Tesla Motors Patent Applications
Tesla Motors patent applications that are pending before the United States Patent and Trademark Office (USPTO).
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Publication number: 20170184345Abstract: A heat-recovering oven system based on temperature gradient comprises: multiple chambers arranged in a sequence, the chambers configured for operating at various temperatures according to a temperature gradient arrangement that spans the sequence; a conveyor configured for transporting product through the multiple chambers in the sequence for heat treatment according to the temperature gradient arrangement; and multiple temperature-segregated heat exchanger systems, each heat exchanger system including a heat exchanger, a conduit to at least one of the chambers based on its temperature in the temperature gradient arrangement, and a return conduit from the at least one chamber to the heat exchanger.Type: ApplicationFiled: December 16, 2016Publication date: June 29, 2017Applicant: Tesla Motors, Inc.Inventors: Christopher Gandhi Van Dyke, Turner Boris Caldwell
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Publication number: 20170177048Abstract: An energy storage system includes: a host; energy storage modules; a plurality of nodes, each implemented at a corresponding one of the energy storage modules and configured to monitor and control that energy storage module; a communications and data transmission medium forming a loop from a first portion of the host and sequentially through the nodes to a second portion of the host; and in each of the nodes, first and second devices configured to perform at least partially redundant communication and data transmission functions using the communications and data transmission medium.Type: ApplicationFiled: April 2, 2015Publication date: June 22, 2017Applicant: Tesla Motors, Inc.Inventor: Ian C. Dimen
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Publication number: 20170162922Abstract: An energy storage pack includes a coolant inlet manifold, a coolant outlet manifold, and a plurality of thermal-exchange tubes extending between the coolant inlet manifold and the coolant outlet manifold to exchange heat between coolant passing through the plurality of thermal-exchange tubes and a plurality of battery cells mounted adjacent to and among the plurality of thermal-exchange tubes within the energy storage pack. In one embodiment, at least one of coolant inlet manifold and the coolant outlet manifold includes a plurality of thermal-exchange tube terminating structures and a plurality of hose segments intercoupling the plurality of thermal-exchange tube terminating structures. The energy storage pack may further include a coolant inlet opening located on the coolant inlet manifold and a coolant outlet opening located on the coolant outlet manifold.Type: ApplicationFiled: February 20, 2017Publication date: June 8, 2017Applicant: Tesla, Inc.Inventors: Robert David Sumpf, JR., Ernest Matthew Villanueva, David Elias Hegeman, Satvik Vipin Batavia, Ganesh Ramanarayan Singh, Alex Prilutsky, Scott Ira Kohn, Bruce Phillip Edwards, Peter Thomas Tennessen, Jayesh Bharat Gorasia, Hugh Burnett Ross
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Publication number: 20170152957Abstract: A multi-port, multi-mode valve includes: a valve housing; multiple ports on the valve housing, a spacing between first and second ports being smaller than a spacing between third and fourth ports; and a stemshell positioned at least partly inside the valve housing, the stemshell having at least two channels configured for selectively coupling one or more of the ports to a selected at least other one of the ports.Type: ApplicationFiled: November 30, 2016Publication date: June 1, 2017Applicant: Tesla Motors, Inc.Inventors: Nicholas Albert Roche, Joseph Stratford Maxwell Mardall, Jan Kopitz, Curt Raymond O'Donnell
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Publication number: 20170144717Abstract: A method for constructing an integrated end structure for a vehicle includes placing a center module for an integrated end structure for a vehicle in a fixture separate from the vehicle, attaching a side bracket to the center module in the fixture to form an assembly, the side bracket configured for holding a light unit of the vehicle, mounting the assembly onto at least a bracket in the vehicle that provides adjustability of the assembly in at least a z-direction, and, after mounting the assembly, mounting a storage compartment module onto the center module and the side bracket.Type: ApplicationFiled: December 16, 2016Publication date: May 25, 2017Applicant: Tesla Motors, Inc.Inventors: James Bellis, P Thomas Vikstrom
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Publication number: 20170130495Abstract: A closure system for a vehicle comprises: a dual-hinge closure comprising a first portion hinged to the vehicle by a first hinge, and a second portion hinged to the first portion by a second hinge; a frame that at least in part surrounds an opening in the vehicle; an adjustable bump stop subassembly mounted to the first portion, wherein the adjustable bump stop subassembly rests on the frame when the first portion is in a closed position; and a latch system comprising a latch configured to engage a horizontal striker, the latch system configured so that an end of the second portion opposite the second hinge latches to and unlatches from a distal portion of the frame by essentially horizontal motion.Type: ApplicationFiled: September 22, 2016Publication date: May 11, 2017Applicant: Tesla Motors, Inc.Inventors: David Wheeler, Steve Klotz, Ian Sadowski, Nermin Mujcinovic, Noam Goldberg, Robert Coleman Skelton, Andy Warburton, Adnan Esmail, Joshua Liu, Andy Wong, Padmanabhan Kumar, Jon Bennett, John Hughes, Hemant Sikaria, Jacob Warman, Chris Satkoski, Nicolas Altenburger
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Publication number: 20170133316Abstract: A semiconductor device includes: a housing; a substrate inside the housing; first and second semiconductor circuits on the substrate; and first and second planar terminals electrically connected to the first and second semiconductor circuits, respectively, the first and second planar terminals stacked on top of each other, wherein each of the first and second planar terminals extends away from the housing.Type: ApplicationFiled: September 23, 2016Publication date: May 11, 2017Applicant: Tesla Motors, Inc.Inventors: Wenjun Liu, Robert James Ramm, Colin Kenneth Campbell
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Publication number: 20170125760Abstract: A system and method for mitigating the effects of a thermal event within a non-metal-air battery pack is provided in which the hot gas and material generated during the event is directed into the metal-air cells of a metal-air battery pack. The metal-air cells provide a large thermal mass for absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers, bystanders, first responders and property are limited.Type: ApplicationFiled: January 16, 2017Publication date: May 4, 2017Applicant: Tesla Motors, Inc.Inventor: Weston Arthur Hermann
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Publication number: 20170096073Abstract: A vehicle includes an energy storage configured to store electric energy for at least propulsion of the vehicle, an energy storage thermal system configured to provide thermal conditioning of the energy storage, and a coupling configured to receive thermal conditioning of the energy storage from a thermal system external to the vehicle. The coupling provides thermal conditioning of the energy storage while charging when available from the thermal system external to the vehicle. The energy storage thermal system provides thermal conditioning of the energy storage while charging when the thermal system external to the vehicle is not available.Type: ApplicationFiled: December 16, 2016Publication date: April 6, 2017Applicant: Tesla Motors, Inc.Inventors: Joseph Mardall, Christopher H. Van Dyke
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Publication number: 20170093157Abstract: An energy storage device includes: a number of cells; and a dual-active-bridge converter connected to the cells, wherein the cells are floating relative to the system and are galvanically isolated therefrom. The energy storage device can be included in an energy storage system that includes: a grid tie unit comprising at least one DC/AC converter; and multiple pods connected to the grid tie unit, each pod including: a number of cells; and a power electronics unit, wherein the cells are floating relative to the system and are galvanically isolated therefrom.Type: ApplicationFiled: September 30, 2016Publication date: March 30, 2017Applicant: Tesla Motors, Inc.Inventors: Brandon Pierquet, Mehmet Ozbek, Andrew David Baglino
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Publication number: 20170093156Abstract: An energy storage system includes: a grid tie unit comprising at least one DC/AC converter; and multiple pods connected to the grid tie unit, each pod including: a number of cells; and a power electronics unit, wherein the cells are floating relative to the system and are galvanically isolated therefrom. The multiple pods may be organized into packs, with a pack including a thermal management system.Type: ApplicationFiled: September 29, 2016Publication date: March 30, 2017Applicant: Tesla Motors, Inc.Inventors: Mehmet Ozbek, Brandon Pierquet, Andrew David Baglino
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Publication number: 20170074918Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.Type: ApplicationFiled: November 22, 2016Publication date: March 16, 2017Applicant: Tesla Motors, Inc.Inventors: Sarah G. Stewart, Christopher Dangler, Clay H. Kishiyama, Weston A. Hermann, Scott I. Kohn, Kurt R. Kelty
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Publication number: 20170059697Abstract: An ultrasonic sensor assembly is placed against an inside surface of a panel for sensing objects on an opposite side of the panel and includes an ultrasonic sensor, a preload structure, a coupling element, and a damping material. The preload structure applies a preload on the ultrasonic sensor toward the inside surface of the panel. The coupling element interfaces between the ultrasonic sensor and the inside surface of the panel. The damping material is placed against the inside surface but not where the coupling element interfaces between the ultrasonic sensor and the inside surface. The coupling element may include a matrix material that is reinforced with a filler.Type: ApplicationFiled: August 31, 2016Publication date: March 2, 2017Applicant: Tesla Motors, Inc.Inventor: Adnan Esmail
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Publication number: 20170062778Abstract: An electrochemical cell includes a can configured to serve as one electric contact of the electrochemical cell, the can containing active materials, a diaphragm configured to serve as an opposite electric contact of the electrochemical cell, and a gasket that is initially of generally cylindrical shape, the diaphragm positioned inside the gasket in an opening of the can wherein an outer edge of the can is crimped onto the gasket, the gasket having an inner periphery inside the can and an outer periphery outside the can, the outer periphery comprising leaves that after crimping extend along an outer surface of the diaphragm.Type: ApplicationFiled: August 23, 2016Publication date: March 2, 2017Applicant: Tesla Motors, Inc.Inventors: Christophe Mille, Kunio Tsuruta, Kenjin Masumoto
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Publication number: 20170030728Abstract: A method includes: receiving information corresponding at least to (i) a state of charge of an energy storage of a vehicle, (ii) route information corresponding to a planned driving route for the vehicle, and (iii) a predicted driver characteristic; determining using the received information, and presenting to a driver of the vehicle, a first energy-versus-distance measure for the planned driving route; receiving a user input indicating a proposed change in at least the driver characteristics, and determining using the received information and the user input, and presenting to the driver, a second energy-versus-distance measure for the planned driving route that takes into account the proposed change.Type: ApplicationFiled: March 19, 2015Publication date: February 2, 2017Applicant: Tesla Motors, Inc.Inventors: Andrew D. Baglino, Thorsten Hayer, Brennan Boblett, Matthew Fox, Vineet H. Mehta, Keijiro Ikebe, Kevin Hsieh, Craig B. Carlson, Jeffrey B. Straubel
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Publication number: 20170011255Abstract: A system that determines an invariant magnetic-resonance (MR) signature of a biological sample is disclosed. During operation, the system determines a magnetic-resonance (MR) model of voxels in a biological sample based on differences between MR signals associated with the voxels in multiple scans and simulated MR signals. The MR signals are measured or captured by an MR scanner in the system during multiple MR scans, and based on scanning instructions, and the simulated MR signals for the biological sample are generated using the MR model and the scanning instructions. Moreover, the system iteratively modifies the scanning instructions (including a magnetic-field strength and/or a pulse sequence) in the MR scans based on the differences until a convergence criterion is achieved. Then, the system stores, in memory, an identifier of the biological sample and a magnetic-field-strength-invariant MR signature of the biological sample that is associated with the MR model.Type: ApplicationFiled: April 3, 2016Publication date: January 12, 2017Applicant: Tesla Health, IncInventors: Jeffrey Howard Kaditz, Andrew Gettings Stevens
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Publication number: 20170007148Abstract: During operation, a system iteratively captures MR signals of one or more types of nuclei in one or more portions of a biological lifeform based on scanning instructions that correspond to a dynamic scan plan. The MR signals in a given iteration may be associated with voxels having associated sizes at three-dimensional (3D) positions in at least a corresponding portion of the biological lifeform. If the system detects a potential anomaly when analyzing the MR signals from the given iteration, the system dynamically modifies the scan plan based on the detected potential anomaly, a medical history and/or an MR-scan history. Subsequent measurements of MR signals may be associated with the same or different: types of nuclei, portions of the biological lifeform, voxels sizes and/or 3D positions.Type: ApplicationFiled: May 31, 2016Publication date: January 12, 2017Applicant: Tesla Health, IncInventors: Jeffrey Howard Kaditz, Andrew Gettings Stevens
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Publication number: 20160197669Abstract: A communication system uses multiple communications links, preferably links that use different communications media. The multiple communications links may include a high latency/high bandwidth link using a fiber-optic cable configured to carry large volumes of data but having a high latency. The communications links may also include a low latency/low bandwidth link implemented using skywave propagation of radio waves and configured to carry smaller volumes of data with a lower latency across a substantial portion of the earth's surface. The two communications links may be used together to coordinate various activities such as the buying and selling of financial instruments.Type: ApplicationFiled: September 2, 2015Publication date: July 7, 2016Applicant: TESLA WIRELESS COMPANY LLCInventor: Kevin Babich
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Publication number: 20160148729Abstract: A magnet apparatus which comprises a first vacuum chamber, a second vacuum chamber, a first magnet disposed within the first vacuum chamber such that the first magnet can be thermally isolated from the exterior of the first vacuum chamber, and a load connector extending from the first vacuum chamber into the second vacuum chamber so that a load on the first magnet can be transferred to the second vacuum chamber, wherein the load connector is in thermal contact with the first magnet and can be thermally isolated from the exterior of the first vacuum chamber and the exterior of the second vacuum chamber.Type: ApplicationFiled: January 27, 2016Publication date: May 26, 2016Applicant: Tesla Engineering LimitedInventors: Frederick Thomas David Goldie, Patrick Brian Clayton
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Publication number: 20160107619Abstract: A battery pack lift system includes: a frame having nutrunners mounted thereon according to a battery pack fastener pattern for a vehicle; a lift configured to raise and lower the frame with regard to the vehicle; a first air bearing positioned between the frame and the lift, the first air bearing configured to allow relative movement between the frame and the lift; and a second air bearing positioned on the frame, the second air bearing configured to allow relative movement between a battery pack and the frame.Type: ApplicationFiled: May 22, 2014Publication date: April 21, 2016Applicant: Tesla Motors, Inc.Inventors: Alan Clarke, Matthew Lee Brown, Eric Orlando GAFFOGLIO, Samuel Milan POZNANOVICH, II
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Publication number: 20160036256Abstract: An inter-protocol charging adapter for equipment to be charged via a bus includes: first connectors corresponding to a first charging protocol that requires the bus to be energized before the equipment closes onto the bus; second connectors corresponding to a second charging protocol that does not energize the bus before the equipment closes onto the bus; and a boost converter coupled to the bus and to at least one of the second connectors, wherein the boost converter uses energy from the second connector to energize the bus before the equipment closes onto the bus.Type: ApplicationFiled: April 2, 2013Publication date: February 4, 2016Applicant: Tesla Motors, Inc.Inventors: Martin SUKUP, Troy A. NERGAARD, Kristoffer J. Donhowe
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Publication number: 20150342092Abstract: A heatsink with an internal cavity for liquid cooling includes: a first part having a first group of fins extending into the internal cavity; a second part attached to the first part so that the internal cavity is formed, the second part having a second group of fins that extend into the internal cavity and that are configured to fit among the first group of fins; an inlet into the internal cavity on at least one of the first and second parts; and an outlet from the internal cavity on at least one of the first and second parts.Type: ApplicationFiled: May 23, 2014Publication date: November 26, 2015Applicant: Tesla Motors, Inc.Inventors: Robert James RAMM, Wenjun Liu, Colin Campbell
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Publication number: 20150318106Abstract: A coil former, also referred to herein as a bobbin, is provided for use in conduction-cooled magnetic components that contain an air gap. The diameter of the disclosed bobbin is increased and ribs/splines or tabs are created to keep the winding centered about the core center post while allowing thermally conductive silicone-based or equivalent encapsulant to fill the voids between the coil former and the core, the coil former and the windings and/or both depending on the placement of the locating tabs. The disclosed bobbin may be fabricated from traditional injection molding resins or from high-thermal conductivity resins. As a result of the disclosed bobbin designs, the achievable power density is increased while maintaining acceptable temperatures.Type: ApplicationFiled: November 27, 2013Publication date: November 5, 2015Applicant: Tesla Motors, Inc.Inventors: Jennifer D Pollock, William T. Chi, Don Chiu
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Publication number: 20150306974Abstract: A method of thermally conditioning an energy storage of a vehicle while charging includes: receiving, at a charging station, thermal information about the energy storage; supplying, by the charging station, electric energy to the energy storage in a charging session; and providing, by the charging station and based on the thermal information, thermal conditioning of the energy storage during at least part of the charging session.Type: ApplicationFiled: April 29, 2014Publication date: October 29, 2015Applicant: Tesla Motors, Inc.Inventors: JOSEPH MARDALL, Christopher H. Van Dyke
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Publication number: 20150298744Abstract: A torque box for a vehicle includes: first and second clamshells joined to each other at respective top and bottom edges and configured to form at least first and second enclosures with an inner joint in between, the first and second enclosures configured to provide top and bottom shear planes at the top and bottom edges, respectively, and at least first and second shear planes at the inner joint.Type: ApplicationFiled: April 17, 2014Publication date: October 22, 2015Applicant: Tesla Motors, Inc.Inventors: N. Petter WINBERG, Tom Spencer, Sachin Shrimant Sawant, Malcolm Burgess
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Publication number: 20150298741Abstract: A subframe for a vehicle has a front attachment to a crush rail in the vehicle, and a rear attachment to the vehicle, the subframe comprising at least one initiator configured to cause the subframe to fold downward in event of impact, the subframe configured so that the front attachment detaches as a result of the impact and the subframe is deflected downward, while the rear attachment does not detach.Type: ApplicationFiled: April 17, 2014Publication date: October 22, 2015Applicant: Tesla Motors, Inc.Inventors: N. Petter WINBERG, Michael J. Eckert, Sachin Shrimant SAWANT
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Publication number: 20150298740Abstract: An adapter for a vehicle includes: an adapter body configured to bridge between a crush rail at a vehicle end and a back-up structure, the adapter body having a socket configured to receive and enclose four sides of the crush rail, the adapter body having a plug configured to fit into the back-up structure; and an opening in the adapter body configured to have a drive shaft extend through the adapter.Type: ApplicationFiled: April 17, 2014Publication date: October 22, 2015Applicant: Tesla Motors, Inc.Inventors: N. Petter WINBERG, Timothy L. SHELDON, Sachin Shrimant SAWANT
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Publication number: 20150298520Abstract: A method of controlling a compressor for an air suspension of an electric vehicle includes: determining a state of a reservoir in the electric vehicle, the reservoir coupled to drive air springs of a suspension system; determining whether the electric vehicle is connected to an external source of electric energy for charging an energy storage of the electric vehicle; in response to determining that the electric vehicle is connected to the external source, applying a first value as a threshold for whether to replenish the reservoir by a compressor; and in response to determining that the electric vehicle is not connected to the external source, applying a second value, different from the first value, as the threshold for whether to replenish the reservoir by the compressor.Type: ApplicationFiled: April 17, 2014Publication date: October 22, 2015Applicant: Tesla Motors, Inc.Inventors: Bradley W. HAYES, Daniel Joseph MARIONI
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Publication number: 20150298633Abstract: A vehicle crush rail includes: a body configured to be at least partially crushed along an axis between first and second ends thereof, the body having a cross section profile that comprises first, second and third cells that are substantially square, wherein at least one of the first, second and third cells extends from the first end to the second end, wherein the first, second and third cells have respective initiators arranged according to a crush pattern for the crush rail.Type: ApplicationFiled: April 17, 2014Publication date: October 22, 2015Applicant: Tesla Motors, Inc.Inventors: N. Petter Winberg, Timothy L. Sheldon, Sachin Shrimant Sawant
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Publication number: 20150244036Abstract: An energy storage system includes: multiple cells, each cell having a first end with anode and cathode terminals, and a second end opposite the first end, the cells arranged so that the second ends are aligned; for each of the cells, electrical connections coupled to the anode and cathode terminals at the first end; and a heat pipe having a flat evaporation surface facing the second ends.Type: ApplicationFiled: February 25, 2014Publication date: August 27, 2015Applicant: Tesla Motors, Inc.Inventors: Robert C. Lane, Hae-Won Choi, Jeff Weintraub, Carlos Mario Aguirre, Mark Riegel, Orion A. King, Nathan Chidiac, Jon Wagner, Augusto E. Barton, Ernest Villanueva, David Rosenberg
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Publication number: 20150222162Abstract: A liquid cooling system for an electric motor includes: a pump for liquid to cool the electric motor; a heat exchanger that removes heat from the liquid; a manifold extending above a stator of the electric motor, the manifold receiving the liquid under pressure and having a first opening that directs a first liquid jet onto the stator; and a first tray above first end turns of the stator, the manifold having a second opening that directs a second liquid jet onto the first tray, the first tray having a third opening that performs gravity-fed liquid distribution onto the first end turns.Type: ApplicationFiled: January 31, 2014Publication date: August 6, 2015Applicant: Tesla Motors, Inc.Inventors: Gary A. Pinkley, David F. Nelson, William R. Fong, Scott Heines, Edwin M. Pearce, JR.
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Publication number: 20150217654Abstract: A charging system for an electric vehicle includes: a power supply; a cable having first and second ends, the first end attached to the power supply, the cable comprising a charging conductor and a cooling conduit, each of which extends from the first end to the second end; and a connector attached to the second end of the cable, the connector having a form factor corresponding to a charge port of the electric vehicle; wherein the cooling conduit is adapted to convey a fluid that cools the charging conductor.Type: ApplicationFiled: February 5, 2014Publication date: August 6, 2015Applicant: Tesla Motors, Inc.Inventors: Yee Shan WOO, Christopher H. VAN DYKE, Joseph MARDALL, Christopher NEWPORT, Joshua W. FERGUSON
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Publication number: 20150206636Abstract: A magnet apparatus which comprises a first vacuum chamber, a second vacuum chamber, a first magnet disposed within the first vacuum chamber such that the first magnet can be thermally isolated from the exterior of the first vacuum chamber, and a load connector extending from the first vacuum chamber into the second vacuum chamber so that a load on the first magnet can be transferred to the second vacuum chamber, wherein the load connector is in thermal contact with the first magnet and can be thermally isolated from the exterior of the first vacuum chamber and the exterior of the second vacuum chamber.Type: ApplicationFiled: March 30, 2015Publication date: July 23, 2015Applicant: TESLA ENGINEERING LIMITEDInventors: Frederick Thomas David Goldie, Patrick Brian Clayton
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Publication number: 20150183997Abstract: One or more techniques are disclosed for a method for functionalized a graphitic material comprising the steps of: 1) providing a graphitic material; 2) providing a first molecule comprising a first group, a spacer, and a second group; 3) providing a second molecule comprising a third group, a spacer, and a fourth group, wherein said third group is a different group from said first group; and 4) bonding the first molecule and the second molecule to the graphitic material. Also disclosed is a tunable material composition comprising the functionalized carbon nanotubes or functionalized graphene prepared by the methods described herein.Type: ApplicationFiled: April 30, 2013Publication date: July 2, 2015Applicant: Tesla Nanocoatings, Inc.Inventor: Jorma Virtanen
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Publication number: 20150155112Abstract: An electromagnetic switch includes: a stationary electrical contact; a moveable electrical contact; an actuated member to which the moveable electrical contact is attached for driving the moveable electrical contact into and out of contact with the stationary electrical contact; and a damping interface between the moveable electrical contact and the actuated member.Type: ApplicationFiled: December 2, 2013Publication date: June 4, 2015Applicant: Tesla Motors, Inc.Inventors: Mark Goldman, Ian C. Dimen, Bennett Sprague
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Publication number: 20150123511Abstract: An electric motor includes: a stator; a shaft; a rotor mounted on the shaft, the rotor having an end ring that is concentric with the shaft; and a flux shield around the shaft inside the end ring.Type: ApplicationFiled: November 1, 2013Publication date: May 7, 2015Applicant: Tesla Motors, Inc.Inventors: Konstantinos Laskaris, Andrew D. Baglino, Chad Furey, David F. Nelson
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Publication number: 20150111082Abstract: A method includes: assembling a thermal-exchange tube in a module housing for an energy storage pack; assembling cells in the module housing, wherein the thermal-exchange tube runs between rows of the cells; applying an adhesive that affixes the cells and the thermal-exchange tube to the module housing; curing a first portion of the adhesive by radiation, wherein a second portion of the adhesive is shielded from the radiation by the cells or the thermal-exchange tube; and curing at least the second portion of the adhesive by a chemical cure mechanism.Type: ApplicationFiled: October 17, 2013Publication date: April 23, 2015Applicant: Tesla Motors, Inc.Inventors: Robert D. Sumpf, Ernest Villanueva, David E. Hegeman, Satvik Vipin Batavia, Ganesh Singh, Alex Prilutsky, Scott I. Kohn, Bruce P. Edwards, Peter Tennessen
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Publication number: 20150039180Abstract: In a vehicle door assembly, controllers processes signals from an extension force sensor and a retraction force sensor to control a door handle. As a motor retracts the handle, a swing arm in the vehicle door presses against the retraction force sensor causing the handle controller to stop the motor. Pushing on the retracted handle presses the swing arm against the retraction force sensor a second time causing the controllers to operate the motor and extend the handle. As the handle extends, the swing arm presses against the extension force sensor and the handle controller stops the motor as the handle is fully extended. Subsequently, a hand pulling on the door handle presses the swing arm against the extension force sensor a second time causing the controllers to unlatch a latch holding the vehicle door shut, and thereby allow the vehicle door to open.Type: ApplicationFiled: September 26, 2012Publication date: February 5, 2015Applicant: Tesla Motors, Inc.Inventors: Joris Aerts, Adam S. Kilgore, Brenda Cucci, Ian Craven
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Publication number: 20140376995Abstract: A method includes: assembling first and second pieces in a slip-fit joint without applying adhesive or sealant, wherein the first piece covers a portion of the second piece in the slip-fit joint; and injecting adhesive through the first piece until the adhesive fills a gap of the slip-fit joint, wherein the adhesive makes the slip-fit joint air tight without applying the sealant. An air-tight slip-fit joint consists essentially of: first and second pieces assembled without applying adhesive or sealant, wherein the first piece covers a portion of the second piece in the slip-fit joint; and adhesive injected through the first piece until the adhesive fills a gap of the slip-fit joint, wherein the adhesive makes the slip-fit joint air tight without applying the sealant.Type: ApplicationFiled: June 20, 2013Publication date: December 25, 2014Applicant: Tesla Motors, Inc.Inventors: Andreas Faass, Aaron Johnson, Derek Ryan Paul, Donald James Parr, Kevin Matthew Anderson
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Publication number: 20140368082Abstract: A rotor including: a shaft; a structure comprising at least one end ring and rotor bars, wherein at least the end ring comprises a material subject to expansion or movement radially outward from the shaft upon a rotor balancing process that involves spinning of the structure; a core that at least partially encloses the rotor bars; and means for limiting the expansion or movement of the structure radially outward. A method including: providing a structure comprising at least one end ring and rotor bars, wherein at least the end ring comprises a material subject to expansion or movement radially outward from the shaft upon spinning of the structure; assembling a rotor from the structure and a core, the core at least partially enclosing the rotor bars; spinning the rotor in a rotor balancing process; and limiting the expansion or movement of the structure radially outward in the rotor balancing process.Type: ApplicationFiled: June 17, 2013Publication date: December 18, 2014Applicant: TESLA MOTORS, INC.Inventor: Augusto E. Barton
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Publication number: 20140347018Abstract: A method for automatically charging the battery pack of an electric vehicle in accordance with a set of location sensitive charging instructions is provided. Exemplary location sensitive charging instructions include preset charging schedules and preset charge level limits. Different charging schedules and different charge level limits may be preset for different charging stations and locations, thus allowing the user to preset the charging instructions for each of multiple locations where the user routinely charges their car. Default charging instructions are used at those charging stations and locations where a set of location sensitive charging instructions has not been preset.Type: ApplicationFiled: May 21, 2013Publication date: November 27, 2014Applicant: Tesla Motors, Inc.Inventors: Brennan Boblett, Nalinichandra Penke, Miriam Vu, Kevin Hsieh, Roy Goldman, Thorsten Hayer
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Publication number: 20140339950Abstract: A rotor assembly and a method for fabricating the same are provided in which a pair of end caps, positioned at either end of the stack of laminated discs, are fusion welded to the rotor bars using an electron beam welder, thereby yielding improved electrical and mechanical characteristics in a low weight assembly.Type: ApplicationFiled: May 18, 2013Publication date: November 20, 2014Applicant: Tesla Motors, Inc.Inventors: David Fred Nelson, Shyi-Perng Phillip Luan, Edwin Marcum Pearce, JR., William Randall Fong
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Publication number: 20140332085Abstract: A method of managing leakage of liquid inside a battery system comprises: containing leaking liquid in a non-liquid sensitive region of the battery system so as to protect internal electrical components of the battery system from coming in contact with the leaking liquid; and in direct response to the leakage, expunging the leaking liquid from the battery system. A drain device includes: a body with a port therethrough, the body configured to be positioned in a wall of a container; means for opening the port in response to a first liquid contacting the drain device on an inside of the container; and means for resisting ingress into the container by a second liquid that contacts the drain device on an outside of the container.Type: ApplicationFiled: May 10, 2013Publication date: November 13, 2014Applicant: Tesla Motors, Inc.Inventors: Dustin Grace, Mark Goldman, Woodruff Phillips, Dorian W. West, Paul Guerra, Angus W. Rittenburg, Ganesh Singh, Kevin Anderson, Adam Horton, Peter How
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Publication number: 20140333086Abstract: A rear-facing seat for a vehicle comprises: a seat portion connected to the vehicle by a hinge so that the rear-facing seat assumes at least a stowed position and an unstowed position; and a back portion connected to the seat portion, wherein in the unstowed position the back portion assumes at least an up position and a down position, wherein in the up position (i) a hook on the back portion engages a first striker on a vehicle wall, and (ii) a latch on the back portion engages a second striker of a back of a forward-facing seat.Type: ApplicationFiled: May 10, 2013Publication date: November 13, 2014Applicant: Tesla Motors, Inc.Inventors: Daryl Zalan, Sohel Merchant
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Publication number: 20140326351Abstract: A method includes: determining a design for a longitudinal piece of a particular length, wherein first and second ends of the longitudinal piece have dissimilar shapes; extruding a piece that is at least twice the particular length, wherein a profile throughout the extruded piece has the first end shape; hydroforming the extruded piece to generate an expanded portion between ends of the extruded piece, wherein the ends retain essentially the first end shape; and cutting through the expanded portion to obtain a piece wherein one end has the first end shape and another end has the second end shape.Type: ApplicationFiled: May 1, 2013Publication date: November 6, 2014Applicant: TESLA MOTORS, INC.Inventors: Michael J. Baldwin, Madan Gopal, Yih-Charng Deng
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Publication number: 20140257613Abstract: Electric vehicles and, more particularly, a control system for an all-wheel drive electric vehicle.Type: ApplicationFiled: May 19, 2014Publication date: September 11, 2014Applicant: Tesla Motors, Inc.Inventor: Yifan Tang
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Publication number: 20140253023Abstract: A battery cell charger for rapidly charging a lithium ion battery cell (or string of series-parallel connected cells) having a maximum battery cell voltage the battery cell charging system including: a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an increasing battery cell voltage with the first stage charging current provided until the first stage charging voltage is about equal to a first stage complete voltage less than the maximum battery cell voltage; one or more intermediate charging stages, each intermediate stage selected from the group consisting of one or more of an intermediate constant voltage stage that provides a decreasing charging current, an intermediate constant current stage that produces an increasing battery cell voltage, and combinations thereof; and aType: ApplicationFiled: May 12, 2014Publication date: September 11, 2014Applicant: Tesla Motors, Inc.Inventors: Anil PARYANI, Clay H. Kishiyama, Scott I. Kohn, Vineet H. Mehta
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Publication number: 20140209344Abstract: The bus bar includes a first bus bar layer formed of a first generally uniform thickness of a first bus bar conductor; a first dielectric layer overlying a top surface of the first bus bar layer; and a second bus bar layer formed of a second generally uniform thickness of a second bus bar conductor overlying a top surface of the first dielectric layer and the top surface of the first bus bar layer wherein: the first bus bar layer includes a first via for receipt of a first electrical lead of an electrical component and a second via for receipt of a second electrical lead of the electrical component and wherein: the first dielectric layer and the second bus bar layer each include a via aligned with the first via wherein the first electrical lead is extendable from beneath the first bus bar layer through the first dielectric layer and through the second bus bar layer.Type: ApplicationFiled: February 24, 2014Publication date: July 31, 2014Applicant: Tesla Motors, Inc.Inventors: Nicholas R. KALAYJIAN, Joshua Willard Ferguson, Benjamin D. Dettmann, Ryan C. Kroeze, Michael R. Kubba, William T. Chi
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Publication number: 20140212708Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system includes a sealed battery pack enclosure configured to hold a plurality of batteries and at least one exhaust nozzle assembly. The exhaust nozzle assembly includes an exhaust nozzle that passes and directs the flow of hot gas from within the battery pack to the ambient environment during a thermal runaway event, a nozzle seal mounted within the exhaust nozzle that seals the exhaust nozzle during normal operation of the battery pack, and a nozzle seal mounting nut that holds the nozzle seal within the exhaust nozzle during normal operation and then melts during a thermal runaway event, thereby allowing the nozzle seal to be ejected through the exhaust nozzle during the event.Type: ApplicationFiled: January 26, 2013Publication date: July 31, 2014Applicant: TESLA MOTORS, INC.Inventors: Paul Frey, Dustin Grace
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Publication number: 20140212695Abstract: A system and method for improving on conventional techniques for connecting energy storage elements of a high-voltage battery pack. A tuned flexible printed circuit individually coupled to each electrode of each cell of a matrix of cells of the battery pack provides improved manufacturability and reliability.Type: ApplicationFiled: January 30, 2013Publication date: July 31, 2014Applicant: TESLA MOTORS, INC.Inventors: Robert Clinton Lane, Jeff Weintraub