Jordan from The Limiting Factor has a new streamed video about the Tabless Patent. He is excited. Link and my partial transcript:
Tabless Patent: The Limiting Factor
There is a triangle of competition amongst discharge and charge rate, cathode thickness, and cell volume. You can’t do all of those things at the same time.
If you crank the discharge and charge rate up too high, or make the cathode too thick, or make the cell too large, it creates too much heat. Of course, discharge and charge rate are positives. If you increase the cathode thickness by 25%, you get a 10% specific energy increase, e.g. from 300 Wh/kg to 330 Wh/kg. And if you increase the cell internal volume by 30 %, that reduces the number of cells you need to create by 30%, which makes it a lot cheaper and easier to manufacture the battery pack (30% fewer welds, separators, cell cans, etc.).
There are 2 ways to "shrink the triangle" to try to fix all of this at once.
The first is Maxwell’s dry electrode technology which uses less additive material, and because the additive material isn’t being corroded by a liquid solvent, the electrons are able to get out of the cell much more quickly, which creates less resistance and therefore less heat.
The other way to combat it is to improve the thermal management system of the battery. Those are the only two solutions that Jordan at The Limiting Factor says he has been able to come up with.
Currently what happens is that the electrons get in and out of the cell through on of two little tabs which is a huge-ass bottleneck, going through all the spirals and reaching one of two little tabs.
Tesla has said the best part is no part, and gotten rid of the tabs.
How is the cathode or anode material going to get to the collector and get to the battery if you don’t have those tabs? They have created an offset at the top of the battery cell, so all you have to do is put some conductive adhesive on the top and the bottom, jam it into the cell, and and all of the electrons can access it at any point from any layer, and you don’t have to fiddle around with those little tabs and weld those fickle little pieces of metal to each other.
A. That makes the manufacturing a lot easier
B. If you’re an electron trying to get through all of that mess and all of that maze, you’re bumping into a lot fewer other pieces of material, and if you’re bumping into fewer pieces of material, it’s creating less heat because there is less friction. That adds a way that we can solve our triangle problem.
The implications of this: Jordan says it looks like this means that Tesla should be able to greatly simplify the manufacturing process by making the cells bigger, so they need fewer cell cans, fewer tabs, less tab welding, fewer separators – all of a sudden, the number of pieces of each material could be cut by 30-70% depending on how big they make the diameter of the battery cells. It also allows for increased discharge and charge rates, because there is less heat generated by the little silver beer cans. It also means increased energy capacity because whenever you keep the can thickness the same and increase the internal volume, the proportion of this metal decreases as the cell gets bigger, so you get more energy capacity per given volume. So you should be able to increase the energy density and potentially increase the cathode thickness. If they can even increase the cathode thickness by 10%, they’d be getting another 3-5% specific energy capacity. This is really cool.
Jordan was hoping Tesla would unleash something straight out of left field that he hadn’t anticipated, and this is it.