Tesla Patente

An electrode for use in energy storage devices including an electrode film formed from an electrode film mixture including water and a solvent additive, and methods thereof, are disclosed. The electrode utilizing water and a solvent additive may aid in reducing compressive stress, creases and/or curvature during formation, thereby achieving improved electrode shape and/or strength.

An inductor cell for vertical power delivery includes a first plate, a second plate, a power conductor, an inductor core, and a ground conductor. The power conductor extends between the first plate and the second plate in a vertical direction. The inductor core extends between the first plate and the second plate in the vertical direction. The ground conductor extends between the first plate and the second plate in the vertical direction. The power conductor is configured to deliver power between the first plate and the second plate along the vertical direction. The inductor cell is configured as an inductor in a power delivery path.

A system for processing an electrode film mixture comprising an inline air milling apparatus coupled to a mixing apparatus, and methods thereof, are disclosed. Such a system may help adjust the particle size distribution and temperatures of the electrode film materials and distribute the materials more effectively, thereby improving material uniformity of the electrode film mixture.

Generally described, one or more aspects of the present disclosure relate to methods, systems, and devices related to forming a wound electrode assembly including a hemmed electrode and a separator, the hemmed electrode including an electrode film and a foil. The foil can include a core edge, a can edge, and a hemmed edge disposed between the core and can edges and extending from the core edge to the can edge. The electrode film can be disposed over the foil and the hemmed edge can extend beyond a top edge of the electrode film. The hemmed electrode can be wound to form a wound hemmed electrode assembly.

Aspects of the present application correspond to utilization of a combined set of inputs from simulation systems to generate or train machine learned algorithms for utilization in vehicles with vision system-only based processing. Aspects of the present application correspond to utilization of a set of inputs from sensors or sensing systems and simulation systems to create updated training sets for use in machine learning algorithms. The combined set of inputs includes a first set of data corresponding to vision system from a plurality of cameras configured in a vehicle. The combined set of inputs further includes a second set of data corresponding to simulated content systems that generate additional training set data including visual images and data labels to supplement the vision system data.

A magnetic component assembly includes a first ferrite body having a first surface and a first metallized layer comprising silver and glass frit disposed on the first surface. A printed circuit board includes a coil pattern, and a second ferrite body having a second surface with a second metallized layer is provided. The first ferrite body is disposed on a first side of the printed circuit board and the second ferrite body is disposed on a second side, with the metallized layers coupled to the coil pattern through solder joints to enable power transfer between windings. The metallized layers provide both mechanical attachment and electrical conductivity, eliminating separate adhesive processes while maintaining isolation capabilities of at least 1000 volts. Methods of manufacturing include ultrasonically washing the ferrite surfaces before applying the metallized layers through screen printing.

Fluid formulations, including low traction fluid, low viscosity motor fluid and high pressure viscosity coefficient fluid formulations, that may be used in vehicle drive trains are described herein. The fluid formulations include a base oil and an additive. The fluid formulations can increase efficiency, reduce friction, and extend drive cycles associated with vehicle drive units.

A separator assembly for use in energy storages devices comprising a separator layer and a supporting tape, and methods thereof are disclosed. Separator assemblies utilizing a supporting tape such as a barrier layer and/or a coil core layer provides additional support to prevent electrode buckling and to protect the separator layer from wear-related electrode buckling and puncture over the life of the energy storage device.

Aspects of the present application correspond to utilization of a set of inputs from vision systems to generate simulations or predicted paths of travel for dynamic objects detected from the vision systems. Illustratively, a service can process the set of inputs (e.g., the associated ground truth label data) collected from one or more vision systems (or additional services) to identify predicted paths of travel for any dynamic objects detected from the captured vision system information. Typically, a plurality of predicted paths of travels can be generated such that more than one path of travel may be considered to meet or exceed a minimal threshold. The resulting predicted paths of travel can be further associated with confidence values that characterize the likelihood that any one predicted path of travel for a detected dynamic object will occur. The generated and processed paths can be provided or used as inputs for additional systems, such as navigation systems/services, semi-automated or automated driving systems/services and the like.

A rotor (200) that utilizes non-magnetic fillers (202) to reduce magnetic flux leakage and maintain structural integrity is disclosed. Said rotor (200) includes at least a plurality of rotor laminations (208), a magnet (112), and one or more non-magnetic fillers (202). Said rotor laminations (208) structurally form at least a first cavity and a second cavity. At least one magnet (112) is disposed in said first cavity. Said one or more non-magnetic fillers (202) are disposed in the second cavity and bonded to the plurality of rotor laminations to structurally support the plurality of rotor laminations (208).

A vehicle seating assembly is provided and includes an armrest configured to rotate about an axis and between an up position and a down position. An inertia latch has a ratchet and is configured to move between a disengaged position and an engaged position to inhibit unintended movement of the armrest in the event of a collision. Certain implementations include one or more gears.

A method for forming an electrode active material comprising mixing a lithium source and an active material precursor utilizing homogenization and sintering processes, and products thereof, are disclosed. Such a method utilizing large lithium source particles removes the need for milling lithium source particles, thereby achieving a cost-effective and simplified electrode active material production process.

A bearing assembly for power transmission includes a bearing outer ring, a bearing housing, and a retaining plunger. The bearing outer ring comprises a first surface and a second surface, the bearing outer ring structurally forming at least a first recess on the first surface. The bearing housing houses the bearing outer ring and forms a cavity. The retaining plunger with a spring is partially enclosed by the cavity. When the first recess and the retaining plunger misalign, the retaining plunger is compressed into the cavity by the first surface of the bearing outer ring.

Calendering methods that accurately and/or precisely calender dry electrode films, and systems thereof, are described. The methods and systems are able to control the calendering nip and/or calendering distance between the calendering rollers with and/or without the presence of an electrode film and/or electrode powder mixture such that the variation of the calendering distance is reduced.

In some examples, a configurable multi-plate compact friction clutch is provided for use in vehicle applications, particularly for protecting actuators from excessive torque. The friction clutch includes an output coupling, a center housing, alternating metal and thermoplastic friction plates engaged with the center housing and output coupling respectively, and a biasing member applying a compressive force to the friction plates. The clutch transfers torque between an input and output while allowing slippage to protect against over-torque conditions. The design enables consistent performance across a wide temperature range and can be scaled for various applications. The clutch's compact nature and silent operation make it suitable for use in vehicle charging door actuators and other automotive closure systems.

A system for managing a battery pack of an electric vehicle includes a sensor and a controller. The sensor is configured to detect a temperature associated with the battery pack. The controller is configured to transmit a request to a charger based on a sensor signal from the sensor, and provide at least a portion of alternating current associated with the request and received from the charger to at least a first battery cell of the battery pack such that heat is generated based on an internal resistance of the first battery cell to increase a temperature associated with the first battery cell. Related electric vehicles, methods, and chargers are disclosed.

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.

Generally described, one or more aspects of the present disclosure relate to methods, systems, and devices related to a powder dispensing system, including a pair of calender rolls, a first conical hopper and a second conical hopper positioned above the pair of calender rolls, each hopper having a first temperature controlled fluidized section, a first flow control system in fluidic connection with the first temperature controlled fluidized section, and a second flow control system in fluidic connection with the second temperature controlled fluidized section, a vertical linear actuator configured to adjust a distance between the first conical hopper, the second conical hopper and the pair of calender rolls, and a horizontal linear actuator positioned between the first conical hopper and the second conical hopper.

A system and method for processing a dry electrode film comprising a roller system, a terahertz measurement device and a dry electrode powder mixture dispenser, are disclosed. The measurement device may comprise a terahertz source and a terahertz sensor. Such terahertz source may be emitted towards an upper and lower surface of the dry electrode film and reflected back towards the terahertz sensor to measure a physical property of the dry electrode film.

Generally described, one or more aspects of the present disclosure relate to methods, systems, and devices related to pre-straining bare lanes of a multilane electrode with a system for calendering a multilane electrode including a pre-strain roll device including a plurality of pre-strain rollers and a pressure roller forming a pre-strain nib and a calender roll device comprising a pair of calendering rollers forming a calendering nip positioned downstream from the pre-strain roll device.

A method of forming a shaped electrode film and products thereof, are described. The electrode film having a shaped edge may aid in the core circularity of electrode assemblies, which may improve the structural stability of energy storage devices with minimal change in electrode assembly design and manufacturing.

A powder dispensing apparatus having an elongate wedge-shaped hopper including one or more fluidized plates is described. The powder dispensing apparatus can be positioned above a pair of calender rolls to distribute a powder, such as a dry electrode material onto the calender rolls. Such a fluidized wedge-shaped hopper advantageously allows for an accurate and/or controlled rate of powder distribution across or substantially across the length of a calender roll.

A wireless charging pad can include an H bridge circuit, a resonant tank electrically connected to the H bridge circuit, and a switch control circuit. The resonant tank can include a coil arranged for wireless power transfer. The switch control circuit can control the H bridge circuit using both a first modulation and a second modulation. The first modulation includes two non-zero switch configurations and two different zero switch configurations. The second modulation includes the two non-zero switch configurations and the two different zero switch configurations in a different sequence than the first modulation.

An actuator assembly or a revolute joint for a device includes a rotating portion, a fixed portion, and a clockspring. The rotating portion is configured to interface the fixed portion. The fixed portion and the rotating portion structurally form a space that is at least partially surrounded by the fixed portion and the rotating portion. The clockspring is shaped to fit into the space, and is configured to transmit at least an electrical power signal or a data signal from the rotating portion to the fixed portion.

A wireless charging pad can include a switching circuit, a resonant tank, and an impedance control circuit. The resonant tank can have a resonant frequency and be electrically connected to the switching circuit. The resonant tank can include a coil arranged for wireless power transfer, and a tunable impedance circuit. The impedance control circuit can be configured to adjust an impedance of the tunable impedance circuit to adjust the resonant frequency of the resonant tank.

Disclosed examples relate to a Heating, Ventilation, and Air Conditioning (HVAC) apparatus for a vehicle. The apparatus includes a suction HVAC unit with a plenum, a hot air pocket extraction duct connected to the plenum, and one or more suction intakes connected to the hot air pocket extraction duct. The hot air pocket extraction duct is configured to draw hot air from a hot air pocket in the vehicle through the suction intakes into the plenum. The apparatus may include dashboard and/or roof suction intakes positioned in regions prone to hot air pocket formation. Methods for controlling climate in a vehicle cabin using the apparatus, manufacturing a vehicle with the apparatus, and optimizing the HVAC system are also described.

Examples relate to an electric vehicle charging system comprising a drive unit with a motor and inverter, a battery pack, a charging interface, and a controller. The controller reconfigures the drive unit to function as a boost converter, boosts voltage received from an external charging source using the reconfigured drive unit, and charges the battery pack with the boosted voltage. The system adaptively controls inverter switches during charging based on conditions, integrates EMI filtering components, and is compatible with various battery architectures. This approach enables efficient charging from different voltage sources while utilizing existing vehicle components.

A direct cooling method and system in charging system utilizing a water-based conductive fluid. The charging system includes a conductive fluid reservoir that provides conductive fluid to charging system components. The charging system further defines conductive fluid return paths for the conductive fluid. The length of a fluid path is specified to exceed a minimal resistance threshold based on the product of the resistivity and return path length. The system can include the incorporation of feedback loop into the charging system that can measure the electrical resistance of the conductive fluid.

Modular processing systems are provided. In one aspect, a modular processing system includes a first electronics module including a first printed circuit board (PCB) and a first electronic component on the first PCB, a second electronics module including a second PCB and a second electronic component on the second PCB, and a cold plate arranged between the first electronics module and the second electronics module. The cold plate is configured to circulate a coolant to cool the first PCB and the second PCB. At least a portion of the cold plate is included in the first electronics module. The first electronics module is removably secured to the second electronics module.

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