Sensor arrangement, high-voltage battery and method for manufacturing such a sensor arrangement

Abstract

The invention relates to a sensor arrangement (4) for monitoring the battery status of a high-voltage battery (2) of a motor vehicle, comprising a multilayer film arrangement (22) having at least one carrier layer and one cover layer (30), wherein a conductor arrangement (26) with at least one temperature sensor and at least one pressure sensor (32, 34) is provided on the carrier layer (24), characterized in that an air chamber (36) is provided directly above the at least one temperature sensor (32). The invention further relates to a high-voltage battery (2) and a method for manufacturing such a sensor arrangement (4).

Description

[0001] The invention relates to a sensor arrangement for monitoring the battery status of a high-voltage battery of a motor vehicle, comprising a multilayer film arrangement having at least one carrier layer and one cover layer, wherein a conductor arrangement with at least one temperature sensor and at least one pressure sensor is arranged on the carrier layer. Furthermore, the invention relates to a high-voltage battery and a method for producing such a sensor arrangement.

[0002] Such control units are known from the prior art, see, for example, DE 11 2016 003 015 T5. Using such a sensor arrangement, the operating state of a high-voltage battery can be monitored and evaluated using suitable evaluation tools and methods. Particularly in pre-series testing of prototype vehicles, it is important to precisely record compressive stresses and temperature distributions acting on the high-voltage battery in order to ensure optimal design of the production vehicle based on an evaluation of the determined data. However, the known sensor arrangement has the disadvantage that the determined values ​​are inaccurate due to interactions between temperature and pressure conditions. In addition, a sensor arrangement for battery cells is known from DE 10 2018 207 436 A1.

[0003] The object of the invention is therefore to provide a sensor arrangement in a simple and cost-effective manner which avoids the above-mentioned disadvantage.

[0004] This task is achieved by arranging an air chamber directly above at least one temperature sensor. This ensures precise, pressure-independent temperature measurement, which can be used in a subsequent evaluation process to eliminate temperature influences when calculating the pressure load.

[0005] Particularly advantageously, the air chambers are fluidically connected to one another via at least one air compensation channel. This increases the compensating capacity, particularly in the case of localized loading of the sensor arrangement, through interaction between the air chambers.

[0006] The compensating capacity of the air chambers can be further increased significantly by arranging at least one air reservoir which is fluidically connected to the at least one air chamber via an air compensation channel.

[0007] Particularly advantageously, the foil arrangement comprises a carrier layer, a conductor arrangement arranged thereon, at least one spacer layer covering the conductor arrangement, in which the air chamber is formed, and a cover layer arranged on the spacer layer. The carrier, spacer, and cover layers can be formed in a wide variety of strength levels. To ensure electrical shielding and improved pressure distribution and thus pressure introduction, the cover layer can be formed as a metal foil.

[0008] To ensure a particularly uniform pressure introduction in the area of ​​the pressure sensor, a compression element is arranged above the at least one pressure sensor. The compression element can be arranged in a recess in the cover layer.

[0009] Particularly advantageously, the temperature and / or pressure sensors are designed as nanocarbon thin-film sensors. This makes it possible to provide a very thin and precise sensor array.

[0010] The object is also achieved by a high-voltage battery with a housing arrangement comprising a number of housing parts in which a number of battery cells are arranged, with at least one such sensor arrangement according to one of the preceding claims, wherein the sensor arrangement is arranged between a battery cell surface and a housing part.

[0011] Advantageously, a pressure distribution body is arranged between the sensor arrangement and the battery cell surface and / or the housing part. This pressure distribution body also serves to uniformly distribute pressure into the sensor arrangement. Furthermore, the battery cell is protected from local pressure peaks.

[0012] Advantageously, a direct or indirect cooling arrangement is arranged in the housing arrangement.

[0013] This object is also achieved by a method for producing such a sensor arrangement, wherein the film arrangement is produced in a continuous lamination process using soft pressure rollers. The soft pressure rollers can also be used to press layers with air chambers or recesses for compression elements.

[0014] Reaction or hot melt adhesives are advantageously used to bond the layers of the film arrangement.

[0015] The invention is explained in more detail with reference to a drawing, which shows: Fig. 1 a schematic sectional view of a high-voltage battery with different installation situations for a sensor arrangement according to the invention, Fig. 2 a schematic sectional view of a film arrangement of the sensor arrangement according to the invention, and Fig. 3 a plan view of the sensor arrangement according to the invention.

[0016] Fig. 1 shows a schematic sectional view of a high-voltage battery 2 with different installation situations for a sensor arrangement 4 according to the invention. The high-voltage battery 2 is located in a motor vehicle (not shown in detail). The high-voltage battery 2 shown here is a high-voltage battery with direct cooling, in which cooling channels 8 are provided in a housing arrangement 6 in order to directly cool a battery cell 10. However, it should be clear that the present invention is not limited to a high-voltage battery 2 with direct cooling. High-voltage batteries with indirect cooling are also included in the scope of protection. A pressure distribution body 12 is provided on both sides of the battery cell 10, which ensures uniform pressure distribution between an adjacent housing part 14 and the facing battery cell surface 16 or between two adjacent battery cell surfaces 18 and 20.

[0017] In order to monitor the battery status of the high-voltage battery 2, and in particular of the battery cells 10, the sensor arrangement 4 can be provided in a wide variety of installation situations. For example, the sensor arrangement 4 can be arranged directly on a battery cell surface 16, 18, and / or 20. However, it can also be provided within the pressure distribution body 12 or adjacent to the housing part 14. The sensor arrangement 4 can also be placed adjacent to a cooling line 8. It should be clear that multiple sensor arrangements 4 can also be provided in a high-voltage battery 2.

[0018] Fig. Figure 2 shows a schematic sectional view through part of a film arrangement 22 of the sensor arrangement 4 according to the invention. The film arrangement 22 has a multi-layer structure and comprises a carrier layer 24, a conductor arrangement 26 arranged on the carrier layer 24, a spacer layer 28, and a cover layer 30. Depending on the application, the carrier layer 24, the spacer layer 28, and the cover layer 30 can have a wide variety of strength levels. The cover layer 30 can, in particular, be designed as a metal foil, which provides electromagnetic shielding and pressure equalization for components with non-uniform surface characteristics.

[0019] In the present embodiment, the conductor arrangement 26 has a temperature sensor 32 and a pressure sensor 34. The temperature and pressure sensors 32, 34 are embodied as nanocarbon thin-film sensors in the present embodiment. These thin-film sensors 32, 34 comprise piezo elements in a known manner, which exhibit a change in resistance depending on a temperature or pressure, which can be measured. By arranging temperature sensors 32 and pressure sensors 34, very precise temperature measurements can be taken in addition to very precise pressure measurements if the pressure influence is eliminated. An additional increase in the accuracy of the temperature measurement results from the fact that an air chamber 36 is provided directly above the temperature sensor 32. In the present embodiment, the air chamber 36 is formed in the spacer layer 28.In addition, the cover layer 30 has a recess 38 for a compression element 40, which is provided above the pressure sensor 34 and which is intended to ensure optimal pressure introduction into the pressure sensor.

[0020] Fig. Figure 3 now shows a top view of a sensor arrangement 4 according to the invention. In addition to other electronic components, four temperature sensors 32 and four pressure sensors 34 are provided. To further increase flexibility and pressure insensitivity, the four temperature sensors 32 are connected to each other via an air compensation channel 42. In addition, so-called air reservoirs 44 are provided, which can absorb displaced air in the area of ​​a temperature sensor 32.

[0021] In the present embodiment, the film arrangement 22 was produced by means of a continuous lamination process (see Fig.2), using soft pressure rollers 46. In the present embodiment, a hot-melt adhesive is used to bond the layers of the film arrangement 22.

Claims

[1] Sensor arrangement for monitoring a battery condition of a high-voltage battery (2) of a motor vehicle, comprising a multi-layer film arrangement (22) which has at least one carrier layer and one cover layer (30), wherein a conductor arrangement (26) with at least one temperature and at least one pressure sensor (32, 34) is arranged on the carrier layer (24), characterized by that an air chamber (36) is arranged directly above the at least one temperature sensor (32). [2] Sensor arrangement according to claim 1, characterized by that the air chambers (36) are fluidically connected to one another via at least one air compensation channel (42). [3] Sensor arrangement according to claim 1 or 2, characterized by that at least one air reservoir (44) is provided which is fluidly connected to the at least one air chamber (36) via an air compensation channel (42). [4] Sensor arrangement according to one of claims 1-3, characterized bythat the film arrangement (22) has a carrier layer (24), a conductor arrangement (26) arranged thereon, at least one spacer layer (28) covering the conductor arrangement (26), in which the air chamber (36) is formed and a cover layer (30) arranged on the spacer layer (28), wherein the carrier, spacer and cover layers (26, 28, 30) are to be formed in a wide variety of strength levels. [5] Sensor arrangement according to claim 4, characterized in that the cover layer (30) is formed as a metal foil. [6] Sensor arrangement according to one of the preceding claims, characterized by that a compression member (40) is arranged above the at least one pressure sensor (34). [7] Sensor arrangement according to one of claims 6, characterized by that the compression member (40) is arranged in a recess (38) of the cover layer (30). [8] Sensor arrangement according to one of the preceding claims, characterized bythat the temperature and / or pressure sensors (32, 34) are designed as nano-carbon thin-film sensors. [9] High-voltage battery with a housing arrangement (6) comprising a number of housing parts in which a number of battery cells (10) are arranged, with at least one sensor arrangement (4) according to one of the preceding claims, characterized by that the sensor arrangement (4) is arranged between a battery cell surface (16, 18) and a housing part (14). [10] High-voltage battery according to claim 9, characterized by that a pressure distribution body (12) is arranged between the sensor arrangement (4) and the battery cell surface (16, 18) and / or the housing part (14). [11] High-voltage battery according to claim 9 or 10, characterized by that a direct or indirect cooling arrangement (8) is arranged in the housing arrangement (6). [12] Method for producing a sensor arrangement (4) according to one of claims 1-8, characterized bythat the film arrangement (22) is produced in a continuous laminating process using soft pressure rollers (46). [13] Method for producing a sensor arrangement (4) according to claim 12, characterized by that reactive or hot melt adhesives are used to bond the layers of the film arrangement.

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