Power supply cable, power charging cable assembly and system thereof

Abstract

A power supply cable (20; 40; 50; 70) comprising a plurality of conductor assemblies (10; 30; 60), each conductor assembly comprising an electrical conductor (14; 63) and a cooling tube (11) defining a central internal passage for carrying a cooling fluid, wherein the cooling tube (11) comprises an inner polymeric layer (12) in contact with the internal passage (17) and an outer polymeric layer (13) surrounding the inner polymeric layer (12), and the inner polymeric layer (12) has a first Shore D hardness value and the outer polymeric layer has a second Shore D hardness value, the first Shore D hardness value being larger than the second Shore D hardness value. The present disclosure further relates to a power charging cable assembly and a charging system including said power supply cable.

Claims

1. A power supply cable comprising: a plurality of conductor assemblies, each conductor assembly comprising an electrical conductor and a cooling tube defining a central internal passage for carrying a cooling fluid, wherein the cooling tube comprises an inner polymeric layer in contact with the internal passage (17) and an outer polymeric layer surrounding the inner polymeric layer, and the inner polymeric layer has a first Shore D hardness value and the outer polymeric layer has a second Shore D hardness value, the first Shore D hardness value being larger than the second Shore D hardness value.

2. The power supply cable of claim 1, wherein the first Shore D hardness value of the inner polymeric layer is of from 55 to 95.

3. The power supply cable of claim 1, wherein the inner polymeric layer is selected from the group consisting of thermoplastic elastomer, polyamide, polyurethane, and silicone.

4. The power supply cable of claim 1, wherein the second Shore D hardness value of the outer polymeric layer is from 15 to 50.

5. The power supply cable of claim 1, wherein the outer polymeric layer is made of a thermoplastic elastomer or polyamide.

6. The power supply cable of claim 1, wherein the inner polymeric layer is made of a non-expanded polymeric material.

7. The power supply cable of claim 6, wherein the outer polymeric layer is made of a non-expanded polymeric material.

8. The power supply cable of claim 1, wherein the cooling tube has a thickness of from 1 to 4 mm.

9. The power supply cable of claim 1, wherein the cooling tube has a thickness and the inner polymeric layer is of less than or equal to 40% of the thickness of the cooling tube.

10. The power supply cable of claim 1, wherein the cooling tube has a thickness and the inner polymeric layer is of less than or equal to 30% of the thickness of the cooling tube.

11. The power supply cable of claim 1, wherein the electrical conductor of each conductor assembly is positioned to surround and be in contact with the outer polymeric layer of the cooling tube.

12. The power supply cable of claim 11, wherein the electrical conductor includes a plurality of metallic wires or a plurality of groups of bunched wires or stranded wires on and around the outer polymeric layer.

13. The power supply cable of claim 11, wherein the outer polymeric layer has a corrugated radially outer surface (25b).

14. The power supply cable of claim 13, wherein the corrugated radially outer surface of the outer polymeric layer comprises peaks and valleys, the peaks extending radially outwardly and the valley radially inwardly.

15. The power supply cable of claim 14, wherein the peak-to-peak distance is of from 0.25 to 0.5 mm.

16. The power supply cable of claim 14, wherein the peak-to-valley height is from 0.02 to 0.2 mm.

17. The power supply cable of claim 1, wherein the electrical conductor of each conductor assembly of the plurality of conductor assemblies is centrally positioned within the internal passage of the cooling tube, wherein the electrical conductor includes a group of stranded or bunched wires wound about a central longitudinal direction of each conductor assembly.

18. The power supply cable of claim 17, wherein each of the plurality of the conductor assemblies comprises a radially outer insulating layer surrounding the cooling tube.

19. A power charging cable assembly comprising a power supply cable according to claim 1, wherein the power supply cable has a first cable end and a second opposite cable end, and the power supply cable is provided with a first plug connector connected at the first cable end and with a termination portion at the second cable end.

20. A charging system comprising: a power charging cable assembly according to claim 18, wherein the power supply cable of the power charging assembly includes first and second conductor assemblies having respective first and second electrical conductors and respective first and second cooling tubes; a charging device comprising a socket outlet configured to be connected, by means of the termination portion of the power charging cable assembly, to said respective electrical conductors of the first and second conductor assemblies, and a cooling unit connected, by means of the termination portion, to the respective first and second cooling tubes of the first and second conductor assemblies, wherein the cooling unit is configured to pump a cooling fluid into the first cooling tube for guiding the fluid from the charging device toward the first plug connector through the first cooling tube and, through the second cooling tube in fluid connection with the first cooling tube, from the first plug connector back to the charging device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] The present disclosure will be now described more in detail hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. Drawings illustrating the embodiments are not-to-scale schematic representations.

[0064] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term about. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

[0065] FIG. 1 is a schematic cross-sectional view of a first embodiment of a conductor assembly for a power supply cable according to the present disclosure.

[0066] FIG. 2 shows a cross-sectional view of a power supply cable including conductor assemblies of the type described with reference to FIG. 1, according to an embodiment of the present disclosure.

[0067] FIG. 3 is a partial perspective view of the power supply cable of FIG. 2.

[0068] FIG. 4 is a cross-sectional view of a power supply cable according to another embodiment of the present disclosure.

[0069] FIG. 5 is a cross-sectional view of a second embodiment of a conductor assembly for a power supply cable according to the present disclosure.

[0070] FIG. 6 shows a cross-sectional view of a power supply cable including conductor assemblies of the type described with reference to FIG. 5, according to an embodiment of the present disclosure.

[0071] FIG. 7 is a cross-sectional view of a third embodiment of a conductor assembly for a power supply cable according to the present disclosure.

[0072] FIG. 8 is a cross-sectional view of a power supply cable including conductor assemblies of the type described with reference to FIG. 7, according to an embodiment of the present disclosure.

[0073] FIG. 9 is a pictorial not-to-scale representation of a waveform of the corrugated surface of the outer polymeric layer, according to an embodiment.

[0074] FIG. 10 is a schematic diagram of a power charging cable assembly, according to an embodiment of the present disclosure.

[0075] FIG. 11 is a schematic diagram for illustrating an exemplary embodiment of a charging system comprising the power charging cable assembly including a power supply cable according to the present disclosure.

[0076] In general, the same reference numeral will be used for possible variant embodiments of similar elements.

DETAILED DESCRIPTION

[0077] FIG. 1 depicts a conductor assembly 10 for a power supply cable according to a first embodiment of the present disclosure. The conductor assembly has a generally circular cross-section and extends along an axial direction. The conductor assembly 10 comprises a centrally positioned cooling tube 11 defining a central internal passage 17 for carrying a cooling fluid (not indicated).

[0078] The cooling tube 11 comprises an inner polymeric layer 12 defining the internal passage 17 and in contact with the cooling fluid, and an outer polymeric layer 13 surrounding the inner polymeric layer 12.

[0079] The cooling tube 11 has a radially inner surface 25a in contact with the internal passage 17 and an opposite radially outer surface 25b.

[0080] Specifically, the inner polymeric layer 12 has a radially inner surface that defines the inner surface 25a of the cooling tube 11, whereas the outer polymeric layer 13 has a radially outer surface that defines the outer surface 25b of the cooling tube.

[0081] In an embodiment, the outer polymeric layer 13 overlays and is in contact with the inner polymeric layer 12.

[0082] In an embodiment, the cooling tube 11 consists of the inner and the outer polymeric layer 12, 13.

[0083] In conductor assembly 10, an electrical conductor 14 is arranged in a radially external position with respect to the cooling tube, in particular on the outer surface 25b of cooling tube 11, i.e. on the outer polymeric layer 13. In embodiments, the electrical conductor 14 includes or consists of a plurality of metallic wires or of groups of wires, wherein the individual wires or the wire groups are stranded on and around the outer polymeric layer 13 of the cooling tube 11. In an embodiment, the plurality of metallic wires or wire groups are helically wound around the outer polymeric layer 13.

[0084] In an embodiment, the groups of stranded wires are grouped as Class 5 or Class 6 stranded conductors.

[0085] In an embodiment (not shown in the Figures), the electrical conductor 14 has a plurality of layers of wires placed one on top of the other, wherein each layer of wires has a helical winding of the wires in different directions.

[0086] An electrically insulating layer 15 surrounds the electrical conductor 14.

[0087] Elements of the conductor assembly 10 placed on/over the cooling tube 11 are located substantially co-axial with the cooling tube 11.

[0088] The inner polymeric layer 12 has a first Shore D hardness value and the outer polymeric layer 13 has a second Shore D hardness value, the first hardness value being larger than the second hardness value.

[0089] In embodiments, the first hardness value is from 55 to 95. In embodiments, the inner polymeric layer 12 is selected from the group consisting of thermoplastic elastomer (TPE), polyamide, polyurethane and silicone.

[0090] In embodiments, the second hardness value is from 15 to 50. In some embodiments, the second hardness value is from 15 to 45.

[0091] In embodiments, the outer polymeric layer 13 is made of TPE or polyamide. In an embodiment, the outer polymeric layer is a TPU (thermoplastic polyurethane) layer with hardness value from 30 to 40. In another embodiment, the outer polymeric layer is a polyamide layer with hardness value from 40 to 45.

[0092] In an example, the inner polymeric layer 12 is made of PA11 or PA12 with hardness value of 55 to 95 and the outer polymeric layer is made of PA11 or PA12 with hardness value from 40 to 45.

[0093] In one or more embodiments, the inner polymeric layer 12 exhibits a good chemical resistance.

[0094] In embodiments, the inner polymeric layer 12 is made of a non-expanded polymeric material.

[0095] In embodiments, the outer polymeric layer 13 is made of a non-expanded polymeric material.

[0096] In an embodiment, each of the inner polymeric layer 12 and the outer polymeric layer 13 is made of non-expanded polymeric material.

[0097] The cooling tube 11 made of the inner and the outer polymeric layer 12, 13 may have a thickness of 1 to 4 mm. In an embodiment, the thickness of the cooling tube 11 is of 1.5 to 3 mm.

[0098] In embodiments, the thickness of the inner polymeric layer 12 is of less than or equal to 40% of the total thickness of the cooling tube 11.

[0099] In an embodiment, the thickness of the inner polymeric layer 12 is of less than or equal to 30% of the total thickness of the cooling tube 11.

[0100] FIGS. 2 and 3 show a power supply cable 20 according to an embodiment of the present disclosure. The cable 20 extends along a central Z-axis (indicated in FIG. 3) for a length (when deployed in a straight line) and comprises a plurality of conductor assemblies 10 described with reference to FIG. 1, in the non-limiting example four conductor assemblies. The conductor assemblies 10 are arranged separately from one another in a radial arrangement about the Z-axis.

[0101] The cable 20 of the embodiments shown in FIGS. 2 and 3 is a round cable having a circular cross-section centered in the Z-axis.

[0102] In the example illustrated in the FIGS. 2-3, the plurality of conductor assemblies 10 are radially arranged about a data transmission unit 22 extending along the Z-axis. The data transmission unit 22, which can be of conventional type, includes one or more transmission cables 23, which can be insulated copper pilot cores and/or optical fibers, for transmission of control signals and/or other data signals. Within the data transmission unit 22, transmission cables 23 are arranged around a central thread member 21 extending along the Z-axis. In the embodiment shown in FIGS. 2 and 3 the transmission cables 23 of the data transmission unit are embedded in a filling material 24. The plurality of conductor assemblies 10 are helically wound about the centrally positioned data transmission unit 22, in accordance with conventional methods.

[0103] However, the data transmission unit 22 may be differently positioned within the cable 20. In particular, the transmission element may be placed at any interstitial space between the conductor assemblies 10.

[0104] An earth conductor 28 is positioned in the interstitial space between two conductor assemblies 10.

[0105] In the embodiment of FIGS. 2-3, the Z-axis is a symmetry axis of the radially external conductor assemblies 10 or more generally of the peripheral core structures, which are radially external to the central thread member 21.

[0106] A polymeric filler 19 is extruded around the core structures 10, 22, 28. As generally known, the main functions of the filler 19 is that to maintain the distance between the peripheral core structures radially external to the central tread member 21 and to fill the interstitial space between the core structures. In particular, the conductor assemblies 10 are positioned within the cable at a distance from one another. The polymeric filler 19 can be made of an electrically insulating material.

[0107] An outer jacket 18 made of a polymeric material surrounds the filler 19. The outer jacket 18 (not shown in FIG. 3), which may be extruded on the filler 19, forms the exterior of the power supply cable 20.

[0108] The core structures may include, in addition to the at least two conductor assemblies 10, additional earth conductors and/or transmission elements (not shown). When power supply cable 20 is in use, a cooling fluid runs through the cooling tubes of the respective conductor assemblies 10. The cooling fluid is per se known. Non-limiting examples of cooling fluids are oil, dielectric fluids, ethylene glycol, a mixture of water and ethylene glycol, and pure water.

[0109] FIG. 4 illustrates a cross-sectional view of a charging cable, according to a second embodiment of the present disclosure. Charging cable 40 comprises two separate conductor assemblies 10 of the type described with reference to FIG. 1. The two separate conductor assemblies 10 are arranged symmetrically with respect to the central Z-axis and run parallel to the Z-axis. In some embodiments, the two separate conductor assemblies 10 are helically wound around Z-axis.

[0110] The cable further includes a data transmission unit 22 and an earth conductor 28, both running parallel with respect to the Z-axis. In some embodiments, the data transmission unit 22 and the earth conductor 28 are helically wound around Z-axis. The core structures 10, 22, 28 are placed at a distance from one another within the charging cable 40.

[0111] A polymeric filler 19 fills the interstitial spaces between the core structures 10, 22, 28 and an outer jacket 18 surrounds and covers the filler 19.

[0112] FIG. 5 is a cross-sectional view of a conductor assembly according to another embodiment consistent with the present disclosure. Same numbers are used to identify like components having the same or similar functions to the elements of FIG. 1. With respect to the embodiment of FIG. 1, conductor assembly 30 comprises an earth conductor 31 placed on the insulating layer 15 surrounding the electrical conductor 14. The earth conductor 31 surrounds the insulating layer 15. An external insulating layer 32 covers the earth conductor 31.

[0113] FIG. 6 is a cross-sectional view of a charging cable according to an embodiment consistent with the present disclosure. Charging cable 50 includes a plurality of conductor assemblies 30 described with reference to FIG. 5. Due to the provision of an earth conductor within the conductor assemblies, an earth conductor as external element from the conductor assemblies may not be necessary. Conductor assemblies 30 are arranged radially about the central axis Z. An optional data transmission element 23 described in the foregoing is placed along the Z-axis. A polymeric filler 19 fills the interstitial spaces between the core structures 30 and an outer jacket 18 surrounds the filler 19.

[0114] FIG. 7 illustrates a cross-sectional view of a conductor assembly 60 according to a further embodiment consistent with the present disclosure. Conductor assembly 60 comprises a cooling tube 11 of the type described with reference to FIG. 1 and an electrical conductor 63 arranged within the internal passage 17 and extending axially along the cooling tube 11. In an embodiment, the conductor 63 is centrally positioned within the internal passage 17 of the cooling tube 11. The conductor 63 includes or consists of a group of stranded wires wound about a central longitudinal direction of the conductor assembly. In an alternative form, a group of wires are stranded about a central thread (not shown) arranged in the central longitudinal direction of the conductor assembly. An insulating layer 62 surrounds the cooling tube 11.

[0115] In an embodiment, the conductor 63 can move in radial direction within the cooling tube 11. Therefore, a relative movement between the cooling tube 11 and conductor 63 is permitted.

[0116] In other embodiments, the conductor 63 is kept in a fixed position within the cooling tube 11, i.e. the conductor is blocked with respect to the cooling tube, for example in the center of the internal passage 17 of the cooling tube 11. In an embodiment, an electrically insulating spacer or yarn (not shown) is helically wound around the conductor 63 ensuring that a constant distance between the conductor 63 and the cooling tube 11 is kept. In an embodiment, the cooling tube 11 includes a spacer (not shown) ensuring that a constant distance between the conductor 63 and the cooling tube 11 is kept.

[0117] FIG. 8 illustrates a cross-sectional view of a charging cable 70 including a plurality of conductor assemblies 60 described with reference to FIG. 7, according to an embodiment of the present disclosure.

[0118] The plurality of conductor assemblies 60 are helically wound about the Z-axis of the charging cable 70. In an embodiment, the Z-axis is a symmetry axis of the radially external conductor assemblies 60 or more generally of the peripheral core structures, which are radially external to the central Z-axis. In the example shown in FIG. 8, the charging cable 70 includes an optional data transmission unit 22 of the type described in the foregoing, which is centrally positioned at the cable Z-axis, and at least one earth conductor 28 (in the illustrated example, two). A polymeric filling material 19 fills the interstitial space between the core structures and an outer jacket 18 made of insulating polymeric material covers the filling material 19.

[0119] Auxiliary tubes, not shown in the figures, may be provided within the power supply cable 20, 40, 50 and 70 according to embodiments consistent with the present disclosure (non shown in the figures). Auxiliary tubes, which do not include a power conductor, may be used in an auxiliary cooling circuit for conveying a cooling fluid to the connector in order to cool the connecting pins down or to supply cold cooling fluid to the battery of an electric vehicle or more generally to an electric device in a machine, such earth-moving or marine equipment, which is being electrically charged.

[0120] The charging cables according to the embodiments shown in the figures are round cables, i.e. cables having a circularly cross section, although cross-sectional geometry of the cable should not be considered as limitative.

[0121] The power supply cable according to the present disclosure can be a DC power cable or an AC power cable.

[0122] An outer polymeric material with relatively low hardness, such as not larger the 50, provides for more adherence of the electrical conductor, in particular of the individual or grouped wires, to the cooling tube. The Applicant has however observed that, in embodiments where the electrical conductor surrounds the cooling tube, individual wires or wire groups, especially if having a relatively small cross-sectional area, may still make relatively small movements on the cooling tube outer surface during stranding.

[0123] In embodiments, the outer surface of the cooling tube 11 is a corrugated surface. In specific embodiments with reference to the conductor assemblies of FIGS. 1 and 5 (corrugations not illustrated), the radially outer surface 25b of the outer polymeric layer 13 (i.e. the outer surface of the cooling tube 11) is corrugated.

[0124] In embodiments, the outer surface 25b comprises waves forming alternating peaks and valleys, the peaks extending radially outwardly and the valley extending radially inwardly.

[0125] A pictorial not-to-scale representation of a waveform of the corrugated surface is given in FIG. 9. The peak-to-peak distance, d, is measured from center-to-center of peaks 101, of the exterior corrugated surface 100, and the peak-to-valley height, h, is the distance between a peak and a valley low (i.e. the lowest point of the valley.

[0126] In an embodiment, d is of at least 0.2 mm. In embodiments, the peak-to-peak distance is of from 0.2 to 0.5 mm.

[0127] In embodiments, the peak-to-valley height, h, is at most 0.2 mm. In an embodiment, the peak-to-valley height is from 0.02 to 0.2 mm.

[0128] It is to be understood that the radially outer surface 25b may exhibit alternating peaks and valleys which are shaped differently compared to the pseudo-sinusoidal ones presented in FIG. 9. In some embodiments, peaks and valleys of the radially outer surface 25b have triangular shape, rectangular shape, or trapezoidal shape.

[0129] Provision of a corrugated surface allows the wires to keep their position during stranding or during the extrusion of the insulating polymeric layer 15 on the stranded wires/wire groups.

[0130] Charging cables according to the embodiments described in the foregoing can be used in a power charging cable assembly for charging a battery, such as an electric vehicle battery. FIG. 10 schematically illustrates a charging cable assembly according to an example consistent with the present disclosure. Charging cable assembly 95 comprises a charging cable 94, the charging cable comprising a first and a second conductor assembly 93, 99 of the type described in the foregoing embodiments. For example, the charging cable is of the type described with reference to FIG. 2, 4, 6 or 8.

[0131] The charging cable 94 has a first cable end and an opposite second cable end (not indicated in the figure). The charging cable assembly 95 comprises a first plug connector 91, which is connected to the first end of the charging cable 94. The first plug connector 91 is designed to be electrically connected to a socket (not shown) of an electric vehicle. When in use, the respective separate cooling tubes of the first and second conductor assemblies 93, 99 carry a cooling fluid flowing in opposite directions as indicated by the arrows. The cooling tubes can be fluidly connected one to another in ways per se known. For example, the charging cable assembly 95 comprises a U-shaped connecting tube 88, which can be housed in the plug connector 91 (as shown in FIG. 10) or can be external from the charging cable assembly 95.

[0132] At the second cable end, the charging cable 94 is connected to a termination portion 87, which is designed to be electrically connected to a socket of a charging device (not shown). Although not indicated in the figure, termination portion 87 typically includes electrical contacts for electrical connections of the first and second conductor assemblies 93, 99 of cable 94 to a charging device (not shown in FIG. 10) and ducts to fluidly connect the first and second conductor assemblies 93, 99 to a cooling circuit within the charging device 92.

[0133] In the example of the figure, the termination portion 87 is or comprises a second plug connector 89 designed to be electrically connected to a socket of a charging device.

[0134] As generally known, different types of plug connectors exist for either alternating current (AC) or for direct current (DC), the latter typically allowing a fast charging.

[0135] FIG. 11 shows diagrammatically a charging system 90 for charging an electric vehicle 96, according to an example consistent with the present disclosure. The charging system 90 comprises a charging device 92 external with respect to vehicle 96 to be charged and a charging cable assembly 95, for example of the type described with reference to FIG. 10.

[0136] In ways per se known, the charging device 92, which can be for example a wall box or a charging station, comprises a socket outlet 97 (only schematically indicated) for electrical connection to the cable assembly 95 at its second end, in particular by means of termination portion 87, e.g. through connection with the second plug connector 89. The socket outlet 97 is configured to connect with the electrical conductors of the first and second conductor assemblies 10, 30, 60 of the charging cable 94.

[0137] Alternatively, the charging cable assembly is not provided with a second plug connector, but the termination portion (87) is configured to provide a direct and permanent connection to the electric network via the socket outlet 97 of the charging device.

[0138] The charging device 92 further comprises a cooling unit 98 (only schematically indicated) connected to the end of the charging cable assembly 95 connected with the charging device, wherein the cooling unit 98 is configured to pump a cooling fluid into a cooling tube of a conductor assembly (93 or 99) of the charging cable 94. The charging cable assembly 95 and the cooling unit 98 are designed to create, in ways per se known, a cooling loop with a fluid duct through the first cooling tube of the first conductor assembly 93 of cable 94 for guiding the fluid from the charging device 92 toward the plug connector 91 and, through a separate fluid duct through the second cooling tube of the second conductor assembly 99, from plug connector 91 back to the charging device 92.

[0139] Cooling arrangements in the charging system may be designed to cool different parts of the charging cable assembly, such as cable and/or plug connectors, and/or of the battery of the electric vehicle. Consequently, the cooling tubes of the first and second conductor assemblies 93, 99 can be fluidly connected one to another in different ways.

[0140] In an embodiment, the cooling tubes of the conductor assemblies 93, 99 are fluidly connected through the U-shaped connecting tube 88 housed in the connector plug 91.

[0141] In an embodiment, the cooling tubes of the first and second conductor assemblies 93, 99 can be fluidly connected, through the connector plug 91, to a cooling circuit configured to remove the heat from an electric device including batteries, such as an electric vehicle 96. In this configuration, the cooling tube of the first conductor assembly 93 is fluidly connected to the cooling tube of the second conductor assembly 99 through a circuit external to the power charging cable assembly 95. In operating condition, the cooling fluid runs from the cooling tube of the first conductor assembly 93 to the cooling tube of the second conductor assembly 99 removing the heat generated during the power exchange between the charging device and the electric device.

[0142] In an example, the cable assembly 95 and the cooling unit 98 may use two separate cooling loops for the cable 94 and the plug connector 91, for example in a configuration described in EP 3734618 A1.

[0143] Those skilled in the art will recognize that it is possible to combine the various features of the embodiments described above in order to obtain further embodiments, all of which are in any case encompassed by the present disclosure as defined by the following claims.