Charging cable with multilayer hose

Abstract

The invention relates to an electrical charging cable, for example for electric vehicles. One embodiment of an electrical charging cable (100) comprises: at least one electrical line (1), wherein the at least one electrical line comprises at least one cooling hose (20), in which a cooling medium (30) can be conducted, and at least one electrical conductor (10) arranged in the cooling hose (20), in particular an uninsulated electrical conductor; and at least one further cooling hose (40), wherein the at least one further cooling hose (40) has a smaller outer diameter than the at least one cooling hose (20).

Description

[0001] LEONI Kabel GmbH - 1 - 30A-170 138

[0002] Charging cable with multi-layer hose

[0003] The invention relates to an electric charging label, in particular for electric vehicles.

[0004] Electric vehicles are typically charged at charging stations using charging cables. These cables are usually connected at one end to a charging station via a plug and can be connected to an electric vehicle via another plug 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.

[0005] In addition to the charging power, the temperature of the charging cable also plays a role in the charging process and thus the duration of the charging process. Generally, charging systems designed for high charging power lead to significant heat generation. 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 lifespan of the cables would be reduced.

[0006] 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 when touching or handling the charging cable. The heat energy generated during charging must therefore be dissipated, for example, by means of a cooling cable.

[0007] Nowadays, cooled charging cables / lines use hoses, so-called cooling hoses, to transport a cooling medium. Currently, there are no sufficiently flexible cooling hoses that meet the electrical and mechanical requirements of the relevant cable standard (EVI-2 according to IEC 62893-1) and simultaneously offer sufficient resistance to the commonly used coolants. LEONI Kabel GmbH - 2 - 30A-170 138

[0008] Consequently, the cooling hoses known from the prior art, and thus the electrical charging cables known from the prior art, cannot fulfill the desired or required properties.

[0009] WO 2022 / 258564 relates to a cable for the transmission of electrical energy and / or electrical signals, with a sheath extending at least sectionally along the cable, wherein at least one hose is arranged inside the sheath, wherein the at least one hose for the transmission of electrical energy comprises at least two load lines of a first electrical pole, wherein the at least two load lines are arranged inside the at least one hose and form at least one channel for guiding a medium with at least one hose section, preferably along the cable.

[0010] DE 10 2020 120 819 relates to a single conductor for a charging cable, for example for electric vehicles, and to a charging cable with such single conductors. An embodiment of the single conductor comprises: a cooling hose in which a cooling medium can be carried, and at least one non-insulated electrical conductor, wherein the at least one non-insulated electrical conductor is in thermally conductive contact with the cooling hose in such a way that the at least one non-insulated electrical conductor can be cooled by the cooling medium.

[0011] CN 218038677 U discloses a high-performance charging cable with a first conductor layer consisting of twisted copper conductors and an outer insulating layer. The cable is equipped with a cooling tube in the center, the outer surface of which is also twisted with copper conductors. A second cooling tube surrounds the outer surface of the insulating layer. A gap layer is located between the inner wall of the cooling tube and the outer surface of the insulating layer. Both the cooling tube and the gap layer are filled with a cooling medium.

[0012] JP H06-82723 U concerns a stranded conductor. The stranded conductor consists of several layers stacked on top of each other, and the water cooling cable, with a hose forming a water passage between the outer and inner circumferences, encloses the conductor. The conductor has a non-magnetic wound body formed from a thin, high-tensile wire wound into a coil, and a concentrically embedded, tubular, rubber-like elastic wire wound spirally between the layers of the hose. LEONI Kabel GmbH - 3 - 30A-170 138

[0013] Therefore, there is a need to provide an improved electric charging cable. In particular, there is a need for a cooled electric charging cable that offers good cooling properties while requiring minimal material for the cooling hoses.

[0014] According to a first aspect, an electric charging cable is proposed. This electric charging cable is designed, for example, as an electric charging cable for electric vehicles. The electric charging cable has at least one electrical conductor. This at least one electrical conductor has at least one cooling hose. A cooling medium can be conveyed within this at least one cooling hose. The at least one electrical conductor has at least one electrical conductor. This at least one electrical conductor is arranged within the at least one cooling hose. The electric charging cable has at least one further cooling hose. This at least one further cooling hose has a smaller outer diameter than the at least one cooling hose.

[0015] For example, the electric charging cable can have two or more electrical conductors. In this case, the electric charging cable can have two or more cooling hoses and two or more electrical conductors. The two or more electrical conductors can each be arranged in one of the at least two associated cooling hoses.

[0016] The at least one electrical conductor can be designed as a solid conductor or as a flexible stranded wire.

[0017] In this context, an electrical conductor can be understood as a conductor-shaped element comprising at least one electrical conductor and at least one cooling hose. The at least one cooling hose and / or the at least one further cooling hose are / are normally cylindrical and / or tubular in shape. The at least one electrical conductor can be configured as at least one non-insulated electrical conductor. "Non-insulated" in relation to the at least one non-insulated electrical conductor means that it is not electrically insulated. The at least one non-insulated electrical conductor can be arranged within the at least one cooling hose. For example, the at least one non-insulated electrical conductor can be arranged inside the at least one cooling hose, such as in a cavity within the cooling hose.The at least one non-insulated electrical conductor can, for example, be designed as a single electrical conductor or individual conductor. LEONI Kabel GmbH - 4 - 30A-170 138.

[0018] The at least one electrical conductor can be made of copper. Due to the high electrical conductivity of copper, the charging power of the charging cable can be high when the at least one electrical conductor is made of copper.

[0019] An electric charging cable, as defined here, is a cable-like element with at least one electrical conductor. It can be understood as a cable-like element with at least one electrical conductor and at least one cooling hose, but without the plugs / connector elements required to connect the charging cable to a charging station / charging column and / or an electric vehicle. Such plugs / connector elements are normally attached to the charging cable, which is typically manufactured as bulk cable, after the fact. In particular, plugs / connector elements are attached to the end sections of the charging cable.Furthermore, the electric charging cable can be understood here as the area which, in addition to the at least one electrical conductor and the at least one cooling hose, has an outer sheath / outer casing that surrounds the components and demarcates and / or externally encompasses / surrounds the charging cable.

[0020] The at least one additional cooling hose does not contain an electrical conductor; that is, the at least one additional cooling hose can be free of electrical conductors. If the at least one additional cooling hose does not contain an electrical conductor, it can easily be designed with a smaller diameter than the at least one cooling hose containing the at least one electrical conductor.

[0021] The sheathing of at least one additional cooling hose can have fewer layers or be composed of fewer layers than the sheathing of at least one cooling hose in the at least one line. This allows, for example, the additional cooling hose to have a smaller outer diameter than the at least one cooling hose. If the at least one additional cooling hose has a smaller diameter, it needs to withstand less pressure. Therefore, it can, for example, have fewer layers and / or a thinner sheathing.

[0022] If no electrical conductor is arranged in the additional cooling hose, the cross-section of the additional cooling hose may be reduced compared to the cross-section of the at least one cooling hose in which an electrical conductor is arranged. LEONI Kabel GmbH - 5 - 30A-170 138

[0023] For example, the cross-section of the electrical conductor can be reduced. Since the smaller, wider cooling hose is more stable simply due to its smaller dimensions, it can, for instance, have fewer layers. This reduces the amount of material required for the wider cooling hose.

[0024] The at least one additional cooling hose can be designed as a supply line for a cooling medium. This allows a charging plug, which requires particularly good cooling, to be cooled by a cooling medium that has not been heated by an electrical conductor.

[0025] The at least one cooling hose of the at least one line can be designed as a return line for the cooling medium.

[0026] In an electric charging cable, the cross-section of the supply line(s) and return line(s) should be at least nearly the same. If at least one cooling hose is designed as a return line and contains an electrical conductor (e.g., a stranded wire), its cross-section is larger than that of the other cooling hose, corresponding to the cross-section of the stranded wire. Since the smaller cooling hose, for example, is more stable simply due to its smaller dimensions (e.g., as a supply line), it does not require a pressure-resistant layer, as described in more detail below, which the larger cooling hose with a conductor (e.g., a stranded wire), for example, has to be sufficiently pressure-resistant.

[0027] The electric charging cable can have a first electrical conductor and a second electrical conductor. A cooling hose of the first electrical conductor can be designed as a return line for a cooling medium, and a cooling hose of the second electrical conductor can also be designed as a return line for a cooling medium.

[0028] Together with a supply line containing at least one additional cooling hose, the cooling medium can circulate completely within the electric charging cable. The supply line can also be referred to as the inlet line. The return line can also be referred to as the return line. For example, the supply line can represent a supply line for the cooling medium to a connector cooling system, and the return line can represent a return line for the cooling medium 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. LEONI Kabel GmbH - 6 - 30A-170 138

[0029] This line leads to a location with low fluid pressure. The cooling fluid can be transported there via the supply line and back via the return line.

[0030] Alternatively, the cooling hose of the first electrical cable can be configured as a supply line and the cooling hose of the second electrical cable as a return line for the cooling medium. Furthermore, the cooling hoses of the first and second electrical cables can each be configured as a supply line for the cooling medium. In this case, an additional return line, such as at least one further cooling hose, for the cooling medium can be arranged in the charging cable.

[0031] The at least one electrical conductor can form at least one direct current (DC) conductor. The DC conductor is used to transmit direct current. For example, the DC conductor can be one of the two DC conductors required for transmitting direct current in a charging cable. The electrical conductor in the first cooling hose can form a positive DC conductor. The electrical conductor in the second cooling hose can form a negative DC conductor. Thus, efficient DC charging of electric vehicles is possible using the charging cable.

[0032] For example, the charging cable can transmit currents of one hundred amperes (A), or several hundred amperes, for example up to approximately 3000 A, without any significant heating of the electrical conductors and / or the charging cable itself, provided the cooling system is functioning correctly. This means that despite the relatively small cross-section of at least one electrical conductor, a high power output can be transferred from the charging station to the vehicle (and thus to the battery).

[0033] The at least one cooling hose and / or the at least one additional cooling hose may have an inner layer. The at least one cooling hose and / or the at least one additional cooling hose may have an outer layer that completely surrounds the inner layer. The inner layer may be thinner than the outer layer in a radial direction of the at least one cooling hose and / or the at least one additional cooling hose.

[0034] By using a thinner inner layer of the cooling hose, a harder material can be used for the inner layer. In this way, a material can be used that offers good performance. LEONI Kabel GmbH - 7 - 30A-170 138

[0035] The cooling hose exhibits resistance to the cooling media used or conducted within it. Nevertheless, the desired flexibility is maintained.

[0036] The inner layer can have higher wear resistance than the outer layer. Additionally or alternatively, the inner layer can have higher abrasion resistance than the outer layer. Additionally or alternatively, the inner layer can have lower sliding properties than the outer layer. Additionally or alternatively, the inner layer can have higher hardness than the outer layer. In other words, the inner layer can be harder / stiffer / stronger than the outer layer. This allows for the use of a material for the inner layer that offers good resistance to the cooling media / coolants used or conducted in the at least one cooling hose and / or the at least one additional cooling hose. If the inner layer has higher hardness, it is advisable to make it thinner to maintain sufficient flexibility.For example, it is conceivable that the inner layer is thinner the harder it is.

[0037] If the inner layer has a higher hardness than the outer layer, the inner layer can also be described as a hard or inflexible layer, or, compared to the outer layer, as a harder or less flexible layer. The outer layer, in this case, can be described as a soft or flexible layer, or, compared to the inner layer, as a softer or more flexible layer. It can also be said that the inner layer has higher dimensional stability, strength, stiffness, or flexural rigidity than the outer layer.

[0038] The inner layer can exhibit higher wear resistance than the outer layer. Wear resistance can also be understood and referred to here as abrasion resistance, particularly according to DIN 50320. Wear resistance can be understood as a body's resistance to wear, especially mechanical abrasion. Wear resistance can be increased, for example, by keeping the coefficient of friction between the inner layer and the electrical conductor low or reducing it compared to known solutions. This results in less wear.

[0039] The inner layer of at least one cooling hose can be copper-stabilized. Copper stabilization can be omitted in at least one other cooling hose, for example, because the burst pressure is already sufficiently high. This also reduces material usage. LEONI Kabel GmbH - 8 - 30A-170 138

[0040] Since the inner layer can be relatively hard, firm, and / or tough, resulting in comparatively poor flexibility, it is advisable to make the inner layer as thin as possible. A certain wall thickness is required to manufacture the hose with stability. The outer layer can serve this purpose. The outer layer can form a complete inner layer together with the inner layer. Generally speaking, the complete inner layer of at least one cooling hose and / or at least one other cooling hose can consist of the inner and outer layers, or be formed by both the inner and outer layers. The outer layer can be softer or made of a softer material than the inner layer. This achieves good overall flexibility despite a harder inner layer.

[0041] The at least one cooling hose and / or the at least one additional cooling hose may have an adhesion promoter placed between the inner and outer layers. In this case, the overall inner layer may consist of the inner layer, the adhesion promoter, and the outer layer, or be formed by the inner layer, the adhesion promoter, and the outer layer. Depending on the material combination of the inner and outer layers, sufficient adhesion may be achieved without an adhesion promoter. In this case, the overall inner layer may consist of the inner and outer layers, or be formed by the inner and outer layers. With some material combinations, an adhesion promoter between the inner and outer layers may lead to improved adhesion between them.

[0042] The at least one cooling hose may have a pressure-resistant layer completely surrounding the outer layer. Additionally or alternatively, the at least one cooling hose may have a pressure-resistant layer completely surrounding the inner layer. The pressure-resistant layer may also be referred to as a pressure stabilization layer. The pressure-resistant layer may increase the pressure resistance and / or burst pressure of the cooling hose. Burst pressure is often also referred to as burst strength. The burst strength value (BSV) is usually specified in kPa (kilopascals). The burst strength (BSV / BST) can be determined according to DIN 53 141.

[0043] The pressure-resistant layer can be applied directly to the outer layer. The at least one cooling hose can act as a sheathing, for example, over the entire inner layer (with or without adhesion promoter) and the LEONI Kabel GmbH - 9 - 30A-170 138

[0044] The pressure-resistant layer may be present or formed by the entire inner layer (with or without adhesion promoter) and the pressure-resistant layer. Additionally or alternatively, the pressure-resistant layer may be applied directly to the inner layer. For example, the pressure-resistant layer may be located between the inner and outer layers, e.g., in direct contact with them. Alternatively, the pressure-resistant layer may be located elsewhere in the at least one cooling tube as an intermediate layer between other layers.

[0045] The pressure resistance layer can comprise, or be formed by, a braid or reinforcement, particularly an open braid. The braid, for example, can be made of polyester or be formed entirely of polyester. The braid / reinforcement can increase the pressure resistance or burst pressure of the at least one cooling hose.

[0046] The at least one additional cooling hose, for example, does not have a pressure-resistant layer. The at least one additional cooling hose can, for example, consist of the entire inner layer (with or without an adhesion promoter) or be formed entirely by the entire inner layer (with or without an adhesion promoter). In particular, the pressure-resistant layer can be omitted in the at least one additional cooling hose if no electrical conductor is located in it. In this case, the at least one additional cooling hose can be smaller than the at least one cooling hose containing the at least one electrical conductor. For example, the cross-section of the at least one additional cooling hose can be reduced by the conductor cross-section (of the at least one electrical conductor in the at least one additional cooling hose) compared to the cross-section of the at least one cooling hose.Due to its reduced size, the pressure exerted is lower. Because of this reduced pressure, the burst pressure of at least one additional cooling hose is sufficient. Therefore, a pressure-resistant layer is unnecessary.

[0047] The at least one cooling hose and / or the at least one further cooling hose may have a secondary insulation layer completely surrounding the outer layer. LEONI Kabel GmbH - 10 - 30A-170 138

[0048] The secondary insulation layer can be applied indirectly to the outer layer. In the case of the at least one cooling hose, the secondary insulation layer can be applied directly to the pressure-resistant layer. The at least one cooling hose can, for example, form a sheath comprising the entire inner layer (with or without an adhesion promoter), the pressure-resistant layer, and the secondary insulation layer, or be formed by the entire inner layer (with or without an adhesion promoter), the pressure-resistant layer, and the secondary insulation layer.

[0049] In the case of at least one additional cooling hose, the secondary insulation layer can be applied directly to the overall inner layer. The at least one additional cooling hose can, for example, form a sheath comprising the overall inner layer (with or without an adhesion promoter) and the secondary insulation layer, or be formed by the overall inner layer (with or without an adhesion promoter) and the secondary insulation layer.

[0050] At least one cooling hose must have a burst pressure of at least 80 bar at 23 °C. Additionally or alternatively, at least one cooling hose must have a burst pressure of at least 30 bar at 90 °C. The burst pressure can be determined according to DIN 53 141.

[0051] The at least one additional cooling hose can have a burst pressure of at least 30 bar at 23 °C. The at least one additional cooling hose can also, or alternatively, have a burst pressure of at least 8 bar at 90 °C. The burst pressure can be determined according to DIN 53 141.

[0052] The at least one cooling hose and / or the at least one additional cooling hose may additionally or alternatively have a tensile strength of at least 8.0 N / mm² 2 exhibit. A test method according to IEC 60811-501 can be used as a test method for determining the tensile strength.

[0053] The at least one cooling hose and / or the at least one further cooling hose may additionally or alternatively have an elongation at break (also referred to as elongation at break) of at least 200%. A test method according to IEC 60811-501 may be used as a test method for determining the elongation at break.

[0054] The at least one cooling hose and / or the at least one additional cooling hose may additionally or alternatively have a hardness of at least 80 IRHD. LEONI Kabel GmbH - 11 - 30A-170 138

[0055] A test method according to ISO 48 can be used to determine the hardness.

[0056] One or more, in particular all, of the aforementioned parameters for the cooling hose and / or for the at least one further cooling hose can lead to a cooling hose and / or a further cooling hose with good insulating properties and / or good flexibility while also having good media resistance.

[0057] The at least one cooling hose and / or the at least one additional cooling hose can generally be a body extending longitudinally along the charging cable. This body can have a cavity in which a cooling medium (which can also be referred to as a coolant) can circulate. The inner layer can be, in particular, the layer that directly borders the cavity or, if a cooling medium is present in the cavity, is in direct contact with the cooling medium. The at least one cooling hose and / or the at least one additional cooling hose are not limited to a specific cross-section. For example, the at least one cooling hose and / or the at least one additional cooling hose can have a round, square, or oval cross-section.The at least one cooling hose and / or the at least one additional cooling hose may take the form of a hollow cylinder, but are not limited to such a shape. The at least one cooling hose and / or the at least one additional cooling hose extend, for example, along the full length of the electrical cable. The at least one cooling hose and / or the at least one additional cooling hose may be flexible, i.e., not rigid. The at least one cooling hose and / or the at least one additional cooling hose is / are, for example, elastically bendable or deformable.

[0058] The at least one cooling hose and / or the at least one further cooling hose can be designed to be at least nearly leak-proof or impermeable to the cooling medium. For this purpose, the cooling hose and / or the at least one further cooling hose can be completely closed in both the longitudinal and circumferential directions. The at least one cooling hose and / or the at least one further cooling hose can have an internal cavity to hold the cooling medium and / or the at least one electrical conductor. In this way, the cooling medium can circulate in the cavity. [LEONI Kabel GmbH - 12 - 30A-170 138]

[0059] However, they can penetrate at least one other cooling hose, or at least almost not at all.

[0060] In the case of at least one cooling hose, both the cooling medium and the at least one electrical conductor can be enclosed by the sheathing. For example, exactly one electrical conductor can be arranged in each cooling hose of the at least one cooling hose. The cooling medium can be, for example, liquid or gaseous. The at least one electrical conductor, in particular uninsulated, can be in thermally conductive contact with the at least one cooling hose such that the at least one electrical conductor, in particular uninsulated, can be cooled by the cooling medium. A thermally conductive connection can be understood as a direct or indirect thermally conductive connection between the electrical conductor and the cooling hose.A thermally conductive connection allows for heat exchange between the cooling hose (more precisely, the cooling medium within the cooling hose) and the electrical conductor, particularly if it is uninsulated. Due to this thermally conductive connection, heat generated by the electrical conductor can be dissipated via the cooling medium within the cooling hose. In other words, the electrical conductor can be cooled directly via the thermally conductive connection using the cooling medium within the cooling hose, for example, without insulation around the electrical conductor impairing heat transfer and / or heat dissipation.

[0061] The at least one uninsulated electrical conductor can be in direct contact with the cooling medium. 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 uninsulated electrical conductor, the conductor can be cooled particularly efficiently. If the at least one uninsulated electrical conductor is in direct contact with the cooling medium, cooling media / coolants other than water are typically used. With such cooling media / coolants, for example, aggressive ones (compared to water), the resistance of the cooling hose is of particular importance. If the electrical conductor is uninsulated, it is directly surrounded by the cooling medium / coolant.In this case, non-conductive cooling media / coolants are used, for example, an oil-glycol mixture or other oil-containing substances. Such non-conductive cooling media / coolants, for example, oil-glycol mixtures, are LEONI Kabel GmbH - 13 - 30A-170 138.

[0062] They are comparatively aggressive and require good resistance from the cooling hose. These requirements are met by the overall inner layer and the cooling hose sheathing described herein.

[0063] The charging cable may have an outer sheath. This sheath protects the cable and can therefore also be called a protective sheath. The shared outer sheath holds the two electrical conductors together and protects them from abrasion and environmental influences, for example. The outer sheath may also provide thermal insulation. Thermal insulation is particularly advantageous when the cooling medium is a coolant fluid. For example, thermal insulation prevents the coolant fluid from freezing.

[0064] The charging cable can have one or more conductors or wires for charging with alternating current (AC). Using the one or more AC conductors, the charging cable can be used to charge an electric vehicle using AC power. For example, the charging cable can be a combination cable that enables both DC and AC charging. Examples of possible configurations include three conductors (live, neutral, ground), five conductors (three live, neutral, ground), or seven conductors (three live, neutral, ground, plus two conductors for communication between a power source, such as a charging station, and a power sink, such as an electric vehicle battery or the vehicle itself). Additionally or alternatively, the charging cable can include data and / or signal lines.The data lines can be configured for data transmission between an energy source, e.g., a charging station, and an energy sink, e.g., a vehicle battery / vehicle. The energy source and the energy sink can communicate with each other via the data lines.

[0065] The charging cable can have at least one protective conductor. This protective conductor can also be referred to as a PE conductor (PE: Protective Earth). A protective conductor is an electrical conductor used for safety purposes, for example, to protect against electric shock.

[0066] According to a second aspect, a charging system can be provided. The charging system can include the charging cable as described in the first aspect, an end connection, and a plug. The end connection can have a supply for the cooling medium, which directs the cooling medium into at least one of the cooling hoses (e.g., the LEONI Kabel GmbH - 14 - 30A-170 138).

[0067] The connector can insert at least one additional cooling hose and receive coolant from another of the cooling hoses (e.g., the at least one cooling hose). The connector is designed to be connected to a vehicle. In addition to the electrical contacts for connecting the existing electrical conductors to the vehicle's wiring, the connector may have a fluid return line that can receive the coolant from one cooling hose and return it to another.

[0068] Furthermore, according to a third aspect, a charging station can be provided with a charging cable according to the first aspect or with a charging system according to the second aspect.

[0069] Even though some of the aspects described above have been described in relation to the electric charging cable according to the first aspect, these aspects can also be implemented in a corresponding way in the charging system according to the second aspect and / or in the charging station according to the third aspect, and vice versa.

[0070] The present invention will be further explained with reference to figures. These figures schematically illustrate:

[0071] Figure 1 shows a cross-section of an electrical line with a cooling hose and an electrical conductor;

[0072] Figure 2a shows a cross-sectional view of an embodiment of a charging cable with an electrical conductor from Figure 1;

[0073] Figure 2b shows a cross-sectional view of an embodiment of a charging cable with two electrical conductors from Figure 1; and

[0074] Figure 2c shows a cross-sectional view of an embodiment of a charging cable with two electrical conductors from Figure 1.

[0075] 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 which may differ from the details set forth below. Furthermore, the figures serve only to illustrate the invention. LEONI Kabel GmbH - 15 - 30A-170 138

[0076] Exemplary embodiments. They are not to scale and are intended only to illustrate the general concept of the invention. For example, features included in the figures should by no means be considered a necessary component.

[0077] Figure 1 shows a cross-section of an electrical cable 1 with a cooling hose 20 and an electrical conductor 10. The electrical cable 1 is designed as an example for use in an electric charging cable for electric vehicles. The electrical cable 1 has, by way of example, exactly one electrical conductor 10, as an example that at least one electrical conductor 10 can be provided. The electrical cable 1 has, by way of example, exactly one cooling hose 20, as an example that at least one cooling hose 20 can be provided.

[0078] The single electrical conductor 10 is arranged within the single cooling hose 20. In the example shown in Figure 1, the single electrical conductor 10 is not insulated and can therefore be referred to as an uninsulated electrical conductor 10. In other words, an uninsulated electrical conductor 10 is arranged inside the electrical cable 1. The cooling hose 20 and the electrical conductor 10 run coaxially within the cable 1, with the longitudinal axis of the cable 1 as their common axis. The uninsulated electrical conductor 10 can be a solid conductor or a flexible stranded wire.

[0079] The cooling hose 20 is designed to hold a cooling medium 30. Once a cooling medium 30 is held, the electrical conductor 10 is surrounded by the cooling medium 30. If a non-insulated electrical conductor 10 is used, the cooling medium 30 is electrically insulating (i.e., non-conductive). The cooling medium 30 is guided within the cooling hose 10. The cooling hose 10 therefore surrounds the cooling medium 30. The cooling hose 20 has an inner wall, surface, or layer that is multilayered. This inner layer is also referred to as the multilayered overall inner layer or simply as the overall inner layer. This overall inner layer is a multilayered structure, meaning it has a multilayered composition.

[0080] An exemplary construction of the entire inner layer and the cooling hose 10 with this entire inner layer is described below. LEONI Kabel GmbH - 16 - 30A-170 138

[0081] The cooling hose 20 has an inner layer 22 and an outer layer 24 that completely surrounds the inner layer 22. The inner layer 22 and the outer layer 24 are part of the overall inner layer. In other words, the overall inner layer comprises—in the radial direction of the cooling hose 20—the inner layer 22 and the outer layer 24. The inner layer is in direct contact with a cavity of the cooling hose in which the cooling medium 30 can be received. According to a first example, the inner layer 22 and the outer layer 24 form the overall inner layer. In other words, according to this first example, the overall inner layer consists of the inner layer 22 and the outer layer 24. According to a second example, which will be described in more detail later, an adhesion promoter 23 is arranged between the inner layer 22 and the outer layer 24.According to this second example, the inner layer 22, the adhesion promoter 23, and the outer layer 24, from the inside out (in the radial direction of the cooling hose 20 and the electrical conductor 1), form the overall inner layer. In other words, according to this second example, the overall inner layer consists of the inner layer 22, the adhesion promoter 23, and the outer layer 24.

[0082] As indicated in Figure 1, the inner layer 22 is thinner in a radial direction of the cooling hose 20 than the outer layer 24. Furthermore, the inner layer 22 exhibits higher wear resistance than the outer layer 24. In particular, the inner layer 22 is harder than the outer layer 24.

[0083] As outlined above, the cooling hose 20 can have an adhesion promoter 23 arranged between the inner layer 22 and the outer layer 24. In Figure 1, the adhesion promoter 23 is shown by way of example arranged directly between the inner layer 22 and the outer layer 24. However, the adhesion promoter 23 can also be omitted if there is sufficient adhesion between the inner layer 22 and the outer layer 24.

[0084] The cooling hose 20 has, by way of example, a pressure-resistant layer 26 that completely surrounds the outer layer 24. In Figure 1, the pressure-resistant layer 26 is applied directly to the outer layer 24. The pressure-resistant layer 26 has, or is formed by, a braid or reinforcement, in particular an open braid. Additionally or alternatively, a pressure-resistant layer can be arranged between the inner layer 22 and the outer layer 24 (not shown in Figure 1). LEONI Kabel GmbH - 17 - 30A-170 138

[0085] The cooling hose 20 has a secondary insulation layer 28 that completely surrounds the outer layer 24. In Figure 1, the secondary insulation layer 28 is applied indirectly to the outer layer 24. In Figure 1, the secondary insulation layer 28 is applied directly to the pressure-resistant layer 26.

[0086] Several exemplary parameters of the cooling hose 20 are now described. The cooling hose 20 can fulfill one or more of these parameters. For example, the cooling hose 20 has a burst pressure of at least 80 bar at 23 °C. For example, the cooling hose 20 has a burst pressure of at least 30 bar at 90 °C. For example, the cooling hose 20 has a tensile strength of at least 8.0 N / mm². 2 The cooling hose 20, for example, exhibits an elongation at break of at least 200%. The cooling hose 20, for example, exhibits a hardness of at least 80 IRHD.

[0087] Figures 2a to 2c show exemplary embodiments of an electric charging cable with at least one electrical conductor 1 from Figure 1.

[0088] Figure 2a shows a first embodiment of an electric charging cable 100 with exactly one electrical conductor 1 from Figure 1. The design of the electric charging cable 100 with exactly one electrical conductor 1, and thus with exactly one electrical conductor 10 and exactly one cooling hose 20, can be considered the simplest possible design. A further cooling hose 40 is also arranged in the charging cable 100. No electrical conductor is arranged in the further cooling hose 40. Furthermore, a protective conductor 50 is arranged in the charging cable 100. The charging cable 100 is surrounded by an outer sheath 60. In addition, a filling element 2, for example in the form of the conductor 1, is arranged in the charging cable 100 to at least nearly fix the protective conductor 50, the electrical conductor 1, and the further cooling hose.

[0089] The electrical conductor 10 and the cooling hose 20 are each configured as described with reference to Figure 1. Thus, the electrical conductor 10 is arranged inside the cooling hose 20.

[0090] In addition to the electrical conductor 1 shown in Figure 2a, another electrical conductor can be provided, for example, instead of the filling element 2. The additional electrical conductor can, for example, be designed differently from the electrical conductor 1. For example, the additional electrical conductor can be indirectly cooled by enclosing one or more electrical conductors around a cooling hose. LEONI Kabel GmbH - 18 - 30A-170 138

[0091] are arranged around, while the electrical conductor 1 can be designed as a directly cooled conductor in which a non-insulated electrical conductor 10 can be arranged in the cooling hose 1 and directly surrounded by cooling medium 30, as shown in Figures 1 and 2a.

[0092] The diameter of the additional cooling hose 40 is smaller than the diameter of the cooling hose 20. The structure of the additional cooling hose 40 is based on the structure of the cooling hose 20. The additional cooling hose 40 has an inner layer 22 and an outer layer 24 as a single inner layer. An adhesion promoter 23 can be arranged between the inner layer 22 and the outer layer 24. The adhesion promoter 23 can also be omitted. A secondary insulating layer 28 is applied directly around the outer layer 24. That is, unlike the cooling hose 20, the additional cooling hose 40 does not have a pressure-resistant layer 26. In other words, unlike the cooling hose 20, the additional cooling hose 40 is free of a pressure-resistant layer 26. Furthermore, no electrical conductor 10 is arranged in the additional cooling hose 40; that is, the additional cooling hose 40 is free of electrical conductors.For example, the further cooling hose 40 is empty except for any cooling medium 30 that may be present.

[0093] Since the diameter of the additional cooling hose 40 is smaller than the diameter of the cooling hose 20, or, in other words, the cross-section of the additional cooling hose 40 is smaller than the cross-section of the cooling hose 20, the burst pressure of the additional cooling hose 40 is sufficient to withstand the lower pressures within it. Therefore, no pressure-resistant layer 26 is required. Thus, the sheathing of the additional cooling hose 40 is thinner than the sheathing of the cooling hose 20. Due to the electrical conductor 10 arranged within the cooling hose 20, the diameter of the cooling hose 20 is larger. The pressures acting within the cooling hose 20 are therefore higher. To ensure that the cooling hose 20 has a sufficiently high burst pressure, it is provided with the pressure-resistant layer 26. Furthermore, the inner layer 22 can be copper-stabilized.

[0094] Figure 2b shows a second embodiment of an electric charging cable 100 with exactly two electrical conductors 1 from Figure 1. Furthermore, a protective conductor 50 is arranged in the charging cable 100. The charging cable 100 is surrounded by an outer sheath 60. The electric charging cable 100 has an additional cooling hose 40. The additional cooling hose 40 from Figure 2b is constructed like the additional cooling hose 40 from Figure 2a. The additional cooling hose 40 has a smaller outer diameter. LEONI Kabel GmbH - 19 - 30A-170 138

[0095] on as the cooling hoses 20 of the two first lines 10. The charging cable 100 also has an outer sheath 60 that completely surrounds all components.

[0096] Both electrical conductors 10 of the lines 1 are each surrounded by their respective cooling hose 20. Each of the two cooling hoses 20 can contain and, for example, circulate a cooling medium 30. The cooling medium 30 is guided within each of the two cooling hoses 20. Each of the two cooling hoses 20 therefore surrounds its respective cooling medium 30. Accordingly, each of the two electrical conductors 10 can each be surrounded by a cooling medium 30. In this case, the cooling medium 30 is an electrically insulating (i.e., non-conductive) cooling medium. The cooling hose 20 is surrounded by a multi-layered sheathing / insulation as described with reference to Figure 1.

[0097] The respective cooling hose 20 is at least nearly impermeable to the associated cooling medium 30. This is achieved by the sheathing described above, which can also be referred to as a jacket, outer casing, or insulating sleeve. In an undamaged state, the insulating sleeve of the respective cooling hose 20 is at least nearly impermeable to the cooling medium 30. This means that, under normal, undamaged conditions, the cooling medium 30 cannot normally leak from the cooling hose 30 into the interior of the charging cable 100.

[0098] Figure 2c shows a third embodiment of an electric charging cable 100 with exactly two electrical conductors 1 from Figure 1. The electric charging cable 100 according to the third embodiment in Figure 2c is essentially the same as the electric charging cable 100 according to the second embodiment in Figure 2b, so that a repetition of the identical features is omitted. The protective conductor 50 in Figure 2c has a smaller diameter compared to the protective conductor 50 in Figure 2b. Additional filler elements 2 are provided for fixing the protective conductor 50.

[0099] According to an example that can be implemented in both the configuration shown in Figure 2b and the configuration shown in Figure 2c, the additional cooling hose 40 is designed as a supply line for a cooling medium 30. According to this example, a cooling hose 20 of a first electrical line 1 is designed as a return line for the cooling medium 30, and a cooling hose 20 of a second electrical line 1 is also designed as a return line for the cooling medium 30. In this way, the coolest possible cooling medium 30 flows from the charging station via the empty cooling hose 40 to LEONI Kabel GmbH - 20 - 30A-170 138

[0100] a charging plug, without being heated by electrical conductors. The charging plug is thus cooled as efficiently as possible. The cooling medium 30, which is slightly warmed by the cooling of the charging plug, is returned to the charging station via the return lines in the cooling hoses 20. The slightly warmed cooling medium 30 is, however, sufficiently cool to absorb and dissipate the heat from the electrical conductors 10.

[0101] In the examples from Figures 2b and 2c, two conductors 1 are provided, each comprising a cooling hose 20 and an electrical conductor 10 according to the setup shown in Figure 1. In each of the first two conductors 1, the cooling hose 20 and the electrical conductor 10 run coaxially with the longitudinal axis of the respective conductor 1 as their common axis. The two electrical conductors 10 can each be solid conductors or flexible stranded wires. The two electrical conductors 10 can each be designed as uninsulated electrical conductors. The electrical conductors 10 can each be copper conductors. The electrical conductors 10 can each form a DC conductor. In other words, each of the electrical conductors 10 can be one of the (two) DC conductors of the charging cable 100 required for the transmission of direct current.For example, one of the two electrical conductors 10 can form a positive DC conductor and the other of the two electrical conductors 10 can form a negative DC conductor. Thus, efficient DC charging of electric vehicles can be achieved using the charging cable 100. The DC conductor(s) serve to transmit direct current in the charging cable 100.

[0102] The charging cable 100 can optionally include AC lines. However, the AC lines can also be omitted. If no AC line is provided, the charging cable 100 is designed as a DC charging cable. If, on the other hand, the two lines 1 and one AC line are provided, the charging cable 100 is designed as a combination charging cable for optional DC and AC charging. A signal line 30 may also be provided.

[0103] In addition, the charging cable 100 according to each of the three embodiments can be equipped with sensors (not shown), for example, one or more temperature sensors. This increases the safety of the charging cable 100 through targeted monitoring, such as temperature monitoring.

[0104] In all embodiments of a charging cable 100 described with reference to Figures 2a to 2c, there are high requirements for the media resistance of the cooling hoses 20. The necessary media resistance is achieved by the inner layer LEONI Kabel GmbH - 21 - 30A-170 138

[0105] 22 is reached. The inner layer 22 provides a hose 20 which has a certain stability and strength.

[0106] The described charging cable 100, according to each of the embodiments, provides an improved connection for charging electric vehicles. In these embodiments, the electrical conductor 10 is in direct contact with the cooling medium 30. This means that an advantage of these embodiments is the improved or even optimal heat transfer compared to the prior art.

[0107] Using the cooled cable 1 from Figure 1 and the cooled charging cable 100 from Figures 2a to 2c, it is possible to transmit high power from the charging station to the vehicle (and thus to the battery) despite smaller cross-sections. Normally, smaller cross-sections would not be able to transmit this power because they would heat up too quickly under the current load. This would lead to exceeding the maximum permissible conductor temperature according to EN 50620 or IEC 62893 after a certain period of time. This could damage the cables and reduce their service life. By integrating the described cooling hoses 20, the temperatures that occur under high current loads can be compensated for. This allows the conductor cross-section to be reduced for the same current load compared to conventional cables. Handling is thus significantly simplified and user-friendly.

[0108] Furthermore, the described embodiments shown in Figures 1 to 2c minimize the number of cooling hoses. For example, the complete charging cable 100 shown in Figures 2a to 2c has only two cooling hoses 20 around the conductors 10. Moreover, no complex or complicated connection technology is required for the hoses 20. The charging cable shown in Figures 2a to 2c remains flexible to withstand normal bending loads, as defined, for example, in IEC 62440, and is optimally designed for DC charging, especially fast charging, and the very high power transmission with active cooling required for this application.

Claims

LEONI Kabel GmbH - 22 - 30A-170 138 Patent claims 1. Electric charging cable (100), for example for electric vehicles, comprising: at least one electrical conductor (1), wherein the at least one electrical conductor (1) comprises at least one cooling hose (20) in which a cooling medium (30) can be guided, and at least one, in particular uninsulated, electrical conductor (10), wherein exactly one electrical conductor (10) of the at least one electrical conductor (10) is arranged in each cooling hose (20) of the at least one cooling hose (20); and at least one further cooling hose (40), wherein the at least one further cooling hose (40) has a smaller outer diameter than the at least one cooling hose (20), wherein no electrical conductor is arranged in the at least one further cooling hose (40).

2. Electric charging cable (100) according to claim 1, wherein a sheathing of the at least one further cooling hose (40) has fewer layers or is formed from fewer layers than a sheathing of the at least one cooling hose (20).

3. Electric charging cable (100) according to claim 1 or 2, wherein the at least one further cooling hose (40) is designed as a supply line for the cooling medium (30).

4. Electric charging cable (100) according to one of claims 1 to 3, wherein the at least one cooling hose (20) is designed as a return for the cooling medium (30).

5. Electric charging cable (100) according to one of claims 1 to 4, wherein the electric charging cable (100) has a first electrical line (1) and a second electrical line (1), wherein a cooling hose (20) of the first electrical line (1) is designed as a return for the cooling medium (30) and a cooling hose (20) of the second electrical line (1) is designed as a return for the cooling medium (30).

6. Electric charging cable (100) according to one of claims 1 to 5, wherein the at least one cooling hose (20) and / or the at least one further LEONI Kabel GmbH - 23 - 30A-170 138 Cooling hose (40) has / have an inner layer (22) and an outer layer (24) surrounding the inner layer (22) and the inner layer (22) is thinner in a radial direction of the at least one cooling hose (20) than the outer layer (24).

7. Electric charging cable (100) according to claim 6, wherein the inner layer (22) has a lower flexibility than the outer layer (24).

8. Electric charging cable (100) according to claim 6 or 7, wherein the at least one cooling hose (20) and / or the at least one further cooling hose (40) has / have an adhesion promoter (23) arranged between the inner layer (22) and the outer layer (24).

9. Electric charging cable (100) according to one of claims 6 to 8, wherein the at least one cooling hose (20) has a pressure resistance layer (26) circumferentially surrounding the inner layer (22) and / or the outer layer (24) and / or the at least one further cooling hose does not have a pressure resistance layer (26) circumferentially surrounding the outer layer (24).

10. Electric charging cable (100) according to claim 9, wherein the pressure resistance layer (26) is applied directly to the outer layer (24) of the at least one cooling hose (20).

11. Electric charging cable (100) according to claim 9 or 10, wherein the pressure resistance layer (26) has a, in particular open, braid or reinforcement or is formed by a, in particular open, braid or reinforcement.

12. Electric charging cable (100) according to one of claims 6 to 11, wherein the at least one cooling hose (20) and / or the at least one further cooling hose (40) has a secondary insulating layer (28) circumferentially surrounding the outer layer (24).

13. Electric charging cable (100) according to claim 12, wherein the secondary insulation layer (28) is applied indirectly to the outer layer (24).

14. Electric charging cable (100) according to one of claims 1 to 13, wherein the at least one cooling hose (20) LEONI Kabel GmbH - 24 - 30A-170 138 has a burst pressure at 23 °C of at least 80 bar; and / or a burst pressure at 90 °C of at least 30 bar; and / or a tensile strength of at least 8.0 N / mm² 2 exhibits; and / or has an elongation at break of at least 200%; and / or has a hardness of at least 80 IRHD; and / or wherein at least one further cooling hose (40): has a burst pressure at 23 °C of at least 30 bar; and / or a burst pressure at 90 °C of at least 8 bar; and / or a tensile strength of at least 8.0 N / mm² 2 exhibits; and / or has an elongation at break of at least 200%; and / or has a hardness of at least 80 IRHD.

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