During the 2024 Shareholder Meeting, Elon Musk announced that Tesla has made new innovations on the 4680 cell standard. Tesla has been working hard for several years to get a functional 4680 cell in production that either matches or beats the performance of the existing 2170 cell. The official Cybertruck account also shared an image (below) of the first 4680 dry-cathode process Cybertruck with its production crew on X.
We’re going to take a bit of a dive into the 4680, what exactly this new process and cell is, and then some of its possible advantages. So, grab your charging cable!
First prototype Cybertruck with in-house dry cathode 4680 cells – making it an all dry electrode vehicle pic.twitter.com/NzJxKQrRBp
Dry Battery Electrode (DBE) is a different process overall from the current Wet Battery Electrode (WBE) that is common today. This dry process removes the highly toxic solvents and furnace baking processes from the equation, saving both time and space, while also being environmentally friendly.
The Dry Cathode we’re talking about specifically means that the electrode – the conducting terminal at the edges of the battery – is produced in a dry process. In the previous process, it was produced with a wet process.
Tesla’s 4680 cell suppliers – LG and Panasonic – have both been working hard to cut down on costs and ramp up their own 4680 cell production while Tesla works on their own internal improvements as well. If Tesla has found a means to easily scale the Dry Cathode method, it’ll make 4680 cells and the batteries that they are a part of - cheaper to produce.
The 4680 Cell
The 4680 cell - 46mm wide, 80mm tall
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Tesla has used the 4680 cells to make structural battery packs for the Model Y. However, these vehicles had poor charging performance and lower energy density, and they were quickly removed from sales. The sheer size of the 4680 cell made it difficult to cool, limiting its performance.
The updated 4680 cell was announced at the November 2023 Earnings Call as Cybercell, making a comeback for the Cybertruck. This new version was going to have better energy density, as well as improved charging performance.
Sandy Munro of Teardown Titan fame showed that this improved version has about a 12% energy density increase, a pretty significant improvement. You can watch his teardown of the Cybertruck below.
Tabless Design
The tabless design of the 4680 cell also has an impact on its production, and how easy it is to manufacture. Think of the tabs as the little nubs on the top of a regular small battery. The lack of tabs means that production of the cell body doesn’t have to pause to add the tabs, reducing the chance for defects with the elimination of a process, and making it faster to boot.
Removing the tab also helps in cutting down the distance that electrons have to travel to get in and out of the cell – this means less resistance, and less energy lost in the process, increasing overall vehicle efficiency.
Advantages
This new 4680 cell process has a few advantages – including an overall cost reduction of up to 50% compared to the current wet process. That’s in addition to the dry process being more environmentally friendly, which will also allow for manufacturing of the cell to scale quicker.
Tesla wants to move from the standard 2170 cell to the 4680 cell for several reasons. The biggest, by far, is cost savings. The 4680 cell is physically a bigger cell and can be used to structurally support the vehicle, meaning cost savings on both, the production of the 4680 cell and the structure of the vehicle.
Easy and Cheap
There’s more too – the 4680 cell will be easier to manufacture because of its bigger size. The 2170 cell is tall and thin, while the 4680 cell is wide and stout. In addition, its unique tab-less design is supposed to generate less resistance, improving charging speeds and cell performance.
Essentially, Tesla can fill the space taken up by 4,400 2170 cells with only 960 4680 cells. This results in a significant reduction in the material used to encase each individual cell, thereby saving space and maximizing energy density for the space the battery pack takes up.
All in all, that could mean a future price drop for the Cybertruck as well as increase the rate of production. Tesla has envisioned producing approximately 250,000 Cybertrucks per year, and they’ll need a lot of 4680 battery packs to do so.
In the future, we can see Tesla bringing the 4680 cell with all these improvements - and more - to the rest of its vehicle lineup, as they will eventually surpass the 2170 cell technology.
Tesla has filed four patents for wireless charging. Previously, Tesla acquired the experience and skills of Wiferion’s engineering team in an acquisition in June 2023. Tesla quickly sold off the company but kept the company’s engineers. This was an acqui-hire, where large companies rapidly onboard top talent by purchasing a company for human capital, rather than products, services, or intellectual products.
Following the Wiferion acquisition, Tesla showed off a wireless charging mat several times and even confirmed they are working on wireless inductive home charging. We expected this to arrive with the Cybertruck, but now we hope to see more details at the upcoming Robotaxi reveal event in October, at the Warner Bro.’s studio in Hollywood.
Wireless Charging Patents
First Patent
The first of the four patents looks at temperature sensors and applications for wireless charging. Tesla intends to track the temperatures across both the wireless charging pad, as well as the inductive charging coils in the vehicle. The third patent details how they’re planning to use this in an innovative way.
WIPO
Second Patent
The second patent is a shorting switch, which is designed to prevent or reduce leakage of energy to ground sources near the wireless charging mat. This shorting switch is used to create a short with the receiving side of the inductive charging, essentially making energy transfer faster and more efficient – while also reducing the amount of energy that is leaked out elsewhere. We’ll leave this one for the electrical engineers to explain in our forums.
Third Patent
The third patent is actually the wireless charging circuit itself, and how to manufacture it. This one is straightforward and explains how Tesla intends to design and build the prototype inductive wireless charging mats. Beyond the basic design, this document also details how Tesla intends to lay out the inductive charging coils and how it expects the entire assembly to function – which includes a small cable that runs to a wall-mounted energy source.
Fourth Patent
The final patent is for intelligently estimating and adapting to variations in wireless charging layouts and systems. This one is probably the most interesting of the four patents, as it involves adjusting the coils in the mat to dynamically account for the positioning of the vehicle, as well as responding to the information from the first patent – the temperature sensors.
Essentially, by varying the coil induction across the mat, Tesla intends to dynamically aim the wireless charger at different parts of the inductive coils in the vehicle, thereby reducing heat. This patent will also help Tesla to determine the adequate charge speed and other key information they may need to relay to the vehicle, or back to fleet management software.
Cybertruck Inductive Charging
While the Cybertruck never actually arrived with inductive charging, it was noted in the Service Manual to have 2 Inductive Charging Headers, so it is ready to be upgraded to have Inductive Charging support. We expect that Tesla will release this as a purchasable upgrade for the Cybertruck sometime in the future – likely as a package with the Inductive Charging Mat.
Robotaxi Inductive Charging
The Robotaxi will likely be the first of Tesla’s vehicles to feature inductive charging – which. makes sense given its autonomous nature. Plugging in a NACS charger will likely be fairly difficult to automate, and the 5-10% efficiency loss of wireless charging isn’t a huge deal. It’s possible Tesla chose this route due to cost, as having an automated NACS cable like the “snake” prototype we saw years ago could be costly.
Having a simple parking stall with an inductive mat on it, alongside all the tech and supplies needed to automatically clean and sanitize the Robotaxi makes far more sense. This means that a Robotaxi will be able to roll in, charge and clean itself, and then roll out to go pick up more customers. Tesla is planning a super-efficient system here that requires minimal intervention from real humans.
Essentially, by effectively managing the Robotaxi fleet, Tesla can offset the increased time that wireless charging would take, and also reduce the amount of waste energy by charging when energy is cheapest. While this could prevent Tesla from taking advantage of the sheer battery mass of a Robotaxi fleet – by selling power when it’s expensive and travel demand is low – this doesn’t make it impossible.
Smartphone manufacturers have demonstrated reverse wireless charging with the inductive charging coils already present in modern smartphones. We could see Tesla low-power bi-directional charging in the future too.
We’re looking forward to seeing Tesla unveil this at the upcoming Robotaxi event. It’ll be something special, for sure.
Tesla has made a spate of improvements to its vehicle software recently, starting with the big Spring Update, and then the Summer Update more recently. While we see most of the updates mentioned in the release notes, Tesla often also adds smaller quality-of-life improvements along the way.
Browser Controls
When using the Tesla Browser in the vehicle, you can now swipe left and right to go back or forward a page in your browser history. When you start swiping on the screen, Tesla’s Chromium-based browser will now display an arrow that slides out from the left or right. The circular icon is initially white, meaning that the action won’t be executed, but if you continue moving to the left/right, the icon will eventually turn blue. The blue icon means that the action will be executed once you let go of the screen.
This is a simple quality-of-life improvement that makes using the built-in browser easier.
We’re happy to see updates like these come to the browser, whose last major feature was the full-screen button that was added in update 2024.14.
Future Browser Improvements
While we’re on the topic, let’s look at some future Tesla web browser improvements we’d love to see.
Access to the Mic
Full access to the vehicle microphone isn’t allowed through the web browser right now. That means if you want to get into a Discord, Slack, or Teams call, you’ll only be able to listen – not speak. All of these apps fully function in the Tesla browser for sending messages, but are fairly limited for meetings.
Better Bookmarks
Tesla’s current bookmark system is simple and barebones. You can bookmark a page and give it a name. Once you visit a bookmarked page enough, it’ll show up as an icon in the center of the browser when you go to the homepage.
However, it's difficult to keep a larger set of bookmarks since there aren’t any organizational tools provided. A better bookmark system or the ability to sync bookmarks would be a welcomed feature.
Custom Homepage
Tesla’s current homepage in its browser is simply just a Tesla logo in black or white, depending on whether your car is in dark mode or not. A custom homepage that provides widgets with basic local news, stock information or other details would be fantastic. We’d ask for weather too, but the recent Summer update shows weather at the top of your screen.
If you’ve got more ideas for the fairly barebones Tesla web browser, let us know.
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