intact even as volatility pressures the broader market.

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Credit: @TeslaLarry/X

Billionaire investor Ron Baron says he isn’t touching a single share of his personal Tesla holdings despite the recent selloff in the tech sector. Baron, one of Tesla’s longest-standing bulls, reiterated that his personal stake in the company remains fully intact even as volatility pressures the broader market.

Baron doubles down on Tesla

Speaking on CNBC’s Squawk Box, Baron stated that he is largely unfazed by the market downturn, describing his approach during the selloff as simply “looking” for opportunities. He emphasized that Tesla remains the centerpiece of his long-term strategy, recalling that although Baron Funds once sold 30% of its Tesla position due to client pressure, he personally refused to trim any of his personal holdings.

“We sold 30% for clients. I did not sell personally a single share,” he said. Baron’s exposure highlighted this stance, stating that roughly 40% of his personal net worth is invested in Tesla alone. The legendary investor stated that he has already made about $8 billion from Tesla from an investment of $400 million when he started, and believes that figure could rise fivefold over the next decade as the company scales its technology, manufacturing, and autonomy roadmap.

A lifelong investment

Baron’s commitment extends beyond Tesla. He stated that he also holds about 25% of his personal wealth in SpaceX and another 35% in Baron mutual funds, creating a highly concentrated portfolio built around Elon Musk–led companies. During the interview, Baron revisited a decades-old promise he made to his fund’s board when he sought approval to invest in publicly traded companies.

“I told the board, ‘If you let me invest a certain amount of money, then I will promise that I won’t sell any of my stock. I will be the last person out of the stock,’” he said. “I will not sell a single share of my shares until my clients sold 100% of their shares. … And I don’t expect to sell in my lifetime Tesla or SpaceX.”

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Watch Ron Baron’s CNBC interview below.

@teslarati :rotating_light: This is why you need to use off-peak rates at Tesla Superchargers! #tesla #evcharging #fyp ♬ Blue Moon – Muspace Lofi
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Tesla CEO Elon Musk responds to Waymo’s 2,500-fleet milestone

While Tesla’s Robotaxi network is not yet on Waymo’s scale, Elon Musk has announced a number of aggressive targets for the service.

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Credit: Tesla

Elon Musk reacted sharply to Waymo’s latest milestone after the autonomous driving company revealed its fleet had grown to 2,500 robotaxis across five major U.S. regions. 

As per Musk, the milestone is notable, but the numbers could still be improved.

“Rookie numbers”

Waymo disclosed that its current robotaxi fleet includes 1,000 vehicles in the San Francisco Bay Area, 700 in Los Angeles, 500 in Phoenix, 200 in Austin, and 100 in Atlanta, bringing the total to 2,500 units. 

When industry watcher Sawyer Merritt shared the numbers on X, Musk replied with a two-word jab: “Rookie numbers,” he wrote in a post on X, highlighting Tesla’s intention to challenge and overtake Waymo’s scale with its own Robotaxi fleet.

While Tesla’s Robotaxi network is not yet on Waymo’s scale, Elon Musk has announced a number of aggressive targets for the service. During the third quarter earnings call, he confirmed that the company expects to remove safety drivers from large parts of Austin by year-end, marking the biggest operational step forward for Tesla’s autonomous program to date.

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Tesla targets major Robotaxi expansions

Tesla’s Robotaxi pilot remains in its early phases, but Musk recently revealed that major deployments are coming soon. During his appearance on the All-In podcast, Musk said Tesla is pushing to scale its autonomous fleet to 1,000 cars in the Bay Area and 500 cars in Austin by the end of the year.

“We’re scaling up the number of cars to, what happens if you have a thousand cars? Probably we’ll have a thousand cars or more in the Bay Area by the end of this year, probably 500 or more in the greater Austin area,” Musk said.

With just two months left in Q4 2025, Tesla’s autonomous driving teams will face a compressed timeline to hit those targets. Musk, however, has maintained that Robotaxi growth is central to Tesla’s valuation and long-term competitiveness.

@teslarati :rotating_light: This is why you need to use off-peak rates at Tesla Superchargers! #tesla #evcharging #fyp ♬ Blue Moon – Muspace Lofi
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