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Tesla patent paves way for compact battery systems that are easier to produce

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6 years ago

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Tesla’s use of batteries for its electric vehicles are crucial to their function. The company’s battery systems are the industry standard as they offer more range and density than their competitors. But despite this lead, a recently submitted patent for an aggregated battery system could put Tesla’s batteries head-and-shoulders above the rest of the pack, bar none.

While Tesla’s current battery system is top of the line, it could still be more cost-effective. Batteries themselves cost a lot to manufacture for Tesla, and not to mention, a lot to replace for an owner. The aim of the company’s newly submitted patent is to create a more efficient system that would simplify the entire battery component by combining the multiple battery systems into one single module.

Small battery cells are more advantageous than large battery cells for a number of reasons, including time, safety, thermal management and production of energy. All of these factors would highlight the advantages of small battery systems and would allow for an increase in the productivity of battery cells. The smaller cells means “a shorter length of electrode material that is devoid of material defects would be required.”

A battery pack made up of multiple battery systems grouped together and positioned within a container. (Credit: US Patent Office)

The new system would arrange the battery cells in an upright manner. The multiple cells would then function with one another by being connected to a series of collector plates with tabs on both the positive and negative ends of the battery. The tabs would then be connected to a positive or negative terminal of the battery cell. This would be done with multiple series of batteries that all have different responsibilities throughout the vehicle. They would all, however, be housed within a single battery container, allowing engineers or service workers easy access to each battery system.

The addition of this new patent could help reduce costs by utilizing smaller battery cells in battery systems. The patent states that while production will increase due to the reduced size and need for materials, the small cells can increase the complexity of the manufacturing of the systems. This makes Tesla’s batteries even easier to produce.

“For instance, with use of many small format cells, it is envisioned that several electrical interconnects could be required to accomplish the conveyance of current from the large number of small format cells and this may also contribute to the complexity in design and manufacture of the battery system. The battery cell could also have some functionalities that may be redundant when aggregated into the battery system. As each battery cell would be manufactured independently of others, time and resources would need to be spent thereafter for combining the cells and for forming the interconnects to the current collectors typically, though a welding, or soldering process. Hence, there is a need to produce battery modules in a simplified manner.”

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The innovations offered by Tesla’s recently published patent could allow the electric car maker to equip its vehicles with battery packs that are both compact and high-density. This would be pivotal to upcoming vehicles such as the next-generation Roadster, the Tesla Pickup Truck, and the Tesla Semi, all of which are expected to require large batteries to achieve their target range, and thus would require large numbers of cells from the electric car maker.

Tesla is the head of the pack in terms of batteries, as the company’s vehicles have considerably longer ranges than the vehicle’s of its competitors. For example, a Tesla Model S Performance variant contains a 100 kWh battery, with a WLTP estimated 365 miles of range when charged to its capacity. The newly released Porsche Taycan Turbo S contains a 93.4 kWh battery with a WLTP estimated 256 miles of range on a full charge.

The full text of Tesla’s novel battery design patent could be accessed here.

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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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Elon Musk

Tesla’s new Robotaxi geofence shape is an FU by Elon Musk to the competition

Maybe it’s all pareidolia. But maybe it’s not. After all, Tesla embraced the first geofence expansion for what it appeared to be.

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3 hours ago

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August 4, 2025

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tesla austin robotaxi geofence and elon musk laugh from meme review

Tesla expanded its Robotaxi geofence in Austin once again early Sunday morning. The new shape seems to be somewhat of a proverbial, and potentially literal, middle finger to the competition.

If you thought the first expansion was a message to the competition and doubters of the company’s ride-hailing service, you probably will believe the second expansion is an even stronger gesture.

Tesla’s first expansion did not go unnoticed, as its shape was particularly recognizable. The company has always operated with a sense of humor, and it embraced what it did. Some, including me, took it as a message to competitors: We can expand in any direction, in any size, at any time. We’ll prove it.”

They picked a shape and went with it:

Tesla’s Robotaxi expansion wasn’t a joke, it was a warning to competitors

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It is evident that Tesla is keeping its humor up to continue to show a few things. The first is that it really can expand in any direction it wants and that’s how it is choosing to show it.

The second, well, maybe it’s an edgier way to show doubters that it is really executing on Robotaxi:

Maybe it’s all pareidolia. But maybe it’s not. After all, Tesla embraced the first geofence expansion for what it appeared to be. This might be a similar occurrence, and it might be sending another message to the competition, critics, and doubters.

The expansion was a near-doubling of the geofence Tesla offered previously. After the initial geofence covered just about 20 square miles, Tesla was able to more than double it to 42 square miles with the first growth. This new geofence shape was just under double, and is about 80 square miles.

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Tesla’s rapid expansion has impressed many, especially considering the service area has roughly doubled for the second time in well under two months. The Robotaxi service was first offered on June 22.

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Elon Musk

Tesla executes ‘a must’ with Musk as race to AI supremacy goes on: Wedbush

Dan Ives of Wedbush says Tesla made the right move getting Elon Musk his pay package.

Published

7 hours ago

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August 4, 2025

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elon musk
Steve Jurvetson, CC BY 2.0 , via Wikimedia Commons

Tesla (NASDAQ: TSLA) executed what Wedbush’s Dan Ives called “a must” this morning as it finalized a new pay package for its CEO Elon Musk.

The move helped give Musk his first meaningful compensation at Tesla since 2017, when the company offered a pay package that was based on performance and proven growth. That package was approved by shareholders on two separate occasions, but was denied to Musk both times by the Delaware Chancery Court.

On Monday, Tesla announced on X that it had created a new package that would give 96 million shares of restricted stock to Musk to compensate him for the “immense value generated for Tesla and all our shareholders.”

The details of the pay package are designed to retain Musk, who has voiced some concerns about his control of Tesla, as “activist shareholders” have used lawsuits to disrupt the previously approved package.

You can read all the details of it here:

Tesla rewards CEO Elon Musk with massive, restricted stock package

Ives says Musk’s retention is ‘a must’

Ives said in a note to investors on Monday that with the raging AI talent war that Tesla made a smart move by doing what it could to retain Musk.

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He wrote:

“With the AI talent war now fully underway across Big Tech, we believe this was a strategic move to keep TSLA’s top asset, Musk, would stay focused at the company with his priority being to bolster the company’s growth strategy over the coming years. With this interim award increasing Musk’s voting rights upon this grant, which Musk honed in on and mentioned was increasingly important to incentivize him to stay focused on the matters at hand, this was a strategic move by the Board to solidify Musk as CEO of Tesla over the coming years with this framework for Musk’s pay package and greater voting control removing a major overhang on the story.”

He went on to say:

“While the groundwork is now in place for the next few years, it will be critical for the Tesla Board of Directors to get this long-term compensation strategy in place prior to the company’s November 6th shareholder meeting which would address the elephant in the room and remove a significant overhang on the stock.”

Wedbush maintained its Outperform rating and its $500 price target on the stock.

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Elon Musk

Tesla CEO Elon Musk reveals ideal timeline for insane self-driving feature

Tesla CEO Elon Musk has extremely optimistic expectations for Full Self-Driving progress by the end of 2025.

Published

9 hours ago

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August 4, 2025

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Credit: Tesla

Tesla CEO Elon Musk has revealed his ideal timeline for what would likely be the most insane self-driving feature: the ability for drivers to play video games at the wheel.

There are a handful of videos out there of drivers already performing this task. Nobody using Tesla’s Full Self-Driving suite should perform these activities, as the company maintains the system is not fully autonomous.

Drivers are responsible for the vehicle and should be prepared to take over.

Tesla has put a lot of faith in its development of Full Self-Driving and has made tremendous strides over the past few years. Capabilities have gotten more refined and accurate through various methods, including data collection and hardware improvements.

Tesla kicks Robotaxi geofence expansion into high gear in Austin

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It has gotten so good that Tesla launched a Robotaxi platform in Austin, Texas, on June 22. Passengers can hop in the back of a Model Y and will be transported around the city in a confined geofence that is about 90 square miles in size. There is nobody in the driver’s seat, but there is a Safety Monitor in the passenger’s seat.

Tesla launched a similar experience in California’s Bay Area last week, but the company has placed the Safety Monitor in the driver’s seat for that region for the time being.

Eventually, Tesla will get to a point where no monitor is needed, and the vehicles will be able to drive themselves. Many believe that it is a few years away, but Musk believes Tesla could achieve it very soon.

After a video of someone playing Grand Theft Auto in their Cybertruck while operating Full Self-Driving was shared on the social media platform X, Musk said this capability would be available in “probably 3 to 6 months, depending on regulatory approval in your city and state.”

It is important to remember that Musk has been very optimistic regarding autonomy timelines with Tesla projects. We heard for many years that the company would have self-driving vehicles “by the end of the year,” and those projects did not come to fruition.

While there was progress, there were no fully autonomous vehicles or software versions for customers.

With that being said, Tesla has made tremendous strides in its quest for autonomous vehicles this year, and launching a Robotaxi platform was a huge step in the right direction.

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