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Tesla explores safer battery production with novel DCM recovery system patent

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In what appears to be yet another step towards its goal of operating the safest car factory in the industry, Tesla has been granted a patent that could pave the way for a safer process in battery production. Published today, the electric car maker’s recent patent describes a system to treat and recycle Dichloromethane (DCM), which is among the materials used in the production of electric car batteries.

DCM is utilized in a variety of industrial processes, particularly in chemical plastic welding, wherein softened plastic pieces or surfaces are welded together. The material is also used to soften plastic sheets for stretching or shaping, and as a solvent to remove unwanted compounds. In Tesla’s case, DCM is among the materials used in the forming of a separator base film for an electric car’s battery system. While DCM is invaluable in manufacturing, though, the material carries some health risks.

Dichloromethane is the least toxic among the simple chlorohydrocarbons, but its high volatility makes it an inhalation hazard nonetheless. Prolonged skin contact with DCM could also result in the material dissolving some of the skin’s fatty tissues, causing irritation or chemical burns. With these risks in mind, the manufacturing industry employs ways to recover DCM. Tesla notes that current systems for DCM treatment and recovery are capital intensive, particularly since the process involves expensive components such as activated carbon beds, condensers, steam boilers and distribution systems, density separation vessels, and waste water treatment systems.

Tesla’s diagrams outlining its Dichloromethane recovery system. [Credit: US Patent Office]

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Tesla describes conventional DCM treatment systems as follows:

“The DCM itself may then be removed through a heating and/or evaporation process with the exhaust collected. This exhaust containing DCM is then combined with the exhaust from other tools and systems used in the manufacturing process. The combined exhaust may then be fed to a recovery plant to recover DCM. In the recovery plant, the waste exhaust stream is typically treated with activated carbon. This scrubbing process requires high capital expenditure (many expensive components), high operating cost (extensive steam and cooling water consumption which accounts for >20% of total process cost), large footprint requirements, and large amounts of waste water that need to be processed. In order to address these cost and environmental-remediation issues, an improved process for the removal of DCM from exhaust streams is needed.”

Tesla’s take on DCM treatment and recovery utilizes a wet scrubber and a density separator vessel as key components of the system. The wet scrubber in Tesla’s patent has a scrubbing chamber, where water is utilized to scrub the waste exhaust stream containing the DCM. Tesla notes that the wet scrubber could adopt a variety of designs to remove DCM from the waste exhaust stream, including a venturi scrubber design, a condensation scrubber design, an impingement-plate scrubber design, or a packed bed tower design, among others.

Tesla’s use of a density separator vessel is described in the following section from the patent.

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“The density separator vessel has an inlet to receive the liquid water and DCM mixture, an outlet to expel DCM, and an outlet to expel waste water. The DCM may be routed back to the industrial process for reuse and/or collected for later use. The waste water may be routed back to the wet scrubber, as shown along (the) waste water return loop. Waste water may also or alternately be routed to waste water treatment system for processing for subsequent treatment by (the) waste water treatment system.

“Typically, a large portion of the waste water is returned to the wet scrubber via (the) waste water return loop and a small portion of the waste water is treated by the waste water treatment system. Even though the waste water may contain small amounts of DCM, the waste water will still retain its ability to scrub the exhaust containing DCM. An advantage of the wet scrubber over the activated carbon beds is that all or most of the water used by the wet scrubber is the waste water from the density separator vessel, resulting in substantial savings of water and energy, and resultantly, substantial cost savings.”

Tesla states that compared to more traditional exhaust treatment systems, the DCM treatment and recovery model outlined in its patent effectively eliminates the use of steam and cooling, while also reducing the amount of throughput needed by a waste water system. With these efficiencies in mind, Tesla notes that it could reduce capital expenditures and operating costs “for the same amount of DCM processed processing.” The increased simplicity of the system and reduced airflow rates are expected to help the company get more savings in both capital expenditures and operating costs as well.

More than a way to optimize its operations, Tesla’s recent patent is also a notable way for the company to keep its battery production lines safer for its employees. Such a system would definitely be invaluable for the company, particularly as Tesla is now preparing the Model 3 for a global rollout. With the Model 3 ramp ever-expanding, and with high-volume vehicles like the Model Y and possibly the Tesla pickup truck in the pipeline, optimizations such as a better DCM treatment and recovery system are all but necessary.

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Tesla’s recently published patent on its DCM treatment system could be accessed here.

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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Investor's Corner

Tesla crushes Wall Street expectations, beats delivery estimates by over 15 percent

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Tesla (NASDAQ: TSLA) beat Wall Street expectations of 406,000 vehicles delivered in Q2 by reporting 480,126 deliveries for the three months ending in June.

Tesla reported it delivered 467,762  Model 3 and Model Y units, while 12,364 Model S, Model X, and Cybertrucks switched hands during the quarter. The Model S and Model X were officially sunset this past quarter and will no longer be part of the company’s Production & Delivery reports moving forward.

The quarter is a pleasant surprise and a good rebound from Q1, when Tesla slightly missed the Wall Street consensus of 365,645 cars by reporting 358,023 deliveries for the first three motnhs of the year.

Energy storage deployments also provided some strength in Tesla’s delivery report, hitting 13.5 GWh for Q2. This is a particular division of Tesla’s business that has been overwhelmingly robust over the past few years, truly being a strong point of the company’s overall model.

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For the year, Tesla analysts still predict deliveries to trend in the 1.69 million unit region, a modest 3 to 5 percent increase from the 1.64 million cars the company delivered last year. Tesla will likely return to more sequential and noticeable year-over-year growth as the Cybercab project starts to ramp up considerably in the next few years.

Tesla has some other potential catalysts to spur vehicle deliveries, too. Not only is it expecting Cybercab to truly start making a change in the next few years, but other vehicles could be entering the company’s lineup.

Tesla sends production Cybercab with no steering wheel, pedals to on-road testing

The slightly longer Model Y L has been a highly speculated release candidate in the U.S. It has already done incredibly well in China, and U.S. buyers have been wanting slightly more interior space than the Model Y. Now that the Model X is gone, it is more needed than ever.

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Q2 highlights a pretty stable automotive division within Tesla, and no true concerns arise from these figures, especially considering it managed to beat expectations convincingly.

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Tesla gets its latest short from Michael Burry: ‘Happy it jumped back to this level’

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Credit: MarcoRP | X

Tesla short seller Michael Burry, the subject of the film “The Big Short,” where he was portrayed by Steve Carell, has revealed he has opened a new bet against the stock.

In a new update to his Substack newsletter in a post titled “Trading Post June 30, 2026,” Burry revealed a new set of bets against Tesla, Caterpillar, NVIDIA, Applied Materials Inc., and the iShares Semiconductor ETF.

In regard to Tesla, Burry wrote:

“And finally I shorted Tesla at 416.22. Happy it jumped back to this level.”

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This means Burry likely opened his new short position after the company’s recent rally on Wall Street, which saw Tesla shares sink in mid-May, only to recover to well over the $400 mark. Currently, shares trade at around $427.

The company saw a big Tuesday as shares climbed considerably, over 10 percent. The size of the Tesla short was not provided, nor did Burry give any information on the position’s structure, the number of shares, dollar value, or whether options were used in the short.

The Tesla and SpaceX merger everyone is talking about is quietly building

Over the years, Burry has been one of the more vocal critics of Tesla, calling its share price “media inflated,” and saying it was “ridiculously overvalued” as recently as December.

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The company has largely transitioned away from being known as an automotive company and instead is much more widely regarded as an AI play, mostly due to its Full Self-Driving efforts, Optimus robot development, and data collection related to both.

This has not pulled those skeptics away from being vocal about their distaste for how Tesla is valued, but there’s no denying that the company is a global force in many things, including sustainable energy, automotive, and AI.

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Investor's Corner

SpaceX gets initial stock coverage from Tesla’s biggest bull

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SpaceX Starship V3 flight 12
SpaceX Starship V3 flight 12 (Credit: SpaceX)

Wedbush Securities is initiating stock coverage on SpaceX (NASDAQ: SPCX), marking the first comments on the company since it went public several weeks ago. Wedbush and its analyst handling coverage, Dan Ives, are widely bullish on fellow Musk company Tesla (NASDAQ: TSLA).

Ives wrote his first note initiating coverage of SpaceX shares on Wednesday with a $190 price target and an ‘Outperform’ rating. The firm believes the company is well positioned off of its IPO because of its wide array of projects, including AI compute power and infrastructure, connectivity projects, and launches.

“We view SpaceX as one of the most differentiated assets within the tech market with a strong footprint across its three core markets, with Starlink driving success with connectivity,” Ives wrote, “Starship launches leading to a demand flywheel and increasing deal flow for its Colossus clusters.”

Elon Musk called it Epic: The full story of SpaceX’s Starship Flight 12

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Wedbush leans heavily on Starlink, which they say is the “profitability driver given the strength of its recurring revenue base of ~12 million subscribers as of June 5th.” Ives believes Starlink is still in the “early innings” of penetrating the global telecommunications and broadband market, as it only holds less than a 1 percent share. However, this number is sure to increase over time.

It also highlights the importance of Starship, which it says is an “essential layer” of SpaceX’s overall success. SpaceX developing and displaying the ability to reuse rockets is a major cost and reliability advantage “as it reduces the necessary hardware launch costs while generating a feedback loop for future flights to improve their launch flight rate without accelerating capex spend.”

Finally, SpaceX’s recent AI/Compute projects are also very elementary, Ives writes. It is worth mentioning Wedbush said its $190 price target is derived from a valuation forecast that sees the company yielding roughly $2.48 trillion of implied enterprise value.

There are also some factors that Wedbush did not take into account with its initial coverage. The firm wrote in the note:

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“We note that there is optional value coming from Starship’s accelerating scale towards sub-$200/kg unit economics, orbital data centers, and enterprise AI monetization as these factors could drive meaningful upside but these face major hurdles, so we do not take that into account with our valuation.”

SpaceX shares are down just over 2 percent today, trading at around $167 at the time of publication.

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