Rigid and Flexible HV Battery Cable

Abstract

A conductor arrangement for an electrical energy or data transmission connection includes at least one conductor portion comprising a flexible internal conductor and a thermoplastic hard plastic sheath surrounding the flexible internal conductor. The thermoplastic hard plastic sheath is transformable into a formable state when heated to a threshold temperature defined at a specific softening point, and the thermoplastic hard plastic sheath hardens into a formed state when cooled.

1 . A conductor arrangement for an electrical energy or data transmission connection, comprising:
 at least one conductor portion comprising a flexible internal conductor;   a thermoplastic hard plastic sheath surrounding the flexible internal conductor;   wherein, the thermoplastic hard plastic sheath is transformable into a formable state when heated to a threshold temperature defined at a specific softening point   wherein, the thermoplastic hard plastic sheath hardens into a formed state when cooled.   
     
     
         2 . The conductor arrangement according to  claim 1 , wherein the thermoplastic hard plastic sheath comprises a bending strength of more than 50 N/mm 2  at an operating temperature of 25° C. 
     
     
         3 . The conductor arrangement according to  claim 1 , wherein the flexible internal conductor extends into the at least one conductor portion. 
     
     
         4 . The conductor arrangement of  claim 3 , wherein the flexible internal conductor is deformable with respect to its cross-section. 
     
     
         5 . The conductor arrangement according to  claim 1 , further comprising an adjoining conductor portion, wherein the flexible internal conductor is surrounded in by the adjoining conductor portion via a flexible protective sheath. 
     
     
         6 . The conductor arrangement according to  claim 1 , wherein the flexible internal conductor comprises a single core. 
     
     
         7 . The conductor arrangement according to  claim 1 , wherein the flexible internal conductor comprises a multi-core design. 
     
     
         8 . The conductor arrangement according to  claim 1 , wherein the flexible internal conductor comprises copper or aluminium. 
     
     
         9 . The conductor arrangement according to  claim 1 , wherein the flexible internal conductor comprises a single core design and is surrounded by a flexible insulation. 
     
     
         10 . The conductor arrangement according to  claim 9 , wherein the flexible insulation comprises PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass. 
     
     
         11 . A conductor assembly for an electrical energy or data transmission connection, comprising:
 a conductor portion comprising a flexible multi-core internal conductor;   a sheath surrounding the flexible internal conductor;   wherein, each core of the multi-core internal conductor comprises a copper strand surrounded by a flexible insulation layer;   further wherein, the sheath is deformable into a desired shape when heated to a threshold temperature and cooled thereafter.   
     
     
         12 . The conductor assembly of  claim 11 , further comprising a metal film surrounding the multi-core internal conductor for shielding electromagnetic interference. 
     
     
         13 . The conductor assembly of  claim 11 , wherein each core of the multi-core internal conductor is spaced from adjacent cores internally of the sheath. 
     
     
         14 . The conductor assembly of  claim 11 , wherein the conductor portion is deformable along its length and with respect to its cross-section. 
     
     
         15 . The conductor assembly of  claim 11 , further comprising:
 a second conductor portion adjoining a first end of the conductor portion;   a third conductor portion adjoining a second end of the conductor portion;   a first contact element coupled to the second conductor portion; and   a second contact element coupled to the third conductor portion.   
     
     
         16 . The conductor assembly of  claim 15 , further comprising a flexible sheath layer disposed around the second conductor portion and the third conductor portion. 
     
     
         17 . The conductor assembly of  claim 16 , wherein the flexible sheath layer comprises a corrugated tube. 
     
     
         18 . The conductor assembly of  claim 15 , wherein the first contact element and the second contact element comprise cable lugs. 
     
     
         19 . The conductor assembly of  claim 15 , further comprising a first multi-pole plug connector coupled to the second conductor portion and a second multi-pole plug connector coupled to the third conductor portion. 
     
     
         20 . A conductor arrangement for an electrical energy or data transmission connection, comprising:
 a first conductor portion comprising an internal conductor having a first end and a second end, the internal conductor comprising a single core;   a sheath layer surrounding the internal conductor;   a second conductor portion adjoining the first end of the conductor portion;   a third conductor portion adjoining the second end of the conductor portion;   a first contact element coupled to the second conductor portion; and   a second contact element coupled to the third conductor portion;   wherein, the internal conductor comprises a single core design and is surrounded by a flexible insulation layer;   wherein, the sheath layer is deformable into a formable state when heated to a threshold temperature and then cooled.