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Tesla patents porous tape to keep battery electrodes fully active

Patent drawing
Patent drawing from the official filing.

Tesla describes a new type of tape used inside batteries that is made of porous materials instead of solid plastic. This design allows the entire surface of the battery's electrodes to work, rather than having parts blocked by the tape, while still preventing electrical shorts.

Why it mattersThis could lead to batteries that use more of their internal material, potentially improving energy capacity or efficiency in electric vehicles and power storage systems.

In the filing’s own words

A porous barrier layer supporting tape for use in energy storages devices comprising a porous adhesive layer and a porous substrate, and methods thereof are disclosed. Porous barrier layer supporting tapes may allow active use of the entire electrode compared to conventional energy storage devices where sections of the electrode are typically rendered inactive by the impermeable barrier layer supporting tape. The porous barrier layer supporting tapes may further provide additional support to prevent short circuiting and provide protection from wear-related puncture over the life of the energy storage device.

What exactly they claim (claim 1)

1. An electrode assembly, comprising: a first electrode, wherein the first electrode comprises an electrode leading edge; a second electrode; and a porous barrier layer supporting tape positioned between the first electrode and the second electrode, wherein the porous barrier layer supporting tape comprises: a porous adhesive layer; and a porous substrate; wherein the porous adhesive layer is disposed directly over the porous substrate.

Facts

Company
Tesla (Tesla, Inc.)
Official title
POROUS BARRIER LAYER SUPPORTING TAPES FOR USE IN ENERGY STORAGE DEVICES, AND METHODS THEREOF
Publication number
US20260321936A1
Application number
19571354
Filed
Mar 18, 2026
Published
Oct 15, 2026
Inventors
3
Claims
23

Classified under

H01M 50/595 Electricity & electronicsC09J 5/00 Chemistry & metalsH01M 10/0587 Electricity & electronicsH01M 50/586 Electricity & electronicsC09J 2203/33 Chemistry & metals
Read the full filing (official PDF) ↗ Open in the Patent Tracker

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Summaries are simplified from the filing’s own abstract and first claim. A patent filing is not a product announcement.
Patent data and drawings: U.S. Patent and Trademark Office (USPTO). Nebula is not affiliated with or endorsed by the USPTO.