DE102024114628A1 - inner contour hose - Google Patents

Abstract

The invention relates to an electrical line and an electrical cable with at least one such electrical line. One embodiment of the electrical line (10) comprises: at least one electrical conductor (16); and a cooling line (12) circumferentially surrounding the at least one electrical conductor (16). A cooling medium (14) can be guided in an interior space of the cooling line (12), and the cooling line (12) has at least one inner contour (18) projecting into the interior space and formed on an inner surface of the cooling line (12).

Description

The invention relates to an electrical conductor, in particular for a charging cable, and an electrical cable, in particular a charging cable for example for electric vehicles, with at least one such electrical conductor.

Electric vehicles are typically charged at charging stations using charging cables. These cables are usually connected to the charging station at one end and can be connected to an electric vehicle for charging. The maximum charging power for an electric vehicle depends on several factors, such as the charging power of the electric vehicle and the charging station. Besides the electric vehicle and charging station, other factors influencing the maximum charging power include the temperature and the battery's state of charge.

Besides the battery temperature, the charging cable temperature also plays a role in the charging power and thus the charging time. Generally, charging systems designed for high charging power generate significant heat. This can be particularly problematic with charging cables that have smaller cross-sections. These smaller cross-sections would typically not be able to transmit the necessary power because they would heat up too quickly under the current load. This could lead to exceeding the maximum permissible conductor temperature according to EN 50620 or IEC 62893 after a certain period. The charging process might then have to be interrupted or aborted. Furthermore, the cables' lifespan would be reduced.

Furthermore, the surface temperature of the charging cable could also rise above the IEC 117 limit and potentially lead to injuries to the user when touching or handling the charging cable. The heat energy generated during charging must therefore be dissipated, for example, by means of a cooling line. One current approach to this is to integrate hoses into the cable construction, which extract the heat from the cable. The medium in the cooling hoses can be gaseous or liquid. Conductive liquids (e.g., a water-glycol mixture) are generally used more frequently for cooling in the thermal management process.

Currently available cooling solutions for charging cables are not optimal in terms of cooling performance. To improve cooling efficiency, the state of the art includes direct cooling, in which the heat-generating conductor elements come into direct contact with a cooling medium, for example, being directly surrounded by a cooling medium without being separated from it by a cooling hose or similar device. With directly cooled charging cables, as well as with other cables, it is advantageous if the conductor within the cable is positioned as centrally as possible within the cooling hose to avoid direct contact with the hose wall. If the conductor touches the hose wall, less cooling occurs in that area. A hot strip can form along the hose wall. This transfers heat into the cable structure and leads to elevated temperatures.

Currently, concentricity in directly cooled charging cables is ensured by means of a so-called helix wire (spiraled stranded wire around a copper cable in the core). This helix wire presents many problems in assembly, manufacturing, and the insertion of the copper cable.

Therefore, there is a need for alternative solutions.

The EP 4 147 903 A1 This relates to a charging cable for an electric vehicle, wherein the charging cable comprises a cooling hose extending longitudinally and configured for transporting a cooling medium through the charging cable, an earthing conductor extending longitudinally substantially parallel to the cooling hose and serving as ground, several current wires extending longitudinally and configured for conducting positive and/or negative direct current, and an outer layer extending longitudinally and surrounding the cooling hose, the earthing conductor, and the several current wires. Each of the several current wires comprises a conductor and insulation surrounding the conductor. Several spacers are arranged between the conductor and the insulation such that a cooling channel is formed between the conductor and the insulation.

There is a need for improved approaches to electrical wiring and electrical cables with such conductors. In particular, there is a need for an electrical wire that reliably prevents contact between an electrical conductor and a cooling line, as well as for an electrical cable with at least one such conductor.

According to a first aspect of the invention, an electrical conductor, in particular for a charging cable, for example for electric vehicles, is provided. The electrical conductor has at least The cooling line includes an electrical conductor. The electrical conductor has a cooling line that surrounds the at least one electrical conductor. The cooling line can, in particular, include a cooling hose or be designed as a cooling hose. A cooling medium can be carried within an interior of the cooling line. The cooling line has at least one internal contour. This internal contour projects into the interior. This internal contour is formed on an inner surface or wall of the cooling line.

In a first state of the electrical conductor, the at least one inner contour is spaced away from the at least one electrical conductor. In other words, the at least one electrical conductor is not in contact with the at least one inner contour in the first state (i.e., it does not touch it). Simultaneously, the cooling conductor is spaced away from the at least one electrical conductor. The first state of the electrical conductor can be one in which the electrical conductor is, in particular, at least substantially undistorted.

In at least one second state of the electrical conductor, the at least one electrical conductor comes into contact with the at least one inner contour. In this second state, the at least one electrical conductor comes into contact with the at least one inner contour in such a way that the inner contour prevents contact between the at least one electrical conductor and the cooling line. In other words, the contact of the at least one inner contour with the at least one electrical conductor prevents contact between the at least one electrical conductor and the cooling line. In particular, the contact of the at least one inner contour with the at least one electrical conductor prevents contact between the at least one electrical conductor and the inner surface (inner wall) of the cooling line. The inner surface (inner wall) of the cooling line can be considered, in cross-section, as a shape that at least almost continuously follows the shape of the cooling line, for example, a shape that is at least almost circular around the center point of the cooling line. The inner surface (inner wall or inner surface) of the cooling line can, in particular, be considered the section of the cooling line that directly borders the interior of the cooling line.

Even if the at least one inner contour is integrally formed with the inside of the cooling line, for example, it can be understood as a different element than the cooling line itself, and in particular, the inside of the cooling line. Thus, contact of the at least one electrical conductor with the cooling line can be understood as contact with areas/sections of the cooling line other than/excluding the at least one inner contour. Similarly, contact of the at least one electrical conductor with the cooling line can be understood as contact with areas/sections of the cooling line other than the at least one inner contour. In other words, contact of the at least one electrical conductor with the inside of the cooling line can be understood as contact with areas/sections of the inside of the cooling line other than the at least one inner contour.

The at least one inner contour can have a lower thermal conductivity than the at least one electrical conductor. In particular, the at least one inner contour can be almost non-conductive. This can, for example, result in less efficient heat conduction through the at least one inner contour. Consequently, the heat is more likely to be transferred to an existing cooling medium than to a conductor core.

The at least one second condition of the electrical conductor can arise from various causes/circumstances. For example, the at least one second condition may involve a situation in which the electrical conductor is at least partially bent.

There can be several second states in which the electrical conductor is bent to varying degrees and/or at different points. In each of these second states, the at least one electrical conductor comes into contact with the at least one inner contour in such a way that the at least one inner contour prevents contact between the at least one electrical conductor and the cooling conductor. Besides the at least one second state, there can be further states in which the electrical conductor is at least partially bent, but the at least one electrical conductor does not come into contact with the at least one inner contour. In these further states, the at least one inner contour does not necessarily have to prevent contact between the at least one electrical conductor and the cooling conductor. dern, because in these further states there would be no contact between the at least one electrical conductor and the cooling line without the at least one inner contour.

The at least one electrical conductor is located within the interior of the cooling line. The at least one electrical conductor can consist of exactly one conductor or be configured as exactly one conductor; that is, the at least one electrical conductor can, for example, be a single conductor within the cooling line, such as a cooling hose. The exact one electrical conductor can be a stranded conductor. The stranded conductor, also called a strand, can consist of a multitude of individual wires. The strand can consist of several (uninsulated) individual conductors or wires. The at least one electrical conductor can be a solid conductor. Regardless of the exact configuration of the at least one electrical conductor, it can be an uninsulated conductor or be configured as an uninsulated conductor. The term "not insulated" (or alternatively "uninsulated") refers to the fact that the at least one non-insulated electrical conductor is not electrically insulated.

A cooling line can generally be a body extending longitudinally along an electrical conductor and/or an electrical cable carrying the conductor. The body may have a cavity in which a cooling medium (which can also be called a coolant) can circulate. The cooling line is not limited to a specific cross-section. For example, it can have a round, square, or oval cross-section. It can take the form of a hollow cylinder, but is not limited to this shape. The cooling line extends, for example, along the entire length of the electrical conductor and/or an electrical cable carrying the conductor. The cooling line can be flexible, i.e., not rigid. For example, it can be elastically bendable or deformable. The cooling line of the electrical conductor can include a cooling hose or be designed as a cooling hose.

The at least one electrical conductor can be cooled by the cooling medium and is indeed cooled when a cooling medium is present. The cooling medium can be, for example, liquid or gaseous. For instance, if the at least one electrical conductor is designed as a non-insulated conductor, it can be cooled directly via a thermally conductive connection using the cooling medium that can be or is carried in the cooling line. The at least one electrical conductor can be in direct contact with the cooling medium of the at least one electrical line. This is also referred to here as "direct cooling." In this case, the cooling medium can be electrically insulating (i.e., non-conductive). Due to the direct contact between the cooling medium and the at least one electrical conductor, the at least one electrical conductor can be cooled particularly efficiently.

The cooling line of the at least one electrical conductor can be designed to be at least nearly impermeable or sealed against the cooling medium. For this purpose, the cooling line can be completely closed in the longitudinal and/or circumferential direction. Alternatively, the cooling line can have a sheathing, creating an internal cavity for the cooling medium. This sheathing can be designed to be at least nearly impermeable or sealed against the cooling medium. In this way, the cooling medium can circulate within the cavity, but is almost entirely prevented from penetrating the sheathing.

The at least one electrical conductor can, in the first state of the electrical line, be arranged at least partially, at least nearly centrally, within the cooling line. For example, the at least one electrical conductor can, in the first state of the electrical line, be arranged along its entire length at least nearly centrally within the cooling line. Due to the at least nearly central arrangement of the at least one electrical conductor within the cooling line, contact between the at least one electrical conductor and the cooling line does not occur in the first state of the electrical line.

The at least one electrical conductor can, in at least one second state of the electrical conductor, be arranged at least partially acentrically within the cooling line. Due to this partially acentric arrangement, the at least one electrical conductor could potentially come into contact with the cooling line in this second state. However, this contact is reliably prevented by the at least one inner contour.

The at least one inner contour can have different shapes. The inner contour can have a cross-section that is, for example, knob-shaped, angular, or round. Regardless of the exact shape, at least one inner contour is formed integrally with the cooling pipe.

The electrical conductor can have at least one filling element. This at least one filling element can be arranged or provided in the at least one inner contour. For example, one filling element can be arranged or provided in each of the at least one inner contour. The at least one filling element can increase the tensile strength of the at least one inner contour. The material of the filling element can be selected to have higher thermal stability and/or higher tensile strength compared to the material of the cooling hose.

According to a first conceivable embodiment, the at least one inner contour can be spiraled or helically shaped on the inside (inner surface) of the cooling line relative to the at least one electrical conductor in the longitudinal direction of the at least one electrical conductor. The lay length of the spiraling can be between 30 mm and 200 mm. A spiraled design of the at least one inner contour can be particularly advantageous when only a single inner contour or exactly two inner contours are provided.

According to a second conceivable embodiment, the at least one inner contour can run parallel to the at least one electrical conductor in the longitudinal direction of the at least one electrical conductor on the inner surface of the cooling line. A parallel configuration can be advantageous, for example, if three or more inner contours are provided. Regardless of the exact configuration, the at least one inner contour can have at least three inner contours or be designed as at least three inner contours. If two or more inner contours are provided, adjacent inner contours of the two or more inner contours can each have an equal distance from each other in the circumferential direction of the electrical conductor or the cooling line.

A diameter of the at least one electrical conductor can be chosen based on: (i) a diameter of the inside/inner surface/inner wall of the cooling conduit, (ii) a minimum distance of contact points of the at least one electrical conductor on the at least one inner contour to the inside/inner surface of the cooling conduit, (iii) a distance between two contact points of an inner contour and (iv) a number of the at least one inner contour.

dL

Durchmesser des elektrischen Leiters

dti

Durchmesser der Innenseite der Kühlleitung

n

Anzahl der mindestens einen Innenkontur

h

minimaler Abstand von Berührpunkten zu der Innenseite der Kühlleitung

bs

Abstand von zwei Berührpunkten einer Innenkontur voneinander.

In particular, the diameter of the at least one electrical conductor can be chosen such that it meets the following condition: $$d_L>\frac{\left(\frac{d_{ti}}{2}-h\right)d_{ti}+hu}{\frac{d_{ti}}{2}-h+u}$$ $$\mathbf{mit}u=\frac{h}{\left[1-\text{cos}\left(\frac{\pi }{n}-\frac{b_s}{d_{ti}-2h}\right)\right]}$$

dL

Diameter of the electrical conductor

dti

Diameter of the inside of the cooling pipe

n

Number of at least one inner contour

h

minimum distance of contact points to the inside of the cooling pipe

bs

Distance between two points of contact of an inner contour.

This condition ensures that the at least one electrical conductor does not touch the inside/inner wall of the cooling line. It also ensures that the at least one electrical conductor is movable within the cooling line and is not trapped between two inner contours. When designed according to the above condition (formula), the inner contours can run straight along the length of the hose, in particular parallel to each other, or they can be spiraled.

According to a second aspect of the invention, an electrical cable, in particular a charging cable for electric vehicles, is provided. The electrical cable has at least one electrical conductor according to the first aspect. The electrical cable has at least one outer sheath that completely surrounds the at least one electrical conductor.

The at least one electrical conductor can include an electrical charging line or be designed as an electrical charging line. The at least one electrical conductor can include a power line or transmission line for electricity or be designed as a power line or transmission line for electricity. A power line or transmission line for electricity heats up relatively significantly due to the, especially high, current flow. In particular, the at least one electrical conductor can contain one or more copper conductors. They may have a copper core or be designed as one or more copper conductors. The current-carrying properties of the electrical conductor increase when it is designed as a copper conductor.

The at least one electrical conductor can be configured as a plurality of electrical conductors, in particular as exactly two or exactly four electrical conductors. Each plurality of electrical conductors can have at least one electrical conductor. Each plurality of electrical conductors can have a cooling line in which a cooling medium can be carried. The respective at least one electrical conductor can be in thermally conductive contact with the associated cooling line in such a way that the respective at least one electrical conductor can be cooled by the cooling medium of the associated cooling line.

If two electrical conductors are provided, a first conductor can be located inside one cooling duct, and a second conductor can be located inside another cooling duct. At least one of the electrical conductors can form a DC conductor. The DC conductor serves to transmit direct current in the charging cable. For example, the DC conductor can be one of the two DC conductors required for transmitting direct current in a charging cable. The first conductor can be a positive DC conductor, and the second conductor can be a negative DC conductor. This enables efficient DC charging of electric vehicles using the charging cable.

For example, the charging cable can transmit currents of one hundred amperes (A), or several hundred amperes, for example up to approximately 3 kA, without any significant heating of the charging cable – provided the cooling system is functioning correctly. This means that a high power output can be transferred from the charging station to the vehicle (and thus to the battery).

The electrical cable can also include a control line, a sensor line, a signal line, a protective line, a data line, and/or an auxiliary power line. Other line types are also conceivable. Two or more of the different lines/line types can be flexibly combined within the charging cable.

The cooling line of the at least one electrical cable can be configured as a supply line or a return line for the cooling medium. Thus, the cooling line of one of the at least one electrical cable can be configured as a supply line, and the cooling line of another of the at least one electrical cable can be configured as a return line, or vice versa. This allows the cooling medium to circulate completely within the charging cable. The supply line can also be referred to as the outflow line. The return line can also be referred to as the return line. For example, the supply line can be a supply line to a connector cooling system, and the return line can be a return line for cooling fluid from the connector cooling system. The supply line can be understood as a channel or hose leading away from a location with high fluid pressure. The return line can be understood as a channel or hose leading to a location with low fluid pressure. The cooling fluid can be transported to the supply line and back to the return line.

Alternatively, the cooling line of at least one electrical line can be configured as the supply line, and an additional cooling line located in the charging cable can be configured as a return line, or vice versa. Similarly, the cooling medium, e.g., a cooling fluid, can be transported through the respective cooling lines, for example, by pumping, and exit at the end.

The at least one electrical conductor may also have insulation. The insulation may surround the cooling conductor of the at least one electrical conductor and the at least one electrical conductor. The insulation may, for example, be in direct contact with the cooling conductor of the at least one electrical conductor, such as the outside surface of the cooling conductor.

The charging cable has an outer sheath. This sheath protects the cable and can therefore also be called a protective jacket. It holds the internal wires together and protects them from abrasion and environmental influences. The outer sheath can also provide thermal insulation. This insulation is particularly advantageous when the cooling medium is a coolant fluid. For example, it prevents the coolant fluid from freezing. The section between the outer sheath and the at least one electrical wire can serve as a supply or return line for the coolant.

In a typical application, the charging cable can be designed as a DC charging cable. The DC charging cable can, for example, have two or four DC charging conductors. The charging cable can also have one or more conductors or wires for AC charging (AC conductors for short). These conductors are used for... The charging cable can also be used for AC charging of an electric vehicle. For example, the charging cable can be a combination cable that enables both DC and AC charging. Examples of possible configurations include three conductors (live, neutral, ground), five conductors (three live, neutral, ground), or seven conductors (three live, neutral, ground, plus two conductors for communication between an energy source, such as a charging station, and an energy sink, such as an electric vehicle battery or the electric vehicle itself).

According to a third aspect, a charging system can be provided. The charging system can include an electrical cable designed as a charging cable, as described in the first aspect, an end connection, and a plug. The end connection can have a coolant supply that can introduce the coolant into at least one of the lines, more precisely into a cooling line of at least one of the lines, and draw it from another of the lines, more precisely from a cooling line of another of the lines. The plug is designed to be connected to the vehicle. In addition to the electrical contacts for electrically connecting the existing electrical conductors to the vehicle's lines, the plug can have a fluid return line that can draw the coolant from the cooling line of one line and direct it to the cooling line of the other line.

Furthermore, according to a fourth aspect, a charging station can be provided with the electrical cable designed as a charging cable according to the second aspect or with a charging system according to the third aspect.

Even though some of the aspects described above have been described in relation to the electrical line according to the first aspect and/or the electrical cable according to the second aspect, these aspects can also be implemented in a corresponding way in the charging system according to the third aspect and/or in the charging station according to the fourth aspect, and vice versa.

• 1a einen Querschnitt eines Ausführungsbeispiel einer elektrischen Leitung in einem ersten Zustand;
• 1b einen Querschnitt eines Ausführungsbeispiel einer elektrischen Leitung in einem zweiten Zustand;
• 2 einen Querschnitt einer Variante des Ausführungsbeispiels einer elektrischen Leitung aus 1 und 1b;
• 3 einen Querschnitt einer Variante des Ausführungsbeispiels einer elektrischen Leitung aus 1a und 1b;
• 4a einen Querschnitt eines ersten Ausführungsbeispiel eines elektrischen Kabels;
• 4b einen Querschnitt eines zweiten Ausführungsbeispiel eines elektrischen Kabels; und
• 4c einen Querschnitt eines dritten Ausführungsbeispiel eines elektrischen Kabels.

The present invention will be further explained with reference to figures. These figures schematically illustrate:

• 1a a cross-section of an embodiment of an electrical conductor in a first state;
• 1b a cross-section of an embodiment of an electrical conductor in a second state;
• 2 a cross-section of a variant of the exemplary embodiment of an electrical conductor made of 1 and 1b ;
• 3 a cross-section of a variant of the exemplary embodiment of an electrical conductor made of 1a and 1b ;
• 4a a cross-section of a first embodiment of an electrical cable;
• 4b a cross-section of a second embodiment of an electrical cable; and
• 4c a cross-section of a third embodiment of an electrical cable.

Specific details are set forth below, without limitation, to provide a complete understanding of the present invention. However, it is clear to a person skilled in the art that the present invention can be used in other embodiments that may differ from the details set forth below. Furthermore, the figures serve only to illustrate embodiments. They are not to scale and are intended only to exemplify the general concept of the invention. For example, features included in the figures should by no means be considered necessary components. Furthermore, an electrical conductor is described below primarily as a charging conductor, but is not limited to this. Similarly, an electrical cable is described below primarily as a charging cable, particularly for electric vehicles, but is not limited to this.

In 1a A first embodiment of an electrical line 10 is shown. The electrical line 10 can, in particular, be configured as a charging line for a charging cable for electric vehicles, as will be described in more detail below. The electrical line 10 has an electrical conductor 16. The electrical line 10 also has a cooling line 12 that surrounds the electrical conductor 16. The cooling line 12 can, in particular, be configured as a cooling hose and can therefore also be referred to as cooling hose 12. A cooling medium 14 can be guided in an interior space of the cooling line 12. The cooling line 12 has at least one internal contour 18 formed on an inner surface of the cooling line 12. In the example from 1a and 1b Four exemplary internal contours 18 are provided as at least one internal contour 18 and formed on the inside of the cooling line 12. The four exemplary internal contours 18 each project into the interior space. How in 1a As can be seen, the inner contours 18 are formed integrally with the cooling line 12 or, in other words, integrally molded onto the cooling line 12. The in 1a The exemplary knob shape of the inner contours 18 shown is purely illustrative, and other shapes are conceivable and possible, for example, an angular shape, such as a rectangular or triangular shape. Adjacent inner contours 18 of the four inner contours 18 are spaced at least nearly equally far apart along the circumference of the cooling line 12. In the example shown, the spacing is 90 degrees.

In 1a A first state of the electrical conductor 10 is shown. In this first state, the electrical conductor 10 can be in a state that is at least substantially undistorted. In this first state, the inner contours 18 of the electrical conductor 10 are spaced apart from the electrical conductor 16. In this first state, the electrical conductor 16 is arranged at least partially, and at least nearly centrally, within the cooling line 12. For example, in this first state, the electrical conductor 16 is not in contact with the cooling line 12 along its entire length.

In 1b A second state of the electrical conductor 10 is shown. In this second state, the electrical conductor 10 can be at least partially bent. In this second state, the electrical conductor 16 is arranged at least partially acentrically in the cooling line 12. 1b The cross-section shows such a section in which the electrical conductor 16 is arranged acentrically in the cooling line 12. In the second state, the electrical conductor 16 comes with a subset (in 1b with two) of the four inner contours 18. The electrical conductor 16 is prevented or blocked from contacting the cooling line 12 by the contact with the two inner contours 18. In other words, in the second state, the electrical conductor 16 comes into contact with a subset (in 1b with two) of the four inner contours 18 in such a way that the two inner contours 18 prevent contact between the at least one electrical conductor 16 and the cooling line 12.

The inner contours 18 can be spiraled or formed on the inside of the cooling line 12 relative to the electrical conductor 16 in the longitudinal direction of the electrical conductor 16. A length of 30 mm to 200 mm is suitable for the spiraling. With a suitable design, particularly with a suitable spiral, a single inner contour 16 can reliably block/prevent contact between the electrical conductor 16 and the cooling line 12.

An alternative to spiralization is in 1a (as can be seen from the perspective drawing). Here, the inner contours 18 run parallel to the electrical conductor 16 and the cooling line 12 in the longitudinal direction of the electrical conductor 16 on the inside of the cooling line 12. With a parallel arrangement of the inner contours 18 relative to the electrical conductor 16, two or more, in particular at least three, inner contours 18 reliably block contact between the electrical conductor 16 and the cooling line 12 if they are suitably designed.

In 2 is a variant of the embodiment from 1a and 1b shown. According to this variant, the electrical conductor 10 has, for example, a filler element 19 in each of the inner contours 18. Thus, four filler elements 19 are provided for example. Alternatively, it is conceivable to provide a filler element 19 in only a subset of the four inner contours 18. The at least one filler element 19 can provide a tensile strength of the at least one inner contour 18 (in the example of 2 : the four inner contours 18). For example, when the cooling line 12 is designed as a cooling hose 12, it is often produced with (very) low-viscosity materials (e.g., made of/with thermoplastic elastomers (TPEE) or polyamides). These materials are sometimes so low in viscosity that, after leaving, for example, a die head, they sink downwards due to gravity, touch the electrical conductor 16 (e.g., made of copper), and adhere to it. Since the cooling hoses 12 are intended to have a defined flow channel for the cooling medium 14, at least one inner contour (in the example of 2 A filler element 19 (e.g., polyethylene (PE) fibers or aramid fibers) is inserted into all four inner contours 18). This allows for the following in at least one inner contour (in the example of 2 In all four inner contours 18, a support structure is formed which supports the material, e.g., the plastic, after it leaves, for example, an extrusion head, sufficiently so that it can be cooled in a calibration unit of a water bath and remains dimensionally stable upon solidification. Furthermore, the filling element/filler 19 ensures that the at least one electrical conductor 16 (e.g., made of copper) and the cooling hose 12 do not touch each other. This prevents the at least one electrical conductor 16 (e.g., made of copper) from adhering to the cooling hose 12 and/or the inner contour 18. Thus, the cooling hose 12 can be calibrated to its nominal dimension and remains molten and calibratable in every area. When using other materials for the at least one inner contour 18 and the cooling line... 12 (for example, the cooling hose), the filling element(s) (the filler(s)) can be omitted, as exemplified in 1a and 1b was shown.

As in 2 As can be seen, the filler elements 19 are arranged in a specific way. Each of the filler elements 19 can, as shown in 2 The filling element(s) 19 are shown to be arranged and configured such that a diameter of the inner wall of the cooling hose 12, or an imaginary circle (since the cooling hose 12 may not be a perfect circle), intersects the filling element(s) 19 on the inner wall of the cooling hose 12. Additionally or alternatively, each of the filling elements 19 can have a larger diameter than other areas/sections of the cooling hose 12 besides the at least one inner contour 18, i.e., sections of the cooling hose 12 that differ from the inner contour 18. Each of the filling elements 19 can have a smaller diameter compared to the at least one inner contour 18.

In 3 is a variant of the embodiment from 1a , 1b and 2 shown in the version from 3 For example, no filling elements 19 are provided. Alternatively, however, one or more filling elements 19 can be arranged in the electrical conductor 10, more precisely in one or more of the inner contours 18. In the example from 3 Five internal contours 18 are provided as an example and are formed on the inside of the cooling line 12. Adjacent internal contours 18 of the five internal contours 18 have the same angular distance from each other in the circumferential direction of the cooling line 12, namely an angle of 72 degrees in the example shown. 3 shows a second state of the electrical line 10 with an electrical conductor 16 that is at least partially acentric. As in 3 As can be seen, the electrical conductor 16 touches two adjacent inner contours 18, each at a contact point P. Through contact at these contact points P, the inner contours 18 prevent the electrical conductor 16 from coming into contact with the inside of the cooling line 12. Furthermore, additional contact points P, specifically exactly two contact points P for each inner contour 18, are visible, where the eccentric electrical conductor 16 could potentially come into contact with the inner contours 18.

The dimensions of the electrical conductor 16, the cooling line 12, and the inner contours 18 are coordinated such that the electrical conductor 16 cannot come into contact with the inside of the cooling line 12, but only with the inner contours 18 molded onto the cooling line 12. In the example from 3 The diameter of the electrical conductor 16 is selected taking into account specific parameters. These parameters include the diameter of the inner surface of the cooling line 12, the minimum distance of the contact points P of the electrical conductor 16 on the inner contours 18 to the inner surface of the cooling line 12, the distance between two contact points P of an inner contour 18, and the number of inner contours 18.

In the following example, we assume that the electrical conductor 16 is made of 3 is designed as a stranded conductor. Accordingly, the electrical conductor 16 is, with respect to 3 designated as stranded conductor 16. Furthermore, by way of example, with regard to 3 Assuming that the cooling line 12 is designed as a cooling hose, the cooling line 12 is then considered to be connected to the... 3 designated as cooling hose 12.

• d_L: Litzendurchmesser
• d_ti: Schlauchinnendurchmesser (Durchmesser der Innenseite/Innenfläche/Innenwandung des Kühlschlauchs 12)
• n: Anzahl der Innenkonturen (Profilelemente) 18 beliebiger Form, die in ihrer Form gleichbleibend in gleicher Teilung am Innenumfang / an der Innenseite des Kühlschlauchs 12 angeordnet sind.
• h: minimaler Abstand der Berührpunkte P zum geometrischen Vollkreis des Schlauchinnendurchmessers d_ti
• b_s: Abstand der beiden Berührpunkte P an einer Innenkontur 18 (an einem Profilelement) als Bogenmaß, wobei der Bogenmittelpunkt dem Schlauchmittelpunkt (=dem Mittelpunkt des Kühlschlauchs 12) entspricht

Taking these assumptions into account, with regard to 3 A diameter of the stranded conductor 16 was chosen which meets the following condition: $$d_L>\frac{\left(\frac{d_{ti}}{2}-h\right)d_{ti}+hu}{\frac{d_{ti}}{2}-h+u}$$ $$\mathbf{mit}u=\frac{h}{\left[1-\text{cos}\left(\frac{\pi }{n}-\frac{b_s}{d_{ti}-2h}\right)\right]}$$

• d _L : strand diameter
• d _ti : Hose inner diameter (diameter of the inside/inner surface/inner wall of the cooling hose 12)
• n: Number of inner contours (profile elements) 18 of any shape, which are arranged in the same division on the inner circumference / on the inside of the cooling hose 12, maintaining the same shape.
• h: minimum distance of the contact points P to the geometric circle of the hose's inner diameter d _ti
• b _s : Distance between the two contact points P on an inner contour 18 (on a profile element) as arc length, where the arc center corresponds to the hose center (=the center point of the cooling hose 12)

The diameter of the stranded conductor 16 must be chosen to be at least large enough that, in a geometrically ideal scenario, the stranded conductor 16 has no point of contact with the inner wall of the hose (= inside of the cooling hose 12). More precisely, the diameter of the stranded conductor 16 must be chosen to be at least large enough that, in a geometrically ideal scenario, the stranded conductor 16 has no further contact with the inner wall of the hose (= inside of the cooling hose 12). The stranded conductor 16 has no contact points with the inner wall of the hose (= inside of the cooling hose 12), except for the contact points P on the inner contours 18. The geometrically ideal scenario can be one in which the stranded conductor 16 simultaneously touches two inner contours/contour elements 18 of the inner wall of the hose (= hose inner wall) according to the formula/condition shown above. In other words, the diameter of the stranded conductor must be chosen to be at least so large that, in a geometrically ideal scenario, it has a maximum of only two simultaneous contact points P on the inner contours 18, according to the formula/condition mentioned above. 3 Two contact points P are given, i.e., points where the conductor 16 touches the hose 12 at the inner contours 18. If the diameter of the conductor 16 becomes smaller, another unwanted contact point would occur on the thinner or offset inner wall of the hose between the two existing contact points P.

The 4a to 4c The following are examples of different embodiments of an electrical cable 100. The electrical cable is shown as an example with regard to the 4a to 4c as a charging cable 100, especially for electric vehicles, and accordingly designated as a charging cable 100. In each of the in the 4a to 4c In the examples shown, the charging cable 100 has at least one electrical conductor 10, as exemplified in relation to the 1a to 3 as described. Furthermore, each of the charging cables 100 has an outer sheath 50 that completely surrounds at least one electrical conductor.

In 4a The charging cable 100 has, for example, two electrical conductors 10. Both electrical conductors 10 are designed, for example, like the electrical conductor 10 from 3 The charging cable 100 also includes, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control line, a sensor line, a signal line, a data line and/or an auxiliary voltage line may be provided in the charging cable 100. An outer sheath 50 surrounds the electrical conductors 10 and the protective conductor 20.

In 4b The charging cable 100 has, for example, two electrical conductors 10. Both electrical conductors 10 are designed, for example, like the electrical conductor 10 from 3 The charging cable 100 also includes, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control line, a sensor line, a signal line, a data line, and/or an auxiliary voltage line may be provided in the charging cable 100. The electrical charging cable also includes a separate cooling hose 30. Consequently, the separate cooling hose 30 can be used as the supply line for the cooling medium 14, and the two electrical lines 10 can be used as the return line for the cooling medium 14, or vice versa. An outer sheath 50 surrounds the electrical lines 10, the protective conductor 20, and the cooling hose 30.

In 4c The charging cable 100 has, for example, four electrical conductors 10. The four electrical conductors 10 are designed, for example, like the electrical conductor 10 from 3 The charging cable 100 also includes, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control line, a sensor line, a signal line, a data line and/or an auxiliary voltage line may be provided in the charging cable 100. An outer sheath 50 surrounds the electrical conductors 10 and the protective conductor 20.

Specific implementation options for the electric charging cable 100 from the 4a to 4c will now be described together.

Each of the two/four electrical lines 10 has a cooling hose 12, as an example of a cooling line 12, and an electrical conductor 16. In each of the two/four electrical lines 10, the cooling hose 12 and the electrical conductor 16 run coaxially with the longitudinal axis of the respective electrical line 10 as their common axis. The two/four electrical conductors 16 can each be a solid conductor or a flexible stranded wire. The two electrical conductors 16 can each be designed as uninsulated electrical conductors. The electrical conductors 16 can each form a DC conductor. In other words, each of the electrical conductors 16 can be one of the (at least two) DC conductors of the charging cable 100 required for the transmission of direct current. For example, one or two of the four electrical conductors 16 can form a positive DC conductor, and another of the two or two of the four electrical conductors 16 can form a negative DC conductor. This allows for efficient DC charging of electric vehicles using the 100 mm² charging cable. The DC conductor(s) serve to transmit direct current within the 100 mm² charging cable.

The two/four electrical conductors 16 are each surrounded by the associated cooling hose 12. Each of the two/four cooling hoses 12 can contain a cooling medium 14, which can, for example, circulate within it. The cooling medium 14 is guided within each of the two/four cooling hoses 12. Therefore, each of the two/four cooling hoses 12 surrounds its associated cooling medium 14. Accordingly, the two/four electrical conductors 16 can each be surrounded by a cooling medium 14. In this case, the cooling medium is a Electrically insulating (i.e., non-conductive) cooling medium 14. The cooling hose 12 may be surrounded by insulation (insulating sheath) (not shown). For example, the insulating sheath of the respective cooling hose 12, in an undamaged state, is at least nearly impermeable to the cooling medium 14. That is, in a normal, undamaged state of the cooling hose 12, the cooling medium 14 cannot normally penetrate from the cooling hose 12 to the outside into an interior of the charging cable 100. In relation to 4a to 4c For example, it can be assumed that the electrical conductors are 16 copper conductors. Therefore, the following discussion will focus on the... 4a to 4c In some cases, copper conductors 16 were also mentioned.

According to a specific embodiment, at least one of the electrical lines 10 can be configured as a supply line and at least one of the electrical lines 10 as a return line for the cooling medium 14. This is to be understood as purely exemplary, and other embodiments are possible. For example, a section 40 between an outer sheath 50 surrounding the elements of the electrical charging cable 100 and the electrical lines 10 can be configured as a supply line for the cooling medium 14 or as a return line for the cooling medium 14.

The charging cable contains 100 4a and 4c Furthermore, a protective conductor 20 is arranged in the charging cable 100. The protective conductor 20 is shown uncooled as an example. However, the protective conductor 20 can also be cooled directly or indirectly. In addition to the electrical conductors 16 serving as power lines in the charging cable 100 and the protective conductor 20, control lines, sensor lines, other signal lines, data lines, and/or auxiliary voltage lines may be present and also cooled. That is, it is intended not only to actively cool the electrical conductors 16 serving as power lines by means of fluid cooling, but also to connect other, passive types of lines (such as control, sensor, signal, auxiliary voltage, data, and/or protective lines) in the charging cable 100 to active fluid cooling.

The charging cable 100, according to each of the three embodiments, can incorporate sensors, for example, one or more temperature sensors. This increases the safety of the charging cable 100 through targeted monitoring, such as temperature monitoring. The temperature sensors can be configured as sensor wires. The one or more temperature sensors can be cooled accordingly. A temperature sensor is designed, for example, to detect the temperature of the charging cable. The temperature sensor can be configured, for example, as a sensor wire or sensor line integrated into the charging cable, such as one woven or braided into the charging cable.

Furthermore, the charging cable 100 can optionally include AC conductors. However, the AC conductors can also be omitted. If no AC conductor is provided, the charging cable is designed as a DC charging cable. If, on the other hand, both DC conductors and AC conductors are provided, the charging cable 100 is designed as a combination charging cable for optional DC and AC charging. The charging cable 100 can have one or more conductors or wires for AC charging (abbreviated AC conductor). Using the one or more AC conductors, the charging cable 100 can be used to charge an electric vehicle using AC charging. By way of example, possible configurations include three conductors/wires (conductor, neutral conductor, ground), five conductors/wires (three conductors, neutral conductor, ground) or seven conductors/wires (three conductors, neutral conductor, ground and two conductors for communication between an energy source, e.g. a charging station, and an energy sink, e.g. a battery of an electric vehicle or an electric vehicle).

The in 4a to 4c The schematically depicted charging cable 100 can be used as a charging cable for electric vehicles. For this application, the charging cable 100 is designed to enable a transmission power of, for example, up to 50 kW, up to 70 kW, up to 250 kW, up to 500 kW, or up to 3 MW.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• EP 4 147 903 A1 [0008]

Claims (15)

Electrical line (10), in particular for a charging cable (100), wherein the electrical line (10) comprises: - at least one electrical conductor (16); and - a cooling line (12), in particular a cooling hose, surrounding the at least one electrical conductor (16), wherein a cooling medium (14) can be guided in an interior of the cooling line (12) and the cooling line (12) has at least one inner contour (18) projecting into the interior and formed on an inner surface of the cooling line (12); wherein, in a first state of the electrical conductor (10), in particular at least substantially undistorted, which is spaced at least one inner contour (18) apart from the at least one electrical conductor (16), and whereby, in a second state of the electrical conductor (10), in particular at least partially bent, the at least one electrical conductor (16) comes into contact with the at least one inner contour (18) in such a way that the at least one inner contour (18) prevents contact between the at least one electrical conductor (16) and the cooling conductor (12). Electrical line (10) to Claim 1 , wherein the at least one electrical conductor (16), in the first state of the electrical line (10), is arranged at least sectionally at least nearly centrally in the cooling line (12). Electrical line (10) to Claim 1 or 2 , wherein the at least one electrical conductor (16) is arranged at least sectionally acentrically in the cooling line (12) in the at least one second state of the electrical line (10). Electrical line (10) to one of the Claims 1 until 3 , wherein the electrical conductor (10) has at least one filling element (19) arranged or provided in the at least one inner contour (18). Electrical line (10) to one of the Claims 1 until 4 , wherein the at least one inner contour (18) is spirally or spirally shaped on the inside of the cooling line (12) relative to the at least one electrical conductor (16) in the longitudinal direction of the at least one electrical conductor (16). Electrical line (10) to Claim 5 , where the stroke length of the spiralization assumes a value between 30 mm and 200 mm. Electrical line (10) to one of the Claims 1 until 6 , wherein the at least one inner contour (18) runs parallel to the at least one electrical conductor (16) in the longitudinal direction of the at least one electrical conductor (16) on the inside of the cooling line (12). Electrical line (10) to one of the Claims 1 until 7 , wherein the at least one inner contour (18) has at least three inner contours (18) or is designed as at least three inner contours (18). Electrical line (10) to Claim 8 , wherein a diameter of the at least one electrical conductor (16) is selected based on: a diameter of the inside of the cooling line (12), a minimum distance of contact points (P) of the at least one electrical conductor (16) on the at least one inner contour (18) to the inside of the cooling line (12), a distance between two contact points (P) on the at least one inner contour (18) and a number of the at least one inner contour (18). Electrical line (10) to Claim 8 or 9 , wherein a diameter of the at least one electrical conductor (16) satisfies the following condition: $$d_L>\frac{\left(\frac{d_{ti}}{2}-h\right)d_{ti}+hu}{\frac{d_{ti}}{2}-h+u}$$ $$\mathbf{mit}u=\frac{h}{\left[1-\text{cos}\left(\frac{\pi }{n}-\frac{b_s}{d_{ti}-2h}\right)\right]}$$ d _L : diameter of the electrical conductor (16) d _ti : diameter of the inside of the cooling line (12) n : number of at least one inner contours (18) h : minimum distance of contact points (P) to the inside of the cooling line (12) b _s : distance between two contact points (P) of an inner contour (18). Electrical cable (100), in particular charging cable, for example for electric vehicles, wherein the electrical cable (100) comprises: - at least one electrical conductor (10) according to one of the Claims 1 until 10 ; and - an outer sheath (50) surrounding at least one electrical conductor (10). Electrical cable (100) to Claim 11 , wherein the at least one electrical line (10) has an electrical charging line or is designed as an electrical charging line. Electrical cable (100) to Claim 11 or 12 , wherein the electrical cable (100) further comprises: a control line, a sensor line, a signal line, a protective line (20), a data line and/or an auxiliary voltage line. Electrical cable (100) to one of the Claims 11 until 13 , wherein the cooling line (12) of the at least one electrical line (10) is designed as a supply line for the cooling medium (14) or as a return line for the cooling medium (14). Electrical cable (100) to one of the Claims 11 until 14 , wherein a region (40) between the outer jacket (50) and the at least one electrical line (10) is designed as a supply line for the cooling medium (14) or as a return line for the cooling medium (14).