Tesla Motors Patent Applications

TRIP PLANNING WITH ENERGY CONSTRAINT

Granted: February 2, 2017
Application Number: 20170030728
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…

Battery Swapping System and Techniques

Granted: April 21, 2016
Application Number: 20160107619
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…

INTER-PROTOCOL CHARGING ADAPTER

Granted: February 4, 2016
Application Number: 20160036256
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…

HEATSINK WITH INTERNAL CAVITY FOR LIQUID COOLING

Granted: November 26, 2015
Application Number: 20150342092
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…

Bobbin Design for Conduction-Cooled, Gapped, High-Permeability Magnetic Components

Granted: November 5, 2015
Application Number: 20150318106
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…

CHARGING STATION PROVIDING THERMAL CONDITIONING OF ELECTRIC VEHICLE DURING CHARGING SESSION

Granted: October 29, 2015
Application Number: 20150306974
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.

CONTROLLING A COMPRESSOR FOR AIR SUSPENSION OF ELECTRIC VEHICLE

Granted: October 22, 2015
Application Number: 20150298520
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…

VEHICLE CRUSH RAIL WITH SUBSTANTIALLY SQUARE CELLS AND INITIATORS

Granted: October 22, 2015
Application Number: 20150298633
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.

ADAPTER FOR CRUSH RAIL AND TORQUE BOX

Granted: October 22, 2015
Application Number: 20150298740
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.

SUBFRAME CONFIGURED TO DETACH UPON IMPACT

Granted: October 22, 2015
Application Number: 20150298741
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.

TORQUE BOX WITH SHEAR PLANES AT INNER JOINT

Granted: October 22, 2015
Application Number: 20150298744
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.

ENERGY STORAGE SYSTEM WITH HEAT PIPE THERMAL MANAGEMENT

Granted: August 27, 2015
Application Number: 20150244036
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.

COOLING OF CHARGING CABLE

Granted: August 6, 2015
Application Number: 20150217654
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…

PRESSURIZED AND GRAVITY-FED LIQUID COOLING OF ELECTRIC MOTOR

Granted: August 6, 2015
Application Number: 20150222162
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…

Electromagnetic Switch with Damping Interface

Granted: June 4, 2015
Application Number: 20150155112
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.

Flux Shield for Electric Motor

Granted: May 7, 2015
Application Number: 20150123511
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.

Cell Module Assemblies

Granted: April 23, 2015
Application Number: 20150111082
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…

CONTROLLER APPARATUS AND SENSORS FOR A VEHICLE DOOR HANDLE

Granted: February 5, 2015
Application Number: 20150039180
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…

Air-tight Slip-on Structural Joint Not Using Sealant

Granted: December 25, 2014
Application Number: 20140376995
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…

LIMITING RADIAL EXPANSION IN ROTOR BALANCING

Granted: December 18, 2014
Application Number: 20140368082
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…