Electrical cable with two ground wires

Abstract

Electrical cable (10) with a core of two ground wires (12) designed as PE conductors and two functional wires (14), and with ten further functional wires (15) arranged around the core, wherein a cable sheath (20) made of a cold-flexible material is provided.

Description

[0001] Electrical cables for mobile applications must withstand changing operating conditions: They are frequently installed, subsequently dismantled, re-installed, and transported repeatedly. Typical examples include events, media technology, or similar applications that require high mechanical strength, flexibility, and safety.

[0002] Conventional cables typically have only a single ground wire (also called the PE conductor). While this is sufficient for many standard applications, it leads to limitations when used over longer distances. Furthermore, the cable construction can be compromised by mechanical stress (e.g., repeated winding and unwinding). The single ground wire must be electrically reliable while also offering the flexibility required in practical use. However, especially in mobile event environments, such a single-PE concept often reaches its limits when longer distances need to be bridged safely.

[0003] The object of the invention is to create a more powerful electrical cable for mobile applications.

[0004] To achieve this object, the invention provides an electrical cable which, in general terms, has ground wires, so that the overall structure results in a significant improvement in power transmission and safe grounding.

[0005] Specifically, the invention provides an electrical cable with a core consisting of four cores, two of which are ground cores, and ten outer cores arranged around the core, with a cable sheath made of a cold-flexible material. The structure of the 14-core cable is stabilized by the two PE protective conductors, each located centrally.

[0006] One variant provides for the core to have a core filler. This further increases stability, which is particularly advantageous for frequent rolling and unrolling in mobile event environments.

[0007] According to a further embodiment, it is provided that the wires have a cross-section of 2.5 mm 2 This ensures a high current-carrying capacity and, in combination with the two PE protective conductors, enables safe and efficient power transmission, as required for indoor and outdoor applications according to DIN 15765.

[0008] The cores can be made of fine-stranded copper. This provides excellent conductivity and flexibility, ensuring the cable's usability, especially in extreme temperature fluctuations (e.g., down to -30°C).

[0009] The cores are preferably made of Cu-EPT1. This ensures a very high degree of copper purity, which further improves conductivity and counteracts corrosion in the long term.

[0010] In one embodiment, the insulation of the wires is made of PVC with a Shore hardness of A 85. This design ensures robust and abrasion-resistant insulation that can withstand frequent mechanical stress during mobile events.

[0011] The cable sheath is preferably made of PVC with a Shore hardness of A 72. This ensures high flexibility combined with sufficient mechanical stability, which supports reliable use even under adverse climatic conditions.

[0012] In one design, the core wires are Z-stranded. This stranding provides better mechanical protection against bending and tensile stresses, and prevents the wires from shifting against each other when bent, making the cable construction more robust.

[0013] Preferably, the outer cores are twisted back so that the electrical cable has a low tendency to twist, thus making it easier to handle in mobile structures.

[0014] According to a preferred embodiment, a 19-pin circular connector is connected to each of the two ends, with one of the ground wires being connected to a central ground contact and the other ground wire to one of six concentrically arranged functional contacts, with the six concentrically arranged functional contacts being electrically connected to one another by a ground ring. In this way, both PE protective conductors are bridged centrally, resulting in an effective conductor cross-section of 5.0 mm2. 2 for the protective conductor. This enables stable 6-channel transmission even over longer distances than with a PE protective conductor with a cross-section of 2.5 mm 2 .

[0015] According to a further preferred embodiment, a flat plug is connected to each end, each flat plug having a ground connection and a PE connection, with one ground wire connected to the ground connection and the other ground wire connected to the PE connection. This provides a simple alternative for assembly with flat plugs, where both PE protective conductors can also be connected, thus again providing an effective PE conductor cross-section of 5.0 mm 2 and thus a high level of operational reliability is ensured.

[0016] The invention is described below with reference to various embodiments illustrated in the accompanying drawings, in which: Fig. 1 shows a section through a cable according to the invention, Fig. 2 shows a schematic side view of a cable according to the invention with two 19-pin circular connectors at the ends, Fig. 3 the connection diagram of the cable from Fig. 2 to the circular connectors, Fig. 4 shows a schematic side view of a cable according to the invention with two 6-channel flat plugs at the ends, and Fig. 5 the connection diagram of the cable from Fig. 4 to the flat plugs.

[0017] In Fig. 1 shows an electrical cable 10 in a cross-section, in which a core of four wires is arranged in the center, of which two wires 12 are designed as ground wires (also referred to as PE conductors) and two further wires 14 as functional wires.

[0018] Within the four wires 12, 14 in the core, an additional core filler 16 is arranged.

[0019] Ten additional functional wires are arranged around the core. Their configuration corresponds to the functional wires 14 of the core, but for the sake of clarity, they are designated by the reference numeral 15. Overall, this results in a 14-wire cable with two ground wires 12 and twelve functional wires 14, 15.

[0020] The core wires 12 and 14 and the ten outer wires 15 are made of fine-stranded copper, preferably Cu-EPT1, to achieve high conductivity and flexibility. The wires have a cross-section of 2.5 mm 2 which ensures a high current carrying capacity.

[0021] The insulation of wires 12, 14, and 15 is made of a PVC material with a Shore hardness of A 85, so that the insulation can withstand the mechanical stresses encountered in mobile applications while retaining the necessary flexibility.

[0022] The cable 10 is provided with a cable sheath 20 around the ten outer conductors 15. This sheath is made of a cold-flexible material to ensure sufficient flexibility even at low temperatures and to prevent mechanical damage caused by winding and unwinding.

[0023] The cable sheath 20 is made of PVC with a Shore hardness of A 72, which results in an advantageous combination of flexibility and robustness, especially at operating temperatures down to -30°C.

[0024] A non-woven polyester fleece is arranged between the cable sheath 20 and the outer wires 14.

[0025] The core wires 12, 14 are Z-stranded, while the outer wires 15 are back-stranded to protect the cable against bending and tensile stresses and to reduce twisting during use.

[0026] The electrical cable 10 is particularly suitable for assembly with Socapex-compatible 19-pin circular connectors. This is demonstrated below using the Fig. 2 and Fig. 3 explained.

[0027] In Fig. 2, the electrical cable is shown assembled with two 19-pin circular connectors 30, 32, wherein the reference numeral 30 designates the plug and the reference numeral 32 the socket.

[0028] In Fig. 3 shows how the wires 12, 14, 15 are connected to the circular connectors 30, 32.

[0029] One of the ground wires 12 is electrically connected to a central ground contact 34, and the other ground wire 12 is electrically connected to one of the functional contacts 36 of the inner ring of functional contacts of the circular connector.

[0030] A ground ring 38 is provided which electrically connects all functional contacts of the inner ring to each other and thus to the ground contact 12.

[0031] This results in a total of seven contacts that are connected to the ground wires 12, and there is an effective conductor cross-section of 5.0 mm 2 This guarantees stable 6-channel transmission over long distances. With a PE conductor cross-section of only 2.5 mm 2 transmission over a much shorter distance would be possible.

[0032] As an alternative to the circular connectors 30, 32, the electrical cable can also be assembled with 6-channel flat connectors. This is explained below using the Fig. 5 and Fig. 6 explained.

[0033] Flat plug connectors 40, 42 are arranged at the ends of the cable, with reference number 40 designating the plug and reference number 42 designating the socket.

[0034] One of the ground wires 12 is connected to a ground terminal 44 of the respective connector and the other ground wire 12 to a PE terminal 46. In total, this also results in a PE cable cross-section of 5 mm 2 available.

Claims

[1] Electric cable (10) with a core of two ground wires (12) designed as PE conductors and two functional wires (14), and with ten further functional wires (15) arranged around the core, wherein a cable sheath (20) made of a cold-flexible material is provided. [2] Electrical cable according to claim 1, characterized by that the core has a core filler (16). [3] Electrical cable according to claim 1 or claim 2, characterized by that the wires (12, 14, 15) have a cross-section of 2.5 mm 2 have. [4] Electrical cable according to one of the preceding claims, characterized by that the wires (12, 14, 15) are made of fine-wire copper. [5] Electrical cable according to one of the preceding claims, characterized by that the wires (12, 14, 15) are made of Cu-EPT1. [6] Electrical cable according to one of the preceding claims, characterized by that the insulation of the wires (12, 14, 15) is made of PVC with Shore hardness A 85. [7] Electrical cable according to one of the preceding claims, characterized by that the cable sheath (20) is made of PVC with a Shore hardness of A 72. [8] Electrical cable according to one of the preceding claims, characterized by that the core wires (12, 14) are Z-stranded. [9] Electrical cable according to one of the preceding claims, characterized by that the outer wires (15) are twisted back. [10] Electrical cable according to one of the preceding claims, characterized by that a 19-pin circular connector (30, 32) is connected to each of the two ends, one of the ground wires (12) being connected to a central ground contact (34) and the other ground wire (12) being connected to one of six concentrically arranged functional contacts (36), the six concentrically arranged functional contacts (36) being electrically connected to one another by a ground ring (38). [11] Electrical cable according to one of claims 1 to 9, characterized bythat a flat plug (40, 42) is connected to each of the two ends, each flat plug (40, 42) having a ground connection (44) and a PE connection (46), and one ground wire (12) is connected to the ground connection (44) and the other ground wire (12) is connected to the PE connection (46).

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