Coolable single line and charging cable

Abstract

The invention relates to a single line for a charging cable, comprising an open support structure (011, 012) with a longitudinal extension, at least one channel conductor (2) of an electrically conductive material, and an insulation (3). The at least one channel conductor (2) is wound along the longitudinal extension of the open support structure and touches the open support structure (011, 012). The insulation (3) covers the open support structure (011, 012) and the at least one channel conductor (2). There is at least one channel (4) for a cooling fluid (5), and the channel (4) is formed through the support structure (011, 012) and the channel conductor (2). The insulation (3) is impermeable for the cooling fluid (5) and electrically insulating.

Description

Technical Field

[0001] The present invention relates to a single circuit for a charging cable, a charging cable having such a single circuit, a charging system using the charging cable, and a method for charging an energy storage device, particularly a vehicle drive battery, in which the charging cable according to the invention is used. Background Technology

[0002] CN 1 06 782 835 A (Shenzhen Baoxing) describes an automotive charging cable. This automotive charging cable includes flexible hoses made of electrically insulating material through which cooling fluid can circulate. The hoses extend within a conductor arrangement structure that transmits current.

[0003] US 2012 199 390 A1 (Hitachi Electric Wire) and CN 1 06 849 227 A (Shenzhen Wol) also proposed similar methods, namely using flexible tubes or pipes inside the conductor arrangement structure.

[0004] The disadvantage of these arrangements is that heat generated in the conductor arrangement must be diverted through the hose material before it can be carried away by the cooling fluid. This results in delayed cooling and inefficiency.

[0005] In contrast, CN 1 06 887 277 A (Jiangsu Saint Peters Electromechanical) and DE 20 2015 009 531 U1 (Porsche) allow cooling fluid to flow over the outside of the conductor arrangement structure because the contact surface is larger there, and therefore heat dissipation can be more efficient.

[0006] The disadvantage of this arrangement is that cooling can be easily disrupted if external pressure is applied to the cable. This is particularly true in the case of charging cables used in vehicles, such as passenger cars, where there is a risk of a person or vehicle being on the cable and compressing the coolant channels. If the coolant channels were reinforced to prevent this problem, the cable would have to become correspondingly thicker, thus losing maneuverability.

[0007] Charging cables should be designed with a diameter that allows for a comfortable grip, ideally less than 5 cm. They should also be as flexible and lightweight as possible for easy handling. Furthermore, they should not generate excessive heat, making them uncomfortable to hold. Gripping objects (such as charging cables) becomes very uncomfortable starting at a surface temperature of approximately 40°C. Charging cables must be robust and able to withstand being run over by a car. In addition to all these requirements, charging cables must be able to carry high currents. Currently, a common charging current is 200A. However, it is entirely conceivable that even higher currents, particularly up to 700A, will be carried in the near future. Therefore, it is desirable to provide a cable that operates in accordance with the current to be transmitted. Summary of the Invention

[0008] The object of this invention is to provide a single-line cable belonging to the aforementioned technical field, which is lightweight and flexible, yet still capable of carrying large currents without becoming uncomfortably hot. Cables incorporating this single-line cable can also be designed to be lighter and more flexible than similar cables with other types of single-line cables.

[0009] The solution to this objective is defined by the features of the subject matter according to the invention.

[0010] The single-line cable for charging according to the present invention includes an open support structure having a longitudinal extension, at least one channel conductor made of conductive material, and an insulator.

[0011] The at least one channel conductor is coiled around and touches the open support structure. An insulator covers the open support structure and the at least one channel conductor. At least one channel is provided for cooling fluid. This channel is formed by the support structure and the channel conductor. The insulator is impermeable to the cooling fluid and is electrically insulating.

[0012] This single-circuit design allows for the effective dissipation of heat generated in the channel conductor due to its ohmic resistance. The single-circuit should be usable under certain weather conditions, i.e., within a temperature range of, for example, -50°C to 50°C.

[0013] Cooling is highly efficient because the cooling fluid can come into direct contact with the channel conductors through the open support structure: on the one hand, heat does not have to be conducted through hoses or other types of partitions; on the other hand, in most cases, a set of channel conductors has a larger surface area than the inside of the cylinder, which the hoses can approximate.

[0014] Compared to the outer sheath, the internal cooling channels are also better protected from compression.

[0015] The single-line flexibility is achieved by using a channel conductor coiled around a support structure: although a channel conductor extending parallel to the support structure provides less flow resistance to the cooling fluid and thus allows for better cooling, in the case of a connection, such a conductor acts like an elastic band system and thus makes the single line with the parallel-extending channel conductor rigid.

[0016] Another advantage of coiling is its simplicity of production: it can essentially be done using rope-making equipment, where only the pulling of the core strand or insert must be adapted to the specific design of the open support structure. Because the channel conductor, through coiling, maintains itself to some extent in its desired position relative to the support structure, intermediate products of a single line can be temporarily stored on the spool until insulation is applied. During insulation application, the separate and intentional guidance of the channel conductor and the support structure, which would be necessary if the conductor extended parallel to the support structure, can be omitted.

[0017] The support structure ensures that the inner diameter always has a specific minimum value. Furthermore, this support structure increases the resistance to overturning of the single circuit: because the pressure acting on the conductor is partially absorbed by the insulator and conductor arrangement structure, and to a certain extent spatially distributed through the conductor arrangement structure, the local load on the inner support structure is lower than the load when the support structure is outside the conductor arrangement structure. The support structure can be constructed so stably that it can withstand the desired forces as required.

[0018] A conductor appearing in a single line can be associated with two groups: the channel conductor and the remaining conductors. The channel conductor group and the remaining conductors (if present) are referred to below as the conductor arrangement structure.

[0019] A channel conductor is a conductor that touches or is located on a convex covering of a support structure at at least one location and restricts a channel for cooling fluid. The ends of the support structure are disregarded here. Furthermore, all wires surrounded by a channel conductor on all sides should preferably be associated with the channel conductor: the core wires of stranded wires whose outer wires are channel conductors are therefore also channel conductors. In cases where all conductors of a structure (e.g., stranded wires or bundles) are considered channel conductors, the structure itself is referred to as a channel conductor. In the example given above, therefore the stranded wire is a channel conductor.

[0020] The remaining conductors are all conductors that extend longitudinally along the supporting structure, are in electrical contact with the channel conductor, but should not be assigned to the channel conductor itself. Here, for example, the structure of stranded wires and bundles is also referred to as "remaining conductors" if all the conductor wires belonging to them constitute "remaining conductors".

[0021] If, for example, the structure of a stranded wire or bundle is partially composed of conductor wires mating with the channel conductor and partially composed of conductor wires mating with the remaining conductors, then the structure is preferably mated with the channel conductor.

[0022] Coiling or winding should be understood as a process in which the structure to be coiled essentially maintains its shape and objects with coiled portions are placed spirally around the structure to be coiled. In contrast, during twisting, all the objects involved therefore follow a spiral shape, the longitudinal axis of which is offset relative to the longitudinal axes of all the objects involved. In this sense, coiling and twisting are twisting techniques.

[0023] Similar to rope technology, stranded wire should be interpreted as a structure composed of multiple strands twisted together. The pitch used in the case of twisting is significantly smaller than the pitch in the bundle described below.

[0024] A bundle should represent a structure consisting of multiple wires extending substantially parallel to each other. The wires in a bundle are also slightly twisted together, but only to the extent necessary to avoid the need for wires of different lengths in the same bundle when winding open support structures or channel conductors. The twisting of the wires in a bundle preferably occurs during winding, compared to stranded wire that is twisted before being used for winding.

[0025] Here and below, the term "conductor cross-section" refers to the total cross-sectional area occupied by the conductor in the cross-section of a given single line. For example, if a line or cable comprises three conductors (each with a circular cross-section of radius r) as conductors, then the conductor cross-section of the line or cable is 3πr. 2 If the conductor cross-section cannot be derived from this geometric consideration, a sample of a cable or line of known length can be used. The conductor is then separated from the rest of the cable and weighed. Given the density of the conductor material, the volume of the conductor can be determined. Dividing this volume by the known length of the sample yields the value of the conductor's cross-section.

[0026] In this application, the convex covering portion of the main body is understood as the smallest covering portion that completely surrounds the main body and in the smallest covering portion, each connecting line between two points is located on the covering portion within the covered volume or on the covering portion.

[0027] The effective radius of a surface or object can be determined by dividing the perimeter of the surface or cross-section of the object by 2π.

[0028] In a mathematical sense, a helix is ​​a curve wound around the circumference of a cylinder at a constant angle. The radius of the cylinder's base surface is the radius of the helix. The pitch is the distance the helix travels when it completes one full rotation around the cylinder along its longitudinal axis. The angle of the helix is ​​the ratio of the pitch to the circumference of the base surface, i.e., the pitch divided by 2π multiplied by the radius of the helix. The angle of the helix is ​​its arctangent. The direction of the helix indicates the direction of winding: if the helix winds clockwise, it is right-handed.

[0029] In the sense of this application, a helical portion is an object in which material extends along a mathematical curve with a substantially constant cross-section, such as a pin made of metal or plastic with a circular or rectangular cross-section. Preferably, the pitch of the helical portion can be varied in the sense of this application, wherein, in this case, an effective pitch is particularly preferred in different embodiments, and the effective pitch is the extension of the helical portion along its longitudinal axis divided by the number of turns along its extension.

[0030] Here and below, a helix should be understood more generally as the spiral portion, that is, a curve that winds around the circumference of a cylinder with an arbitrary base plane at a constant slope. The base plane of the cylinder is also the base plane of the helix. The radius of the helix is ​​the effective radius of the base plane. The pitch is the distance the helix winds around the cylinder in one complete revolution along its longitudinal axis. The slope of the spiral portion is the ratio of the pitch to the circumference of the base plane. The slope angle is the arctangent of the slope. The direction of the helix indicates the direction of the spiral portion: if the helix winds clockwise, it is right-handed.

[0031] In the sense of this application, a helix is ​​an object in which material extends along a mathematical curve with a substantially constant cross-section, such as a pin made of metal or plastic with a circular or rectangular cross-section.

[0032] An open support structure is an elongated structure in which the convex covering portion has a columnar shape, wherein at least one continuous channel, i.e., a channel that is not interrupted by the structure, extends along the convex covering portion and within the interior of the convex covering portion. With this in mind, it is preferable to assume that the support structure extends infinitely in its longitudinal direction.

[0033] An example of an open support structure is a helical section made of round wire with a diameter d and a pitch h greater than the diameter d.

[0034] In this case, the convex covering is cylindrical. The channel also forms a helical portion and extends offset relative to the wire by half the pitch h, and additionally extends within the space enclosed by the helical portion. The width of the channel on the outer side of the helical portion is equal to the pitch h minus the wire diameter d. This channel is not interrupted by the support structure. Therefore, an open support structure is involved in the sense of this invention.

[0035] Another example is an open profile with a cross-shaped or star-shaped cross-section: in this case, the convex covering is a column with a rectangular or polygonal base. Multiple channels extend parallel to the longitudinal axis of the column or profile. Therefore, this is also an open support structure in the sense of the present invention.

[0036] In contrast, hoses or tubes are not open support structures because the channels formed by hoses or tubes do not extend along their convex coverings, but extend entirely within them.

[0037] In contrast, if the hose or pipe has openings in its sidewalls, the channel extends along the convex covering at least in the areas of these openings. This is an open support structure.

[0038] In the context of this invention, the conductor is elongated and made of a conductive material. For example, the conductor can be a wire or strip made of metal. The conductor is preferably made of a material with good conductivity, and the conductor may be coated. The material with good conductivity preferably has a conductivity of less than 10 at 20°C. -5 The resistivity is measured in Ωm. For example, the coating can provide protection against corrosion. The coating should preferably also be conductive, but its conductivity may be lower than that of a highly conductive material. Here, the coating is particularly thinner than 100 μm. Specifically, the conductor is normally conductive.

[0039] Electrical insulation in the sense of this invention refers especially to electrical resistance greater than 10 ohms. 5 Ωm, preferably greater than 10 10 Materials with an Ωm thickness. In particular, the present invention can use ethylene propylene diene monomer (EPDM), ethylene propylene rubber (EPR), and / or thermoplastic elastomers (TPE) as insulating materials.

[0040] A woven fabric is a product created by regularly intersecting strands vertically. For example, the strands can be single or grouped twisted or combined fibers or conductors. The strands can intersect at 90° angles or other angles. The woven fabric can form a flat surface or pad, extending arbitrarily in two dimensions, or exist in a columnar shape, extending arbitrarily in only one dimension while being constrained in other spatial dimensions. Preferably, the strands intersect at angles not equal to 90° and the woven fabric forms a columnar shape.

[0041] Herein and in the following text, "direct covering" specifically refers to the absence of an additional layer or structure between the covered object and the covering. Hollow spaces and / or cooling fluids should not be considered layers or structures.

[0042] Herein and in the following text, “covering” specifically refers to the presence of an additional layer or structure between the covered material and the covering material, but such additional layer or structure is not necessarily required.

[0043] In different implementations, different ratios are quasi-irrational numbers. A quasi-irrational number should be an irrational number as well as a rational number represented as a short decimal with a large numerator and a large denominator. The numerator or denominator is preferably large if it is greater than or equal to 5, especially greater than or equal to 10 or 100. To determine whether a ratio is quasi-irrational, the periodicity of a relevant portion of a single line or charging cable can be examined: this should be as inconsequential as possible in quasi-irrational ratios, or the repetition length should be large, for example, extending more than 5, 10, or 100 times the larger of the two numbers being compared.

[0044] In one embodiment, each channel conductor follows a helix having a helix direction, pitch, and radius. The helix direction and pitch of all channel conductors are substantially the same in this embodiment.

[0045] Preferably, the radii of all helices in all channel conductors are also the same.

[0046] This embodiment has the following advantages: it is particularly easy to manufacture. The channel conductors are all treated identically and wound around an open support structure. The support structure here is similar to a core wire or insert used in the stranding method. Therefore, the tools and methods known from stranding technology can be used to produce single lines of arbitrary lengths with particular simplicity and efficiency. Production can be performed particularly quickly and easily.

[0047] If the radius of the helix of a single channel conductor is chosen to be slightly larger than the radius of the helix of other channel conductors, the permeability of the channel conductor layer, i.e. the permeability of the collection of all channel conductors in the arrangement structure of the channel conductors in a single line, can be increased for cooling fluid and cable flexibility.

[0048] In contrast, choosing the same radius for the helix of all channel conductors is a preferred solution that is simpler and more advantageous in manufacturing, and results in better and more predictable durability of the single circuit due to the resulting unchanging single-circuit structure.

[0049] Preferably, the channel conductors follow a spiral with a circular base.

[0050] In another implementation, the base plane of the spiral is a polygon, a circular segment, or an ellipse.

[0051] Each channel conductor has a cross-sectional area. In one implementation of a single-line circuit, all channel conductors have the same cross-sectional area.

[0052] If all the channel conductors have the same cross-sectional area, it is easier to manufacture because, for example, in a stranding method, the conductor guides can be designed to be identical, and on the other hand, the resulting unchanging single-line structure leads to better and more predictable durability of the single line.

[0053] Preferably, given a certain number of channel conductors, the pitch and radius of the helix followed by the channel conductors are chosen such that adjacent channel conductors just touch.

[0054] This implementation has the following advantages: Firstly, it is particularly stable in terms of manufacturing and storage: the channel conductors are fixed to each other in their relative positions. Furthermore, the volume of the guiding current directly adjacent to the coolant channel is particularly large. If cooling fluid flows through the cable, the channel conductors are pressed away from the channel, creating a gap through which the cooling fluid can exit from the channel.

[0055] Preferably, given the number of channel conductors, the pitch and radius of the helix followed by the channel conductors are chosen such that there is a spacing between the channel conductors that is less than 0.5 times the diameter of the channel conductor, preferably less than 0.25 times, and more preferably less than 0.1 times.

[0056] This implementation offers the following advantages: even at low cooling fluid pressures, the cooling fluid can reach areas far from the channels and provide efficient cooling. Furthermore, when the spacing is less than 0.5 times the diameter of the channel conductor, the channel conductors can always be sufficiently secured to each other to prevent damage due to slippage. With smaller spacing, this stability, along with the significantly improved cooling capacity, increases the line volume.

[0057] In one embodiment, each channel conductor is a single conductor wire. Preferably, each channel conductor is a conductor wire with a circular cross-section.

[0058] Given a conductor cross-section, a relatively small amount of wire with a large radius is obtained. Therefore, a relatively large volumetric hollow space can exist next to and between the channel conductors, in which cooling fluid can flow. Although the ratio of cooled surface area to volume is smaller than that when using many conductor wires, the improved cooling fluid flow can result in sufficient or even better cooling compared to using a large number of smaller wires. Furthermore, the relatively solid channel conductor itself acts as an additional support structure and improves the anti-flipping resistance of the single line. Therefore, this embodiment is particularly suitable if a cooling fluid with a higher viscosity is required or if particularly high anti-flipping resistance is required.

[0059] In another embodiment, the channel conductor is a strand or bundle of many individual fine conductor wires.

[0060] In the case of stranded wires, the conductor wires are twisted together; in the case of bundled wires, the conductor wires extend substantially parallel to each other.

[0061] Bundles and stranded wires have a particularly high surface area to volume ratio due to their composition of many fine wires. Furthermore, as is known from ropes, stranded wires are also particularly flexible. Thus, particularly flexible single-circuit conductors can be manufactured by using stranded wires as channel conductors. In contrast, bundles can be flowed through particularly well by fluids because the wires extend substantially parallel to each other, and are therefore cooled better internally than stranded wires. Bundles are also significantly more flexible than their corresponding individual conductor wires because they are composed of many fine wires. Therefore, these implementations are particularly suitable if a cooling fluid with low viscosity is required, or if high flexibility of the single-circuit conductor is particularly important.

[0062] In one particular embodiment, the cross-section of the channel conductor is oval, rectangular, or has a ring-shaped section.

[0063] In these cross-sectional shapes, the surface area to volume ratio is particularly large, and at the same time, the cross-sectional shape is simple enough to provide the stability required for a single line in a charging cable. Therefore, using this type of channel conductor can improve cooling.

[0064] In one particular implementation, all conductors are channel conductors. Therefore, the insulator directly covers the channel, which includes an open support structure and the channel conductor.

[0065] This implementation has the advantage that all channel conductors are in direct contact with the cooling fluid from the channels. Therefore, whether and how much cooling fluid can pass between the channel conductors into the region between the insulator and the channel conductors is less important. The latter is particularly affected by the cooling fluid pressure in a single line. Therefore, this implementation is particularly independent of the cooling fluid pressure.

[0066] In one embodiment of a single-circuit system, the channel, including an open support structure and a channel conductor, is surrounded by an additional conductor. This additional conductor is in electrical contact with the channel conductor. Either the additional conductor is designed as one or more braids arranged coaxially around the channel, or the additional conductor is a wire, bundle, and / or stranded wire wound around or arranged parallel to the channel.

[0067] The additional conductor is preferably a wire, bundle, and / or stranded wire wound around the channel such that the helix direction of the winding corresponds to the helix direction of the channel conductor, and the pitch of the helix of the additional conductor is different from the pitch of the helix of the channel conductor. Particularly preferably, the larger of the two pitches is 1.1 to 5 times the smaller pitch, and more preferably 1.5 to 2 times the smaller pitch, wherein the ratio of the two pitches is preferably a quasi-irrational number.

[0068] The additional conductor in this embodiment is the remaining conductor.

[0069] There may also be some conductors arranged in a braid coaxial with the channel, while other conductors are either twisted between braids around the channel or another braid, or twisted around all the braids.

[0070] To carry large currents, a single line should have a certain conductor cross-section. However, when arranging and selecting the channel conductor, the following requirement is always paramount: the channel conductor and the supporting structure must be stable relative to each other, maintaining the channel's arrangement. Therefore, increasing the conductor cross-section by using a thicker conductor is only feasible to a certain extent. A thicker conductor should be understood here in particular as a conductor with an effective radius greater than 1.25 mm. Increasing the conductor cross-section is more easily achieved by arranging additional conductors around the channel conductor coiled around the supporting structure.

[0071] These additional conductors can be arranged as a braid, which has the advantage that the channel conductors are held together outward and thus stabilized.

[0072] On the other hand, twisting conductors, strands, or bundles around the channel conductor is faster and more advantageous in manufacturing. Since the channel for the coolant is already formed and covered by the channel conductor and is therefore protected from the slippage of other conductors, additional conductors can be twisted onto the channel without affecting the channel itself.

[0073] The resistance of a conductor, and therefore the heat generated when a particular current flows through it, is proportional to the conductor's cross-sectional area. Therefore, a larger conductor cross-section reduces the heat generated. At the same time, conductor materials are dense and generally not very flexible. Thus, it is advantageous for charging cables to have the smallest possible conductor cross-section, which is still sufficient to meet the requirements for heat formation. This also applies to single-line charging cables.

[0074] In a preferred embodiment, the additional conductors of the single circuit are arranged such that they are also permeable to the cooling fluid. For this purpose, the additional conductors are arranged relative to each other with a small spacing and slight gaps, thereby forming small passages through which the cooling fluid can enter under pressure. In particular, the small spacing is less than 0.1 times the effective radius of the smaller conductor in the two conductors that are mated together. This embodiment has the advantage of providing a very large area for dissipating heat generated in the conductors. Furthermore, a relatively uniform temperature distribution is achieved in a simple manner among all the participating conductors.

[0075] Winding the channel conductor and the other conductor in the same direction around the inner layer (either around the support structure or around the intermediate product consisting of the support structure, wherein the winding is done through the channel conductor) results in a favorable distribution of torsional force.

[0076] In one particular embodiment, the additional conductor is wound in a different direction of rotation than the channel conductor. This has the advantage that the intermediate product, "the support structure with the conductor arrangement," is more stable and thus simplifies production.

[0077] Choosing different pitches for the helices of the additional conductor and the channel conductor prevents the additional conductor from being pressed into the gaps between the channel conductors. This increases the resistance to flipping of the single line. With different but similar pitch differences, the wire length and flexibility of the different conductor layers remain similar. The selection of a quasi-irrational pitch ratio has the advantage of providing little to no repeating structure along the length of the cable, which increases the lifespan of the single line.

[0078] In one particular embodiment, there are multiple layers of additional conductors. The statement regarding the relationship between the channel conductor and the additional conductors can be applied to this embodiment, more precisely, in that the corresponding inner layer of the additional conductors assumes the role of the channel conductor and the corresponding outer layer of the additional conductors assumes the role of the additional conductor according to the foregoing embodiment.

[0079] Preferably, there are two or three additional conductors. This allows for easy increases in conductor cross-section without significantly reducing cooling efficiency.

[0080] In one embodiment, the support structure is a helical section or an open profile. In particular, the open profile has a star-shaped cross-section.

[0081] The helical section is easy to manufacture, lightweight, flexible, and stable under pressure perpendicular to the longitudinal axis. By selecting the pitch, the contact area between the cooling fluid and the conductor braid can be set, i.e., how efficient the cooling should be and how stable the support structure should be under pressure. The helical section can have multiple pitches along its length. Thus, in areas that are particularly prone to rolling, a single line has a helical section with a smaller pitch than in other areas. For ease of manufacturing, the pitch is preferably constant over the entire length.

[0082] The angle of the spiral portion is preferably between 0.1 and 0.3, and particularly preferably about 0.2.

[0083] Support structures in the form of open profiles can also be easily manufactured, for example, by extruding suitable plastics. While the spiral section has relatively large channels along its longitudinal axis, multiple smaller channels can be achieved using open profiles, or the cooling fluid can be forced to flow within the spiral. Open profiles allow for better mixing of the cooling liquid and prevent it from partially flowing through a single line without contact with the conductor arrangement and without any heat absorption.

[0084] A star-shaped cross-section has a connecting surface and multiple ribs extending radially from it. The ribs are connected to each other only via the connecting surface. In the first type of star-shaped cross-section, the connecting surface is circular, and the ribs all have the same length. Furthermore, the ribs are arranged relative to each other at equal angular spacing. In this case, there are as many channels as there are ribs, and all channels have the same cross-section.

[0085] In the case of the second type of star-shaped cross-section, the connecting surfaces can be arbitrary, and the ribs can have different lengths and be arranged relative to each other at different angular intervals. Similarly, there are as many channels as the ribs, but their cross-sections can deviate significantly from each other.

[0086] The connecting surfaces and ribs can have hollow spaces. This saves weight.

[0087] In one particular embodiment, the support structure is a helical section whose helix direction differs from that of the helix of the channel conductor.

[0088] In one particular embodiment, the support structure is a helical portion, and the pitch of the helix in one of the channel conductors is greater than the pitch of the support structure.

[0089] In one particular embodiment, the support structure is a helical portion, and the pitch ratio (which is the minimum pitch of one of the helices in the channel conductor divided by the pitch of the helical portion of the support structure) is greater than 4 / 3, preferably greater than 2, and very particularly preferably, the quasi-irrational number is greater than 4, and especially greater than 6.

[0090] In one particular implementation, the pitch ratio is less than 50.

[0091] In one particular embodiment, the support structure is a helical portion, and the pitch of the helix of one of the channel conductors is greater than the pitch of the helical portion of the support structure, and the direction of rotation of the helical portion of the support structure is different from the direction of rotation of the helix of the channel conductor.

[0092] In one particular embodiment, the support structure is a helical portion, and the pitch ratio (which is the minimum pitch of one of the helices in the channel conductor divided by the pitch of the helical portion of the support structure) is greater than 4 / 3, preferably greater than 2, and very particularly preferably, the quasi-irrational number is greater than 4, and the helix direction of the helical portion of the support structure is different from the helix direction of the channel conductor.

[0093] All these implementations create a particularly stable channel within the charging cable, even in single-line use. The charging cable is moved by the user, bends in all directions, and is frequently run over by vehicles. All of this can lead to relative movement between the support structure and the channel conductors. If this relative movement is too large for the chosen single-line architecture, a single channel conductor may slide into the channel. This event is known as channel "entrapment." The absence of entrapment in the original position of the channel conductor gives surrounding channel conductors more freedom of movement, allowing other channel conductors to slide into the channel, potentially leading to loops and subsequent conductor breakage and similar problems. Conductor breakage and the channel blocked by entrapped conductors increase the resistance and flow resistance of the single line. Both contribute to increased temperature during use. The result is malfunction of the charging system using the cable.

[0094] Therefore, a single line should be designed such that the channel conductor is loosely wound around the support structure to allow cooling fluid to penetrate into the space between the insulator and the conductor arrangement and thus achieve efficient cooling, while on the other hand, the movement of the channel conductor will never cause channel intrusion.

[0095] One possibility for such a structure is to interchange the helical directions of the support structure and the channel conductor: in this case, there will always be a point where the helix of the channel conductor lies on the helix of the support structure. Therefore, the possibility of a break along the entire length is eliminated.

[0096] Another possibility is to choose a pitch for the helix portion of the support structure that is smaller than, and preferably significantly smaller than, the pitch of the helix portion of the channel conductor. For example, if the pitch of the helix portion of the channel conductor is 4 / 3 of the pitch of the helix portion of the support structure, then there exists a point every 3 turns of the channel conductor and every 4 turns of the helix portion of the support structure where the channel conductor is fully supported on the support structure. This may be sufficient for a smaller pitch and a more stable channel conductor.

[0097] However, at pitch ratios of 2 or greater, the system becomes more stable: the channel conductor is now supported on the support structure at least once per turn. With pitch ratios of 4 or greater, the channel conductor is supported at least once every half turn, thus ensuring "break-in protection" when moving to either side. As the pitch ratio increases, the angle at which the channel conductor intersects the support structure at the support point increases: if the pitch ratio is greater than approximately 6, an intersection angle greater than 45° can be achieved: the probability of the channel conductor "slipping" off the support structure is thus reduced again.

[0098] The pitch ratio is particularly preferably a quasi-irrational number: thus, the point where the channel conductor is supported on the support structure always shifts to other angles along the length of the cable. Therefore, there is no direction in which the movement of the channel conductor relative to the support structure significantly increases the risk of channel intrusion.

[0099] Particularly preferred is that the pitch ratio is a quasi-irrational number greater than 6. For example, pitch ratios √(37) or 6.1 or √(44) or 6.63, √(48) or 6.93 can be chosen, because these numbers are not only quasi-irrational, but also have a certain distance from rational numbers with denominators less than or equal to 7.

[0100] By combining different directions of rotation with pitch ratios greater than 1, especially greater than 4 / 3, preferably greater than 2, and very particularly preferred with quasi-irrational numbers greater than 4 and especially greater than 6, a particularly stable channel that can be manufactured very easily can be achieved.

[0101] A pitch ratio of less than 50 is preferred: the very high pitch of the helix of the channel conductor significantly limits the flexibility of a single line. Furthermore, the very small pitch of the helix portion of the support structure limits flexibility, reduces the flow of cooling fluid in the cable region between the channel and the insulator, and increases the weight of the line, which is therefore undesirable in many cases.

[0102] By utilizing a pitch ratio between 4 and 50 (which is particularly preferably a quasi-irrational number), very good penetration resistance can be ensured under conditions of high flexibility.

[0103] In one embodiment, the support structure is an open profile whose cross-section remains constant in shape and size along its longitudinal extension, but whose shape is twisted about the longitudinal axis along its longitudinal extension.

[0104] Such profiles are also referred to below as twisted profiles. Twisting creates spiral channels. The cooling fluid flowing through these channels is thus placed in a vortex. The travel distance is shorter near the longitudinal axis than at the outside. Therefore, different velocities exist in the fluid within the channels, resulting in stronger mixing of the cooling fluid. This allows for better utilization of the entire volume of cooling fluid.

[0105] In one embodiment, the convex covering portion of the support structure has a cross-section with a shape that remains substantially the same along the longitudinal extension of the support structure. In this embodiment, the contact points between the support structure and its convex covering portion form support structure lines. The angles at which at least some of the channel conductors intersect at least some of the support structure lines are between 45° and 135°, preferably between 60° and 120°.

[0106] The support structure line is the area where the channel conductor is supported on the support structure.

[0107] If the channel conductor extends almost parallel to its supporting surface on the support structure, then the breaking into the channel formed by the support structure is particularly likely to occur.

[0108] If all the channel conductors intersect the support surface of the support structure at a flat angle, then channel penetration should be of particular concern. Therefore, it is preferable that at least some of the channel conductors intersect the support surface, i.e., the support structure line, at an angle greater than 45°. Thus, the probability of channel penetration even during movement and under external pressure is low.

[0109] Particularly preferably, all channel conductors intersect at least some of the support structure lines at an angle between 45° and 135°, and more preferably at an angle between 60° and 120°.

[0110] In this implementation, the possibility of a channel conductor breaking into one of the channels is eliminated to some extent for each channel conductor. The single line becomes more robust again.

[0111] When the support structure is a helix and the channel conductor follows a helix with a circular cross-section, the angle at which the channel conductor and the support structure intersect, i.e., the crossing angle, depends not only on the pitch ratio but also on the ratio of the radius of the helix portion of the support structure to the pitch of the helix portion. For example, a crossing angle greater than 45° can be achieved using a pitch ratio of √37 or 6.1 and a helix radius that is 0.4 times the pitch of the support structure.

[0112] For example, a cross angle greater than 60° can be achieved using a pitch ratio of approximately 15, such as √226 or 15.05, and a helix radius that is 0.6 times the pitch of the helix portion of the support structure.

[0113] In one embodiment, the support structure is a helical section made of metal. The metal can be steel, particularly chromium-nickel steel.

[0114] Most metals can be formed into spiral sections and conduct current, thus serving both as a supporting structure and a means of conducting some current.

[0115] Steel wire can be relatively easily shaped to the desired form. The helical section made of steel is flexible and shape-stable. Furthermore, this support structure is relatively insensitive to heat, allowing for the construction of single lines that do not fail in the event of coolant failure or only fail after a considerable period. Chromium-nickel steel is rust-resistant and has proven particularly suitable in trials because this support structure is easy to machine and can be used with a wide range of possible cooling fluids and channel conductor materials.

[0116] Copper has good electrical conductivity. Therefore, the copper spiral section can conduct some of the current itself. This saves material, making the cable lighter. Besides copper, copper alloys are also suitable.

[0117] Aluminum also has good electrical conductivity and can be formed into a spiral.

[0118] In one embodiment, the conductor of a single line, particularly the channel conductor, is made of copper. The channel conductor is preferably made of uncoated or tin-plated copper wire.

[0119] Copper is a good and common conductor of both electricity and heat, and it is relatively malleable. Silver has even better conductivity but is less economical. Aluminum is also a good conductor, but not as good as copper. However, aluminum has a lower density than copper. Therefore, cables using aluminum conductors will be lighter.

[0120] The term "copper" should preferably refer to copper materials having a minimum content of 99.5%, particularly preferably 99.9% Cu by weight.

[0121] Tin plating offers the advantage of protecting wires from corrosion. However, depending on the choice of cooling fluid, tin plating or other types of coatings may be omitted. This is especially true if the cooling fluid contains additives that form a protective corrosion barrier. Untinned and other uncoated wires are less expensive than tinned wires.

[0122] Therefore, when using uncoated wires, the cooling fluid serves at least two purposes: the cooling fluid provides corrosion protection for the wires that make up the conductor, and the cooling fluid cools the conductor.

[0123] In one embodiment, the insulator is a fiber-reinforced insulator.

[0124] The insulator should, on the one hand, keep the cooling fluid inside the single conductor, and on the other hand, provide electrical insulation between the conductor and the environment. Simultaneously, the flexibility of the single conductor should be limited as little as possible by the insulator. Therefore, the insulator is typically made of flexible plastics, such as EPDM, EPR, or TPE.

[0125] The flexibility of plastic helps to almost unrestrict the flexibility of a single cable as a whole, but plastic also causes the cable sheath to expand under the pressure of cooling fluid during operation. In the absence of cooling fluid, a certain expansion, for example, not exceeding 10% of the outer radius, is absolutely advantageous, as it creates an opening that allows cooling fluid to flow in.

[0126] However, if the insulation expands beyond the desired extent, this can lead to insulation damage and, on the other hand, an unexpected and sharp drop in pressure within a single circuit. To limit the expansion to the desired level, fiber-reinforced insulators are preferred, in which fibers are arranged within or around a plastic material.

[0127] In one embodiment, the fiber-reinforced insulating material comprises fibers having a high modulus of elasticity and good temperature resistance, the fibers being embedded in an electrically insulating plastic.

[0128] Electrically insulating plastics include, in particular, ethylene propylene diene monomer (EPDM), ethylene propylene rubber (EPR), and / or thermoplastic elastomers (TPE).

[0129] The elastic modulus of the fiber is preferably higher than 50 GPa at 20°C. The fiber is preferably heat-resistant up to 100°C or higher. Particularly preferred are aramid fibers, especially poly(terephthalamide) fibers, hemp fibers or polyethylene fibers.

[0130] In one particular embodiment, the fiber-reinforced insulation material is composed of aramid fibers in ethylene propylene rubber (EPR) or hemp fibers in ethylene propylene rubber (EPR).

[0131] Unlike traditional electrical cables, the insulation of a single-circuit wire is also subjected to potentially high internal pressure generated by the cooling fluid. Fiber reinforcement absorbs some of this internal pressure, thereby increasing the reliability of the insulation.

[0132] Fibers with high elastic modulus and good temperature resistance are particularly well-suited for controlling the expansion of a single circuit, and more specifically, even if the single circuit is heated more intensely than expected due to special circumstances. In one embodiment, the fiber is attached to the outer side of the insulator. The fiber can be protected there, for example, by using varnish or a protective sleeve, to prevent abrasion. However, the fiber is preferably embedded in the insulator. Thus, the fiber is protected from environmental influences and abrasion without material transition and the associated durability problems.

[0133] The combination of “aramid fiber in EPR” and “hemp fiber in EPR” has proven to be particularly suitable and durable.

[0134] In one embodiment, the fibers of the fiber-reinforced insulator are woven into a braid.

[0135] Fiber reinforcement of insulators can also be achieved by randomly scattering fibers within the insulator or by winding fibers or yarns around the insulator. However, using braided fabrics has the advantage of allowing for a uniform and vortex-free support of the insulator in a simple manner, which allows expansion to a certain extent and then effectively prevents further expansion of the insulator.

[0136] In one embodiment, the fibers are located on the outside of the insulator. In this embodiment, the insulator and the fibers thereon are covered by an electrically insulating single-line sheath.

[0137] The individual charging sheath and insulator are preferably substantially identical in composition, but the sheath may be additionally colored. The identical material selection prevents stress at the interface between the insulator and the individual charging sheath, as both respond identically to temperature changes and mechanical loads. Different color choices allow for clear identification of damage to individual charging sheaths.

[0138] However, single-line sheaths can also differ significantly from insulators in their material selection, and can be specifically equipped for resistance to specific environmental conditions, for example.

[0139] In one embodiment of the single-circuit fiber-reinforced insulator, the fibers are substantially arranged in a single layer. In this layer, the area of ​​the fiber-covered layer is between 30% and 90%, preferably between 50% and 70%, and particularly preferably about 60%.

[0140] If the fibers cover too little of the area of ​​the layer they belong to, there is a risk that the fibers will cut into the sheath. If the fibers cover the area too densely, the flexibility of a single line may be reduced.

[0141] In one embodiment, the ratio of the free volume of a single line to the volume of the conductor is greater than 0.25, preferably greater than 1, and particularly preferably greater than 1.5.

[0142] The ratio of the free volume of a single circuit to the volume of the conductor is preferably less than 3, and especially less than 2.

[0143] The free volume of a single line here specifically refers to a volume inside an insulator that is neither occupied by the conductor, especially not by the channel conductor, nor by the supporting structure, and that can therefore be traversed by cooling fluid during operation.

[0144] It has been confirmed that effective cooling of the conductor is particularly possible if the volume ratio is greater than 0.25. Increasing the volume ratio means that more cooling fluid can flow through the single line without high pressure. Therefore, even a larger volume ratio can achieve good cooling if only a limited pressure can be applied to the cooling fluid. However, the single line becomes heavier, thicker, and less lightweight due to the large amount of cooling fluid, such as that generated at a large volume ratio during operation, thus a ratio of 3 and preferably 2 is obtained as a preferred upper limit.

[0145] The charging cable according to the invention includes a first single circuit and a second single circuit according to the invention, as well as a common protective sleeve.

[0146] A common protective sheath holds the two individual cables together and protects them from wear and environmental factors such as UV radiation, fuel residue, debris, etc. The sheath can be constructed in multiple layers, including different colored layers, making it easy to identify critical wear. The sheath can be pulled through using fine test lines, which can be used to identify overheating and / or damage to the cable, for example, by observing an increase in resistance in these test lines. The sheath can be locally or entirely reinforced, or may have a structure or coating for better grip. Furthermore, the sheath can be thermally insulated to prevent the cooling fluid from freezing at lower external temperatures, for example (especially when using water), and also to dissipate heat generated during use primarily via the cooling fluid and prevent overheating of the outer side of the sheath.

[0147] In one embodiment, the common sheath covers the single line only in sections, for example, at regular intervals and / or where there is concern about particular load. The common sheath preferably covers the first and second single lines according to the invention substantially along its entire length.

[0148] The first and second single-line circuits according to the invention are preferably constructed identically, and if there is a difference, it lies only in the coloring of their insulators. In another embodiment, the first and second single-line circuits according to the invention differ in the design and / or dimensions of their support structure, conductor arrangement structure, and / or other aspects.

[0149] In one embodiment, the charging cable further includes a grounding conductor braid that surrounds the first single circuit and the second single circuit and is covered by or integrated into a common protective sheath.

[0150] Grounding conductor braid is a braid made of conductive wires.

[0151] Depending on the operating method of the charging cable, this grounding conductor braid can be used as a neutral conductor and / or shield. Furthermore, the grounding conductor braid can be used to determine cable damage or overheating.

[0152] If the grounding conductor braid is integrated into the protective sheath, the protective sheath material is present both above and below the grounding conductor braid. This allows the grounding conductor braid to be protected and can be used to determine cable damage or high sheath temperature.

[0153] In contrast, if the grounding conductor braid is located within the hollow space defined by the protective sleeve but outside the protective sleeve itself, the grounding conductor braid is more flexible.

[0154] In addition, the grounding conductor braid can be fixed to the inside of the protective sleeve.

[0155] Alternatively or additionally, the charging cable includes a grounding conductor, which is in the form of side-by-side wires, strands, or bundles integrated into a common protective sheath and coiled together around two single lines. Such a grounding conductor preferably comprises multiple sets of such side-by-side wires, strands, or bundles, separated from each other by sections of the protective sheath material that do not contain any wires, strands, or bundles.

[0156] This implementation has the following advantages: in addition to having the same conductor function as the grounding conductor braid described above, the grounding conductor also contributes to the mechanical stability of the charging cable.

[0157] That is, the two individual wires and other components of the charging cable (referred to here as the inner structure) are preferably twisted together before the protective sheath is applied: this results in a round and flexible charging cable. Without reverse winding, the charging cable may unwind under a load. The grounding conductor, in the form of parallel or stranded wires, can be wound together around the inner structure, more precisely, wound around the inner structure in the opposite direction of the twisting. Thus, the grounding conductor constitutes the winding portion of the charging cable.

[0158] In one embodiment of the charging cable, the charging cable includes a grounding conductor, which is composed of stranded wire twisted together with two single wires and covered by a common protective sheath. The grounding conductor preferably also includes an electrically insulating grounding conductor insulator.

[0159] The charging cable preferably includes not only a first grounding conductor twisted together with the two single lines, but also a second grounding conductor that together surrounds the two single lines and the first grounding conductor.

[0160] The second grounding conductor may be a grounding conductor braid that surrounds the first single line and the second single line as well as the first grounding conductor, and is covered by or integrated into a common protective sheath, and / or the grounding conductor may be a grounding conductor in the form of wires, strands or bundles arranged side by side, integrated into a common protective sheath and jointly coiled around the two single lines and the first grounding conductor.

[0161] Such a first grounding conductor can be a commonly used current cable. Charging cables with grounding conductors integrated in this way are particularly easy to manufacture and cost-effective.

[0162] The first grounding conductor is preferably located outside the single line. The grounding conductor is preferably located outside the flexible conduit.

[0163] The first grounding conductor is part of the internal structure of the charging cable.

[0164] In one embodiment, the charging cable includes signal cables. The signal cables are preferably grouped together, with members directly close to and preferably touching each other. Particularly preferably, each group comprises exactly three signal cables.

[0165] In one embodiment, the charging cable includes one or more signal cables, which are preferably arranged within a common sheath. The signal cables are preferably arranged within a common protective sleeve in the common sheath. Each signal cable has a signal conductor and a protective layer. The protective layer covers the signal conductor.

[0166] In at least one signal cable, the signal conductor is composed of a conductor in the form of a wire. The cross-sectional area of ​​the signal conductor is less than 1 / 20, preferably less than 1 / 40, of the cross-sectional area of ​​the conductor of the first single line. The protective layer is electrically insulating.

[0167] Multiple signal cables are typically present. By grouping them together in a common sheath, the construction and connection of the charging cable are simplified, as all signal cables are spatially close to each other. In addition to signal conductors made of conductors, signal conductors made of glass fiber can also be used.

[0168] Signal conductors, made of conductors, should transmit significantly less power than a single line. Therefore, their conductor cross-section is significantly smaller.

[0169] Preferably, the signal cables of the respective group are first twisted together, and then the signal cable group is twisted together with the other components of the internal structure of the two single lines and the charging cable, and then particularly preferably covered by a second grounding conductor and a common protective sheath.

[0170] In one embodiment, the charging cable includes at least one, preferably two, three, or four, flexible tubes made of a fluid-tight material. The tubes are housed within a common protective sheath but outside a first or second single circuit.

[0171] The hose is used to deliver cooling fluid outside of a single line. The hose is part of the cable's internal structure. In a preferred embodiment, the charging cable includes exactly two hoses with the same inner and outer diameters.

[0172] Polypropylene, polyurethane (PUR), EPDM, nylon, polyamide, and silicone are particularly suitable materials for hoses. The material should be suitable for the cooling fluid used, be flexible, and able to withstand high internal pressure. Hose can be fiber-reinforced.

[0173] In the first embodiment, the cooling fluid is pumped through a single line and flows out and is removed at the end of the cable. For example, air can be provided as the cooling fluid.

[0174] In another embodiment, the cooling fluid is delivered out via a first single line and returned via a second single line.

[0175] In another embodiment, the cooling fluid is delivered out through two single lines and returned through one or two hoses.

[0176] In another embodiment, the cable additionally includes two hoses, which are the outflow line and return line leading to the plug cooling device.

[0177] In another embodiment, the cable includes two hoses, one of which is an outflow line to the plug cooling device, and the other is a return line for cooling fluid from the plug cooling device and from the two single lines.

[0178] Here, the outflow path should be understood as a channel or hose leading from the pump or a location with high fluid pressure. The return path should be understood as a channel or hose leading to the pump or a location with low fluid pressure. The assignment of which constitutes the outflow path and which constitutes the return path preferably changes midway as the cooling fluid returns from the pump's outlet to its inlet, or midway between a location with high fluid pressure and a location with low fluid pressure. Here, high fluid pressure is a pressure higher than low fluid pressure.

[0179] Hose can come in various diameters. The diameter of the hose is selected based on space constraints and the desired fluid velocity at the desired flow rate.

[0180] The one or more hoses may have a circular or non-circular cross-section. Hoses with a circular cross-section are easier to manufacture and come in a wider variety. In contrast, hoses with a non-circular cross-section can make optimal use of space in the charging cable.

[0181] In one embodiment, the single line is contained within a flexible conduit. In this embodiment, a common protective sleeve may form the flexible conduit.

[0182] The hose arrangement in this invention is for conveying cooling fluid. Therefore, the ends of the hose are particularly fluid-tightly connected, and the hose is constructed of a fluid-tight material. The interior of the hose is preferably free, except for the cooling fluid in operation.

[0183] In one embodiment, the charging cable includes one or more of the following components: a grounding conductor, a signal cable, a flexible tube, and a filler (Beilauf).

[0184] Each of these components has a substantially circular cross-section, and that cross-section has a circumscribed circle radius.

[0185] The first single circuit and the second single circuit each have a circular cross-section, and the cross-sections of the first single circuit and the second single circuit have the same circumscribed circle radius R.

[0186] The circumcircle radius of each component in the existing components is less than or equal to the circumcircle radius R of the first single circuit, and preferably less than or equal to 2 / 3 of the circumcircle radius R of the first single circuit.

[0187] The components belong to the internal structure of the charging cable.

[0188] In a preferred embodiment, the outer circle radius of the hose and the filler is substantially equal to 1 / 3 or 2 / 3 of the outer circle radius R of the first single circuit. In particular, in the charging cable of this embodiment, there are no more than two components with an outer circle radius of 2 / 3 of the outer circle radius R of the first single circuit, and no more than four components with an outer circle radius of 1 / 3 of the outer circle radius R of the first single circuit.

[0189] According to this embodiment, a single line determines the circumference of the charging cable, and the current charging cable has a circular cross-section. All other components share the space created within the outer circles surrounding the two single lines. This embodiment has the advantages of: the relatively stable single line supports the entire cable against pressure loads in at least one direction. Through optimal space utilization, the cable circumference is kept as small as possible, which improves its grip.

[0190] The filler element is composed of twisted or parallel-stretched fibers or strips and functions to maintain the shape of the cable, and is essentially a filler. However, this filler element can also be used to absorb mechanical tensile forces applied to the cable. Therefore, this filler element is particularly used for anti-twisting properties. The filler element is particularly made of advantageous thermoplastic materials that are halogen-free. Examples of such materials are polypropylene and polyethylene.

[0191] All components of the internal structure are preferably twisted together.

[0192] The connection system includes a single line and two connection components. Each of the two connection components includes a fluid connection and an electrical connection.

[0193] The fluid connection allows fluid to flow into and out of the single circuit. The electrical connection establishes a path for transmitting electrical energy between the tap and the conductors of the single circuit.

[0194] Each of the connecting components is preferably constructed as a chamber. The chamber has a first opening for fluid-tightly connecting a single line. The chamber also has a second opening for connecting a fluid line. This is the fluid connection. Within the chamber are electrical contacts for establishing an electrical connection with the conductor of the single line. These electrical contacts within the chamber are connected to current conductors leading to the tap point. This is the electrical connection.

[0195] The connection system allows the single line according to the invention to be used both in the cooling fluid loop and in the circuit.

[0196] The charging system includes a first connection system and a second connection system. The first connection system includes a first single line of a charging cable, and the second connection system includes a second single line of the charging cable. A first end of the first single line and a first end of the second single line are located at the first end of the charging cable. A second end of the first single line and a second end of the second single line are located at the second end of the charging cable. The terminal connection includes a connection member at the first end of the first single line and a connection member at the first end of the second single line. The plug includes a connection member at the second end of the first single line and a connection member at the second end of the second single line.

[0197] The charging system allows the charging cable according to the invention to be used in a circuit in which the single line used is cooled.

[0198] In one embodiment of the charging system, the fluid couplings of the two connecting parts included in the plug are connected to each other such that fluid can flow from one fluid coupling to the other.

[0199] The plug thus establishes a fluid connection between the two single lines. While the fluid loop is thus closed at the plug, the current loop continues to guide the consumer or energy storage device.

[0200] In operation of this embodiment, the cooling fluid flows to the plug through a single line and returns to the connecting component through another single line.

[0201] In one embodiment of the charging system, each of the fluid coupling portions of the two connecting parts included in the plug is respectively connected to the flexible tubing of the charging cable.

[0202] The plug thus establishes a fluid connection between the single line and the hose, respectively. While the fluid circuit is thus closed at the plug, the current circuit continues to guide to the consumer or energy storage device.

[0203] In operation of this embodiment, the cooling fluid flows through a single line to the plug and returns to the connecting component through a hose, and vice versa.

[0204] In one embodiment of the charging system, at least the fluid connection portion of one of the two connecting components, preferably the fluid connection portions of the two connecting components forming a terminal connection portion, are connected to a fluid line leading to an external fluid source.

[0205] In this way, cooling fluid can be supplied to a single line of the charging system.

[0206] Preferably, both fluid connections are connected to a fluid source, and the hose guides the cooling fluid from the plug back to the fluid source. In this embodiment, the cooling fluid in the fluid source is cooled during operation and, under pressure, is introduced back into the single line via the fluid connections.

[0207] The charging system includes a charging cable with at least two hoses for supplying a plug cooling device and a plug with the plug cooling device. The plug includes two hose connections. The plug cooling device includes at least one cooling line connecting the two hose connections to each other. Therefore, cooling fluid can be introduced into the cooling line of the plug cooling device through one of the at least two hoses, and the cooling fluid can flow out again through the other of the at least two hoses.

[0208] A significant amount of heat is generated, especially at areas with high resistance. This often occurs at the contact surfaces and connection points, precisely in the plug area. However, the plug portion should be touchable to the user and therefore should have a surface temperature below 40°C. Other components, particularly conductor connections, may fail due to excessive heat. To prevent this, a plug cooling device is provided. The plug cooling device can use a single-line cooling fluid or have its own cooling fluid supply line. Since no additional hose is required, using a single-line cooling fluid in the plug cooling device allows for a compact cable design. If the primary purpose of using the plug cooling device is to reduce the surface temperature so that the user can touch the plug, it is more efficient to supply the plug cooling device through two hoses: preferably, the same rating should be applied to the surface temperatures of the charging cable and the plug. The flow rate of the cooling fluid can then be precisely selected so that this rating is achieved at the cable end. However, generally, using such heated cooling fluid does not reduce the plug to its rated temperature. Instead, in variations without a hose for supplying the plug cooling device, the cable must be cooled more intensely than desired to keep the plug at its rated temperature. This enhanced cooling translates to higher flow rates and therefore higher fluid velocities and / or larger free volume in a single line. Higher fluid velocities and thus higher pressures make the charging cable less flexible; the larger free volume makes the charging cable less lightweight and more heavy. Ultimately, given the rated current, desired maximum surface temperature, cable length, and a given plug design, it can be calculated whether cooling the plug via the cooling fluid in a single line or via a supply hose will result in a more compact charging cable with sufficient flexibility.

[0209] A method according to the invention for charging an energy storage device, particularly a vehicle battery, at a fixed charging station, the charging station being capable of providing cooling fluid and electrical energy and having a first end of a charging cable according to the invention connected to the charging station, the method comprising the following steps:

[0210] Connect the second end of the charging cable to the energy storage device, especially the vehicle's battery.

[0211] Under pressure, especially when pumping cooling fluid, the cooling fluid is introduced into the single-line channel of the charging cable.

[0212] Electrical energy is transmitted through the channel conductor and, if necessary, the additional conductor of the charging cable.

[0213] Here, in particular, the signal cable of the charging cable is used to transmit signals for controlling and / or monitoring the charging process and / or state of charge of energy storage devices, especially batteries.

[0214] In one embodiment, the method further includes cooling the cooling fluid before introducing it into the channel of a single line of the charging cable.

[0215] By using a cooled cooling fluid, higher current can be transmitted via the charging cable, and the charging method is independent of the temperature of the cooling fluid.

[0216] The energy storage device of a vehicle is, in particular, the battery used to power the vehicle. The connection between the charging cable and the vehicle's battery is preferably achieved via a plug installed at the charging cable and a socket installed in the vehicle and connected to the battery. The plug can be inserted into the socket for connection.

[0217] The introduction of cooling fluid under pressure is preferably achieved by a pump locally installed at or within the charging station. However, the charging station can also be connected to a tank or line that provides cooling fluid at a certain pressure. For example, it is conceivable to use cooling fluid water and a water tower for supply, wherein the water is pumped to a higher storage tank separately from the charging station and the charging process in time and place, and then drawn from the line at the desired pressure and introduced directly into a single line.

[0218] Signal cables can establish communication between the vehicle and the charging station. Therefore, the charging station can, for example, interrupt current flow upon fault notification or check that the charging cable is correctly connected to the vehicle's battery before charging begins. However, signal cables can also be used to monitor the charging cable itself by transmitting sensor signals from sensors in the plug or cable to the charging station. For example, if a sensor determines that the temperature is above a certain threshold, the charging station can increase cooling fluid flow or interrupt the charging process.

[0219] The method for manufacturing a single circuit according to the present invention includes the following steps, preferably performed sequentially in a production line:

[0220] a) Provides an open support structure and multiple channel conductors as continuous material.

[0221] b) Wrap the channel conductor around the support structure.

[0222] c) Preferably, another conductor is wound around the structure created in step b).

[0223] d) Co-extrude an insulator around the product of step b) or c).

[0224] e) Preferably, a woven fabric or wrapped fibers are woven around the insulator produced in step d).

[0225] f) Preferably, a second layer of insulating material is co-extruded around the product of step e) to produce a fiber-reinforced insulator.

[0226] According to step d), the insulator is preferably co-extruded onto the wound channel conductor and any other conductor present, if necessary, using a hose tool.

[0227] The use of hose tools has the following advantages: the insulating material will not be pressed against or between the external conductors, depending on the structure of the channel conductor or the other conductors. Thus, the cooling fluid can also surround and cool the external conductor on all sides during operation.

[0228] The co-extrusion of the second layer of insulation material according to step f) is preferably carried out in such a way that the first layer of insulation produced in step d) is bonded and connected to the second layer produced in step f), and the fibers are here surrounded by the insulation material as completely and tightly as possible. Therefore, a compression tool is preferably used for this co-extrusion step.

[0229] If a fiber-reinforced insulator is produced, it is preferable to apply a first layer of insulating material in step d), apply a fiber reinforcement in a layer in step e), and apply a second layer of insulating material in step f), so that the fiber-reinforced insulator comprises two layers of insulating material and a fiber layer.

[0230] The method according to the invention is particularly easy to implement. Using this method, a single circuit according to the invention can be comfortably and fully automatically manufactured as a continuous product. Time-consuming and error-prone steps, such as conductor braiding, are eliminated.

[0231] The method for manufacturing charging cables according to the present invention includes the following steps, preferably performed sequentially in a production line:

[0232] a) Provide additional components of the internal structure of the two single lines according to the invention and, if necessary, the desired charging cable as a continuous product.

[0233] b) Twist the components of the internal structure together in the first direction.

[0234] c) Preferably, the twisted components of the internal structure are wound in a second direction different from the first direction using wire, bundle, or stranded wire.

[0235] d) Co-extruded protective sleeve.

[0236] The method according to the invention is particularly easy to implement. Using this method, the charging cable according to the invention can be conveniently and fully automatically manufactured as a continuous product.

[0237] Since the protective sleeve of the charging cable can completely fill the gaps in the internal structure of the charging cable, and in many embodiments it should also be filled in order to improve the stability of the cable, it is preferable to perform co-extrusion of the protective sleeve according to step d) using a compression tool.

[0238] The vehicle according to the invention includes a single circuit according to the invention, which preferably establishes an electrical connection between a drive energy storage device and a drive unit and / or an electrical connection between a socket on the outside of the vehicle and the drive energy storage device.

[0239] The charging station according to the present invention includes a single line according to the present invention, the single line connecting the plug of the charging cable to a fixed current source.

[0240] In a particularly preferred embodiment, the plug and the socket on the outside of the vehicle are configured such that the conductor arrangement of the single circuit, which is part of the vehicle, is electrically connected to the conductor arrangement of the single circuit, which is part of the fixed charging station, and that cooling fluid in the single circuit, which is part of the vehicle, can flow into the single circuit, which is part of the fixed charging station, and vice versa. The socket here includes two connecting parts that connect to the two single circuits of the vehicle.

[0241] In one embodiment, the taps of the connecting components belonging to the plug and socket are respectively constructed as hollow cylinders and form fluid connection portions of the respective connecting components. The outer diameter of the plug tap substantially corresponds to the inner diameter of the socket tap, or vice versa, such that the plug tap and the socket tap can respectively be pushed into each other at least a certain distance, and a conductive connection is formed therein. Preferably, the tap with the smaller outer diameter has a region with a larger outer diameter at its end facing the single line, which forms a stop portion. A cooling fluid seal portion may be provided at this stop portion.

[0242] In one embodiment of the charging system, the fluid couplings of the two connecting parts forming the plug are interconnected such that fluid can flow from one fluid coupling to the other. When the plug is inserted into the socket, each connecting part belonging to the socket makes electrical contact with the tap of one connecting part belonging to the plug at its tap point. In the inserted state, the fluid coupling of the connecting part belonging to the socket is in fluid-tight contact with the fluid passage of the plug, wherein the fluid passage extends the two flexible tubes of the charging cable mounted at the plug in the plug, thereby ensuring a single-line cooling fluid supply to the vehicle during charging.

[0243] In a preferred embodiment, there is a kit consisting of two single lines and two connecting components, wherein the two single lines can be connected to each other in a releasable and reconnectable manner by means of the two connecting components. Here, one single line is connected to a first type of connecting component, while the other single line is connected to a second type of connecting component.

[0244] Ambient air, water, oil (especially transformer oil), or ester-based liquids can be used as cooling fluids. It is preferable to add additives to the water to provide corrosion protection, lower the freezing point, or increase heat capacity.

[0245] The preferred cooling fluid is a mixture of distilled water, propylene glycol, and other additives, particularly preferred for corrosion protection. In one embodiment, an additive is also added to reduce the conductivity of the mixture. This mixture has high heat capacity and low viscosity.

[0246] Water has the following advantages: it has a high heat capacity, is non-toxic, and is readily available. Additives can lower its freezing point and affect its other properties. This also allows for corrosion protection or increases in heat capacity.

[0247] Transformer oils and ester liquids (such as saturated pentaerythritol tetrafatty acid esters) are known from their use in transformers, where they are also used to cool electronic components.

[0248] Ambient air has the following advantages: it is always available and does not require storage.

[0249] In addition to the cooling fluid, cooling power may also be affected by the flow rate.

[0250] According to a preferred embodiment, the charging cable includes a fluid-coolable first single wire and a second single wire, as well as a common protective sheath. Furthermore, the charging cable includes two flexible tubes made of a fluid-sealing material, which guide cooling fluid, more specifically, in the same amount as the two single wires. This embodiment of the charging cable also includes signal lines, preferably 12 signal lines, present in four groups of three signal lines each. The charging cable also includes a ground conductor. The ground conductor is a conductor constructed with its own insulation and is arranged within the common protective sheath. Finally, the charging cable includes a filler made of synthetic or hemp fibers. The single wires, flexible tubes, signal lines, ground conductor, and filler are twisted together in a first direction to form the internal structure of the charging cable of this embodiment. The side-by-side single wires or stranded wires are wound around this internal structure in a second direction, different from the first direction, and are surrounded by the protective sheath. Multiple groups of side-by-side single wires or stranded wires are separated from each other by sections of the protective sheath material that do not contain any conductors.

[0251] In a preferred embodiment, the charging cable comprises two fluid-coolable single circuits with a chrome steel spiral support structure. The channel conductor is an uncoated bundle of copper wire, and no other conductors are present. Each single circuit is surrounded by fiber-reinforced insulation. The charging cable also includes two hoses, a first ground conductor with a circular cross-section surrounded by its own insulation, and four sets of signal cables, each set containing three signal cables surrounded by a common signal cable sheath. The two single circuits, the first ground conductor, the two hoses, and the four sets of signal cables are housed within a common protective sheath. The protective sheath comprises four sets of conductors arranged side-by-side, separated from each other by sections of sheath material without embedded conductors. The conductors in the protective sheath also serve as ground conductors. This preferred embodiment of the charging cable presents a particularly good trade-off in terms of crush resistance, flexibility, weight, and safety. Attached Figure Description

[0252] In the accompanying drawings used to explain the embodiments:

[0253] Figure 1a This illustrates a circular single-circuit circuit with a helical section as a support structure, which utilizes a channel conductor coiled around it.

[0254] Figure 1b This illustrates a circular single-circuit circuit with an open profile as a support structure, utilizing a bundle of channel conductors wound around it.

[0255] Figure 1c This illustrates a circular single-circuit circuit with a helical section as a support structure and a second layer of additional conductor on the channel conductor.

[0256] Figure 2a Showing open profiles,

[0257] Figure 2b Showing a twisted open profile,

[0258] Figure 2c The diagram shows a helical section with variable pitch.

[0259] Figure 3a shows the helical section serving as a support structure, which utilizes a channel conductor coiled around it. The support structure and the channel conductor differ in their helical directions.

[0260] Figure 3b The diagram shows a helical section serving as a support structure, which utilizes a channel conductor wound around itself. The support structure and the channel conductor are identical in the direction of rotation.

[0261] Figure 4a A charging cable with two single lines is shown.

[0262] Figure 4b A first embodiment of the charging cable is shown, which has two single lines, a ground conductor, a flexible tube, and a signal cable.

[0263] Figure 4c A second embodiment of the charging cable is shown, which has two single lines, a ground conductor, a flexible tube, and a signal cable.

[0264] Figure 4d A charging cable with two single lines, a flexible tube, a stuffing, a signal cable, and a grounding conductor braid is shown.

[0265] Figure 5 The charging system is shown.

[0266] Figure 6 A plug with a plug cooling device is shown.

[0267] Figure 7 The vehicle shown has two single lanes.

[0268] In principle, identical parts are given the same reference numerals in the drawings. Detailed Implementation

[0269] Figure 1aA cross-section of a circular single-line 6 passing through a helical portion 011 serving as a support structure and a channel conductor 21 is shown. The channel conductor follows a helix with a circular base and coils around and touches the helical portion 011. The channel conductor 21 conducts current flowing through the single-line 6. The channel conductor 21 is directly covered by an insulator 3. The insulator is fiber-reinforced. The insulator consists of an inner layer and an outer layer of insulating material, and an intermediate layer, in which a fiber fabric surrounded by the insulating material serves as a fiber reinforcement 31. The free volume of the channel 4 formed by the helical portion 011 and the channel conductor 21 is located inside the helical portion 011. However, this channel 4 is not sealed for cooling fluid, allowing cooling fluid 5 to diffuse radially toward the insulator 3.

[0270] Figure 1b The cross-section of a circular single line 6 passing through an open profile 012 serving as a support structure and a channel conductor 21a configured as a bundle is shown. The channel conductor 21a conducts current flowing through the single line 6. The channel conductor 21a follows a helix with a circular base. All helices followed by the channel conductor 21a have the same radius, the same direction of rotation, and the same pitch. The channel conductor 21a is directly covered by an insulator 3. The support structure has a star shape in cross-section, with a circular connecting surface and six ribs evenly arranged around the connecting surface. Therefore, a first type of star cross-section is involved. There are a total of six channels 4 of the same size, formed by the open profile 012 and the channel conductor 21a, wherein, in this case, the structure of the channel conductor 21a and therefore the channels 4 should also be permeable to the cooling fluid 5. The cooling fluid 5 can therefore diffuse toward the insulator 3.

[0271] Figure 1c The distribution of cooling fluid 5 in another single line is shown. A cross-section of a circular single line 6 is shown passing through a helical portion 011, which serves as a support structure, and a channel conductor 21, which follows a helix with a circular base and coils around and touches the helical portion 011. The channel conductor 21 is surrounded by another conductor 22. The other conductor 22 is in electrical contact with the channel conductor 21 but does not touch the support structure itself. The diameter of the channel conductor 21 is significantly smaller than the diameter of the other conductor 22. The channel conductor 21 and the other conductor 22 jointly conduct the current flowing through the single line 6. The other conductor 22 is directly covered by an insulator 3. The free volume of the channel 4 formed by the helical portion 011 and the channel conductor 21 is located inside the helical portion 011. However, this channel 4 is not sealed for cooling fluid, allowing the cooling fluid 5 to diffuse radially around the other conductor 22 and toward the insulator 3.

[0272] Cooling fluid 5 is shown in gray. Insulator 3 is fluid-tight. Conductors 21 and 22 are generally impermeable to fluids, but the fluid is distributed in the free space between the conductors. This results in the distribution shown, in which substantially all of the conductors 21 and 22 are in contact with the fluid over most of their surface area.

[0273] Figure 2a An open profile 012 with a second type of star-shaped cross-section is shown, having a circular connecting surface and four ribs of different lengths distributed at uniform angular intervals. The open profile 012 has a longitudinal axis 0121. The cross-sections 0122a,b,c along this longitudinal axis are always identical and have a vertical cross shape, wherein the horizontal extension is always less than the vertical extension.

[0274] Figure 2b An open profile 012 with a first-type star-shaped cross-section is shown, having a circular connecting surface and four ribs of equal length distributed at uniform angular intervals. The open profile 012 has a longitudinal axis 0121. Although the cross-sections 0122a, b, c along this longitudinal axis are always identical in shape, they are twisted relative to each other. The shape of the cross-section is a cross shape with approximately triangular ribs, where the triangles have the same height. Here is an example of a twisted open profile.

[0275] Figure 2c The diagram shows a helical section 011 with different pitches 0111. This helical section 011 is made of round wire. The helical section 011 also has a longitudinal axis 0121.

[0276] Figure 3a shows a side view of the helical portion 011 with a constant pitch 0111. For example, the pitch 0111 can be easily seen in this view by observing the distance between two points where the helical portion 011 appears in the field of view. Here, the pitch 0111 is one unit of length. Furthermore, in this view, the diameter 0112 of the cylinder defined by the helical portion 011 is equal to the width of the rectangle presented by the cylinder in this view. Here, the base radius of the cylinder is equal to 1.15 units of length.

[0277] The convex covering portion of the spiral portion 011 is a cylinder shown in the side view. The point of contact between the supporting structure (i.e., the spiral portion 011) and the cylinder (i.e., its convex covering portion) is exactly the point on the spiral portion 011 furthest from its longitudinal axis 0121. Therefore, the line of the supporting structure in the present case (since the wire defining the extension of the spiral portion 011 is not shown) is exactly equal to the line shown in Figure 3a depicting the spiral portion 011.

[0278] The helix 211 of the channel conductor has a pitch of approximately 4.5 length units and is left-handed. The slant angle is arctan(pitch / (π diameter)) = arctan(4.5 / (2*1.15*π)) = 32°.

[0279] The helical part 011 of the support structure is right-handed with a pitch of 1, and therefore the slope angle is arctan(1 / (2.3*π))=8°.

[0280] In the example shown, the spiral 211 of the channel conductor thus intersects the support structure line at an angle 113 of (180°-32°)-8°=140°.

[0281] The pitch ratio is 4.5.

[0282] Figure 3a shows the orientation of a support structure in the form of a helical portion 011 and a helix 211 with a circular base, along which a channel conductor follows in one embodiment. The helical portion 011 and the helix 211 have different directions of rotation. All helices 211 have the same pitch, the same direction of rotation, and the same radius, while the helical portion 011 of the support structure, although having a substantially the same radius, has a significantly smaller pitch. In the example shown, the channel conductor 21 following one of the helices 211 is supported on the helical portion 011 of the support structure a total of six times during its rotation around the longitudinal axis of the support structure.

[0283] Figure 3b An embodiment very similar to that shown in Figure 3a is illustrated. However, the helixes 011 of the support structure and 211 of the channel conductor now have the same direction of rotation. Both helixes 211 have the same pitch, the same direction of rotation, and the same radius, while the helix 011 of the support structure has a substantially the same radius but a significantly smaller pitch. In the example shown, the channel conductor 21, following one of the helixes 211, rests on the helix 011 of the support structure only a total of four times during its rotation around the longitudinal axis of the support structure.

[0284] In the example shown, the spiral 211 of the channel conductor now intersects the support structure line at an angle 0113 of 32°-8°=24° due to the same direction of rotation.

[0285] Here, the pitch ratio is also 4.5.

[0286] In addition to the helix 211 of the channel conductor, Figure 3b The diagram also shows two channel conductors 21 in the form of stranded wires. A small gap 24 exists between the channel conductors 21 to allow cooling fluid to exit through the channels. Although... Figure 3bThey may look different, but the channel conductor 21 is externally supported on the support structure and coiled around the support structure.

[0287] Figure 4a A charging cable 12 with a first single-channel 61 and a second single-channel 62 is shown. The first single-channel 61 and the second single-channel 62 have a spiral portion 011 as a support structure and both have a circular cross-section and the same diameter. The first single-channel 61 and the second single-channel 62 are shown only schematically. Whether only a channel conductor 21 or another conductor 22 is present is left open. All variations are possible, and the first single-channel 61 can be constructed differently from the second single-channel 62. The first single-channel 61 and the second single-channel 62 can also differ in their diameter and / or shape. The first single-channel 61 and the second single-channel 62 are arranged side-by-side and located within a common protective sleeve 7. The protective sleeve 7 here has a rectangular cross-section with rounded corners and slightly convex edges. In this case, the protective sleeve 7 fills the entire space between its surface and the first single-channel 61 and the second single-channel 62.

[0288] Figure 4b An additional charging cable 12 is shown. This additional charging cable includes a first single wire 61 and a second single wire 62. The first single wire 61 and the second single wire 62 have the same diameter and are arranged side by side, thus determining the inner diameter of the protective sleeve 7 surrounding the first single wire 61 and the second single wire 62. The first single wire 61 and the second single wire 62 shown correspond to the... Figure 1a The single-line circuit. Within the protective sleeve 7, specifically in the region between the inner and outer radii of the protective sleeve, there exists an extended grounding conductor 93, which is in the form of numerous parallel-extending copper wires wound inside the cable. The extended grounding conductor 93 can also be implemented using conductor braiding. The extended grounding conductor 93 can serve as a neutral conductor, or as a shield against defects or excessive temperatures within the protective sleeve 7, or as a sensor. Inside the protective sleeve 7, there is also a grounding conductor 9, which is composed of twisted copper wire and has its own insulation, completely within the inner radius of the protective sleeve 7. Furthermore, inside the protective sleeve 7, there are two flexible tubes 81, a filler element 11 made of synthetic fibers, and four sets of signal cables 101, each set containing three signal cables.

[0289] Figure 4cAn additional charging cable 12 is shown. This additional charging cable includes a first single-wire 61 and a second single-wire 62, a grounding conductor 9, seven signal cables 101 and four flexible tubes 81 within a common sheath 10. All of these are surrounded by a common protective sleeve 7. The protective sleeve 7 has the shape of a circular hollow cylinder, the inner diameter of which is twice the diameter of a single-wire. Both the first single-wire 61 and the second single-wire 62 have a circular cross-section and the same diameter. The first single-wire and the second single-wire differ in their support structure: the first single-wire 61 uses a spiral portion 011, while the second single-wire 62 uses an open profile 012.

[0290] The grounding conductor 9 also has a circular cross-section. This grounding conductor consists of a neutral conductor wire 91 and a neutral conductor insulation portion 92. The diameter of the grounding conductor 9 is 2 / 3 of the diameter of the first single-circuit 61.

[0291] The sheath 10 of the covered signal cable 101 also has approximately two-thirds the diameter of the first single line 61. In cross-section, the sheath 10 of the covered signal cable 101 is circular. Each individual signal cable in the signal cable 101 also has a circular cross-section. The sheath 10 is relatively thin. The two signal cables in the illustrated signal cable 101 are composed of signal conductors 1011, which are directly surrounded by a protective layer 1012. The signal conductors 1011 have a signal conductor cross-section 1013.

[0292] Similarly, the conductor cross-section 23 of the first single line 61 is drawn. This conductor cross-section includes not only the conductor cross-section of the channel conductor 21 of the first single line 61, but also the conductor cross-section of any other conductor 22 that may be in electrical contact with the channel conductor 21.

[0293] The conductor cross-section 23 of the first single line 61 is 20 times larger than the signal conductor cross-section 1013.

[0294] Each of the four hoses 81 has a circular cross-section and an outer diameter that is approximately one-third the diameter of the first single line 61.

[0295] The first single wire 61 and the second single wire 62 are arranged side by side and touch. The cover 10, together with the signal cable 101 it covers, is arranged above the touch point and in contact with the first single wire 61 and the second single wire 62. The grounding conductor 9 is arranged below the touch point and in contact with the first single wire 61 and the second single wire 62. Two hoses 81 that guide the cooling fluid 5 back to the first single wire 61 and the second single wire 62 are arranged such that each hose is in contact with one of the single wires of the first single wire 61 or the second single wire 62 and the grounding conductor 9. Two hoses 81 that supply the plug cooling device 146 are arranged such that each hose is in contact with one of the single wires of the first single wire 61 or the second single wire 62 and the cover 10. Thus, all components of the charging cable 12 and the first single wire 61 and the second single wire 62 are tightly packaged. Furthermore, in this arrangement, there are also eight points located on the periphery of the arrangement. The inner side of the protective sleeve 7 corresponds exactly to the periphery of the arrangement. Four of the eight points are exactly 90° apart from each other and are formed by a signal cable 101 consisting of a solid conductor, a first single-line 61, a second single-line 62, and a ground conductor 9 of its sheath 10. Potentially compressible hoses 81 are located between these nearly incompressible structures. The hoses 81 may deform slightly under pressure, but they are protected from complete closure by the nearly incompressible structures on both sides.

[0296] In a preferred embodiment, the support structure for the first single line 61 and the second single line 62 is a spiral portion 011, which is made of chromium-nickel steel wire with a diameter of 0.6 mm. This spiral portion is surrounded by 14 channel conductors 21 made of uncoated copper wire, each channel conductor having a cross-sectional area of ​​2.5 mm². 2 This results in a 35mm 2 The first single-line conductor 61 has a conductor cross-section 23. Preferably, an insulator made of TPE or EPDM surrounds the channel conductor 21 and completes the first single-line conductor 61. The insulator is reinforced with aramid or hemp fiber braid. The second single-line conductor 62 is constructed similarly. In addition to the first single-line conductor 61 and the second single-line conductor 62, the charging cable 12 also contains conductors with cross-sections 1013 of 0.75 mm². 2 The cable includes six signal cables 101, which are arranged around the filler 11 and held together by a common sheath 10. The cable also includes two flexible tubes 81 with inner diameters of 4 mm and conductor cross-sections of 16 mm². 2 The grounding conductor 9 and two filler strands 11. This arrangement is preferably as follows: Figure 4c As described above, however, the hose 81 used to supply the plug cooling device 146 is replaced by the filler 11.

[0297] Figure 4d An additional charging cable 12 is shown. This additional charging cable includes a first single line 61 and a second single line 62, three flexible tubes 81, three stuffing strands 11, six signal cables 101, a grounding conductor 93 extended in the form of a braid, and a protective sleeve 7. The six signal cables 101 are arranged around the stuffing strands 11 and combined with the sheath 10.

[0298] The signal cable 101, the filler strands 11, the hose 81, and the first single wire 61 and the second single wire 62 all have a circular cross-section. The protective sleeve 7 has a hollow cylindrical shape. An extended grounding conductor 93, also having a circular hollow cylindrical shape, rests against the inside of the protective sleeve. The first single wire 61, the second single wire 62, and all other components of the charging cable are located inside the hollow cylinder formed by the extended grounding conductor 93. The inner radius of the braid of the extended grounding conductor 93 is equal to the diameter of the first single wire 61. The diameters of the first single wire 61 and the second single wire 62 are the same. The braid of the extended grounding conductor 93 is designed to allow for a smaller increase in its inner radius. The diameter of one of the hoses in the sheath 10 and the hose 81 is approximately 2 / 3 the diameter of the first single wire 61. The diameters of the two remaining hoses 81 and the two filler strands 11 located outside the sheath 10 are preferably approximately 1 / 3 the diameter of the first single wire 61.

[0299] In a preferred embodiment, the single line 6 has a helical portion 011 with a diameter of 7.4 mm as a support structure, which is made of chromium-nickel steel wire with a diameter of 0.6 mm. The single line is surrounded by multiple layers of copper wire, wherein the copper wire layer closest to the support structure constitutes the channel conductor. This selection of the number and diameter of the wires results in a conductor cross-section 23 of 35 mm² for the single line 6. 2 These channel conductors 21 and the additional conductors 22 are preferably surrounded by an insulator of 2 mm thickness made of EPDM or TPE, so that the single line 6 has a diameter of 12 mm.

[0300] In a preferred embodiment of the charging cable 12, the charging cable includes two single wires of the first single wire 61 and the second single wire 62, two flexible tubes 81 with an outer diameter of 4.0 mm made of polyurethane (PUR), and a flexible tube 81 with an outer diameter of 8.0 mm. The larger flexible tube 81 has a wall thickness of 1 mm, and in the case of the smaller flexible tube 81, the wall thickness is 0.5 mm. The 8.0 mm outer diameter flexible tube 81 receives cooling fluid 5 that has flowed through and cooled the channels 4 of the first single wire 61 and the second single wire 62. The 4.0 mm outer diameter flexible tube 81 serves as both the outflow and return lines for the plug cooling device 146. Furthermore, the charging cable 12 includes six signal cables 101, each with a diameter of 0.75 mm. 2 The conductor has a cross-sectional area 1013 and a conductor diameter of 1 mm. It is surrounded by an insulator 3 with a wall thickness of 0.5 mm. The six signal cables 101 are arranged around a filler 11, which is preferably made of PP or PE and has a diameter of 2 mm. A sheath 10 with a thickness of 0.5 mm is arranged around the six signal cables 101. The entire arrangement is surrounded by a braid made of copper wire with a diameter of 0.25 mm, wherein the braid forms a column with an inner diameter of 24 mm. A protective sheath 7 with a wall thickness of 2.75 mm surrounds all components, so that the charging cable 12 has an overall diameter of 30 mm. The charging cable 12 is easy to grip. When the charging cable 12 is running with water as the cooling fluid 5, the charging cable contains 90.5 mm per millimeter. 3 The copper volume and length per millimeter are 67.5 mm. 3 Water volume. This results in a weight slightly less than 1 g / mm² of charging cable length or 1 kg / m of cable length. With cooling using warm water at 20°C and a current carrying rate of 1.8 L / min, this charging cable 12 can transmit 700 A of current over a length of 7 m, while the surface temperature does not exceed 50°C at an ambient temperature of 20°C. Under the same conditions, approximately 600 A can be transmitted, and the charging cable 12 does not exceed 40°C anywhere on its surface.

[0301] Figure 5A charging system with a charging cable 12, a plug 14, and a terminal connection 13 is shown. The terminal connection 13 includes an electrical contact 131 and a fluid supply section 132 for cooling fluid 5. The terminal connection 13 includes two connecting parts, but these connecting parts are not visible in the current figure. The fluid supply section 132 is designed to provide a pump or wiring system that provides cooling fluid 5 with a desired pressure difference between the inlet and outlet of the fluid supply section 132. The fluid supply section 132 includes a fluid connection section with two connecting parts, including the terminal connection 13. The electrical contact 131 is designed to be connected to a current source that provides the power to be transmitted. The electrical contact 131 is the tap point of the connecting parts including the terminal connection 13.

[0302] The plug 14 includes two connecting parts 147a,b, whose common boundary is indicated by a dashed line in this figure.

[0303] The plug 14 internally includes a fluid return section 141 that receives cooling fluid 5 from one of the first single-line circuits 61 and 62 and directs the cooling fluid to the other single-line circuit, or receives cooling fluid from both the first and second single-line circuits 61 and directs the cooling fluid to one or both hoses 81 of the charging cable. The fluid return section 141 is implemented through the design of a fluid connection between the two connecting parts included in the plug. Furthermore, the plug 14 includes an electrical contact 142, through which an electrical connection can be established with the energy storage device to be charged. The electrical contact 142 is the tap point of the two connecting parts included in the plug 14. The plug 14 may also include additional contacts that connect to the signal cable 101 and via which data exchange can be performed between devices connected to the charging cable 12.

[0304] Figure 6A cross-section of the plug 14 with a plug cooling device 146 is shown. The plug 14 includes three connectors 145, 144 for a flexible hose 81 for a cable and two connectors 143 for a single line. The two connectors 143 for the single line are formed as tubes made of a highly conductive material. The channel conductor 21 and, if possible, additional conductors 22 are brought into contact with the tube, for example, by placing them on the outside of the tube and clamping and / or brazing them there. This clamping and / or brazing prevents the cooling fluid 5 from reaching the outside of the tube. The tube preferably has a diameter that is approximately the same as or slightly larger than the channel 4 of the single line 6 to be connected. The interior of the tube is preferably made of an electrically insulating material. Fluid enters the interior of the tube. Not far behind the connectors, inside the plug 14, the tube separates: the highly conductive material of the tube wall is combined, and it transitions to the desired shape of the electrical contact 142 at the plug outlet, the tap point. An insulating material forms a tube inside the pipe, which converges with the tube of the connector 143 for the second single line and ultimately leads to the connector 144 for the hose. This is the fluid return section 141 of the plug 14. The connector 144 for the hose can be constructed from a tube that tapers in the direction of the plug. The hose 81 can be pulled onto this tube and then clamped. The other two connectors 145 for the hose can be designed in the same manner. These connectors constitute the outlet and return sections for the plug cooling device 146. The outlet and return sections are constructed from one or more cooling lines that guide through those parts of the plug 14 that should be specifically cooled.

[0305] For clarity, the two connecting parts 147a and 147b are not specifically labeled in this figure: the electrical contact 142 constitutes the tap point of the connecting parts 147a and 147b. The fluid connection of one connecting part is guided into the fluid connection of the other connecting part. The fluid connection of the other connecting part includes a fluid return part 141 and a connection part 144 for a hose.

[0306] Figure 7 A vehicle 15 is shown with two single lines 16, which establish a connection between a socket 152 and a drive energy storage device 151.

[0307] In summary, the conductor cross-sections of the single-line 6, grounding conductor 9, and signal cable 101 can be selected according to the corresponding requirements. The arrangement of the components of the charging cable can also be adapted to the requirements. Therefore, for example, the sensor can be integrated into the charging cable 12, and the number of signal cables 101 can be selected in more or fewer ways. In particular, the filler strands 11 can be replaced by the signal cable 101, the sensor, an additional flexible tube 81, an additional conductor for transmitting electrical power, or unstructured filler. The protective sleeve 7 can be reinforced, for example, using an electrically insulating ring or a wire spiral to further improve anti-twisting properties. Additional reinforcements can also be installed around the protective sleeve 7. Instead of tin-plated copper, bare copper, copper alloys, aluminum, or other conductor materials can be used in various places or only in sections of the single-line 6 and / or the charging cable. Similarly, the flexible tube 81 can be made of EPDM, nylon, polyamide, or silicone. The flexible tube can be fiber-reinforced. The wall thickness of the insulator and the flexible tube 81 can be selected according to the corresponding requirements. The material of the protective sleeve 7 can be the same as the material of the insulation 3 of the first single line 61 and the second single line 62. The sheath 10 of the signal cable 101 can be omitted. The channel conductor 21 can be designed as a single wire, a bundle of wires, or a stranded wire. Wires and wire bundles can be replaced by a strip or stranded wire composed of multiple wires. The protective sleeve 7 does not have to be circular, but can also be adapted to the shape or external conditions of the cable components.

Claims

1. A single line (6) for a charging cable (12), comprising: a) an open support structure with a longitudinal extension, b) at least one channel conductor (21) of an electrically conductive material, and c) an insulation (3), wherein d) the at least one channel conductor (21) is wound along the longitudinal extension of the open support structure and touches the open support structure, and e) the insulation (3) covers the open support structure and the at least one channel conductor (21), and f) there is at least one channel (4) for a cooling fluid (5), and the channel (4) is formed by the support structure and the channel conductor (21), g) wherein the insulation (3) is impermeable to the cooling fluid (5) and electrically insulating, h) wherein each of the channel conductors follows a helix with a handedness, a pitch and a radius, and the handedness and the pitch of the helices of all channel conductors are identical, i) wherein the support structure is a helix (011), characterized in that j) the pitch ratio of the smallest pitch of the helix of one of the channel conductors divided by the pitch of the helix of the support structure is a quasi-irrational number greater than 4 and less than 50, wherein a quasi-irrational number is an irrational number and a rational number expressed as a short decimal and having a numerator greater than or equal to 5 and a denominator greater than or equal to 5.

2. Single line (6) according to claim 1, wherein The radius of all helices of all channel conductors is identical.

3. Single line (6) according to any one of claims 1 to 2, wherein, Each of the channel conductors is a strand or bundle of a number of individual thin conductor wires.

4. Single line (6) according to any one of claims 1 to 2, wherein, The handedness of the support structure is different from the handedness of the helix of the channel conductors.

5. Single line (6) according to one of claims 1 to 2, wherein, The support structure is an open profile (012) whose cross section remains constant in shape and size along the longitudinal extension, but the shape is twisted around a longitudinal axis (0121) along the longitudinal extension.

6. Single line (6) according to any one of claims 1 to 2, wherein, The insulation is a fiber-reinforced insulation.

7. Single line (6) according to claim 6, wherein The fibers are woven into a braid.

8. Single line (6) according to claim 6, wherein The fibers are arranged in one layer and cover between 30% and 90% of the area of the layer in the layer.

9. Single line (6) according to claim 6, wherein The fibers are arranged in one layer and cover between 50% and 70% of the area of the layer in the layer.

10. The single line (6) according to claim 6, wherein The fibers are arranged in one layer and cover 60% of the area of the layer in the layer.

11. A charging cable (12) for transmitting high charging currents to charge an energy store (151) of a vehicle (15), comprising: a first single line (61) and a second single line (62) and a common protective jacket (7), characterized in that the first single line (61) and the second single line (62) are single lines (6) according to any one of claims 1 to 10.

12. The charging cable (12) according to claim 11, further comprising: a ground conductor braid (93) surrounding the first single line (61) and the second single line (62) and covered by or integrated into the common protective jacket (7), and / or a ground conductor in the form of parallel arranged wires or strands or bundles which are integrated into the common protective sheath (7) and are jointly coiled around the two single lines, wherein a plurality of groups of such parallel arranged wires, strands or bundles are separated from one another by sections of the protective sheath material which do not contain any ground conductor.

13. The charging cable (12) according to any one of claims 11 to 12, wherein, All components of the internal structure of the first single line (61) and the second single line (62) and the charging cable (12) are twisted together.

14. A coupling system comprising a single line (6) according to any one of claims 1 to 10 and two coupling parts, wherein, Each of the two coupling components comprises a fluid coupling and an electrical coupling, and wherein the fluid coupling enables a flow of fluid into or out of the single line and the electrical coupling constitutes a path for the transmission of electrical energy between a tapping point and a conductor of a single line, and wherein each of the coupling components is configured as a chamber having an opening for fluid-tightly coupling a single line and a second opening for coupling a fluid line, and wherein within the chamber there is an electrical contact for establishing an electrical connection with a conductor of the single line and the contact is connected with an electrical current lead which leads to a tapping point.

15. A charging system comprising a first coupling system and a second coupling system, wherein, The first coupling system and the second coupling system are coupling systems according to claim 14, wherein the first coupling system comprises a first single line of a charging cable (12) according to any one of claims 11 to 13 and the second coupling system comprises a second single line of the charging cable (12), and wherein the first end of the first single line and the first end of the second single line are at a first end of the charging cable, and the second end of the first single line and the second end of the second single line are at a second end of the charging cable, and a terminal coupling (13) comprises the coupling components at the first end of the first single line and at the first end of the second single line, and a plug (14) comprises the coupling components at the second end of the first single line and at the second end of the second single line.

16. A method for charging an energy store of a vehicle at a stationary charging station, which charging station can provide a cooling fluid (5) and electrical energy and to which a first end of a charging cable (12) according to any one of claims 11 to 13 is coupled, the method comprising the following steps: a) coupling a second end of the charging cable (12) at an energy store of the vehicle, b) introducing a cooling fluid (5) under pressure into the channels (4) of the first single line (61) and the second single line (62) of the charging cable (12), c) transmitting electrical energy via the channel conductors (21) and further conductors (22) of the first single line (61) and the second single line (62) of the charging cable (12), wherein a signal cable (101) of the charging cable (12) is used to transmit signals for controlling and / or monitoring the charging process and / or the state of charge of the energy store.

17. A method for manufacturing a single line (6) according to any one of claims 1 to 10, the method comprising the following steps carried out in succession in a production line: a) providing an open support structure and a plurality of channel conductors as continuous material, b) winding the channel conductors onto the support structure, c) winding further conductors around the structure produced in step b), d) co-extruding an insulator around the product of step b) or c), e) weaving a braid consisting of fibres or winding fibres around the insulator produced in step d), f) co-extruding a second layer of insulator material around the product of step e), thereby producing a fibre-reinforced insulator.

18. A method for manufacturing a charging cable according to any one of claims 11 to 13, comprising the following steps carried out in succession in a production line: a) providing two single lines according to the application and further components of the internal structure of the charging cable as continuous products, b) twisting the components of the internal structure to one another in a first direction, c) winding the twisted components of the internal structure with wire, strand or stranded wire in a second direction different from the first direction, d) co-extruding a protective jacket.

19. A vehicle comprising a single line (6) according to any one of claims 1 to 10, wherein, The single lines are part of a coupling system according to claim 14, which establishes an electrical connection between a drive energy store and a drive unit and / or between a socket at the outside of the vehicle and a drive energy store.

20. A charging post comprising a single line according to any one of claims 1 to 10, which connects the plug of a charging system according to claim 15 with a fixed current source.

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