Patents Assigned to Tesla Motors
  • Localized Energy Dissipation Structures For Vehicles
    Publication number: 20130270864
    Abstract: 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: Application
    Filed: April 13, 2012
    Publication date: October 17, 2013
    Applicants: Tesla Motor Inc., Toyota Motor Engineering & Manufacturing North America, Inc.
    Inventors: Jonathan Richard Young, Donald James Robert Parr, Ernest Matthew Villanueva, Derek Paul
  • EMBEDDED OPTICS IN MODULAR ASSEMBLIES
    Publication number: 20130270749
    Abstract: An enhanced multiobject potting fixture for exposure to a curing modality that sets an adhesive includes a fixture housing supporting a plurality of objects, the fixture housing having a wall defining a plurality of bonding wells with each the bonding well receiving a first portion of one of the objects, each the bonding well including an aperture in the wall proximate the first portion wherein each bonding well includes a target zone for selective cure of the adhesive to inhibit the adhesive from exiting the aperture; and a fixture enhancement structure integrated into the wall concentrating the curing modality in each the target zone.
    Type: Application
    Filed: April 12, 2012
    Publication date: October 17, 2013
    Applicant: TESLA MOTORS, INC.
    Inventors: Brian Dean Hachtmann, Mark Riegel, David Elias Hegeman, William Christopher Bishop, William Vucich Beecher
  • Impact Protection Structures for Vehicles and Vehicles Incorporating the Same
    Publication number: 20130270863
    Abstract: Impact protection structures for vehicles are described. An impact protection structure includes a support structure of the vehicle, an interior rail coupled to the support structure, and an exterior rail coupled to the interior rail. The exterior rail has an inboard boundary wall positioned between an upper mounting region and a lower mounting region. The upper and the lower exterior mounting region of the exterior rail are coupled to an upper and a lower mounting region of the interior rail. At least a portion of the inboard boundary wall is spaced apart from an outboard wall of the interior rail such that when the exterior rail is impacted by a blunt-object barrier, the inboard boundary wall of the exterior rail deforms, thereby damping energy of the impact at the exterior rail and arresting crack propagation between the exterior rail and the interior rail.
    Type: Application
    Filed: April 13, 2012
    Publication date: October 17, 2013
    Applicants: Tesla Motor, Inc., Toyota Motor Engineering & Manufacturing North America, Inc.
    Inventors: Jonathan Richard Young, Donald James Robert Parr, Ernest Matthew Villanueva, Nathan Nelson, Paul Dewitt Frey
  • Battery pack venting system
    Patent number: 8557415
    Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a sealed battery pack enclosure configured to hold a plurality of batteries, where the battery pack enclosure is divided into a plurality of sealed battery pack compartments. The system also includes a plurality of battery venting assemblies, where at least one battery venting assembly is integrated into each of the sealed battery pack compartments, and where each of the battery venting assemblies includes an exhaust port integrated into an outer wall of the battery pack compartment and a valve, the valve being configured to seal the exhaust port under normal operating conditions and to unseal the exhaust port when at least one of the batteries within the battery pack compartment enters into thermal runaway.
    Type: Grant
    Filed: May 19, 2012
    Date of Patent: October 15, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Nicholas Hayden Herron, Scott Ira Kohn, Weston Arthur Hermann, Andrew Hill Leutheuser, Jeffrey C. Weintraub, Dustin Grace, Bruce Philip Edwards, Nicolas Verzeni, Joseph Mardall
  • Method for optimizing battery pack temperature
    Patent number: 8555659
    Abstract: A method for limiting the adverse effects of temperature on the electrical energy storage system (ESS) of an electric vehicle after the vehicle has been turned off is provided. In general, whether or not coolant is circulated through a coolant loop coupled to the ESS depends on the difference between the ambient temperature and a preset temperature, the preset temperature typically corresponding to the temperature of the ESS.
    Type: Grant
    Filed: November 1, 2011
    Date of Patent: October 15, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Weston Arthur Hermann, Scott Ira Kohn, Kurt Russell Kelty, Vineet Haresh Mehta, Jeffrey Brian Straubel
  • Battery pack directed venting system
    Patent number: 8557416
    Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack, the system using an integrated battery venting assembly comprised of an integrated exhaust port, a valve retention plate that covers the exhaust port and includes a plurality of retention plate ports, and a plurality of valves that are configured to seal the retention plate ports under normal conditions and unseal the retention plate ports during thermal runaway. As hot gas passes through the retention plate ports, the plate is configured to melt and be ejected, thereby allowing subsequent hot gas to pass through the larger exhaust port. A perforated cover plate may be used to protect the external surfaces of the retention plate and valves. An internally mounted exhaust guide may be used to direct the flow of hot gas expelled during the thermal runaway event.
    Type: Grant
    Filed: May 19, 2012
    Date of Patent: October 15, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Joseph Mardall, Nicholas Hayden Herron, Dustin Grace, Weston Arthur Hermann, Jeffrey C. Weintraub, Gary Allen Pinkley
  • Control, collection and use of metal-air battery pack effluent
    Patent number: 8557414
    Abstract: A system and method for maintaining an ambient oxygen concentration below a preset concentration while charging a metal-air battery pack is provided, the system utilizing an on-board means for collecting and storing the oxygen-rich effluent generated during the charge cycle.
    Type: Grant
    Filed: February 25, 2011
    Date of Patent: October 15, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Weston Arthur Hermann, Jeffrey Brian Straubel
  • Low temperature charging of Li-ion cells
    Patent number: 8552693
    Abstract: A battery cell charging system, including a charger and a controller, for low-temperature (below about zero degrees Celsius) charging a lithium ion battery cell, the battery cell charging system includes: 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 having: a non-low-temperature charging stage for charging the battery cell using a charging profile adapted for battery cell temperatures above about zero degrees Celsius; and a low-temperature charging stage with a variable low-temperature stage charging current that decreases responsive to a battery cell temperature falling below zero degrees Celsius.
    Type: Grant
    Filed: September 30, 2009
    Date of Patent: October 8, 2013
    Assignee: Tesla Motors, Inc.
    Inventor: Anil Paryani
  • Battery Pack Pressure Monitoring System for Thermal Event Detection
    Publication number: 20130260192
    Abstract: A system for detecting thermal events, e.g., thermal runaway, within a sealed battery pack based on a characterization of monitored pressure variations within the pack is provided. The system includes at least one pressure sensor coupled to the battery pack and to a pressure monitoring system that outputs pressure data representative of the battery pack pressure over time; a system controller that analyzes the pressure data and outputs a control signal when the pressure data fits a specific curve shape; and a thermal event response subsystem that performs a preset response upon receipt of the control signal from the system controller. The system may include a secondary effect monitoring system, wherein the thermal event response subsystem performs the preset response when the pressure data fits a specific curve shape and the secondary effect is detected by the secondary effect monitoring system.
    Type: Application
    Filed: March 29, 2012
    Publication date: October 3, 2013
    Applicant: TESLA MOTORS, INC.
    Inventor: Francisco Richard LePort
  • Vehicle port door with wirelessly actuated unlatching assembly
    Patent number: 8539990
    Abstract: A port door unlatching system is provided that may be used to open the door covering the charge port of an electric vehicle, or the door covering the fuel filler port of a conventional vehicle. The system includes a fuel delivery subsystem with a fuel coupler (e.g., a charging connector or a gas nozzle) designed to transfer fuel from the source to the vehicle via the vehicle's fuel port. The fuel coupler includes a switch that when toggled, causes a control signal to be wirelessly transmitted over a short distance. Upon receipt of the control signal by a receiver integrated into a vehicle that is in close proximity to the fuel port, an unlatching actuator within the vehicle unlatches the port door, thereby allowing it to open and provide port access.
    Type: Grant
    Filed: June 6, 2012
    Date of Patent: September 24, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Joshua Willard Ferguson, Daryl Zalan, Andrew Dai, Troy Adam Nergaard, Nicholas Robert Kalayjian, Scott Ira Kohn
  • Efficient dual source battery pack system for an electric vehicle
    Patent number: 8543270
    Abstract: A method of optimizing the operation of the power source of an electric vehicle is provided, where the power source is comprised of a first battery pack (e.g., a non-metal-air battery pack) and a second battery pack (e.g., a metal-air battery pack). The power source is optimized to minimize use of the least efficient battery pack (e.g., the second battery pack) while ensuring that the electric vehicle has sufficient power to traverse the expected travel distance before the next battery charging cycle.
    Type: Grant
    Filed: December 10, 2010
    Date of Patent: September 24, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Kurt Russell Kelty, Vineet Haresh Mehta, Jeffrey Brian Straubel
  • Thermal barrier structure for containing thermal runaway propagation within a battery pack
    Patent number: 8541126
    Abstract: A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells.
    Type: Grant
    Filed: August 31, 2009
    Date of Patent: September 24, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Weston Arthur Hermann, Scott Ira Kohn, Vineet Haresh Mehta, David G. Beck
  • Overmolded thermal interface for use with a battery cooling system
    Patent number: 8541127
    Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is overmolded onto the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.
    Type: Grant
    Filed: May 6, 2011
    Date of Patent: September 24, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Peter Thomas Tennessen, Jeffrey C. Weintraub, Weston Arthur Hermann
  • Method of Operating a Dual Motor Drive and Control System for an Electric Vehicle
    Publication number: 20130241445
    Abstract: A method for optimizing the torque applied by each motor of a dual motor drive system of an all-electric vehicle is provided, the torque adjustments taking into account wheel slip as well as other vehicular operating conditions.
    Type: Application
    Filed: April 19, 2013
    Publication date: September 19, 2013
    Applicant: Tesla Motors, Inc.
    Inventor: Yifan Tang
  • Dynamic antiwhiplash apparatus and method
    Patent number: 8534703
    Abstract: A passenger seat protection system for a seated passenger of a vehicle includes a seat back supporting a pressurizable vessel storing a quantity of pressurized gas within a compartment, the compartment defined by one or more walls that collapse responsive to a force applied to the seat back by the seated passenger in a rear impact of the vehicle; a headrest including a bladder responsive to a gas pressure from the quantity of pressurized gas to transition an expansion of the headrest from a first expansion mode to a second expansion mode; and a gas channel communicating the quantity of pressurized gas to the bladder after a collapsing of the one or more walls.
    Type: Grant
    Filed: March 9, 2012
    Date of Patent: September 17, 2013
    Assignee: Tesla Motors, Inc.
    Inventor: Michael John Baldwin
  • State of charge range
    Patent number: 8536825
    Abstract: A system and method for improving cycle lifetimes for a lithium-ion battery pack, particularly for adapting to a dynamic use profile for a user.
    Type: Grant
    Filed: December 31, 2009
    Date of Patent: September 17, 2013
    Assignee: Tesla Motors, Inc.
    Inventors: Clay Hajime Kishiyama, Vineet Haresh Mehta, Christopher David Gadda
  • LOW TEMPERATURE FAST CHARGE
    Publication number: 20130234648
    Abstract: An automated charge preparation method periodically determines critical parameters for the set of relevant operating conditions, determines whether fast charging is possible, applies fast charging when possible, otherwise applies a dynamically scaled charging rate that is optimized based upon current critical parameters (while optionally heating the individual battery cells as long as fast charging is not available) to reduce/eliminate a risk of lithium-plating.
    Type: Application
    Filed: March 9, 2012
    Publication date: September 12, 2013
    Applicant: Tesla Motors, Inc.
    Inventors: Kurt Russell Kelty, Clay Hajime Kishiyama, Sarah G. Stewart
  • Electrical Interface Interlock System
    Publication number: 20130228431
    Abstract: A high voltage (HV) interface housing is provided that includes an assembly of levers within the housing that detect whether or not the HV lines are coupled to the interface housing. If the HV lines are not in place, the lever assembly prevents the interface cover from being fully installed onto the interface housing, thereby preventing the HV interlock loop switch from being closed. As a result, when the HV cables are not in place, the HV interlock loop switch prevents power from being applied to the HV circuit. If, however, the HV lines are properly positioned within the interface housing, the levers of the lever assembly automatically retract, thus allowing the interface cover to be fully installed onto the interface housing. In this state, the interface cover closes the HV interlock loop switch, thus closing the HV interlock loop and allowing power to be applied to the HV circuit.
    Type: Application
    Filed: October 19, 2012
    Publication date: September 5, 2013
    Applicant: TESLA MOTORS, INC.
    Inventors: Nicholas Robert Kalayjian, Ryan Thomas Davis, Michael Kaojen Fang
  • Electric Vehicle Battery Lifetime Optimization Operational Mode
    Publication number: 20130221916
    Abstract: A multi-mode operating system for an electric vehicle is provided, the system including means for a user to select a preferred mode of operation from a plurality of operational modes that include at least a Battery Life mode and a Standard mode, wherein the Battery Life mode is configured to select operating and charging parameters that emphasize battery health and battery life over vehicle range and/or vehicle performance. The system includes a thermal management system for maintaining the vehicle's battery pack to within any of a plurality of temperature ranges, and a charging system for charging the vehicle's battery pack to any of a plurality of minimum and maximum SOC levels and at any of a plurality of charging rates.
    Type: Application
    Filed: February 28, 2012
    Publication date: August 29, 2013
    Applicant: TESLA MOTORS, INC.
    Inventors: Kurt Russell Kelty, Weston Arthur Hermann, Scott Ira Kohn, Clay Hajime Kishiyama, Vineet Haresh Mehta, Sarah G. Stewart
  • Electric Vehicle Battery Lifetime Optimization Operational Mode
    Publication number: 20130221928
    Abstract: A method of setting the operational mode of an electric vehicle is provided, where the operational mode is selected from a plurality of operational modes that include at least a Battery Life mode and a Standard mode, wherein the Battery Life mode is configured to select operating and charging parameters that emphasize battery health and battery life over vehicle range and/or vehicle performance. The system includes a thermal management system for maintaining the vehicle's battery pack to within any of a plurality of temperature ranges, and a charging system for charging the vehicle's battery pack to any of a plurality of minimum and maximum SOC levels and at any of a plurality of charging rates.
    Type: Application
    Filed: February 28, 2012
    Publication date: August 29, 2013
    Applicant: TESLA MOTORS, INC.
    Inventors: Kurt Russell Kelty, Weston Arthur Hermann, Scott Ira Kohn, Clay Hajime Kishiyama, Vineet Haresh Mehta, Sarah G. Stewart