vcor
Tech Specialist
We will not know for many years if the new structural pack delivers on reliability. Many new design changes should result in better long-term reliability:...I don't see how structural battery helps the key factory on battery reliability....
1) Fewer electrical connections are a huge advantage. Every connection is a weak point that may fail over time due to corrosion or vibration. The structural pack has about 1/10 the number of connections, so failures from this should be about 1/10 that of other packs.
2) Reduced coolant connections - again, every connection is a risk point for failure. The fewer connections, resulting in fewer risk points. The structural pack has the fewest fluid connections of any pack to date.
3) Reduced number of coolant pipes. Using larger cells reduces the number of coolant channels required. This may increase reliability, although I've never heard of these failing even on the oldest packs.
4) Sealed BMS electronics. It appears the BMS electronics are far better sealed than in prior packs. While this makes the BMS electronics impossible to be fixed, it also shields them from the most common problem - corrosion of connections.
5) Sealing the entire pack in rigid foam further reduces vibration failure risks.
6) The 4680 battery cell design should be more reliable. The internal tab design will have little effect if a tab breaks internally as there are hundreds of tabs within the cell. On prior cells, a broken tab means the cell becomes open. Again, this has yet to be proven, but I suspect making a more reliable cell was a major consideration in the new cell design.