Patents Assigned to Tesla Motors, Inc.
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Patent number: 9257825Abstract: 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: GrantFiled: February 24, 2014Date of Patent: February 9, 2016Assignee: 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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Patent number: 9257729Abstract: A controller identifies a condition of a hazardous internal short by comparing patterns of series element voltages to the last known balance condition of the series elements. If the loaded or resting voltage of one or more contiguous series elements uniformly drop from the previously known condition by an amount consistent with an over-current condition, an over-current internal short circuit fault is registered. The desired response is to prevent the affected series elements from heating to a hazardous temperature by summoning the maximum heat rejection capability of the system until the short ceases and the affected elements cool, the cooling function is no longer able to operate due to low voltage, or the affected series string has drained all of its energy through the short. Also includes are responses that allow the battery pack to continue to power the cooling system even though it may enter an over-discharged state.Type: GrantFiled: November 25, 2013Date of Patent: February 9, 2016Assignee: Tesla Motors, Inc.Inventors: Weston A. Hermann, Scott I. Kohn
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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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Patent number: 9252400Abstract: A battery cell design is disclosed that provides a predictable pathway through a portion of the cell (e.g., the cell cap assembly) for the efficient release of the thermal energy that occurs during thermal runaway, thereby reducing the chances of a rupture in an undesirable location. Furthermore the disclosed design maintains the functionality of the cell cap as the positive terminal of the cell, thereby having minimal impact on the manufacturability of the cell as well as its use in a variety of applications.Type: GrantFiled: August 6, 2012Date of Patent: February 2, 2016Assignee: Tesla Motors, Inc.Inventors: Francisco LePort, Scott Ira Kohn, Orion Andrew King, Alex Prilutsky
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Patent number: 9250020Abstract: A vehicle thermal management system is provided that includes two or more heat exchangers configured in a non-stacked arrangement, where separate air inlets corresponding to each of the heat exchangers allow a direct intake of ambient air. Active louver systems consisting of sets of adjustable louvers and a control actuator are used to control and regulate air flowing directly into one or more of the heat exchangers, where the adjustable louvers are either adjustable between two positions, i.e., opened and closed, or adjustable over a range of positions. Air ducts may be used to couple the output from one heat exchanger to the input of a different heat exchanger.Type: GrantFiled: May 10, 2012Date of Patent: February 2, 2016Assignee: Tesla Motors, Inc.Inventors: Per Thomas Vikstrom, Vincent George Johnston, Franz von Holzhausen, Paul Daniel Yeomans
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Patent number: 9221343Abstract: A system for decoupling a HV source from an electric vehicle's electrical system is provided that includes (i) at least one electrical contactor, where the HV source is electrically connected to the vehicle's electrical system when the electrical contactor is in a closed state and not electrically connected to the vehicle's electrical system when the electrical contactor is in an open state; (ii) a supplemental restraint system (SRS) that monitors collision data from a plurality of impact sensors and outputs an activation signal in response to monitored collision data; and (iii) a pyrotechnic switch, where the pyrotechnic switch has a pre-activated first state that provides a conductive path that allows the HV source to be electrically connected to the vehicle's electrical system and an activated second state that severs the conductive path and prevents the HV source from being electrically connected to the vehicle's electrical system.Type: GrantFiled: October 10, 2012Date of Patent: December 29, 2015Assignee: Tesla Motors, Inc.Inventors: Nicholas Paul Tokarz, Madan Gopal
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Patent number: 9225197Abstract: A method for charging an energy storage system (ESS) from an AC line voltage having differing input voltages (e.g., 120 Vac or 240 Vac), the method includes a) determining which of the AC line voltages is provided for charging the ESS as a charging AC voltage; b) boosting the charging AC voltage to an intermediate voltage responsive to the provided AC line voltage; c) scaling, responsive to the particular one of the AC line voltages, the intermediate voltage to a secondary voltage using a scaling factor; and d) converting the secondary voltage to a charging voltage applied to the ESS.Type: GrantFiled: May 6, 2011Date of Patent: December 29, 2015Assignee: Tesla Motors, Inc.Inventor: Jean-Pierre Krauer
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Patent number: 9209631Abstract: A method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle.Type: GrantFiled: September 22, 2012Date of Patent: December 8, 2015Assignee: Tesla Motors, Inc.Inventors: Weston Arthur Hermann, Jeffrey Brian Straubel, David G. Beck
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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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Patent number: 9197091Abstract: An electric charging system for a battery pack of an electric vehicle, including a charging station electrically coupled to the battery pack, the charging station transferring charging energy to the battery pack at a maximum fast charge rate in a first operational mode and transferring charging energy to the battery pack at a slower charge rate in a second operational mode; a data collection system acquiring a set of data indicating a state of charge (SOC) of the battery pack and one or more desired charge optimization parameters; and a station control, responsive to the set of data and to the desired charge optimization parameters, automatically establishing a charging profile for the battery pack to assert a control signal and operate the charging station in the second operational mode whenever the charging station is able to transfer sufficient energy to the battery pack at the slower charge rate to meet an SOC target and a charge completion time target, otherwise asserting the control signal and operate tType: GrantFiled: January 26, 2015Date of Patent: November 24, 2015Assignee: Tesla Motors, Inc.Inventors: Clay H. Kishiyama, Kurt R. Kelty
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Patent number: 9187131Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.Type: GrantFiled: November 7, 2013Date of Patent: November 17, 2015Assignees: Toyota Motor Engineering & Manufacturing North America, Inc., Tesla Motors, Inc.Inventors: Jonathan Richard Young, Donald James Robert Parr, Ernest Matthew Villanueva, Derek Paul
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Patent number: 9182438Abstract: A system and method for low-cost, fault tolerant, EMI robust data communications, particularly for an EV environment.Type: GrantFiled: February 18, 2015Date of Patent: November 10, 2015Assignee: Tesla Motors, Inc.Inventors: Nathaniel B. Martin, Ian C. Dimen, S. Douglas Crowder
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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: 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: 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: 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: 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: 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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Patent number: D749503Type: GrantFiled: June 30, 2015Date of Patent: February 16, 2016Assignee: Tesla Motors, Inc.Inventors: Joshua Willard Ferguson, Franz Von Holzhausen, Javier Verdura, Radu I Muntean, Patrick Grimmel