Inner contour tube

Abstract

The invention relates to an electrical line and an electrical cable having at least one electrical line of this type. One embodiment of the electrical line (10) has: at least one electrical conductor (16); and a cooling line (12) which circumferentially surrounds the at least one electrical conductor (16). A cooling medium (14) can be conducted in an interior of the cooling line (12), and the cooling line (12) has at least one inner contour (18) which protrudes into the interior and is formed on an inner side of the cooling line (12).

Description

[0001] inner contour hose

[0002] The invention relates to an electrical conductor, in particular for a charging cable, and an electrical cable, in particular a charging cable for example for electric vehicles, with at least one such electrical conductor.

[0003] Electric vehicles are typically charged at charging stations using charging cables. These cables are usually connected to the charging station at one end and can be connected to an electric vehicle for charging. The maximum charging power for an electric vehicle depends on several factors, such as the charging power of the electric vehicle and the charging station. Besides the electric vehicle and charging station, other factors influencing the maximum charging power include the temperature and the battery's state of charge.

[0004] Besides the battery temperature, the charging cable temperature also plays a role in the charging power and thus the charging time. Generally, charging systems designed for high charging power generate significant heat. This can be particularly problematic with charging cables that have smaller cross-sections. These smaller cross-sections would typically not be able to transmit the necessary power because they would heat up too quickly under the current load. This could lead to exceeding the maximum permissible conductor temperature according to EN 50620 or IEC 62893 after a certain period. The charging process might then have to be interrupted or aborted. Furthermore, the cables' lifespan would be reduced.

[0005] Furthermore, the surface temperature of the charging cable could also rise above the limit specified in IEC 117 and potentially lead to injuries to the user upon contact with or handling of the charging cable. The heat energy generated during charging must therefore be dissipated, for example, by means of a cooling line. One current approach to this is to integrate hoses into the cable construction, which extract the heat from the cable. The medium in the cooling hoses can be gaseous or liquid. Conductive liquids (e.g., a water-glycol mixture) are generally used more frequently for cooling in the thermal management process.

[0006] Currently available cooling solutions for charging cables are not optimal in terms of cooling performance. To improve cooling efficiency, the state of the art includes direct cooling, in which the heat-generating conductor elements come into direct contact with a cooling medium, for example, being directly surrounded by a cooling medium without being separated from it by a cooling hose or similar device. With directly cooled charging cables, as well as with other cables, it is advantageous if the conductor within the cable is positioned as centrally as possible within the cooling hose to avoid direct contact with the hose wall. If the conductor touches the hose wall, less cooling occurs in that area. A hot strip can form along the hose wall. This transfers heat into the cable structure and leads to elevated temperatures.

[0007] Currently, concentricity in directly cooled charging cables is ensured by means of a so-called helix wire (spiraled stranded wire around a copper cable in the core). This helix wire presents many problems in assembly, manufacturing, and the insertion of the copper cable.

[0008] Therefore, there is a need for alternative solutions.

[0009] EP 4 147 903 Al relates to a charging cable for an electric vehicle, wherein the charging cable comprises a cooling hose extending longitudinally and designed to transport a cooling medium through the charging cable, an earthing conductor extending longitudinally substantially parallel to the cooling hose and serving as a ground, several current wires extending longitudinally and designed to conduct positive and / or negative direct current, and an outer layer extending longitudinally and surrounding the cooling hose, the earthing conductor, and the several current wires. Each of the several current wires comprises a conductor and insulation surrounding the conductor. Several spacers are arranged between the conductor and the insulation such that a cooling channel is formed between the conductor and the insulation.

[0010] There is a need for improved approaches to electrical wiring and electrical cables with such conductors. In particular, there is a need for an electrical wire in which contact between an electrical conductor and a cooling line is avoided as reliably as possible, as well as for an electrical cable with at least one such electrical conductor. According to a first aspect of the invention, an electrical wire, particularly for a charging cable, for example for electric vehicles, is provided. The electrical wire has at least one electrical conductor. The electrical wire has a cooling line surrounding the at least one electrical conductor. The cooling line can, in particular, have a cooling hose or be designed as a cooling hose. A cooling medium can be carried in an interior space of the cooling line. The cooling line has at least one internal contour.The at least one inner contour projects into the interior. The at least one inner contour is formed on an inner surface (inner wall) of the cooling pipe.

[0011] In a first state of the electrical line, the at least one inner contour is spaced apart from the at least one electrical conductor. In other words, the at least one electrical line is not in contact with (i.e., does not touch) the at least one inner contour in the first state. Simultaneously, the cooling line is spaced apart from the at least one electrical conductor. The first state of the electrical line may include or involve a state in which the electrical line is, in particular, at least substantially undistorted.

[0012] In at least one second state of the electrical conductor, the at least one electrical conductor comes into contact with the at least one inner contour. In this second state, the at least one electrical conductor comes into contact with the at least one inner contour in such a way that the inner contour prevents contact between the at least one electrical conductor and the cooling conductor. In other words, the contact of the at least one inner contour with the at least one electrical conductor prevents contact between the at least one electrical conductor and the cooling conductor. Specifically, the contact of the at least one inner contour with the at least one electrical conductor prevents contact between the at least one electrical conductor and the inner surface (inner wall) of the cooling conductor.The inner surface (inner wall) of the cooling line can be considered, in cross-section, as a shape that at least almost continuously follows the shape of the cooling line, for example, an almost circular shape around the center of the cooling line. The inner surface (inner wall or inner surface) of the cooling line can be considered, in particular, the section of the cooling line that directly borders the interior of the cooling line. Even if the at least one inner contour is integrally formed with the inner surface of the cooling line, for example, it can be understood as a different element than the cooling line itself and, in particular, its inner surface. Therefore, contact between the at least one electrical conductor and the cooling line can be understood as contact with areas / sections of the cooling line other than / excluding the at least one inner contour.Accordingly, contact of the at least one electrical conductor with the cooling line can be understood as contact with areas / sections of the cooling line other than the at least one inner contour. Similarly, contact of the at least one electrical conductor with the inside of the cooling line can be understood as contact with areas / sections of the inside of the cooling line other than / excluding the at least one inner contour. In other words, contact of the at least one electrical conductor with the inside of the cooling line can be understood as contact with areas / sections of the inside of the cooling line other than the at least one inner contour.

[0013] The at least one inner contour can have a lower thermal conductivity than the at least one electrical conductor. In particular, the at least one inner contour can be almost non-conductive. This can, for example, result in less efficient heat conduction through the at least one inner contour. Consequently, the heat is more likely to be transferred to an existing cooling medium than to a conductor core.

[0014] The at least one second condition of the electrical conductor can arise from various causes / circumstances. For example, the at least one second condition may involve a situation in which the electrical conductor is at least partially bent.

[0015] There can be several second states in which the electrical conductor is bent to varying degrees and / or at different points. In each of these second states, the at least one electrical conductor comes into contact with the at least one inner contour in such a way that the at least one inner contour prevents contact between the at least one electrical conductor and the cooling conductor. In addition to the at least one second state, there can be further states in which the electrical conductor is at least partially bent, but the at least one electrical conductor does not come into contact with the at least one inner contour.In these further states, the at least one inner contour does not need to prevent contact between the at least one electrical conductor and the cooling line, because in these further states there would be no contact between the at least one electrical conductor and the cooling line without the at least one inner contour.

[0016] The at least one electrical conductor is arranged within the interior of the cooling line. The at least one electrical conductor can be exactly one conductor, meaning it can be configured as a single conductor within the cooling line, such as a cooling hose. The at least one electrical conductor can be a stranded conductor. A stranded conductor, also called a strand, can consist of multiple individual wires. The strand can have multiple (uninsulated) conductors or wires, or consist of multiple (uninsulated) conductors or wires. The at least one electrical conductor can also be a solid conductor.Regardless of the precise configuration of the at least one electrical conductor, it may be a non-insulated conductor or be designed as a non-insulated conductor. "Non-insulated" (alternatively "uninsulated") in relation to the at least one non-insulated conductor means that it is not electrically insulated.

[0017] A cooling line can generally be a body extending longitudinally along an electrical conductor and / or an electrical cable carrying the conductor. The body may have a cavity in which a cooling medium (which can also be called a coolant) can circulate. The cooling line is not limited to a specific cross-section. For example, it can have a round, square, or oval cross-section. It can take the form of a hollow cylinder, but is not limited to this shape. The cooling line extends, for example, along the entire length of the electrical conductor and / or an electrical cable carrying the conductor. The cooling line can be flexible, i.e., not rigid. For example, it can be elastically bendable or deformable.The cooling line of the electrical conductor can include a cooling hose or be designed as a cooling hose. The at least one electrical conductor is coolable by the cooling medium and is actually cooled when the cooling medium is present. The cooling medium can be, for example, liquid or gaseous. For instance, if the at least one electrical conductor is designed as a non-insulated conductor, the non-insulated conductor can be cooled directly via a thermally conductive connection using the cooling medium that can be or is carried in the cooling line. The at least one electrical conductor can be in direct contact with the cooling medium of the at least one electrical conductor. This is also referred to herein as "direct cooling." In this case, the cooling medium can be electrically insulating (i.e., non-conductive).Due to the direct contact between the cooling medium and the at least one electrical conductor, the at least one electrical conductor can be cooled particularly efficiently.

[0018] The cooling line of the at least one electrical conductor can be designed to be at least nearly impermeable or sealed against the cooling medium. For this purpose, the cooling line can be completely closed in the longitudinal and / or circumferential direction. Alternatively, the cooling line can have a sheathing, creating an internal cavity for the cooling medium. This sheathing can be designed to be at least nearly impermeable or sealed against the cooling medium. In this way, the cooling medium can circulate within the cavity, but is almost entirely prevented from penetrating the sheathing.

[0019] The at least one electrical conductor can, in the first state of the electrical line, be arranged at least partially, at least nearly centrally, within the cooling line. For example, the at least one electrical conductor can, in the first state of the electrical line, be arranged along its entire length at least nearly centrally within the cooling line. Due to the at least nearly central arrangement of the at least one electrical conductor within the cooling line, contact between the at least one electrical conductor and the cooling line does not occur in the first state of the electrical line.

[0020] The at least one electrical conductor can, in at least one second state of the electrical conductor, be arranged at least partially acentrically within the cooling line. Due to this partially acentric arrangement, the at least one electrical conductor could potentially come into contact with the cooling line in this second state. However, this contact is reliably prevented by the at least one inner contour.

[0021] The at least one inner contour can have various shapes. For example, the at least one inner contour can have a knobby, angular, or round cross-section. Regardless of the exact shape, the at least one inner contour is formed integrally with the cooling pipe.

[0022] The cooling line material can be a high-viscosity material or be made of a high-viscosity material. This high-viscosity material can be cross-linked polyethylene (PE) or be made of cross-linked polyethylene. The cross-linked polyethylene can be XLPE or VPE.

[0023] Viscosity is generally understood to mean the resistance or thickness of fluids, such as liquids and gases. "Viscous" and "thick" can describe the property of a substance to have high internal friction and thus be less fluid. Viscosity can be seen as a measure of this resistance. The higher the viscosity, the thicker the substance. Viscosity can result in part from attractive forces between particles of a fluid (cohesion). In less viscous fluids, the momentum flow within the fluid can also play a role. The higher the viscosity, the thicker (less fluid) the fluid; the lower the viscosity, the thinner (more fluid) it is. In other words, high viscosity (high-viscosity) means lower fluidity, low viscosity (low-viscosity) means better fluidity.

[0024] A highly viscous material, such as a highly viscous fluid, is a substance that exhibits above-average, for example, exceptionally high, viscosity. This means that this fluid is more viscous than average and / or has significantly higher internal friction than low-viscosity or moderately fluid materials, such as low-viscosity or moderately fluid materials, such as low-viscosity or moderately fluid materials. Highly viscous fluids tend to move more slowly and flow with greater difficulty. This can manifest as a thick, sticky consistency that differs (significantly) from that of low-viscosity fluids. For example, fluids, such as liquids, with a kinematic viscosity of up to 100 mm³ / h can be considered highly viscous. 2Materials with a viscosity of / s or higher are considered highly viscous. However, the viscosity of materials depends on the test temperature. As the test temperature decreases, the viscosity increases (the more viscous the material). Therefore, the limit for viscosity is usually temperature-dependent.

[0025] The material of the cooling line can have a melt flow index from 0.5 to 35 g / 10 min inclusive, in particular a melt flow index from 0.5 to 25 g / 10 min inclusive, e.g., a melt flow index from 4 to 23 g / 10 min inclusive. Such a melt flow index can be referred to as a low melt flow index. According to a first example, the melt flow index can be in the range of 3 to 17 g / 10 min inclusive. According to a second example, the melt flow index can be in the range of 0.5 to 15 g / 10 min inclusive. A test method according to DIN EN ISO 1133 can be used to determine the melt flow index. The melt flow index can be determined, in particular, at values ​​of 190°C and 21.6 kg. The melt flow index is usually referred to as the Melt Flow Index (MFI) in English.

[0026] The cooling line material can be a low-viscosity material or be made of a low-viscosity material. The low-viscosity material can be a polyamide or a TPE-E (thermoplastic polyester elastomer). A low-viscosity material can be understood to be, in particular, a material with a lower viscosity than a high-viscosity material. A low-viscosity material can have a lower viscosity than a material with average viscosity. A high-viscosity material can have a higher viscosity than a material with average viscosity. In a first example, using a TPE-E, the melt flow index can be approximately 10 g / 10 min. In a second example, using a polyamide, the melt flow index can be approximately 60 g / 10 min.The melt flow index according to the two preceding examples can be described as a high melt flow index. The melt flow index can be determined according to DIN EN ISO 1133. The melt flow index can be determined, in particular, at values ​​of 230°C and 2.16 kg. The melt flow index of the low-viscosity material can be higher than that of the high-viscosity material. The electrical conductor can have at least one filler element. The at least one filler element can be arranged or provided in the at least one inner contour. For example, one filler element can be arranged or provided in each of the at least one inner contour. The at least one filler element can increase the tensile strength of the at least one inner contour. The material of the filler element can be selected such that it is more durable than the material of the cooling conductor, e.g.,of the cooling hose, exhibiting higher thermal stability and / or higher tensile strength. The at least one filling element may be provided, in particular, if a low-viscosity material is used for the cooling line. The at least one filling element may be omitted, for example, if a high-viscosity material is used for the cooling line.

[0027] According to a first conceivable embodiment, the at least one inner contour can be spiraled or helically wound along the inside (inner surface) of the cooling line relative to the at least one electrical conductor in the longitudinal direction of the at least one electrical conductor. The lay length of the spiraling can be between 30 mm and 200 mm. A spiraled design of the at least one inner contour can be particularly advantageous when only a single inner contour or exactly two inner contours are provided.

[0028] According to a second conceivable embodiment, the at least one inner contour can run parallel to the at least one electrical conductor in the longitudinal direction of the at least one electrical conductor on the inner surface of the cooling line. A parallel configuration can be advantageous, for example, if three or more inner contours are provided. Regardless of the exact configuration, the at least one inner contour can have at least three inner contours or be designed as at least three inner contours. If two or more inner contours are provided, adjacent inner contours of the two or more inner contours can each have an equal distance from each other in the circumferential direction of the electrical conductor or the cooling line.

[0029] A diameter of the at least one electrical conductor can be chosen based on: (i) a diameter of the inside / inner surface / inner wall of the cooling conduit, (ii) a minimum distance of contact points of the at least one electrical conductor on the at least one inner contour to the inside / inner surface of the cooling conduit, (iii) a distance between two contact points of an inner contour and (iv) a number of the at least one inner contour.

[0030] In particular, the diameter of the at least one electrical conductor can be chosen such that it meets the following condition: di_: Diameter of the electrical conductor dti: Diameter of the inside of the cooling pipe n: Number of at least one inner contour h: Minimum distance of contact points to the inside of the cooling pipe b s : Distance between two points of contact of an inner contour.

[0031] This condition ensures that the at least one electrical conductor does not touch the inside / inner wall of the cooling line. It also ensures that the at least one electrical conductor is movable within the cooling line and is not trapped between two inner contours. When designed according to the above condition (formula), the inner contours can run without spiraling in the longitudinal direction of the hose, particularly parallel to each other, or spirally.

[0032] According to a second aspect of the invention, an electrical cable, in particular a charging cable, for example for electric vehicles, is provided. The electrical cable has at least one electrical conductor according to the first aspect. The electrical cable has at least one outer sheath that completely surrounds the at least one electrical conductor. The at least one electrical conductor can be an electrical charging conductor or be configured as such. The at least one electrical conductor can be a power line or transmission line for electricity or be configured as such. A power line or transmission line for electricity heats up considerably due to the, in particular high, current flow. In particular, the at least one electrical conductor can be one or more copper conductors or be configured as one or more copper conductors.The current-carrying properties of the electrical conductor increase through its training as a copper conductor.

[0033] The at least one electrical conductor can be configured as a plurality of electrical conductors, in particular as exactly two or exactly four electrical conductors. Each plurality of electrical conductors can have at least one electrical conductor. Each plurality of electrical conductors can have a cooling line in which a cooling medium can be carried. The respective at least one electrical conductor can be in thermally conductive contact with the associated cooling line in such a way that the respective at least one electrical conductor can be cooled by the cooling medium of the associated cooling line.

[0034] If two electrical conductors are provided, a first conductor can be located inside one cooling duct, and a second conductor can be located inside another cooling duct. At least one of the electrical conductors can form a DC conductor. The DC conductor serves to transmit direct current in the charging cable. For example, the DC conductor can be one of the two DC conductors required for transmitting direct current in a charging cable. The first conductor can be a positive DC conductor, and the second conductor can be a negative DC conductor. This enables efficient DC charging of electric vehicles using the charging cable.

[0035] For example, the charging cable can transmit currents of one hundred amperes (A), or several hundred amperes, for example up to approximately 3 kA, without any significant heating of the charging cable – provided the cooling system is functioning correctly. This means that a high power output can be transferred from the charging station to the vehicle (and thus to the battery).

[0036] The electrical cable can also include a control line, a sensor line, a signal line, a protective line, a data line, and / or an auxiliary power line. Other line types are also conceivable. Two or more of the different lines / line types can be flexibly combined within the charging cable.

[0037] The cooling line of the at least one electrical conductor can be configured as a supply line or a return line for the cooling medium. Thus, the cooling line of one of the at least one electrical conductor can be configured as a supply line, and the cooling line of another of the at least one electrical conductor can be configured as a return line, or vice versa. This allows the cooling medium to circulate completely within the charging cable. The supply line can also be referred to as the outflow line. The return line can also be referred to as the return line. For example, the supply line can be a supply line to a connector cooling system, and the return line can be a return line for cooling fluid from the connector cooling system. The supply line can be understood as a channel or hose leading away from a location with high fluid pressure. The return line can be understood as a channel or hose leading to a location with low fluid pressure.The cooling fluid can be transported to the surface via the flow line and back via the return line.

[0038] Alternatively, the cooling line of at least one electrical line can be configured as the supply line, and an additional cooling line located in the charging cable can be configured as a return line, or vice versa. Similarly, the cooling medium, e.g., a cooling fluid, can be transported through the respective cooling lines, for example, by pumping, and exit at the end.

[0039] The at least one electrical conductor may also have insulation. The insulation may surround the cooling conductor of the at least one electrical conductor and the at least one electrical conductor. The insulation may, for example, be in direct contact with the cooling conductor of the at least one electrical conductor, such as the outer side / surface of the cooling conductor.

[0040] The charging cable has an outer sheath. This sheath protects the cable and can therefore also be called a protective jacket. It holds the individual wires together and protects them from abrasion and environmental influences. The outer sheath can also provide thermal insulation. This insulation is particularly advantageous when the cooling medium is a coolant fluid. It prevents the coolant from freezing, for example. The section between the outer sheath and the at least one electrical wire can serve as a supply or return line for the coolant. In typical applications, the charging cable is designed as a DC charging cable. A DC charging cable can, for example, have two or four DC charging wires.The charging cable can additionally have one or more conductors or wires for charging with alternating current (AC). By means of the one or more AC conductors, the charging cable can also be used for AC charging of an electric vehicle. For example, the charging cable can be a combination cable that enables both DC and AC charging. Examples of possible configurations include three conductors (conductor, neutral, ground), five conductors (three conductors, neutral, ground), or seven conductors (three conductors, neutral, ground, and two conductors for communication between a power source, e.g., a charging station, and a power sink, e.g., an electric vehicle battery or an electric vehicle itself).

[0041] According to a third aspect, a charging system can be provided. The charging system can include an electrical cable designed as a charging cable, as described in the first aspect, an end connection, and a plug. The end connection can have a coolant supply that can introduce the coolant into at least one of the lines, more precisely into a cooling line of at least one of the lines, and draw it from another of the lines, more precisely from a cooling line of another of the lines. The plug is designed to be connected to the vehicle. In addition to the electrical contacts for electrically connecting the existing electrical conductors to the vehicle's lines, the plug can have a fluid return line that can draw the coolant from the cooling line of one line and direct it to the cooling line of the other line.

[0042] Furthermore, according to a fourth aspect, a charging station can be provided with the electrical cable designed as a charging cable according to the second aspect or with a charging system according to the third aspect.

[0043] Although some of the aspects described above have been described in relation to the electrical conductor according to the first aspect and / or the electrical cable according to the second aspect, these aspects can also be implemented in a corresponding manner in the charging system according to the third aspect and / or in the charging station according to the fourth aspect, and vice versa. The present invention will be further explained with reference to the figures. These figures schematically depict:

[0044] Figure 1a shows a cross-section of an embodiment of an electrical conductor in a first state;

[0045] Figure 1b shows a cross-section of an embodiment of an electrical conductor in a second state;

[0046] Figure 2 shows a cross-section of a variant of the embodiment of an electrical conductor from Figures 1 and 1b;

[0047] Figure 3 shows a cross-section of a variant of the embodiment of an electrical conductor from Figures 1a and 1b;

[0048] Figure 4a shows a cross-section of a first embodiment of an electrical cable;

[0049] Figure 4b shows a cross-section of a second embodiment of an electrical cable; and

[0050] Figure 4c shows a cross-section of a third embodiment of an electrical cable.

[0051] Specific details are set forth below, without limitation, to provide a complete understanding of the present invention. However, it is clear to a person skilled in the art that the present invention can be used in other embodiments that may differ from the details set forth below. Furthermore, the figures serve only to illustrate embodiments. They are not to scale and are intended only to exemplify the general concept of the invention. For example, features included in the figures should by no means be considered necessary components. Furthermore, an electrical conductor is described below primarily as a charging conductor, but is not limited to this. Similarly, an electrical cable is described below primarily as a charging cable, particularly for electric vehicles, but is not limited to this.Figure 1a shows a first embodiment of an electrical line 10. The electrical line 10 can, in particular, be configured as a charging line for a charging cable for electric vehicles, as will be described in more detail below. The electrical line 10 has an electrical conductor 16. The electrical line 10 also has a cooling line 12 that surrounds the electrical conductor 16. The cooling line 12 can, in particular, be configured as a cooling hose and can therefore also be referred to as a cooling hose 12. A cooling medium 14 can be guided in an interior space of the cooling line 12. The cooling line 12 has at least one internal contour 18 formed on its inner surface. In the example shown in Figures 1a and 1b, four internal contours 18 are provided as an example and formed on the inner surface of the cooling line 12.The four exemplary inner contours 18 each project into the interior space. As can be seen in Figure 1a, the inner contours 18 are formed integrally with the cooling line 12, or, in other words, integrally molded onto the cooling line 12. The knobby shape of the inner contours 18 shown in Figure 1a is purely exemplary, and other shapes are conceivable and possible, for example, an angular, rectangular, or triangular shape. Adjacent inner contours 18 of the four inner contours 18 are spaced at least nearly equally far apart along the circumference of the cooling line 12. In the example shown, the spacing is 90 degrees.

[0052] Figure 1a shows a first state of the electrical conductor 10. In this first state, the electrical conductor 10 can be in a state that is at least substantially straight. In this first state, the inner contours 18 of the electrical conductor 10 are spaced apart from the electrical conductor 16. In this first state, the electrical conductor 16 is arranged at least partially, and at least nearly centrally, within the cooling line 12. For example, in this first state, the electrical conductor 16 is not in contact with the cooling line 12 along its entire length.

[0053] Figure 1b shows a second state of the electrical conductor 10. In this second state, the electrical conductor 10 can be at least partially bent. In this second state, the electrical conductor 16 is arranged acentrically in the cooling line 12, at least in some sections. Figure 1b shows a cross-section of such a section in which the electrical conductor 16 is arranged acentrically in the cooling line 12. In this second state, the electrical conductor 16 comes into contact with a subset (two in Figure 1b) of the four inner contours 18. The electrical conductor 16 is prevented or blocked from contacting the cooling line 12 by the contact with the two inner contours 18.In other words, in the second state the electrical conductor 16 comes into contact with a subset (two in Figure 1b) of the four inner contours 18 in such a way that the two inner contours 18 prevent contact between the at least one electrical conductor 16 and the cooling line 12.

[0054] The inner contours 18 can be spiraled or helically formed on the inside of the cooling line 12 relative to the electrical conductor 16 in the longitudinal direction of the electrical conductor 16. A length of helical twist between 30 mm and 200 mm is suitable. With a suitable design, particularly with a suitable helical twist, a single inner contour 16 can reliably block contact between the electrical conductor 16 and the cooling line 12.

[0055] An alternative to spiraling is realized in Figure 1a (as can be seen from the perspective view). Here, the inner contours 18 run parallel to the electrical conductor 16 and the cooling line 12 in the longitudinal direction of the electrical conductor 16 on the inside of the cooling line 12. With a parallel arrangement of the inner contours 18 relative to the electrical conductor 16, two or more, in particular at least three, inner contours 18 reliably block contact between the electrical conductor 16 and the cooling line 12 if suitably designed.

[0056] Figure 2 shows a variant of the embodiment shown in Figures 1a and 1b. In this variant, for example, a low-viscosity material can be used for the cooling hose 12 and / or the at least one inner contour 18 described below. The low-viscosity material can be, for example, a polyamide or a TPE-E. When using a TPE-E, the melt flow index can be approximately 10 g / 10 min. When using a polyamide, the melt flow index can be approximately 60 g / 10 min. According to this variant, the electrical conductor 10 has, for example, a filler element 19 in each of the inner contours 18. Thus, four filler elements 19 are provided by way of example. Alternatively, it is conceivable to provide a filler element 19 in only a subset of the four inner contours 18. The at least one filler element 19 can increase the tensile strength of the at least one inner contour 18 (in the example of Figure 2: of the four inner contours 18).For example, when the cooling line 12 is designed as a cooling hose 12, it is often produced with (very) low-viscosity materials (e.g., made of / with thermoplastic elastomers (TPEE) or polyamides). These materials are sometimes so low in viscosity that, after leaving, for example, a die head, they sink downwards due to gravity, touch the electrical conductor 16 (e.g., made of copper), and adhere to it. Since the cooling hoses 12 are intended to have a defined flow channel for the cooling medium 14, a filler element 19 (e.g., polyethylene (PE) fibers or aramid fibers) can be introduced into the at least one inner contour (in the example of Figure 2, into all four inner contours 18). This allows a support structure to be formed in the at least one inner contour (in the example of Figure 2, into all four inner contours 18), which supports the material, e.g.,The plastic, after exiting, for example, an extrusion head, is supported sufficiently so that it can be cooled in a calibration unit of a water bath and retains its shape as it solidifies. Furthermore, the filler element 19 prevents the at least one electrical conductor 16 (e.g., made of copper) and the cooling tube 12 from touching. This prevents the at least one electrical conductor 16 (e.g., made of copper) from adhering to the cooling tube 12 and / or the inner contour 18. Thus, the cooling tube 12 can be calibrated to its nominal dimension and remains molten and calibratable in any area. If other materials are used for the at least one inner contour 18 and the cooling tube 12 (e.g., the cooling tube), the filler element(s) can be omitted, as shown by way of example in Figures 1a and 1b.

[0057] As can be seen in Figure 2, the filling elements 19 are arranged in a specific way. Each of the filling elements 19 can be arranged and configured, as shown in Figure 2, such that a diameter of the inner wall of the cooling hose 12, or an imaginary circle (since the cooling hose 12 may not be a perfect circle), intersects the filling element 19 or elements 19 on the inner wall of the cooling hose 12. Additionally or alternatively, each of the filling elements 19 can have a larger diameter than other areas / sections of the cooling hose 12 other than the at least one inner contour 18, i.e., sections of the cooling hose 12 that differ from the inner contour 18. Compared to the at least one inner contour 18, each of the filling elements 19 can have a smaller diameter.

[0058] Figure 3 shows a variant of the embodiment shown in Figures 1a, 1b, and 2. In the variant shown in Figure 3, no filling elements 19 are provided. In this variant, for example, a highly viscous material can be used as the material for the cooling hose 12 and / or the at least one inner contour 18 described below. The highly viscous material can, for example, be a cross-linked polyethylene (PE), such as XLPE or VPE. The material of the cooling hose 12 can have a melt flow index of 0.5 to 35 g / 10 min inclusive, in particular a melt flow index of 0.5 to 25 g / 10 min inclusive, e.g., a melt flow index of 4 to 23 g / 10 min inclusive. According to a first example, the melt flow index can be in a range of 3 to 17 g / 10 min inclusive.According to a second example, the melt flow index can range from 0.5 to 15 g / 10 min. Alternatively, one or more filling elements 19 can be arranged in the electrical conductor 10, more precisely in one or more of the inner contours 18. In the example shown in Figure 3, five inner contours 18 are provided and formed on the inside of the cooling conductor 12. Adjacent inner contours 18 of the five inner contours 18 are spaced at the same angular distance from each other in the circumferential direction of the cooling conductor 12, namely an angle of 72 degrees in the example shown. Figure 3 shows a second state of the electrical conductor 10 with an electrical conductor 16 that is at least partially acentric. As can be seen in Figure 3, the electrical conductor 16 contacts two adjacent inner contours 18 at a contact point P.The contact points P on the inner contours 18 prevent the electrical conductor 16 from coming into contact with the inside of the cooling line 12. Furthermore, additional contact points P, specifically two contact points P per inner contour 18, are visible, where the acentric electrical conductor 16 could potentially come into contact with the inner contours 18.

[0059] The dimensions of the electrical conductor 16, the cooling line 12, and the inner contours 18 are coordinated such that the electrical conductor 16 cannot come into contact with the inside of the cooling line 12, but only with the inner contours 18 formed on the cooling line 12. In the example shown in Figure 3, the diameter of the electrical conductor 16 is selected taking into account specific parameters. These parameters include the diameter of the inside surface of the cooling line 12, the minimum distance between the contact points P of the electrical conductor 16 on the inner contours 18 and the inside surface of the cooling line 12, the distance between two contact points P of an inner contour 18, and the number of inner contours 18.

[0060] In the following example, we assume that the electrical conductor 16 from figure

[0061] 3 is designed as a stranded conductor. Accordingly, the electrical conductor 16 is referred to as stranded conductor 16 with reference to Figure 3. Furthermore, it is assumed by way of example with reference to Figure 3 that the cooling line 12 is designed as a cooling hose. Accordingly, the cooling line 12 is referred to as cooling hose 12 with reference to Figure 3.

[0062] Taking these assumptions into account, a diameter of the stranded conductor 16 is chosen with reference to Figure 3 which satisfies the following condition: di_: Strand diameter dti: Hose inner diameter (diameter of the inside / inner surface / inner wall of the cooling hose 12) n: Number of inner contours (profile elements) 18 of any shape, which in their

[0063] The shape is consistent and arranged in the same division on the inner circumference / on the inside of the cooling hose 12. h: minimum distance of the contact points P to the geometric circle of the

[0064] Hose inner diameter dti bs : Distance between the two contact points P on an inner contour 18 (on a profile element) as arc length, where the arc center point corresponds to the hose center point (=the center point of the cooling hose 12)

[0065] The diameter of the stranded conductor 16 must be chosen to be at least large enough that, in a geometrically ideal scenario, the stranded conductor 16 has no point of contact with the inner wall of the hose (= inside of the cooling hose 12). More precisely, the diameter of the stranded conductor 16 must be chosen to be at least large enough that, in a geometrically ideal scenario, the stranded conductor 16 has no other point of contact with the inner wall of the hose (= inside of the cooling hose 12) except for the points of contact P on the inner contours 18. The geometrically ideal scenario can be one in which the stranded conductor 16 simultaneously touches two inner contours / contour elements 18 of the inner wall of the hose (= inner hose wall) according to the formula / condition shown above.In other words, the diameter of the wire must be chosen to be at least large enough that, in a geometrically ideal scenario, it has a maximum of only two simultaneous contact points P on the inner contours 18, according to the formula / condition mentioned above. Figure 3 shows two contact points P, i.e., locations where the conductor 16 touches the hose 12 on the inner contours 18. If the diameter of the conductor 16 were smaller, another unwanted contact point would occur on the thinner or offset inner wall of the hose between the two existing contact points P.

[0066] Figures 4a to 4c show various exemplary embodiments of an electrical cable 100. For the purposes of this illustration, the electrical cable shown in Figures 4a to 4c is assumed to be a charging cable 100, particularly for electric vehicles, and is accordingly referred to as such. In each of the examples shown in Figures 4a to 4c, the charging cable 100 has at least one electrical conductor 10, as described by way of example in Figures 1a to 3. Furthermore, each of the charging cables 100 has an outer sheath 50 that completely surrounds the at least one electrical conductor.

[0067] Figure 4a shows an example of a charging cable 100 with two electrical conductors 10. Both electrical conductors 10 are designed similarly to the electrical conductor 10 in Figure 3. The charging cable 100 also includes an example of a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control conductor, a sensor conductor, a signal conductor, a data conductor, and / or an auxiliary voltage conductor can be provided in the charging cable 100. An outer sheath 50 surrounds the electrical conductors 10 and the protective conductor 20.

[0068] In Figure 4b, the charging cable 100 has, by way of example, two electrical conductors 10. Both electrical conductors 10 are designed, by way of example, like the electrical conductor 10 from Figure 3. The charging cable 100 also has, by way of example, a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control conductor, a sensor conductor, a signal conductor, a data conductor, and / or an auxiliary voltage conductor can be provided in the charging cable 100. The electrical charging cable also has a separate cooling hose 30. Consequently, the separate cooling hose 30 can be used as the supply line for the cooling medium 14, and the two electrical conductors 10 can be used as the return line for the cooling medium 14, or vice versa. An outer sheath 50 surrounds the electrical conductors 10, the protective conductor 20, and the cooling hose 30.

[0069] Figure 4c shows an example of a charging cable 100 with four electrical conductors 10. These four electrical conductors 10 are designed similarly to the electrical conductor 10 shown in Figure 3. The charging cable 100 also includes an example of a protective conductor 20. In addition to or as an alternative to the protective conductor 20, a control conductor, a sensor conductor, a signal conductor, a data conductor, and / or an auxiliary voltage conductor may be provided in the charging cable 100. An outer sheath 50 surrounds the electrical conductors 10 and the protective conductor 20.

[0070] Specific implementation possibilities of the electric charging cable 100 from figures 4a to 4c are now described together.

[0071] Each of the two / four electrical lines 10 has a cooling hose 12, as an example of a cooling line 12, and an electrical conductor 16. In each of the two / four electrical lines 10, the cooling hose 12 and the electrical conductor 16 run coaxially with the longitudinal axis of the respective electrical line 10 as their common axis. The two / four electrical conductors 16 can each be a solid conductor or a flexible stranded wire. The two electrical conductors 16 can each be designed as uninsulated electrical conductors. The electrical conductors 16 can each form a DC conductor. In other words, each of the electrical conductors 16 can be one of the (at least two) DC conductors of the charging cable 100 required for the transmission of direct current.For example, one or two of the four electrical conductors 16 can form a positive DC conductor, and another of the two or two of the four electrical conductors 16 can form a negative DC conductor. Thus, efficient DC charging of electric vehicles using the charging cable 100 is possible. The DC conductor(s) serve to transmit direct current in the charging cable 100.

[0072] The two / four electrical conductors 16 are each surrounded by their respective cooling hose 12. Each of the two / four cooling hoses 12 can contain and, for example, circulate a cooling medium 14. The cooling medium 14 is guided within each of the two / four cooling hoses 12. Each of the two / four cooling hoses 12 therefore surrounds its respective cooling medium 14. Accordingly, the two / four electrical conductors 16 can each be surrounded by a cooling medium 14. In this case, the cooling medium is an electrically insulating (i.e., non-conductive) cooling medium 14. The cooling hose 12 can be surrounded by insulation (insulating sheath) (not shown). For example, the insulating sheath of the respective cooling hose 12, in an undamaged state, is at least nearly impermeable to the cooling medium 14.This means that, under normal, undamaged conditions, the cooling medium 14 cannot normally leak from the cooling hose 12 into the interior of the charging cable 100. With reference to Figures 4a to 4c, it can be assumed by way of example that the electrical conductors 16 are copper conductors. Therefore, in the following, the term copper conductors 16 will also be used in reference to Figures 4a to 4c.

[0073] According to a specific embodiment, at least one of the electrical lines 10 can be configured as a supply line and at least one of the electrical lines 10 as a return line for the cooling medium 14. This is to be understood as purely exemplary, and other embodiments are possible. For example, a section 40 between an outer sheath 50 surrounding the elements of the electrical charging cable 100 and the electrical lines 10 can be configured as a supply line for the cooling medium 14 or as a return line for the cooling medium 14.

[0074] The charging cable 100 shown in Figures 4a and 4c also includes a protective conductor 20. The protective conductor 20 is shown uncooled as an example. However, the protective conductor 20 can also be cooled directly or indirectly. In addition to the electrical conductors 16 serving as power lines in the charging cable 100 and the protective conductor 20, control lines, sensor lines, other signal lines, data lines, and / or auxiliary voltage lines can be present and also cooled. This means that it is intended not only to actively cool the electrical conductors 16 serving as power lines by means of fluid cooling, but also to connect other, passive types of lines (such as control, sensor, signal, auxiliary voltage, data, and / or protective lines) in the charging cable 100 to active fluid cooling.

[0075] The charging cable 100, according to each of the three embodiments, can incorporate sensors, for example, one or more temperature sensors. This increases the safety of the charging cable 100 through targeted monitoring, such as temperature monitoring. The temperature sensors can be configured as sensor wires. The one or more temperature sensors can be cooled accordingly. A temperature sensor is designed, for example, to detect the temperature of the charging cable. The temperature sensor can be configured, for example, as a sensor wire or sensor line integrated into the charging cable, such as one woven or braided into the charging cable.

[0076] Furthermore, the charging cable 100 can optionally include AC conductors. However, the AC conductors can also be omitted. If no AC conductor is provided, the charging cable is designed as a DC charging cable. If, on the other hand, both DC conductors and AC conductors are provided, the charging cable 100 is designed as a combination charging cable for optional DC and AC charging. The charging cable 100 can have one or more conductors or wires for AC charging (abbreviated AC conductor). Using the one or more AC conductors, the charging cable 100 can be used to charge an electric vehicle using AC charging.By way of example, possible configurations include three conductors / wires (conductor, neutral conductor, ground), five conductors / wires (three conductors, neutral conductor, ground) or seven conductors / wires (three conductors, neutral conductor, ground and two conductors for communication between an energy source, e.g. a charging station, and an energy sink, e.g. a battery of an electric vehicle or an electric vehicle).

[0077] The charging cable 100, shown schematically in Figures 4a to 4c, can be used as a charging cable for electric vehicles. For this application, the charging cable 100 is designed to enable a transmission power of, for example, up to 50 kW, up to 70 kW, up to 250 kW, up to 500 kW, or up to 3 MW.

Claims

Patent claims 1. Electrical line (10), in particular for a charging cable (100), wherein the electrical line (10) comprises: - at least one electrical conductor (16); and - a cooling line (12), in particular a cooling hose, circumferentially surrounding the at least one electrical conductor (16), wherein a cooling medium (14) can be guided in an interior of the cooling line (12) and the cooling line (12) has at least one inner contour (18) projecting into the interior and formed on an inner surface of the cooling line (12); wherein, in a first state of the electrical line (10), in particular at least substantially unbent, the at least one inner contour (18) is spaced apart from the at least one electrical conductor (16), and wherein, in at least a second state of the electrical line (10), in particular at least partially bent, the at least one electrical conductor (16) comes into contact with the at least one inner contour (18) in such a way that the at least one inner contour (18) prevents contact between the at least one electrical conductor (16) and the cooling line (12).

2. Electrical line (10) according to claim 1, wherein the at least one electrical conductor (16), in the first state of the electrical line (10), is arranged at least sectionally at least nearly centrally in the cooling line (12).

3. Electrical line (10) according to claim 1 or 2, wherein the at least one electrical conductor (16) is arranged at least sectionally acentrically in the cooling line (12) in the at least one second state of the electrical line (10).

4. Electrical conductor (10) according to one of claims 1 to 3, wherein a material of the cooling conductor (12) comprises a highly viscous material, in particular a cross-linked polyethylene, or is formed from a highly viscous material, in particular a cross-linked polyethylene.

5. Electrical conductor (10) according to one of claims 1 to 4, wherein a material of the cooling conductor (12) has a melting flux index of 0.5 to 35 g / 10min, in particular a melting flux index of 0.5 to 25 g / 10min.

6. Electrical conductor (10) according to one of claims 1 to 5, wherein a material of the cooling conductor (12) comprises a low-viscosity material, in particular a polyamide or a TPE-E, or is formed from a low-viscosity material, in particular a polyamide or a TPE-E.

7. Electrical conductor (10) according to one of claims 1 to 6, wherein the electrical conductor (10) has at least one filling element (19) arranged or provided in the at least one inner contour (18).

8. Electrical conductor (10) according to one of claims 1 to 7, wherein the at least one inner contour (18) is spirally or spirally arranged on the inside of the cooling conductor (12) relative to the at least one electrical conductor (16) in the longitudinal direction of the at least one electrical conductor (16).

9. Electrical conductor (10) according to claim 8, wherein the lay length of the spiralization assumes a value between 30 mm and 200 mm.

10. Electrical conductor (10) according to one of claims 1 to 9, wherein the at least one inner contour (18) runs parallel to the at least one electrical conductor (16) in the longitudinal direction of the at least one electrical conductor (16) on the inside of the cooling conductor (12).

11. Electrical conductor (10) according to one of claims 1 to 10, wherein the at least one inner contour (18) has at least three inner contours (18) or is designed as at least three inner contours (18).

12. Electrical conductor (10) according to claim 11, wherein a diameter of the at least one electrical conductor (16) is selected based on: a diameter of the inside of the cooling conductor (12), a minimum distance of contact points (P) of the at least one electrical conductor (16) on the at least one inner contour (18) to the inside of the cooling conductor (12), a distance between two contact points (P) on the at least one inner contour (18) and a number of the at least one inner contour (18).

13. Electrical conductor (10) according to claim 11 or 12, wherein a diameter of the at least one electrical conductor (16) satisfies the following condition: di_: Diameter of the electrical conductor (16) dti: Diameter of the inside of the cooling pipe (12) n: Number of at least one inner contours (18) h: Minimum distance from contact points (P) to the inside of the cooling pipe (12) b s: Distance between two points of contact (P) of an inner contour (18).

14. Electrical cable (100), in particular charging cable, for example for electric vehicles, wherein the electrical cable (100) comprises: - at least one electrical conductor (10) according to one of claims 1 to 13; and - an outer sheath (50) surrounding at least one electrical conductor (10).

15. Electrical cable (100) according to claim 14, wherein the at least one electrical line (10) has an electrical charging line or is designed as an electrical charging line.

16. Electrical cable (100) according to claim 14 or 15, wherein the electrical cable (100) further comprises: a control line, a sensor line, a signal line, a protective line (20), a data line and / or an auxiliary voltage line.

17. Electrical cable (100) according to one of claims 14 to 16, wherein the cooling line (12) of the at least one electrical line (10) is designed as a supply line for the cooling medium (14) or as a return line for the cooling medium (14).

18. Electrical cable (100) according to one of claims 14 to 17, wherein a region (40) between the outer sheath (50) and the at least one electrical The line (10) is designed as a supply line for the cooling medium (14) or as a return line for the cooling medium (14).

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