Tesla Motors Patents Granted
Patents granted to Tesla Motors by the U.S. Patent and Trademark Office (USPTO).
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Patent number: 11960901Abstract: An autonomous driving controller includes a plurality of parallel processors operating on common input data. Each of the plurality of parallel processors includes a general processor, a security processor subsystem (SCS), and a safety subsystem (SMS). The general processors, the SCSs, and the SMSs of the plurality of parallel processors are configured to first, boot the plurality of SCSs from ROM second, boot the plurality of SMSs of the plurality of parallel processors from RAM or ROM, and, third, boot the plurality of general processors of the plurality of parallel processors from RAM. Between booting of the SCSs and the SMSs, at least one of the plurality of SCSs may load SMS boot code into the RAM that is dedicated to the plurality of SMSs.Type: GrantFiled: February 23, 2023Date of Patent: April 16, 2024Assignee: Tesla, Inc.Inventors: Patryk Kaminski, Thaddeus Fortenberry, David Glasco
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Patent number: 11962030Abstract: An integrated, unitary battery pack may be formed and used as part of the structural support for a vehicle frame. The unitary battery pack includes arrays cells having all positive and negative electrical terminals aligned in-plane on a common face of the product assembly. The unitary battery pack includes cooling components for passively or actively cooling the cell arrays. The unitary battery pack is encased in a potting material that allows that forms part of the structure support for the unitary battery pack. The unitary batter pack may be integrated into the vehicle with or without additional support structures.Type: GrantFiled: November 20, 2020Date of Patent: April 16, 2024Assignee: Tesla, Inc.Inventors: Andrew Pires, Robert David Sumpf, Jr., William B. Stockton, Cole Spooner, Cole Prodan, Jayesh Bharat Gorasia, Kenton Harris, Dan Burke, Dafna Gabriela Szafer, Krupal Patel, Benjamin Parker, David Elias Hegeman
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Patent number: 11961959Abstract: A nonaqueous electrolyte for a lithium ion battery includes a lithium salt, a first nonaqueous solvent, and an additive mixture comprising a first operative additive of lithium difluorophosphate and a second operative additive of either fluoro ethylene carbonate or vinylene carbonate. A lithium-ion battery includes a negative electrode, a positive electrode comprising NMC with micrometer-scale grains, a nonaqueous electrolyte having lithium ions dissolved in a first nonaqueous solvent, and an additive mixture having a first operative additive of either fluoro ethylene carbonate or vinylene carbonate and a second operative additive of either 1,3,2-dioxathiolane-2,2-dioxide, another sulfur-containing additive, or lithium difluorophosphate.Type: GrantFiled: July 31, 2018Date of Patent: April 16, 2024Assignees: Tesla, Inc., Panasonic Holdings CorporationInventors: Lin Ma, Xiaowei Ma, Stephen Laurence Glazier, Jing Li, Jeffery Raymond Dahn
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Patent number: 11955921Abstract: One embodiment can provide a photovoltaic roof tile. The photovoltaic roof tile can include a transparent front cover, a transparent back cover, and a plurality of polycrystalline-Si-based photovoltaic structures positioned between the front cover and the back cover. A respective polycrystalline-Si-based photovoltaic structure has a front surface facing the front cover and a back surface facing the back cover. The photovoltaic roof tile can further include a paint layer positioned on a back surface of the back cover facing away from the front cover. A color of the paint layer substantially matches a color of the front surface of the respective polycrystalline-Si-based photovoltaic structure.Type: GrantFiled: June 15, 2022Date of Patent: April 9, 2024Assignee: Tesla, Inc.Inventors: John Liu, Yangsen Kang, Anh N. Duong, Yongkee Chae, Milan Padilla, Chen Wang, Remy D. Labesque
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Patent number: 11949089Abstract: An energy storage device can include a cathode, an anode, and a separator between the cathode and the anode. At least one of the electrodes can include an electrode film prepared by a dry process. The electrode film and/or the electrode can comprise a prelithiating material. Processes and apparatuses used for fabricating the electrode and/or electrode film are also described.Type: GrantFiled: January 14, 2020Date of Patent: April 2, 2024Assignee: Tesla, Inc.Inventors: Ziying Wang, Hieu Minh Duong
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Patent number: 11942591Abstract: A method for constructing a battery that includes a can, a jelly roll contained in the can, a top insulator contained in the can adjacent to and above the jelly roll, and a battery cap. The method includes forming the can, forming the jelly roll, inserting the jelly roll into the can, inserting a top insulator into the can adjacent to and above the jelly roll, assembling the battery cap, including an outer conductive ring, an insulator ring, a conductive top plate, a conductive rupture plate, connecting a cathode to the conductive rupture plate, inserting the battery cap into the can, and welding the battery cap to an inner surface of the can.Type: GrantFiled: November 4, 2022Date of Patent: March 26, 2024Assignee: Tesla, Inc.Inventors: Kenjin Masumoto, Christophe Mille
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Patent number: 11938796Abstract: A vehicle having an exoskeleton exterior panel that provides crash resistance is described. The exterior panel may be formed from a monolithic metal sheet and attached to an exterior portion of the vehicle frame, and the exterior panel does not comprise an additional support structure. At least one component may be directly attached to the exterior panel, and the exterior panel may bear the load of the at least one component. Methods of manufacturing the vehicle are also described.Type: GrantFiled: November 19, 2020Date of Patent: March 26, 2024Assignee: Tesla, Inc.Inventors: Alan Paul Clarke, Xiaoping Cai, Lars Moravy, Ted Antony
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Patent number: 11932078Abstract: Systems, apparatuses, and methods for an enhanced heat pump are provided. An example embodiment includes a housing, the housing having a particular number of connection ports, each connection port being connected to a component of the electric vehicle, and the connection ports being configured to pass fluid; and a stemshell positioned within the housing, the stemshell comprising a plurality of channels, wherein at least a portion of the channels are in fluidic connection with the connection ports, wherein the stemshell is configured to rotate within the housing, and wherein rotation causes adjustment of the connection ports correspond which correspond to the channels.Type: GrantFiled: March 30, 2022Date of Patent: March 19, 2024Assignee: Tesla, Inc.Inventors: Prem Pinto, Daniel F. Hanks
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Patent number: 11932184Abstract: A wiring system for an automobile connecting a processor and a plurality of devices, using one or more backbone sections. The processor and devices are connected to one another to form a first loop and a second loop, such that data may be transmitted along the first loop and data may be transmitted along the second loop.Type: GrantFiled: October 21, 2022Date of Patent: March 19, 2024Assignee: Tesla, Inc.Inventors: Adnan Esmail, In Jae Chung, Lakshya Jain, Brijesh Tripathi
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Patent number: 11933660Abstract: Techniques are disclosed for systems and methods to detect and/or classify a vehicle occupant, such as a passenger seated within the cockpit of a vehicle. An occupant classification system includes an occupant weight sensor, an occupant presence sensor, and a logic device configured to communicate with the occupant weight sensor and the occupant presence sensor. The logic device is configured to receive occupant weight sensor signals from the occupant weight sensor and occupant presence sensor signals from the occupant presence sensor, determine an estimated occupant weight and an occupant presence response based, at least in part, on the occupant weight sensor signals and the occupant presence sensor signals, and determine an occupant classification status corresponding to the passenger seat based, at least in part, on the estimated occupant weight and/or the occupant presence response.Type: GrantFiled: June 28, 2021Date of Patent: March 19, 2024Assignee: Tesla, Inc.Inventors: Akin Aina, Markell Baldwin, Bronson Aden, Zach Stuart
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Patent number: 11919411Abstract: A cable assembly includes a cable having a first end and a second end. The cable has an electric conductor and a cooling conduit, each of which extends from the first end to the second end. The cooling conduit is adapted to convey a fluid that cools the electric conductor. The cable assembly includes a leak detection module to detect a leak of the fluid from the cooling conduit. The leak detection module includes a power source to generate an input voltage signal which is applied at a first node contact with the fluid. The leak detection module includes a controller to monitor an output voltage signal at the first node and to detect a leak of the fluid from the cooling conduit based on the output voltage signal.Type: GrantFiled: January 5, 2023Date of Patent: March 5, 2024Assignee: Tesla, Inc.Inventors: Pascal-Andre Fortin, Martin Sukup, Tim Murphy, Chuen Chou, Aria Tedjarati
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Patent number: 11904713Abstract: 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: GrantFiled: August 31, 2020Date of Patent: February 20, 2024Assignee: Tesla, Inc.Inventor: Weston Arthur Hermann
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Patent number: 11909041Abstract: This invention provides an environmental friendly method for the production of high capacity cathode materials for use in Li-ion batteries. Traditional methods for producing lithium mixed metal oxide cathode materials typically generate large amounts of effluent which effluent must be treated prior to discharge. The present process uses mixed metals as raw materials, in a wet chemical reaction with an oxidant, in order to make high-quality metal hydroxide precursors which can be used to prepare high-quality cathode materials after lithiation. As a key feature, in the precursor preparation process, the bulk of the aqueous solution used for the wet chemical reaction can be recycled back to the reactor, so that the total process has little or no effluent generated during production of the cathode precursor material.Type: GrantFiled: April 3, 2019Date of Patent: February 20, 2024Assignee: Tesla, Inc.Inventors: Feng Zou, Yang Liu
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Patent number: 11908171Abstract: Systems and methods for enhanced object detection for autonomous vehicles based on field of view. An example method includes obtaining an image from an image sensor of one or more image sensors positioned about a vehicle. A field of view for the image is determined, with the field of view being associated with a vanishing line. A crop portion corresponding to the field of view is generated from the image, with a remaining portion of the image being downsampled. Information associated with detected objects depicted in the image is outputted based on a convolutional neural network, with detecting objects being based on performing a forward pass through the convolutional neural network of the crop portion and the remaining portion.Type: GrantFiled: December 22, 2022Date of Patent: February 20, 2024Assignee: Tesla, Inc.Inventors: Anting Shen, Romi Phadte, Gayatri Joshi
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Patent number: 11901549Abstract: An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode or the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode or the second electrode can include combining elemental lithium metal and a plurality of carbon particles.Type: GrantFiled: August 12, 2022Date of Patent: February 13, 2024Assignee: Tesla, Inc.Inventors: Hieu Minh Duong, Porter Mitchell, Mohammed-Yazid Saidi
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Patent number: 11901310Abstract: An electronic assembly includes a substrate having a first surface and a second surface opposite to the first surface and a plurality of stiffening members coupled to the substrate. The substrate further includes a plurality of substrate interconnects. The electronic assembly further includes a plurality of semiconductor dies mounted on the first surface of the substrate. The plurality of semiconductor dies are electrically connected to each other via the plurality of substrate interconnects. The electronic assembly further includes a plurality of power supply modules mounted on the second surface of the substrate. Each power supply module is disposed opposite to a respective semiconductor die.Type: GrantFiled: September 19, 2019Date of Patent: February 13, 2024Assignee: Tesla, Inc.Inventors: Mengzhi Pang, Shishuang Sun, Ganesh Venkataramanan, William Arthur McGee, Steven Butler
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Patent number: 11893393Abstract: A microprocessor system comprises a computational array and a hardware arbiter. The computational array includes a plurality of computation units. Each of the plurality of computation units operates on a corresponding value addressed from memory. The hardware arbiter is configured to control issuing of at least one memory request for one or more of the corresponding values addressed from the memory for the computation units. The hardware arbiter is also configured to schedule a control signal to be issued based on the issuing of the memory requests.Type: GrantFiled: October 22, 2021Date of Patent: February 6, 2024Assignee: Tesla, Inc.Inventors: Emil Talpes, Peter Joseph Bannon, Kevin Altair Hurd
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Patent number: 11893774Abstract: Systems and methods for training machine models with augmented data. An example method includes identifying a set of images captured by a set of cameras while affixed to one or more image collection systems. For each image in the set of images, a training output for the image is identified. For one or more images in the set of images, an augmented image for a set of augmented images is generated. Generating an augmented image includes modifying the image with an image manipulation function that maintains camera properties of the image. The augmented training image is associated with the training output of the image. A set of parameters of the predictive computer model are trained to predict the training output based on an image training set including the images and the set of augmented images.Type: GrantFiled: December 14, 2021Date of Patent: February 6, 2024Assignee: Tesla, Inc.Inventors: Matthew John Cooper, Paras Jagdish Jain, Harsimran Singh Sidhu
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Patent number: 11894770Abstract: A Voltage Regulator Module (VRM) includes a first voltage rail circuit board oriented in a first plane having formed therein a first plurality of conductors and configured to produce a first rail voltage, a second voltage rail circuit board oriented in a second plane that is substantially parallel to the first plane having formed therein a second plurality of conductors and configured to produce a second rail voltage. The VRM also includes a first capacitor circuit board oriented in a third plane that is substantially perpendicular to the first plane and a second capacitor circuit board oriented in a fourth plane that is substantially parallel to the third plane. The VRM includes a plurality of conductors intercoupling the first voltage rail circuit board, the first capacitor circuit board, the second voltage rail circuit board, and the second capacitor circuit board.Type: GrantFiled: November 7, 2018Date of Patent: February 6, 2024Assignee: Tesla, Inc.Inventors: Shishuang Sun, Kevin Hurd, Satyan Chandra
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Patent number: 11888108Abstract: An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode includes an electrochemically active material and a porous carbon material, and the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode includes combining an electrochemically active material and a porous carbon material, and forming the second electrode includes combining elemental lithium metal and a plurality of carbon particles.Type: GrantFiled: November 16, 2020Date of Patent: January 30, 2024Assignee: Tesla, Inc.Inventors: Hieu Minh Duong, Porter Mitchell, Mohammed-Yazid Saidi, Joon Ho Shin, Haim Feigenbaum
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Patent number: 11882628Abstract: A method is provided for interacting with audience members in an event, each of the potential attendees having available thereto a unique identifier. The method comprises creating, for an attendee, a unique ID (UID) on a mobile wireless device (MWD) by the steps of inputting to the MWD one of the unique identifiers, combining the obtained unique identifier with a UID time stamp at the time of creation of the UID; receiving with a server on a first wireless channel communications from the MWD; registering the UID at the physical location of the event; generating a visual query; displaying on the MWD response indicators; receiving at the server from the registered attendee a response, to the query over the first wireless channel; and storing in a database on the server the received response in association with the displayed query.Type: GrantFiled: August 3, 2022Date of Patent: January 23, 2024Assignee: Tesla Laboratories, LLCInventor: Jovan Hutton Pulitzer
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Patent number: 11876230Abstract: An energy storage device can include a cathode and an anode, where at least one of the cathode and the anode are made of a polytetrafluoroethylene (PTFE) composite binder material including PTFE and at least one of polyvinylidene fluoride (PVDF), a PVDF co-polymer, and poly(ethylene oxide) (PEO). The energy storage device can be a lithium ion battery, a lithium ion capacitor, and/or any other lithium based energy storage device. The PTFE composite binder material can have a ratio of about 1:1 of PTFE to a non-PTFE component, such a PVDF, PVDF co-polymer and/or PEO. Methods of fabricating the anode and/or the cathode of the energy storage device are also disclosed.Type: GrantFiled: July 27, 2020Date of Patent: January 16, 2024Assignee: Tesla, Inc.Inventors: Hieu Minh Duong, Haim Feigenbaum, Jian Hong
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Patent number: 11855373Abstract: A cable assembly includes a first cable and a second cable that is arranged co-axial to the first cable. Proximal ends of the first and second cables are provided with a connector assembly. The connector assembly from each proximal end is adapted to connect with one another, or a pair of receptacle ports located within a PCB, the PCB being disposed alongside the co-axially arranged first and second cables.Type: GrantFiled: December 28, 2020Date of Patent: December 26, 2023Assignee: Tesla, Inc.Inventors: In Jae Chung, Zheng Gao, Ron Rosenberg, Joel Torres Diaz, Adnan Esmail, Satyan Chandra
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Patent number: 11841434Abstract: An annotation system uses annotations for a first set of sensor measurements from a first sensor to identify annotations for a second set of sensor measurements from a second sensor. The annotation system identifies reference annotations in the first set of sensor measurements that indicates a location of a characteristic object in the two-dimensional space. The annotation system determines a spatial region in the three-dimensional space of the second set of sensor measurements that corresponds to a portion of the scene represented in the annotation of the first set of sensor measurements. The annotation system determines annotations within the spatial region of the second set of sensor measurements that indicates a location of the characteristic object in the three-dimensional space.Type: GrantFiled: June 10, 2022Date of Patent: December 12, 2023Assignee: Tesla, Inc.Inventor: Anting Shen
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Patent number: 11837523Abstract: A transistor package comprising: a substrate; a first transistor in thermal contact with the substrate, wherein the transistor comprises a gate; the substrate sintered to a heat sink through a sintered layer; an encapsulant that at least partially encapsulates the first transistor; and a Kelvin connection to the transistor gate.Type: GrantFiled: October 14, 2022Date of Patent: December 5, 2023Assignee: Tesla, Inc.Inventors: Wenjun Liu, Robert James Ramm, Alan David Tepe, Colin Kenneth Campbell, Dino Sasaridis
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Patent number: 11821420Abstract: An electric pump system and method of operating the same involves pumping a fluid through a fluid passageway defined in a mechanical pump from a pump inlet to a hollow shaft of a motor, through the hollow shaft to an internal motor cavity defined by a housing of the motor, and through another fluid passageway defined in the motor housing and mechanical pump that leads to a pump outlet. The system and method further involve pumping the fluid through another fluid passageway defined in the mechanical pump from yet another pump inlet to the pump outlet. The temperature of fluid exiting the hollow shaft can be assessed and used by an electronic control unit (ECU) of the electric pump system to control the same. The electric pump system can be part of a cooling and lubrication system for an electric vehicle transmission, gearbox, differential or transfer case, for example.Type: GrantFiled: April 4, 2018Date of Patent: November 21, 2023Assignee: Tesla, Inc.Inventors: Scott Michael Graves, Eric Bellemare, Yufei Zhu, Benjamin Dellal, Diego Alberto Silva Rodriguez
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Patent number: 11824160Abstract: Improved battery systems have been developed for lithium-ion based batteries. The improved battery systems consist of two-additive mixtures in an electrolyte solvent. Such battery systems are prepared by assembling a positive electrode and a negative electrode in the sealed cell, removing residual water from the sealed cell, filling the sealed cell with a nonaqueous electrolyte under an inert atmosphere, vacuum-sealing the sealed cell, carrying out a formation process comprising charging and discharging the sealed cell until the sealed cell achieves an initial capacity. The nonaqueous electrolyte includes lithium ions, a first nonaqueous solvent comprising a carbonate solvent, a second nonaquaeous solvent comprising methyl acetate, and an additive mixture of a first operative additive of either vinylene carbonate or fluoroethylene carbonate and a second operative additive of 2-furanone. Gas formation is suppressed in the battery system during the formation process.Type: GrantFiled: July 5, 2018Date of Patent: November 21, 2023Assignees: Tesla, Inc., Panasonic Holdings CorporationInventors: Jeffery Raymond Dahn, Xiaowei Ma
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Patent number: 11816585Abstract: Systems and methods include machine learning models operating at different frequencies. An example method includes obtaining images at a threshold frequency from one or more image sensors positioned about a vehicle. Location information associated with objects classified in the images is determined based on the images. The images are analyzed via a first machine learning model at the threshold frequency. For a subset of the images, the first machine learning model uses output information from a second machine learning model, the second machine learning model being performed at less than the threshold frequency.Type: GrantFiled: December 3, 2019Date of Patent: November 14, 2023Assignee: Tesla, Inc.Inventor: Anting Shen
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Patent number: 11807067Abstract: A vehicle thermal management system includes a vehicle heat pump system, a battery system coolant loop, a drive train coolant loop, and control electronics. The vehicle heat pump system includes a compressor, a cabin condenser, a cabin evaporator, a cabin blower, and a chiller. The battery system coolant loop is in thermal communication with a battery system and with the chiller and selectively in thermal communication with the drive train coolant loop. The control electronics control the components of the vehicle thermal management system to heat the cabin, cool the cabin, heat the battery system, cool the battery system, and cool the drive train. The control electronics may control the compressor to operate in an efficient mode or a lossy mode in which the compressor generates heat. The control electronics may also control the components of the vehicle thermal management system to precondition the battery.Type: GrantFiled: March 19, 2021Date of Patent: November 7, 2023Assignee: Tesla, Inc.Inventors: Nicholas Mancini, Joseph Stratford Maxwell Mardall, Jan Kopitz, Curt Raymond O'Donnell, Daniel F. Hanks, Huize Li
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Patent number: 11811066Abstract: Provided herein are dry process electrode films, and energy storage devices incorporating the same, including a microparticulate non-fibrillizable binder having certain particle sizes. The electrode films exhibit improved mechanical and processing characteristics. Also provided are methods for processing such microparticulate non-fibrillizable electrode film binders, and for incorporating the microparticulate non-fibrillizable binders in electrode films.Type: GrantFiled: November 11, 2022Date of Patent: November 7, 2023Assignee: TESLA, INC.Inventors: Ziying Wang, Hieu Minh Duong, Yudi Yudi, Joon Ho Shin, Prince Magsino
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Patent number: 11806968Abstract: A multilayer glass stack for a vehicle windshield with improved durability is described. The multilayer glass stack includes an external-facing glass layer, an internal-facing glass layer, and an adhesive interlayer positioned between the external-facing and internal-facing glass layers. The external-facing glass layer may include borosilicate and/or does not include soda lime glass. Methods of manufacturing the multilayer glass stack are also described.Type: GrantFiled: October 26, 2022Date of Patent: November 7, 2023Assignee: Tesla, Inc.Inventors: Rosemary Mottsmith, Michael Pilliod, William S. Sweney, Dante Lamastra, Christos Gougoussis
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Patent number: 11797304Abstract: A microprocessor system comprises a vector computational unit and a control unit. The vector computational unit includes a plurality of processing elements. The control unit is configured to provide at least a single processor instruction to the vector computational unit. The single processor instruction specifies a plurality of component instructions to be executed by the vector computational unit in response to the single processor instruction and each of the plurality of processing elements of the vector computational unit is configured to process different data elements in parallel with other processing elements in response to the single processor instruction.Type: GrantFiled: January 19, 2023Date of Patent: October 24, 2023Assignee: Tesla, Inc.Inventors: Debjit Das Sarma, Emil Talpes, Peter Joseph Bannon
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Patent number: 11790664Abstract: A system is comprised of one or more processors coupled to memory. The one or more processors are configured to receive image data based on an image captured using a camera of a vehicle and to utilize the image data as a basis of an input to a trained machine learning model to at least in part identify a distance of an object from the vehicle. The trained machine learning model has been trained using a training image and a correlated output of an emitting distance sensor.Type: GrantFiled: March 23, 2022Date of Patent: October 17, 2023Assignee: Tesla, Inc.Inventors: James Anthony Musk, Swupnil Kumar Sahai, Ashok Kumar Elluswamy
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Patent number: 11773000Abstract: Systems and methods for texturing substrates (e.g., glass, metal, and the like) and the textured substrates produced using such systems and methods are disclosed. An exemplary textured substrate includes a surface having a portion with a root-mean-square roughness between 40 to 1000 microns and an autocorrelation function greater than 0.5 for distances less than 50 microns. An exemplary system for texturing a substrate includes a plunger with a textured surface, where a portion of the textured surface has a root-mean-square roughness between 40 to 1000 microns and an autocorrelation function greater than 0.5 for distances less than 50 microns. An exemplary method for texturing a substrate includes the steps of generating a pattern defining a texture, and 3-D printing the pattern on the substrate to form the texture.Type: GrantFiled: January 11, 2022Date of Patent: October 3, 2023Assignee: Tesla, Inc.Inventors: William S. Sweney, Michael Pilliod, Christos Gougoussis
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Patent number: 11777070Abstract: Materials and methods for preparing dry cathode electrode film including reduced binder content are described. The cathode electrode film may be a self-supporting film including a single binder. The binder loading may be 3 weight % or less. In a first aspect, a method for preparing a dry free standing electrode film for an energy storage device is provided, comprising nondestructively mixing a cathode active material, a porous carbon, and optionally a conductive carbon to form an active material mixture, adding a single fibrillizable binder to the active material mixture, nondestructively mixing to form an electrode film mixture, and calendering the electrode film mixture to form a free standing electrode film.Type: GrantFiled: May 13, 2019Date of Patent: October 3, 2023Assignee: Tesla, Inc.Inventors: Yudi Yudi, Hieu Minh Duong, Joon Ho Shin
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Patent number: 11764432Abstract: A battery system includes multiple cells arranged in a common cell enclosure that can also be used for a structure and heat transfer fluid conduit. The battery system also includes a first collector plate. The first collector plate has multiple collector tabs that correspond to the multiple cells. Each collector tab is connected to a cathode of a corresponding cell from amongst the multiple cells present in the battery system.Type: GrantFiled: March 28, 2019Date of Patent: September 19, 2023Assignee: Tesla, Inc.Inventor: Kevin Cornelius Matthews
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Patent number: 11757093Abstract: Provided herein are energy storage device electrode films comprising a hybrid electrode film, and methods of forming such multilayer hybrid electrode films and energy storage devices comprising multilayer hybrid electrode films. Each hybrid electrode film may comprise a self-supporting dry coated active layer and a wet cast active layer, wherein each active layer comprises a binder and an active material. The binder and/or active material may be the same or different as any other active layer. The hybrid multilayer electrode film may further comprise at least one additional layer, and the hybrid multilayer electrode film may be laminated with a current collector to form an electrode.Type: GrantFiled: March 26, 2020Date of Patent: September 12, 2023Assignee: Tesla, Inc.Inventors: Joon Ho Shin, Hieu Minh Duong, Amado Marcelino Garcia Acevedo
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Patent number: 11757320Abstract: An electric motor includes a case, a stator having stator windings, a rotor having a rotor shaft, and at least one main rotor bearing coupling the rotor shaft to the case. Common mode charge builds up on the rotor due to imbalances of the stator. The at least one main rotor bearing has a first electrical resistance between the rotor shaft and the case. The electric motor further includes a rotor discharge bearing coupling the rotor shaft to the case. The rotor discharge bearing has a second electrical resistance between the rotor shaft and the case that is less than the first electrical resistance, causing the common mode charge to discharge through the rotor discharge bearing. In a differing embodiment, a rotor discharge brush coupled between the case and the rotor shaft along the longitudinal axis of the rotor shaft discharges the common mode charge.Type: GrantFiled: August 5, 2021Date of Patent: September 12, 2023Assignee: Tesla, Inc.Inventors: Scott Michael Graves, Diego Alberto Silva Rodriguez, Tyler Nils Grendahl, Alexander Hain
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Patent number: 11748620Abstract: Sensor data, including a group of time series elements, is received. A training data set is determined, including by determining for at least a selected time series element in the group of time series elements a corresponding ground truth. The corresponding ground truth is based on a plurality of time series elements in the group of time series elements. A processor is used to train a machine learning model using the training dataset.Type: GrantFiled: April 20, 2021Date of Patent: September 5, 2023Assignee: Tesla, Inc.Inventors: Ashok Kumar Elluswamy, Matthew Bauch, Christopher Payne, Andrej Karpathy, Joseph Polin
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Patent number: 11749842Abstract: A cell of an energy storage device with at least one electrode that is tabless, and methods of forming thereof, are described. The cell includes a first substrate having a first coating disposed thereon, wherein a second portion of the first substrate at a proximal end along the width of the first substrate comprises a conductive material. An inner separator is disposed over the first substrate. A second substrate is disposed over the inner separator. The second substrate has a second coating disposed thereon. The first substrate, the inner separator, and the second substrate in a successive manner, the first substrate, the inner separator, and the second substrate are rolled about a central axis.Type: GrantFiled: November 4, 2019Date of Patent: September 5, 2023Assignee: Tesla, Inc.Inventors: Kunio Tsuruta, Mikel Ehrlich Dermer, Rajeev Dhiman
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Patent number: 11734562Abstract: An image captured using a sensor on a vehicle is received and decomposed into a plurality of component images. Each component image of the plurality of component images is provided as a different input to a different layer of a plurality of layers of an artificial neural network to determine a result. The result of the artificial neural network is used to at least in part autonomously operate the vehicle.Type: GrantFiled: December 16, 2021Date of Patent: August 22, 2023Assignee: Tesla, Inc.Inventors: Timofey Uvarov, Brijesh Tripathi, Evgene Fainstain
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Patent number: 11734095Abstract: A system for handling errors in a neural network includes a neural network processor for executing a neural network associated with use of a vehicle. The neural network processor includes an error detector configured to detect a data error associated with execution of the neural network and a neural network controller configured to receive a report of the data error from the error detector. In response to receiving the report, the neural network controller is further configured to signal that a pending result of the neural network is tainted without terminating execution of the neural network.Type: GrantFiled: September 23, 2021Date of Patent: August 22, 2023Assignee: Tesla, Inc.Inventors: Christopher Hsiong, Emil Talpes, Debjit Das Sarma, Peter Bannon, Kevin Hurd, Benjamin Floering
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Patent number: 11728697Abstract: A stator for an electric motor is described. An example stator includes a stator core having teeth that are radially arranged about a common central axis of the stator and located in a spaced apart manner from one another. Each tooth has an inward portion and an outward portion. The example stator further includes an electrically transmissive coil of wire that is wound contiguously upon the inward portions of at least a subset of teeth from the plurality of teeth. The stator also includes wedge members that are radially arranged about the common central axis and located intermittently with the plurality of teeth such that each wedge member abuts with the outward portions of adjacently located teeth.Type: GrantFiled: January 6, 2020Date of Patent: August 15, 2023Assignee: TESLA, INC.Inventors: Kalonica Christie, James Murphy, Leif Olsen, David Nelson, Christopher Edwards
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Patent number: 11703340Abstract: A method includes: determining, based, at least in part, on a predicted driver characteristic, a first energy-versus-distance measure for a planned driving route of a vehicle, the first energy-versus-distance measure determined using an energy model; presenting the first energy-versus-distance measure on a user interface associated with the vehicle; identifying an already-driven part of the planned driving route; determining, based on information associated with the already-driven part of the planned driving route, a model error associated with the energy model; determining a second energy-versus-distance measure by modifying the first energy-versus-distance measure to account for the model error; and presenting the second energy-versus-distance measure on the user interface associated with the vehicle.Type: GrantFiled: May 10, 2019Date of Patent: July 18, 2023Assignee: Tesla, 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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Patent number: 11705855Abstract: Building integrated photovoltaic (BIPV) systems provide for solar panel arrays that can be aesthetically pleasing to an observer. BIPV systems can be incorporated as part of roof surfaces as built into the structure of the roof, particularly as photovoltaic modules having the appearance of a plurality of roofing tiles that each have photovoltaic cells. Each photovoltaic module may include a metal backer, photovoltaic cells, and light transmissive top sheets adhered to both the metal backer and the photovoltaic cells. BIPV systems can also include non-photovoltaic modules that appear similar to photovoltaic modules, but do not collect solar energy.Type: GrantFiled: May 7, 2021Date of Patent: July 18, 2023Assignee: Tesla, Inc.Inventors: Martin Seery, Charles Bernardo Almy, Kathryn Austin Pesce
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Patent number: 11698773Abstract: Various embodiments of the disclosure relate to an accelerated mathematical engine. In certain embodiments, the accelerated mathematical engine is applied to image processing such that convolution of an image is accelerated by using a two-dimensional matrix processor comprising sub-circuits that include an ALU, output register and shadow register. This architecture supports a clocked, two-dimensional architecture in which image data and weights are multiplied in a synchronized manner to allow a large number of mathematical operations to be performed in parallel.Type: GrantFiled: July 29, 2022Date of Patent: July 11, 2023Assignee: Tesla, Inc.Inventors: Peter Joseph Bannon, Kevin Altair Hurd, Emil Talpes
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Patent number: 11699548Abstract: A structure for forming inductor windings includes a first portion and a second portion of a clamshell casing. The first portion includes a first set of electrically conductive segments, a first inner carrier, and a first outer carrier. The second portion includes a second set of electrically conductive segments, a second inner carrier, and a second outer carrier. An inductor core is mountable between the first inner carrier and the first outer carrier within the first portion. A control assembly aligns and joins the first portion to the second portion of the clamshell casing such that the first set of electrically conductive segments arranged in the first pattern that correspond to first half-turns of the inductor windings, are attached to the second set of electrically conductive segments arranged in the second pattern that correspond to second half-turns of the inductor windings, to form continuous turns around the inductor core.Type: GrantFiled: July 29, 2022Date of Patent: July 11, 2023Assignee: Tesla, Inc.Inventor: Tobias S. Ricco
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Patent number: 11692278Abstract: A coating system includes an electrocoat (e-coat) bath having an e-coat fluid with a first amount of dissolved gases, a plurality of ultrasonic transducers mounted on at least two sides of the e-coat bath, a carrier frame and control circuitry. The control circuitry is configured to control a trajectory of a metal part dipped in the e-coat bath using the carrier frame, control the plurality of ultrasonic transducers to direct a plurality of acoustic waves at a defined ultrasonic operating frequency and at a first intensity to cause a plurality of localized pressure drops in the e-coat fluid, the first amount of dissolved gases is reduced or removed as bubbles from the e-coat fluid of the e-coat bath based on the directed plurality of acoustic waves, and increase the first intensity of the directed plurality of acoustic waves over a defined time period to accelerate dispersion of an e-coat pigment.Type: GrantFiled: December 7, 2018Date of Patent: July 4, 2023Assignee: TESLA, INC.Inventors: Gunjan Agarwal, Sundaresan Avudaiappan, Christopher Lillywhite
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Patent number: 11685293Abstract: A seat system includes: a base; a seatback; at least one recliner connecting the base and the seatback to each other for pivoting of the seatback relative to the base; a slider coupled to the base and configured for sliding engagement with a track having a detent region and a tilt-and slide region; and an electronic controller, wherein without mechanical interlock between the recliner and the slider, the electronic controller causes the recliner to place the seatback in a non-passenger position when the slider is within the tilt-and-slide region, and causes the recliner to place the seatback in a passenger position when the slider is within the detent region.Type: GrantFiled: July 1, 2022Date of Patent: June 27, 2023Assignee: Tesla, Inc.Inventors: David Eduardo Banales Cano, Nathan Di Giusto
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Patent number: D1017512Type: GrantFiled: November 15, 2018Date of Patent: March 12, 2024Assignee: Tesla, Inc.Inventors: Peter Blades-Nixon, Franz von Holzhausen