It cited a Leaked Tesla email that said Tesla knew of a problem with the battery cooling device when it massproduced the Model S in 2012 and could have shorted or even caught fire. At the same time, Tesla commissioned three companies to test the cooling configuration, and all three results showed problems with the end connection slots of the cooling system bars.
To cool the battery, the Tesla Model S’s battery cooling system is installed in the battery plus coolant pipe, but because the aluminum material used in the end connection fitting is soft, it is easy to wear and leak coolant during use.
People familiar with the matter said IMR Labs told Tesla in July 2012 that the aluminum material attached to the end-end fittings did not reach the hardness it should and was likely to rupture and leak. Test participants, who spoke on condition of anonymity, said that with this result clear, Tesla would continue to deliver the Model S as usual during that period.
Tesla commissioned two other companies to test the system’s software, and both companies showed that the end-of-line connections to the cooling system were not stable and that there was a high probability of a leak.
Then, at the end of 2012, Tesla employees discovered the problem during production, and the production line had to use hammers to reinforce the end connections to the cooling system to ensure the connection was complete.
In addition,media said, Tesla finally improved the battery cooling system, but when, the exact source is still not known. Tesla has yet to respond to the question.