Tesla Motors Patent Applications

Induction Motor Lamination Design

Granted: August 18, 2011
Application Number: 20110198962
A high efficiency, high torque density, high speed induction motor is provided, the motor utilizing (i) stator teeth with parallel side surfaces; (ii) rotor teeth with parallel side surfaces; (iii) wide open stator slots; (iv) closed rotor slots with thick tooth bridges; and (v) deep stator and rotor slots.

Dual Layer Winding Pattern

Granted: August 18, 2011
Application Number: 20110198963
A dual-winding layer arrangement for a three-phase, four pole motor is provided.

Triple Layer Winding Pattern and Methods of Manufacturing Same

Granted: August 18, 2011
Application Number: 20110198961
A triple-winding layer arrangement for a three-phase, four pole motor is provided as well as a method of manufacturing the same.

Battery Pack Gas Exhaust System

Granted: July 21, 2011
Application Number: 20110174556
A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a multi-sided, substantially airtight battery pack enclosure configured to hold a plurality of batteries, where at least one side of the battery pack enclosure includes at least one cavity. An inner wall of the enclosure includes a plurality of perforations configured to pass gas from within the enclosure to the cavity within the at least one side…

Corrosion resistant cell mounting well

Granted: July 7, 2011
Application Number: 20110165446
A battery mounting structure, preferably for use within a battery pack housing, is provided that prevents condensation-induced corrosion from occurring between the terminals of a battery.

STATE OF CHARGE RANGE

Granted: June 30, 2011
Application Number: 20110156641
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. A battery cell pack charging system, including a charger and a controller, for charging a lithium-ion battery cell pack, the battery cell pack charging system has a circuit for charging the battery cell pack using an adjustable charging system including an adjustable charge profile to charge the battery cell pack wherein the adjustable charge…

FAST CHARGING WITH NEGATIVE RAMPED CURRENT PROFILE

Granted: June 30, 2011
Application Number: 20110156661
A battery cell charging system, including a charger and a controller, for rapidly charging a lithium ion battery cell, the battery cell charging system having 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…

Battery Cell with a Center Pin Comprised of a Low Melting Point Material

Granted: May 19, 2011
Application Number: 20110117403
A battery is provided that includes a cell case, an electrode assembly and a center pin within the electrode assembly, where the electrode assembly is wrapped around the center pin, and where the center pin is comprised of a material that is rigid within the normal operating temperature range of the battery and deforms, and/or melts, when the battery temperature exceeds the normal operating temperature range of the battery.

System and Method for Inhibiting the Propagation of an Exothermic Event

Granted: April 21, 2011
Application Number: 20110091760
A system and method disperses a sudden increase in heat generated by one battery cell to a large area including multiple battery cells, thereby preventing the sudden increase from being absorbed primarily by a small number of other battery cells, such as a single battery cell, that could otherwise cause the other battery cells to fail or release their own heat.

Vehicle User Interface with Proximity Activation

Granted: April 7, 2011
Application Number: 20110082616
A method for using a vehicle user interface is provided, the user interface utilizing a touch screen display mounted within the vehicle. A proximity detection system provides a means for switching the touch screen display from the sleep mode to the normal use mode without the user having to touch the screen, thus expediting user interaction with the touch screen. The proximity detection system may be configured to distinguish the user's presence per touch screen zone, thereby allowing…

Morphing Vehicle User Interface

Granted: April 7, 2011
Application Number: 20110082627
A method for operating a vehicle user interface is provided, the user interface utilizing a touch-screen display mounted within the vehicle. In one aspect, the visual or visual/interactive properties of the interface change after the user initiates interface interaction. In another aspect, the interface allows a user to utilize any of a variety of different control interaction techniques, all to achieve the same function.

Adaptive Vehicle User Interface

Granted: April 7, 2011
Application Number: 20110082620
A method is provided for configuring a vehicle interface in response to a monitored vehicle condition. For example, the vehicle condition sensor may be a precipitation sensor, in which case the set of vehicle subsystem touch-sensitive soft buttons correspond to windshield wiper controls when the precipitation sensor indicates a non-zero precipitation level. Alternately, the vehicle condition sensor may be a GPS sensor, in which case the set of vehicle subsystem touch-sensitive soft…

Adaptive Soft Buttons for a Vehicle User Interface

Granted: April 7, 2011
Application Number: 20110082619
A system and a method are provided for configuring the touch-sensitive area and/or the tap duration associated with a plurality of touch-sensitive soft buttons of a vehicle user interface in response to varying vehicle conditions. In particular, as a monitored vehicle condition deteriorates, the system controller coupled to the vehicle user interface expands the touch-sensitive region and/or increases the tap duration of the touch-sensitive soft buttons, thereby improving the user's…

Adaptive Audible Feedback Cues for a Vehicle User Interface

Granted: April 7, 2011
Application Number: 20110082618
A system and a method are provided for adapting a vehicle user interface to generate audible feedback cues when the user interacts with the vehicle interface via touch-sensitive soft buttons and the vehicle speed exceeds a preset speed. When the vehicle speed does not exceed the preset speed, either no audible feedback cues are provided to the user during interaction via the touch-sensitive soft buttons, or the volume level of the audible feedback cues is less than that used when the…

User Configurable Vehicle User Interface

Granted: April 7, 2011
Application Number: 20110082615
A method for configuring and personalizing a vehicle user interface is provided, the user interface utilizing a touch screen display mounted within the vehicle. User configurable aspects of the user interface include the number of zones within the touch screen display, the size of each zone, the subsystem interface assigned to each zone, the style and information contained within each subsystem interface, display brightness levels for the overall display or per zone, and the assignment…

Method and apparatus for the external application of a battery pack adhesive

Granted: March 31, 2011
Application Number: 20110076538
A method and apparatus for simplifying battery pack assembly that allows inspection of the cell-to-housing bonding region is provided. In particular, a battery pack housing member is provided that includes an interior surface that partially defines the interior region of the battery pack and that includes a plurality of cell mounting wells and an exterior surface that includes a plurality of bonding wells. Adhesive introduced into the bonding wells forms a mechanical bond between an…

DETERMINING BATTERY DC IMPEDANCE

Granted: March 31, 2011
Application Number: 20110077879
A method and apparatus for measuring battery cell DC impedance by controlling charging of the battery cell. The method includes real-time characterization of a battery, (a) measuring periodically a DC impedance of the battery to determine a measured DC impedance; (b) ratioing the measured DC impedance to a reference DC impedance for the battery to establish an impedance degradation factor; (c) obtaining, during use of the battery and responsive to a set of attributes of the battery, an…

Rotor Design for an Electric Motor

Granted: March 17, 2011
Application Number: 20110062819
A rotor assembly and a method for fabricating the same are provided in which a solid rotor ring is formed at either end of a stack of laminated discs, the solid rotor rings yielding improved electrical and mechanical characteristics in a low weight assembly. The solid rotor rings are fabricated by brazing slugs between the end portions of the rotor bars, the braze joints contacting a large percentage (at least 90%) of the rotor bar end portions.

LOW TEMPERATURE CHARGING OF LI-ION CELLS

Granted: January 20, 2011
Application Number: 20110012562
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…

Method and Apparatus for Maintaining Cell Wall Integrity Using a High Yield Strength Outer Sleeve

Granted: January 20, 2011
Application Number: 20110014506
A method and apparatus is provided in which a pre-formed sleeve or pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed sleeve/secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.