Tesla Motors, Inc.

Tesla, Inc.

Benjamin David Dettmann

Nicholas Robert Kalayjian

Michael Raj Kubba

Edwin Marcum Pearce, Jr

Jim Robbins

Joshua Willard Ferguson

Ryan Carter Kroeze

William Thomas Chi

Peter Dore Rawlinson

Vincent George Johnston

Gary Allen Pinkley

David Fred Nelson

Dino Sasaridis

Nicholas John Sampson

Wulfer Adrijan De Bruijn

Nicolas Verzeni

An electric vehicle includes an energy storage system, an integrated drive system assembly having a gearbox, a power inverter, and an electric motor, wherein the gearbox, the electric motor and the power inverter are assembled into a single unit with a multi-piece housing. The electric vehicle may also include two half shafts for respective wheels of the electric vehicle. The gearbox, the electric motor and the power inverter may be oriented such that the gearbox extends along a center line of the electric vehicle and the electric motor and the power inverter extend from the gearbox in opposite directions. The electric vehicle may also include a mutual thermal management system coupled to the integrated drive system assembly and having at least one liquid coolant loop that is thermally coupled to the electric motor, the power inverter, the gearbox, a cooling system, a refrigeration system, and an HVAC system.

Integrated electric motor assembly

An integrated drive system assembly is provided that combines an electric motor, a power inverter assembly and a gearbox into a single, multi-piece enclosure. Combining these components into a single enclosure reduces weight, reduces drive system complexity, reduces system volume, simplifies assembly integration into an electric vehicle, reduces manufacturing cost, allows the flexible and lengthy electrical cables between the power inverter and the electric motor to be replaced with short, low loss, rigid bus bars, and simplifies component cooling by allowing the use of a common thermal management system. The common thermal management system includes a liquid coolant loop that is thermally coupled to the electric motor, the power inverter assembly and the gearbox.

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 lead of an electrical component and a second via for receipt of a second electrical lead of the electrical component and wherein: the first dielectric layer and the second bus bar layer each include a via aligned with the first via wherein the first electrical lead is extendable from beneath the first bus bar layer through the first dielectric layer and through the second bus bar layer.

Power electronics interconnection for electric motor drives

An integrated drive system assembly is provided that combines an electric motor, a power inverter assembly and a gearbox into a single, multi-piece enclosure. Combining these components into a single enclosure reduces weight, reduces drive system complexity, reduces system volume, simplifies assembly integration into an electric vehicle, reduces manufacturing cost, allows the flexible and lengthy electrical cables between the power inverter and the electric motor to be replaced with short, low loss, rigid bus bars, and simplifies component cooling by allowing the use of a common thermal management system, i.e., a mutual thermal management system. The common thermal management system includes a liquid coolant loop that is thermally coupled to the electric motor, the power inverter assembly and the gearbox.

Thermal management system for use with an integrated motor assembly

A system and method for a shielded coaxial cable including a collar including a cylindrical housing having a cylindrical inner bore, the inner bore having top and bottom openings the top opening having a diameter about equal to an outer diameter of an outer insulating layer of the cable and the bottom opening having a diameter about equal to an outer diameter of a shield layer of the cable with a terminating portion of the shield layer exposed and returned over an exterior portion of said collar near the bottom opening with the terminating portion overlapping said exterior portion; and a termination ferrule joined to the terminating portion that overlaps the exterior portion to simultaneously provide an electrical communication between the shield layer and the collar and provide a strain relief for the shielded cable disposed within the inner bore.

High voltage cable connector

Growing community of inventors

San Francisco, CA, United States of America

Benjamin David Dettmann