Granted Patent B2

US 12,567,518 · App. 17/911,801 · Granted Mar 3, 2026

Inventors: Tomasz Oslislok (Bad Zurzach, CH); Albert Martinez Vall (Baden, CH)

Assignee: BRUGG eConnect AG

H01B7/423B60L53/16B60L53/18B60L53/302H01B7/0266H02J7/0042

Abstract

Claims (72)

1 . A single line for a charging cable, comprising:

a) an open support structure in the form of a helix and having a longitudinal extent,

b) at least one channel conductor made of an electrically conductive material, and

c) an insulation,

wherein:

d) the at least one channel conductor is the form of a helix that wraps around and contacts the open support structure along its longitudinal extent,

e) the insulation encases the open support structure and the at least one channel conductor,

f) at least one channel for a cooling fluid is formed by the support structure and the at least one channel conductor,

g) the insulation is impermeable to the cooling fluid and is electrically insulating, and

wherein:

h) the support structure has a first thread direction, the at least one channel conductor has a second thread direction, and the second thread direction differs from the first thread direction, or

i) the pitch ratio, which is the smallest pitch of the helix of the at least one channel conductor divided by the pitch of the helix of the open support structure, is greater than 4/3 and less than 50.

2 . The single line according to claim 1 , wherein:

the at least one channel conductor is a plurality of channel conductors,

each of said channel conductors follows a helical line having the second thread direction, the pitch and a radius, and the thread direction and the pitch of the helical lines of all of said channel conductors are at least substantially equal, and

the radii of all helical lines of all of the channel conductors are equal.

3 . The single line according to claim 1 , wherein:

the at least one channel conductor is a plurality of channel conductors, and

each of the channel conductors is a stranded wire or a bundle of individual thin conductor wires.

4 . The single line according to claim 1 , wherein the open support structure has a cross-section that remains constant in shape and size along the longitudinal extent, but has a shape that twists about a longitudinal axis along the longitudinal extent.

5 . The single line according to claim 1 , wherein the insulation is a fibre reinforced insulation.

6 . The single line according to claim 5 , wherein the fibres are woven into a braid.

7 . The single line according to claim 5 , wherein the fibres in the insulation are arranged substantially in a layer and in said layer cover between 30 and 90% of the area of the layer.

8 . A charging cable comprising:

a first and a second single line according to claim 1 , and

a common protective sheath.

9 . The charging cable according to claim 8 , further comprising:

a grounded conductor braid surrounding the first and second single lines and enveloped by or integrated into the common protective sheath, and/or

a grounded conductor in the form of juxtaposed wires or strands or bundles which are integrated into the common protective sheath and which wrap both of the first and second single lines together, wherein strands or bundles are separated from one another by sections of protective sheath material which does not contain any grounded conductor.

10 . The charging cable according to claim 8 , further comprising:

at least one hose made of a fluid-tight material, which is located inside the common protective sheath but outside the first and second single lines.

11 . A connection system comprising the single line according to claim 1 and two connection parts, each of the two connection parts respectively comprising a fluid connection and an electrical connection,

wherein each of the fluid connections enables fluid to flow into or out of the single line and each of the electrical connections provides a path for conducting electrical power between a tap point and the at least one conductor of the single line,

wherein each of the connection parts is formed as a chamber which has an opening for the fluid-tight connection of the single line and a second opening for the connection of a fluid line, and

wherein an electrical contact for establishing an electrical connection with the at least one conductor of the single line is located within this chamber, and this contact is connected to a current line which leads to the tapping point.

12 . A charging system comprising a first and a second connection system according to claim 11 , wherein the first connection system comprises the first single line of a charging cable and the second connection system comprises a second single line of the charging cable, the charging cable comprising a common protective sheath,

wherein:

a first end of the first single line and a first end of the second single line are located at the first end of the charging cable,

a second end of the first single line and a second end of the second single line are located at the second end of the charging cable,

an end connector comprises the connection part at the first end of the first single line and the connection part at the first end of the second single line, and

a plug comprises the connection part at the second end of the first single line and the connection part at the second end of the second single line.

13 . A method of charging an energy storage device, at a stationary charging station configured to provide cooling fluid and electrical power and to which a first end of the charging cable according to claim 8 is connected, comprising:

a) connecting a second end of the charging cable to the energy storage device,

b) introducing the cooling fluid under pressure into the channels of the first and second single lines of the charging cable, and

c) conducting electrical energy via the channel conductors of the first and second single lines of the charging cable,

wherein signal cables of the charging cable transmit signals for controlling and/or monitoring the charging process and/or the state of charge of the energy storage device.

14 . A single line for a charging cable, comprising:

an open support structure having a longitudinal extent,

at least one channel conductor made of an electrically conductive material, the at least one channel conductor being wrapped around and contacting the open support structure along its longitudinal extent,

an insulation encasing the open support structure and the at least one channel conductor, the insulation being reinforced by fibres, and

at least one channel for a cooling fluid defined by the support structure and the channel conductors,

wherein:

the insulation is impermeable to the cooling fluid and is electrically insulating, and

the fibres in the insulation are arranged substantially in a layer and in said layer cover between 30 and 90% of the area of the layer.

15 . A method of manufacturing the charging cable according to claim 8 comprising the following steps, which are carried out sequentially in a production line:

a) providing the first and second single lines and additional components of an inner structure of the charging cable as endless products;

b) twisting the components of the inner structure together in a first direction;

c) wrapping the twisted components of the inner structure with wires, bundles or strands in a second direction different from the first direction, and

d) co-extruding a protective sheath.

16 . A vehicle comprising at least two single lines according to claim 1 , wherein the at least two single lines electrically connect a drive energy storage unit and a drive unit and/or electrically connect a socket in the exterior of a vehicle and a drive energy storage unit.

17 . A charging station comprising at least two single lines according to claim 1 configured to connect a plug of a charging system to a stationary power source.

18 . The single line according to claim 1 , wherein:

the support structure has the first thread direction, the at least one channel conductor has the second thread direction, and the second thread direction differs from the first thread direction, and

the pitch ratio is a quasi-irrational number in the range of 6 to 50.

19 . A method of manufacturing the single line according to claim 14 , comprising the following steps which are carried out successively in a production line:

a) providing the open support structure and multiple channel conductors as a continuous material;

b) winding the channel conductors onto the open support structure;

c) winding further conductors around the structure created in step b);

d) co-extruding the insulation around the result of step or;

e) weaving a braid of fibres or winding fibres around the insulation produced in step d), and

f) co-extruding a second layer of material of the insulation around the product of step e) to form a fibre reinforced insulation.

20 . The single line according to claim 14 , wherein the fibres in said layer cover between 50 and 70% of the area of the layer.

Assignments (1)

Priority Claims (1)

Continuity (1)

References Cited (54)