Charging cable for a charging station with a wear indicator

Abstract

Charging cable (1) for a charging station, comprising: an inner region (2) which has at least one current-carrying line (3, 4); a sheath surrounding the inner region (2), the sheath comprising at least a first insulation layer (6) having a first color, and a second insulation layer (7) arranged between the first insulation layer (6) and the inner region (2), which second insulation layer has a second color different from the first color; and a charging plug which is located at one end of the charging cable.

Description

[0001] The present invention relates to a charging cable for a charging station with a wear indicator in the form of a multi-layer sheath, each of the layers having a different color.

[0002] AC and DC charging cables for electric and hybrid vehicles, as well as charging cables at charging stations used to charge these vehicles, are subject to mechanical stress such as abrasion or notching depending on the frequency and type of use in everyday life. These processes particularly affect the outer insulation layer of the charging cable. It is often difficult for customers, workshops, and service personnel to determine how badly the insulation has been damaged and whether the charging cable actually needs to be replaced to ensure safe and reliable charging. In cases of doubt, there is a greater tendency to replace the charging cable too early for safety reasons, which results in unnecessary costs. Charging cables at charging stations typically cost 500-1000 euros per linear meter, with several meters of charging cable usually being used per charging station to connect it to the corresponding charging plug.In the other case, if a worn charging cable is used for too long and maintenance is postponed, an insulation fault can lead to problems with the charging process or even the entire charging station failing. This leads to customer dissatisfaction on the one hand and loss of income for the charging station operator on the other.

[0003] The charging cables used today at charging stations have a single-colored insulation, which is usually black. This color choice of insulation makes damage to the charging cable difficult to detect. In the case of extensive abrasion of the outer sheath of the charging cable, the remaining thickness of the insulation is also difficult to estimate.

[0004] The object of the present invention is to provide a charging cable for an electric vehicle in which excessive wear of the insulating sheath can be easily repaired without the use of tools.

[0005] The problem is solved by means of a charging cable for a charging station and by means of a charging station for charging electric vehicles according to the independent patent claims. Advantageous embodiments arise from the dependent patent claims.

[0006] The charging cable according to the invention for a charging station has an inner region which has at least one current-carrying line. Furthermore, the charging cable has a sheath which surrounds the inner region, wherein the sheath has at least a first insulation layer which has a first color, and a second insulation layer having a second color arranged between the first insulation layer and the inner region. In this case, the first color is different from the second color. In addition, the charging cable has a charging plug which is arranged at one end of the charging cable. The charging cable according to the invention is coupled to the charging station with its other end and thus provides the electrical connection between the charging station and the charging plug.

[0007] The charging cable according to the invention has a multi-layer sheath that encloses the interior of the charging cable and fulfills the usual function of an insulating layer. However, the multi-layer sheath also functions as a wear indicator, in that it is designed as an indicator that indicates in good time that the charging cable needs to be replaced before the charging infrastructure fails. In other words, the sheath according to the invention is designed in multiple layers, whereby the degree of wear on the charging cable can be determined depending on whether a layer is visible beneath the outermost insulation layer. The multi-layer sheath thus provides a simple system that allows defects in the insulation of the charging cable to be detected with the naked eye and, in particular, without the use of tools.This allows customers to easily inspect the charging cable themselves and report when it needs to be replaced. This can prevent charging station failures due to damaged or frayed charging cables not being detected in time. Furthermore, unnecessary maintenance costs due to premature replacement of the charging cable can be avoided.

[0008] The insulation layer of the charging cable is not a single color, but rather has at least two concentrically arranged insulation layers along the length of the cable. The colors of these insulation layers vary, so that, for example, with the appropriate color selection of the layers within the sheath, a "traffic light effect" can be used to determine whether the charging cable still has a sufficiently thick insulation layer to conduct charging processes safely and reliably, or whether it should be replaced. With a two-layer sheath design, for example, the first insulation layer can be the usual black color, and the second insulation layer underneath can be red.The first insulation layer, which represents the outermost insulation layer of the charging cable according to the invention, can be thicker than the underlying second insulation layer, but the thicknesses of the two layers can also be the same. The thickness of the innermost insulation layer can be selected such that, even if the first insulation layer is completely removed, charging can still take place safely and the charging station does not fail.

[0009] In further embodiments of the charging cable, the inner region can have at least one communication line. In general, the interior of the charging cable can have a conventional configuration (i.e., the structure and arrangement of the lines within) and, for example, can have two current-carrying lines, one or more communication lines, and one or more coolant lines.

[0010] In further embodiments of the charging cable, the inner region can be surrounded by a metallic winding. The metallic winding can be arranged between the inner region and the innermost insulation layer of the sheath and can be used to provide EMC shielding.

[0011] In further embodiments of the charging cable, the sheathing can further comprise a third insulation layer having a third color, which is arranged between the second insulation layer and the inner region of the charging cable. The third color can be different from both the first color and the second color. For example, the first color can be black, the second color yellow, and the third color red, although any other color combination is also suitable. Each insulation layer can, for example, comprise or consist of a polymer mixture having the corresponding color. The colors of the insulation layers can expediently be selected such that they are easily distinguishable from one another. For example, the colors of adjacent insulation layers can correspond to pairs of contrasting colors or complementary colors.

[0012] According to further embodiments, a charging station for charging an electric vehicle is provided, wherein the charging station has the charging cable described herein and the charging cable electrically connects the charging plug of the charging station to the charging station.

[0013] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified but also in other combinations or on their own, without departing from the scope of the present invention.

[0014] Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawings. Fig. 1A shows an embodiment of the charging cable according to the invention with a two-layer sheath. Fig. 1B shows an embodiment of the charging cable according to the invention with a three-layer sheath.

[0015] In Fig. 1A shows an embodiment of the charging cable 1 according to the invention, which has a two-layer sheath. The charging cable 1 has an inner region 2 in which a first current-carrying line 3 and a second current-carrying line 4 are arranged. The inner region 2 also contains additional lines 5, which represent one or more communication lines, one or more coolant lines, and other suitable lines. The sheath, which surrounds the inner region 2, has a first insulation layer 6 and a second insulation layer 7 arranged underneath. The first insulation layer 6 corresponds to the outermost insulation layer of the charging cable 1.The first insulation layer 6 and the second insulation layer 7 are arranged concentrically around the inner region 2, with the second insulation layer 7 abutting the inner region 2 over its entire surface, and the first insulation layer 6 correspondingly abutting the second insulation layer 7 over its entire surface. The first insulation layer 6 can be black, for example, and the second insulation layer 7 can be red.

[0016] In Fig. 1B shows an embodiment of the charging cable 1 according to the invention, which has a Fig. 1A, with the difference that a three-layer sheath is provided here. The third insulation layer 8 is arranged between the second insulation layer 7 and the inner region 2 of the charging cable.

Claims

[1] Charging cable (1) for a charging station, comprising: an inner region (2) which has at least one current-carrying line (3, 4); a sheath surrounding the inner region (2), the sheath comprising at least a first insulation layer (6) having a first color, and a second insulation layer (7) arranged between the first insulation layer (6) and the inner region (2), which second insulation layer has a second color different from the first color; and a charging plug which is located at one end of the charging cable. [2] Charging cable according to claim 1, wherein the inner portion (2) further comprises at least one communication line (5). [3] Charging cable according to claim 1 or 2, wherein the inner region (2) is surrounded by a metallic winding. [4] Charging cable according to one of claims 1 to 3, wherein the sheath further comprises a third insulation layer (8) having a third color arranged between the second insulation layer (7) and the inner region (2), the third color being different from both the first color and the second color. [5] Charging station for charging an electric vehicle with a charging cable according to one of claims 1 to 4.

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