Conductive cable for a battery electric vehicle

Patent metadata

Field	Value
Publication number	US-12476018-B2
Application number	US-202318322211-A
Country	US
Kind code	B2
Filing date	May 23, 2023
Priority date	May 23, 2023
Publication date	Nov 18, 2025
Grant date	Nov 18, 2025

Abstract

A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.

First claim

What is claimed is:

1 . A conductive cable for a battery electric vehicle, the conductive cable comprising:
a plurality of first members in alignment to define a longitudinal axis of the conductive cable, each first member comprising a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis, the first outer layer comprising a first metal substrate having a first side and an opposite second side, the first outer layer comprising a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate, each first conductive wire comprising a first metallic material, the plurality of first members being disposed together along the longitudinal axis to define a cable bundle; and a non-conductive layer disposed about the cable bundle to define the conductive cable.

2 . The conductive cable of claim 1 wherein the first metal substrate has a thickness of between 5 microns and 25 microns.

3 . The conductive cable of claim 1 wherein the first metal substrate comprises one of copper, aluminum, carbon steel and stainless steel.

4 . The conductive cable of claim 1 wherein each of the first and second Cu-Gr multilayer composites comprises at least two Cu-Gr layers, and wherein each Cu-Gr layer comprises copper and graphene and has a thickness of between 0.1 micron and 0.5 micron.

5 . The conductive cable of claim 1 wherein each of the first and second Cu-Gr multilayer composites has a thickness of between 0.2 micron to 200 micron.

6 . The conductive cable of claim 1 wherein each of the first and second Cu-Gr multilayer composites has a graphene volume fraction of 0.002% to 0.2%.

7 . The conductive cable of claim 1 wherein the first metallic material is copper.

8 . The conductive cable of claim 1 further comprising:
at least one second member in alignment with the plurality of first members along the longitudinal axis, the at least one second member comprising a second conductive wire about which a second outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis, the second outer layer comprising a second metal substrate having a first side and an opposite second side, the second outer layer comprising a third copper-graphene (Cu-Gr) multilayer composite disposed on the first side of the second metal substrate and a fourth Cu-Gr multilayer composite disposed on the second side of the second metal substrate, each second conductive wire comprising one of aluminum and steel, the at least one second member being disposed together with the plurality of first members along the longitudinal axis defining the cable bundle.

9 . The conducive cable of claim 8 wherein the second metal substrate has a thickness of between 5 microns and 25 microns.

10 . The conducive cable of claim 8 wherein the second metal substrate comprises one of copper, aluminum, carbon steel and stainless steel.

11 . The conducive cable of claim 8 wherein each of the third and fourth Cu-Gr multilayer composites comprises at least two Cu-Gr layers, and
wherein each Cu-Gr layer of the third and fourth Cu-Gr multilayer comprises copper and graphene and has a thickness of 0.1 micron and 0.5 micron.

12 . The conducive cable of claim 8 wherein each of the third and fourth Cu-Gr multilayer composites has a thickness of 0.2 micron to 200 micron.

13 . The conducive cable of claim 8 wherein each of the third and fourth Cu-Gr multilayer composites has a graphene volume fraction of 0.002% to 0.2%.

14 . A conductive cable for a battery electric vehicle, the conductive cable comprising:
a plurality of first members in alignment to define a longitudinal axis of the conductive cable, each first member comprising a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis, the first outer layer comprising a first metal substrate having a first side and an opposite second side, the first outer layer comprising a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate, each first conductive wire comprising one of copper and aluminum, the plurality of first members being disposed together along the longitudinal axis to define a cable bundle; at least one second member in alignment with the plurality of first members along the longitudinal axis, the at least one second member comprising a second conductive wire about which a second outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis, the second outer layer comprising a second metal substrate having a first side and an opposite second side, the second outer layer comprising a third copper-graphene (Cu-Gr) multilayer composite disposed on the first side of the second metal substrate and a fourth Cu-Gr multilayer composite disposed on the second side of the second metal substrate, each second conductive wire comprising steel, the at least one second member being disposed together with the plurality of first members along the longitudinal axis defining the cable bundle; and a non-conductive layer disposed about the cable bundle to define the conductive cable.

15 . The conductive cable of claim 14 wherein each of the first and second metal substrates has a thickness of between 5 microns and 25 microns, and
wherein each of the first and second metal substrates comprises one of copper, aluminum, carbon steel and stainless steel.

16 . The conductive cable of claim 14 wherein each of the first, second, third, and fourth Cu-Gr multilayer composites comprises at least two Cu-Gr layers, and wherein each Cu-Gr layer comprises copper and graphene and has a thickness of between 0.1 micron and 0.5 micron.

17 . The conductive cable of claim 14 wherein each of the each of the first, second, third, and fourth Cu-Gr multilayer composites has a thickness of between 0.2 micron to 200 micron, and
wherein each of the first, second, third, and fourth Cu-Gr multilayer composites has a graphene volume fraction of 0.002% to 0.2%.

18 . The conductive cable of claim 14 wherein each of the first and second Cu-Gr multilayer composites comprises at least two Cu-Gr layers, and wherein each Cu-Gr layer comprises copper and graphene and has a thickness of between 0.1 micron and 0.5 micron.

19 . The conductive cable of claim 14 wherein each of the each of the first and second Cu-Gr multilayer composites has a thickness of between 0.2 micron to greater than 200 microns, and
wherein each of the first and second Cu-Gr multilayer composites has a graphene volume fraction of 0.002% to 3%.

20 . A conductive cable for a battery electric vehicle, the conductive cable comprising:
a plurality of first members in alignment to define a longitudinal axis of the conductive cable, each first member comprising a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis, the first outer layer comprising a first copper-graphene (Cu-Gr) multilayer composite, each first conductive wire comprising a first metallic material, the plurality of first members being disposed together along the longitudinal axis; at least one second member in alignment with the plurality of first members alo

Assignees

• Gm Global Tech Operations Llc

Inventors

• Liu Yi
• Wang Qigui
• Li Huaxin
• Sonta Kestutis A
• Wilson Daniel J

Classifications

• H01B1/023 Primary

  Alloys based on aluminium · CPC title

• H01B5/08

  Several wires or the like stranded in the form of a rope · CPC title

• B60L53/18

  Cables specially adapted for charging electric vehicles · CPC title

• H01B1/04

  mainly consisting of carbon-silicon compounds, carbon or silicon · CPC title

• H01B7/0009

  Details relating to the conductive cores · CPC title