Tesla Motors Patent Applications

Method for Determining Battery Pack Isolation Resistance Via Dual Bus Monitoring

Granted: January 31, 2013
Application Number: 20130027049
A method for measuring and calculating the isolation resistance of a battery pack is provided, the method being invulnerable to changes in the bus voltage that may take place between measurements.

Charge Rate Modulation of Metal-Air Cells as a Function of Ambient Oxygen Concentration

Granted: January 17, 2013
Application Number: 20130015823
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.

Charge Disruption Monitoring and Notification System

Granted: January 17, 2013
Application Number: 20130015814
A system and method for notifying a designated party when an electric vehicle charging operation is unexpectedly disrupted is provided. The system monitors the connection between the electric vehicle and the external battery pack charging source, issues a command to a notification system to send a notification message to the designated party when an interruption is detected, and then issues the notification message in accordance with a set of notification instructions. The notification…

Battery Coolant Jacket

Granted: January 3, 2013
Application Number: 20130004820
A battery coolant jacket for use with a plurality of cells is provided, the jacket comprised of a hollow enclosure configured to permit a liquid coolant to flow through the enclosure, entering via a coolant inlet and exiting via a coolant outlet; a plurality of cell apertures that extend completely through the hollow enclosure, where each cell aperture is sized to fit a cell; and a plurality of coolant segregation walls that are integrated into the hollow enclosure and separate the cells…

TRACTION MOTOR CONTROLLER WITH DISSIPATION MODE

Granted: January 3, 2013
Application Number: 20130002173
An apparatus in an electric vehicle including a propulsion electric motor powered by energy from an energy storage system, including a field oriented motor controller generating motor control signals for the electric motor, the motor control signals responsive to a flux command signal and a torque command signal; a torque command calculator, coupled to the motor controller, generating the torque command signal to command a desired torque; an optimal efficiency controller, coupled to the…

Battery Pack Dehumidifier with Active Reactivation System

Granted: December 13, 2012
Application Number: 20120315517
A battery pack dehumidifier system for controlling the relative humidity within a battery pack enclosure is provided, the dehumidifier system including a desiccant that absorbs/adsorbs water vapor from the battery pack enclosure. The system heats and reactivates the desiccant at predetermined time intervals or when the humidity within the system reaches a preset level, thereby allowing the desiccant to regain its potential for absorbing/adsorbing water vapor.

Vehicle Battery Pack Ballistic Shield

Granted: December 13, 2012
Application Number: 20120312615
An improved protection system for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the system utilizing a ballistic shield mounted under the electric vehicle and interposed between the battery pack enclosure and the driving surface, where the ballistic shield is spaced apart from the enclosure bottom panel. A layer of a compressible material is interposed between the ballistic shield and the battery pack enclosure.

POWER ELECTRONICS INTERCONNECTION FOR ELECTRIC MOTOR DRIVES

Granted: December 6, 2012
Application Number: 20120305283
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…

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

Granted: December 6, 2012
Application Number: 20120308857
A method and apparatus is provided in which a 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 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.

Battery Pack Enclosure with Controlled Thermal Runaway Release System

Granted: December 6, 2012
Application Number: 20120308858
A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

Battery Pack Enclosure with Controlled Thermal Runaway Release System

Granted: December 6, 2012
Application Number: 20120308859
A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

CHARGING EFFICIENCY USING VARIABLE ISOLATION

Granted: November 8, 2012
Application Number: 20120280662
A method for charging an energy storage system (ESS) from an AC line voltage having differing input voltages (e.g., 120Vac or 240Vac), 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…

CLEANING FEATURE FOR ELECTRIC CHARGING CONNECTOR

Granted: October 25, 2012
Application Number: 20120266914
A contamination cleaner for a socket of a charging connector used with a charging station for an electric vehicle wherein the charging connector mates to a charging coupler of the electric vehicle during charging includes a housing mechanically configured generally similarly to the charging coupler enabling the housing to mechanically mate to the charging connector; and a cleaning contact, coupled to the housing and complementary to the socket, for engaging the socket and removing…

Integrated Battery Pressure Relief and Terminal Isolation System

Granted: October 25, 2012
Application Number: 20120270080
A system for integrating the venting feature of a battery with a means for simultaneously disconnecting the cell from the battery pack, thereby isolating the cell, is provided. The provided battery interconnect system is comprised of a battery, a connector plate for electrically coupling the battery to a battery pack, and an interruptible electrical connector for electrically coupling the connector plate to a battery terminal vent. The venting region, defined by scoring on the battery…

CHARGING EFFICIENCY USING SELECTABLE ISOLATION

Granted: September 13, 2012
Application Number: 20120229098
The apparatus for charging an energy storage system (ESS) from an AC line voltage includes a boost stage for converting the AC line voltage to a first ESS charging voltage; an isolation stage, coupled to the boost stage, for converting the first ESS charging voltage to a second ESS charging voltage with the second ESS charging voltage less than the first ESS charging voltage, the isolation stage removing a common mode current between the ESS and the boost stage; a configurator,…

Battery Pack Venting System

Granted: September 13, 2012
Application Number: 20120231306
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…

Active Louver System for Controlled Airflow in a Multi-Function Automotive Radiator and Condenser System

Granted: September 6, 2012
Application Number: 20120222833
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…

FAST SWITCHING FOR POWER INVERTER

Granted: August 2, 2012
Application Number: 20120194119
An apparatus includes an inverter including a high-side switch coupled to a low-side switch, the inverter generating a time-varying drive current from a plurality of drive control signals, a positive rail voltage, and a negative rail voltage wherein controlling the switches to generate the time-varying drive current produces a potential transitory overshoot condition for one of the switches of the inverter; a drive control, coupled to the inverter, to generate the drive control signals…

FAST SWITCHING FOR POWER INVERTER

Granted: August 2, 2012
Application Number: 20120195079
An apparatus includes an inverter including a high-side switch coupled to a low-side switch, the inverter generating a time-varying drive current from a plurality of drive control signals, a positive rail voltage, and a negative rail voltage wherein controlling the switches to generate the time-varying drive current produces a potential transitory overshoot condition for one of the switches of the inverter; a drive control, coupled to the inverter, to generate the drive control signals…

FAST SWITCHING FOR POWER INVERTER

Granted: August 2, 2012
Application Number: 20120195085
An apparatus includes an inverter including a high-side switch coupled to a low-side switch, the inverter generating a time-varying drive current from a plurality of drive control signals, a positive rail voltage, and a negative rail voltage wherein controlling the switches to generate the time-varying drive current produces a potential transitory overshoot condition for one of the switches of the inverter; a drive control, coupled to the inverter, to generate the drive control signals…