Battery, method of manufacturing a sensor for implantation inside the battery, and system

Abstract

The application provides a battery, a preparation method and a system for a sensor implanted in the battery, the battery comprising a positive electrode (i.e. a positive pole), a negative electrode (i.e. a negative pole) and a sensor, wherein the sensor is made of a first substrate, a second substrate and at least one sensitive element array hot-press packaged, the first substrate is provided with a first electrode circuit, the second substrate is provided with a second electrode circuit, the sensitive element array is coupled with the positive electrode through the first electrode circuit, and the sensitive element array is coupled with the negative electrode through the second electrode circuit. When the battery is in a working state, the sensitive element array can collect internal battery parameters of the battery, and the internal battery parameters can be used to determine whether the battery is in thermal runaway. Based on the application, the internal battery parameters of the battery can be collected in real time by the sensitive element array to determine whether the battery is in thermal runaway, the sampling accuracy is higher, and the safety and reliability of the battery are improved.

Description

Technical Field

[0001] This application relates to the field of microelectronic devices, and more particularly to a battery, a method and system for fabricating a sensor for implantation inside the battery. Background Technology

[0002] With the widespread application of batteries in various industries such as electric vehicles, communications, and energy, market demand for batteries is gradually increasing, and high requirements are being placed on battery safety. Because batteries continuously generate heat during operation, thermal runaway (such as battery fire and explosion) can occur when a large amount of heat accumulates inside the battery, potentially leading to safety accidents. Therefore, real-time monitoring of the battery's internal heat (such as internal temperature) is crucial. Summary of the Invention

[0003] This application provides a battery, a method and system for fabricating sensors for implantation inside the battery, which can determine whether the battery is thermally runaway by real-time acquisition of internal battery parameters through a sensitive element array, with higher sampling accuracy, thereby improving the safety and reliability of battery use.

[0004] Firstly, this application provides a battery comprising a positive electrode (also referred to as the positive electrode), a negative electrode (also referred to as the negative electrode), and a sensor. The sensor is fabricated by thermocompression encapsulation of a first substrate, a second substrate, and at least one sensitive element array. The at least one sensitive element array is disposed between the first and second substrates, and the sensitive elements in each sensitive element array may be the same or different. The first and second substrates are made of a polymer with good compatibility with the corrosive electrochemical environment inside the battery; therefore, the first and second substrates can be understood as flexible substrates made of polymer. A first electrode circuit can be fabricated on the first substrate, and a second electrode circuit can be fabricated on the second substrate. The sensitive element array can be coupled to the positive electrode through the first electrode circuit, and the sensitive element array can also be coupled to the negative electrode through the second electrode circuit. In other words, the sensitive element array can be directly connected to the positive electrode through the first electrode circuit, or the first electrode circuit can be indirectly connected to the positive electrode through other devices; the sensitive element array can be directly connected to the negative electrode through the second electrode circuit, or the second electrode circuit can be indirectly connected to the negative electrode through other devices. The dimensions of the first substrate, the second substrate, and the sensing element array are all smaller than the internal dimensions of the battery. When the battery is in operation, the aforementioned sensing element array can be used to acquire the battery's internal battery parameters, which can be used to determine whether the battery is experiencing thermal runaway. These internal battery parameters may include, but are not limited to, the battery's internal temperature, internal pressure, and parameters corresponding to its operating state.

[0005] In this application, the internal battery parameters of the battery can be collected in real time by the sensitive element array to determine whether the battery is thermally runaway. The sampling accuracy is higher, which improves the safety and reliability of battery use and extends the battery life. In addition, the aforementioned sensitive element arrays, the first substrate and the second substrate can constitute a complete sensor that can realize multi-point (i.e., multiple positions) and multi-parameter (i.e., internal battery parameters) sensing. The first substrate and the second substrate can serve as electrical connection carriers for each sensitive element array and physically protect the sensitive element array, which improves the stability and reliability of the sensitive element array and makes it more adaptable.

[0006] In conjunction with the first aspect, in a first possible implementation, the aforementioned sensitive element array includes at least two sensitive elements, each of which includes a first electrode and a second electrode. The first electrode of each sensitive element is electrically connected to a first electrode circuit to couple a positive electrode, and the second electrode of each sensitive element is electrically connected to a second electrode circuit to couple a negative electrode. This application refers to electronic components in a sensor that sensitively detect physical, chemical, or biological information and convert it into electrical information as sensitive elements, such as temperature sensitive elements or pressure sensitive elements. Temperature sensitive elements can be used to collect the internal temperature of a battery, and pressure sensitive elements can be used to collect the internal pressure of a battery. In the battery provided in this application, battery parameters (such as internal temperature, internal pressure, and other parameters) at multiple locations (i.e., multiple points) inside the battery can be collected through each sensitive element in the sensitive element array, resulting in higher sampling accuracy and greater sampling flexibility.

[0007] In conjunction with the first possible implementation of the first aspect, in the second possible implementation, conductive adhesive is coated on the first electrode circuit and the first electrode of the sensing element. The first electrode of the sensing element can be electrically connected to the first electrode circuit via the conductive adhesive to couple the positive electrode. Here, conductive adhesive can be understood as an adhesive that has a certain degree of conductivity after curing or drying, and can be used to connect multiple conductive materials (such as the first electrode of the sensing element and the first electrode circuit) together to form an electrical path between the connected conductive materials. In the battery provided in this application, the first electrode of the sensing element and the first electrode circuit can form an electrical path through the conductive adhesive, thereby establishing a reliable and stable electrical connection with the positive electrode in the battery. This method is low-cost, simple to operate, has higher battery parameter sampling efficiency, and is more adaptable.

[0008] In a third possible implementation, combining the first or second possible implementation of the first aspect, conductive adhesive is coated on the second electrode circuit and the second electrode of the sensing element. The second electrode of the sensing element can be electrically connected to the second electrode circuit via the conductive adhesive to couple the negative electrode. It is understood that the conductive adhesive can form an electrical path between the second electrode of the sensing element and the second electrode circuit, thereby establishing a reliable and stable electrical connection with the negative electrode in the battery. This approach is low-cost, simple to operate, and offers higher sampling efficiency and greater adaptability for battery parameters. Optionally, when conductive adhesive is coated on both the first electrode circuit and the first electrode of the sensing element, and the second electrode circuit and the second electrode of the sensing element, the first electrode of the sensing element can be electrically connected to the first electrode circuit via the conductive adhesive, and the second electrode of the sensing element can be electrically connected to the second electrode circuit via the conductive adhesive. This allows for the simultaneous establishment of reliable and stable electrical connections with both the positive and negative electrodes in the battery, further improving the reliability and stability of the sensing element array and enhancing its adaptability.

[0009] In a fourth possible embodiment, in conjunction with any one of the first to third possible embodiments of the first aspect, the first and second electrodes of each sensitive element in the above-mentioned sensitive element array can be made by an electroplating process, which can improve the corrosion resistance of the sensitive element, thereby making it compatible with the corrosive electrochemical environment inside the battery, and thus improving the stability and reliability of the sensitive element array.

[0010] In conjunction with any one of the first to fourth possible embodiments of the first aspect, in the fifth possible embodiment, the aforementioned sensitive element further includes a sensitive layer disposed between the first electrode and the second electrode. The shape of the sensitive element may include, but is not limited to, a square or a rectangle, and the area of ​​the sensitive element is greater than or equal to 1.5mm × 1mm and less than or equal to 4.5mm × 2.5mm, and the thickness of the sensitive element is greater than or equal to 100μm and less than or equal to 600μm. The thickness of both the first electrode and the second electrode is greater than or equal to 10nm and less than or equal to 1000nm. The row spacing and column spacing of the sensitive elements in the aforementioned sensitive element array are greater than or equal to 5.5mm and less than or equal to 20.5mm, wherein the distance between the location of the sensitive element and the edge location of each substrate in the first substrate and the second substrate is greater than or equal to 2.5mm and less than or equal to 7.5mm. It is understood that the shape, area, and thickness of the sensing element, the thickness of the first electrode, the thickness of the second electrode, the row and column spacing of the sensing elements in the sensing element array, and the specific location of the sensing elements can be determined by the internal dimensions of the battery and existing processes, and are not limited here. The materials of the first and second electrodes may include, but are not limited to, aluminum (Al), gold (Au), platinum (Pt), platinum-titanium (PtTi), AuPtTi, or NiCr. The material of the sensing layer may include, but is not limited to, ceramic materials, quartz crystals, or lanthanum gallium silicate (La₂Ga₅SiO₅). 14 This can be abbreviated as LGS crystal. In the battery provided in this application, the sensing element array fabricated according to the above parameters has the characteristics of small volume (e.g., the thickness of the sensing element array is less than 500 μm), thereby reducing the impact on the battery capacity and thus efficiently maximizing the battery's performance. In addition, the sensing element array fabricated according to the above parameters can meet the fabrication technology requirements of small-area, high-density, large-scale array devices, and can obtain a high number of parameter (internal battery parameter) sensing, making it more versatile.

[0011] In conjunction with any of the first to fifth possible embodiments of the first aspect, in the sixth possible embodiment, the first electrode circuit and the second electrode circuit described above can be made by flexible printed circuit board (FPC) technology, which can greatly reduce the size and weight of the sensor, thereby making a high-density, miniaturized, and highly reliable flexible sensor with lower cost and wider applicability.

[0012] In conjunction with any of the first to sixth possible embodiments of the first aspect, in the seventh possible embodiment, the first and second substrates can be flexible substrates made of polymer, wherein the thickness of each substrate is greater than or equal to 25 μm and less than or equal to 100 μm, and the length and width of each substrate are greater than or equal to 70 mm and less than or equal to 160 mm. It is understood that the length, width, and thickness of each substrate can be determined by the internal dimensions of the battery and existing processes, and are not limited herein. In the battery provided in this application, the sensor made according to the above parameters is more flexible and has minimal impact on the battery capacity (i.e., smaller size), and the sensor is better compatible with the corrosive electrochemical environment inside the battery, making it easy to achieve industrial production; in addition, the sensor can exist stably inside the battery for a long time (i.e., it will not affect the sensor's performance and accuracy), thereby ensuring that the sensor collects battery parameters at multiple locations inside the battery in real time, further improving the sampling accuracy of internal battery parameters and making it more applicable.

[0013] Secondly, this application provides a method for fabricating a sensor for implantation inside a battery. This method can be performed by equipment with sensor manufacturing capabilities (hereinafter referred to as sensor manufacturing equipment). In this method, the sensor manufacturing equipment can fabricate a first electrode circuit on a first substrate to obtain a first substrate with the first electrode circuit, and fabricate a second electrode circuit on a second substrate to obtain a second substrate with the second electrode circuit. Then, the sensor manufacturing equipment can fabricate at least one sensitive element array according to the array pattern of the sensitive element array, the size of the sensitive elements in the sensitive element array, and the processing technology. The array pattern can include the arrangement position of each sensitive element in the sensitive element array, and the sensitive element includes a first electrode and a second electrode. Here, the array pattern, the size of the sensitive elements, and the processing technology can be determined by the internal dimensions of the battery, the electrochemical environment inside the battery, and the requirements for the sensor to collect internal battery parameters. After fabricating at least one sensitive element array, the sensor manufacturing equipment can perform thermo-press packaging of the first substrate with the first electrode circuit, the second substrate with the second electrode circuit, and each sensitive element array to obtain the sensor. In this method, the first electrode of each sensitive element in the aforementioned sensitive element array is electrically connected to a first electrode circuit, which is used to couple the positive electrode of the battery. The second electrode of each sensitive element in the sensitive element array is electrically connected to a second electrode circuit, which is used to couple the negative electrode of the battery. It is understood that the sensor manufacturing equipment can implant the sensor into the battery after it has been manufactured to collect internal battery parameters, or it can manufacture the sensor during the battery manufacturing process to collect internal battery parameters. The specific method can be determined according to the actual application scenario and is not limited here. This method can produce a complete array sensor capable of multi-point, multi-parameter sensing. The first and second substrates can serve as electrical connection carriers for the sensitive element array and physically protect the sensitive element array. Furthermore, this array sensor has better compatibility with the corrosive electrochemical environment inside the battery, improving the reliability and stability of the sensor. In addition, this array sensor can better detect the internal battery parameters to determine whether the battery is experiencing thermal runaway, with higher sampling accuracy, improving the safety and reliability of battery use, and offering stronger adaptability.

[0014] In conjunction with the second aspect, in the first possible implementation, the aforementioned sensor manufacturing equipment can perform photoimaging pattern transfer and etching on the first substrate based on the circuit pattern of the first electrode circuit to fabricate the first electrode circuit on the first substrate. Here, the circuit pattern of the first electrode circuit can be determined by the array pattern of the sensitive element array and the size of the sensitive elements in the sensitive element array. In other words, the sensor manufacturing equipment can fabricate the first electrode circuit on the first substrate based on the pattern of the first electrode circuit using flexible printed circuit board technology, which can greatly reduce the size and weight of the sensor and produce a high-density, miniaturized, and highly reliable flexible sensor with lower cost and wider applicability.

[0015] In conjunction with the second aspect or the first possible implementation of the second aspect, in the second possible implementation, the sensor manufacturing equipment described above can perform photoimaging pattern transfer and etching on the second substrate based on the circuit pattern of the second electrode circuit to fabricate the second electrode circuit on the second substrate. Here, the circuit pattern of the second electrode circuit can be determined by the array pattern of the sensitive element array and the size of the sensitive elements in the sensitive element array. In other words, the sensor manufacturing equipment can fabricate the second electrode circuit on the second substrate based on the pattern of the second electrode circuit using flexible printed circuit board technology, which can greatly reduce the size and weight of the sensor and produce a high-density, miniaturized, and highly reliable flexible sensor with lower cost and wider applicability.

[0016] In conjunction with any of the second aspect to the second possible implementation, in the third possible implementation, the sensor manufacturing equipment described above can coat the first electrode circuit and the first electrode of the sensitive element in each sensitive element array with conductive adhesive, thereby achieving the effect of electrically connecting the first electrode of the sensitive element in each sensitive element array to the first electrode circuit through conductive adhesive, and thus establishing a reliable and stable electrical connection with the positive electrode in the battery. This method is low in cost and simple in operation.

[0017] In a fourth possible embodiment, combining any of the second to third possible implementations of the second aspect, the sensor manufacturing equipment can coat the second electrode circuit and the second electrodes of the sensitive elements in each sensitive element array with conductive adhesive. This achieves the effect of electrically connecting the second electrodes of the sensitive elements in each sensitive element array to the second electrode circuit through the conductive adhesive, thereby establishing a reliable and stable electrical connection with the negative electrode in the battery. This method is low-cost and simple to operate. Optionally, if the first electrode of each sensitive element in each sensitive element array is electrically connected to the first electrode circuit through conductive adhesive, and the second electrode of each sensitive element in each sensitive element array is electrically connected to the second electrode circuit through conductive adhesive, a reliable and stable electrical connection can be established simultaneously with both the positive and negative electrodes in the battery, thereby improving the reliability and stability of the sensitive element array and enhancing its adaptability.

[0018] Thirdly, this application provides a battery system including a battery management system (BMS) and multiple batteries connected to the BMS, as described in any of the first to seventh possible embodiments above. Each sensing element array within the battery can collect internal battery parameters and output these parameters to the BMS. The BMS can then determine whether the battery is experiencing thermal runaway based on these internal parameters. This battery system is applicable to electric devices, including but not limited to electric vehicles, electric amusement equipment, electric trains, electric bicycles, golf carts, ventilation equipment, stamping equipment, crystal equipment, water pumps, and various machine tools. In this application, more accurate internal battery parameters can be collected in real time through each sensing element array and output to the BMS, thereby enabling more accurate determination of whether the battery is experiencing thermal runaway, thus improving the safety and reliability of battery use and broadening its applicability.

[0019] Fourthly, this application provides a power supply system including an energy storage module and a direct current (DC) / DC converter module connected to the energy storage module. The energy storage module can be composed of multiple batteries connected in series and parallel as described in any of the first to seventh possible embodiments above. It is understood that since each battery has an embedded sensor, during battery operation, the sensors can collect internal battery parameters in real time to determine whether the battery is experiencing thermal runaway, thereby improving the safety and reliability of battery use to ensure its normal operation, and thus improving the system's power supply efficiency and reliability. Furthermore, it can extend battery life, reduce system power supply costs, and has strong applicability.

[0020] In conjunction with the fourth aspect, in the first possible implementation, in a hybrid power supply application scenario, the power supply system further includes a power supply module and a power conversion module connected to the power supply module. The power conversion module can supply power to the load based on the voltage provided by the power supply module, thereby improving the system's power supply efficiency and flexibility, and making it more applicable.

[0021] In conjunction with the first possible implementation of the fourth aspect, in the second possible implementation, in the application scenario of photovoltaic-storage hybrid power supply, the above power supply module may include a photovoltaic array, and the power conversion module may be a DC / DC conversion module.

[0022] In conjunction with the first possible implementation of the fourth aspect, in the third possible implementation, in the wind-storage hybrid power supply application scenario, the power supply module includes a generator, and the power conversion module can be an alternating current (AC) / DC conversion module.

[0023] In a fourth possible implementation, combining any one of the first to third possible implementations of the fourth aspect, the power supply system further includes a DC bus and a DC / AC conversion module. The DC / DC conversion module and the power conversion module can be connected to the input terminal of the DC / AC conversion module via the DC bus. The output terminal of the DC / AC conversion module can be connected to an AC load or an AC power grid to supply power to the AC load or AC power grid, thereby improving the system's power supply efficiency. Optionally, the power supply system may also include a grid-connected junction box, and the output terminal of the DC / AC conversion module can be connected to an AC load or an AC power grid via the grid-connected junction box. The specific connection method between the functional modules in the power supply system provided in this application can be determined according to the actual application scenario and is not limited here.

[0024] In this application, the internal battery parameters of the battery can be collected in real time through the sensitive element array to determine whether the battery is thermally runaway. The sampling accuracy is higher, which improves the safety and reliability of battery use. In addition, the aforementioned sensitive element array, the first substrate and the second substrate can constitute a complete sensor that can realize multi-point and multi-parameter (internal battery parameter) sensing. The first substrate and the second substrate can serve as electrical connection carriers for the sensitive element array and physically protect the sensitive element array, which improves the stability and reliability of the sensitive element array and makes it more adaptable. Attached Figure Description

[0025] Figure 1 This is a schematic diagram illustrating the application scenarios of the battery provided in this application;

[0026] Figure 2 This is a schematic diagram of the battery structure provided in this application;

[0027] Figure 3 This is a schematic diagram of the structure of the sensor provided in this application;

[0028] Figure 4 This is a schematic diagram of the structure of the temperature-sensitive element provided in this application;

[0029] Figure 5 This is a schematic diagram of the structure of the pressure-sensitive element provided in this application;

[0030] Figure 6 This is a structural schematic diagram of the power supply system provided in this application;

[0031] Figure 7This is another structural schematic diagram of the power supply system provided in this application;

[0032] Figure 8 This is yet another structural schematic diagram of the power supply system provided in this application;

[0033] Figure 9 This is a schematic flowchart of the method for fabricating a sensor for implantation inside a battery provided in this application;

[0034] Figure 10 This is a schematic diagram of the fabrication process of the sensor provided in this application. Detailed Implementation

[0035] The battery provided in this application is applicable to various fields, including new energy smart microgrids, power transmission and distribution, new energy fields (such as photovoltaic grid connection or wind power grid connection), photovoltaic-storage power generation (such as powering electrical equipment (such as refrigerators and air conditioners) or the power grid), wind-storage power generation, high-power converters (such as converting DC power to high-power high-voltage AC power), and electric equipment (such as various electric devices). The specific application can be determined according to the actual application scenario, and no restrictions are imposed here. The battery system provided in this application can be adapted to different application scenarios, such as photovoltaic-storage power supply scenarios, wind-storage power supply scenarios, pure energy storage power supply scenarios, electric vehicle applications, or other application scenarios. The following explanation will use the energy storage power supply application scenario as an example, and will not be elaborated further.

[0036] Please see also Figure 1 , Figure 1 This is a schematic diagram illustrating the application scenarios of the battery provided in this application. In a pure energy storage power supply application scenario, such as... Figure 1As shown, the power supply system includes a battery system, a DC / DC converter, and a DC / AC converter. The battery system can be connected to the DC / AC converter via the DC / DC converter. The battery system may include a battery management system and multiple batteries connected to the battery management system, with each battery having an embedded sensor. During the power supply process, the DC / DC converter can output a target DC voltage to the DC / AC converter based on the DC voltage provided by the multiple batteries. The DC / AC converter then converts the target DC voltage input to the DC / DC converter into an AC voltage, which is used to supply power to the grid and electrical equipment. During the power supply process, the batteries continuously generate heat due to their constant operation. Accumulated heat can even lead to thermal runaway (such as battery fire and explosion), necessitating real-time monitoring of internal battery heat changes. The sensors embedded within the batteries can collect internal battery parameters in real time and output these parameters (i.e., parameters characterizing the internal heat of the battery) to the battery management system. The aforementioned battery management system can accurately determine whether the battery is in thermal runaway based on internal battery parameters, thereby improving the safety and reliability of battery use to ensure normal battery operation, extending battery life, and improving system power supply efficiency and reliability, making it more versatile.

[0037] The following will combine Figures 2 to 8 The battery, power supply system, and their working principle provided in this application are illustrated with examples.

[0038] Please see Figure 2 , Figure 2 This is a schematic diagram of the battery structure provided in this application. Figure 2As shown, battery 1 includes a positive electrode 10, a negative electrode 11, and a sensor 12. The sensor 12 can be manufactured by hot-pressing (i.e., hot-pressing process) using a first substrate 121, a second substrate 122, and at least one sensitive element array (i.e., one or more sensitive element arrays, such as sensitive element arrays 123a to 123n). The sensitive element arrays 123a to 123n can be disposed between the first substrate 121 and the second substrate 122. The hot-pressing process can be understood as heating and pressurizing the preform (i.e., the first substrate 121, the second substrate 122, and the sensitive element arrays 123a to 123n) after it has been laid out, to produce a fiberboard (i.e., sensor 12) with certain mechanical strength and water resistance. The battery 1 may include, but is not limited to, a lithium-ion battery (or simply a lithium battery). The first substrate 121 and the second substrate 122 may be made of a polymer that is highly compatible with the corrosive electrochemical environment inside the battery. Therefore, the first substrate 121 and the second substrate 122 can be understood as flexible substrates made of polymers. The polymers may include, but are not limited to, polyimide (PI), polyvinylidene fluoride (PVDF), polyethylene (PE), and polypropylene (PP).

[0039] In some feasible implementations, the aforementioned sensing element arrays 123a to 123n can be of the same type or of different types. The specific type of sensing element array can be determined by the internal battery parameters (i.e., parameters used to determine whether battery 1 is experiencing thermal runaway) that sensor 12 needs to collect. This sensing element array may include, but is not limited to, temperature sensing element arrays and pressure sensing element arrays. For example, sensing element arrays 123a to 123n can all be either temperature or pressure sensing element arrays; or, a portion of the sensing element arrays 123a to 123n can be temperature sensing element arrays, while another portion can be pressure sensing element arrays. The temperature sensing element array can be used to collect the temperature at multiple locations inside battery 1, and the pressure sensing element array can be used to collect the pressure at multiple locations inside battery 1.

[0040] In some feasible implementations, the above Figure 2A first electrode circuit 1211 is formed on the first substrate 121, and a second electrode circuit 1221 is formed on the second substrate 122. The sensitive element arrays 123a to 123n can be coupled to the positive electrode 10 (i.e., directly or indirectly connected) through the first electrode circuit 1211, and the sensitive element arrays 123a to 123n can also be coupled to the negative electrode 11 through the second electrode circuit 1221. In other words, the sensitive element arrays 123a to 123n can be directly connected to the positive electrode 10 through the first electrode circuit 1211; or, the sensitive element arrays 123a to 123n are electrically connected to the first electrode circuit 1211, and the first electrode circuit 1211 can be indirectly connected to the positive electrode 10 through other devices. The aforementioned sensitive element arrays 123a to 123n can be directly connected to the negative electrode 11 via the second electrode circuit 1221; alternatively, the sensitive element arrays 123a to 123n are electrically connected to the second electrode circuit 1221, and the second electrode circuit 1221 can be indirectly connected to the negative electrode 11 via other devices. In this application, the circuit (or electrode) on the first substrate used for coupling with the positive electrode can be referred to as the first electrode circuit, and the circuit (or electrode) on the second substrate used for coupling with the negative electrode can be referred to as the second electrode circuit.

[0041] In some feasible embodiments, the materials used to fabricate the first electrode circuit 1211 and the second electrode circuit 1221 may include, but are not limited to, aluminum (Al), gold (Au), platinum (Pt), platinum-titanium (PtTi), AuPtTi, or NiCr. The first electrode circuit 1211 and the second electrode circuit 1221 may be fabricated using flexible printed circuit board (PCB) technology. PCB technology refers to the process of fabricating conductor circuits (i.e., the first electrode circuit 1211 or the second electrode circuit 1221) on the surface of a flexible substrate (i.e., the surface of the first substrate 121 or the surface of the second substrate 122) using photolithography pattern transfer and etching processes. It is understood that because the first electrode circuit 1211 and the second electrode circuit 1221 are electrode circuits fabricated using flexible PCB technology, the size and weight of the sensor 12 can be greatly reduced, thereby creating a high-density, miniaturized, and highly reliable flexible sensor 12 with lower cost and wider applicability.

[0042] In some feasible embodiments, the dimensions of the first substrate 121, the second substrate 122, and the sensing element arrays 123a to 123n are all smaller than the internal dimensions of the battery 1 to ensure that the sensor 12 can be implanted inside the battery 1. For example, the first substrate 121 and the second substrate 122 are flexible substrates made of polymer. The thickness of each substrate in the first substrate 121 and the second substrate 122 can be greater than or equal to 25 μm and less than or equal to 100 μm, and the length and width of each substrate can be greater than or equal to 70 mm and less than or equal to 160 mm. The length and width of each substrate can be the same or different. The length, width, and thickness of each substrate can be determined by the internal dimensions of the battery 1 and existing processes, and are not limited here. It is understood that the sensor 12 made according to the above parameters is more flexible and has minimal impact on the capacity of the battery 1 (i.e., smaller size), and the sensor 12 is better compatible with the corrosive electrochemical environment inside the battery, making it easy to achieve industrial production. In addition, the aforementioned sensor 12 can exist stably inside the battery 1 for a long time (i.e., it will not affect the performance and accuracy of the sensor 12), thereby ensuring that the sensor 12 (i.e., the sensitive element array 123a to the sensitive element array 123n) collects battery parameters at multiple locations inside the battery 1 in real time, further improving the sampling accuracy of the internal battery parameters and making it more applicable.

[0043] In some feasible implementations, when battery 1 is in an operational state (also known as a service state), each of the aforementioned sensitive element arrays 123a to 123n can collect internal battery parameters of battery 1 in real time. These internal battery parameters can be used to determine whether battery 1 is experiencing thermal runaway. These internal battery parameters may include, but are not limited to, the temperature at multiple locations within battery 1, the pressure at multiple locations, and parameters corresponding to the operational state. Therefore, each sensitive element array can monitor the temperature distribution, pressure distribution, and operational state within battery 1 in real time, thereby more accurately determining whether battery 1 is experiencing thermal runaway. In this case, sensor 12 can be understood as a built-in array sensor for sensing the internal temperature distribution, pressure distribution, and state of the battery. It can be understood that the aforementioned sensitive element arrays 123a to 123n can collect internal battery parameters of battery 1 in real time to determine whether battery 1 is experiencing thermal runaway, resulting in higher sampling accuracy, improved battery safety and reliability, and extended battery life. Furthermore, the aforementioned sensitive element arrays 123a to 123n, the first substrate 121, and the second substrate 122 can constitute a complete sensor 12 capable of sensing multiple points (i.e., multiple locations) and multiple parameters (i.e., internal battery parameters). The first substrate 121 and the second substrate 122 can serve as electrical connection carriers for the sensitive element arrays 123a to 123n and physically protect the sensitive element arrays 123a to 123n, thereby ensuring that the sensitive element arrays 123a to 123n will not be corroded by the electrochemical environment inside the battery, resulting in unusability or reduced performance. This improves the stability and reliability of the sensitive element arrays and enhances their adaptability.

[0044] In some feasible embodiments, each of the aforementioned sensitive element arrays 123a to 123n can be composed of at least two sensitive elements arranged together. Each sensitive element includes a first electrode and a second electrode. The first electrode of the sensitive element is electrically connected to the first electrode circuit 1211 to couple the positive electrode 10, and the second electrode of the sensitive element is electrically connected to the second electrode circuit 1221 to couple the negative electrode 11. This application refers to an electronic component in a sensor that sensitively senses certain physical, chemical, or biological information and converts it into electrical information as a sensitive element (also called a sensitive component or sensitive device), such as a temperature sensitive element or a pressure sensitive element. For example, a temperature sensitive element can collect the internal temperature of the battery 1, and a pressure sensitive element can collect the internal pressure of the battery 1. This application refers to the electrode in the sensitive element that is electrically connected to the first electrode circuit as the first electrode, and the electrode in the sensitive element that is electrically connected to the second electrode circuit as the second electrode. The materials of the first and second electrodes may include, but are not limited to, aluminum (Al), gold (Au), platinum (Pt), platinum-titanium (PtTi), AuPtTi, or NiCr, and the material of the sensitive layer may include, but is not limited to, ceramic materials, quartz crystals, or lanthanum gallium silicate (La2Ga5SiO2). 14 This can be abbreviated as LGS crystal, and the ceramic material may include, but is not limited to: CaCu3Ti4O 12 Ca 1-x Ba x Cu3Ti4O 12 Ca 1- x Sr x Cu3Ti4O 12 CaCu3Ti 1-y Zr y O 12 CaCu3Ti 1-y Mn y O 12 (1-α)Ba 1-x Sr x Zr y Ti 1-y O3-αBiNaTiO3, Ba 1- x Sr x Zr y Ti 1-y-z Y z O3, Ba 1-x Sr x Zr y Ti 1-y-z Gd z O3, Ba 1-x Sr x Zr y Ti 1-y-zYb z O3 and Ba 1-x Sr x Zr y Ti 1-y- z Dy z O3, quartz crystals can include AT-cut, SC-cut, X-cut, and Y-cut crystals. It can be understood that the sensing elements in each sensing element array can collect battery parameters (such as temperature, pressure, and other parameters) at multiple locations inside the battery, resulting in higher sampling accuracy and greater sampling flexibility.

[0045] Optionally, in some feasible embodiments, conductive adhesive may be coated on the first electrode circuit 1211 and the first electrodes of the sensitive elements in each sensitive element array. The first electrodes of the sensitive elements in each sensitive element array can be electrically connected to the first electrode circuit 1211 via the conductive adhesive to couple the positive electrode 10. Here, the conductive adhesive can be understood as an adhesive that has a certain conductivity after curing or drying. This conductive adhesive can be used to connect various conductive materials (such as the first electrodes of the sensitive elements in each sensitive element array and the first electrode circuit 1211) together to form an electrical path between the connected conductive materials. It is understood that the conductive adhesive can form an electrical path between the first electrodes of the sensitive elements in each sensitive element array and the first electrode circuit 1211, thereby establishing a reliable and stable electrical connection with the positive electrode 10 in the battery 1 to enable the sensitive element to work normally. This method is low-cost, simple to operate, and more adaptable. Optionally, conductive adhesive may be coated on the second electrode circuit 1221 and the second electrodes of the sensitive elements in each sensitive element array. The second electrodes of the sensitive elements in each sensitive element array can be electrically connected to the second electrode circuit 1221 via the conductive adhesive to couple the negative electrode 11. It is understood that conductive adhesive can be used to form an electrical path between the second electrode of each sensitive element in the sensitive element array and the second electrode circuit 1221, thereby establishing a reliable and stable electrical connection with the negative electrode 11 in the battery 1 to enable the sensitive element to work normally. This method is low-cost, simple to operate, and more adaptable. Optionally, if conductive adhesive is coated on the first electrode circuit 1211 and the first electrode of each sensitive element in the sensitive element array, and conductive adhesive is also coated on the second electrode circuit 1221 and the second electrode of each sensitive element in the sensitive element array, the first electrode of each sensitive element in the sensitive element array can be electrically connected to the first electrode circuit 1211 through conductive adhesive, and the second electrode of the sensitive element can be electrically connected to the second electrode circuit 1221 through conductive adhesive. This allows for the simultaneous establishment of a reliable and stable electrical connection with both the positive electrode 10 and the negative electrode 11 in the battery 1, further improving the reliability and stability of the sensitive element array and enhancing its adaptability.

[0046] In some feasible embodiments, the first and second electrodes of the sensing elements in the aforementioned sensing element arrays 123a to 123n can be manufactured using an electroplating process, which can improve the corrosion resistance of the sensing elements, thereby making them compatible with the corrosive electrochemical environment inside the battery, and thus improving the stability and reliability of the sensing element array. Optionally, the aforementioned sensing element further includes a sensing layer disposed between the first and second electrodes. The shape of the sensing element may include, but is not limited to, a square or a rectangle, and the area of ​​the sensing element is greater than or equal to 1.5mm × 1mm and less than or equal to 4.5mm × 2.5mm, and the thickness of the sensing element is greater than or equal to 100μm and less than or equal to 600μm. The thickness of both the first and second electrodes is greater than or equal to 10 nm and less than or equal to 1000 nm. The row spacing and column spacing of the sensing elements in the sensing element array are greater than or equal to 5.5 mm and less than or equal to 20.5 mm. The distance between the location of the sensing element and the edge of each substrate in the first substrate 121 and the second substrate 122 is greater than or equal to 2.5 mm and less than or equal to 7.5 mm. It can be understood that the sensing element array made according to the above parameters has the characteristics of small volume (e.g., the thickness of the sensing element array is less than 500 μm), thereby reducing the impact on the capacity of battery 1 and thus efficiently maximizing the performance of battery 1. In addition, the sensing element array made according to the above parameters can meet the fabrication technology requirements of small-area, high-density, large-scale array devices, and can obtain a high number of parameters (i.e., battery parameters at multiple locations) for sensing, making it more versatile.

[0047] In some feasible implementations, the area and thickness of the first substrate 121 and the second substrate 122, the shape of the sensing element, the area and thickness of the sensing element, the thickness of the first electrode, the thickness of the second electrode, the row spacing and column spacing of the sensing elements in the sensing element array, and the specific position of the sensing elements can be determined by the internal dimensions of the battery 1 and the existing process, and are not limited here. For example, the first substrate 121 and the second substrate 122 can be PI substrates with an area of ​​70mm × 95mm. The first electrode circuit and the second electrode circuit can be Cu electrodes with a thickness of 4μm, which are made by flexible printed circuit board technology. The sensing element array can be composed of 4×4 identical pressure sensing elements, wherein the sensing element is square in shape, has an area of ​​3.18mm × 2.18mm, and a thickness of 100μm. The row spacing and column spacing of the sensing elements in the sensing element array are 7.5mm and 10mm, respectively, and the distance between the position of the sensing element and the edge position of each substrate in the first substrate 121 and the second substrate 122 can be 10.5mm. The first electrode and the second electrode in the sensing element can be Au electrodes with a thickness of 1μm, which are made by electroplating technology. The sensing layer in the sensing element can be a quartz wafer made by wafer processing technology. The sensing element array made according to these parameters has the characteristics of small volume (such as the thickness of the sensing element array is less than 500μm), thereby reducing the impact of the sensor 12 on the capacity of the battery 1, and thus efficiently exerting the performance of the battery 1. For ease of description, the following explanation will take sensor 12, which includes a sensing element array (such as sensing element array 123a), as an example. Please refer to the examples below. Figure 3 , Figure 3 This is a schematic diagram of the structure of the sensor provided in this application.

[0048] In some feasible embodiments, the sensor 12 can be fabricated by thermo-pressing a first substrate 121 with a first electrode circuit 1211, a second substrate 122 with a second electrode circuit 1221, and a sensing element array 123a. The sensing element array 123a can be composed of 4×4 identical sensing elements. In this case, the top view of the sensor 12 can be as shown... Figure 3 As shown in 3a, this top view directly displays the arrangement position (i.e., array pattern) of each sensitive element in the sensitive element array 123a. The sensitive element array 123a may include sensitive elements 1231a, 1232a, and other sensitive elements. The left view of the sensor 12 described above can be shown as follows: Figure 3 As shown in 3b, the left view can directly display the column of sensitive elements where sensitive element 1231a is located; the right view of the aforementioned sensor 12 can be as follows: Figure 3As shown in 3c, the right view directly displays the column of sensitive elements where sensitive element 1232a is located. In the above left and right views, since the first electrode circuit 1211 is located above the sensitive element array 123a, it can also be called the upper electrode circuit; since the second electrode circuit 1221 is located below the sensitive element array 123a, it can also be called the lower electrode circuit.

[0049] In some feasible implementations, where the aforementioned sensing element 1231a is a temperature sensing element, please also refer to... Figure 4 , Figure 4 This is a schematic diagram of the temperature sensing element provided in this application. The front view of the aforementioned sensing element 1231a can be seen as follows... Figure 4 As shown in 4a, the sensing element 1231a may include a first electrode 12311a, a second electrode 12312a, and a sensing layer 12313a. Since the first electrode 12311a is located above the sensing layer 12313a, it can be understood as the upper electrode of the sensing element 1231a; since the second electrode 12312a is located below the sensing layer 12313a, it can be understood as the lower electrode of the sensing element 1231a. A top view of the sensing element 1231a can be shown as follows. Figure 4 As shown in 4b, the side view of sensitive element 1231a can be as follows: Figure 4 As shown in 4c. It should be noted that the front, top, and side views of the other sensitive elements in the sensitive element array 123a can be found in the front, top, and side views of the sensitive element 1231a, and will not be repeated below. The aforementioned sensitive element array 123a can collect the temperature at multiple locations inside the battery 1 using 4×4 temperature sensitive elements, thereby accurately determining whether the battery 1 is experiencing thermal runaway. This results in higher temperature sampling accuracy, improving the safety and reliability of battery use, and extending battery life.

[0050] In some feasible implementations, where the aforementioned sensing element 1232a is a pressure sensing element, please also refer to... Figure 5 , Figure 5 This is a schematic diagram of the pressure-sensitive element provided in this application. The front view of the aforementioned pressure-sensitive element 1232a can be seen as follows... Figure 5As shown in 5a, the sensing element 1232a may include a first electrode 12321a, a second electrode 12322a, and a sensing layer 12323a. Since the first electrode 12321a is located above the sensing layer 12323a, it can be understood as the upper electrode of the sensing element 1232a; since the second electrode 12322a is located below the sensing layer 12323a, it can be understood as the lower electrode of the sensing element 1232a. A top view of the sensing element 1232a can be shown as follows. Figure 5 As shown in 5b, the side view of sensitive element 1232a can be as follows: Figure 5 As shown in 5c. It should be noted that the front, top, and side views of the other sensitive elements in the sensitive element array 123a can be found in the front, top, and side views of the sensitive element 1232a. The aforementioned sensitive element array 123a can collect pressure data at multiple locations inside the battery 1 using 4×4 pressure sensitive elements. This allows for accurate determination of whether the battery 1 is experiencing thermal runaway, resulting in higher pressure sampling accuracy, thus improving the safety and reliability of battery use and extending battery life.

[0051] In the battery 1 provided in this application, the aforementioned sensitive element arrays 123a to 123n can collect battery parameters at multiple locations inside the battery in real time to determine whether the battery 1 is experiencing thermal runaway. This results in higher sampling accuracy, improved battery safety and reliability, and extended battery life. Furthermore, the aforementioned sensitive element arrays 123a to 123n, the first substrate 121, and the second substrate 122 can constitute a complete sensor 12 capable of multi-point, multi-parameter sensing. The first substrate 121 and the second substrate 122 serve as electrical connection carriers for the sensitive element arrays 123a to 123n and physically protect them, improving the stability and reliability of the sensitive element arrays and enhancing their adaptability.

[0052] For some feasible implementation methods, please refer to Figure 6 , Figure 6 This is a structural schematic diagram of the power supply system provided in this application. In a pure energy storage power supply application scenario, such as... Figure 6 As shown, the power supply system 2 includes an energy storage module 20 and a DC / DC converter module 21 connected to the energy storage module 20. The energy storage module 20 can be composed of multiple batteries (such as batteries 200a to 200m) connected in series and parallel. For example, each of batteries 200a to 200m can be the aforementioned... Figures 2 to 5The battery 1 is shown. When a DC load is connected to the output of the DC / DC converter module 21, the DC / DC converter module 21 can supply power to the DC load based on the DC voltage provided by batteries 200a to 200m. This is because each of the batteries 200a to 200m has a sensor embedded inside (as described above). Figures 2 to 5 As shown in the sensor 12), during the battery's operation, the sensor can collect the battery's internal battery parameters in real time to determine whether the battery is thermally runaway, thereby improving the safety and reliability of the battery to ensure its normal operation, and thus improving the system's power supply efficiency and reliability; in addition, it can also extend the battery's lifespan, reduce the system's power supply cost, and has strong applicability.

[0053] For some feasible implementation methods, please refer to Figure 7 , Figure 7 This is another structural schematic diagram of the power supply system provided in this application. For example... Figure 7 As shown above, Figure 6 The power supply system 2 shown also includes a power supply module 22 and a power conversion module 23 connected to the power supply module 22. In a photovoltaic-storage hybrid power supply application scenario, the power supply module 22 may include a photovoltaic array, and the power conversion module 23 may be a DC / DC conversion module. The photovoltaic array may be composed of multiple photovoltaic strings connected in series and parallel, and a photovoltaic string may include multiple photovoltaic modules (also called solar panels or photovoltaic panels). In a wind-storage hybrid power supply application scenario, the power supply module 22 may include a generator, and the power conversion module 23 may be an AC / DC conversion module. When the output terminal of the power conversion module 23 is connected to a DC load, the power conversion module 23 can supply power to the DC load based on the DC voltage provided by the photovoltaic array or the AC voltage provided by the generator. It can be understood that if the batteries 200a to 200m do not experience thermal runaway, the batteries 200a to 200m and the photovoltaic array (or generator) can simultaneously supply power to the DC load, further improving the system's power supply efficiency and flexibility; if the batteries 200a to 200m experience thermal runaway, the photovoltaic array (or generator) can also supply power to the DC load, improving the system's power supply reliability.

[0054] For some feasible implementation methods, please refer to Figure 8 , Figure 8 This is yet another structural diagram of the power supply system provided in this application. For example... Figure 8 As shown above, Figure 7The power supply system 2 shown may further include a DC bus 24 and a DC / AC conversion module 25. The DC / DC conversion module 21 and the power conversion module 23 can be connected to the input terminals of the DC / AC conversion module 25 via the DC bus 24, and the output terminal of the DC / AC conversion module 25 can be connected to an AC load or an AC power grid. Optionally, the power supply system 2 may further include a grid-connected junction box (not shown in the figure), through which the output terminal of the DC / AC conversion module 25 can be connected to an AC load or an AC power grid. During the process of supplying power to the AC load or AC power grid, the DC / DC conversion module 21 can output DC voltage to the DC / AC conversion module 25 based on the DC voltage provided by batteries 200a to 200m, and the power conversion module 23 can output DC voltage to the DC / AC conversion module 25 based on the DC voltage provided by the photovoltaic array or the AC voltage provided by the generator. At this time, the DC / AC conversion module 25 can convert the DC voltage input to the DC / DC conversion module 21 and the DC voltage input to the power conversion module 23 into AC voltage, and supply power to the AC load or AC power grid based on this AC voltage, thereby improving the system's power supply efficiency.

[0055] In the power supply system 2 provided in this application, since each of the batteries 200a to 200m is equipped with a sensor, the sensor can collect the internal battery parameters of the battery in real time during the battery operation to determine whether the battery is thermally runaway, thereby improving the safety and reliability of the battery to ensure its normal operation, and thus improving the system power supply efficiency and reliability; in addition, it can also extend the battery life, reduce the system power supply cost, and has strong applicability.

[0056] Please see Figure 9 , Figure 9 This is a schematic flowchart illustrating the fabrication method of the sensor for implantation inside a battery provided in this application. This method is applicable to the above-mentioned... Figures 2 to 8 The battery shown in the image, this method can be performed by equipment with sensor manufacturing capabilities (which may be simply referred to as sensor manufacturing equipment), such as... Figure 9 As shown, the method includes the following steps S101 to S103:

[0057] Step S101: A first electrode circuit is fabricated on a first substrate to obtain a first substrate having the first electrode circuit, and a second electrode circuit is fabricated on a second substrate to obtain a second substrate having the second electrode circuit.

[0058] In some feasible implementations, the sensor manufacturing equipment can perform photoimaging pattern transfer and etching (i.e., flexible printed circuit board process) on a first substrate based on the circuit pattern of the first electrode circuit, thereby fabricating the first electrode circuit on the first substrate to obtain a first substrate having the first electrode circuit. The circuit pattern of the first electrode circuit can be determined by the array pattern of the sensitive element array and the size of the sensitive elements in the sensitive element array. The thickness of the first substrate can be greater than or equal to 25 μm and less than or equal to 100 μm, and the length and width of the first substrate can be greater than or equal to 70 mm and less than or equal to 160 mm. The length and width of the first substrate can be the same or different. Furthermore, the sensor manufacturing equipment can also perform photoimaging pattern transfer and etching on a second substrate based on the circuit pattern of the second electrode circuit, thereby fabricating the second electrode circuit on the second substrate to obtain a second substrate having the second electrode circuit. The circuit pattern of the second electrode circuit can be determined by the array pattern of the sensitive element array and the size of the sensitive elements in the sensitive element array. The thickness of the second substrate can be greater than or equal to 25 μm and less than or equal to 100 μm, and the length and width of the second substrate can be greater than or equal to 70 mm and less than or equal to 160 mm. The length and width of the second substrate can be the same or different. The first and second substrates here can be understood as flexible substrates made of polymers, wherein the polymers can include, but are not limited to, PI, PVDF, PE, and PP.

[0059] It is understood that the aforementioned sensor manufacturing equipment can use flexible printed circuit board technology to fabricate a first electrode circuit on a first substrate based on the pattern of the first electrode circuit, and fabricate a second electrode circuit on a second substrate based on the circuit pattern of the second electrode circuit. This can greatly reduce the size and weight of the sensor, and produce a high-density, miniaturized, and highly reliable flexible sensor with lower cost and wider applicability.

[0060] Step S102: At least one sensitive element array is fabricated based on the array pattern of the sensitive element array, the size of the sensitive elements in the sensitive element array, and the processing technology.

[0061] In some feasible implementations, the array pattern of the sensing element array may include the arrangement of each sensing element in the array, wherein each sensing element includes a first electrode, a second electrode, and a sensing layer disposed between the first and second electrodes. The array pattern, the size of the sensing elements, and the fabrication process can be determined by the internal dimensions of the battery, the internal electrochemical environment of the battery, and the requirements for the sensor to collect internal battery parameters. In the above array pattern, the row spacing and column spacing of the sensing elements in the array are greater than or equal to 5.5 mm and less than or equal to 20.5 mm, wherein the distance between the location of the sensing element and the edge positions of each substrate in the first substrate 121 and the second substrate 122 is greater than or equal to 2.5 mm and less than or equal to 7.5 mm. The dimensions of the aforementioned sensitive element may include: the shape of the sensitive element may be, but is not limited to, a square or a rectangle, and the area of ​​the sensitive element is greater than or equal to 1.5mm × 1mm and less than or equal to 4.5mm × 2.5mm; the thickness of the sensitive element is greater than or equal to 100μm and less than or equal to 600μm; the thickness of both the first electrode and the second electrode is greater than or equal to 10nm and less than or equal to 1000nm; the processing technology of the sensitive element may include, but is not limited to, flexible printed circuit board technology. The shape, area, and thickness of the sensitive element, the thickness of the first electrode, the thickness of the second electrode, the row spacing and column spacing of the sensitive elements in the sensitive element array, and the specific location of the sensitive element can be determined by the internal dimensions of the battery and existing processes, and are not limited herein.

[0062] In some feasible implementations, the aforementioned sensor manufacturing equipment can prepare multiple sensitive elements constituting at least one sensitive element array based on the size and processing technology of the sensitive elements in the sensitive element array, and arrange the multiple sensitive elements according to a certain arrangement position based on the array pattern of the sensitive element array to obtain at least one sensitive element array (i.e., one or more sensitive element arrays), wherein the sensitive element array may include at least two sensitive elements. The at least one sensitive element array here may include, but is not limited to, temperature sensitive element arrays and / or pressure sensitive element arrays. The specific type of sensitive element array can be determined by the sensor's need to collect internal battery parameters and is not limited here. At least one sensitive element array can be used to collect temperature, pressure, and other parameters at multiple locations inside the battery, resulting in higher sampling accuracy.

[0063] Step S103: The first substrate with the first electrode circuit, the second substrate with the second electrode circuit, and each sensitive element array are thermo-pressed to obtain the sensor.

[0064] In some feasible implementations, after fabricating at least one sensitive element array, the sensor manufacturing equipment can heat and pressurize a first substrate with a first electrode circuit, a second substrate with a second electrode circuit, and each sensitive element array to fabricate a sensor for implantation inside a battery. Specifically, the first electrode of each sensitive element in the array is electrically connected to the first electrode circuit, which is used to couple the positive electrode of the battery. The second electrode of each sensitive element is electrically connected to the second electrode circuit, which is used to couple the negative electrode of the battery. More specifically, the sensor manufacturing equipment can heat and pressurize the first substrate with the first electrode circuit, the second substrate with the second electrode circuit, and each sensitive element array under certain pressure and temperature to obtain a heated and pressurized sensor. After holding the heated and pressurized sensor at a certain temperature for a period of time, it is then naturally cooled to a certain temperature to obtain a sensor for implantation inside a battery.

[0065] In some feasible implementations, since the sensor needs to be implanted inside the battery, the dimensions of the first substrate, the second substrate, and at least one sensing element array are all smaller than the internal dimensions of the battery. For example, the first and second substrates can be PI substrates (also called polymer PI films) with an area of ​​70mm × 160mm and a thickness of 25μm. The first and second electrode circuits can be Cu electrodes with a thickness of 4μm, fabricated using flexible printed circuit board technology. The sensing element array can consist of 4 × 10 identical temperature sensing elements, with each element being rectangular, 4mm × 2mm in area, and 100μm thick. The row spacing and column spacing of the sensing elements in the array are 10mm and 20mm, respectively, and the distance between the location of the sensing element and the edge of each substrate in the first and second substrates can be 5mm. The first and second electrodes in the sensing element can be Au electrodes with a thickness of 1μm, fabricated using electroplating technology. The sensitive layer in the sensing element can be a ceramic material (such as 0.96Ba) fabricated using ceramic casting technology. 0.9 Sr 0.1 Zr 0.18 Ti 0.82 O3-0.04BiNaTiO3).

[0066] It is understood that sensor manufacturing equipment can fabricate a complete array sensor capable of multi-point, multi-parameter sensing. The first and second substrates serve as electrical connection carriers for the sensitive element array and physically protect it. Furthermore, this array sensor exhibits better compatibility with the corrosive electrochemical environment inside the battery, improving its reliability and stability. Optionally, the sensor manufacturing equipment can implant it inside the battery after fabrication to collect internal battery parameters, or it can fabricate the sensor during battery manufacturing to collect internal battery parameters. The specific method depends on the actual application scenario and is not limited here. After implanting the aforementioned sensor inside the battery (i.e., the first electrode circuit couples the positive electrode of the battery, and the second electrode circuit couples the negative electrode), the sensor can collect internal battery parameters in real time to determine whether the battery is experiencing thermal runaway. This results in higher sampling accuracy, improved battery safety and reliability, and greater adaptability.

[0067] In some feasible implementations, the aforementioned sensor manufacturing equipment can coat conductive adhesive onto the first electrode circuit and the first electrodes of the sensitive elements in each sensitive element array, thereby achieving the effect of electrically connecting the first electrodes of the sensitive elements in each sensitive element array to the first electrode circuit through conductive adhesive, and thus establishing a reliable and stable electrical connection with the positive electrode in the battery. This method is low-cost and simple to operate. Optionally, the aforementioned sensor manufacturing equipment can also coat conductive adhesive onto the second electrode circuit and the second electrodes of the sensitive elements in each sensitive element array, thereby achieving the effect of electrically connecting the second electrodes of the sensitive elements in each sensitive element array to the second electrode circuit through conductive adhesive, and thus establishing a reliable and stable electrical connection with the negative electrode in the battery. This method is also low-cost and simple to operate. Optionally, when the first electrodes of the sensitive elements in each sensitive element array are electrically connected to the first electrode circuit through conductive adhesive, and the second electrodes of the sensitive elements in each sensitive element array are electrically connected to the second electrode circuit through conductive adhesive, a reliable and stable electrical connection can be established simultaneously with both the positive and negative electrodes in the battery, thereby improving the reliability and stability of the sensitive element array and enhancing its adaptability.

[0068] In some feasible implementations, the fabrication process of the above-mentioned sensor can also be found in [reference needed]. Figure 10 , Figure 10 This is a schematic diagram of the fabrication process of the sensor provided in this application. For ease of description, the following will use a single sensing element array as an example. Figure 10As shown, the aforementioned sensor manufacturing equipment can fabricate a first electrode circuit 3011 on a first substrate 30 based on the pattern 301 of the first electrode circuit to obtain a first substrate 30 having the first electrode circuit 3011, and fabricate a second electrode circuit 3111 on a second substrate 31 based on the pattern 311 of the second electrode circuit to obtain a second substrate 31 having the second electrode circuit 3111. Here, the first substrate 30 and the second substrate 31 can be flexible substrates made of polymer PI, and the areas of the first substrate 30 and the second substrate 31 can be 70mm × 95mm, and the thickness of the first substrate 30 and the second substrate 31 can be 25μm. The first electrode circuit 3011 (such as a lead electrode) and the second electrode circuit 3111 (such as a lead electrode) can be Cu electrodes fabricated using flexible printed circuit board technology, and the thickness of the lead electrodes can be 4μm. At this point, the sensor manufacturing equipment can fabricate a sensor array 32 based on the array pattern, the dimensions of the sensor elements, and the processing technology. The sensor array 32 can consist of 4×4 identical temperature sensor elements. In the sensor array 32, the sensor elements can be square in shape, with an area of ​​2mm×2mm and a thickness of 100μm. The row spacing and column spacing are 10mm and 20.5mm, respectively. The distance between the sensor element and the edge of each substrate in the first substrate 30 and the second substrate 31 can be 7.5mm. The first and second electrodes of the sensor element can be Au electrodes with a thickness of 1μm, fabricated using an electroplating process. The sensitive layer of the sensor element can be a ceramic sensitive layer (such as CaCu3Ti4O3) fabricated using a ceramic casting process. 12 ).

[0069] Furthermore, the aforementioned sensor manufacturing equipment can perform thermo-press encapsulation on a first substrate 30 having a first electrode circuit 3011, a second substrate 31 having a second electrode circuit 3111, and a sensing element array 32 to obtain a sensor 3. For example, the aforementioned sensor manufacturing equipment can heat and pressurize the first substrate 30 having the first electrode circuit 3011, the second substrate 31 having the second electrode circuit 3111, and the sensing element array 32 under a certain pressure (e.g., 0.2 MPa) and temperature (e.g., 125°C) to obtain a heated and pressurized sensor. After holding the heated and pressurized sensor at the temperature for 10 minutes, it is naturally cooled to 50°C to obtain the sensor 3. This sensor 3 can be implanted inside a battery and collect internal battery parameters to determine whether the battery is experiencing thermal runaway, thereby improving the safety and reliability of battery use.

[0070] The method provided in this application can fabricate a complete array sensor capable of sensing multiple points and multiple parameters (internal battery parameters). The first and second substrates can serve as electrical connection carriers for the sensitive element array and physically protect the sensitive element array. Furthermore, this array sensor has better compatibility with the corrosive electrochemical environment inside the battery, improving the reliability and stability of the sensor. In addition, this array sensor can better detect the internal battery parameters of the battery to determine whether the battery is in thermal runaway, with higher sampling accuracy, improving the safety and reliability of battery use, and having stronger adaptability.

[0071] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A battery, characterized by, The battery includes a positive electrode, a negative electrode, and a sensor. The sensor is made by hot-pressing a first substrate, a second substrate, and at least one sensitive element array. The first substrate and the second substrate are flexible substrates made of polymers, including at least one of polyimide, polyvinylidene fluoride, polyethylene, and polypropylene. The at least one sensitive element array is disposed between the first substrate and the second substrate. A first electrode circuit is formed on the first substrate, and a second electrode circuit is formed on the second substrate. The sensitive element array is coupled to the positive electrode through the first electrode circuit and to the negative electrode through the second electrode circuit. The sensitive element array includes at least two sensitive elements, each including a first electrode, a second electrode, and a sensitive layer disposed between the first electrode and the second electrode. The first electrode of the sensitive element is electrically connected to the first electrode circuit, and the second electrode of the sensitive element is electrically connected to the second electrode circuit. The material of the sensitive layer includes ceramic material, quartz crystal, or lanthanum gallium silicate crystal, wherein the ceramic material includes CaCu3Ti4O. 12 Ca 1-x Ba x Cu3Ti4O 12 Ca 1- x Sr x Cu3Ti4O 12 CaCu3Ti 1-y Zr y O 12 CaCu3Ti 1-y Mn y O 12 (1-α)Ba 1-x Sr x Zr y Ti 1-y O3-αBiNaTiO3, Ba 1- x Sr x Zr y Ti 1-y-z Y z O3, Ba 1-x Sr x Zr y Ti 1-y-z Gd z O3, Ba 1-x Sr x Zr y Ti 1-y-z Yb z O3 and Ba 1-x Sr x Zr y Ti 1-y- z Dy z At least one of O3; The sensitive element array is used to collect the internal battery parameters of the battery, and the internal battery parameters are used to determine whether the battery is in thermal runaway.

2. The battery of claim 1, wherein, The first electrode circuit and the first electrode of the sensing element are coated with conductive adhesive, and the first electrode of the sensing element is electrically connected to the first electrode circuit through the conductive adhesive.

3. The battery of claim 1, wherein, The second electrode circuit and the second electrode of the sensitive element are coated with conductive adhesive, and the second electrode of the sensitive element is electrically connected to the second electrode circuit through the conductive adhesive.

4. The battery according to any one of claims 1 to 3, characterized in that The first and second electrodes of each sensitive element are made by electroplating.

5. The battery according to any one of claims 1 to 3, wherein The sensitive element is square or rectangular in shape, with an area greater than or equal to 1.5mm × 1mm and less than or equal to 4.5mm × 2.5mm, a thickness greater than or equal to 100μm and less than or equal to 600μm, a thickness of the first electrode and the second electrode greater than or equal to 10nm and less than or equal to 1000nm, a row spacing and column spacing of the sensitive elements in the sensitive element array greater than or equal to 5.5mm and less than or equal to 20.5mm, and a distance between the location of the sensitive element and the edge of each substrate greater than or equal to 2.5mm and less than or equal to 7.5mm.

6. The battery according to any one of claims 1 to 3, wherein The first electrode circuit and the second electrode circuit are manufactured using flexible printed circuit board technology.

7. The battery of any one of claims 1-3, wherein, The thickness of each of the first and second substrates is greater than or equal to 25 μm and less than or equal to 100 μm, and the length and width of each substrate are greater than or equal to 70 mm and less than or equal to 160 mm.

8. A method of making a sensor for implantation inside a battery, characterized in that, The method includes: A first electrode circuit is fabricated on a first substrate to obtain a first substrate having the first electrode circuit, and a second electrode circuit is fabricated on a second substrate to obtain a second substrate having the second electrode circuit; At least one sensitive element array is manufactured according to the array pattern of the sensitive element array, the size of the sensitive elements in the sensitive element array, and the processing technology. The array pattern includes the arrangement position of the sensitive elements in the sensitive element array, and the sensitive element includes a first electrode and a second electrode. A sensor is obtained by thermo-pressing a first substrate having the first electrode circuit, a second substrate having the second electrode circuit, and each sensitive element array. The first electrode of each sensitive element in the sensitive element array is electrically connected to the first electrode circuit, which is used to couple the positive electrode of the battery. The second electrode of each sensitive element in the sensitive element array is electrically connected to the second electrode circuit, which is used to couple the negative electrode of the battery.

9. The method of claim 8, wherein, The fabrication of the first electrode circuit on the first substrate includes: The first electrode circuit is fabricated on the first substrate by performing optical imaging pattern transfer and etching based on the circuit pattern of the first electrode circuit.

10. The method of claim 8, wherein, The fabrication of the second electrode circuit on the second substrate includes: The second electrode circuit is fabricated on the second substrate by performing photoimaging pattern transfer and etching based on the circuit pattern of the second electrode circuit.

11. The method according to any one of claims 8-10, characterized in that, Before thermo-press packaging the first substrate having the first electrode circuit, the second substrate having the second electrode circuit, and each sensor array, the process includes: Conductive adhesive is coated on the first electrode circuit and the first electrode of the sensitive element in each sensitive element array; wherein the first electrode of the sensitive element in each sensitive element array is electrically connected to the first electrode circuit through the conductive adhesive.

12. The method according to any one of claims 8-10, characterized in that, Before thermoforming the first substrate having the first electrode circuit, the second substrate having the second electrode circuit, and the respective sensor arrays, the process includes: Conductive adhesive is coated on the second electrode circuit and the second electrodes of the sensitive elements in each sensitive element array; wherein the second electrodes of the sensitive elements in each sensitive element array are electrically connected to the second electrode circuit through the conductive adhesive.

13. A battery system characterized by, The battery system includes a battery management system and a plurality of batteries as described in any one of claims 1-7 connected to the battery management system; Each sensitive element array in the battery is used to collect the internal battery parameters of the battery and output the internal battery parameters of the battery to the battery management system. The battery management system is used to determine whether the battery is in thermal runaway based on the battery's internal battery parameters.

14. A power supply system characterized by comprising: The power supply system includes an energy storage module and a DC / DC converter module connected to the energy storage module, wherein the energy storage module is composed of a plurality of batteries as described in any one of claims 1-7.

15. The power supply system of claim 14, wherein, The power supply system also includes a power supply module and a power conversion module connected to the power supply module.

16. The power supply system of claim 15, wherein, The power supply module is a photovoltaic array, and the power conversion module is a DC / DC conversion module.

17. The power supply system of claim 15, wherein, The power supply module is a generator, and the power conversion module is an AC / DC conversion module.

18. A power supply system according to any of claims 15-17, characterized in that, The power supply system also includes a DC bus and a DC / AC conversion module. The DC / DC conversion module and the power conversion module are respectively connected to the input terminal of the DC / AC conversion module through the DC bus, and the output terminal of the DC / AC conversion module is connected to the AC power grid or an AC load.

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