Electric vehicle charging cable

Abstract

The invention relates to an electric vehicle charging cable (1, 1', 1'') comprising a charging-cable portion (6, 6', 6'') having a conductor-wire group (4) of mutually insulated conductor wires (2) for transmitting current. The electric vehicle charging cable (1, 1', 1'') also comprises at least a first plug (10, 11) at a first end piece (13) of the charging-cable portion (6, 6', 6''), and optionally a second plug (10, 11) at a second end piece of the charging-cable portion (6, 6', 6''). The electric vehicle charging cable (1, 1', 1'') comprises a covering sheath (5) which encloses the conductor-wire group (4), the covering sheath (5) comprising a braided fiber structure having carbon fibers, and the covering sheath (5) being connected to a grounding connection element (27E). The invention also relates to a corresponding method for producing an electric vehicle charging cable (1, 1', 1''), and to a use of the electric vehicle charging cable (1, 1', 1'') for electrically charging an electric vehicle.

Description

[0001] Electric vehicle charging cable

[0002] The invention relates to an electric vehicle charging cable, a method for producing an electric vehicle charging cable, and a use of an electric vehicle charging cable for electrically charging an electric vehicle.

[0003] An electric vehicle is a vehicle that is powered electrically, among other things, by an electric motor. In the context of this invention, an electric vehicle is understood to be a car, motorcycle, or bicycle that includes a corresponding electric motor, such as a hybrid or battery-powered electric vehicle. The electric motor draws its power from a battery housed in the electric vehicle. This battery must be recharged after being discharged. An electric vehicle charging cable, which is often stored in the vehicle itself, is used to charge the battery. If the electric vehicle is to be charged, a plug attached to one section of the charging cable is inserted into the car's charging device, and a second plug attached to the charging cable is connected to a power source. As an alternative to the second plug, the cable can also be permanently connected to the power source.The power source can be, for example, a household socket, wall box, or a charging column at a public charging station.

[0004] Many public charging stations in Germany have an alternating current (AC) connection, a direct current (DC) connection, or a combination of alternating current (AC) and direct current (DC). Most electric vehicles can only accept a low AC charging power. In addition, many vehicles now offer fast charging with direct current (DC) and high charging power.

[0005] Depending on the charging current, charging station, and vehicle, a corresponding plug or charging cable section is required. A relatively common plug is the Type 1 plug. This is used primarily in Asia and North America. The plug is designed for single-phase alternating current from 6 to 32 A and therefore allows charging power of up to 7.4 kW. The Type 1 plug has two current-carrying contacts (phase L and neutral conductor N), a protective conductor (PE), and two smaller signal contacts: the CP pin (Control Pilot) and PP pin (Proximity Pilot). Communication between the charging point and the vehicle takes place via the CP pin, and the PP pin allows the vehicle to detect the cable cross-section used and, accordingly, the permissible charging current. Furthermore, it detects whether the connection plug has been pulled to abort the charging process, so that the connection plug can be disconnected without any voltage or power being applied.

[0006] The most commonly used plug in Europe is the Type 2 plug. This consists of four live contacts (three phases (L1, L2, L3) and a neutral conductor (N)), a protective earth (PE), and two smaller signal contacts CP (Control Pilot) and PP (Proximity Pilot). However, single- or two-phase charging can also be carried out using the Type 2 plug. In this case, the third contact pin (L3) and possibly the second contact pin (L2) are not used. For direct current charging, the Type 2 plug has a positive pole and a negative pole.

[0007] Two other plug types are the Chinese GB / T standard, which includes charging plugs and sockets for alternating current and direct current, and the Tesla NACS (North American Charging Standard) plug or Supercharger plug from Tesla.

[0008] There are also different types of charging cables themselves. The Mode 2 charging cable and the Mode 3 charging cable are the most common. The Mode 2 charging cable is available in various versions. The Mode 2 charging cable is often supplied by the vehicle manufacturer for connection to a standard household socket. Communication between the electric vehicle and the socket is handled by a box (ICCB, in-cable control box) that is installed between the vehicle plug and the connector.

[0009] The Mode 3 charging cable connects an electric vehicle to a charging station, such as a wallbox. As described above, the Type 2 plug has become the standard in Europe. Charging stations are often equipped with a Type 2 socket. To enable both electric vehicles with a Type 1 plug and electric vehicles with a Type 2 plug to charge at a charging station, either a Mode 3 charging cable from a Type 2 plug to a Type 2 plug or a (adapter) Mode 3 charging cable from a Type 2 plug to a Type 1 plug is required.

[0010] Another charging cable is the Mode 4 charging cable, which is particularly suitable for charging at rapid charging stations with direct current. As explained at the beginning, an electric vehicle can usually be charged with either alternating current or direct current. When charging with alternating current, the flow of alternating current generates electromagnetic radiation emitted by live wires. This electromagnetic radiation can lead to unwanted interactions with nearby devices or living beings. Furthermore, live wires can sometimes become electrostatically charged, which can lead to unwanted electrostatic discharges via a user of the cable, as the outer sheath of the cable is not grounded. However, the lack of grounding is not noticeable to a layperson. Electric vehicles often also lack appropriate protection to protect people from electrostatic discharge.Under certain circumstances, it may happen that the current is discharged via people.

[0011] It is an object of the present invention to further develop an electric vehicle charging cable and a use of such an electric vehicle charging cable and a method for producing an electric vehicle charging cable in such a way that their electromagnetic compatibility, weight or handling and functional reliability are improved.

[0012] This object is achieved by an electric vehicle charging cable according to claim 1 and, on the other hand, by a method for producing an electric vehicle charging cable according to claim 16 and by a use of the electric vehicle charging cable according to claim 19.

[0013] According to the invention, the electric vehicle charging cable, hereinafter referred to as "charging cable," comprises a charging cable section with a group of mutually insulated conductor tracks for transmitting a current. At least some of the conductor tracks serve to transmit the charging current and to charge the electric vehicle. These conductor tracks are designed such that a current suitable for charging an energy storage device of an electric vehicle can be transmitted. Other conductor tracks can serve as protective conductors or as control or data lines and / or measuring lines, such as the control / data line CP (Control Pilot) and the charging cable detection contact PP (Proximity Pilot / Plug Present) in a Type 2 connector. In principle, a charging cable according to the invention can have any other conductor tracks for any purpose in addition to the conductor tracks for charging the electric vehicle. The design of the conductor tracks will be explained in more detail later.Preferably, they are designed so that the charging cable section is at least somewhat flexible, as will also be explained later. As explained at the beginning, an electric vehicle is understood here to mean a car, motorcycle, or even a bicycle. It should be noted that the invention is not limited to a specific group of conductor tracks. The design of the conductor track group can be based, in particular, on national or regional standards and / or norms.

[0014] In addition, the charging cable has at least a first plug at a first end of the cable section and optionally a second plug at a second or the other end of the charging cable section. Charging cables often have a plug at both ends, with one of the plugs, also referred to below as the "connector plug," serving to connect a power source to the conductors of the charging cable section, and the other plug, referred to below as the "vehicle plug," serving to connect an electric vehicle to the conductors of the charging cable section.

[0015] In the connector, the conductors are electrically connected to corresponding connection contacts, usually in the form of contact pins. This means that this is usually a so-called male connector.

[0016] Depending on the design of the plug and the corresponding conductor paths, the charging cable can be plugged into a corresponding socket of a power source (e.g. household socket, wall box, charging station) using the connection plug and the electric vehicle can be charged - provided the charging cable is connected to the electric vehicle at the other end.

[0017] In a vehicle connector, the conductors are also electrically connected to corresponding connection contacts, but usually in the form of contact sockets (corresponding to the pins in the vehicle's connector). This means that this is usually a so-called female connector, or more accurately a socket, that can be coupled to a corresponding vehicle-side connector (which is usually accessible through a lockable flap in the vehicle body or similar).

[0018] If the charging cable has only one plug, e.g., only one vehicle plug, it is usually the case that it has only one vehicle plug and is then permanently connected to a wallbox or similar device at the other end. However, it is also conceivable for the charging cable to have only one connector and then be permanently connected to the vehicle at the other end, e.g., rolled up and stored in a suitable storage space. All such charging cables can be designed according to the invention, although a variant with two plugs is generally preferred due to its versatility.

[0019] The charging cable connector and the charging cable's vehicle connector are designed according to the standards for the design of electric vehicle cable routing and will be explained in more detail later. For example, the TYPE 1 connector can be designed according to IEC 62196-1 / -2 / -3, ISO 15118, DIN SPEC 70121, or IEC 61851. The TYPE 2 connector can be designed according to IEC 62196-1 / -2 / -3, SAE J1772, ISO 15118, SAE J2931, DIN SPEC 70121, or IEC 61851. The CHAdeMO, for example, can be designed according to IEC 62196-1 / -2 / -3, SAE J1772, or IEC 61851-1 / -23 / -24. For the Tesla variants, the respective technical specifications provided by Tesla apply. Please note that the invention is not limited to specific connectors or connector types. The design of the respective connector may, in particular, be based on national or regional standards and / or norms.

[0020] According to the invention, the charging cable has a cover jacket that encloses the conductor track group. The cover jacket comprises a fiber braid with carbon fibers. It is possible for the cover jacket to consist only (entirely) of carbon fibers. Carbon fibers are also referred to as carbon fibers. The carbon fibers can, in particular, be anisotropic fibers. Preferably, the cover jacket comprises braided carbon fibers and / or consists of braided carbon fibers. This will be described later. The cover jacket with carbon fibers can be formed in a single layer. In principle, the cover jacket with carbon fibers can also be formed in multiple layers.

[0021] A major advantage of a conductive carbon fiber sheath is that it can shield electromagnetic radiation.

[0022] In addition, a cover sheath with a fiber braid with carbon fibers can be comparatively lighter than conventionally used materials such as steel, which can then have a positive effect on the overall weight of the charging cable.

[0023] Since most charging cables are often transported within the vehicle, this can, in turn, also affect the overall weight of the electric vehicle. Reducing the vehicle's weight leads to a reduction in the vehicle's energy consumption. If, for example, fossil fuels are used to generate electricity, this can also lead to reduced CO2 emissions. The lower weight also influences acceleration and the resulting achievable speeds, which is of great interest for sports cars or in racing, for example. The lower weight also makes the charging cable much more comfortable to handle, for example, when removing it from the trunk and packing it away.

[0024] A further advantage of the cover jacket is that it better protects the charging cable from mechanical influences such as tensile stress, friction (when the charging cable is pulled across the ground), or tearing of the conductors. This also prevents environmental influences such as moisture penetration and the associated oxidation. Furthermore, the cover jacket can also serve as additional kink protection for the charging cable. This high degree of robustness of the cover jacket also has a positive effect on the service life of the charging cable. This can also lead to the reduction or elimination of conventional protective layers in charging cables, resulting in a lighter charging cable and thus a positive effect on vehicle consumption.

[0025] Optionally, the fiber braid of the cover jacket can also contain aramid and / or glass fibers and / or metallic fibers and / or fibers from a renewable raw material (abbreviated to NawaRo) or from different renewable raw materials. For example, the cover jacket can contain carbon fibers, aramid fibers, glass fibers, metallic fibers and / or a mixture of carbon fibers, aramid fibers and / or glass fibers and / or NawaRo. The shielding effect can be further enhanced by a proportion of metallic fibers. The aramid fibers or glass fibers can be used to individually mark the charging cable. For example, a black and yellow marbled cover jacket can be created by mixing carbon and aramids. These targeted color markings on the cover jacket can thus serve, for example, as a quick and easy way to identify the manufacturer. The use of NawaRo reflects the increasing environmental awareness of many people.In its general sense, "renewable resources" refers to agricultural and forestry products that are used, for example, as materials, outside the food and feed sector. Natural fibers such as hemp, kenaf, and / or flax (as "renewable resources") are preferred. This allows the charging cable to be provided in a particularly sustainable manner. If the sheath contains aramid and / or glass fibers, this may also provide increased wear protection.

[0026] Since, as mentioned, carbon fibers are electrically conductive, electrical charges can still be present on the cover sheath. In order to divert any such currents, the cover sheath is connected according to the invention to an earthing connection element. This earthing connection element can be, for example, a protective conductor or an earthing pin of the connection plug. The protective conductor is preferably connected to the cover sheath via an electrical line and particularly preferably via a flat contact point, such as an electrically conductive clamp that is in contact with the cover sheath. The cover sheath is preferably connected to the earthing connection element via an electrically conductive strain relief. In the case of a cable that is permanently connected to a wall box or the like, this can also be an earthing connection for a protective conductor or similar.With a connection plug for a household socket, the protective conductor contacts can also be used, which come into contact with the earth contact springs in the socket housing when the plug is inserted into the socket.

[0027] By connecting the cover jacket to a grounding connection element, a permanent grounding of the cover jacket is achieved, preventing any currents from being discharged via a user of the charging cable during or after the charging process. Furthermore, the grounding enables shielding of electromagnetic radiation.

[0028] A corresponding method for producing (manufacturing method) of the electric vehicle charging cable according to the invention comprises at least the following steps:

[0029] First, a conventional charging cable section is provided. This charging cable section has a group of conductors with a defined number of conductors.

[0030] In addition, at least a first connector and optionally a second connector are provided.

[0031] A further step of the method according to the invention is the coating of a covering sheath over the conductor track group, wherein the covering sheath comprises a fiber mesh with carbon fibers (and optionally aramid fibers and / or glass fibers and / or metallic fibers and / or fibers from a renewable raw material or from different renewable raw materials).

[0032] The first plug is then connected to a first end of the charging cable section and optionally the second plug is connected to a second end of the charging cable section.

[0033] As described above, the two connectors can be a connection plug and a vehicle plug, provided (as is preferred) that plugs are required at both ends of the charging cable. If only one plug is required, it depends on whether the other end of the charging cable is permanently installed on the vehicle (in which case, a connection plug for the power source is required at the other end) or on a wallbox or similar device (in which case, a vehicle plug is required at the other end).

[0034] To electrically connect the connector plug or the vehicle connector to the charging cable section, a corresponding wire of a cable track is connected to a connection contact or a corresponding plug contact (pin or contact socket) of the connector plug or the vehicle connector, as explained above.

[0035] To dissipate any charges on the cover jacket and achieve electromagnetic shielding, the cover jacket is connected, according to the invention, to a grounding connection element, e.g., by means of a clamp and an electrical conductor, e.g., a protective conductor (or a grounding pin of a plug, preferably the connector plug) or the like. The clamp can rest directly (externally) on the cover jacket. The clamp can extend along the entire (outer) circumference of the cover jacket.

[0036] It should be noted at this point that the timing and sequence in which the charging cable is manufactured can vary and be individually adapted to the respective manufacturing process. For example, the first connector could be connected to the charging cable section first, after which the cover jacket could be pulled over the conductor group, and only then would the second connector be connected to the cable section.

[0037] Since the charging cable section of the charging cable according to the invention is covered by a sheath, in particular along its entire longitudinal extent, the charging cable is, on the one hand, very robust. On the other hand, however, the charging cable can also be very lightweight due to the carbon fiber braiding in the sheath. Conventionally, steel or copper layers are often used as a type of sheath. However, these are much heavier than a sheath made of carbon. The lower weight of such a sheath, which consists entirely or predominantly of carbon fibers (hereinafter also referred to as a carbon sheath), has a positive effect on the vehicle's energy consumption during transport.

[0038] Another major advantage of the charging cable is that the charging cable or its cover is grounded, so that no charges on the charging cable can be discharged via the user of the cable.

[0039] Using a charging cable according to the invention, electric vehicles can be charged safely, quickly and conveniently.

[0040] Further, particularly advantageous embodiments and developments of the invention emerge from the dependent claims and the following description, wherein the claims of one claim category can also be developed analogously to the claims and description parts to form another claim category and, in particular, individual features of different embodiments or variants can be combined to form new embodiments or variants.

[0041] To further protect the conductors, the conductor group can preferably have a, usually insulating, conductor sheath. The conductor sheath encloses all the conductors of the conductor group. This means that all conductors of the charging cable are enclosed by the conductor sheath. Material from the conductor sheath can also extend between the conductors of the conductor group, thus insulating them from one another.

[0042] Various materials can be used in the manufacture of the cable sheath. Preferably, however, the cable sheath comprises a thermoplastic and / or elastomer, particularly preferably a thermoplastic elastomer, e.g., polyvinyl chloride (PVC) and / or thermoplastic polyurethane. Furthermore, the cable sheath can also comprise polychloroprene, polytetrafluoroethylene, or silicone-based plastics.

[0043] The cover jacket can then, in turn, enclose the cable jacket. In a preferred variant of the invention, the cover jacket is additionally enclosed by a protective jacket. The protective jacket provides insulation for the charging cable. The protective jacket can form the outermost layer of the charging cable, particularly along the charging cable section with the conductor track group. This can further reduce the risk of unintentional current discharge via the user of the charging cable during or after a charging process. In addition, the protective jacket provides additional protection for the charging cable against mechanical and environmental influences (pulling along the ground, significant temperature fluctuations between summer and winter, and high UV radiation). This design variant can therefore also be useful as an alternative to grounding the cover jacket and can therefore be a standalone invention, regardless of whether the cover jacket is connected to a grounding connection element with carbon fibers.

[0044] Accordingly, the method according to the invention for producing the electric vehicle charging cable according to the invention can comprise a step in which the cover sheath is coated with a protective sheath.

[0045] Depending on the charging current, charging station, and vehicle type, the charging cable according to the invention can have different designs. For example, the charging cable can be designed as an AC charging cable, a DC charging cable, or even a high DC charging cable.

[0046] Thus, the arrangement of the conductor tracks of the conductor track group in the charging cable section of the charging cable can preferably be standardized and preferably designed to form a Mode 2 charging cable or Mode 3 charging cable or Mode 4 charging cable.

[0047] All plug types, in particular those mentioned above (such as Type 1 and Type 2 plugs, CHAdeMO plugs, CCS plugs, GB / T plugs, Tesla NACS (North American Charging Standard) plugs or Tesla Supercharger plugs or even connection plugs for household sockets) or other plug types yet to come, and all charging cable types, in particular those mentioned above such as Mode 2, Modes' or Mode 4 charging cables, can be designed or further developed in the manner according to the invention. The vehicle plug is preferably designed as a ChadeMo plug or GB / T plug. The connection plug is also preferably designed as a ChadeMo plug or GB / T plug.

[0048] The CHAdeMO plug is suitable for fast charging of electric vehicles with direct current.

[0049] However, the connection plug and / or the vehicle plug are particularly preferably designed as a CCS plug or as a Type 1 plug or as a Type 2 plug or as a Tesla NACS (North American Charging Standard) plug.

[0050] A CSS (Combined Charging System) connector is designed like a Type 2 connector, but has two additional power contacts that also serve to quickly charge the electric vehicle with direct current. The CCS connector can therefore charge both alternating current and direct current with up to 350 kW of power.

[0051] In principle, the invention is not restricted to specific plugs, e.g. those mentioned. The design of the respective plug can in particular be based on national or regional standards and / or norms. It is also possible to combine different plug types in the same charging cable. For example, different plug types can be combined in the form of adapter cables. For example, a charging cable can preferably have a Tesla NACS (North American Charging Standard) plug or Supercharger plug from Tesla as the first plug and a Type 2 plug as the second plug. A further preferred combination option is that the first plug is a CHAdeMO plug and the second plug is a Type 2 plug. The terms first plug and second plug are freely chosen here. Of course, the charging cable could, for example,also have a Type 2 plug as the first plug and a Tesla NACS (North American Charging Standard) plug or Tesla Supercharger plug as the second plug.

[0052] Preferably, at least one of the plugs, e.g., the connection plug and / or the vehicle plug, also has, at least in part, a plug cover or (plug) housing comprising a fiber composite material with carbon fibers, e.g., a fiber composite material containing a fiber braid and / or a fiber fabric or similar material with carbon fibers. Thus, the entire charging cable is electromagnetically shielded from neighboring devices and living beings. Optionally, the plug cover can also comprise aramid fibers and / or glass fibers and / or metallic fibers and / or fibers made from renewable raw materials.

[0053] Preferably, a (respective) plug can be arranged at least partially, in particular completely, in a carbon shell which forms a (plug) housing. The carbon shell contains carbon fibers and can optionally comprise other materials. The carbon shell preferably contains 1K, 3K and / or 6K fibers, although other fibers, such as glass and aramid fibers as well as fibers from renewable raw materials (NaWaRos) are also possible. Particularly preferably, the carbon shell comprises a carbon fiber composite material in which carbon fibers are cross-linked with resin. The carbon shell can advantageously be produced by means of resin transfer molding (RTM) or in the prepreg process. Advantageously, such a plug, e.g. with a carbon shell, can improve electromagnetic compatibility. Another advantageous feature is that the weight can be reduced compared to known (plug) housings.A further advantage is that a plug with a carbon shell provides particularly effective wear protection and a particularly high resistance to breakage, e.g. when driven over by a car, especially in comparison to known (plug) housings, e.g. made of plastic.

[0054] If one of the plugs has such a plug cover or a (plug) housing as described above, in particular a carbon shell, this plug sheath itself could also be grounded or form a suitable contact for grounding. However, it is also possible that such a (plug) housing, in particular a carbon shell, is not grounded.

[0055] When a plug according to the invention is inserted into a corresponding power source or socket, a grounding pin of the plug first comes into contact with the socket before the current-carrying contacts of the plug come into contact with the power source.

[0056] For example, if a suitable connection plug is inserted into a household socket, the earth contact springs of the household socket are pressed into the socket housing and the connection plug slides into the socket, whereby the earth contact springs and the outer earthing sheath inevitably come into contact. When the connection plug is inserted, the plug cover of the connection plug first comes into contact with the earth contact springs, and only then do the live poles. When the connection plug is pulled out of the socket, the live poles also leave the contact with the socket and only then does the plug cover lose contact with the earth contact springs. Other plug types (in particular the above-mentioned plug types and the corresponding sockets) could be designed in a similar way.

[0057] Preferably, at least one of the plugs, i.e. the connection plug and / or the vehicle plug, has a housing comprising a plug head and a receptacle. The plug head, on a plug-in side, usually comprises the connection contacts, such as contact pins and / or contact sockets. By means of the plug head, the plug can be coupled into the connection on the vehicle or the charging station or the like. On a cable side of the plug facing away from the plug-in side, the receptacle, which is preferably somewhat flexible at least in regions, can be connected to this plug head. The receptacle can at least partially accommodate the end piece of the charging cable section assigned to this plug and thus enclose the cover sheath of the charging cable section and / or optionally the protective sheath. In the receptacle, the conductor tracks of the charging cable section can then be individually fed to the individual connection contacts (or plug poles).

[0058] To ensure easy storage in the vehicle and to keep its weight as low as possible, the charging cable should preferably be no more than 10 m long. On the other hand, to ensure easy access to a power source from the vehicle, the charging cable should preferably be at least 1 m long.

[0059] Preferably, the charging cable is designed so that the cover sheath slides over the conductor track group or its optional cable sheath, and / or the protective sheath slides over the cover sheath. As the layers slide over each other, the charging cable remains pliable and flexible. A further advantage is that the cover sheath can be recycled particularly efficiently, for example, by pulling the cover sheath out of a tubular protective sheath in one piece.

[0060] The cover jacket can preferably be braided at least in sections or provided by braiding. The manufacturing method can preferably provide for the cover jacket, in particular a carbon jacket or carbon tube, to be braided externally around the conductor track group or the conductor jacket. In other words, the cover jacket can be braided (externally) on and / or over the conductor track group or the conductor jacket. Preferably, several fiber spools can be guided around a braided core, e.g. 50% clockwise and 50% counterclockwise. The fiber spools can run in a meandering manner, so that a braid is created as the cover jacket. It is particularly possible for the carbon fibers to be braided directly onto a core (also referred to as overbraiding). The core can be provided by the conductor track group or the conductor jacket.The cover obtained by braiding can preferably be a carbon fiber braided sleeve. Accordingly, the cover can contain and / or be formed from a braided carbon (fiber) fabric. The carbon fiber braided sleeve can consist entirely of carbon fibers. Particularly preferably, the carbon braided sleeve can consist of 6K carbon fibers (fiber bundles with 6,000 filaments). Furthermore, in addition to carbon fibers (e.g., 6K), the braided sleeve can contain other materials, in particular aramid fibers and / or glass fibers and / or metallic fibers and / or fibers from a renewable raw material.

[0061] Preferably, 6K carbon fibers are used for braiding. Alternatively or additionally, other common fibers can be used, in particular 1K, 3K and / or 12K fibers. Carbon fibers of type FT300 from the manufacturer Toray (TORAY INDUSTRIES, INC., Japan) are used. Fibers of type T700, T800, T1000 or M40, M46J or comparable fibers from other manufacturers can also be used. Braiding is preferably carried out using 24 bobbins. Alternatively or additionally, a braiding machine with a different common number of bobbins can be used, such as 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, or 50 bobbins.

[0062] Preferably, the thickness of the carbon sheath or carbon tube, regardless of the manufacturing method, can be at least 0.05 mm and / or at most 5 mm, in particular 0.5 mm to 1 mm. Such a carbon sheath can preferably be obtained by braiding.

[0063] In order to enable the layers to slide over one another, according to one embodiment a lubricant can be arranged between the conductor track group or its optional conductor sheath and the cover sheath and / or between the cover sheath and the protective sheath of the charging cable. For example, during production of the charging cable according to the invention the cover sheath can be slidably pushed over the conductor track group or optionally over the conductor sheath, preferably using a lubricant such as oil, silicone oil and / or silicone spray, graphite powder or other lubricants. This can preferably be done as an alternative to braiding. It would also be optionally possible for the cover sheath to have two or more differently manufactured parts that are connected to one another in the finished cover sheath. In this case, for example, one part of the cover sheath can be braided and another part pushed onto the conductor track group.Accordingly, it may generally be preferred that the cover jacket is arranged in a sliding manner on the conductor track group, optionally on the conductor jacket, during the manufacturing process.

[0064] Furthermore, a coefficient of friction can preferably be set between the cable sheath and the cover sheath. With relatively low coefficients of friction, the cover sheath can slide on the cable sheath. The sliding of the cover sheath on the cable ensures that the charging cable section is as flexible and bendable as possible. This also makes the charging cable according to the invention easier to handle and can therefore be easily rolled up, for example, to be stored in a trunk. With comparatively higher coefficients of friction, the charging cable tends to be stiffened, which represents additional kink protection for the cable tracks that can be defined via the coefficient of friction. This is advantageous both for cables containing copper and especially for lightweight cables made of aluminum. In other words, a defined optimum of flexibility and kink protection can be created in the charging cable by means of a defined coefficient of friction between the cable sheath and cover sheath.

[0065] Preference is given to lubricants that exhibit the highest possible chemical and long-term stability and do not react chemically with the cable assembly, or optionally the cable sheath, nor with the cover sheath or protective sheath, thus ensuring that the coefficient of friction is hardly or not at all changed over the service life. Preferred lubricants for these purposes are oils, greases, and waxes based on organic substances, but also lubricants containing silicone or PTFE, for example. These can also be mixed with solvents to improve processability and can therefore be applied in liquid or spray form. Depending on the desired coefficient of friction, the lubricants can be applied in varying quantities to the outside of the cable sheath, the outside and inside of the protective sheath, and the inside of the cover sheath. In principle, lubricants can also be used with a braided cover sheath.Depending on the charging cable design, high kink resistance may also be desired. In this case, lubricants can be largely or entirely omitted. Instead of lubricants, substances with a friction-enhancing effect can be used, such as pastes with mineral additives or, for maximum stability, adhesives or resins.

[0066] If appropriate kink protection is required for a charging cable, a thermoplastic and / or a thermoplastic elastomer can be used between the individual conductors to increase the cable's kink resistance and thus protect the conductors against overload or cable breakage. The aforementioned plastics are also suitable here, but cross-linked polyolefin (XLPO) is also preferred.

[0067] In a particularly preferred embodiment, a graphite layer can be inserted between the conductor group, optionally the conductor sheath, and the cover sheath, which can also act as a sliding layer. This graphite layer can also contribute to EMC shielding, since the graphite layer, similar to the carbon cover sheath, also shields against electromagnetic radiation. The graphite layer can be applied, for example, in or on the charging cable using a graphite spray.

[0068] If a protective sheath is used, according to one embodiment, the charging cable section with the cover sheath (and the components enclosed thereby) is pulled into the protective sheath using a pull-in aid, for example, a wire, rope, or preferably a spiral or a pull-in spiral. The pull-in aid is inserted through the protective sheath, connected to one end of the charging cable section, and then pulled through the cover sheath. Furthermore, the protective sheath can also be slid over the cover sheath, for example, using a lubricant.

[0069] The protective sheath can be designed as a hose, regardless of the exact manufacture of the protective sheath. The protective sheath can generally consist, partially or entirely, of a thermoplastic polymer. Preferably, the protective sheath can (generally) comprise thermoplastic polyurethanes (TPU) and / or polyvinyl chloride (PVC). Particularly preferably, the protective sheath can generally consist, in particular entirely (apart from optional inclusions), of thermoplastic polyurethanes (TPU) and / or polyvinyl chloride (PVC). This hose can optionally be filled with carbon, for example with soot and / or graphite particles, to improve wear resistance. Depending on the application, a protective sheath can preferably be designed as a normal hose or as a shrink hose. In this case, the protective sheath preferably comprises thermoplastics and / or thermoplastic elastomers.If the cover jacket has been drawn into the protective jacket, the protective jacket is preferably subjected to a heat treatment so that the protective jacket contracts and tightly encloses the cover jacket.

[0070] A further possibility would be to apply the protective jacket in liquid or molten form to the outer jacket, e.g., by spraying or extruding the protective jacket. According to one embodiment, the protective jacket is provided by an extrusion process, preferably using a pressure or hose tool, also referred to as a hose extrusion machine. The protective jacket can be applied externally, preferably in a sliding manner, to the outer jacket. Single-screw extruders with barrier or multi-zone screws can be used for this purpose. A temperature profile of the extruder during extrusion processing can be at least 170°C and / or at most 240°C. Accordingly, a temperature of the base material (TPU) of the protective jacket during processing can be at least 190°C and / or at most 240°C. Preferably, thermoplastic polyurethanes based on aromatic or aliphatic polyester polyols or polyether polyols are used for the extrusion.The base material (TPU) can be such that the melt flow rate is at least 10 g / 10 min and / or at most 80 g / 10 min (measured at 190°C / 21.6 kg according to DIN EN ISO 1133).

[0071] If the protective sheath comprises, or in particular consists of, polyvinyl chloride (PVC), the protective sheath can also be produced by extrusion using a pressure or hose die. Single-screw extruders with barrier or multi-zone screws can be used, which can have a temperature profile of at least 160°C and / or at most 200°C during extrusion processing. Accordingly, the temperature of the base material (PVC) of the protective sheath during processing can be at least 170°C and / or at most 200°C. Soft PVCs are preferably used, i.e., PVCs that are particularly elastic and flexible due to the addition of plasticizers.

[0072] Preferably, the manufacturing process can generally provide for the base material of the protective sheath, in particular a thermoplastic polymer, to be applied or laid onto the cover sheath at the lowest possible processing temperature (in the extrusion process). Advantageously, a melt as cold as possible, e.g., a thermoplastic polymer, can assist the sliding of the protective sheath relative to the cover sheath in the finished charging cable. Accordingly, the manufacturing process can apply the protective sheath to the cover sheath in such a way that an inner surface of the protective sheath is as smooth or flat as possible, in particular while reducing waves, valleys, or reliefs in the material.

[0073] According to one embodiment, the protective sheath is applied externally to the cover sheath using a pressure tool. Preferably, during the manufacturing process, a molten base material, in particular a thermoplastic polymer, can be pressed and / or injected under pressure into the fabric of the cover sheath, in particular into the fabric of the carbon tube. The thermoplastic polymer can preferably be TPU and / or PVC. An (extrusion) pressure during manufacturing (pressure extrusion) can be at least 100 bar and / or at most 200 bar. A temperature of the base material during processing can be at least 190°C and / or at most 240°C (for TPU) or at least 170°C and / or at most 200°C (for PVC).

[0074] The protective sheath and the cover sheath can be joined together, e.g., firmly, at least in the area of ​​an interface. With the described parameters, sufficient flexibility of the charging cable during handling is still guaranteed. Advantageously, a uniformly high-quality and optically brilliant surface can be produced by pressure extrusion. Advantageously, after its intended use, the charging cable can be processed in the form of a recycled composite material, e.g., comprising carbon fiber reinforced TPU, and used as a construction material in additive manufacturing. For this purpose, the connection between carbon braid and protective sheath can be completely detached from other parts of the charging cable and can be further processed as a fiber composite thermoplastic.

[0075] To produce the protective sheath, basically any sufficiently insulating and flexible material can be used, regardless of the manufacturing method. However, regardless of the manufacturing method, the protective sheath preferably comprises a thermoplastic (thermoplastic polymer) and / or an elastomer, particularly preferably a thermoplastic elastomer. In particular, polyvinyl chloride and / or thermoplastic polyurethane can be used. Furthermore, thermoplastic materials such as polyolefins, polyethylene or polytetrafluoroethylene or silicone-based plastics can be used. Preferably, mixtures of different polymers can also be used. In order to detect, for example, small cracks in the cover sheath, the protective sheath is preferably at least slightly translucent, e.g. tinted, and particularly preferably (completely) transparent.

[0076] Advantageously, a carbon fiber sheath in combination with an outer protective sheath, in particular made of TPU and / or PVC, can provide a charging cable with particularly effective fire protection or high flame resistance. Tests have shown that a charging cable according to the invention with a (pure) carbon sheath (carbon sheath thickness: approximately 0.5 mm to 1 mm) combined with a protective sheath made of thermoplastic polyurethanes (aromatic or aliphatic thermoplastic polyurethanes based on polyester polyol or polyether polyol. The TPUs contain plasticizers in one test and no plasticizers in another test) meets the requirements of DIN EN 60332-1-2 (VDE 0482-332-1-2:2022-07). In particular, after this test, the internal conductors within the carbon fiber sheath are completely intact.Furthermore, such a charging cable also meets the requirements (regarding flame resistance) according to DIN EN 50620 (VDE 0285-620:2020-03). The EN 50620 standard refers to DIN EN 60332-1-2 regarding the conduct of the flame test. The DIN EN 50620 standard applies to charging cables for electric vehicles and is a prerequisite for approval. Advantageously, the cable substructure, i.e. at least the conductor group, also meets the requirements regarding the flame test according to DIN EN 50620 (and is approved accordingly) or according to one of the following standards. Advantageously, a charging cable according to the invention can be designed such that the requirements regarding the flame test according to IEC 62893 and according to GB / T 18380.12 and according to UL2263 are met. Accordingly, the charging cable according to the invention can be certified according to the aforementioned standards.Depending on the standard, the protective sheath can preferably contain TPU or PVC, or TPU and PVC, preferably consisting of both, particularly in combination with a (pure) carbon sheath. This makes it possible to provide a charging cable, particularly one approved according to DIN EN 50620 or one of the aforementioned standards, that offers advantages in electromagnetic compatibility, weight, handling, and functional reliability, combined with effective fire protection.

[0077] Without being bound by any theory, there is evidence that the carbon sheath in particular significantly improves the flame resistance of the charging cable. This can lead to numerous advantages in the complete charging cable, such as less or no flame spread along the charging cable in the event of a fire, reduced use of flame retardants (or complete omission), optimization of materials towards greater flexibility in intended use, better wear resistance and / or UV resistance through targeted optimization of the materials for the latter properties, since the flame protection aspects need to be considered less or not at all. For example, the carbon sheath can help ensure that in the event of flame development in the area of ​​the protective sheath, the internal conductor paths are protected from the (direct) flame and the flame is dissipated by this additional fuel, e.g.the insulation of the conductors is cut off.

[0078] Furthermore, due to its high thermal conductivity, the carbon sheath can dissipate heat particularly effectively, e.g. along its entire length, so that a fire spreads less quickly or may not spread at all. This is probably because the ignition energy required for a fire cannot be generated or is not achieved. The high thermal energy actually present in the initial flame is not available locally in sufficient quantities because the energy is widely distributed due to the high conductivity of the carbon fibers and is therefore reduced so much locally, e.g. in a part of the charging cable adjacent to a currently burning area, that the ignition energy can no longer be achieved. Accordingly, the insulation of the conductor paths in the area next to a flame cannot ignite or can only ignite with difficulty because the necessary ignition energy is not available locally.The braiding of the carbon sheath can therefore have a type of cooling effect, separating areas subject to high thermal stress from the rest of the cable. This prevents both spread in the (axial) longitudinal direction of the charging cable and radial spread. This means that fire spread from the inside outwards as well as from the outside inwards can be significantly contained or prevented. Furthermore, when heated to a high degree, carbon monoxide and / or carbon dioxide can be released from the carbon fibers, e.g. in the area of ​​a fire source, which reduces or prevents the access of air or oxygen to the flame and thus limits or prevents flame spread. It should be noted again that the aforementioned effects are possible theories for the high flame resistance of the charging cable, although other effects are also possible.

[0079] Particularly advantageously, (standard-compliant) flame resistance can also be achieved with a charging cable without added, e.g., chemical, flame retardant additives (in the protective sheath). This also allows charging cables to be provided with a (fully) transparent protective sheath, especially a protective sheath made of transparent TPU. Such charging cables also ensure sufficiently high flame resistance.

[0080] Advantageously, reliable fire protection can be achieved with a charging cable that has relatively few layers or plies. In particular, the charging cable can consist exclusively of the following layers (at least in the area of ​​the charging cable section with the conductor track group): an internal conductor track group with mutually insulated conductor tracks, a cover sheath with carbon fibers lying on top of this (outside), in particular a carbon fiber braid, e.g. consisting only of carbon fibers, and a protective sheath lying on top of this (outside), in particular made of TPU and / or PVC. Further (intermediate) layers can be omitted. This has a beneficial effect on the lightweight construction of the charging cable. For the sake of completeness, it should be mentioned that the charging cable can in principle have further layers or plies, e.g. made of colorless polymer, if desired. For example, the protective sheath can comprise two or more layers.The layers can be made of the same or different materials. For example, the protective sheath can be manufactured by coextrusion.

[0081] The aforementioned advantages regarding flame resistance result in particular from the carbon sheath, so that it can be assumed that a similarly advantageous flame resistance can also be achieved with a charging cable with a carbon braid in combination with a protective sheath made of PVC and / or comparable polymers.

[0082] The conductor tracks of the charging cable according to the invention can, in principle, be made of any electrically conductive material, such as copper. Since the conductor tracks make up a large part of the charging cable, it is desirable for the conductor tracks to be lightweight, such as the charging cable's sheath.

[0083] Therefore, at least one of the conductor tracks can preferably comprise at least one carbon conductor, particularly preferably a graphene conductor and / or a carbon nanotube conductor. To reduce the weight of the charging cable, at least one of the conductor tracks can preferably also comprise at least one aluminum conductor or be made entirely of aluminum.

[0084] It is possible for different conductor paths in the charging cable to be made of different materials, e.g., some conductor paths may be made of graphene, others of carbon nanotubes, and yet others of aluminum or copper. Any combination is conceivable. However, it is also possible for all conductor paths in the charging cable to be made of the same materials, and in particular, to be constructed in the same way.

[0085] Preferably, however, the current-carrying lines are constructed as aluminum lines. Particularly preferably, the protective conductor and / or the signal contact CP (Control Pilot) are constructed as aluminum lines.

[0086] In order to create a long-term stable connection between the aluminum (cable) and the copper (cable), especially in the vehicle plug and / or connection plug, the charging cable can preferably comprise at least one connector, particularly preferably at least one compression cable lug. In particular, the connector can have a copper segment, such as a connection contact, for example in the form of a contact pin or a contact socket in the plug, as well as an aluminum receiving element, preferably a sleeve, for receiving an end piece of an aluminum conductor track. The sleeve is preferably filled with an abrasive contact grease so that an oxide layer on an aluminum surface can be removed and oxygen and condensation water are prevented from getting between the contact point and triggering a decomposition process. The connection is preferably crimped, particularly preferably soldered or pressed.To further protect the contact point from contact with water, the connector is preferably surrounded by a sheath, particularly preferably by a shrink tube.

[0087] During the charging process, temperatures in charging cables can rise. For additional safety during the charging process, the charging cable preferably includes at least one temperature monitor to monitor the temperature in the charging cable. During charging, the temperature is preferably monitored in the charging cable section and plug, e.g. using at least one sensor. If an increased temperature is detected, e.g. above 90°C, the charging power is reduced accordingly or the charging process is stopped completely. This communication can take place, for example, using a PP contact pin, which passes on corresponding information about the maximum permissible charging current. A resistor is preferably installed between the proximity pilot (PP) and the protective conductor (PE), which signals the maximum permissible charging power to the power source and / or the vehicle.To achieve temperature monitoring, a further temperature-sensitive resistor or sensor, for example a PTC thermistor, is preferably connected (in series) before or after the resistor. If the temperature is below the selected maximum temperature (e.g. 90°C), the current can flow more or less unhindered through the PTC thermistor and the control units in the power source and / or vehicle are signaled as to the regular maximum charging power or maximum permissible current of the charging cable, so that the charging process can be carried out normally. If the temperature rises above the permissible temperature (e.g. over 90°C), the internal resistance of the PTC thermistor increases suddenly, which signals a defect to the control units in the power source and / or the vehicle. The charging process is stopped immediately to prevent the temperature from increasing further. If a reduction in temperature is detected, at which the temperature in the charging cable, e.g.For example, if the temperature is between 50°C and 85°C, the charging process continues at its original charging power. Instead of a fixed resistor and an additional temperature-sensitive second resistor connected in series, etc., a single suitable temperature-sensitive resistor could be used. This resistor normally provides the usual resistance value between the proximity pilot (PP) and the protective conductor (PE) and increases significantly above a critical temperature increase.

[0088] Another option for controlling or reducing the temperature in the charging cable is a cooling layer for cooling the charging cable. This can preferably be arranged between the conductor track group or optionally between the conductor sheath and the cover sheath. Additionally or alternatively, a cooling layer can also be arranged between the cover sheath and the protective layer. For cooling, the cooling layer preferably comprises a fluid. Fluid is generally understood to mean any liquid or gas that is suitable for cooling the charging cable. However, the cooling layer particularly preferably comprises water. For this purpose, the charging cable preferably has a separating sheath that separates the colder fluid for cooling at the conductor sheath (inlet) from the heated fluid at the protective sheath (return).

[0089] The charging cable preferably has at least one strain relief on at least one end piece in at least one of the plugs, i.e., in the connection plug and / or the vehicle plug, which can be arranged, for example, in the receptacle of the respective plug. This can help ensure that the cable does not lose its connection to the plug even when the cable is repeatedly bent and pulled, and preferably also securely holds the cover jacket and, if applicable, the protective jacket at the ends. The strain relief can also simultaneously form the contact between the fiber braid of the cover jacket and the earth, thus earthing the charging cable, which will be explained in more detail later.

[0090] Preferably, the strain relief can comprise at least one clamp (e.g., in the receiving part). The clamp is preferably arranged around the protective sheath in such a way that it encloses and compresses the protective sheath.

[0091] To further protect the charging cable against water ingress, the charging cable preferably has at least one water protection grommet, particularly preferably a rubber grommet. This is preferably arranged in the vehicle plug and / or in the connection plug, in particular in the aforementioned (outer) grommet of the plug, and encloses the cover sheath or the protective sheath. One rubber grommet is preferably arranged on a plug-in side of the plug head, and a second rubber grommet is preferably arranged on a cable-side end of the receptacle. Particularly preferably, the rubber grommet, which is arranged on the cable-side end of the receptacle, is enclosed by a previously described clamp and pressed against the protective sheath or the cover sheath so that no water can penetrate into the charging cable section.

[0092] Alternatively, dust and water tightness can also be achieved using other common sealing concepts, such as cable glands used in electrical engineering, i.e., screwable cable entries whose tightness increases with increasing torque. These cable entries or cable glands are preferably mounted on the cable-side end of the receptacle. This type of sealing can be selected especially for an otherwise watertight connector head.

[0093] As described, the charging cable preferably has a grounding connection element that is in operative contact with the covering sheath. According to one embodiment, the charging cable can have a (metal) clamp that rests externally on the protective sheath and / or on an electrically conductive element. The (metal) clamp itself preferably does not contact the covering sheath directly (in this embodiment). The clamp can be connected to one end of an electrically conductive element, e.g. one or more metal sheets. The respective element can be in contact with the covering sheath at the other end, in particular by the respective element being pushed or inserted under the covering sheath and / or between the covering sheath and the cable sheath. The electrically conductive element can lie flat against the covering sheath and / or can contact the covering sheath flatly.In particular, the electrically conductive element can have an I-shaped profile and / or can contact the cover sheath along its entire (inner) circumference. Preferably, a stamped and bent part can be provided that combines the functions of the clamp and the electrically conductive element. Advantageously, this allows a simple connection between the grounding connection element and the cover sheath to be realized in a charging cable in which the cover sheath and protective sheath are firmly connected.

[0094] At least one plug of the charging cable, i.e., the connection plug and / or the vehicle plug, preferably the vehicle plug, can have an analog and / or digital charging power indicator. A charging power indicator can preferably be integrated into a housing of the plug. This makes using the charging cable particularly convenient.

[0095] The charging cable can preferably have a fingerprint scanner designed to lock and / or unlock the charging cable. The fingerprint scanner can be designed to control a locking mechanism for the charging cable in order to temporarily lock the charging cable in a charging socket of an electric vehicle and / or in a charging station. The function of such locking mechanisms, which can be implemented, for example, as part of the charging station or the electric vehicle, is known to those skilled in the art. Advantageously, the fingerprint scanner, which is preferably implemented in a plug of the charging cable, can be used to achieve particularly convenient and at the same time personalized operation of the charging cable and the charging process.Advantageously, it is no longer necessary to access an app (application), for example, for the charging station or electric vehicle, for locking and unlocking. Instead, the locking and unlocking process can be initiated directly via the fingerprint scanner on the plug, thus saving a work step. The invention is explained in more detail below with reference to the accompanying figures using exemplary embodiments. In the various figures, identical components are provided with identical reference numerals. The figures are generally not to scale. They show:

[0096] Figure 1 is a perspective view of a first embodiment of a section of an electric vehicle charging cable with a plug according to the invention,

[0097] Figure 2 is a perspective view of a second embodiment of a section of an electric vehicle charging cable with a plug according to the invention,

[0098] Figure 3 is a perspective view of a third embodiment of a section of an electric vehicle charging cable with a plug according to the invention,

[0099] Figure 4 is a schematic representation of the covering of a cover sheath over a cable sheath of the electric vehicle charging cable according to the invention,

[0100] Figure 5 is a schematic representation of the insertion of the charging cable with a cover according to Figure 4 into a protective sheath of the electric vehicle charging cable according to the invention,

[0101] Figure 6 is a schematic representation of part of an electric vehicle charging cable according to the invention.

[0102] Figure 1 shows an example of an (end) section of an embodiment of a charging cable 1 according to the invention.

[0103] As already explained, public charging stations in Germany generally have an alternating current (AC) connection, a direct current (DC) connection, or a combination of an alternating current (AC) and direct current (DC) connection. The plug or the conductor paths of a cable are designed accordingly. As an example, Figure 1 shows a charging cable 1 for charging with alternating current. A conventional Type 2 plug 10 and a corresponding conventional charging cable section 6 are used for this purpose. In the figures, a connection plug 10 for connecting to a power source (usually a male plug) is shown as an example. The plug 10 has a fixed plug head SK, which has the contact pins 27 on the plug-in side for connection to the power source.In addition, the connector 10 has a relatively flexible receiving part T on the cable side, connected to the connector head SK, for receiving a first end piece 13 of the charging cable section 6. Alternatively, the connector could also be a vehicle connector for connection to a vehicle, which then—since this is usually a female connector or socket—has contact sockets instead of contact pins.

[0104] For charging with alternating current, the charging cable section 6 has four current-carrying conductors 2. These current-carrying conductors 2 are three phases L1, L2, L3 and a neutral conductor N. The charging cable section 6 also has a protective conductor PE and two signal contacts CP, PP; a control pilot contact CP and a proximity pilot PP. The signal contacts CP, PP can be used, for example, to detect whether an electric vehicle is connected. Using the pilot contact CP, the charging station tells the electric car what the maximum charging current is. Using the proximity pilot PP contact, both the charging station and the electric car can detect how much load the connected charging cable 1 can be subjected to.

[0105] To protect them from external influences, the conductor tracks 2 are covered by a cable sheath 3. The conductor tracks 2 together with the cable sheath 3 thus form the charging cable section 6.

[0106] As mentioned, all electrical systems and devices fundamentally generate electromagnetic waves and are therefore sources of electromagnetic interference. The flow of alternating current also generates electromagnetic radiation, which can be emitted by the current-carrying conductors. However, by means of a suitable cover sheath 5 arranged over the cable sheath 3, these electromagnetic waves can be shielded and their propagation beyond the cable reduced or completely prevented. The cover sheath here is a preferred carbon sheath 5 (i.e., a sheath consisting predominantly of carbon fibers). Even if the cover sheath 5 is therefore sometimes referred to synonymously as carbon sheath 5 below, the feature combinations described in the exemplary embodiments are also possible with cover sheaths whose proportion of carbon fibers is not as high, e.g.because a significant proportion of aramid fibers and / or glass fibers were used. For this purpose, the carbon sheath 5 is pushed over the cable sheath 3 (see Figure 4), which is possible because the outer diameter of the cable sheath 3 (including the conductor tracks 2) is slightly smaller than the inner diameter of the carbon sheath 5. A lubricant (not shown in the figures) or a friction-enhancing paste can be applied to the cable sheath 3 and / or to the inner surfaces of the carbon sheath 5. This allows the sliding properties of the carbon sheath 5 on the cable sheath 3 to be specifically adjusted and thus varied either in favor of flexibility or kink resistance.

[0107] Since carbon fibers are conductive, electrical charges can sometimes be present on the carbon sheath 5. To dissipate these charges, the carbon sheath 5 was grounded here with a grounding connection element 27E of the plug 10. For this purpose, a grounding connection E or a grounding cable E connects the carbon sheath 5 or cover sheath 5 with carbon fibers to the protective conductor PE, which is connected in the usual way to the grounding connection element 27E in the plug 10. The grounding connection element E is connected to an electrically conductive strain relief 15, here a metallic clamp 15. The clamp 15 also serves to fix the cover sheath 5 to the cable sheath 3 and rests directly on the cover sheath 5, enclosing it. To ensure that the entire charging cable 1 is electromagnetically shielded, the plug 10 also has an outer plug cover sheath 7, which comprises a fiber composite material with carbon fibers.

[0108] The plug cover 7 can also be grounded. For this purpose, the plug cover 7 is connected to the electrically conductive strain relief via a symbolic grounding connection element 15'.

[0109] To further protect the charging cable 1 against mechanical and environmental influences, the carbon sheath 5 in this exemplary embodiment is additionally covered by a protective sheath 8, in this case a transparent tube made of thermoplastic polyurethane (TPU). The protective sheath 8 also provides the charging cable 1 with additional electrical insulation.

[0110] In order to cover the carbon sheath 5 with the protective sheath 8, as shown in Figure 5, a sufficiently large end piece of the carbon sheath 5 is attached to a pulling aid 17, here a so-called "pulling spiral" 17, which has been pushed through the protective sheath 8, for example (wherein the outer diameter of the pulling spiral 17 has a significantly smaller outer diameter than the inner diameter of the protective sheath 8). The pulling spiral 17 is then pulled through the protective sheath 8 and thus pulls the carbon sheath 5 or cover sheath 5 and thus the charging cable section 6 into the protective sheath 8. The carbon sheath 5 or cover sheath 5 is designed in such a way that, due to the tensile force exerted by the pulling spiral, a radial compression force is generated on the charging cable section 6, and the charging cable section is thus fixed by the carbon sheath 5 and thus pulled into the protective sheath 8.Once the charging cable section 6 has been retracted into the protective sheath 8, the retraction spiral 17 can be removed again.

[0111] This ensures that the protective sheath 8 is arranged in a sliding manner on the cover sheath 5. For this purpose, a lubricant can also be used, for example, which is sprayed onto the cover sheath 5 or into the protective sheath 8.

[0112] Additional protection against environmental influences is provided by water protection grommets 25 in the plugs, which are arranged at least on one insertion side of the plug head SK and on a cable-side end of the receptacle T in order to seal the plug and prevent water and dust from entering the plug. For this purpose, a rubber grommet 25 is arranged in the outer receptacle T of the plug 10 as an example in the figures, which surrounds the protective sheath 8 together with the charging cable section 6 and the cover sheath 5 and the cable tracks 2. The rubber grommet 25 is compressed here by means of a strain relief 16 (clamp 16), which encloses the rubber grommet 25 together with the charging cable section 6 at a cable-side end in the receptacle T, so that no water can penetrate into the charging cable section 6.

[0113] In order to monitor the temperatures in the charging cable 1, the charging cable 1 here (Figure 1) has a temperature monitor 20. The temperature monitor 20 has a resistor 21. This resistor 21 signals to a control on the power supply and / or the vehicle how high the maximum current may be that flows through the charging cable 1 due to its design in order to counteract overheating of the charging cable 1. In addition, the temperature monitor can have one or more further sensors that check the temperature in the charging cable section 1, the connection plug 10, the vehicle plug and, for example, in the wallbox. For this purpose, a heat-sensitive sensor 22 (e.g. heat-dependent resistor) is shown as an example in Figure 1, which is connected to the Proximity Pilot PP of the connection plug 10.The temperature monitor 20 represents a series circuit consisting of the resistor 21 (charging cable coding of the maximum permissible charging power) and the heat-sensitive sensor 22. For example, a PTC thermistor can be used as the heat-sensitive sensor 22, which leads to no significant increase in resistance below the defined cut-off temperature and thus enables a normal charging process. Above the defined cut-off temperature, however, a very strong increase in resistance occurs within the heat-sensitive sensor 22, so that a fault is signaled via the signal contact PP, which leads to the shutdown of the charging process.

[0114] Figure 2 shows a charging cable T suitable for charging with direct current. This is achieved by the connecting plug 11, in this case a CCS plug 11. The CCS plug 11 comprises two parts 11a, 11b. The first part 11a consists of a protective conductor and two smaller contact pins CP, PP. The second part of the CCS plug 11b is suitable for charging with direct current. For this purpose, the charging cable section 6' does not have the four current-carrying conductors L1, L2, L3, N, but rather a positive pole + and a negative pole -.

[0115] The rest of the structure of the charging cable T corresponds to the charging cable 1 in Figure 1. Only the temperature monitor 20 is not shown in this embodiment of the charging cable T. Nevertheless, a temperature monitor 20 could also be arranged accordingly in this variant. Or only the resistor 21 (charging cable coding of the maximum permissible charging power), without the corresponding heat-sensitive sensor 22, could be arranged in the embodiment.

[0116] The charging cable T in Figure 2 shows a further variant for controlling or reducing the temperature of the charging cable T. For this purpose, the charging cable T has a multi-layer cooling layer 18 (shown here only schematically as a single layer) between the cable sheath 3 and the cover sheath 5, which in this case carries cooling water. By means of this cooling layer 18, the temperature of the charging cable T can be cooled, whereby the charging cable T does not overheat. However, the cooling layer can also be arranged at a different position in the charging cable 6'; for example, a cooling layer can also be arranged between the cover sheath 5 and the protective sheath 8 or can also be used in addition to the aforementioned cooling layer in order to be able to reduce the temperature in the charging cable T even further.

[0117] Since a low weight of the charging cable also indirectly affects the energy consumption of the vehicle, as already explained, low-weight materials are preferably used for the charging cable 1, 1', 1". In principle, any conductive material can be used for the conductor tracks 2. Due to their low weight, conductor tracks 2 comprising carbon conductors 23, 24 are suitable. For this purpose, in the embodiment of Figure 1, the conductor tracks 2 are designed as graphene conductors 23 or carbon nanotube conductors 24.

[0118] Another suitable material for the conductor tracks 2 due to its weight is aluminum. For this purpose, the conductor tracks 2 in Figure 3 are designed as aluminum conductors 9. Another possibility would be for a charging cable to comprise graphene conductors 23 and / or carbon nanotube conductors 24 and / or aluminum conductors 9 and / or copper conductors 26.

[0119] In order to create a secure connection between the cables, particularly the aluminum cables 9, and a copper component, in this case one of the contact pins 27, 27E in the connector 11, these two components are connected in a strain-relieving manner (see Figure 3) by means of a connector 14, specifically in this case a compression cable lug 14. The cable lug 14 has a receiving element, in this case a sleeve, into which an end of the aluminum cable 9 to be connected is inserted and then pressed or crimped. The sleeve is filled with contact grease so that an oxide layer on an aluminum surface can be removed and so oxygen and condensation water can be prevented from settling between the contact point and triggering a new and undesirable oxidation process, since the oxide layer would lead to a high contact resistance and thus negatively affect conductivity. By means of a copper connection element 19, orCopper segment 19, the compression cable lug 14 can be connected to a corresponding contact pin 27, 27E, in the connector 11. However, the connector 14 can also be designed such that it is already formed as an aluminum part, e.g., as a sleeve, on one side and as a copper part, e.g., as a contact pin, on the other side, with the parts already firmly connected to one another, e.g., welded or soldered. A shrink tube (not visible in the figures) is also arranged around the connector 14 to protect the connection point from water ingress.

[0120] Figure 6 shows a purely schematic view of part of a charging cable 1 according to the invention without a plug. The charging cable 1 comprises conductor tracks 2, shown in sections, which are surrounded by a cable sheath 3. A cover sheath 5, in this case a carbon sheath 5, rests on the outside of the cable sheath 3. The charging cable 1 comprises a grounding connection element (not shown in detail), which is connected to an electrically conductive strain relief 28, in this case a metallic clamp 28. The clamp 28 also serves to fix the protective sheath 8 and the cover sheath 5 to the cable sheath 3. In this example, the clamp 28 rests directly on the U-shaped metal sheet 29 (in the operational state) and is spaced apart from the cover sheath 5. The U-shaped metal sheet 29 is bent or shaped such that an end of the metal sheet 29 pointing away from the clamp 28 is arranged between the cable sheath 3 and the cover sheath 5. The plate 29 can, unlike shown here, be an integral part of the clamp 28, e.g.in the form of a stamped and bent part. The clamp 28 then also rests on the protective sheath 8. Regardless of the specific design, the sheet metal 29 extends in partial segments (not shown) or completely circumferentially along the entire circumference (as in Figure 6) of the cable sheath 3. Here, the sheet metal 29 forms a circumferential U-profile. Furthermore, the charging cable 1, particularly with regard to the grounding connection element and the plug, can be constructed as described with reference to the other figures.

[0121] Finally, it should be noted once again that the devices described in detail above are merely exemplary embodiments that can be modified in a variety of ways by a person skilled in the art without departing from the scope of the invention. For example, a charging cable that has temperature monitoring can also additionally comprise a cooling layer. Furthermore, the charging cable is not limited to specific plugs and / or conductor track groups. In principle, the design or structure of the respective plug and / or the charging cable section with the conductor track group can be based on national or regional standards and / or norms. Furthermore, the use of the indefinite article "a" or "an" does not exclude the possibility that the relevant features may be present multiple times.

[0122] List of reference symbols

[0123] 1 , T, 1“ charging cable

[0124] 2 conduction pathways

[0125] 3 Cable sheath

[0126] 4 Conductive pathway group

[0127] 5 Top coat / carbon coat

[0128] 6, 6', 6" charging cable section

[0129] 7 Plug cover

[0130] 8 Protective sheath

[0131] 9 aluminum cable

[0132] 10,11 Connection plug

[0133] 11a first part plug

[0134] 11b second part plug

[0135] 13 End of charging cable section

[0136] 14 compression cable lug

[0137] 15 electrically conductive strain relief and contact

[0138] 15' grounding connection element

[0139] 16 Strain relief

[0140] 17 retraction spiral

[0141] 18 Cooling layer

[0142] 19 copper connection element

[0143] 20 Temperature monitoring

[0144] 21 Resistance

[0145] 22 Sensor

[0146] 23 Graphene line

[0147] 24 Carbon Nanotubes Cable

[0148] 25 rubber grommets

[0149] 26 copper cables

[0150] 27, 27' contact pins

[0151] 27E Earthing connection element

[0152] 28 clamp

[0153] 29 sheet metal

[0154] CP signal contact Control Pilot

[0155] E Grounding

[0156] L1, L2, L3 phases N neutral conductors

[0157] PE protective conductor

[0158] PP signal contact proximity pilot

[0159] SK plug head T socket

[0160] + positive pole

[0161] - Negative pole

Claims

Patent claims 1. Electric vehicle charging cable (1 , 1', 1") comprising - a charging cable section (6, 6', 6") with a conductor group (4) of mutually insulated conductor tracks (2) for transmitting a current, - at least one first plug (10, 11) on a first end piece (13) of the charging cable section (6, 6', 6"), - optionally a second plug (10, 11) on a second end piece of the charging cable section (6, 6', 6"), characterized by a cover sheath (5) which encloses the conductor track group (4), - wherein the cover sheath (5) comprises a fiber braid with carbon fibers, wherein the fiber braid optionally comprises aramid fibers and / or glass fibers and / or metallic fibers and / or fibers from a renewable raw material, and - wherein the cover jacket (5) is connected to an earthing connection element (27E), preferably via an electrically conductive strain relief (15).

2. Electric vehicle charging cable according to claim 1, wherein the conductor track group (4) has a conductor sheath (3) which completely encloses the conductor tracks (2) of the conductor track group (4), wherein preferably the cover sheath (5) slides on the conductor sheath (3).

3. Electric vehicle charging cable, in particular according to one of the preceding claims, comprising - a charging cable section (6, 6', 6") with a conductor track group (4) of mutually insulating conductor tracks (2) for transmitting a current, - at least one first plug (10, 11) on a first end piece (13) of the charging cable section (6, 6', 6"), - optionally a second plug (10, 11) on a second end piece of the charging cable section (6, 6', 6"), characterized by a cover sheath (5) which encloses the conductor track group (4), - wherein the cover sheath (5) comprises a fiber braid with carbon fibers, wherein the fiber braid optionally comprises aramid fibers and / or glass fibers and / or metallic fibers and / or fibers from a renewable raw material, and wherein the cover jacket (5) is covered by a protective jacket (8).

4. Electric vehicle charging cable according to claim 3, wherein the protective sheath (8) comprises thermoplastic polyurethanes and / or polyvinyl chloride, and / or wherein the cover sheath (5) comprises braided carbon fibers.

5. Electric vehicle charging cable according to claim 3 or 4, wherein the protective sheath (8) is translucent, preferably transparent.

6. Electric vehicle charging cable according to one of the preceding claims, comprising at least one cooling layer (18) for cooling the electric vehicle charging cable (1), which cooling layer is preferably arranged between the conductor track group (4), optionally its conductor sheath (3), and the cover sheath (5) and / or between the cover sheath (5) and the protective sheath (8), wherein the cooling layer preferably comprises a fluid, particularly preferably water.

7. Electric vehicle charging cable according to one of the preceding claims, wherein the protective sheath (8) is designed such that it slides on the cover sheath (5), and / or wherein at least one lubricant is arranged between the conductor track group (4) and the cover sheath (5) and / or between the cover sheath (5) and the protective sheath (8), wherein preferably at least the lubricant between the conductor track group (4), optionally its conductor sheath (3), and the cover sheath (5) has a graphite layer.

8. Electric vehicle charging cable according to one of the preceding claims, wherein the first plug (10, 11) and / or second plug (10, 11) have at least in regions a plug cover jacket (7) which comprises a fiber composite material, with carbon fibers and optionally with aramid fibers and / or glass fibers and / or metallic fibers and / or fibers from a renewable raw material, and / or wherein at least one plug (10, 11) has an analog and / or a digital charging power display.

9. Electric vehicle charging cable according to one of the preceding claims, wherein at least one of the conductor tracks (2) comprises at least one aluminum conductor (9).

10. Electric vehicle charging cable according to claim 9, comprising at least one connection (14), preferably a press connection (14), for connecting the at least one aluminum line (9) and a copper segment (19).

11. Electric vehicle charging cable according to one of the preceding claims, wherein at least one of the conductor tracks (2) comprises at least one carbon conductor (23, 24), preferably a graphene conductor (23) and / or a carbon nanotube conductor (24).

12. Electric vehicle charging cable according to one of the preceding claims, comprising at least one temperature monitor (20), wherein the temperature monitor (20) comprises at least one heat-sensitive sensor (22), preferably a heat-dependent resistor (22), which is connected, for example, in series with another resistor (21).

13. Electric vehicle charging cable according to one of the preceding claims, comprising at least one strain relief (15, 16), wherein preferably at least one strain relief (15, 16) is arranged on an end piece (13) of the charging cable section (6, 6', 6").

14. Electric vehicle charging cable according to one of the preceding claims, wherein at least one of the plugs (10, 11) has a receiving part (T) which at least partially receives the end piece (13) of the charging cable section (6, 6', 6") associated with this plug (10, 11).

15. Electric vehicle charging cable according to one of the preceding claims, wherein the electric vehicle charging cable (1, T, 1") has a fingerprint scanner for locking and / or unlocking the electric vehicle charging cable (1, T, 1").

16. A method for producing an electric vehicle charging cable (1, T, 1") according to one of the preceding claims, comprising at least the following steps: - Providing a charging cable section (6, 6', 6"), - providing at least one first connector (10, 11), - optionally providing a second connector (10, 11), - Covering a group of conductors (4) with a covering sheath (5) comprising a fiber braid with carbon fibers and optionally with aramid fibers and / or glass fibers and / or metallic fibres and / or fibres from a renewable raw material, - optionally covering the cover (5) with a protective cover (8), - connecting the first plug (10, 11) to a first end (13) of the charging cable section (6, 6', 6") and optionally connecting the second plug (10, 11) to a second end of the charging cable section (6, 6', 6"), - Connecting the cover sheath (5) to an earthing connection element (27E).

17. The method according to claim 16, wherein the cover sheath (5) is slidably pushed over the conductor track group (4) and / or is arranged slidably on the conductor track group (4), and / or wherein the cover sheath (5) is braided at least in sections.

18. Method according to claim 16 or 17, wherein the charging cable section (6, 6', 6") with the cover sheath (5), preferably by means of a pulling-in aid (17), is pulled into the protective sheath (8), and / or wherein the protective sheath (8) is provided by extrusion.

19. Use of an electric vehicle charging cable (1, 1', 1") according to one of the preceding claims 1 to 15, for electrically charging an electric vehicle.

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