US 9,030,063 B2Granted

Thermal management system for use with an integrated motor assembly

AssigneeTesla Motors, Inc.

InventorsPeter Dore Rawlinson, Nicholas John Sampson, Nicholas Robert Kalayjian, Vincent George Johnston, David Fred Nelson, Gary Allen Pinkley, Wulfer Adrijan de Bruijn, Benjamin David Dettmann, Nicolas Verzeni, Michael Raj Kubba, Edwin M. Pearce, Jr., Jim Robbins

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Abstract

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.

Claims16

Dependent claims

An integrated drive system assembly of an electric vehicle, comprising:

a single, multi-piece enclosure;
an electric motor disposed within said single, multi-piece enclosure;
a power inverter assembly operable to convert DC current supplied by an energy storage system of said electric vehicle to AC current capable of operating said electric motor, wherein said power inverter assembly is disposed within said single, multi-piece enclosure;
a gearbox disposed within said single, multi-piece enclosure and coupled to said electric motor, wherein said electric motor is coupled to a drive train of said electric vehicle via said gearbox, and wherein said electric motor provides propulsive power to said electric vehicle;
and
a mutual thermal management system coupled to said integrated drive system assembly and comprised of a liquid coolant loop containing a liquid coolant, wherein said liquid coolant loop is thermally coupled to said electric motor, said power inverter assembly and said gearbox.

3 more elements

Dependencies are inferred from the claim text.

Facts

Application: 13/326,463Filed 15 Dec 2011 · us provisional application
Priority: 17 Dec 2010
Published: US 2012/0153718 A121 Jun 2012
Granted: 12 May 2015
Term ends: Not estimatedThe source records don’t support an estimate.

Classification46 codes

B60L 1/003
Supplying electric power to auxiliary equipment of vehicles: to auxiliary motors, e.g. for pumps, compressors
B60H 1/00278
HVAC devices specially adapted for particular vehicle parts or components and being connected to the vehicle HVAC unit: for the battery
B60H 1/00392
For vehicles having an electrical drive, e.g. hybrid or fuel cell: for electric vehicles having only electric drive means
B60K 1/00
Arrangement or mounting of electrical propulsion units