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

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.

“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.
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Tesla rolls out new Supercharging safety feature in the U.S.
Tesla has rolled out a new Supercharging safety feature in the United States, one that will answer concerns that some owners may have if they need to leave in a pinch.
It is also a suitable alternative for non-Tesla chargers, like third-party options that feature J1772 or CCS to NACS adapters.
The feature has been available in Europe for some time, but it is now rolling out to Model 3 and Model Y owners in the U.S.
With Software Update 2026.2.3, Tesla is launching the Unlatching Charge Cable function, which will now utilize the left rear door handle to release the charging cable from the port. The release notes state:
“Charging can now be stopped and the charge cable released by pulling and holding the rear left door handle for three seconds, provided the vehicle is unlocked, and a recognized key is nearby. This is especially useful when the charge cable doesn’t have an unlatch button. You can still release the cable using the vehicle touchscreen or the Tesla app.”
The feature was first spotted by Not a Tesla App.
This is an especially nice feature for those who commonly charge at third-party locations that utilize plugs that are not NACS, which is the Tesla standard.
For example, after plugging into a J1772 charger, you will still be required to unlock the port through the touchscreen, which is a minor inconvenience, but an inconvenience nonetheless.
Additionally, it could be viewed as a safety feature, especially if you’re in need of unlocking the charger from your car in a pinch. Simply holding open the handle on the rear driver’s door will now unhatch the port from the car, allowing you to pull it out and place it back in its housing.
This feature is currently only available on the Model 3 and Model Y, so Model S, Model X, and Cybertruck owners will have to wait for a different solution to this particular feature.
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LG Energy Solution pursuing battery deal for Tesla Optimus, other humanoid robots: report
Optimus is expected to be one of Tesla’s most ambitious projects, with Elon Musk estimating that the humanoid robot could be the company’s most important product.
A recent report has suggested that LG Energy Solution is in discussions to supply batteries for Tesla’s Optimus humanoid robot.
Optimus is expected to be one of Tesla’s most ambitious projects, with Elon Musk estimating that the humanoid robot could be the company’s most important product.
Humanoid robot battery deals
LG Energy Solution shares jumped more than 11% on the 28th after a report from the Korea Economic Daily claimed that the company is pursuing battery supply and joint development agreements with several humanoid robot makers. These reportedly include Tesla, which is developing Optimus, as well as multiple Chinese robotics companies.
China is already home to several leading battery manufacturers, such as CATL and BYD, making the robot makers’ reported interest in LG Energy Solution quite interesting. Market participants interpreted the reported outreach as a signal that performance requirements for humanoid robots may favor battery chemistries developed by companies like LG.
LF Energy Solution vs rivals
According to the report, energy density is believed to be the primary reason humanoid robot developers are evaluating LG Energy Solution’s batteries. Unlike electric vehicles, humanoid robots have significantly less space available for battery packs while requiring substantial power to operate dozens of joint motors and onboard artificial intelligence processors.
LG Energy Solution’s ternary lithium batteries offer higher energy density compared with rivals’ lithium iron phosphate (LFP) batteries, which are widely used by Chinese EV manufacturers. That advantage could prove critical for humanoid robots, where runtime, weight, and compact packaging are key design constraints.
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Tesla receives approval for FSD Supervised tests in Sweden
Tesla confirmed that it has been granted permission to test FSD Supervised vehicles across Sweden in a press release.
Tesla has received regulatory approval to begin tests of its Full Self-Driving Supervised system on public roads in Sweden, a notable step in the company’s efforts to secure FSD approval for the wider European market.
FSD Supervised testing in Sweden
Tesla confirmed that it has been granted permission to test FSD Supervised vehicles across Sweden following cooperation with national authorities and local municipalities. The approval covers the Swedish Transport Administration’s entire road network, as well as urban and highways in the Municipality of Nacka.
Tesla shared some insights into its recent FSD approvals in a press release. “The approval shows that cooperation between authorities, municipalities and businesses enables technological leaps and Nacka Municipality is the first to become part of the transport system of the future. The fact that the driving of the future is also being tested on Swedish roads is an important step in the development towards autonomy in real everyday traffic,” the company noted.
With approval secured for FSD tests, Tesla can now evaluate the system’s performance in diverse environments, including dense urban areas and high-speed roadways across Sweden, as noted in a report from Allt Om Elbil. Tesla highlighted that the continued development of advanced driver assistance systems is expected to pave the way for improved traffic safety, increased accessibility, and lower emissions, particularly in populated city centers.
Tesla FSD Supervised Europe rollout
FSD Supervised is already available to drivers in several global markets, including Australia, Canada, China, Mexico, New Zealand, and the United States. The system is capable of handling city and highway driving tasks such as steering, acceleration, braking, and lane changes, though it still requires drivers to supervise the vehicle’s operations.
Tesla has stated that FSD Supervised has accumulated extensive driving data from its existing markets. In Europe, however, deployment remains subject to regulatory approval, with Tesla currently awaiting clearance from relevant authorities.
The company reiterated that it expects to start rolling out FSD Supervised to European customers in early 2026, pending approvals. It would then be unsurprising if the company secures approvals for FSD tests in other European territories in the coming months.