Electrical cable

Abstract

The present invention relates to an electrical cable. One exemplary embodiment of the electrical cable (100) has at least one first core. The first core has a first electrical conductor (110). The first core also has a first insulator (120) surrounding the first electrical conductor. The electrical cable has at least one first shielding foil (130). The first shielding foil surrounds the first core. The first shielding foil (130) has at least one metal layer. The electrical cable has at least one wire shield (140). The wire shield is applied to the first shielding foil (130). The wire shield (140) has wires with a non-circular, in particular elliptical, cross-sectional shape. The wires have a first width. The electrical cable (100) also has a sheath (150). The sheath peripherally surrounds the wire shield (140). An indentation depth of the wires into the shielding foil (130) in the event of an application of force is less than a reference indentation depth of wires having a circular cross-sectional area, and having a diameter corresponding to the first width, in the event of the application of force.

Description

[0001] Electrical line

[0002] The present invention relates to an electrical line, in particular an electrical data line.

[0003] Electrical cables are used in a wide variety of fields. Examples of electrical cables include charging cables and data cables. Cables for transmitting data (or simply data cables) are used in a wide range of technical applications. A data cable is a medium for transmitting signals; that is, data is usually transmitted using signals as data signals. Transmission can be electrical (electrical data cable), optical (optical data cable), or a combination of both (usually called a hybrid cable, sometimes also a combination cable).

[0004] Electrical data cables typically have at least one core consisting of a conductor made of copper, an alloy material, or a composite material with one or more metallic components, and a cylindrical sheath made of a high-frequency-resistant plastic. Electrical data cables also usually have a foil shield and a wire shield to improve the shielding effect of the electrical data cable.

[0005] Such electrical data cables are frequently used in mechanically demanding, dynamic installation situations, such as in a vehicle door. In these environments, the mechanical forces, particularly between the shielding foil and the wire shield, lead to wear, especially of the shielding foil, and thus to a reduction in the service life of the electrical data cable. Furthermore, due to space constraints, electrical data cables are often limited to a fixed outer diameter. This fixed outer diameter of the electrical data cable specifically limits the diameter of the first conductor, which in turn determines the insertion loss and thus the signal attenuation per transmission path.

[0006] Based on this, an improved electrical conductor is to be provided. In particular, there is a need for an electrical conductor with good shielding performance in the smallest possible size and / or with the least possible use of material. The solution to this problem is achieved by the subject matter of the attached independent patent claim.

[0007] According to a first aspect, an electrical cable is provided. The electrical cable has at least one first conductor. The first conductor has a first electrical conductor. The first conductor also has first insulation surrounding the first electrical conductor. The electrical cable has at least one shielding foil. The first shielding foil surrounds the first conductor. The first shielding foil has at least one metal layer. The electrical cable has at least one wire shield. The wire shield is applied to the first shielding foil. The wire shield has wires with a non-circular, in particular elliptical, cross-sectional shape. The wires have a first width. The electrical cable also has a sheath. The sheath completely surrounds the wire shield.The indentation depth of the wires into the first shielding foil under load is less than a reference indentation depth (into the first shielding foil) of wires with a round cross-sectional area and a diameter corresponding to the first width under load.

[0008] Indentation depth describes the depth to which one of the wires, or the entire group of wires, dents or presses into the inner shielding foil when subjected to a force. A force applied here describes any force that pushes the wires towards the shielding foil. This force can, for example, be a bending of the electrical conductor. It can also be a torsion and / or a crushing of the electrical conductor. A force can originate from the sheath surrounding the wire shield. A force can also arise from applying the wire shield with a tensile stress greater than zero.

[0009] The width here describes the extent of the wires in the direction of rotation of the electrical conductor. The height of the wires describes their extent in the radial direction.

[0010] The reference indentation depth describes the depth to which wires with round cross-sections / areas, under identical force, indent or press into the inner first shielding foil. The reference indentation depth is a hypothetical value, since the wires with the round cross-sectional area are not part of the electrical conductor as described in the first aspect.

[0011] A wire screen with wires having a non-circular, especially elliptical, cross-section offers the following advantages compared to wires with a round cross-section:

[0012] - Maintaining optical coverage with reduced material usage,

[0013] - Reduction of reflections of the injected signals by reducing the contact points of the wires on the shielding foil while maintaining the same optical coverage,

[0014] - Increased durability of the shielding foil under dynamic loads by reducing the contact points of the wires on the shielding foil,

[0015] - Increased first insulation and thus attenuation with the same outer diameter due to a reduced height of the elliptical wires.

[0016] Optical coverage describes the proportion of the perimeter that is covered by the wires of the wire screen. High optical coverage generally corresponds to high shielding effectiveness. Optical coverage depends on the width of the wires, but not on their height, in addition to other criteria such as material properties.

[0017] The first electrical conductor can be a solid conductor or a stranded conductor. For example, the first electrical conductor can be a solid copper conductor. Such a conductor has very good high-frequency properties, especially in terms of attenuation. Alternatively, the first electrical conductor can be a stranded copper conductor, a solid alloy conductor, a solid copper-clad steel (CCS) conductor, a stranded CCS conductor, or a stranded alloy conductor. These conductors are more flexible than the previously mentioned solid copper conductor. Alternatively, the first electrical conductor can be a stranded CCS conductor or a stranded alloy conductor. Depending on the alloy and / or strands used, such a conductor can be even more flexible.Depending on the design and / or alloy used, solid CCS conductors or solid alloy conductors can also be very flexible. CCS conductors typically consist of a steel core coated with a thin layer of copper. The first layer of insulation can be arranged / formed in a cylindrical shape around the first electrical conductor. In other words, the first electrical conductor can be provided with a cylindrical insulating layer. The insulating layer can have a plastic dielectric or be formed entirely from a plastic. The plastics used can be selected based on their high-frequency properties. For example, polyethylene (PE), polypropylene (PP), or fluoroethylene propylene (FEP) can be used in solid or multilayered form, either as solid or foam layers.The choice between solid or foamed insulation materials can be made according to the specific mechanical requirements of the finished cable.

[0018] The first shielding foil can completely surround the first conductor. The first shielding foil can be applied directly to the first conductor. This allows the first shielding foil to hold the first conductor even when the electrical conductor is subjected to mechanical stresses or strains, such as bending or torsion. The first shielding foil can have an overlap of approximately 5% to approximately 55%, particularly approximately 20% to 35%, of the circumference of the first insulation.

[0019] An overlap area of ​​the first shielding foil offers the advantage that even under torsional or bending stress and a resulting movement of the shielding foil, complete coverage of at least one inner conductor by the first shielding foil is ensured.

[0020] The metal layer can be located on the side of the first shielding foil facing the wire screen. The metal layer can be located on the side of the first shielding foil facing away from the first conductor. The metal layer can be an aluminum layer. The metal layer can be a copper layer.

[0021] The first shielding foil can have an additional metal layer. This additional metal layer can be made of aluminum. The additional metal layer can be located on the side of the first shielding foil facing the first conductor. The first shielding foil can be made at least partially of a plastic. The first shielding foil can be made at least partially of polyethylene terephthalate (PET) or polypropylene (PP). The formation of a laminated shielding foil with at least one metallic shielding layer applied to a plastic shielding layer offers the advantage of improved shielding performance with a reduced layer thickness due to the different materials.

[0022] The first shielding foil may have a sliding layer on the side facing the wire screen. The first shielding foil may have a sliding layer on the side facing the first conductor.

[0023] Applying a sliding layer to the side of the shielding foil facing the wire screen and / or the side facing the first conductor reduces friction and thus wear of the shielding layer when in contact with the wire screen, the first conductor and / or a part of the shielding foil itself in the overlap area.

[0024] The sliding layer can be at least partially composed of or contain a fluoropolymer. The fluoropolymer can be a perfluoropolyether (PFPE) or polytetrafluoroethylene (PTFE). The sliding layer can also be at least partially composed of or contain a siloxane polymer, a silicone oil, and / or a silicone grease.

[0025] The sliding layer can have a thickness of less than 50 pm, in particular less than 25 pm. The thickness of the sliding layer here refers specifically to its extent in the radial direction.

[0026] The wire screen can be a woven screen, a woven screen, or a reversible screen. The wire screen can be designed as a woven screen, a woven screen, or a reversible screen. The wire screen can be applied directly to the first screen foil.

[0027] The wires of the wire screen can be arranged as plies of three to six wires.

[0028] The arrangement as a lattice structure results in an increase in the optical coverage of the wire screen compared to an arrangement with individual wires. The braided screen can have a braid pitch of approximately 10 mm to approximately 70 mm.

[0029] A braid pitch of less than approximately 10 mm would result in increased friction between the wires when the cable is torsioned. Conversely, a braid pitch of more than approximately 70 mm leads to a decrease in the mechanical stability of the braided shield.

[0030] The braided shield can have an angle of inclination of approximately 50° to approximately 87° to a cross-sectional area of ​​the electrical conductor. The braided shield can have an angle of inclination of approximately 3° to approximately 40° to a longitudinal axis of the electrical conductor.

[0031] A slope angle of approximately 50° to approximately 87° ensures, on the one hand, that the number of intersection points of the wires with each other in the longitudinal direction does not become too small, thus preventing a decrease in mechanical stability, and on the other hand, that the friction between the wires in the tangential direction does not increase under torsional stress.

[0032] The wires can have a width and / or height of approximately 0.1 mm to approximately 0.2 mm. The wires can have a maximum height of 0.16 mm. The wires can have a width-to-height ratio of up to 3:1.

[0033] A width-to-height ratio of no more than 3:1 offers the advantage of avoiding processing problems during wire braiding, and in particular, the twisting of the wires from a radial orientation of the height axis to a radial orientation of the width axis. Such twisting of the wires would lead to a deterioration of the transmission characteristics and a decrease in the optical coverage of the wire screen.

[0034] The wires can be made at least partially of tinned copper. The wires can be made at least partially of copper. The wires can be made at least partially of copper-clad aluminum. The wires can be made at least partially of a copper alloy. The wires can be made at least partially of a composite material with one or more metallic components. The wires can have a tensile strength of approximately 200 N / mm². 2 up to approximately 800 N / mm 2 exhibit.

[0035] The wires may have an oil-coated surface. The laminations may have an oil-coated surface.

[0036] An oil-coated surface on the wires or the laminations reduces friction between the wires.

[0037] The sheath can be applied directly to or arranged on the wire shield. Alternatively, a separating element or separating agent can be provided between the wire shield and the sheath. In other words, the electrical conductor can have a separating element or separating agent that can be provided between the wire shield and the sheath. Thus, a separating element or separating agent can be used between the wire shield, e.g., the braided shield, and the sheath as needed. The separating element can, for example, be in the form of a film or have a film component. The separating agent can, for example, be in powder form.

[0038] The shell can have a wall thickness that is at least nearly uniform or constant along its entire circumference. In other words, the shell can be designed or constructed with a uniform wall thickness across its entire circumference.

[0039] The sheath, and thus the electrical conductor, can have an outer diameter ranging from approximately 2 mm to approximately 4 mm. The first conductor can have a diameter ranging from approximately 1.5 mm to approximately 3.5 mm. The diameter of the first conductor can be approximately 80%, and in particular approximately 85%, of the outer diameter of the sheath.

[0040] The electrical cable may additionally have a second conductor. The second conductor may contain a second electrical conductor and a second layer of insulation surrounding it. The second conductor may be constructed and / or designed in the same way as the first conductor.

[0041] The first conductor and the second conductor can each have separate insulation. In other words, the first insulation and the second insulation can be separate from each other. Alternatively, the first insulation and the second insulation can be formed by a common insulation. In other words, the first and second electrical conductors can be surrounded by a common insulation.

[0042] Regardless of the precise design of the first and second insulation layers, the first and second conductors can form a conductor pair or be configured as a single conductor pair. The first and second conductors can run parallel to each other along the length of the electrical conductor. The first and second conductors can run parallel to each other along their entire length and / or along the entire length of the electrical conductor. The parallel arrangement of the first and second conductors can achieve (very) high torsional stability. The first and second conductors can be stranded together. Within the limits of technical feasibility, the two conductors can be manufactured to be at least nearly identical in their properties and / or dimensions.

[0043] The first shielding foil can completely surround the first and second conductors. In particular, the first shielding foil can be applied directly to the first and second conductors.

[0044] The electrical conductor may have a second shielding foil. This second shielding foil may have an overlap of approximately 20% to 30% along its circumference. The second shielding foil may include a metal layer. The second shielding foil may be designed as a metal layer.

[0045] The second shielding foil can be positioned between the first conductor and the first shielding foil. The second shielding foil can be positioned between the first shielding foil and the wire screen. The second shielding foil can be positioned between the wire screen and the jacket.

[0046] The metal layer can be arranged on a radially inner side of the second shielding foil. The metal layer can be designed as an aluminum layer.

[0047] The second shielding foil can have an additional metal layer. This additional metal layer can be made of aluminum. The additional metal layer can be located on a radially outer side of the second shielding foil. The second shielding foil can be made at least partially of a plastic. The second shielding foil can be made at least partially of polyethylene terephthalate (PET) or polypropylene (PP).

[0048] The second shielding film can have a sliding layer on its radially inner side. The second shielding film can have a sliding layer on its radially outer side.

[0049] According to a second aspect, an electrical cable is provided. The electrical cable has at least one first conductor. The first conductor has a first electrical conductor. The first conductor also has first insulation surrounding the first electrical conductor. The electrical cable has at least one shielding foil surrounding the first conductor. The first shielding foil has at least one metal layer. The electrical cable has at least one wire screen applied to the first shielding foil. The wire screen has wires with a non-circular, in particular elliptical, cross-sectional shape. The wire screen is designed as a braided shield. The wires of the wire screen are arranged in plies of three to six wires. The electrical cable also has a jacket that completely surrounds the wire screen.

[0050] All the aforementioned features described in relation to electrical conductivity according to the first aspect can also be realized or implemented in electrical conductivity according to the second aspect.

[0051] Further details, features, advantages, and effects of the electrical conductor described herein will become apparent from the following description of specific embodiments and from the drawings. These show:

[0052] Fig. 1 shows a schematic representation of a cross-section of the electrical conductor according to the first and second aspects;

[0053] Fig. 2a is a schematic representation of a cross-section of a wire with a non-circular cross-section;

[0054] Fig. 2b is a schematic representation of a cross-section of a wire with a round cross-section; Fig. 3a is a schematic representation of a layer of wires with a round cross-section;

[0055] Fig. 3b shows a schematic representation of a lattice with wires having a non-circular cross-section;

[0056] Fig. 3c shows a schematic representation of a layer of wires with a round cross-section penetrating the shielding foil when a force is applied;

[0057] Fig. 3d shows a schematic representation of a lattice with wires having a non-circular cross-section penetrating the shielding foil when a force is applied;

[0058] Fig. 4a a schematic representation of a cross-section of the electrical conductor according to the first and second aspects with an overlap area of ​​the shielding foil;

[0059] Fig. 4b shows a schematic representation of the first screen foil with an overlap area;

[0060] Fig. 5a shows a schematic representation of a first variant of a screen film according to the first and second aspects;

[0061] Fig. 5b shows a schematic representation of a second variant of a screen film according to the first and second aspects;

[0062] Fig. 5c shows a schematic representation of a third variant of a screen film according to the first and second aspects;

[0063] Fig. 5d shows a schematic representation of a fourth variant of a screen film according to the first and second aspects; and

[0064] Fig. 6 shows a schematic top view of a wire screen designed as a wire mesh. Fig. 1 schematically shows a cross-section of an electrical conductor 100 according to the first and second aspects. The electrical conductor has a first core which in turn has a first electrical conductor 110 and a first insulation 120 surrounding the first electrical conductor 110. The electrical conductor 100 further has a first shielding foil 130, wherein the shielding foil 130 has at least one metal layer 133.

[0065] The structure of the shielding foil 130 in various exemplary embodiments is shown in Figures 5a-5d. The metal layer 133 is not explicitly shown in Figure 1, but will be described with reference to Figures 5a-5d.

[0066] The electrical conductor 100 further comprises a wire screen 140, which in this embodiment is designed as a braided screen. The braided screen has plies 144 with four wires 141 having a non-circular cross-section. A non-plyed design of the braided screen is conceivable and feasible. The wires 141 from the embodiment shown in Fig. 1 have an elliptical cross-section by way of example, to illustrate a possible design of non-circular wires. Other non-circular designs of the wires are conceivable and feasible. In total, the braided screen in the embodiment shown here has sixteen plies 144. The eight radially outer plies extend in a first direction 45 around the screen foil 130, and the radially inner plies 144 extend in a direction 46 opposite to the first direction around the screen foil.The sixteen layers 144 are interwoven at the intersection points 44, thus forming a woven screen.

[0067] Fig. 1 shows a cross-section of the electrical conductor 100 at a random position relative to its length. The relative positions of the plies 144 vary due to the opposing rotation of the plies around the shielding foil over the length of the electrical conductor 100 and repeat periodically depending on the lay length / braid pitch 42 and the pitch angle 43.

[0068] Fig. 2a shows a cross-section of a wire 141 with an elliptical cross-section corresponding to the wires of the wire screen 140 in Fig. 1. In the embodiment shown here, the wire 141 has a width 142 to height 143 ratio of 3:1. However, the wire 141 is not limited to this ratio. Fig. 2b shows a cross-section of a wire 148 with a round cross-section. The wire 148 has a diameter 142' which corresponds to the width 142 of the wire 141 according to Fig. 2a.

[0069] A comparison of the cross-sections of the wires 141 and 148 in Figs. 2a and 2b clearly shows the material savings when using wires 141 with an elliptical cross-section compared to using wires 148 with a round cross-section.

[0070] To illustrate the material savings with identical optical coverage, the following definition applies:

[0071] Ai = cross-section of the wire 141 b = width 142 h = height 143

[0072] Ä2 = cross-sectional area of ​​the wire 148 d = diameter 142'

[0073] The cross-sectional area and thus the material requirement of a wire 141 with an elliptical cross-section is calculated by

[0074] Ai= (h / 2)*(b / 2)*n

[0075] For a wire 141 with an exemplary width 142 of b=0.13mm and a height 143 of h=0.07mm, this results in a cross-sectional area of

[0076] Ai=0.00715mm 2 .

[0077] The wire 148, with a diameter 142' corresponding to the width 142 and a diameter of d=0.13mm, and thus an identical optical coverage, has a cross-sectional area of

[0078] Ä2 = n*(d / 2) 2 = n*0.065 2 = 0.01327mm 2A wire 141 with an elliptical cross-section and the width-to-height ratio of 1.85:1 (0.13mm:0.07mm) shown in the exemplary calculation thus results in a material saving of approximately 45% compared to a wire 148 with a round cross-section and a diameter 142', which corresponds to the width 142 of the wire 141.

[0079] Referring to the exemplary electrical conductor 100 shown in Fig. 1, the use of wires 141 with an elliptical cross-section allows not only for material savings but also for a reduction in the height of the wire shield 140 and thus a reduction in the radial extent of the wire shield 140 compared to the use of wires 148 with a round cross-section. Since electrical conductors are often limited in their outer diameter by the available installation space, reducing the height of the wire shield 140 allows the diameter of the first conductor with the electrical conductor 110 and the first insulation 120 to be increased. The larger the diameter of the first conductor, the lower the insertion loss of the electrical conductor and the longer the maximum possible transmission distance. The insertion loss describes the signal attenuation per transmission distance.

[0080] In addition to saving material and / or reducing insertion loss, the use of elliptical wires 141, as shown in Fig. 1 and Fig. 2a, offers further advantages, which are explained in more detail in the following description of Figs. 3a to 3d.

[0081] Figures 3a and 3b show a lamination 147 with four wires 148 with a round cross-section (Fig. 3a) and a lamination 144 with three wires 141 with an elliptical cross-section (Fig. 3b), which lie directly against the first screen foil 130 without any force F being applied.

[0082] A force F here represents any force F that can press or does press the plies 147 / 144 against or onto the first shielding foil 130. This force F can be exerted, for example, by a sheath 150 surrounding the wire shield 140. Furthermore, the force F can be exerted, for example, but not limited to, by bending and / or torsion and / or compression of the electrical conductor 100 and / or the wire shield 140 itself, which is applied under tensile stress during the braiding process. In the embodiment shown here, the plies 147 and 144 have an identical ply width 146.

[0083] Electrical cables are used not only in static installation situations but also in dynamically stressed installation situations, such as in a tailgate or a vehicle door. The wires 141 in the wire shield 140 are subjected to frequently increased force F and are also moved relative to the shielding foil 130, causing the wires 141 to rub against the shielding foil 130 at their contact points 91. This leads to wear of the shielding foil 130 and thus to a reduction in the service life of the electrical cable 100.

[0084] By using wires 141 with an elliptical cross-section and a width 142 greater than the diameter 142' of the wires 148, the number of contact points 92 of the wires 141 on the shielding foil 130 can be reduced compared to the number of contact points 91 of the wires 148, while maintaining an identical ply width 146 and at least the same radial extent of the wire shield 140 and thus of the electrical conductor 100. This consequently reduces the number of friction points and extends the service life of the electrical conductor 100 in dynamic installation situations.

[0085] The following calculation illustrates the reduction in the number of support points (91) when using elliptical wires. The exemplary values ​​used are not limiting and serve only for illustrative purposes.

[0086] With an exemplary ply width 146 of 0.30 mm, the four wires 148 of the ply 147 have a diameter 142' of 0.075 mm. Using elliptical wires 141 with a width 142 of 0.10 mm reduces the number of wires 141 required per ply 144 and thus the number of support points 92 to three. With a width-to-height ratio of, for example, 1:2, the height of the elliptical wires 141 is 0.05 mm, which, in addition to reducing the number of support points 92, also reduces the radial extent of the wire screen 140.

[0087] Figures 3c and 3d show the lamination 147 (Figure 3c) and the lamination 144 (Figure 3d) according to Figures 3a and 3b, with four wires 148 and three wires 141, respectively, under a force F. The applied force F is identical for both laminations 144 / 147. The lamination 147 and the lamination 144 are in direct contact with the first shielding foil 130.

[0088] Due to the elliptical shape itself and the width 142 of the wires 141, which in the example shown here is larger than a diameter 142' of the round wires 148, the wires 141 of the layering 144 have a larger contact area 94 on the first screen foil 130.

[0089] The pressure on the first shielding foil 130 and thus also the penetration of the pleat 147 or the pleat 144 into the first shielding foil 130 when a force F is applied depends on the applied force F and the respective contact area 93 / 94, whereby an increase in the contact area leads to a reduction in the pressure.

[0090] The indentation depth 149 represents the depth to which the wires 148 or the ply 147 penetrate into the first shielding foil 130, or by which the first shielding foil 130 is indented. The indentation depth 145 represents the depth to which the wires 141 or the ply 144 penetrate into the first shielding foil 130, or by which the first shielding foil 130 is indented.

[0091] Since the contact area 94 of the wires 141 is larger than the contact area 93 of the wires 148 due to the elliptical design, the indentation depth 145 of the wires 141 is consequently less than the indentation depth 149 of the wires 148.

[0092] The foregoing explanation also applies when comparing exemplary laminations 147 and 144 with an identical number of wires, where a width 142 of a wire 141 with an elliptical cross-section corresponds to the diameter 142' of a wire 148 with a round cross-section, since solely due to the smaller height 143 and thus the smaller radial extent of the wires 141, the bearing surface 94 is larger than the bearing surface 93 of the round wires 148.

[0093] Reducing the indentation depth 145 when using wires 141 with an elliptical cross-section leads in particular to a reduction in deformation of the shielding foil 130 and thus to a changed return loss characteristic. Reflections of an injected signal back to the near end of the electrical line 100 (injection) are characterized by the return loss (sll scattering quantity). In order not to impair the electrical function of the overall system, the permissible return loss must comply with a certain limit within a specified bandwidth.

[0094] Impedance disturbances within an electrical transmission line (100) lead to reflections of the injected signal. If these disturbances occur periodically, the reflections superimpose constructively at the near end of the line at one or more frequencies (Fourier transform), becoming visible as peak(s) in the return loss curve. These peaks typically stand out significantly in magnitude compared to the rest of the return loss curve, so their magnitude and frequency are crucial for maintaining the required return loss level and specified bandwidth. A peak that is less pronounced than the specified limit (level) does not restrict the bandwidth. However, if a peak exceeds the permissible level at a particular frequency, this peak limits the permissible bandwidth to precisely that frequency.

[0095] One cause of these return loss peaks can be the periodic deformation of the shielding foil 130 by the wires 141 of the wire screen 140 above it. Ideally, the first shielding foil 130 and the underlying dielectric, i.e., the first insulation 120, lie directly against each other, so that there is no gap (air inclusion) between them. In reality, however, these air inclusions cannot be completely avoided, so air can be present between the first shielding foil 130 and the underlying first insulation 120. By applying the wire screen 140 over the first shielding foil 130 with a tensile stress F > 0 N, this mechanical stress causes the first shielding foil 130 to be pressed against the first insulation 120 at the contact points 92 of the wires 141 above it.This periodic displacement leads to imprints of the wires 141 on the first shielding foil 130 and thus to periodic disturbances, which manifest themselves as peak(s) in the return loss (RL).

[0096] Figures 4a and 4b schematically show the electrical conductor 100 according to Figure 1 with the first shielding foil 130 and the first shielding foil 130 with an overlap area 131. In the embodiment shown here, the shielding foil 130 is folded circumferentially around the first insulation 120 of the first conductor, so that an overlap area 131 of the first shielding foil 130 is created.

[0097] The overlap area 131 is approximately 25% of the circumference of the first insulation 120. The overlap area 131 ensures that even under mechanical stress on the electrical conductor 100, such as through torsion or bending, and thus under possible displacement or deformation of the first shielding foil 130 relative to the first conductor, the first shielding foil 130 continues to completely enclose the first conductor.

[0098] In further embodiments, the first shielding foil 130 can be applied helically to the first conductor in a first lay direction, with the individual wraps of the shielding foil also having an overlap area. The width and pitch of the first shielding foil can be selected accordingly. The first lay direction can be a so-called "S" lay direction (S-lay) or a "Z" lay direction (Z-lay).

[0099] Figures 5a to 5d show exemplary embodiments of the first screen foil 130.

[0100] Fig. 5a shows a variant of the first shielding foil 130, which is designed as a double-sided laminated first shielding foil 130. The first shielding foil 130 has a core layer 132 made of a plastic, in particular polyethylene terephthalate (PET). On one side 136 of the core layer 132 facing the first conductor and thus radially inner, the first shielding foil 130 has an aluminum layer 133, on which a sliding layer 135 is applied. On one side 137 of the core layer 132 facing the wire screen 140 and thus radially outer, the shielding foil 130 has a further aluminum layer 134, which corresponds in thickness and design to the aluminum layer 133. A sliding layer 135 is also applied to the further aluminum layer 134. The sliding layer 135, for example, is made of a fluoropolymer and has a thickness of less than 25 pm.The sliding layer reduces friction between the aluminum layer 133 and the further aluminum layer 134 in the overlap area 131 when the shielding layer 130 is arranged as shown in Fig. 4a. Furthermore, the friction between the aluminum layer 133 and the first conductor and the friction between the aluminum layer 134 and the wire shield 140 is reduced. This significantly increases the service life of the first shielding foil 130 and thus the service life of the electrical conductor 100.

[0101] Fig. 5b shows a variant of the first shielding foil 130, which is designed as a single-sided laminated first shielding foil 130. The first shielding foil 130 has a core layer 132 made of a plastic, in particular polyethylene terephthalate (PET). On one side 136 of the core layer 132 facing the first conductor and thus radially inner, the first shielding foil 130 has an aluminum layer 133, on which a sliding layer 135 is applied. The sliding layer 135 thus forms the outermost layer on one side 136 of the first shielding foil 130 facing the first conductor. The core layer 132 forms the outermost layer on one side 137 of the first shielding foil 130 facing the wire screen 140.

[0102] Fig. 5c shows a variant of the first shielding foil 130, which has a core layer 133 made of aluminum. A sliding layer 135 is applied to one side 136 of the core layer 133 facing the first conductor and thus radially inner. A sliding layer 135 is also applied to another side 137 of the core layer 133 facing the wire screen 140 and thus radially outer.

[0103] The sliding layer 135 thus forms both the outermost layer on the side of the first conductor and on the side 136 / 137 of the first screen foil 130 facing the wire screen 140.

[0104] Fig. 5d shows a variant of the first shielding foil 130, which is designed as a double-sided laminated first shielding foil 130. The first shielding foil 130 has a core layer 132 made of a plastic, in particular polyethylene terephthalate (PET). On one side 136 of the core layer 132 facing the first conductor and thus radially inner, the first shielding foil 130 has an aluminum layer 133, on which a sliding layer 135 is applied. On one side 137 of the core layer 132 facing the wire screen 140 and thus radially outer, the shielding foil 130 has a further aluminum layer 134, which corresponds in thickness and design to the aluminum layer 133. The sliding layer 135 thus forms the outermost layer on one side 136 of the first shielding foil 130 facing the first conductor.The aluminum layer 134 forms the outermost layer on a side 137 of the first shielding foil 130 facing the wire screen 140. Figures 5a to 5d show only exemplary embodiments of the first shielding layer 130. Further embodiments of the first shielding layer 130 are conceivable.

[0105] Fig. 6 schematically shows a wire screen 140 of the electrical line 100 according to Fig. 1, which is designed as a braided screen.

[0106] Fig. 6 shows, for the sake of simplicity, the wire screen 140 applied over the entire circumference 41 to the first screen foil 130 in a two-dimensional plane.

[0107] The wire screen 140 is designed here as a braided screen 140. For the sake of clarity, only two layers 144 of the braided screen 140 are shown in Fig. 6. The exemplary braided screen 140, as shown in Fig. 1, comprises a total of 16 layers 144.

[0108] The plies 144 each comprise four wires 141 with an elliptical cross-section. A first ply 144, shown here, is wound around the first shielding foil 130 with a first lay direction 45. Due to the representation of the braided shield 140 in a plane, the wires 141, as soon as they reach one side of the plane, begin on the opposite side of the plane, as indicated by the dashed wire 141.

[0109] A second layer 144 is wrapped around the first shielding foil 130 with a lay direction 46 opposite to the first lay direction 45. At the intersection points 44 of the two layers 144, they are interwoven to form a wire mesh. Each layer 144 with the first lay direction 45 can alternately cross over and under a layer 144 with the opposite lay direction 46 in the direction of extension, i.e., in the longitudinal direction of the cable. Similarly, each layer 144 with the opposite lay direction 46 can alternately cross over and under a layer 144 with the first lay direction 45 in the direction of extension.

[0110] Alternatively, each layer 144 with the first beat direction 45 can alternately cross two layers 144 with the opposite beat direction 46 in the direction of extension, and then undercross two layers 144 with the opposite beat direction 46. Similarly, each layer 144 with the opposite beat direction 46 can alternately cross two layers 144 with the first beat direction 45 in the direction of extension, and then undercross two layers 144 with the first beat direction 45.

[0111] As an alternative to interlacing the layers, the two layers can also be wound together. More precisely, a first layer could be wound around the first shielding foil 130 in a first twist direction, and a second layer could be wound around the first shielding foil 130 and onto the first layer in a second twist direction.

[0112] The two exemplary layers 144 shown are wound around the first shielding foil 130 with a lay length / braid pitch 42 of approximately 10 mm to approximately 60 mm. The layers are further wound around the first shielding foil 130 with a pitch angle 43 or 43' of 50° to 87° to form a cross-sectional area of ​​the electrical conductor 100. The cross-sectional area is not explicitly shown in the embodiment depicted in Fig. 6 due to its representation in a two-dimensional plane. The pitch angle 43 or 43' is shown here analogously to the cross-sectional area in a three-dimensional representation with respect to the side of the two-dimensional plane representing the entire circumference 41.

[0113] The previously described variants of the electrical conductor, their construction and operational aspects, serve only to better understand the structure, function, and properties; they do not limit the disclosure to the exemplary embodiments. Some of the figures are schematic. In some cases, essential properties and effects are shown significantly enlarged to clarify the functions, operating principles, technical designs, and features. Each function, principle, technical design, and feature disclosed in the figures or text can be freely and arbitrarily combined with all claims, features in the text and in other figures, other functions, principles, technical designs, and features contained in or arising from this disclosure, so that all conceivable combinations can be attributed to the described procedure.This includes combinations of all individual descriptions in the text, that is, in every section of the description, in the claims, and also combinations of different variants in the text, in the claims, and in the figures. The claims do not limit the disclosure and thus the possible combinations of all the identified features. All disclosed features are explicitly disclosed here, both individually and in combination with all other features.

Claims

Patent claims 1. Having an electrical conductor (100): - at least one first conductor, wherein the at least one first conductor comprises a first electrical conductor (110) and a first insulation (120) surrounding the first electrical conductor (110); - at least a first shielding foil (130) surrounding the first conductor, wherein the first shielding foil (130) has at least one metal layer (133); - comprising at least one wire screen (140) with wires (141) having a non-circular, in particular elliptical, cross-sectional shape and a first width (142) which is applied to the first screen foil (130); - a sheath (150) that completely surrounds the wire screen (140); - wherein a penetration depth (145) of the wires (141) into the first shielding foil (130) under a force (F) is less than a reference penetration depth (149) of wires (148) with a round cross-sectional area and a diameter (142') corresponding to the first width (142) under the force (F).

2. The electrical conductor (100) according to claim 1, wherein the first shielding foil (130) has an overlap area (131) of about 5% to about 55%, in particular about 20% to about 35%, of a circumference of the first insulation (120).

3. The electrical conductor (100) according to one of the preceding claims, wherein the metal layer (133) is arranged on a side (136) of the first shielding foil (130) facing the wire screen (140) and / or wherein the metal layer (133) is designed as an aluminum layer or as a copper layer.

4. The electrical conductor (100) according to one of the preceding claims, wherein the first shielding foil (130) has a further metal layer (134), in particular an aluminum layer, on one side (137) of the first shielding foil (130) facing the first conductor and / or wherein the first shielding foil (130) is formed at least partially from a plastic, in particular from polyethylene terephthalate, PET.

5. The electrical conductor (100) according to one of the preceding claims, wherein the first shielding foil (130) is on the side facing the wire screen (140). (137) and / or has a sliding layer (135) on the side (136) facing the first conductor.

6. The electrical conductor (100) according to claim 5, wherein the sliding layer (135) is formed at least partially from a fluoropolymer and / or a siloxane polymer and / or a silicone oil and / or a silicone grease or at least partially comprises a fluoropolymer and / or a siloxane polymer and / or a silicone oil and / or a silicone grease.

7. The electrical conductor (100) according to one of the preceding claims, wherein the wire screen (140) is designed as a braided screen and / or the wires (141) are arranged as plies (144) including three to including six wires.

8. The electrical conductor (100) according to claim 7, wherein the braided shield (140) has a braid pitch (42) of about 10mm to about 60mm.

9. The electrical conductor (100) according to one of claims 7 or 8, wherein the braided screen (140) has a slope angle (43) of about 50° to about 87°.

10. The electrical conductor (100) according to one of the preceding claims, wherein the wires (141) have a width of about 0.1 mm to about 0.2 mm, in particular a maximum of 0.16 mm, and / or wherein a width(142)-to-height(143) ratio of the wires (141) is a maximum of 3:

1.

11. The electrical conductor (100) according to any of the preceding claims, wherein the wires (141) are at least partially made of tinned copper or of copper or of copper-clad aluminum or of a copper alloy.

12. The electrical conductor (100) according to one of the preceding claims, wherein the wires (141) have a tensile strength of about 200 N / mm² 2 up to approximately 800 N / mm 2 exhibit.

13. The electrical conductor (100) according to any one of the preceding claims, wherein the wires (141) have an oil-coated surface and / or wherein the bracing (144) has an oil-coated surface.

14. The electrical conductor (100) according to any one of the preceding claims, wherein the the sheath (150) has an outer diameter in the range of about 2 mm to about 4 mm and / or the first conductor has a diameter in the range of about 1.5 mm to about 3.5 mm or the first conductor has a diameter of about 80%, in particular about 85%, of the outer diameter of the sheath (150).

Images