Motor vehicle charging cable

Patent metadata

Field	Value
Publication number	US-11220188-B2
Application number	US-202016876231-A
Country	US
Kind code	B2
Filing date	May 18, 2020
Priority date	May 16, 2019
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

A motor vehicle charging cable for DC voltage charging of an electrical energy store of a motor vehicle has a cable sheath that encloses conductors, such as first and second cooling-fluid-cooled electrical conductor for first and second DC voltage phases, a ground conductor or equipotential bonding conductor and/or at least one control conductor. Shaped elements are arranged between the cable sheath and the conductors at positions of the motor vehicle charging cable that are fixed in mounts. The shaped elements guide, clamp and restrict a relative movement between the conductors. The cable sheath restricts a relative movement between the conductors between those positions at which the motor vehicle charging cable is fixed in mounts.

First claim

What is claimed is:

1. A motor vehicle charging cable for DC voltage charging of an electrical energy store of a motor vehicle, the motor vehicle charging cable having a first end, via which the motor vehicle charging cable is able to be coupled to a charging socket of a motor vehicle via a charging plug secured to the first end, and a second end, via which the motor vehicle charging cable is able to be coupled to a charging station, the motor vehicle charging cable comprising:
conductors that include at least one of: a cooling-fluid-cooled first electrical conductor for a first DC voltage phase, a cooling-fluid-cooled second electrical conductor for a second DC voltage phase, a ground conductor, an equipotential bonding conductor and/or at least one control conductor;
a cable sheath enclosing the conductors;
at least first and second shaped elements arranged between the cable sheath and the conductors at positions in proximity respectively to the first end and the second end of the motor vehicle charging cable, and first and second mounts in proximity to the first and second ends of the motor vehicle charging cable, areas of the motor vehicle charging cable in proximity to the first and second ends being fixed respectively in the first and second mounts, the shaped elements guiding, clamping and restricting a relative movement between the conductors, and wherein the cable sheath restricts a relative movement between the conductors at positions of the motor vehicle charging cable between those positions of the motor vehicle charging cable that are fixed in mounts.

2. The motor vehicle charging cable of claim 1 , wherein each of the respective shaped elements has a cylindrical main body with a lateral surface formed with slots or grooves that run in a longitudinal direction of the motor vehicle charging cable and via which the conductors are insertable into cutouts of the respective shaped element.

3. The motor vehicle charging cable of claim 1 , wherein the respective shaped element are made of a polyamide material.

4. The motor vehicle charging cable of claim 1 , further comprising clamping elements arranged around the cable sheath at positions along the motor vehicle charging cable at which the shaped elements are disposed, the clamping elements pressing the cable sheath against the shaped elements and thereby clamping the conductors of the motor vehicle charging cable.

5. The motor vehicle charging cable of claim 4 , further comprising clamping elements arranged around the cable sheath at positions aligned respectively with the shaped elements.

6. The motor vehicle charging cable of claim 5 , wherein each of the clamping elements is a clamping ring having two parts that are screwed to one another.

7. The motor vehicle charging cable of claim 1 , wherein the charging station has a roof, and the motor vehicle charging cable further has an intermediate mount fixed at a position on the motor vehicle charging cable between the first end and the second end of the motor vehicle charging cable and the intermediate mount being fixed in the roof of the charging station, and an intermediate shaped element arranged between the cable sheath and the conductors at a position inward of the intermediate mount.

8. The motor vehicle charging cable of claim 7 , further comprising a handle adjacent to the first end and comprising one of the mounts, one of the shaped elements being inward of the handle.

9. The motor vehicle charging cable of claim 1 , wherein the conductors include the first and second electrical conductors each of which comprises:
a conductor sleeve;
a conductor core running within the conductor sleeve and including conductor core strands;
a first cooling fluid channel enclosed by the conductor core strands of the respective conductor core for cooling the respective conductor core from positions inward of the conductor core strands;
a second cooling fluid channel enclosing an outside the respective conductor core for cooling the respective conductor core strands of the respective conductor core; and
tubular spacers positioned between the conductor core strands of the respective electrical conductor and the conductor sleeve of the respective electrical conductor, the tubular spacers subdividing the respective second cooling fluid channel so that cooling fluid flows through and around the tubular spacers, and the tubular spacers bearing against one another and against the conductor sleeve of the respective electrical conductor.

10. The motor vehicle charging cable of claim 9 , wherein the conductor sleeve comprises an outer sleeve layer and an inner sleeve layer, the tubular spacers being positioned between the conductor core strands of the respective electrical conductor and the inner sleeve layer of the conductor sleeve of the respective electrical conductor, and the tubular spacers bearing against one another and against the inner sleeve layer of the conductor sleeve of the respective electrical conductor.

11. The motor vehicle charging cable of claim 10 , wherein
the tubular spacers that are adjacent to one another bear loosely against one another,
the inner sleeve layer is coated with an adhesive or is self-adhesive at the side facing the spacers and the tubular spacers bear adhesively against the inner sleeve layer of the conductor sleeve of the respective electrical conductor,
the tubular spacers bear against the conductor cores and are twisted around the conductor cores.

12. The motor vehicle charging cable of claim 9 , wherein
the cooling fluid is able to flow through the first cooling fluid channel of the respective electrical conductor in a first direction and through the second cooling fluid channel of the respective electrical conductor in an opposite, second direction,
the first and second cooling fluid channels of the respective electrical conductor define a conductor-specific cooling circuit of the respective electrical conductor.

Assignees

• Porsche Ag

Inventors

• Heyne Raoul
• Roenfanz Jari
• Koehler David

Classifications

• H02J7/751

  concerning the insertion or the connection of the batteries · CPC title

• H01B9/028

  with screen grounding means, e.g. drain wires · CPC title

• H01B7/40

  with arrangements for facilitating mounting or securing · CPC title

• B60Y2200/91

  Electric vehicles · CPC title

• H01B7/17

  Protection against damage caused by external factors, e.g. sheaths or armouring · CPC title