Power Line Assemblies and Automotive

Abstract

The power transmission line assembly (10) for conducting current from a charging socket (160) of a vehicle (100) to an energy storage device (150) of the vehicle (100) includes a DC cable (20) having two single DC cables (21, 22) for conducting direct current (DC) from a DC interface (120) of the charging socket (160) to the energy storage device (150), and an AC cable (30) having a plurality of single AC cables (31) for conducting alternating current (AC) from an AC interface (130) of the charging socket (160) to the energy storage device (150), each of the single DC cables (21, 22) having an aluminum profile (25) as a conductor for conducting the direct current (DC).

Description

[Technical Field]

[0001] The present disclosure relates to a power transmission line assembly for conducting electrical current from a charging socket of a vehicle to an energy storage device of the vehicle. The present disclosure also relates to a vehicle. [Background technology]

[0002] The ongoing mobility transformation is an important aspect of the increasingly environmentally necessary sustainability framework. For this and other reasons, the production and use of electric vehicles is a core part of achieving more sustainable mobility. A central component of an electric vehicle is the charging cable or charging unit, which connects the energy storage device through a power line assembly to a charging socket, to which an external charging station can be connected to charge the energy storage device.

[0003] The charging unit typically includes a power line assembly and a charging connector or interface for connecting the power line assembly to the charging socket and to a connection end of the energy storage device. The power line assembly or cable extends between the energy storage device and the charging socket. The charging unit is typically a single, integrated component.

[0004] Vehicles can be charged with alternating current (AC) or direct current (DC), typically via AC and DC cable harnesses, respectively.

[0005] According to the prior art, DC cable harnesses usually consist of two round copper conductors. When carrying current, one of the round conductors carries a positive charge and the other a negative charge. Copper is suitable for the round conductors because, in addition to the basic requirement of current-carrying capacity, copper is mechanically flexible and can compensate for the tolerances in the arrangement of the charging unit or charging socket and the energy storage device.

[0006] However, copper generates a relatively large amount of heat when a direct current is passed through it, and copper is relatively expensive and has a relatively large mass.

[0007] Patent Document 1 discloses a vehicle having a charging cable and an electrical energy storage device that can be recharged by an external power source, and a vehicle body with at least one vehicle body opening that can be closed by a vehicle body opening / closing cover, wherein the vehicle is provided with a charging cable that is connected or connectable to the storage device to transmit electricity and that extends at least partially inside the vehicle body, the vehicle body opening is a trunk room opening or a door opening, and the vehicle body opening / closing cover is a trunk room rear gate or a vehicle door, the charging cable is formed as a flexible ribbon cable or comprises at least a portion of a flexible ribbon cable, the flexible ribbon cable or at least a portion of the flexible ribbon cable is capable of being inserted through a gap in the vehicle body between the edge of the body opening and the vehicle body opening / closing cover, and the conductor of the ribbon cable or at least a portion of the flexible ribbon cable comprises current-carrying conductors arranged side by side, and is formed as a flat, band-shaped conductor and is enclosed in a common electrically insulating sheath. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. 2016 / 020512 Summary of the Invention [Problem to be solved by the invention]

[0009] Against this background of the prior art, it is an object of the present disclosure to provide an improved power transmission line assembly adapted to further satisfy the prior art. Particular embodiments of the present disclosure may solve the object of providing a power transmission line assembly that is cost-effective, lightweight, easy to maintain, and that relatively efficiently avoids heat-related problems. [Means for solving the problem]

[0010] This problem is solved by the features of the independent claims. The dependent claims contain preferred developments of the disclosure.

[0011] According to the document, this problem is solved by a power transmission line assembly for conducting current from a charging socket of a vehicle to an energy storage device of the vehicle, which includes a DC cable with two single DC cables for conducting direct current from a DC interface of the charging socket to the energy storage device, and an AC cable with multiple single AC cables for conducting alternating current from an AC interface of the charging socket to the energy storage device, where each of the single DC cables includes an aluminum profile as a conductor for conducting the direct current.

[0012] The power transmission line assembly is thus positioned between the charging socket in the vehicle and the energy storage device. The power transmission line assembly has a DC cable and an AC cable to enable combined charging, which allows both direct current and alternating current charging methods to be implemented to charge the energy storage device.

[0013] The DC cable includes two DC single cables, one of which corresponds to a positive pole and the other of which corresponds to a negative pole.

[0014] The AC cable has multiple single AC cables, which allows charging with multi-phase AC and / or three-phase AC.

[0015] The DC cable and the AC cable are provided to be connected to the energy storage device via corresponding interfaces, respectively. The energy storage device includes power electronics for converting DC and / or AC to charge the battery cells of the energy storage device.

[0016] Each of the DC single cables includes an aluminum profile as a conductor for conducting direct current. The aluminum profile is configured to conduct direct current. Aluminum is lighter than copper and is available at low cost because it is efficiently recyclable. Furthermore, aluminum has a relatively high thermal conductivity. The shape of the DC single cable as a profile improves heat radiation and / or heat conduction of the heated DC cable, thereby enabling the DC cable to be cooled effectively. As a result, the charging time for charging the energy storage device can be shortened. The profile here is, for example, a member formed from a flat block.

[0017] The aluminum profiles of the DC single cable may be arranged parallel to each other. This allows the magnetic fields of the two DC single cables to partially cancel each other out. When current flows through a conductor, an electromagnetic field is generated. Because the two aluminum profiles are oppositely charged, the two generated electromagnetic fields partially cancel each other out, and little or no additional measures are required to cancel the electromagnetic fields. The proposed arrangement of the aluminum profiles makes it easy to achieve the electromagnetic compatibility limit values. Here, electromagnetic compatibility (EMC) refers to the ability of technical equipment not to disturb or be disturbed by any other equipment with unwanted electrical and / or electromagnetic effects.

[0018] The aluminum profile may be a flat profile, i.e., the aluminum profile has two main directions of extension, in which the aluminum profile is more extended than in the other directions of extension. It has been found that, for example, a round aluminum profile is relatively rigid and cannot compensate for tolerances that may occur when arranging the charging unit and the energy storage device. The flat profile configuration provides the aluminum profile with the necessary flexibility. The flat profile is relatively flexible and can adequately compensate for such tolerances in a vehicle.

[0019] A thermal paste can be placed between the DC cables. For example, a thermal paste made of so-called LH2C is inserted between two aluminum profiles. This paste has a high thermal mass and can absorb the heat from the conductors. This increases the current carrying capacity, shortens charging times, and heat absorption via the thermal paste applied between the aluminum profiles is less expensive than active cooling.

[0020] The above can be summarized as follows, based on the specific embodiment described without limiting the present disclosure: It is proposed to replace the two copper round-profile conductors of a DC charging cable with two aluminum flat-profile conductors. The flat profiles are overlapped so that the magnetic fields of the two flat-profile conductors cancel each other out. When a current flows through the conductor, an electromagnetic field is generated. Because the two flat profiles are oppositely charged, the two generated electromagnetic fields partially cancel each other out, and no additional measures are required to cancel the electromagnetic fields. Electromagnetic compatibility (EMC) refers to the ability of technical equipment not to interfere with or be interfered with by any other equipment due to unwanted electrical or electromagnetic effects. The proposed flat-profile arrangement makes it easier to achieve EMV limits. Using aluminum instead of copper reduces costs and allows for improved heat dissipation and therefore shorter charging times. However, round aluminum profiles are very rigid and cannot compensate for potential tolerances in the charging unit and high-voltage battery. Moreover, because the charging unit is made up of many components, tolerances between the individual components of the charging unit are essential. Changing the shape provides the necessary flexibility for the aluminum profile. Flat profiles are easier to bend and can better compensate for tolerances. Maintaining a low temperature in the charging path is important to improve the efficiency of the charging process and shorten charging times. While heat dissipation due to resistance within the conductor can affect the surroundings (e.g., the sheath), charging performance decreases above a certain temperature. Air and water cooling methods are not suitable due to their drawbacks in terms of complexity, cost, packaging (installation space), and weight. Therefore, a thermal cooling system using a thermal mass (LH2C) between two flat aluminum profiles is proposed. A thermal paste made of LH2C is inserted between the two aluminum profiles. This paste has a high thermal capacity and can absorb the heat from the conductor.

[0021] Further provided is a vehicle having a charging socket, an energy storage device, and the above-described power line assembly.

[0022] The motor vehicle may be a private vehicle, in particular a passenger car. The motor vehicle may be an electric vehicle. To that end, the motor vehicle may be equipped with an electric drive that may be supplied with electrical energy from an energy storage device in order to convert the electrical energy into kinetic energy. Optionally, the automated motor vehicle may be configured to at least partially and / or at least temporarily take over forward and / or lateral steering when driving the motor vehicle automatically. The automated driving may be performed such that the forward movement of the motor vehicle is (largely) automatic. The automated driving may be at least partially and / or at least temporarily controlled by a data processing device. The motor vehicle may be a motor vehicle with an automated driving level of 0 to 5.

[0023] What has been described above with respect to power line assemblies applies equally to automobiles, and vice versa.

[0024] An embodiment will be described below with reference to FIGS. [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a diagram illustrating a schematic diagram of a vehicle according to one embodiment of the present disclosure. [Figure 2] FIG. 1 is a perspective view of an electrical power transmission line assembly according to one aspect of the present disclosure. [Figure 3] 1A-1C are cross-sectional views of respective DC cables of a power transmitter assembly according to one embodiment of the present disclosure. [Figure 4] FIG. 10 is a schematic diagram illustrating a threaded connection of a power transmission body assembly according to one aspect of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0026] FIG. 1 illustrates a schematic diagram of a vehicle 100 according to one embodiment of the present disclosure.

[0027] The vehicle 100 includes a charging socket 160, an energy storage device 150, and a power transmission line assembly 10. The charging socket 160 is configured to provide an electrical connection between the vehicle 100 and a charging station 200 external to the vehicle. Furthermore, the vehicle 100 or its energy storage device 150 can be charged by supplying electrical current thereto.

[0028] To this end, the charging socket 160 is electrically connected to the energy storage device 150 via the power transmission line assembly 10. The power transmission line assembly 10 is configured to conduct electrical current from the charging socket 160 to the energy storage device 150.

[0029] The power transmission line assembly 10 includes a DC cable 20 and an AC cable 30 .

[0030] The DC cable 20 is configured to conduct direct current (DC) from the DC interface 120 of the charging socket 160 to the energy storage device 150. The AC cable 30 is configured to conduct alternating current (AC) from the AC interface 130 of the charging socket 160 to the energy storage device 150.

[0031] The AC cable 30 includes a plurality of AC single cables 31 (only one AC single cable 31 is shown for ease of illustration).

[0032] The power transmission line assembly 10 is further described with reference to FIGS.

[0033] Figure 2 is a perspective view of an electric power transmission line assembly 10 according to one aspect of the present disclosure. The electric power transmission line assembly 10 is for a motor vehicle 100. Such a motor vehicle 100 has been described with reference to Figure 1. Figure 2 will be described with reference to Figure 1 and its description.

[0034] 2 includes a plurality of AC single cables 31 arranged within a sheath 38 and electrically insulated from one another. These AC single cables 31 are made of, for example, copper and each has a circular cross section. The sheath 38 is electrically insulating and is made of, for example, plastic.

[0035] The power transmission line assembly 10 includes an AC connector 33 that can be connected to the AC cable 30. The AC connector 33 is configured to connect the power transmission line assembly 10 to an AC interface 160. The AC connector 33 includes a plug and a corresponding socket (not shown). The power transmission line assembly 10 includes another AC connector 33 at an end (not shown) of the AC cable 30 that is configured to connect the power transmission line assembly 10 to the energy storage device 150. Thus, the energy storage device 150 can be connected to the charging socket 160 for transmission of alternating current AC via the AC connector 33 and the AC cable 30.

[0036] As shown in Fig. 2, the DC cable 20 is configured to be conductively fastened to the DC interface 120 by a threaded connection 24 having a plurality of screws 23. Such threaded connection 24 will be described in more detail with reference to Fig. 4. At an end of the DC cable 20 not shown in Fig. 2, the DC cable 20 is configured to be conductively fastened to the energy storage device 150 by a threaded connection 24 having another plurality of screws 23. Thus, the energy storage device 150 can be connected to the charging socket 160 for transmitting direct current (DC) via the threaded connection 24 and the DC cable 20. The DC cable 20 will be described in more detail with reference to Fig. 3.

[0037] As shown in FIG. 2, the power line assembly 10 includes a ground 40 for connection to the vehicle 100 .

[0038] Figure 3 shows a schematic cross section of the DC cable 20 of the power transmitter assembly 10 according to one embodiment of the present disclosure. Figure 3 shows the power transmitter assembly 10 described with reference to Figures 1 and 2. Figure 3 will be described with reference to Figures 1 and 2 and their descriptions.

[0039] FIG. 3 shows four different embodiments of the DC cable 20 (FIGS. 3(A), 3(B), 3(C) and 3(D)).

[0040] According to Fig. 3, the DC cable 20 includes two single DC cables 21, 22 for conducting direct current (DC). Each of the single DC cables 21, 22 includes an aluminum profile 25 as a conductor for conducting direct current (DC). The aluminum profile 25 is a flat profile 26. That is, each of the aluminum profile 25 has two main extension directions (here, the horizontal direction and the direction into the paper) and also has another extension direction (here, the vertical direction). The aluminum profile 25 is more expanded in the main extension direction than in this other extension direction. The aluminum profile 25 can be manufactured by, for example, rolling and forming.

[0041] The aluminum profiles 25 of the DC single cables 21, 22 are arranged parallel to each other. The main extension directions of the aluminum profiles 25 define the planes in which the aluminum profiles 25 have their widest surfaces. At this time, the aluminum profiles 25 of the DC single cables 21, 22 are arranged so that their widest surfaces are parallel to each other.

[0042] The DC cable 20 includes an insulating portion 28. The insulating portion 28 is provided around the DC single cables 21 and 22 and between the DC single cables 21 and 22. The insulating portion 28 is electrically insulating and is made of, for example, plastic.

[0043] Figure 3(B) explains the differences from Figure 3(A). According to Figure 3(B), the DC cable 20 has an insulating portion 28. The insulating portion 28 is provided around each of the single DC cables 21 and 22. A gap is provided between the insulating portions 28 of the single DC cables 21 and 22. This gap allows heat to be more efficiently carried away from the single DC cables 21 and 22 to the surrounding area.

[0044] Fig. 3(C) explains the difference from Fig. 3(A). According to Fig. 3(C), the DC cable 20 includes a heat storage paste 27 disposed between the DC single cables 21 and 22.

[0045] The heat storage paste 27 has a larger heat capacity than aluminum and is provided to absorb the heat generated in the DC cable 20 during charging. This reduces the temperature rise of the DC cable 20, which can be advantageous for charging.

[0046] The thermal storage paste 27 has a paste-like consistency, which allows it to be effectively positioned over the contours of the DC cable 20, which may be curved (see FIG. 2).

[0047] The heat storage paste 27 contacts each of the single DC cables 21, 22 on one of their largest surfaces to enable efficient transfer of heat from each of the single DC cables 21, 22 to the heat storage paste 27. The heat storage paste 27 is electrically insulating and forms an electrical insulation between the single DC cables 21, 22.

[0048] Figure 3(D) explains the difference from Figure 3(C). According to Figure 3(D), the sheath 28 is provided to encase the heat storage paste 27. The heat storage paste 27 is not in direct electrical contact with the DC single cables 21 and 22. This allows the use of a conductive heat storage paste 27.

[0049] Figure 4 schematically illustrates a threaded connection 24 of a power transmitter assembly 10 according to one embodiment of the present disclosure. Figure 4 illustrates the power transmitter assembly 10 described with reference to Figures 1 to 3. Figure 4 will be described with reference to Figures 1 to 3 and their accompanying descriptions.

[0050] The DC cable 20 is conductively fastened to the DC interface 120 by a screw connection 24 with two screws 23. Each screw 24 is now positioned perpendicular to one of the aluminum sections 25 in the installed state, so that each screw 24 is in electrical contact with exactly one of the aluminum sections 25.

[0051] Each aluminum profile 25 has a first through hole 29a and a second through hole 29b for receiving one of the screws 24. The through holes 29a, 29b of each aluminum profile 25 have different diameters D. In other words, each aluminum profile 25 has a through hole 29a with one diameter D that is larger than the diameter D of the other through hole 29b. A tolerance range is provided for the through holes 29b with the smaller diameter D, that is, the diameter D of each of the smaller through holes 29b is slightly larger than the diameter D of the screw 24. In this case, the diameter D of each of the smaller through holes 29b is selected to ensure a reliable mechanical and electrical connection between the single DC cables 21, 22 and the charging socket 160. The diameter D of each of the larger through holes 29a is selected to eliminate contact of the screw 24 with each of the single DC cables 21, 22 in the larger through holes 29a. For example, the larger through hole 29 a has a diameter D that is equal to a multiple of the diameter of the screw 24 .

[0052] The screws 24 are guided vertically through the DC cables 21, 22 so that each screw 24 connects to only one DC cable 21, 22. The two screws 24 each contact a different DC cable 21, 22. Both screws 24 are guided through both DC cables 21, 22, but each contact only one DC cable 21, 22. The connection between the screws 24 and the DC cables 21, 22 for electrical connection or disconnection is achieved by a small or large gap between the screws 24 and the DC cables 21, 22, i.e., by different diameters D of the through holes 29a, 29b.

[0053] The power transmission line assembly 10 is provided with a cover cap 41 or contact cap. The cover cap 41 is electrically insulating. The cover cap 41 can protect the screw connection 24 from mechanical influences. [Explanation of symbols]

[0054] 10 Transmission Line Assembly 20 DC cable 21 DC single cable 22 DC single cable 23 Threaded connection 24 screws 25 Aluminum Extrusions 26 Flat profile 27 Heat storage paste 28 Insulation 29a First through hole 29b Second through hole 30 AC cable 31 AC single cable 33 AC connector 38 Sheath 40 Earth 41 Cover cap 100 Automobiles 120 DC interface 130 AC interface 150 Energy Storage Device 160 charging socket 200 charging stations AC alternating current DC direct current D diameter

Claims

1. 1. A power transmission line assembly (10) for conducting electrical current from a charging socket (160) of a motor vehicle (100) to an energy storage device (150) of the motor vehicle (100), comprising: a DC cable (20) comprising two DC single cables (21, 22) for conducting direct current (DC) from the DC interface (120) of said charging socket (160) to said energy storage device (150); an AC cable (30) having a plurality of AC single cables (31) for conducting alternating current (AC) from an AC interface (130) of the charging socket (160) to the energy storage device (150), a power transmission line assembly, characterized in that each of said DC single cables (21, 22) comprises an aluminium profile (25) as a conductor for conducting direct current (DC);

2. 2. The power transmission line assembly (10) according to claim 1, wherein the aluminum sections (25) of the single DC cables (21, 22) are arranged parallel to each other.

3. 3. The electric power transmission line assembly (10) according to claim 1 or 2, wherein the aluminum profile (25) is a flat profile (26).

4. 4. The power transmission line assembly (10) according to claim 1, wherein a heat storage paste (27) is disposed between the DC single cables (21, 22).

5. A motor vehicle (100) having a charging socket (160), an energy storage device (150), and the power transmission line assembly (10) of any one of claims 1 to 4.

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