Sensor arrangement, energy system and procedure

Abstract

A sensor arrangement (200), comprising: a transmitter (210) which is to be arranged inside a battery cell (100) and which is to wirelessly transmit a signal based on at least one detected operating parameter of the battery cell (100); and a semiconductor die (220), wherein the semiconductor die (220) comprises at least a part of a circuit arrangement of the sensor arrangement (200), wherein the semiconductor die (220) is attached to a substrate (230) and electrically coupled to the same, wherein the substrate is a printed circuit board, wherein the semiconductor die (220) is attached to the substrate (230) using a flip-chip technique.

Description

AREA

[0001] Examples of implementation relate to a sensor arrangement, an energy system, and a method. BACKGROUND

[0002] Battery cells are used in a wide variety of applications today. Possible applications include mobile devices such as laptops, phones, and other electronic devices. Other applications include automotive applications, for example, in electric or hybrid cars.

[0003] Many of these applications utilize high-performance battery cells. In these, as well as other battery cells, it may be advisable to monitor one or more operating parameters of the respective battery cells to evaluate their behavior, condition, or other safety-critical conditions.

[0004] However, in applications that have a plurality of individual batteries, battery cells or similar units, the effort required to read out the relevant data with regard to the individual batteries, battery cells or units can become considerable.

[0005] WO 2011 / 117089 A1 discloses a monitoring system for monitoring the condition of an energy storage cell. The energy storage cell includes integrated control circuitry (ICC). Each energy storage cell can communicate, preferably wirelessly, with a battery management unit (BMU) via its integrated ICC. To implement the ICC, an RFID chip is mounted on a carrier film. To assemble the energy storage cell, anode, cathode, and separator films can be stacked on top of each other. The ICC carrier film is also included in the assembly.

[0006] US 2009 / 0140870 A1 discloses a battery assembly comprising a battery cell and an RF cell monitor. The RF cell monitor is embedded in the battery cell and is used to monitor the battery cell and to generate an alarm signal indicating a predetermined state of the battery cell.

[0007] US 2004 / 0159939 A1 discloses a structure and fabrication method for an improved multi-chip semiconductor package that reduces the package resistance to negligible values ​​and provides excellent thermal performance. The integration of multiple chips is facilitated by providing electrically isolated leadframes separated from a common base substrate by a non-conductive layer of laminating material. A silicon chip is mounted in a cavity within each leadframe. Direct contact between the active surface of the silicon chip and the leadframe is then achieved through a series of solder joints distributed across the surface of each chip and along the edges of the leadframe adjacent to each chip.

[0008] US 2002 / 0053744 A1 discloses a protection circuit device using a MOSFET with multiple electrically separated conductive paths, a MOSFET chip integrating two power MOSFETs in one chip, with a gate electrode and a source electrode attached to the desired conductive path, conductive material provided on a common drain electrode of the MOSFET, and insulating resin covering the MOSFET and supporting the conductive path in a body.

[0009] DE 10 2012 203 444 A1 discloses a sensor device (110) for a battery cell (100). The battery cell (100) has a housing (102) with a membrane (104). The sensor device (110) has a sensor element configured to detect a property of the membrane (104) that depends on the internal pressure within the housing (102) of the battery cell (100) as sensor data. The sensor device (110) also has a processing unit for processing the sensor data.

[0010] Therefore, there is a need to simplify the monitoring of a battery cell. SUMMARY

[0011] Such a need can be met by the object of any one of the claims.

[0012] A sensor arrangement according to one embodiment includes a transmitter which is to be arranged inside a battery cell and which is to wirelessly transmit a signal based on at least one detected operating parameter of the battery cell.

[0013] Optionally, the transmitter is designed to transmit the signal via radio-based transmission.

[0014] Optionally, at least one operating parameter of the battery cell indicates a safety-critical condition of the battery cell.

[0015] Optionally, at least one operating parameter of the battery cell includes a parameter from a group of parameters, wherein the group of parameters includes a temperature of the battery cell, a temperature of an electrolyte or electrolyte solution, a pressure inside the battery cell, a concentration of a chemical element or compound inside the battery cell, a mechanical stress on a housing of the battery cell, a mechanical stress on a component of the battery cell, a current value of a current flowing at least either inside, out of or into the battery cell, a potential of an electrode of the battery cell and a voltage of the battery cell.

[0016] The sensor arrangement comprises a semiconductor die, wherein the semiconductor die comprises at least part of a circuit arrangement of the sensor arrangement, wherein the die is attached to a substrate and electrically coupled to the same.

[0017] The die is attached to the substrate using a flip-chip technique.

[0018] Optionally, with regard to an electrolyte or electrolyte solution of the battery cell, a chemically inert underfill material is arranged between the die and the substrate.

[0019] Optionally, the die is at least partially encapsulated by either a casting compound, a resin, or an epoxy resin.

[0020] Optionally, the die or a package containing the die is covered, at least partially, with respect to an electrolyte or electrolyte solution of the battery cell by a chemically inert protective cover.

[0021] Optionally, the protective cover has at least one carbon layer, perylene or polytetrafluoroethylene.

[0022] Optionally, the sensor arrangement also includes at least one sensor to detect at least one of the operating parameters within the battery cell.

[0023] Optionally, the transmitter has an antenna and a transmit signal generator coupled to the antenna, with at least one sensor and the transmit signal generator being integrated into a single package.

[0024] Optionally, the transmitter has an antenna and a transmit signal generator coupled to the antenna, wherein at least the transmit signal generator is integrated into a first package, and wherein at least one sensor of the at least one sensor is integrated into a second package.

[0025] Optionally, the sensor arrangement is designed to be coupled to at least one electrode of the battery cell in order to supply the sensor arrangement with operating energy.

[0026] Optionally, the sensor assembly also includes a battery cell to supply the sensor assembly with operating energy.

[0027] Optionally, the battery cell can be a lithium-ion battery cell.

[0028] Optionally, the battery cell contains at least either an aprotic solvent or lithium hexafluorophosphate.

[0029] Optionally, the sensor array can be arranged inside the battery cell.

[0030] An energy system according to one embodiment comprises a plurality of battery cells, each battery cell having a sensor arrangement, each sensor arrangement having a transmitter located within the battery cell and configured to wirelessly transmit a signal based on at least one detected operating parameter of the battery cell. The energy system further comprises a battery management system located outside the plurality of battery cells and configured to receive signals from the sensor arrangements of the plurality of battery cells.

[0031] A method according to one embodiment comprises the detection of at least one operating parameter of the battery cell within the battery cell and the wireless transmission of the signal based on the at least one detected operating parameter of the battery cell from within the battery cell. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Several exemplary embodiments are described below with reference to the accompanying figures. Fig. Figure 1 shows a simplified cross-sectional view of a battery cell; Fig. 2 shows a block diagram of a sensor arrangement according to an exemplary embodiment; Fig. Figure 3 shows a flowchart of a process according to an exemplary embodiment; Fig. 4 shows a vehicle according to an embodiment which has an energy system according to an embodiment; Fig. Figure 5 shows a cross-sectional view of a sensor arrangement according to an exemplary embodiment; Fig. Figure 6 shows a top view of the sensor arrangement of Fig. 5; Fig. Figure 7 shows another sensor arrangement according to an exemplary embodiment; Fig. Figure 8 shows a block diagram of a conventional energy system; Fig. Figure 9 shows a block diagram of an energy system according to an exemplary embodiment; Fig. Figure 10 shows a simplified cross-sectional view of a battery cell having a sensor arrangement according to an exemplary embodiment; and Fig. Figure 11 shows a simplified cross-sectional view of a battery cell which has a further sensor arrangement according to an exemplary embodiment. DETAILED DESCRIPTION

[0033] Exemplary embodiments according to the present invention are described in more detail below. In this context, collective reference numerals are used to describe several objects simultaneously or to describe common features, dimensions, characteristics, or the like of these objects. The collective reference numerals are based on their individual reference numerals. Furthermore, objects that appear in several exemplary embodiments or several figures, but which are identical or at least identical with respect to some of their functions or structural features, are designated by the same or similar reference numerals.To avoid unnecessary repetition, parts of the description that refer to such objects also refer to the corresponding objects in the different embodiments or figures, unless explicitly stated otherwise or—taking into account the context of the description and the figures—implicitly stated otherwise. Therefore, similar or related objects may be implemented with at least some identical or similar features, dimensions, and characteristics, but they may also be implemented with different properties.

[0034] Battery cells are used today in a wide variety of applications, including high-performance battery cells for electric vehicles, such as electric or hybrid vehicles. Depending on the battery technology involved, critical conditions in high-performance battery cells can lead to serious consequences. For example, gas overpressure can develop within a high-performance battery or battery cell, which in turn can lead to cell destruction, fire, or even an explosion. Sensors are now used to monitor these critical conditions in high-performance battery cells.

[0035] As explained in more detail below, a battery cell can contain the necessary components to generate electrical energy based on electrochemical reactions. A battery can contain one or more battery cells. If a battery has more than one battery cell, the individual cells can be connected in series, in parallel, or both. If a battery has exactly one battery cell, the battery and the single battery cell it contains can be identical or different.

[0036] Fig. Figure 1 shows a simplified cross-sectional view of a battery cell 100, which is, for example, a lithium-ion battery cell (Li + ) can be implemented. Such a battery cell can, for example, be used for an electromobility application.

[0037] The battery cell 100 has a housing 110 in which a wound stack 120 can, for example, comprise an electrode material, an active material, a separator, another active material, and another electrode material. The stack 120 can contain or be immersed in an electrolyte or an electrolyte solution. The electrolyte can, for example, comprise lithium hexafluorophosphate (LiPF6), which can be dissolved in a (polar) aprotic solvent containing, for example, methyl carbonate and / or ethylene carbonate. The housing 110 can, for example, be made of aluminum (Al).

[0038] The battery cell 100 further comprises a first electrode 130-1 and a second electrode 130-2, which may be electrically insulated from a cover 150 of the housing 110 by an insulator 140. The electrodes 130 may be coupled to the electrode material of the stack 120. The insulators 140 may also serve as a seal to prevent the electrolyte, electrolyte solution, and / or other chemical elements and compounds from leaving the battery cell 100. The insulators 140, functioning as seals, may also prevent substances from entering the battery cell 100 or the housing 110 from the outside.For example, in the case of a lithium-based battery cell, it might be highly advisable to prevent moisture and / or oxygen from entering the battery cell in order to avoid a serious exothermic reaction with the lithium contained in the casing 110, which in turn could damage or even destroy the battery cell 100 and furthermore risk damage to other components of a system or to people.

[0039] A battery cell 100 like the ones used in Fig. As shown in Figure 1, the battery cell is typically constructed by placing the stack 120 in the housing 110, with the electrodes 130 being electrically coupled to the corresponding electrode materials of the stack 120. The electrolyte or electrolyte solution can then be filled into the housing 110 of the battery cell through one or more openings 160-1, 160-2, which can be closed by the corresponding number of hole closures 170-1, 170-2.

[0040] As a precautionary measure against high pressures inside the housing 110 of the battery cell 100, the cover 150 may also have a burst disc 180 which can be destroyed as soon as a critical pressure level is reached inside the housing 110 of the battery cell 100.

[0041] Electrodes 130 can, in principle, be made of any suitable material. For example, the first electrode 130-1 can be a copper electrode (Cu), and the second electrode 130-2 can be an aluminum electrode (Al). Naturally, the electrodes 130 can have a specific shape, for example, outside the housing 110, to facilitate easier coupling of the battery cell to a power system or similar device. For example, the electrodes 130 can have threads or even additional covers made of different materials, such as stainless steel or similar.

[0042] However, it should be noted that exemplary embodiments are by no means limited to specific design details of such a battery cell, such as the battery cell described in Fig. Figure 1 shows that other battery cell types include, for example, a battery cell 100 based on pouch cells or solid cells, which may be combined within a larger module package. Furthermore, design details are by no means limited to the design shown in Figure 1. Fig. Figure 1 shows an example. For instance, the number of individual elements, such as the 160 openings, the 180 rupture discs, the number of electrodes, and other parameters can vary. A battery cell used in the context of an exemplary embodiment may also differ with regard to the materials and chemical compounds mentioned above.

[0043] As the preceding discussion has shown, modern battery cells can use chemical media that can evaporate if the temperature inside the battery cell 110 rises, for example, due to local defects within the electrode stack 120. This can lead to an overload or a similar situation. Due to such an overload, malfunction, short circuit, or other similar situation, for example in a lithium-polymer battery cell, a gas can be formed that can generate high internal pressure. Depending on the chemistry involved, the gas may contain, for example, hydrogen fluoride (HF). Consequently, the battery cells can swell and even burst. Due to the oxygen entering the battery cell in such a case, the organic electrolytes can ignite, and the battery cell can burn.

[0044] In order to develop safety technology for battery cells for an application such as electromobility, customers of these battery cells want to detect gas generation at a very early stage, for example with the help of pressure sensors or gas sensors, in order to enable the corresponding battery cell to be switched off at a very early stage.

[0045] The condition of battery cell 100 can be detected or monitored, for example, using temperature sensors located on the outside of housing 110. If battery cell 100 is prone to overheating, an emergency shutdown can be initiated. However, since the temperature sensor is located on the outside of housing 110, the corresponding malfunction within the battery cell may only be detected at a very late stage, which may be too late to react quickly enough with an emergency shutdown.

[0046] However, to prevent the battery cell 100 and its casing 110 from exploding, the rupture disc 180 has a predetermined pressure point and can be integrated into the casing 110 or its cover 150. If the pressure inside the battery cell becomes too high, the rupture disc 180 can rupture irreversibly. This can prevent the battery cell from exploding. However, since oxygen enters the battery cell 100, the previously mentioned risk exists that the chemistry inside the casing 110 could lead to spontaneous combustion, thus creating a delayed fire hazard. For example, the battery cell could catch fire days later in a repair shop or in a temporary storage facility for defective battery cells.

[0047] As detailed below, exemplary embodiments can help prevent such critical conditions by integrating them into the battery cell 110. One such embodiment might, for example, include a sensor system and an integrated wireless data transmission system. More precisely, some embodiments might have the necessary sensor system integrated directly into the battery cell, enabling very fast and highly accurate measurement of critical operating parameters. To facilitate data access, the acquired operating parameters can be transmitted wirelessly, for example, using radio-based transmission rather than a conventional wired or cable-based solution.This can reduce the complexity of a power system, essentially by eliminating the need for signal wiring to electrically connect the sensors of each battery cell to a battery management system or similar control unit. For example, in a power system with a large number of battery cells, each cell must be electrically connected by a signal wire to allow the battery management system to read the sensor data from the cells. In some applications, the number of battery cells can be several tens or even exceed 100.

[0048] Fig. Figure 2 shows a block diagram of a sensor arrangement 200, which includes a transmitter 210 that is to be arranged inside a battery cell 100 and wirelessly transmits a signal based on at least one detected operating parameter of the battery cell. As described above, the transmitter 210 can be configured to transmit the signal via radio transmission.

[0049] To increase the operational safety of such a battery cell, at least one operating parameter of the battery cell can indicate a safety-critical condition of battery cell 100. For example, at least one operating parameter of battery cell 100 can be any parameter of a group of parameters that includes, for example, the temperature of battery cell 100, the temperature of an electrolyte or electrolyte solution, a pressure inside battery cell 100, a concentration of a chemical element or chemical compound inside battery cell, a mechanical stress on the casing 110 of battery cell 100, a mechanical stress on another component of battery cell 100, a current value of a current flowing at least within, from, or into battery cell 100, a potential of an electrode of battery cell 100, and a voltage of battery cell 100.Depending on the battery cell technology involved, any of these operating parameters can indicate a safety-critical condition, for example, if the corresponding operating parameter meets a predetermined condition. For instance, depending on the operating parameter, it can indicate that such a safety-critical condition of the battery or battery cell has been reached when the corresponding parameter becomes greater or less than a threshold.

[0050] The sensor assembly 200 can include a semiconductor die 220, which can include at least part of a circuit arrangement of the sensor assembly 200. The die 220 is attached to and electrically coupled to a substrate 230, which is a printed circuit board (PCB) 230 for the semiconductor die 220. For example, the substrate 230 can be flexible.

[0051] How more detailed in the context of Fig. 5, Fig. 6 and Fig. As described in section 7, the die 220 can be attached to the substrate 230 using a flip-chip technique. In this case, a chemically inert backfill material, with respect to an electrolyte or electrolyte solution of the battery cell 100, can be arranged between the die 220 and the substrate 230. This can, for example, enable a compact yet chemically stable attachment of the die to the substrate 230, which can be advantageous with regard to the manufacturing effort of the sensor assembly 200.

[0052] The die 220 can be at least partially encapsulated by a potting compound, a resin, and / or an epoxy resin. Furthermore, the die, or a package comprising the die 220, can be at least partially covered by a chemically inert protective cover with respect to the electrolyte or electrolyte solution of the battery cell. The protective cover can, for example, comprise a carbon layer of perylene, polytetrafluoroethylene (PTFE), or a combination thereof. This can further help to protect the sensor assembly from adverse chemical effects to which the sensor assembly 200 is exposed, for example, by the electrolyte or electrolyte solution of the battery cell 100.

[0053] To record at least one operating parameter of the battery cell 100, the sensor arrangement 200 can further comprise at least one sensor 240. To be more precise, the sensor arrangement 200 has at least one sensor 240. Fig. In two schematically shown embodiments, the sensor arrangement 200 comprises three sensors 240-1, 240-2, and 240-3. The first sensor 240-1 is integrated on or in the semiconductor die 220. In contrast, the second sensor 240-2 is implemented outside the semiconductor die 220, but on or as part of the substrate 230, which together with the semiconductor 220 forms a package 250. However, sensors can also be implemented independently of the package 250, which comprises a semiconductor die 220 and a substrate 230. To illustrate this, the sensor arrangement 200, shown in Figure 2, has three sensors 240-1, 240-2, and 240-3. Fig. Figure 2 shows a third sensor 240-3, which is coupled to the transmitter 210 by a contact surface 260 and a measuring connection 270, such as a cable or wire. The third sensor 240-3 accordingly forms a further package 250' or a second package 250' with respect to the first package 250. The second package 250' can be independent of the first package 250, which is shown in Figure 2. Fig. 2 shown embodiment has the semiconductor die 220.

[0054] The transmitter 210 can have a transmit signal generator 280 and an antenna 290. With respect to the first and second sensors 240-1 and 240-2, the transmit signal generator 280 is integrated into the same or a single package 250. However, with respect to the third sensor 240-3, the transmit signal generator 280 is integrated into a first package 250, while sensor 240-3 is integrated into or part of a second package 250', which is distinct from the first package 250'.

[0055] The transmit signal generator 280 can be capable of receiving the signals provided by the sensors 240 and generating a signal capable of being transmitted via the antenna 290. However, it is by no means necessary for the antenna 290 to be implemented in the same package 250 or on the same die 220 as the transmit signal generator 280. In the case of the Fig. In the embodiment shown in Figure 2, however, the antenna 290 is implemented as part of the package 250, which also includes the transmit signal generator. The antenna 290 is, however, part of the substrate 230.

[0056] Thus, the transmitting signal generator 280 can have a microcontroller capable of reading or acquiring the data or signals provided by the sensors 240 in order to process the corresponding signals and convert them, for example, into high-frequency signals, which are then provided to the antenna 209 for transmission outside the battery cell 100 (in Fig. 2 not shown). However, instead of a high-frequency antenna 290, a transmitter can also be used.

[0057] To power the sensor arrangement 200, the sensor arrangement 200 can be configured to be coupled to at least one electrode 130 of the battery cell 100 in order to obtain electrical energy for operation from the battery cell 100. For example, the substrate 230 can have one or more supply terminals 300-1, 300-2, which are coupled to the electrodes 130 of the battery cell 100 to supply the sensor arrangement 200 with electrical energy for operation. In other embodiments, however, one of the supply terminals 300 can be coupled to a different reference potential, such as ground potential. In other words, supplying the sensor arrangement 200 with the necessary operating energy can be delegated to the battery cell 100 to be monitored by the sensor arrangement 200 itself.

[0058] The sensor arrangement can further include a supply battery cell 310 to provide the sensor arrangement 200 with the necessary operating energy. Fig. Figure 2 shows the optional power supply battery cell 310 implemented in package 250, or more precisely, as part of, integrated into, or on substrate 230. In other words, battery cell 310 is part of package 250 or contained within package 250. However, battery cell 310 could also be contained in a second package 250, which, for example, includes a sensor 240, or in another package, such as a custom package.

[0059] As previously stated, the sensor assembly 200 can be designed to operate within a battery cell, such as a lithium-ion battery cell. In this case, the battery cell can contain at least either an aprotic solvent or lithium hexafluorophosphate, against which the sensor assembly 200 should exhibit at least sufficient resistance such that at least occasional contact between the sensor assembly 200 and the battery cell chemicals does not cause immediate failure of the sensor assembly 200.

[0060] Of course, as explained above, the number of components used, such as the number of sensors 240 or the number of supply connections 300, can vary between the embodiments depending on other parameters and design features. For example, a sensor arrangement 200 can have any number of sensors 240. Naturally, the number of supply connections 300 can also vary depending on the number of voltages that need to be supplied externally to the sensor arrangement 200. If a supply battery cell 310 is implemented, implementing a supply connection 300 may not be necessary.

[0061] Fig. Figure 3 shows a flowchart of a method according to an embodiment. The method includes, in operation P100, the acquisition of at least one operating parameter of a battery cell from within the battery cell. Furthermore, in operation P110, it includes the wireless transmission of a signal based on the at least one acquired operating parameter of the battery cell from within the battery cell.

[0062] Fig. Figure 4 shows a vehicle 320 according to an embodiment, which has an energy system 330 according to an embodiment. The energy system has a plurality of battery cells 100-1, ..., 100-3, each battery cell 100 having a sensor arrangement 200-1, ..., 200-3, as described above. The sensor arrangements 200 can be implemented identically or can differ at least partially from one another.

[0063] The energy system 330 further comprises a battery management system 340, which is located outside the plurality of battery cells 100 and is configured to receive signals from the sensor assemblies 200 of the plurality of battery cells 100. The battery management system 340 may therefore have an antenna to receive the radio-based transmissions from the sensor assemblies 200. In the case of a different wireless transmission scheme used by the sensor assemblies 200, the battery management system 340 may have a corresponding receiver. Naturally, the battery management system 340 may also have multiple receivers to allow different wireless transmission schemes to be used by the battery cells 100.

[0064] The battery management system 340 can be configured to provide a signal based on the signals received from the sensor arrays 200 of the plurality of battery cells. The signal provided by the battery management system 340 can, for example, indicate a malfunction, overload, or other condition of at least one of the battery cells 100 of the plurality of battery cells. For example, the battery management system 340 can read the signals provided by the sensor arrays 200 of the individual battery cells 100 in order to extract one or more operating parameters from these signals.If one or more of these operating parameters of one or more of the battery cells 100 fulfill a predetermined relationship, for example, if they are greater or less than a threshold value, the signal provided by the battery management system 340 can indicate a malfunction of the corresponding battery cell 100 or battery cells 100. Based on the signal provided to the battery cells 100, it may be possible to initiate a shutdown or another fail-safe mechanism that informs the driver of the vehicle 320 of the malfunction.

[0065] Of course, the sensor arrangements 200 can also be configured to transmit only the signal indicating at least one operating parameter when a predetermined relationship with respect to that parameter is met. For example, the signal transmitted by one of the sensor arrangements 200 can indicate only the corresponding battery cell. In this case, the battery management system 340 can determine the presence of a malfunction and the corresponding battery cell 100 simply by receiving the corresponding signal from that battery cell or cells. However, the sensor arrangements 200 can also provide and transmit additional data, such as the operating parameter and / or the value that fulfills the predetermined relationship.Of course, the sensor arrangements 200 can also transmit the signals intermittently, continuously or according to another pattern or as required, responding to a demand signal through the battery management system 340.

[0066] Vehicle 320, for example, can be any motorized vehicle, such as a car, truck, locomotive, agricultural machine, or construction machine, to name just a few. Such a vehicle can operate solely on electrical energy, like an electric car, or electrical energy can contribute to the vehicle's movement, like in a hybrid car.

[0067] Fig. Figure 5 shows a schematic cross-section through a sensor arrangement 200 according to an embodiment, which includes a pressure sensor for integration into a battery cell 100. The sensor arrangement 200 has a semiconductor die 220 which includes at least one transmit signal generator 280 (in Fig. 5 not shown). The die 220 further comprises a pressure sensor 240 based on microelectromechanical system (MEMS) technology. The semiconductor die 220 is mounted on a substrate 230 using flip-chip technology. The substrate 230 has circuit paths 350 that are at least partially buried within the substrate 230 to prevent the circuit path material 350 from being affected by the aforementioned chemicals of the battery cell 100 (in Fig. 5 not shown) is attacked.

[0068] In the cross-sectional view of Fig. Figure 5 shows only one circuit path 350, which connects one of the supply terminals 300 to a contact surface 360-1, to which the semiconductor die 220 is mechanically and electrically coupled by a solder point 370-1. The substrate 230 also has a second contact surface 360-2 in the cross-sectional view, which is shown in Fig. Figure 5 shows that the semiconductor die 220 is coupled to the second contact pad 360-2 using an additional solder point 370-2. To electrically insulate and mechanically stabilize the semiconductor die 220 on the substrate 230, a chemically inert underfill material 380, compatible with the chemicals used in the battery cell 100, can be applied between the semiconductor die 220 and the substrate 230.

[0069] However, to allow the atmosphere inside the battery cell to interact with the sensor 240, both the substrate 230 and the backfill material 380 have an opening 390 through which the pressure inside the battery cell can interact with the sensor 240. The opening 390 can be arranged such that the sensitive area of ​​the semiconductor die 220 (sensor 240) is substantially aligned with the opening 390, so that no mechanical stress is exerted on the semiconductor die 220 by the substrate 230. The substrate 230 can be a flexible substrate. The circuit paths 350 can be produced, for example, by printing the circuit paths 350 onto a layer of the substrate 230, which may be at least partially coated to protect the circuit paths 350 after the printing process.

[0070] Fig. Figure 6 shows a top view of the sensor array 200, which is located in Fig. 5 is shown. In the top view of Fig. Figure 6 shows the die 220 from its rear side, with the chemically inert backfill material 380 essentially protruding from under the die 220 in all directions in one plane of the substrate 230.

[0071] The sensor arrangement 200 has three circuit paths 350-1, 350-2 and 350-3, wherein the second circuit path 350-2 is formed as a loop around the antenna 290 of the sensor 210 (in Fig. 5 and Fig. 6 (not shown). The other two circuit paths 350-1, 350-3 are electrically coupled to the supply terminals 300-1 and 300-2 respectively, through which the sensor arrangement 200 is able to be supplied with electrical energy from the battery cell 100.

[0072] In other words, they show Fig. 5 and Fig. Figure 6 shows a schematic cross-sectional view and a top view of a sensor assembly 200 mounted on a flexible ink substrate 230, forming a flexible ink-based pressure sensor package with a chemically stable underfill material. The sensor chip or sensor die 220, which also includes the transmit signal generator 280, has a MEMS-based sensor 240 to measure the pressure inside the battery cell 100 (in Fig. 5 and Fig. (6 not shown) to measure or detect. The sensor arrangement 200 shown here is implemented using flip-chip technology and chemically stable underfill material to protect the chip within the package as much as possible from chemical influences.

[0073] However, how Fig. As will be shown in Figure 7, the sensor arrangement 200 can optionally also have an additional protective cover that can completely or at least partially cover the silicon die 220 and / or the substrate 230 in order to increase resistance to chemical influences.

[0074] At the in Fig. In the embodiment shown in Figure 7, the sensor arrangement 200 is substantially completely covered by a protective cover layer 400, including the substrate 230 except for the supply terminals 300, wherein the semiconductor die 220 comprises the area under the opening 390 directly adjacent to the sensor 240. The protective cover 400 can be formed essentially from any chemically stable layer used in the battery cell (in Figure 7). Fig. 7 not shown). Examples include perylene, plasma-coated carbon layers, and polytetrafluoroethylene (PTFE).

[0075] While at the in Fig. In the embodiments shown in Figure 7, where the protective cover 400 is applied directly to the substrate 230 and the silicon die 220, the protective cover 400 can also be applied to an encapsulation material to encapsulate the die 220 and / or the substrate 230. Any potting compound, resin, or epoxy resin can be used as an encapsulation material, to name just a few examples. Of course, any combination thereof can also be used.

[0076] By using a battery cell with an integrated sensor and a high-frequency transmitter, it may be possible to significantly reduce the wiring harness. To illustrate this, [the following is shown]. Fig. Figure 8 shows a schematic block diagram of a conventional energy system 600. The energy system 600, also referred to as a (complete) battery cell module, typically comprises a substantial number of battery cells 100-1, ..., 100-N, coupled to a conventional battery management system 610, where N is an integer greater than 1. Each of the N battery cells is coupled to the battery management system 610 by at least one wire to allow the battery cells 100 to be individually detected and monitored. Consequently, many wires must be used to link all the corresponding battery cell sensors to the battery management system 610. In other words, a very large and expensive wiring harness is required to properly link the battery cells 100 to the battery management system.For example, in the case of a hybrid or electric car, the number of battery cells can be more than several tens of cells. For example, in an electric car, the number of battery cells contained in an energy system of 600 can be 100 or more.

[0077] Fig. Figure 9 shows a schematic view of an energy system 330 according to an embodiment which – similar to the conventional solution described in Fig. Figure 8 shows a number N of battery cells 100-1,..., 100-N, where N is again an integer greater than 1 (N ≥ 2). Each of the battery cells 100 has a sensor arrangement 200, which is located in Fig. 9 was omitted solely for the sake of simplicity. However, each of the 200 sensor arrays that are in Fig. Not shown, each of the battery cells contains 100, which allows the corresponding sensor arrangement 200 to communicate wirelessly with the battery management system 340, for example via radio.

[0078] By using a radio communication system or another wireless communication system, the number of cables required within the energy system 300 can be dramatically reduced, which can be essential for larger energy systems 330 that have many individual battery cells 100. In other words, each battery cell 100, apart from a sensor, has a transmitter within the corresponding battery cell that draws its power from the battery cell 100 itself or from its own supply battery cell 300 (in Fig. (9 not shown). The information obtained by the sensor arrangement 200 is sent from the battery cells 100 to a central battery management system 340 via a wireless communication scheme.

[0079] Fig. Figure 10 shows a schematic cross-sectional view of a battery cell 100, which has a sensor assembly 200. Due to the sensor assembly 200, the battery cell 100 has an integrated sensor and a wireless transmitter. The battery cell 100 itself is essentially identical to the one described in Fig. 1 is shown. Therefore, with regard to the description of battery cell 100, reference is made to Fig. 1 taken.

[0080] The battery cell 100 also includes the sensor assembly 200, as mentioned previously. The sensor assembly 200 comprises, in a first package 250-1, a microcontroller with an RF transmitter (RF = radio frequency), which is located within the gas-filled space inside the battery cell 100. The gas-filled space is located above the stack 120 of electrodes and the cover 150 of the housing 110 of the battery cell 100. It should be noted, however, that the gas-filled space in Fig. Figure 10 is not drawn to scale. To be more precise, the space may be reduced in scale during implementations in Fig. The space can be drawn 10 times larger than the actual space in an implementation. In principle, a larger gas space can also be implemented.

[0081] The first package 250-1, contained in the microcontroller (µ-controller; µC; uC), and the RF transmitter are connected to the electrodes 130-1, 130-2 of the battery cell 100 by cables to supply the sensor arrangement 200 with the necessary operating energy. The cables for the power connection are arranged inside the battery cell. In other embodiments, however, the implementation of a supply battery cell 310 (in Fig. (10 not shown) may be omitted.

[0082] A second package 250-2 contains a sensor 240, which is coupled to the first package 250-1 to enable at least one operating parameter to be detected by the sensor arrangement 200. The sensor 240 can, for example, be a temperature sensor, a chemical sensor, a gas pressure sensor, a load sensor, a current sensor, an optical sensor, or another sensor that detects a physical or chemical property.

[0083] Fig. Figure 11 shows a schematic cross-sectional view of another battery cell 100, which has a sensor arrangement 200. In the case of the Fig. In the embodiment shown in Figure 11, the sensor arrangement 200 is implemented as a single package 250 comprising a microcontroller with the high-frequency transmitter, an optional low-frequency receiver (LF receiver; LF = low frequency) together with at least one sensor, and a power supply battery cell to provide the sensor arrangement 200 with the necessary operating energy. The sensor arrangement 200 can include multiple sensors 240, which may be sensitive, for example, to pressure in the gas space above the electrolyte and the electrode stack 220, the temperature of the gas or, more precisely, of the chip, and other operating parameters. In contrast to the embodiments described above, the sensor arrangement 200 also includes a receiver that can be used to perform measurements in response to a request triggered by a corresponding signal.For example, the receiver can be a low-frequency receiver, for instance, approximately 125 kHz or another suitable frequency. Other wireless communication technologies can be used to communicate with the sensor array 200 to provide commands and instructions to the array 200. The measurements or data acquisition can also be triggered autonomously by the sensor array 200 itself.

[0084] The in Fig. The system shown in Figure 11 can operate completely autonomously after being installed in the battery cell 100. However, temperature measurement may not be as accurate as possible, since a sudden change in the temperature of the electrode stack 120 will raise the temperature of the sensor arrangement 200, or parts thereof, so that it is detected by the sensor 240. Nevertheless, such a system can be implemented with a small footprint due to the ease of integrating the necessary circuitry.

[0085] To improve the accuracy of a temperature measurement or a measurement of another operating parameter, an external sensor can be used, which is installed as a second package (in Fig.(11 not shown) can be implemented. The temperature, for example, can be measured directly within or in direct contact with the electrolyte. Again, the sensors can be used for internal or external applications, such as temperature, chemical, gas pressure, load, current, optical, or other types of sensors.

[0086] The description and drawings represent only the principles of the invention. Those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are encompassed within its essence and scope of protection. Furthermore, all examples cited herein are expressly for educational purposes only, to assist the reader in understanding the principles of the invention and the concepts contributed by the inventor(s) to advance the technology, and should not be regarded as limiting such examples and conditions. Furthermore, all statements cited herein that specify principles, aspects, and embodiments of the invention, as well as specific examples thereof, should also include correspondences thereof.

[0087] Functional blocks that perform a specific function should be considered as functional blocks that have a circuit arrangement adapted to perform or execute a particular function. Thus, such a block can also be understood as a circuit arrangement, element, or similar that is adapted, configured, or suitable for a specific operation. A block adapted to perform a particular operation does not imply that such an operation will be executed at any given time.

[0088] The procedures described herein can be implemented as software, for example, as a computer program. The subprocesses can be executed by such a program, for example, by writing to a memory location. Similarly, reading or receiving data can be performed by reading from the same or a different memory location. A memory location can be a register or other memory of suitable hardware. The functions of the various elements shown in the figures can be provided by the use of dedicated hardware. If provided by a processor, the functions can be provided by a single, dedicated processor, a single, shared processor, or by a plurality of individual processors, some of which may be shared.Furthermore, the explicit use of the terms "processor" or "controller" should not be interpreted as referring exclusively to hardware capable of executing software, and may implicitly and without limitation include digital signal processor hardware (DSP hardware; DSP = digital signal processor), a network processor, an application-specific integrated circuit (ASIC; application-specific integrated circuit), a field-programmable gate array (FPGA; field-programmable gate array), read-only memory (ROM = read-only memory) for storing software, random-access memory (RAM = random-access memory), and non-volatile storage. Other hardware, whether conventional and / or custom, may also be included. Similarly, any switches shown in the figures are purely conceptual.Its function can be performed by the operation of program logic, by dedicated logic, or by the interaction of program control and dedicated logic, with the specific technique being selectable by the implementer as being more understandable from the context.

[0089] Those skilled in the art should recognize that any block diagrams herein represent conceptual views of a circuit arrangement illustrating the principles of the invention. Similarly, it is indicated that any flowcharts, process diagrams, state transition diagrams, pseudocode, and the like represent various processes that may be embodied essentially in a computer-readable medium and thus be executed by a computer or processor, whether or not such a computer or processor is explicitly shown.

[0090] Furthermore, the following claims are incorporated into the detailed description herein, each claim being capable of representing a separate embodiment. While each claim can represent a separate embodiment, it should be noted that—although a dependent claim may refer to a specific combination with one or more other claims—other embodiments may also include a combination of the dependent claim with the subject matter of any other dependent claim. Such combinations are proposed herein unless it is stated that a specific combination is not intended. Furthermore, it is intended to incorporate features of any claim into any other independent claim, even if that claim is not directly dependent on the independent claim.

[0091] It is further noted that methods disclosed in the description or in the claims may be implemented by a device comprising a means for carrying out any of the corresponding steps of these methods.

[0092] It is further noted that the disclosure of multiple steps or functions disclosed in the description or in the claims is not limited to their specific order. Therefore, the disclosure of multiple steps or functions does not restrict them to a particular sequence, unless such steps or functions are not interchangeable for technical reasons.

[0093] Furthermore, in some embodiments, a single process may comprise or be divided into several subprocesses. Such subprocesses may be included in the disclosure of that single step and be part of it, unless expressly excluded.

Claims

[1] A sensor arrangement (200) comprising: a transmitter (210) which is to be arranged inside a battery cell (100) and which is to wirelessly transmit a signal based on at least one detected operating parameter of the battery cell (100); and a semiconductor die (220), wherein the semiconductor die (220) comprises at least a part of a circuit arrangement of the sensor arrangement (200), wherein the semiconductor die (220) is attached to a substrate (230) and electrically coupled to the same, wherein the substrate is a printed circuit board, wherein the semiconductor die (220) is attached to the substrate (230) using a flip-chip technique. [2] The sensor arrangement (200) according to claim 1, wherein the transmitter (210) is configured to transmit the signal by means of a radio-based transmission. [3] The sensor arrangement (200) according to one of the preceding claims, wherein at least one operating parameter of the battery cell (100) indicates a safety-critical state of the battery cell (100). [4] The sensor arrangement (200) according to one of the preceding claims, wherein the at least one operating parameter of the battery cell (100) comprises a parameter of a group of parameters, wherein the group of parameters comprises a temperature of the battery cell (100), a temperature of an electrolyte or an electrolyte solution, a pressure inside the battery cell (100), a concentration of a chemical element or a chemical compound inside the battery cell (100), a mechanical stress of a housing of the battery cell, a mechanical stress of a component of the battery cell (100), a current value of a current flowing at least either inside, out of or into the battery cell (100), a potential of an electrode of the battery cell and a voltage of the battery cell (100). [5] The sensor arrangement (200) according to one of the preceding claims, wherein, with regard to an electrolyte or an electrolyte solution of the battery cell (100), a chemically inert underfill material is arranged between the semiconductor die (220) and the substrate (230). [6] The sensor arrangement (200) according to one of the preceding claims, wherein the semiconductor die (220) is at least partially encapsulated by at least either a potting compound, a resin or an epoxy resin. [7] The sensor arrangement (200) according to one of the preceding claims, wherein the semiconductor die (220) or a package (250) comprising the semiconductor die (220) is at least partially covered by a chemically inert protective cover with respect to an electrolyte or electrolyte solution of the battery cell (100). [8] The sensor arrangement (200) according to claim 7, wherein the protective cover comprises at least either a carbon layer, Peylene or polytetrafluoroethylene. [9] The sensor arrangement (200) according to one of the preceding claims, which further comprises at least one sensor to detect at least one of the at least one operating parameter within the battery cell (100). [10] The sensor arrangement (200) according to claim 9, wherein the transmitter (210) has an antenna (290) and a transmit signal generator (280) coupled to the antenna (290), wherein at least one sensor (240) of the at least one sensor and the transmit signal generator (280) are integrated into a single package (250). [11] The sensor arrangement (200) according to claim 9 or 10, wherein the transmitter (210) has an antenna (290) and a transmit signal generator (280) coupled to the antenna (290), and wherein at least the transmit signal generator (280) is integrated into a first package (250), and wherein at least one sensor of the at least one sensor is integrated into a second package (250'). [12] The sensor arrangement (200) according to one of the preceding claims, wherein the sensor arrangement (200) is configured to be coupled to at least one electrode of the battery cell (100) in order to supply the sensor arrangement (200) with operating energy. [13] The sensor arrangement (200) according to one of the preceding claims, which further comprises a battery cell (100) to supply the sensor arrangement (200) with operating energy. [14] The sensor arrangement (200) according to one of the preceding claims, wherein the battery cell (100) is a lithium-ion battery cell. [15] The sensor arrangement (200) according to one of the preceding claims, wherein the battery cell (100) comprises at least either an aprotic solvent or lithium hexafluorophosphate. [16] The sensor arrangement (200) according to one of the preceding claims, wherein the sensor arrangement (200) is arranged inside the battery cell (100). [17] An energy system, comprising: a plurality of battery cells (100), wherein the battery cells comprise a sensor arrangement (200) according to any one of the preceding claims 1-16, and a battery management system arranged outside the plurality of battery cells (100) and configured to receive signals from the sensor arrangement (200) of the plurality of battery cells (100).

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