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Tesla patent points to battery cell improvements with clever deformation detection process

Tesla's 2170 battery cells. (Credit: Tesla)

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A recent patent published late August has revealed that Tesla is working on a monitoring system and apparatus that will allow the electric car maker to detect deformations in battery cells in a more effective manner. 

Tesla’s patent application, titled “Apparatus and Method for Detection of Deformation in Battery Cells,” notes that battery cycle life is among the most crucial parameters to ensure optimal performance in machines such as electric vehicles and energy storage devices. Over the course of their lifetime, battery cells will be subjected to multiple charge and discharge cycles, at times in vastly varying conditions and environments.  

As noted by the company in its patent application, there are instances when cells operate in an environment where the ambient temperature may intermittently surge to levels above the stable thermal temperature for normal operations. Cells could also be subjected to high charge and discharge rates and large periodic loads, which could result in significant heating, among other reactions. 

Subjected to these factors, battery cells could experience several effects, such as the thickening of electrodes or the volume expansion of electrochemically active materials within the cell itself. These expansions could ultimately result in cells experiencing deformation, which could, in turn, result in both reversible and irreversible mechanical strain, as well as the potential degradation of the battery’s electrodes. 

An illustration depicting Tesla’s apparatus and method for detecting deformations in battery cells. (Credit: US Patent Office)

These battery cell deformations are traditionally monitored using strain gauges or optical gauges that exclusively detect and evaluate deformations at single points in a cell. Tesla noted that this system has space for improvements, since optical evaluations might not provide the correct status of deformation across the entire surface of a battery. This could result in strain and deformation measurements that are inaccurate. 

With these factors in mind, Tesla has come up with a deformation detection apparatus that enables the contactless detection of deformations and/or swelling of the battery across the entire surface of the cell itself. Tesla describes the deformation detection apparatus as follows. 

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“A deformation detection apparatus includes a cell movement-control assembly to handle a linear motion and a rotational motion of a battery cell, a body that supports the cell movement-control assembly, a digital micrometer, and control circuitry. The control circuitry controls a displacement of the battery cell between a first position and a second position along a longitudinal axis through a scanning region of the digital micrometer and a plurality of rotational positions of the battery cell at a plurality of charge states and a plurality of discharge states. The control circuitry measures a plurality of outer diameter values of the battery cell for a plurality of linear positions and a plurality of rotational positions along the longitudinal axis of the battery cell and determines a change in a geometrical shape (deformation and/or strain) of the battery cell for the plurality of linear positions and the plurality of rotational positions.”

An illustration depicting Tesla’s apparatus and method for detecting deformations in battery cells. (Credit: US Patent Office)

According to the electric car maker, the battery cell deformation monitoring process outlined in its patent will provide advantages over traditional monitoring methods. 

“The disclosed apparatus, such as the apparatus 100 and method of determination of deformations in the battery cell 112 advantageously provides a contactless solution for deformation detection in the battery cells, as compared to conventional contact-based solutions. Further, instead of measuring the plurality of outer diameter values/strain values at a specific point in time, the disclosed apparatus 100 advantageously facilitates measurement of the plurality of outer diameter values/strain values at a plurality of points on the battery cell 112. The apparatus 100 enables detection of localized/non-localized deformation regions on the battery cell 112, which may exhibit signs of deformation at different charge/discharge states at different points in time.”

Tesla’s recently published patent application for its new battery cell deformation detection apparatus could be accessed in full here

The implications of Tesla’s recent patent are notable. By adopting its deformation detection system, the company would be able to evaluate the quality of its cells and their operating limits more effectively. This could open the doors to improvements in the company’s batteries, which could, in turn, result in even more range and performance for Tesla’s electric vehicles. 

Tesla holds a notable lead among automakers in terms of battery technology, as exhibited by the company’s electric vehicles’ vastly superior range compared to the competition. This is represented by Tesla’s recent “Raven” update to the 100 kWh Model X, which allowed the SUV to travel 325 miles in one charge. This is notably impressive, considering that the Audi e-tron, a smaller, lighter vehicle equipped with a 95 kWh battery pack (5% smaller than the Model X), is only EPA-rated for 204 miles per charge (38% less range than Tesla’s larger, heavier vehicle). A report from German business newspaper Wirtschaftswoche has also determined that Tesla’s batteries for the Model 3 have over four times less cobalt compared to the batteries utilized by Volkswagen today.

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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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Tesla is bringing back something it took from the Model 3…for a price

“Modify your Model 3 by replacing the turn signal buttons on your steering wheel with turn signal stalks. This modification is included in the purchase price and is installed by a Tesla Service Center.”

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Credit: Tesla

Tesla is bringing back the Model 3’s turn signal stalk in China after removing the part with the refresh of the all-electric sedan early last year.

However, it is going to cost you.

In 2024, Tesla launched the Model 3 “Highland,” a refreshed version of the vehicle that included several large-scale changes. One of the most noticeable was the lack of a turn signal stalk, something the company chose to remove and instead implement turn signal buttons on the steering wheel.

The buttons were met with mixed reviews, as some drivers complained that it was too difficult to get used to them. Others had no problem with the change, noting that it was slightly more convenient for them or that they enjoyed the minimalistic look.

Now, Tesla is offering Model 3 owners in China the opportunity to replace the stalk for a price of ¥ 2,499, or about $350:

“Modify your Model 3 by replacing the turn signal buttons on your steering wheel with turn signal stalks. This modification is included in the purchase price and is installed by a Tesla Service Center.”

Tesla notes on its website that the service is available for Model 3 vehicles without stalks manufactured after February 7, 2025. Any car without a stalk that was manufactured before that date will have the service available to them in the future.

Installation can be performed at a Service Center or by the owner. However, Tesla notes that it is not responsible for any damages resulting from self-installation and recommends that the part be put in by an employee.

The cockpit of the Tesla lineup has been under intense scrutiny by the company in recent years. After a few changes to things like the stalk, steering wheel shape, and others, Tesla has usually given drivers the chance to have things reverted back to their preferences if they want.

They did this for the Model S and Model X a few years ago after implementing the yoke steering wheel.

Tesla Steering Wheel Retrofits have started, and it’s easy to get rid of your yoke

The stalk was not supposed to be removed from the Model 3 and Model Y, but Tesla chose to do so with the refresh last year.

It seems the minimalization of the cockpit, overall, is a move that prepares drivers for autonomy, as eventually, Teslas will be void of pedals, steering wheels, and any other apparatus that are used to control the car.

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Tesla launches new loaner program that owners will love

Tesla is now giving owners the opportunity to rent a vehicle from them, and it includes a few very attractive features that will have you second-guessing another loaner from insurance.

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tesla service tech
Credit: Tesla

Tesla has launched a new loaner program that owners will love, as it resolves some concerns over a replacement vehicle while it is being repaired.

Earlier this week, Tesla launched the option to rent a Tesla loaner vehicle for just $45 per day if your vehicle is in Collision Repair. Collision repairs did not formerly warrant the issuance of loaner vehicles, as the insurance provider of the car owner would provide transportation arrangements.

Tesla is now giving owners the opportunity to rent a vehicle from them, and it includes a few very attractive features that will have you second-guessing another loaner from insurance.

The Tesla you rent while your car is in collision repair will come with free Full Self-Driving, free Supercharging, and free toll coverage, no small print included.

All things considered, this is a great deal for those who require a car for transportation while their car is being repaired.

The cost of Supercharging and Full Self-Driving alone would warrant the $45 per day price tag. Add in the tolls for those who commute on turnpikes for work or are planning an extensive trip that would require it, and it truly becomes an even more attractive deal.

Tesla has done a good job at improving its Service division over the past few years, and it truly needed it. In hopes of launching an F1-style service experience, Tesla started doing away with some of its perks, including loaner vehicles for single-day visits and even Uber credits.

Tesla’s ‘F1’ Service strategy eliminates same-day loaner vehicles, Uber credits

However, it has listened to the complaints of its owners and tried to cater an experience that is more advantageous and less of a hassle. It’s already made tremendous steps in the past few years, and this is the icing on the cake.

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SpaceX Starship Flight 10: What to expect

SpaceX implemented hardware and operational changes aimed at improving Starship’s reliability.

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Credit: SpaceX

SpaceX is preparing to launch the tenth test flight of its Starship vehicle as early as Sunday, August 24, with the launch window opening at 6:30 p.m. CT. 

The mission follows investigations into anomalies from earlier flights, including the loss of Starship on its ninth test and a Ship 36 static fire issue. SpaceX has since implemented hardware and operational changes aimed at improving Starship’s reliability.

Booster landing burns and flight experiments

The upcoming Starship Flight 10 will expand Super Heavy’s flight envelope with multiple landing burn trials. Following stage separation, the booster will attempt a controlled flip and boostback burn before heading to an offshore splashdown in the Gulf of America. One of the three center engines typically used for landing will be intentionally disabled, allowing engineers to evaluate whether a backup engine can complete the maneuver, according to a post from SpaceX.

The booster will also transition to a two-engine configuration for the final phase, hovering briefly above the water before shutdown and drop. These experiments are designed to simulate off-nominal scenarios and generate real-world data on performance under varying conditions, while maximizing propellant use during ascent to enable heavier payloads.

Starship upper stage reentry tests

The Starship upper stage will attempt multiple in-space objectives, including deployment of eight Starlink simulators and a planned Raptor engine relight. SpaceX will also continue testing reentry systems with several modifications. A section of thermal protection tiles has been removed to expose vulnerable areas, while new metallic tile designs, including one with active cooling, will be trialed.

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Catch fittings have been installed to evaluate their thermal and structural performance, and adjustments to the tile line will address hot spots observed on Flight 6. The reentry profile is expected to push the structural limits of Starship’s rear flaps at maximum entry pressure.

SpaceX says lessons from these tests are critical to refining the next-generation Starship and Super Heavy vehicles. With Starfactory production ramping in Texas and new launch infrastructure under development in Florida, the company is pushing to hit its goal of achieving a fully reusable orbital launch system.

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