Electrical conductor with inner contour and filling element, as well as electrical cable with such a conductor

Abstract

Electrical line (10), in particular for a charging cable (100), wherein the electrical line (10) comprises: - at least one electrical conductor (16); and - a cooling line (12) surrounding the at least one electrical conductor (16), in particular a cooling hose, wherein a cooling medium (14) can be guided in an interior of the cooling line (12) and the cooling line (12) has at least one inner contour (18) projecting into the interior and formed on an inner surface of the cooling line (12); - at least one filling element (19) arranged or provided in the at least one inner contour (18); wherein, in a first state of the electrical conductor (10), which is at least substantially undistorted and is spaced at least one inner contour (18) apart from the at least one electrical conductor (16), and wherein, in at least one, in particular at least partially bent, second state of the electrical conductor (10), the at least one electrical conductor (16) comes into contact with the at least one inner contour (18) in such a way that the at least one inner contour (18) prevents contact between the at least one electrical conductor (16) and the cooling conductor (12).

Description

[0001] The invention relates to an electrical conductor, in particular for a charging cable, and an electrical cable, in particular a charging cable for example for electric vehicles, with at least one such electrical conductor.

[0002] Electric vehicles are typically charged at charging stations using charging cables. These cables are usually connected to the charging station at one end and can be connected to an electric vehicle for charging. The maximum charging power for an electric vehicle depends on several factors, such as the charging power of the electric vehicle and the charging station. Besides the electric vehicle and charging station, other factors influencing the maximum charging power include the temperature and the battery's state of charge.

[0003] Besides the battery temperature, the charging cable temperature also plays a role in the charging power and thus the charging time. Generally, charging systems designed for high charging power generate significant heat. This can be particularly problematic with charging cables that have smaller cross-sections. These smaller cross-sections would typically not be able to transmit the necessary power because they would heat up too quickly under the current load. This could lead to exceeding the maximum permissible conductor temperature according to EN 50620 or IEC 62893 after a certain period. The charging process might then have to be interrupted or aborted. Furthermore, the cables' lifespan would be reduced.

[0004] Furthermore, the surface temperature of the charging cable could also rise above the limit specified in IEC 117 and potentially lead to injuries to the user when touching or handling the charging cable. The heat energy generated during charging must therefore be dissipated, for example, by means of a cooling line. One current approach to this is to integrate hoses into the cable construction, which extract the heat from the cable. The medium in the cooling hoses can be gaseous or liquid. Conductive liquids (e.g., a water-glycol mixture) are generally used more frequently for cooling in the thermal management process.

[0005] Currently available cooling solutions for charging cables are not optimal in terms of cooling performance. To improve cooling efficiency, the state of the art includes direct cooling, in which the heat-generating conductor elements come into direct contact with a cooling medium, for example, being directly surrounded by a cooling medium without being separated from it by a cooling hose or similar device. With directly cooled charging cables, as well as with other cables, it is advantageous if the conductor within the cable is positioned as centrally as possible within the cooling hose to avoid direct contact with the hose wall. If the conductor touches the hose wall, less cooling occurs in that area. A hot strip can form along the hose wall. This transfers heat into the cable structure and leads to elevated temperatures.

[0006] Currently, concentricity in directly cooled charging cables is ensured by means of a so-called helix wire (spiraled stranded wire around a copper cable in the core). This helix wire presents many problems in assembly, manufacturing, and the insertion of the copper cable.

[0007] Therefore, there is a need for alternative solutions.

[0008] EP 4 147 903 A1 relates to a charging cable for an electric vehicle, wherein the charging cable comprises a cooling hose extending longitudinally and designed to transport a cooling medium through the charging cable, an earthing conductor extending longitudinally substantially parallel to the cooling hose and serving as ground, several current wires extending longitudinally and designed to conduct positive and / or negative direct current, and an outer layer extending longitudinally and surrounding the cooling hose, the earthing conductor, and the several current wires. Each of the several current wires comprises a conductor and insulation surrounding the conductor. Several spacers are arranged between the conductor and the insulation such that a cooling channel is formed between the conductor and the insulation.

[0009] CN 1 10 289 513 A shows a cable for use with a charging plug (also called a charging gun) for an electric vehicle. A coolant, such as an insulating oil, flows through the cable for cooling. From the inside out, the cable comprises numerous twisted copper wires, a braided conductor layer, an inner sheath, and a jacket. Numerous through-slots are axially uniformly arranged on the inner wall of the cable jacket and on the inner wall of the inner sheath. The coolant flows through a gap between the inner sheath, the through-slots, and the braided conductor layer.

[0010] US 2024 / 0075832A1 concerns an air cooling system for an electric vehicle charging cable, which is cooled with compressed air. Part of this charging system is a charging cable. The charging cable comprises a multi-core conductor, an insulator surrounding the conductor, and a sheath surrounding the insulator. The charging cable also has air channels arranged parallel to the conductor to direct the compressed air longitudinally along the cable.

[0011] US 2022 / 0242260A1 pertains to a fast-charging cable for an electric vehicle. The fast-charging cable comprises an insulated conductor, a first sheath (such as tape), a thermal layer, and a jacket. The thermal layer is arranged around the first sheath and consists of a solid material with extremely low density and extremely low thermal conductivity. Air channels are also incorporated into the cable to allow airflow to carry heat away from the insulated conductor.

[0012] US Patent 2024 / 0092205A1 discloses a fast-charging cable for charging electric vehicles. The cable has an insulated conductor, one or more gaps in the conductor's insulation, an air channel within an air hose, and a sheath that surrounds the insulated conductor and the air hose. The air hose is located in a space between the insulated conductor and the sheath. Furthermore, the air channel and the one or more gaps provide an airflow that dissipates heat from the insulated conductor.

[0013] There is a need for improved approaches to electrical wiring and electrical cables with such conductors. In particular, there is a need for an electrical wire that reliably prevents contact between an electrical conductor and a cooling line, as well as for an electrical cable with at least one such conductor.

[0014] According to a first aspect of the invention, an electrical cable, particularly for a charging cable, for example for electric vehicles, is provided. The electrical cable has at least one electrical conductor. The electrical cable has a cooling line that surrounds the at least one electrical conductor. The cooling line can, in particular, have a cooling hose or be designed as a cooling hose. A cooling medium can be guided in an interior space of the cooling line. The cooling line has at least one inner contour. The at least one inner contour projects into the interior space. The at least one inner contour is formed on an inner surface (inner wall) of the cooling line.

[0015] In a first state of the electrical line, the at least one inner contour is spaced apart from the at least one electrical conductor. In other words, the at least one electrical line is not in contact with (i.e., does not touch) the at least one inner contour in the first state. Simultaneously, the cooling line is spaced apart from the at least one electrical conductor. The first state of the electrical line may include or involve a state in which the electrical line is, in particular, at least substantially undistorted.

[0016] In at least one second state of the electrical conductor, the at least one electrical conductor comes into contact with the at least one inner contour. In this second state, the at least one electrical conductor comes into contact with the at least one inner contour in such a way that the inner contour prevents contact between the at least one electrical conductor and the cooling conductor. In other words, the contact of the at least one inner contour with the at least one electrical conductor prevents contact between the at least one electrical conductor and the cooling conductor. Specifically, the contact of the at least one inner contour with the at least one electrical conductor prevents contact between the at least one electrical conductor and the inner surface (inner wall) of the cooling conductor.The inner surface (inner wall) of the cooling pipe can be considered, in cross-section, as a shape that at least almost continuously follows the shape of the cooling pipe, for example, a shape that is at least nearly circular around the center of the cooling pipe. The inner surface (inner wall or inner area) of the cooling pipe can, in particular, be considered the section of the cooling pipe that directly borders the interior of the cooling pipe.

[0017] Even if the at least one inner contour is integrally formed with the inside of the cooling line, for example, this at least one inner contour can be understood as a different element than the cooling line itself, and in particular, the inside of the cooling line. Therefore, contact of the at least one electrical conductor with the cooling line can be understood as contact with areas / sections of the cooling line other than / excluding the at least one inner contour. Similarly, contact of the at least one electrical conductor with the cooling line can be understood as contact with areas / sections of the cooling line other than the at least one inner contour.Accordingly, contact of the at least one electrical conductor with the inside of the cooling pipe can be understood as contact with areas / sections of the inside of the cooling pipe other than / excluding the at least one inner contour. In other words, contact of the at least one electrical conductor with the inside of the cooling pipe can be understood as contact with areas / sections of the inside of the cooling pipe other than the at least one inner contour.

[0018] The at least one inner contour can have a lower thermal conductivity than the at least one electrical conductor. In particular, the at least one inner contour can be almost non-conductive. This can, for example, result in less efficient heat conduction through the at least one inner contour. Consequently, the heat is more likely to be transferred to an existing cooling medium than to a conductor core.

[0019] The at least one second condition of the electrical conductor can arise from various causes / circumstances. For example, the at least one second condition may involve a situation in which the electrical conductor is at least partially bent.

[0020] There can be several second states in which the electrical conductor is bent to varying degrees and / or at different points. In each of these second states, the at least one electrical conductor comes into contact with the at least one inner contour in such a way that the at least one inner contour prevents contact between the at least one electrical conductor and the cooling conductor. In addition to the at least one second state, there can be further states in which the electrical conductor is at least partially bent, but the at least one electrical conductor does not come into contact with the at least one inner contour.In these further states, the at least one inner contour does not need to prevent contact between the at least one electrical conductor and the cooling line, because in these further states there would be no contact between the at least one electrical conductor and the cooling line without the at least one inner contour.

[0021] The at least one electrical conductor is arranged within the interior of the cooling line. The at least one electrical conductor can be exactly one conductor, meaning it can be configured as a single conductor within the cooling line, such as a cooling hose. The at least one electrical conductor can be a stranded conductor. A stranded conductor, also called a strand, can consist of multiple individual wires. The strand can have multiple (uninsulated) conductors or wires, or consist of multiple (uninsulated) conductors or wires. The at least one electrical conductor can also be a solid conductor.Regardless of the precise configuration of the at least one electrical conductor, it may be a non-insulated conductor or be designed as a non-insulated conductor. "Non-insulated" (or alternatively "uninsulated") in relation to the at least one non-insulated conductor means that it is not electrically insulated.

[0022] A cooling line can generally be a body extending longitudinally along an electrical conductor and / or an electrical cable carrying the conductor. The body may have a cavity in which a cooling medium (which can also be called a coolant) can circulate. The cooling line is not limited to a specific cross-section. For example, it can have a round, square, or oval cross-section. It can take the form of a hollow cylinder, but is not limited to this shape. The cooling line extends, for example, along the entire length of the electrical conductor and / or an electrical cable carrying the conductor. The cooling line can be flexible, i.e., not rigid. For example, it can be elastically bendable or deformable.The cooling line of the electrical line may have a cooling hose or be designed as a cooling hose.

[0023] The at least one electrical conductor can be cooled by the cooling medium and is indeed cooled when a cooling medium is present. The cooling medium can be, for example, liquid or gaseous. For instance, if the at least one electrical conductor is designed as a non-insulated conductor, it can be cooled directly via a thermally conductive connection using the cooling medium that can be or is carried in the cooling line. The at least one electrical conductor can be in direct contact with the cooling medium of the at least one electrical line. This is also referred to herein as "direct cooling." In this case, the cooling medium can be electrically insulating (i.e., non-conductive).Due to the direct contact between the cooling medium and the at least one electrical conductor, the at least one electrical conductor can be cooled particularly efficiently.

[0024] The cooling line of the at least one electrical conductor can be designed to be at least nearly impermeable or sealed against the cooling medium. For this purpose, the cooling line can be completely closed in the longitudinal and / or circumferential direction. Alternatively, the cooling line can have a sheathing, creating an internal cavity for the cooling medium. This sheathing can be designed to be at least nearly impermeable or sealed against the cooling medium. In this way, the cooling medium can circulate within the cavity, but is almost entirely prevented from penetrating the sheathing.

[0025] The at least one electrical conductor can, in the first state of the electrical line, be arranged at least partially, at least nearly centrally, within the cooling line. For example, the at least one electrical conductor can, in the first state of the electrical line, be arranged along its entire length at least nearly centrally within the cooling line. Due to the at least nearly central arrangement of the at least one electrical conductor within the cooling line, contact between the at least one electrical conductor and the cooling line does not occur in the first state of the electrical line.

[0026] The at least one electrical conductor can, in at least one second state of the electrical conductor, be arranged at least partially acentrically within the cooling line. Due to this partially acentric arrangement, the at least one electrical conductor could potentially come into contact with the cooling line in this second state. However, this contact is reliably prevented by the at least one inner contour.

[0027] The at least one inner contour can have various shapes. For example, the at least one inner contour can have a knobby, angular, or round cross-section. Regardless of the exact shape, the at least one inner contour is formed integrally with the cooling pipe.

[0028] According to the invention, the electrical conductor has at least one filling element. The at least one filling element is arranged or provided in the at least one inner contour. For example, one filling element of the at least one filling element can be arranged or provided in each of the at least one inner contour. The at least one filling element can increase the tensile strength of the at least one inner contour. The material of the filling element can be selected such that it has higher thermal stability and / or higher tensile strength compared to the material of the cooling hose.

[0029] According to a first conceivable embodiment, the at least one inner contour can be spiraled or helically shaped on the inside (inner surface) of the cooling line relative to the at least one electrical conductor in the longitudinal direction of the at least one electrical conductor. The lay length of the spiraling can be between 30 mm and 200 mm. A spiraled design of the at least one inner contour can be particularly advantageous when only a single inner contour or exactly two inner contours are provided.

[0030] According to a second conceivable embodiment, the at least one inner contour can run parallel to the at least one electrical conductor in the longitudinal direction of the at least one electrical conductor on the inner surface of the cooling line. A parallel configuration can be advantageous, for example, if three or more inner contours are provided. Regardless of the exact configuration, the at least one inner contour can have at least three inner contours or be designed as at least three inner contours. If two or more inner contours are provided, adjacent inner contours of the two or more inner contours can each have an equal distance from each other in the circumferential direction of the electrical conductor or the cooling line.

[0031] A diameter of the at least one electrical conductor can be chosen based on: (i) a diameter of the inside / inner surface / inner wall of the cooling conduit, (ii) a minimum distance of contact points of the at least one electrical conductor on the at least one inner contour to the inside / inner surface of the cooling conduit, (iii) a distance between two contact points of an inner contour and (iv) a number of the at least one inner contour.

[0032] In particular, the diameter of the at least one electrical conductor can be chosen such that it meets the following condition: dL>(dti2−h)dti+hudti2−h+u with u=h[1−cos(πn−bsdti−2h)] d L Diameter of the electrical conductor d ti Diameter of the inside of the cooling pipe n Number of at least one inner contour h minimum distance of contact points to the inside of the cooling pipe bs Distance between two points of contact of an inner contour.

[0033] This condition ensures that the at least one electrical conductor does not touch the inside / inner wall of the cooling line. It also ensures that the at least one electrical conductor is movable within the cooling line and is not trapped between two inner contours. When designed according to the above condition (formula), the inner contours can run straight along the length of the hose, in particular parallel to each other, or they can be spiraled.

[0034] According to a second aspect of the invention, an electrical cable, in particular a charging cable for electric vehicles, is provided. The electrical cable has at least one electrical conductor according to the first aspect. The electrical cable has at least one outer sheath that completely surrounds the at least one electrical conductor.

[0035] The at least one electrical conductor can include an electrical charging line or be designed as such. The at least one electrical conductor can include a power line or transmission line for electricity, or be designed as such. A power line or transmission line for electricity heats up considerably due to the current flow, which is particularly high. Specifically, the at least one electrical conductor can include one or more copper conductors or be designed as such. Designing it as a copper conductor increases the current-carrying properties of the electrical conductor.

[0036] The at least one electrical conductor can be configured as a plurality of electrical conductors, in particular as exactly two or exactly four electrical conductors. Each plurality of electrical conductors can have at least one electrical conductor. Each plurality of electrical conductors can have a cooling line in which a cooling medium can be carried. The respective at least one electrical conductor can be in thermally conductive contact with the associated cooling line in such a way that the respective at least one electrical conductor can be cooled by the cooling medium of the associated cooling line.

[0037] If two electrical conductors are provided, a first conductor can be located inside one cooling duct, and a second conductor can be located inside another cooling duct. At least one of the electrical conductors can form a DC conductor. The DC conductor serves to transmit direct current in the charging cable. For example, the DC conductor can be one of the two DC conductors required for transmitting direct current in a charging cable. The first conductor can be a positive DC conductor, and the second conductor can be a negative DC conductor. This enables efficient DC charging of electric vehicles using the charging cable.

[0038] For example, the charging cable can transmit currents of one hundred amperes (A), or several hundred amperes, for example up to approximately 3 kA, without any significant heating of the charging cable – provided the cooling system is functioning correctly. This means that a high power output can be transferred from the charging station to the vehicle (and thus to the battery).

[0039] The electrical cable can also include a control line, a sensor line, a signal line, a protective line, a data line, and / or an auxiliary power line. Other line types are also conceivable. Two or more of the different lines / line types can be flexibly combined within the charging cable.

[0040] The cooling line of the at least one electrical conductor can be configured as a supply line or a return line for the cooling medium. Thus, the cooling line of one of the at least one electrical conductor can be configured as a supply line, and the cooling line of another of the at least one electrical conductor can be configured as a return line, or vice versa. This allows the cooling medium to circulate completely within the charging cable. The supply line can also be referred to as the outflow line. The return line can also be referred to as the return line. For example, the supply line can be a supply line to a connector cooling system, and the return line can be a return line for cooling fluid from the connector cooling system. The supply line can be understood as a channel or hose leading away from a location with high fluid pressure. The return line can be understood as a channel or hose leading to a location with low fluid pressure.The cooling fluid can be transported to the surface via the flow line and back via the return line.

[0041] Alternatively, the cooling line of at least one electrical line can be configured as the supply line, and an additional cooling line located in the charging cable can be configured as a return line, or vice versa. Similarly, the cooling medium, e.g., a cooling fluid, can be transported through the respective cooling lines, for example, by pumping, and exit at the end.

[0042] The at least one electrical conductor may also have insulation. The insulation may surround the cooling conductor of the at least one electrical conductor and the at least one electrical conductor. The insulation may, for example, be in direct contact with the cooling conductor of the at least one electrical conductor, such as the outside surface of the cooling conductor.

[0043] The charging cable has an outer sheath. This sheath protects the cable and can therefore also be called a protective jacket. It holds the internal wires together and protects them from abrasion and environmental influences. The outer sheath can also provide thermal insulation. This insulation is particularly advantageous when the cooling medium is a coolant fluid. For example, it prevents the coolant fluid from freezing. The section between the outer sheath and the at least one electrical wire can serve as a supply or return line for the coolant.

[0044] In a typical application, the charging cable can be designed as a DC charging cable. The DC charging cable can, for example, have two or four DC charging conductors. The charging cable can also have one or more conductors or wires for AC charging (AC conductors). Using the one or more AC conductors, the charging cable can also be used for AC charging of an electric vehicle. For example, the charging cable can be a combination cable that enables both DC and AC charging. Examples of possible configurations include three conductors (conductor, neutral, ground), five conductors (three conductors, neutral, ground), or seven conductors (three conductors, neutral, ground, plus two conductors for communication between a power source, e.g., a charging station, and a power sink).a battery of an electric vehicle or an electric vehicle).

[0045] According to a third aspect, a charging system can be provided. The charging system can include an electrical cable designed as a charging cable, as described in the first aspect, an end connection, and a plug. The end connection can have a coolant supply that can introduce the coolant into at least one of the lines, more precisely into a cooling line of at least one of the lines, and draw it from another of the lines, more precisely from a cooling line of another of the lines. The plug is designed to be connected to the vehicle. In addition to the electrical contacts for electrically connecting the existing electrical conductors to the vehicle's lines, the plug can have a fluid return line that can draw the coolant from the cooling line of one line and direct it to the cooling line of the other line.

[0046] Furthermore, according to a fourth aspect, a charging station can be provided with the electrical cable designed as a charging cable according to the second aspect or with a charging system according to the third aspect.

[0047] Even though some of the aspects described above have been described in relation to the electrical line according to the first aspect and / or the electrical cable according to the second aspect, these aspects can also be implemented in a corresponding way in the charging system according to the third aspect and / or in the charging station according to the fourth aspect, and vice versa.

[0048] The present invention will be further explained with reference to figures. These figures schematically illustrate: Fig. 1a a cross-section of an embodiment of an electrical conductor in a first state; Fig. 1b a cross-section of an embodiment of an electrical conductor in a second state; Fig. 2 a cross-section of a variant of the embodiment of an electrical conductor made of Fig. 1 and Fig. 1b; Fig. 3 a cross-section of a variant of the embodiment of an electrical conductor made of Fig. 1a and Fig. 1b; Fig. 4a a cross-section of a first embodiment of an electrical cable; Fig. 4b a cross-section of a second embodiment of an electrical cable; and Fig. 4c a cross-section of a third embodiment of an electrical cable.

[0049] Specific details are set forth below, without limitation, to provide a complete understanding of the present invention. However, it is clear to a person skilled in the art that the present invention can be used in other embodiments that may differ from the details set forth below. Furthermore, the figures serve only to illustrate embodiments. They are not to scale and are intended only to exemplify the general concept of the invention. For example, features included in the figures should by no means be considered necessary components. Furthermore, an electrical conductor is described below primarily as a charging conductor, but is not limited to this. Similarly, an electrical cable is described below primarily as a charging cable, particularly for electric vehicles, but is not limited to this.

[0050] In Fig. Figure 1a shows a first embodiment of an electrical line 10. The electrical line 10 can, in particular, be configured as a charging line for a charging cable for electric vehicles, as will be described in more detail below. The electrical line 10 has an electrical conductor 16. The electrical line 10 also has a cooling line 12 that surrounds the electrical conductor 16. The cooling line 12 can, in particular, be configured as a cooling hose and can therefore also be referred to as cooling hose 12. A cooling medium 14 can be guided in an interior space of the cooling line 12. The cooling line 12 has at least one internal contour 18 formed on an inner surface of the cooling line 12. In the example from Fig. 1a and Fig. 1b shows four exemplary internal contours 18, which are provided as at least one internal contour 18 and formed on the inside of the cooling line 12. The four exemplary internal contours 18 each project into the interior space. As in Fig. As can be seen in Figure 1a, the inner contours 18 are formed integrally with the cooling line 12 or, in other words, integrally molded onto the cooling line 12. The in Fig. The exemplary knob shape of the inner contours 18 shown in Figure 1a is purely illustrative, and other shapes are conceivable and possible, for example, an angular shape, such as a rectangular or triangular shape. Adjacent inner contours 18 of the four inner contours 18 are spaced at least nearly equally far apart along the circumference of the cooling line 12. In the example shown, the spacing is 90 degrees.

[0051] In Fig. Figure 1a shows a first state of the electrical conductor 10. In this first state, the electrical conductor 10 can be in a state that is at least substantially undistorted. In this first state, the inner contours 18 of the electrical conductor 10 are spaced apart from the electrical conductor 16. In this first state, the electrical conductor 16 is arranged at least partially, and at least nearly centrally, within the cooling line 12. For example, in this first state, the electrical conductor 16 is not in contact with the cooling line 12 along its entire length.

[0052] In Fig. Figure 1b shows a second state of the electrical conductor 10. In this second state, the electrical conductor 10 can be at least partially bent. In this second state, the electrical conductor 16 is arranged at least partially acentrically in the cooling line 12. Fig. Figure 1b shows a cross-section of such a section in which the electrical conductor 16 is arranged acentrically in the cooling line 12. In the second state, the electrical conductor 16 comes with a subset (in Fig. 1b with two) of the four inner contours 18. The electrical conductor 16 is prevented or blocked from contacting the cooling line 12 by the contact with the two inner contours 18. In other words, in the second state, the electrical conductor 16 comes into contact with a subset (in Fig. 1b with two) of the four inner contours 18 in such a way that the two inner contours 18 prevent contact between the at least one electrical conductor 16 and the cooling line 12.

[0053] The inner contours 18 can be spiraled or formed on the inside of the cooling line 12 relative to the electrical conductor 16 in the longitudinal direction of the electrical conductor 16. A length of 30 mm to 200 mm is suitable for the spiraling. With a suitable design, particularly with a suitable spiral, a single inner contour 16 can reliably block / prevent contact between the electrical conductor 16 and the cooling line 12.

[0054] An alternative to spiralization is in Fig. 1a (as can be seen from the perspective drawing) is realized. Here, the inner contours 18 run parallel to the electrical conductor 16 and the cooling line 12 in the longitudinal direction of the electrical conductor 16 on the inside of the cooling line 12. With a parallel arrangement of the inner contours 18 relative to the electrical conductor 16, two or more, in particular at least three, inner contours 18 reliably block contact between the electrical conductor 16 and the cooling line 12 if they are suitably designed.

[0055] In Fig. 2 is a variant of the embodiment from Fig. 1a and Fig. Figure 1b shows that, according to this variant, the electrical conductor 10 has, for example, a filler element 19 in each of the inner contours 18. Thus, four filler elements 19 are provided for example. Alternatively, it is conceivable to provide a filler element 19 in only a subset of the four inner contours 18. The at least one filler element 19 can provide a tensile strength of the at least one inner contour 18 (in the example of Fig. 2: of the four inner contours 18). For example, when the cooling line 12 is designed as a cooling hose 12, it is often produced with (very) low-viscosity materials (e.g., made of / with thermoplastic elastomers (TPEE) or polyamides). These materials are sometimes so thin that, after leaving, for example, a die head, they sink downwards due to gravity, touch the electrical conductor 16 (e.g., made of copper), and adhere to it. Since the cooling hoses 12 are to have a defined flow channel for the cooling medium 14, at least one inner contour (in the example of Fig. 2. A filler element 19 (e.g., polyethylene (PE) fibers or aramid fibers) is inserted into all four inner contours 18). This allows a filler element 19 to be inserted into at least one inner contour (in the example of...). Fig. 2. A support structure is formed in all four inner contours 18, which supports the material, e.g., the plastic, after it leaves, for example, an extrusion head, sufficiently so that it can be cooled in a calibration unit of a water bath and remains dimensionally stable upon solidification. Furthermore, the filling element / filler 19 ensures that the at least one electrical conductor 16 (e.g., made of copper) and the cooling hose 12 do not touch each other. This prevents the at least one electrical conductor 16 (e.g., made of copper) from adhering to the cooling hose 12 and / or the inner contour 18. Thus, the cooling hose 12 can be calibrated to its nominal dimension and remains molten and calibratable in every area.When using other materials for the at least one inner contour 18 and the cooling line 12 (for example, the cooling hose), the filling element(s) (the filler(s)) can be omitted, as shown by example in . Fig. 1a and Fig. 1b was shown.

[0056] As in Fig. As can be seen in section 2, the filler elements 19 are arranged in a specific way. Each of the filler elements 19 can, as shown in Fig. As shown in Figure 2, the filling element(s) 19 are arranged and configured such that a diameter of the inner wall of the cooling hose 12, or an imaginary circle (since the cooling hose 12 may not be a perfect circle), intersects the filling element(s) 19 on the inner wall of the cooling hose 12. Additionally or alternatively, each of the filling elements 19 can have a larger diameter than other areas / sections of the cooling hose 12 other than the at least one inner contour 18, i.e., sections of the cooling hose 12 that differ from the inner contour 18. Each of the filling elements 19 can have a smaller diameter compared to the at least one inner contour 18.

[0057] In Fig. 3 is a variant of the embodiment from Fig. 1a, Fig. 1b and Fig. 2 shown. In the variant from Fig. In example 3, no filling elements 19 are provided. Alternatively, however, one or more filling elements 19 can be arranged in the electrical conductor 10, more precisely in one or more of the inner contours 18. In the example from Fig. Figure 3 shows five exemplary internal contours 18, which are formed on the inside of the cooling line 12. Adjacent internal contours 18 of the five internal contours 18 have the same angular distance from each other in the circumferential direction of the cooling line 12, namely an angle of 72 degrees in the example shown. Fig. Figure 3 shows a second state of the electrical line 10 with an electrical conductor 16 that is at least partially acentric. As in Fig. As can be seen in Figure 3, the electrical conductor 16 touches two adjacent inner contours 18, each at a contact point P. Through contact at these contact points P, the inner contours 18 prevent the electrical conductor 16 from coming into contact with the inside of the cooling line 12. Furthermore, additional contact points P, specifically exactly two contact points P for each inner contour 18, are visible, where the eccentric electrical conductor 16 could potentially come into contact with the inner contours 18.

[0058] The dimensions of the electrical conductor 16, the cooling line 12, and the inner contours 18 are coordinated such that the electrical conductor 16 cannot come into contact with the inside of the cooling line 12, but only with the inner contours 18 molded onto the cooling line 12. In the example from Fig. 3. The diameter of the electrical conductor 16 is selected taking into account specific parameters. These parameters include a diameter of the inner surface of the cooling line 12, a minimum distance of the contact points P of the electrical conductor 16 on the inner contours 18 to the inner surface of the cooling line 12, a distance between two contact points P of an inner contour 18, and a number of inner contours 18.

[0059] In the following example, we assume that the electrical conductor 16 is made of Fig. 3 is designed as a stranded conductor. Accordingly, the electrical conductor 16 is, with respect to Fig. 3 is designated as stranded conductor 16. Furthermore, by way of example, with regard to Fig. 3. Assume that the cooling line 12 is designed as a cooling hose. Accordingly, the cooling line 12 is considered to be in relation to the Fig. 3 is designated as cooling hose 12.

[0060] Taking these assumptions into account, with regard to Fig. 3. A diameter of the stranded conductor 16 was chosen which meets the following condition: dL>(dti2−h)dti+hudti2−h+u with u=h[1−cos(πn−bsdti−2h)] d L Strand diameter d ti Hose inner diameter (diameter of the inside / inner surface / inner wall of the cooling hose 12) n Number of inner contours (profile elements) 18 of any shape, which are arranged in the same division on the inner circumference / on the inside of the cooling hose 12, maintaining the same shape. h minimum distance of the contact points P to the geometric circle of the hose's inner diameter d ti b s Distance between the two contact points P on an inner contour 18 (on a profile element) as arc length, where the arc center corresponds to the hose center (=the center point of the cooling hose 12)

[0061] The diameter of the stranded conductor 16 must be chosen to be at least large enough that, in a geometrically ideal scenario, the stranded conductor 16 has no point of contact with the inner wall of the hose (= inside of the cooling hose 12). More precisely, the diameter of the stranded conductor 16 must be chosen to be at least large enough that, in a geometrically ideal scenario, the stranded conductor 16 has no other point of contact with the inner wall of the hose (= inside of the cooling hose 12) except for the points of contact P on the inner contours 18. The geometrically ideal scenario can be one in which the stranded conductor 16 simultaneously touches two inner contours / contour elements 18 of the inner wall of the hose (= inner hose wall) according to the formula / condition shown above.In other words, the diameter of the strand must be chosen to be at least large enough that, in a geometrically ideal scenario, it has a maximum of only two simultaneous points of contact P on the inner contours 18, according to the formula / condition mentioned above. Fig. 3. Two contact points P are given, i.e., points where the conductor 16 touches the hose 12 at the inner contours 18. If the diameter of the conductor 16 becomes smaller, another unwanted contact point would occur on the thinner or offset inner wall of the hose between the two existing contact points P.

[0062] The Fig. Figures 4a to 4c show various exemplary embodiments of an electrical cable 100. The electrical cable is shown as an example with regard to the Fig. 4a to 4c are assumed to be charging cables 100, especially for electric vehicles, and are accordingly designated as charging cables 100. In each of the sections in the Fig. In the examples shown in 4a to 4c, the charging cable 100 has at least one electrical conductor 10, as exemplified in relation to the Fig. 1a to 3 as described. Furthermore, each of the charging cables 100 has an outer sheath 50 that completely surrounds at least one electrical conductor.

[0063] In Fig. 4a shows that the charging cable 100 has, by way of example, two electrical conductors 10. Both electrical conductors 10 are designed, by way of example, like the electrical conductor 10 from Fig. 3. The charging cable 100 also includes, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control line, a sensor line, a signal line, a data line and / or an auxiliary voltage line may be provided in the charging cable 100. An outer sheath 50 surrounds the electrical conductors 10 and the protective conductor 20.

[0064] In Fig. Figure 4b shows that the charging cable 100 has two electrical conductors 10 as an example. Both electrical conductors 10 are designed as an example, like the electrical conductor 10 from Fig. 3. The charging cable 100 also includes, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control line, a sensor line, a signal line, a data line, and / or an auxiliary voltage line may be provided in the charging cable 100. The electrical charging cable also includes a separate cooling hose 30. Consequently, the separate cooling hose 30 can be used as the supply line for the cooling medium 14, and the two electrical lines 10 can be used as the return line for the cooling medium 14, or vice versa. An outer sheath 50 surrounds the electrical lines 10, the protective conductor 20, and the cooling hose 30.

[0065] In Fig. Figure 4c shows that the charging cable 100 has, by way of example, four electrical conductors 10. The four electrical conductors 10 are designed, by way of example, like the electrical conductor 10 from Fig. 3. The charging cable 100 also includes, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control line, a sensor line, a signal line, a data line and / or an auxiliary voltage line may be provided in the charging cable 100. An outer sheath 50 surrounds the electrical conductors 10 and the protective conductor 20.

[0066] Specific implementation options for the electric charging cable 100 from the Fig. Sections 4a to 4c will now be described together.

[0067] Each of the two / four electrical lines 10 has a cooling hose 12, as an example of a cooling line 12, and an electrical conductor 16. In each of the two / four electrical lines 10, the cooling hose 12 and the electrical conductor 16 run coaxially with the longitudinal axis of the respective electrical line 10 as their common axis. The two / four electrical conductors 16 can each be a solid conductor or a flexible stranded wire. The two electrical conductors 16 can each be designed as uninsulated electrical conductors. The electrical conductors 16 can each form a DC conductor. In other words, each of the electrical conductors 16 can be one of the (at least two) DC conductors of the charging cable 100 required for the transmission of direct current.For example, one or two of the four electrical conductors 16 can form a positive DC conductor, and another of the two or two of the four electrical conductors 16 can form a negative DC conductor. Thus, efficient DC charging of electric vehicles using the charging cable 100 is possible. The DC conductor(s) serve to transmit direct current in the charging cable 100.

[0068] The two / four electrical conductors 16 are each surrounded by their respective cooling hose 12. Each of the two / four cooling hoses 12 can contain and, for example, circulate a cooling medium 14. The cooling medium 14 is guided within each of the two / four cooling hoses 12. Each of the two / four cooling hoses 12 therefore surrounds its respective cooling medium 14. Accordingly, the two / four electrical conductors 16 can each be surrounded by a cooling medium 14. In this case, the cooling medium is an electrically insulating (i.e., non-conductive) cooling medium 14. The cooling hose 12 can be surrounded by insulation (insulating sheath) (not shown). For example, the insulating sheath of the respective cooling hose 12, in an undamaged state, is at least nearly impermeable to the cooling medium 14.This means that, under normal, undamaged conditions, the cooling medium 14 cannot normally leak from the cooling hose 12 into the interior of the charging cable 100. Regarding... Fig. For examples 4a to 4c, it can be assumed that the electrical conductors are 16 copper conductors. Therefore, the following discussion will focus on the Fig. 4a to 4c are sometimes also referred to as copper conductors 16.

[0069] According to a specific embodiment, at least one of the electrical lines 10 can be configured as a supply line and at least one of the electrical lines 10 as a return line for the cooling medium 14. This is to be understood as purely exemplary, and other embodiments are possible. For example, a section 40 between an outer sheath 50 surrounding the elements of the electrical charging cable 100 and the electrical lines 10 can be configured as a supply line for the cooling medium 14 or as a return line for the cooling medium 14.

[0070] The charging cable contains 100 Fig. 4a and Fig. 4c furthermore, a protective conductor 20 is arranged in the charging cable 100. The protective conductor 20 is shown uncooled as an example.

[0071] However, the protective conductor 20 can also be cooled directly or indirectly. In addition to the electrical conductors 16 serving as power lines in the charging cable 100 and the protective conductor 20, control lines, sensor lines, other signal lines, data lines, and / or auxiliary voltage lines may be present and also cooled. This means that it is intended not only to actively cool the electrical conductors 16 serving as power lines by means of fluid cooling, but also to connect other, passive types of lines (such as control, sensor, signal, auxiliary voltage, data, and / or protective lines) in the charging cable 100 to active fluid cooling.

[0072] The charging cable 100, according to each of the three embodiments, can incorporate sensors, for example, one or more temperature sensors. This increases the safety of the charging cable 100 through targeted monitoring, such as temperature monitoring. The temperature sensors can be configured as sensor wires. The one or more temperature sensors can be cooled accordingly. A temperature sensor is designed, for example, to detect the temperature of the charging cable. The temperature sensor can be configured, for example, as a sensor wire or sensor line integrated into the charging cable, such as one woven or braided into the charging cable.

[0073] Furthermore, the charging cable 100 can optionally include AC conductors. However, the AC conductors can also be omitted. If no AC conductor is provided, the charging cable is designed as a DC charging cable. If, on the other hand, both DC conductors and AC conductors are provided, the charging cable 100 is designed as a combination charging cable for optional DC and AC charging. The charging cable 100 can have one or more conductors or wires for AC charging (abbreviated AC conductor). Using the one or more AC conductors, the charging cable 100 can be used to charge an electric vehicle using AC charging.By way of example, possible configurations include three conductors / wires (conductor, neutral conductor, ground), five conductors / wires (three conductors, neutral conductor, ground) or seven conductors / wires (three conductors, neutral conductor, ground and two conductors for communication between an energy source, e.g. a charging station, and an energy sink, e.g. a battery of an electric vehicle or an electric vehicle).

[0074] The in Fig. The charging cable 100, schematically depicted in figures 4a to 4c, can be used as a charging cable for electric vehicles. For this application, the charging cable 100 is designed to enable a transmission power of, for example, up to 50 kW, up to 70 kW, up to 250 kW, up to 500 kW, or up to 3 MW.

Claims

[1] Electrical line (10), in particular for a charging cable (100), wherein the electrical line (10) comprises: - at least one electrical conductor (16); and - a cooling line (12) surrounding the at least one electrical conductor (16), in particular a cooling hose, wherein a cooling medium (14) can be guided in an interior of the cooling line (12) and the cooling line (12) has at least one inner contour (18) projecting into the interior and formed on an inner surface of the cooling line (12); - at least one filling element (19) arranged or provided in the at least one inner contour (18); wherein, in a first state of the electrical conductor (10), which is at least substantially undistorted and is spaced at least one inner contour (18) apart from the at least one electrical conductor (16), and wherein, in at least one, in particular at least partially bent, second state of the electrical conductor (10), the at least one electrical conductor (16) comes into contact with the at least one inner contour (18) in such a way that the at least one inner contour (18) prevents contact between the at least one electrical conductor (16) and the cooling conductor (12). [2] Electrical line (10) according to claim 1, wherein the at least one electrical conductor (16), in the first state of the electrical line (10), is arranged at least sectionally at least nearly centrally in the cooling line (12). [3] Electrical line (10) according to claim 1 or 2, wherein the at least one electrical conductor (16) is arranged at least sectionally acentrically in the cooling line (12) in the at least one second state of the electrical line (10). [4] Electrical conductor (10) according to one of claims 1 to 3, wherein the at least one inner contour (18) is spirally or spirally arranged on the inside of the cooling conductor (12) relative to the at least one electrical conductor (16) in the longitudinal direction of the at least one electrical conductor (16). [5] Electrical conductor (10) according to claim 4, wherein a lay length of the spiraling assumes a value between 30 mm and 200 mm. [6] Electrical conductor (10) according to one of claims 1 to 3, wherein the at least one inner contour (18) runs parallel to the at least one electrical conductor (16) in the longitudinal direction of the at least one electrical conductor (16) on the inside of the cooling conductor (12). [7] Electrical conductor (10) according to one of claims 1 to 6, wherein the at least one inner contour (18) has at least three inner contours (18) or is designed as at least three inner contours (18). [8] Electrical conductor (10) according to claim 7, wherein a diameter of the at least one electrical conductor (16) is selected based on: a diameter of the inside of the cooling conductor (12), a minimum distance of contact points (P) of the at least one electrical conductor (16) on the at least one inner contour (18) to the inside of the cooling conductor (12), a distance between two contact points (P) on the at least one inner contour (18) and a number of the at least one inner contour (18). [9] Electrical conductor (10) according to claim 7 or 8, wherein a diameter of the at least one electrical conductor (16) satisfies the following condition: dL>(dti2−h)dti+hudti2−h+u with u=h[1−cos(πn−bsdti−2h)] d L Diameter of the electrical conductor (16) d ti Diameter of the inside of the cooling pipe (12) n Number of at least one internal contours (18) h minimum distance of contact points (P) to the inside of the cooling pipe (12) b s Distance between two points of contact (P) of an inner contour (18). [10] Electrical cable (100), in particular charging cable, for example for electric vehicles, wherein the electrical cable (100) comprises: - at least one electrical conductor (10) according to one of claims 1 to 9; and - an outer sheath (50) surrounding at least one electrical conductor (10). [11] Electrical cable (100) according to claim 10, wherein the at least one electrical line (10) has an electrical charging line or is designed as an electrical charging line. [12] Electrical cable (100) according to claim 10 or 11, wherein the electrical cable (100) further comprises: a control line, a sensor line, a signal line, a protective line (20), a data line and / or an auxiliary voltage line. [13] Electrical cable (100) according to one of claims 10 to 12, wherein the cooling line (12) of the at least one electrical line (10) is designed as a supply line for the cooling medium (14) or as a return line for the cooling medium (14). [14] Electrical cable (100) according to one of claims 10 to 13, wherein a region (40) between the outer sheath (50) and the at least one electrical conductor (10) is designed as a supply line for the cooling medium (14) or as a return line for the cooling medium (14).

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