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Tesla structural battery pack patent hints at clever contingencies for crashes, cell failures

Credit: Tesla

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Tesla’s next generation of vehicles like the Cybertruck and the Made-in-Texas Model Y will likely be built with a structural battery pack. Together with the company’s 4680 cells and megacasted parts, Tesla’s integrated battery system is expected to improve its vehicles’ mass and range significantly. 

During Battery Day, Elon Musk explained that the use of structural batteries on electric cars could be compared to how passenger aircraft eventually used their wings to store fuel. In the case of airplanes, the weight of the fuel actually provided rigidity to the wing, reducing wing flutter, or the vibrations of the wings due to airflow. Musk noted that a structural battery pack could provide a 10% mass reduction and an opportunity for a 12% range increase for its vehicles. 

Credit: US Patent Office

A recently published patent for Tesla’s structural battery pack reveals that the EV maker did not only look at cost reduction and range improvements when it was developing its next-generation batteries. Tesla also looked at how the structural battery packs could help maintain–if not improve–its vehicles’ safety. This was hinted at in the patent’s detailed description, which reveals that the bottom layer of the structural battery would be created from a strong, stiff material that is also capable of deforming in the event of a crash. 

Tesla’s structural battery pack patent also outlined how parts of the integrated energy system are designed to allow gasses to escape from the battery in the event that a cell becomes damaged. Following is the pertinent section from Tesla’s structural battery pack patent. 

“Illustratively, an integrated, unitary battery pack may be formed and used as part of the structural support for a vehicle frame. For example, the battery pack may include a bottom layer that is formed from a honeycomb or ridged surface which is mechanically linked to cells within the battery pack. The bottom layer is designed so that it can absorb and distribute impact energy from below, mitigating potential damage sensitive battery materials or breach of the sealed battery pack enclosure. 

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Credit: US Patent Office

“In one embodiment, the bottom layer is made from a material that has sufficient stiffness and strength to support the battery cells and react mechanical loads from normal vehicle operation, but also can deform in response to a road strike from below that would otherwise cause failure in the battery pack system. In addition to creating a flexible or crushable structure, the series of ridges can allow gasses to escape from the battery pack should damage occur to a particular cell, or in the event of a thermal runaway occurring within one or more cells of the battery pack.”

Tesla’s vehicles are famed for their excellent safety ratings. Built without a heavy internal combustion engine in front, Tesla’s EVs feature generous crumple zones that help absorb the impact in a collision. If the EV maker’s structural batteries really make its cars more structurally sound, then Tesla could further establish itself as the maker of the safest cars on the road, bar none. 

Tesla’s full patent for its structural battery pack could be viewed here

Don’t hesitate to contact us for news tips. Just send a message to tips@teslarati.com to give us a heads up.

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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 hasn’t adopted Apple CarPlay yet for this shocking reason

Many Apple and iPhone users have wanted the addition, especially to utilize third-party Navigation apps like Waze, which is a popular alternative. Getting apps outside of Tesla’s Navigation to work with its Full Self-Driving suite seems to be a potential issue the company will have to work through as well.

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Credit: Michał Gapiński/YouTube

Perhaps one of the most requested features for Tesla vehicles by owners is the addition of Apple CarPlay. It sounds like the company wants to bring the popular UI to its cars, but there are a few bottlenecks preventing it from doing so.

The biggest reason why CarPlay has not made its way to Teslas yet might shock you.

According to Bloomberg‘s Mark Gurman, Tesla is still working on bringing CarPlay to its vehicles. There are two primary reasons why Tesla has not done it quite yet: App compatibility issues and, most importantly, there are incredibly low adoption rates of iOS 26.

Tesla’s Apple CarPlay ambitions are not dead, they’re still in the works

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iOS 26 is Apple’s most recent software version, which was released back in September 2025. It introduced a major redesign to the overall operating system, especially its aesthetic, with the rollout of “Liquid Glass.”

However, despite the many changes and updates, Apple users have not been too keen on the iOS 26 update, and the low adoption rates have been a major sticking point for Tesla as it looks to develop a potential alternative for its in-house UI.

It was first rumored that Tesla was planning to bring CarPlay out in its cars late last year. Many Apple and iPhone users have wanted the addition, especially to utilize third-party Navigation apps like Waze, which is a popular alternative. Getting apps outside of Tesla’s Navigation to work with its Full Self-Driving suite seems to be a potential issue the company will have to work through as well.

According to the report, Tesla asked Apple to make some changes to improve compatibility between its software and Apple Maps:

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“Tesla asked Apple to make engineering changes to Maps to improve compatibility. The iPhone maker agreed and implemented the adjustments in a bug fix update to iOS 26 and the latest version of CarPlay.”

Gurman also said that there were some issues with turn-by-turn guidance from Tesla’s maps app, and it did not properly sync up with Apple Maps during FSD operation. This is something that needs to be resolved before it is rolled out.

There is no listed launch date, nor has there been any coding revealed that would indicate Apple CarPlay is close to being launched within Tesla vehicles.

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Starlink restrictions are hitting Russian battlefield comms: report

The restrictions have reportedly disrupted Moscow’s drone coordination and frontline communications.

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A truckload of Starlink dishes has arrived in Ukraine. (Credit: Mykhailo Fedorov/Twitter)

SpaceX’s decision to disable unauthorized Starlink terminals in Ukraine is now being felt on the battlefield, with Ukrainian commanders reporting that Russian troops have struggled to maintain assault operations without access to the satellite network. 

The restrictions have reportedly disrupted Moscow’s drone coordination and frontline communications.

Lt. Denis Yaroslavsky, who commands a special reconnaissance unit, stated that Russian assault activity noticeably declined for several days after the shutdown. “For three to four days after the shutdown, they really reduced the assault operations,” Yaroslavsky said.

Russian units had allegedly obtained Starlink terminals through black market channels and mounted them on drones and weapons systems, despite service terms prohibiting offensive military use. Once those terminals were blocked, commanders on the Ukrainian side reported improved battlefield ratios, as noted in a New York Post report.

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A Ukrainian unit commander stated that casualty imbalances widened after the cutoff. “On any given day, depending on your scale of analysis, my sector was already achieving 20:1 (casuality rate) before the shutdown, and we are an elite unit. Regular units have no problem going 5:1 or 8:1. With Starlink down, 13:1 (casualty rate) for a regular unit is easy,” the unit commander said.

The restrictions come as Russia faces heavy challenges across multiple fronts. A late January report from the Center for Strategic and International Studies estimated that more than 1.2 million Russian troops have been killed, wounded, or gone missing since February 2022.

The Washington-based Institute for the Study of War also noted that activity from Russia’s Rubikon drone unit declined after Feb. 1, suggesting communications constraints from Starlink’s restrictions may be limiting operations. “I’m sure the Russians have (alternative options), but it takes time to maximize their implementation and this (would take) at least four to six months,” Yaroslavsky noted. 

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Tesla Korea hiring AI Chip Engineers amid push for high-volume AI chips

Tesla Korea stated that it is seeking “talented individuals to join in developing the world’s highest-level mass-produced AI chips.”

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Credit: xAI/X

In a recent post on X, Tesla Korea announced that it is hiring AI Chip Design Engineers as part of a project aimed at developing what the company describes as the world’s highest-volume AI chips. CEO Elon Musk later amplified the initiative.

Tesla Korea stated that it is seeking “talented individuals to join in developing the world’s highest-level mass-produced AI chips.”

“This project aims to develop AI chip architecture that will achieve the highest production volume in the world in the future,” Tesla Korea wrote in its post on X.

As per Tesla Korea, those who wish to apply for the AI Chip Design Engineer post should email Ai_Chips@Tesla.com and include “the three most challenging technical problems you have solved.”

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Elon Musk echoed the hiring push in a separate post. “If you’re in Korea and want to work on chip design, fabrication or AI software, join Tesla!” he wrote.

The recruitment effort in South Korea comes as Tesla accelerates development of its in-house AI chips, which power its Full Self-Driving (FSD) system, Optimus humanoid robot, and data center training infrastructure.

Tesla has been steadily expanding its silicon development teams globally. In recent months, the company has posted roles in Austin and Palo Alto for silicon module process engineers across lithography, etching, and other chip fabrication disciplines, as noted in a Benzinga report.

Tesla Korea’s hiring efforts align with the company’s long-term goal of designing and producing AI chips at massive scale. Musk has previously stated that Tesla’s future AI chips could become the highest-volume AI processors in the world.

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The move also comes amid Tesla’s broader expansion into AI initiatives. The company recently committed about $2 billion into xAI as part of a Series E funding round, reinforcing its focus on artificial intelligence across vehicles, robotics, and compute infrastructure.

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