A standardized unit module battery and battery system for a forklift truck

Abstract

The utility model relates to a forklift power battery technical field especially relates to a kind of standardization unit module battery and battery system suitable for forklift, comprising: box, by heat conduction protective housing, panel, bottom plate are constituted, panel and bottom plate are respectively sealed and fixed in the upper and lower end surface of heat conduction protective housing, and positive terminal stud and negative terminal stud are equipped on panel;Unit battery module, encapsulation in box, comprising: multiple single battery cell;Flexible electrical connection component, single battery cell is connected with series or parallel form to constitute battery pack;Wherein, flexible electrical connection component is directly connected to positive terminal stud and negative terminal stud, forms battery pack external circuit interface.The scheme has the advantages of improving the standardization degree of battery system, reducing customization cost, facilitating maintenance and flexible expansion.

Description

Technical Field

[0001] This utility model relates to the field of forklift power battery technology, and in particular to a standardized unit module battery and battery system suitable for forklifts. Background Technology

[0002] In the field of forklift power systems, lead-acid batteries have long dominated, but their inherent defects are becoming increasingly apparent. Energy density limitations: Lead-acid batteries have an energy density of only 40-60 Wh / kg, requiring forklifts to have larger battery compartments (accounting for more than 20% of the total vehicle area). Low electrical efficiency: A full charge takes 8-10 hours, requiring work interruption during charging, resulting in a decrease in battery utilization of approximately 35%. Short cycle life: After 400-600 cycles, the capacity decays to 80%, requiring users to replace the battery every 2-3 years, adding downtime costs; waste electrolyte causes tens of thousands of tons of heavy metal pollution annually. Complex maintenance: Regular water addition and equalization charging are required, increasing annual maintenance costs by 10%, and there is a risk of acid leakage. Currently, lithium batteries have increasingly obvious advantages, and lithium battery technology is constantly breaking through, achieving high energy density: Lithium iron phosphate (LFP) batteries have an energy density of 150-250 Wh / kg, reducing volume by 65% ​​for the same capacity, contributing to forklift lightweighting and space optimization. Fast charging and discharging: Supports 1-2 hour fast charging, with charging efficiency 2-4 times that of traditional lead-acid batteries, enabling "charge and use immediately". Long cycle life: Over 4000-6000 cycle life (capacity retention ≥80%), extending service life to 5-8 years and reducing replacement frequency. Intelligent management: The BMS system monitors cell status in real time, supporting fault warnings, accurate SOC estimation, and thermal management, improving system reliability.

[0003] However, current lithium battery systems for forklifts still follow the traditional structural design of new energy vehicles, employing a fixed, integrated housing layout that cannot be flexibly configured according to different forklift models. This non-modular design necessitates the custom development of a dedicated battery system for each forklift model, increasing both R&D and production costs and hindering the large-scale application of lithium batteries in the forklift field. Existing technology lacks a forklift power battery solution that can both leverage the performance advantages of lithium batteries and achieve standardized, modular design. Summary of the Invention

[0004] To address the aforementioned issues, the present invention aims to provide a standardized unit module battery and battery system suitable for forklifts, which offers advantages such as improved standardization of the battery system, reduced customization costs, ease of maintenance, and flexible expansion.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This application provides a standardized unit module battery suitable for forklifts, the technical solution of which is as follows: A standardized unit module battery suitable for forklifts includes: a housing, comprising a thermally conductive protective shell, a panel, and a base plate, wherein the panel and the base plate are respectively sealed and fixed to the upper and lower end faces of the thermally conductive protective shell, and the panel is provided with a positive terminal and a negative terminal; a unit battery module, encapsulated in the housing, comprising:

[0007] • Multiple individual battery cells;

[0008] • Flexible electrical connection components connect individual battery cells in series or parallel to form a battery pack;

[0009] • The flexible electrical connection component is directly connected to the positive and negative terminals, forming the external circuit interface of the battery pack.

[0010] This technical solution achieves the universality of forklift lithium batteries through standardized modular design. The housing consists of a thermally conductive protective shell, a panel, and a base plate, forming a sealed structure. The panel and base plate are fixed by the upper and lower end faces to form a stable encapsulation space, resulting in a simplified, safe, and reliable structure. Simultaneously, the panel integrates positive and negative terminals as a unified external interface, eliminating the need to redesign battery interfaces for different vehicle models. Each battery module encapsulates multiple individual cells, which are connected in series and parallel via flexible electrical connection components. This flexible connection method can adapt to different cell layout requirements, directly connecting to external terminals to form a standardized circuit interface, avoiding the customized design required by traditional wiring harness connections. The thermally conductive protective shell, in conjunction with the sealed structure, ensures thermal management requirements while achieving independent module encapsulation. This provides a basic unit for the subsequent detachable assembly of battery systems, facilitating widespread application and enabling large-scale production.

[0011] Furthermore, this application proposes that the unit battery module is fixed to the housing using a potting thermally conductive adhesive; the outer surface of the thermally conductive protective shell is equipped with a heat dissipation fin structure. This solution uses the potting thermally conductive adhesive to fix the unit battery module, leveraging the adhesive's bonding and thermal conductivity to achieve a dual function: firstly, it rigidly connects the battery pack to the housing to resist mechanical vibrations during forklift operation; secondly, it conducts the heat generated by the battery cells to the outer shell through the adhesive. The outer surface of the thermally conductive protective shell is equipped with a heat dissipation fin structure, which enhances air convection heat dissipation by increasing the surface area, forming a synergistic heat dissipation path with the potting thermally conductive adhesive—internal heat is transferred to the outer shell through the thermally conductive adhesive, and then quickly dissipated to the external environment through the fin structure. This combined design ensures the structural stability of the battery module under dynamic operating conditions and solves the problem of heat accumulation in high-power forklift battery systems through a multi-stage heat conduction mechanism, providing a guarantee for the reliable operation of standardized modules under complex operating conditions.

[0012] Furthermore, this application proposes that a battery insulating plate be provided between adjacent individual cells; a flexible electrical connection assembly be located on the side of the battery pack; and a battery insulating plate be provided between the flexible electrical connection assembly and the inner wall of the thermally conductive protective shell. This solution achieves safety protection and spatial adaptability through a triple insulation isolation design. First, a battery insulating plate is set between adjacent individual cells to directly eliminate the risk of short circuits caused by electrode contact due to vibration or deformation when cells are stacked, ensuring operational safety under high-density arrangement; second, the flexible electrical connection assembly is arranged on the side of the battery pack, which avoids occupying the top space of the battery module, facilitating subsequent expansion, and also forms a clearance fit space with the side wall of the forklift battery compartment; finally, a battery insulating plate is added between the flexible electrical connection assembly and the inner wall of the shell to construct a double insulation barrier to prevent leakage accidents caused by contact between conductive components and the metal shell due to vehicle bumps. This three-dimensional insulation layout solves the insulation protection problems between cells, between modules, and between modules and the shell in a limited space, providing structural protection for the reliable operation of standardized modules.

[0013] Furthermore, this application proposes a flexible electrical connection assembly comprising: a flexible thermoformed plate; positive and negative electrode buffer aluminum busbars disposed at both ends of the thermoformed plate; and multiple wire harness plates disposed on the thermoformed plate; wherein: the positive electrode buffer aluminum busbar is directly connected to the positive electrode terminal; the negative electrode buffer aluminum busbar is directly connected to the negative electrode terminal; and the wire harness plates connect to the individual cell electrodes. This technical solution uses the flexible thermoformed plate as a connection carrier, whose bendable characteristics adapt to spatial layout adjustments between different unit modules, providing a physical support basis for the series and parallel expansion of standardized battery modules. The positive and negative electrode buffer aluminum busbars are respectively disposed at both ends of the thermoformed plate, forming the shortest current path by directly connecting the positive and negative electrode terminals. This reduces line impedance and avoids the space occupation caused by traditional cable entanglement. Simultaneously, the buffering characteristics of the aluminum busbars can absorb the mechanical vibration energy during forklift operation, preventing metal fatigue fracture caused by rigid connections. Multiple wire harness plates are distributed on the thermoformed plate, connecting the individual cell electrodes point-to-point, enabling flexible configuration of parallel or series cell topologies. The integrated design of the wire harness board and the vacuum-formed board transforms the originally scattered wire connections into a planar layout, significantly reducing assembly steps. Furthermore, the insulation properties of the vacuum-formed board complement the conductivity of the aluminum busbar, ensuring electrical safety while improving energy transmission efficiency. This overall structure, through synergistic innovation in material properties and spatial layout, constructs a standardized electrical connection system that combines flexibility and high reliability.

[0014] Furthermore, this application proposes that the wire harness board is press-fitted and fixed to the blister pack; individual battery cells are connected to the wire harness board via wire harnesses; and the wire harness board has a protrusion in the middle that faces the inner wall of the thermal protection shell. This technical solution improves the stability of the electrical connection through a triple structural design. The wire harness board is press-fitted to the blister pack, forming a rigid connection base to ensure the overall structural stability of the connection assembly and avoid displacement caused by forklift operation vibration. The individual battery cells are connected to the wire harness board via wire harnesses. Compared with the traditional hard connection method, this retains the necessary flexibility to accommodate the slight deformation of the battery cells, and achieves standardized interfaces through controllable wiring of the wire harness. The protrusion in the middle of the wire harness board forms a mechanical preload through the protrusion structure. When temperature changes cause the material to expand and contract, its elastic deformation can absorb internal stress. At the same time, the protrusion forms a contact support with the inner wall of the thermal protection shell, establishing multiple stress release paths and effectively preventing the risk of breakage due to stress concentration at the connection point.

[0015] Furthermore, this application proposes a battery buffer pad between the bottom of the unit battery module and the base plate; and a fiberglass tape covering the perimeter of the unit battery module. This technical solution enhances the structural stability and safety of the battery module through a dual-protection structure. The buffer pad at the bottom of the unit battery module effectively absorbs vibration energy generated during forklift operation, preventing mechanical damage to the battery cells caused by rigid contact. Simultaneously, this buffer layer compensates for assembly tolerances between the battery pack and the base plate. The fiberglass tape covering the perimeter of the battery module utilizes its high strength and high-temperature resistance to form a continuous insulating layer. This prevents short circuits between the battery cells and the metal casing and enhances the overall structural strength of the battery pack through winding and fixing, particularly resisting the shearing forces generated by frequent forklift starts and stops. The combined effect of these two elements maintains the reliability of the internal connections of the battery module under dynamic operating conditions, extending its service life.

[0016] Furthermore, this application also proposes that the panel integrates a handle, and its structure can be one-piece, separate, or foldable.

[0017] Furthermore, this application proposes a double-sided heating film sandwiched between the large surfaces of two adjacent individual battery cells, simultaneously contacting the surfaces of both battery cells; the double-sided heating film is a PI film, epoxy resin film, or thermosetting resin film. This solution achieves bidirectional synchronous heating by directly sandwiching the double-sided heating film between the large surfaces of adjacent individual battery cells, utilizing its structural design of simultaneously contacting the surfaces of both battery cells, thereby improving heating efficiency and saving costs. This structure eliminates the problem of asymmetrical heating of the battery cells caused by traditional single-sided heating films, improves heating efficiency, and ensures a uniform temperature distribution between battery cells, thus avoiding battery performance degradation caused by local temperature differences. Using PI film, epoxy resin film, or thermosetting resin film as the heating film material satisfies the requirements for heat resistance and insulation under high-temperature environments, and achieves uniform heat diffusion through the material's own thermal conductivity characteristics, while avoiding the risk of poor cell contact or short circuits due to material thermal deformation.

[0018] Furthermore, this application proposes a battery system suitable for forklifts, comprising: multiple aforementioned unit battery modules; a high-voltage box connecting each unit battery module and an external electronic control system via high-voltage resistant wiring harnesses; wherein, the multiple unit battery modules are detachably connected in series or parallel to form an extended battery array adapted to the shape of the forklift battery compartment, thereby creating battery systems with different voltage platforms and capacities. This technical solution achieves flexible expansion and adaptation of the forklift battery system through modular combination and standardized interface design. Multiple unit battery modules, as basic units, can be combined in series or parallel in a detachable manner, allowing for array arrangement according to the actual spatial form of the forklift battery compartment, breaking through the spatial limitations of traditional customized battery systems. The high-voltage box, as a centralized electrical connection node, integrates each module with the external electronic control system via high-voltage resistant wiring harnesses, ensuring the stability and safety of high-current transmission. The extended battery array construction method allows the battery system to dynamically adjust the voltage platform (by changing the number of series connections) and capacity (by changing the number of parallel connections) according to the forklift's operational needs, meeting the differentiated needs of different vehicle models while maintaining standardized module production, significantly reducing redundant development costs. Among them, the feature of "adapting to the volume and shape of forklift battery compartments" particularly emphasizes the ability to fill irregularly shaped battery compartments when combining modules, and achieves optimal space utilization by adjusting the gaps between modules or by arranging them asymmetrically.

[0019] Furthermore, this application also proposes a battery management system for: real-time monitoring of the voltage, temperature, and health status of each battery module; and for feeding back fault information to the electronic control system via a communication protocol bus.

[0020] As can be seen from the above, the standardized unit module battery and battery system for forklifts provided in this application realizes the standardized production and flexible combination of forklift power batteries through modular box structure design and expandable battery array configuration. It solves the problems of high customization cost and poor adaptability of traditional lithium battery systems, and has the advantages of improving the standardization of battery systems, reducing customization costs, facilitating maintenance and flexible expansion. Attached Figure Description

[0021] Figure 1 This invention provides a three-dimensional view of a unit module battery suitable for forklifts.

[0022] Figure 2 This is an exploded structural diagram of a unit module battery (2 cells) provided according to the present invention.

[0023] Figure 3 This is a front view of the exploded structure of a unit module battery (8 cells) provided according to the present invention.

[0024] Figure 4 This is a reverse side view of the exploded structure of a unit module battery (8 cells) provided according to the present invention.

[0025] Figure 5 This is a schematic diagram of the structure of a single-cell battery module.

[0026] Figure 6 This is an exploded view of the structure of a single-cell battery module.

[0027] Figure 7 This is a schematic diagram of the flexible electrical connection assembly.

[0028] Figure 8 This is a schematic diagram of a battery system structure suitable for forklifts. Detailed Implementation

[0029] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0030] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0031] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0032] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0033] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0034] In current technology, forklift power systems have long relied on lead-acid batteries, which suffer from low energy density, poor charging efficiency, and complex maintenance. While lithium iron phosphate batteries offer advantages in energy density and cycle life with the development of lithium battery technology, traditional forklift lithium battery systems still utilize the integrated structure of new energy vehicles, requiring customized battery housings and connection systems for different models. This non-standardized design prevents battery modules from being universally compatible across models, resulting in high R&D costs and severely hindering the large-scale application of lithium batteries in the forklift field.

[0035] To address these issues, researchers discovered that the root cause of the difficulty in platformizing forklift battery systems lies in the lack of a unified interface and scalability in the battery module structure. Traditional battery packs use fixed wiring harnesses, requiring the cell layout and external interfaces to be redesigned according to the vehicle's battery compartment dimensions. After repeated verification, the design approach shifted to building independently packaged standard unit modules: achieving unified physical packaging through a modular enclosure structure, coupled with flexible circuit connections to adapt to different cell combinations, ultimately forming a standardized external interface. This design allows individual battery modules to directly serve as basic units, and can be combined in series and parallel to meet the needs of different vehicle models.

[0036] Example 1:

[0037] like Figure 1-7As shown, this embodiment proposes a standardized unit module battery suitable for forklifts, including: a housing, which is composed of a thermally conductive protective shell 100, a panel 101, and a base plate 102. The panel 101 and the base plate 102 are respectively sealed and fixed to the upper and lower end faces of the thermally conductive protective shell 100, and the panel 101 is provided with a positive terminal 200 and a negative terminal 201; the unit battery module is encapsulated in the housing, including multiple individual cells 300 and a flexible electrical connection assembly 301. The assembly connects the individual cells 300 in series or parallel to form a battery pack, and directly connects to the positive terminal 200 and the negative terminal 201 to form an external circuit interface.

[0038] The thermally conductive protective shell 100 is a closed container with thermal conductivity, specifically made using an aluminum alloy extrusion molding process, i.e., an aluminum shell. Its function is to maintain the uniformity of the battery's operating temperature and improve the overall structural strength of the module. The panel 101 is a mounting base plate located on top of the shell, specifically a sheet metal panel, which is laser-welded to the shell to form a sealed connection for integrating standardized circuit interfaces. The base plate 102 is a support plate located at the bottom of the shell, specifically a sheet metal shell base plate, used to enhance the module's impact resistance. The flexible electrical connection assembly 301 is a conductive connection structure that can adapt to cell position deviations, specifically made by combining a stamped aluminum busbar with a flexible circuit board. Its function is to eliminate assembly stress caused by rigid connections and simplify the connection path for different cell arrangement methods. In this solution, the thermally conductive protective shell 100, panel 101, and base plate 102 together form a sealed space, providing physical protection and a foundation for thermal management of the unit battery module. Multiple individual battery cells 300 are integrated into the circuit within the enclosure via a flexible electrical connection assembly 301. The number of individual battery cells 300 can range from 2 to 8. This assembly automatically adjusts the connection angle according to the cell arrangement, avoiding the accumulation of assembly errors inherent in traditional rigid busbars. The positive and negative terminals 200201 serve as a unified interface, directly connecting to the flexible electrical connection assembly 301, eliminating intermediate wiring harness adapters and enabling plug-and-play functionality for individual modules. When adapting to different vehicle models, only the number and combination of modules need to be adjusted; there is no need to redesign the internal circuit structure.

[0039] Compared to existing technologies, traditional forklift lithium battery systems employ an integrated battery box structure, requiring customized internal cell connections and external interfaces to match the specific vehicle model's battery compartment dimensions. This solution utilizes a modular box design, encapsulating the cell assembly as an independent functional unit. Combined with flexible connections and a unified interface, this allows individual modules to be produced independently of specific vehicle models. This design breaks the strong coupling between traditional battery systems and vehicle models, enabling cross-platform reuse of battery modules. Through this technical solution, this application achieves standardized production of forklift lithium battery modules, reducing vehicle model adaptation development costs. The modular packaging structure allows the battery system's capacity to be flexibly adjusted by adding or removing modules, adapting to the power requirements of forklifts of different tonnages. The unified external interface design simplifies system integration and shortens the vehicle assembly cycle. The flexible electrical connection component 301, combined with a heat-conducting shell design, ensures electrical connection reliability while improving module thermal management efficiency and extending battery life.

[0040] In this specific design, the battery module is fixed to the housing using a potting thermally conductive adhesive, and the outer surface of the thermally conductive protective shell 100 is equipped with a heat dissipation fin structure. The potting thermally conductive adhesive is a colloidal material with thermal conductivity, specifically a silicone-based thermally conductive adhesive or an epoxy resin thermally conductive adhesive. It fills the gap between the battery module and the housing, forming a rigid connection and transferring heat. The heat dissipation fin structure refers to protrusions or extensions on the surface of the shell, specifically an array of aluminum or copper fins, which increases the surface area and promotes heat diffusion to the surrounding air. In this design, after curing, the potting thermally conductive adhesive forms a supporting structure, integrating the battery module with the housing as a whole and limiting the displacement of internal components in a vibration environment. The thermally conductive adhesive also acts as a heat conduction medium, transferring the heat generated by the battery cell along the adhesive path to the thermally conductive protective shell 100. The heat dissipation fins on the outer surface of the shell increase the contact area, accelerating heat convection to the air, forming a heat transfer chain from the internal battery cell to the external environment. This solution integrates structural fixation and heat conduction through potting thermally conductive adhesive, combined with finned heat dissipation to simplify the structure and improve thermal management efficiency. Through the above technical solution, this application effectively suppresses the risk of structural instability of the battery module caused by vibration during forklift operation, and reduces the cell operating temperature through a coordinated heat conduction path, avoiding performance degradation caused by heat accumulation.

[0041] Furthermore, a battery insulating plate 305 is provided between adjacent individual battery cells 300; a flexible electrical connection assembly 301 is located on the side of the battery pack, and the battery insulating plate 305 is provided between the flexible electrical connection assembly 301 and the inner wall of the thermally conductive protective shell 100. The battery insulating plate 305 refers to an insulating material layer used to isolate conductive components, its function being to block direct contact between components with different potentials. The flexible electrical connection assembly 301 refers to a conductive connection structure with deformation capability, specifically implemented using a combination of a vacuum-formed plate and a buffer aluminum busbar, its function being to accommodate cell expansion and reduce mechanical stress. In this solution, the battery insulating plate 305 is inserted between adjacent individual battery cells 300, blocking the contact path of the cell electrodes through physical isolation, eliminating the risk of short circuits caused by electrode overlap due to vibration. The flexible electrical connection assembly 301 is arranged in the side area of ​​the battery pack, utilizing the lateral space of the battery module to complete the electrical connection, avoiding occupying the top expansion interface space. The battery insulation plate 305 added between the flexible electrical connection component 301 and the inner wall of the outer casing forms a second protective barrier to prevent leakage accidents caused by contact between conductive components and the metal casing under vehicle bumpy conditions. This three-dimensional insulation layout constructs a multi-protection system within a limited space, which not only meets the requirements of high-density cell arrangement, but also ensures the electrical safety of modular batteries under complex operating conditions.

[0042] like Figure 7 As shown, the flexible electrical connection assembly 301 includes a flexible thermoformed plate 3011, positive electrode buffer aluminum bars 3012 and negative electrode buffer aluminum bars 3013 disposed at both ends of the thermoformed plate 3011, and multiple wire harness plates 3014 disposed on the thermoformed plate 3011. The positive electrode buffer aluminum bar 3012 is directly connected to the positive electrode terminal 200, and the negative electrode buffer aluminum bar 3013 is directly connected to the negative electrode terminal 201. The wire harness plates 3014 are connected to the electrodes of the individual battery cells 300. The flexible thermoformed plate 3011 refers to an insulating substrate with bendable deformation capability, specifically made of polypropylene or PET material through a thermoforming process, used to support the electrical connection components and adapt to spatial layout adjustments between different unit modules. The positive electrode buffer aluminum bars 3012 and negative electrode buffer aluminum bars 3013 are conductive metal strips with elastic deformation capability, specifically made of aluminum alloy and stamped into a wave-shaped, serpentine, or L-shaped structure, absorbing the mechanical vibration energy generated during forklift operation through elastic deformation. Among them, the wire harness board 3014 refers to a conductive copper plate, on which a wire harness connector is provided to establish an electrical connection path between the electrode of the single cell 300 and the buffer aluminum busbar.

[0043] Specifically, the flexible thermoformed plate 3011 serves as the connection carrier, and its bending characteristics allow the battery module to bend and deform within the forklift battery compartment. The positive and negative electrode buffer aluminum busbars 3012 and 3013 are directly connected to the terminal blocks, forming the shortest current path to reduce impedance. Simultaneously, the corrugated structure generates elastic deformation under vibration conditions, preventing metal fatigue fracture. The wiring harness plates 3014 are distributed in a matrix on the thermoformed plate 3011, achieving stable contact with the cell electrodes through press-fitting. Each wiring harness plate 3014 independently connects to a specific cell, supporting series or parallel topology reconfiguration. The insulation properties of the thermoformed plate 3011 combined with the conductivity of the aluminum busbars form a safe and reliable electrical isolation and energy transfer system. This solution achieves spatial layout adjustment through the flexible thermoformed plate 3011, eliminates vibration stress through the buffer aluminum busbars, and simplifies the assembly process through the distributed wiring harness plates 3014. The synergistic effect of these three components simultaneously improves modular expansion capabilities and connection reliability. Through the above technical solutions, this application solves the problems of poor spatial adaptability, low assembly efficiency, and insufficient vibration resistance of traditional electrical connection structures in forklift applications. The flexible thermoforming plate 3011 allows the battery modules to be adjusted in angle as needed, the buffer aluminum busbar effectively absorbs operational vibration energy, and the distributed wiring harness plate 3014 transforms discrete cable connections into a planar layout, significantly reducing assembly complexity. This structure provides fundamental support for the rapid assembly of standardized battery modules while maintaining stable electrical performance.

[0044] In a further embodiment, the wire harness plate 3014 is press-fitted to the vacuum forming plate 3011; the individual battery cell 300 is connected to the wire harness plate 3014 via a wire harness; the wire harness plate 3014 has a protrusion 3015 in the middle protruding towards the inner wall of the thermal protection housing 100. The press-fitting of the wire harness plate 3014 refers to forming a rigid connection between the wire harness plate 3014 and the vacuum forming plate 3011 through mechanical pressing or bolt fastening. Specifically, this can be achieved by stamping with a die or by pre-drilling mounting holes and locking with bolts. Its function is to provide a stable mounting base for the electrical connection components and prevent relative displacement caused by vibration. The wire harness connection refers to connecting the electrodes of the individual battery cell 300 to the wire harness plate 3014 through flexible wires. This can be achieved by welding or plugging terminals. Its function is to absorb the stress generated by the slight deformation of the battery cell through the flexible wire harness, while maintaining the stability of the electrical connection. The protrusion 3015 refers to a protruding structure in the central area of ​​the wiring harness plate 3014 designed with elastic deformation capability. This can be achieved by stamping spring steel plates or using a silicone-filled cavity structure. Its function is to provide contact support with the inner wall of the thermally conductive protective shell 100, dispersing localized stress concentration and preventing hard contact. In this design, the wiring harness plate 3014 forms a rigid connection base with the vacuum-formed plate 3011 through press fitting, ensuring that the overall structure of the electrical connection assembly does not shift under forklift vibration conditions. The individual battery cell 300 is connected to the wiring harness plate 3014 via the wiring harness. The flexibility of the wiring harness offsets the minor deformation of the battery cell caused by temperature fluctuations, avoiding the risk of breakage due to hard connection. Under forklift vibration conditions, the protrusion 3015 in the central area of ​​the wiring harness plate 3014 forms a support through contact with the inner wall of the thermally conductive protective shell 100, establishing a stress release path, further dispersing the mechanical load generated by vibration and deformation, preventing hard contact, and protecting the battery cell.

[0045] Furthermore, a battery buffer pad 304 is provided between the bottom of the unit battery module and the base plate 102, and the perimeter of the unit battery module is covered with fiberglass tape 306. The battery buffer pad 304 is an elastic support structure between the battery module and the base plate 102, which can be made of silicone or rubber. Its function is to absorb the vibration energy generated during forklift operation, preventing mechanical damage caused by rigid contact between the battery module and the base plate 102, and compensating for assembly tolerances. The fiberglass tape 306 is an insulating wrapping tape with fiberglass as the base material, which can be made of high-temperature resistant fiberglass tape. Its function is to form a continuous insulating protective layer, preventing short circuits between the battery module and the metal casing, and enhancing the overall structural strength of the battery module through wrapping and fixing. Specifically, the battery buffer pad 304 is arranged between the unit battery module and the base plate 102, utilizing the deformation characteristics of the elastic material to convert vibration impact into heat dissipation, reducing the mechanical stress transmitted to the battery module, thereby protecting the stability of the battery cell and internal connection structure. Fiberglass tape 306 is spirally wound to cover the sides and edges of the battery module. Its high tensile strength can withstand the shearing forces generated by frequent forklift starts and stops, while the high-temperature resistance of fiberglass ensures that insulation performance is maintained within the battery's operating temperature range. The combined application of these two materials forms a dual protection system of bottom buffering and lateral insulation, maintaining the reliability of the internal connections of the battery module under dynamic operating conditions.

[0046] like Figure 1 and 2As shown, the panel 101 integrates a handle 103, which can be one-piece, separate, or foldable. The one-piece structure means that the handle 103 and panel 101 are formed into a single solid structure through an integral molding process, specifically injection molding or die casting. This structure enhances the connection strength between the handle 103 and panel 101, avoiding the risk of breakage due to stress concentration during handling. The separate structure means that the handle 103 is assembled to the panel 101 via detachable connectors, specifically using bolt fixing or snap-locking methods. This structure allows for the replacement of handles 103 of different sizes or materials according to the usage scenario, meeting the module adaptation requirements under the space constraints of the forklift battery compartment. The foldable structure means that the handle 103 switches between unfolded and retracted states through a hinge mechanism, specifically using a rotating shaft and a limiting slot mechanical design. This structure allows the handle 103 to be retracted to a position flush with the panel 101 when not in use, reducing the probability of damage from external collisions during transportation and storage. When the battery modules need to be moved, operators can create a lifting fulcrum by unfolding the folding handle 103 or installing the detachable handle 103, utilizing ergonomic design to reduce the intensity of the handling operation. In the case of installation in a confined battery compartment, the folding handle 103 reduces space occupation when stored, ensuring a compact layout of the module array. During maintenance operations, the detachable handle 103 can be quickly removed to expose the interface on the surface of the panel 101, avoiding interference with the operating space of maintenance tools caused by the traditional fixed handle 103.

[0047] Furthermore, the double-sided heating film 303 is sandwiched between the large surfaces of two adjacent single-cell batteries 300 and simultaneously contacts the surfaces of both battery cells. The double-sided heating film 303 is a PI film, an epoxy resin film, or a thermosetting resin film.

[0048] The double-sided heating film 303 refers to a thin-film structure with bidirectional heating function. It can be made of polyimide, epoxy resin composites, or thermosetting resin materials, and achieves bidirectional heat conduction by directly adhering to the surface of the battery cell. The contact surfaces on both sides of the battery cell refer to the planar area where the heating film covers the maximum contact area of ​​the battery cell. This can be achieved by adjusting the size of the heating film to match the surface of the battery cell, ensuring that the heat transfer path covers the main heat-generating areas of the battery cell. The PI film refers to a high-temperature resistant insulating film based on polyimide, which can be prepared using a chemical vapor deposition process. Its high heat resistance and low coefficient of thermal expansion maintain the structural stability of the heating film.

[0049] Specifically, a double-sided heating film 303 is sandwiched between adjacent individual battery cells 300, with its two side surfaces in direct contact with the large-area planes of both cells. In low-temperature environments, the heat generated by the heating film 303 after being energized is simultaneously transferred to the adjacent cells through both side surfaces, ensuring uniform heating of the entire cell. Because the heating film 303 covers the main heat dissipation surface of the cell, heat can diffuse evenly along the thickness direction of the cell, avoiding localized temperature differences caused by unilateral heating. When using polyimide or epoxy resin materials, the heating film 303 maintains shape stability in high-temperature environments, preventing poor contact with the cell due to material deformation, while the insulating layer blocks current leakage paths.

[0050] Compared to existing technologies, traditional forklift lithium batteries mostly use single-sided heating elements or external heating devices, with heat transferred only from one side of the cell. This leads to an increased internal temperature gradient within the cell, and the contact area between the heating element and the cell is limited. This solution uses a bidirectional synchronous heating design to allow heat to be introduced from both sides of the cell simultaneously, shortening heating time, reducing energy consumption, improving heating efficiency, and saving costs. At the same time, it utilizes the heat-resistant properties of the heating film material to avoid contact failure caused by high-temperature deformation.

[0051] Example 2:

[0052] like Figure 8 As shown, this embodiment proposes a battery system suitable for forklifts, including multiple unit battery modules 32 as described in Embodiment 1. A high-voltage box 31 connects each unit battery module 32 to an external electronic control system via a high-voltage resistant wiring harness. Multiple unit battery modules 32 are connected in series or parallel in a detachable manner to form an extended battery array adapted to the volume and shape of the forklift's battery compartment, thereby creating battery systems with different voltage platforms and capacities.

[0053] The detachable series or parallel combination refers to the physical connection and disconnection of the unit battery modules 32 through standardized electrical interfaces. This can be achieved using pluggable connectors or bolt-fixed structures, ensuring that electrical connections and mechanical fixation are completed simultaneously. The extended battery array refers to the three-dimensional arrangement of multiple modules according to the battery compartment's spatial shape. This can be achieved through module spacing adjustment or asymmetrical layout to match the varying volumes of different forklift battery compartments. Adapting to the forklift battery compartment's volume shape means that the battery system can fill the effective space of the battery compartment. This can be achieved through standardized module dimensions and optimized array arrangement to maximize space utilization. The high-voltage box 31, as a centralized electrical node, can be implemented using copper busbar integration and insulation protection structures to integrate the power output of each module and connect it to an external electrical control system.

[0054] Specifically, multiple battery modules 32 serve as basic units, mechanically connected and electrically coupled through standardized interfaces. When the system voltage needs adjustment, the total voltage value is changed by increasing or decreasing the number of series-connected modules. When the capacity needs adjustment, multiple series-connected groups are connected in parallel to achieve capacity aggregation; for example, connecting two 48V modules in parallel doubles the capacity. The high-voltage box 31 centrally transmits the power from each module to the forklift drive system via high-voltage resistant wiring harnesses, while integrating overcurrent protection devices to ensure safe high-current transmission. During the construction of the extended battery array, the modules can be arranged asymmetrically according to the geometry of the battery compartment, such as arranging them at right angles in an L-shaped battery compartment, or using a single-row stacked layout in a narrow space, thereby making full use of space.

[0055] This solution utilizes a modular design, enabling the same batch of standardized modules to adapt to various forklift battery compartments. For example, counterbalance forklifts employ a compact array layout, while reach trucks use a distributed layout. Existing technologies use battery system voltage and capacity with fixed values, which cannot be adjusted according to operating conditions. This solution, however, allows for flexible voltage and capacity configuration by increasing or decreasing the number of modules. For instance, logistics forklifts can use a basic capacity configuration under light load conditions and expand with parallel module groups under heavy load conditions. Through this technical solution, this application addresses the high cost problem caused by customized development of forklift lithium battery systems. The free combination of standardized modules adapts to the irregular spaces of battery compartments for different vehicle models, while simultaneously achieving dynamic adjustment of voltage platform and capacity. The modular design allows the battery system to quickly respond to the power needs of different forklifts, eliminating the need for repeated development of the entire battery pack and significantly reducing R&D and manufacturing costs. The expandable array arrangement effectively improves the battery compartment space utilization rate, solving the space waste problem caused by the fixed size of traditional integral battery packs. The combined use of high-voltage wiring harnesses and a centralized high-voltage box 31 ensures the safety and reliability of the modular system in high-current transmission scenarios.

[0056] Furthermore, it also includes a battery management system (BMS) for real-time monitoring of the voltage, temperature, and health status of each battery module 32, and for feeding back fault information to the electronic control system via a communication protocol bus. The BMS is a control unit that collects and processes battery module operating data. Specifically, it can be implemented using an embedded system integrating voltage sensors, temperature sensors, and state estimation algorithms to identify voltage imbalances, temperature anomalies, and lifespan degradation trends. The communication protocol bus is a standardized communication interface for transmitting data signals, which can be implemented using a CAN bus or RS485 bus, used to transmit battery module fault information to the electronic control system. The BMS collects voltage data from each battery module 32 using voltage sensors to determine if there is a risk of overcharging or over-discharging; it monitors the surface and internal temperature distribution of the battery modules using temperature sensors to identify localized overheating; and it analyzes the degree of battery capacity degradation using a health status estimation algorithm to predict remaining lifespan. When abnormal data is detected, the BMS sends fault codes and warning signals to the electronic control system via the communication protocol bus, triggering protection mechanisms or adjusting charging and discharging strategies. Thus, the status data of each battery module 32 is independently monitored and maintains global traceability when combined into an extended battery array.

[0057] In summary, this application provides a standardized unit module battery and battery system suitable for forklifts. Through modular box structure design and scalable battery array configuration, it realizes standardized production and flexible combination of forklift power batteries, solving the problems of high customization cost and poor adaptability of traditional lithium battery systems. It has the advantages of improving the standardization of battery systems, reducing customization costs, facilitating maintenance and flexible expansion.

[0058] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0059] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A standardized unit module battery suitable for forklifts, characterized in that, include: The housing is composed of a thermally conductive protective shell (100), a panel (101), and a bottom plate (102). The panel (101) and the bottom plate (102) are respectively sealed and fixed to the upper and lower end faces of the thermally conductive protective shell (100). The panel (101) is provided with a positive terminal (200) and a negative terminal (201). The unit battery module, encapsulated within the housing, includes: - Multiple individual battery cells (300); - A flexible electrical connection assembly (301) connects the individual battery cells (300) in series or parallel to form a battery pack; -The flexible electrical connection component (301) is directly connected to the positive terminal (200) and the negative terminal (201) to form the external circuit interface of the battery pack.

2. The standardized unit module battery suitable for forklifts according to claim 1, characterized in that: -The unit battery module is fixed to the box body by potting thermally conductive adhesive; - The outer surface of the thermally conductive protective shell (100) is provided with a heat dissipation fin structure.

3. A standardized unit module battery suitable for forklifts according to claim 1, characterized in that: - A battery insulation plate (305) is provided between adjacent individual battery cells (300); - The flexible electrical connection assembly (301) is disposed on the side of the battery pack; A battery insulating plate (305) is provided between the flexible electrical connection assembly (301) and the inner wall of the thermally conductive protective shell (100).

4. A standardized unit module battery suitable for forklifts according to claim 1, characterized in that, The flexible electrical connection assembly (301) includes: - Flexible vacuum forming board (3011); - Positive electrode buffer aluminum busbar (3012) and negative electrode buffer aluminum busbar (3013) are provided at both ends of the thermoforming plate (3011); - Multiple wire harness boards (3014) disposed on the vacuum forming board (3011); in: The positive electrode buffer aluminum busbar (3012) is directly connected to the positive electrode terminal (200); The negative electrode buffer aluminum busbar (3013) is directly connected to the negative electrode terminal (201); The wire harness board (3014) connects to the electrodes of the individual battery cell (300).

5. A standardized unit module battery suitable for forklifts according to claim 4, characterized in that: - The wire harness plate (3014) is press-fitted and fixed to the vacuum forming plate (3011); - The individual battery cell (300) is connected to the wiring harness board (3014) via a wiring harness; - The wire harness plate (3014) has a protrusion (3015) in the middle that protrudes toward the inner wall of the heat-conducting protective shell.

6. A standardized unit module battery suitable for forklifts according to claim 1, characterized in that: - A battery buffer pad (304) is provided between the bottom of the unit battery module and the base plate (102); - The cell module is surrounded by fiberglass tape (306).

7. A standardized unit module battery suitable for forklifts according to claim 1, characterized in that: - The panel (101) integrates a handle (103), and its structure is one-piece, separate or foldable.

8. A standardized unit module battery suitable for forklifts according to claim 1, characterized in that: - A double-sided heating film (303) is sandwiched between the large surfaces of two adjacent individual cells (300) and simultaneously contacts the surfaces of both cells; - The double-sided heating film (303) is a PI film, an epoxy resin film, or a thermosetting resin film.

9. A battery system suitable for forklifts, characterized in that, include: -A unit battery module (32) according to any one of claims 1-8; - High voltage box (31) is connected to each unit battery module (32) and external electronic control system through high voltage resistant wire harness; -The multiple unit battery modules (32) are connected in series or in parallel in a detachable manner to form an extended battery array that adapts to the volume shape of the forklift battery compartment, so as to form a battery system with different voltage platforms and capacities.

10. A battery system suitable for forklifts according to claim 9, characterized in that, Also includes: - Battery Management System (BMS), used for: Real-time monitoring of the voltage, temperature and health status of each unit battery module (32); Fault information is fed back to the electronic control system via a communication protocol bus.

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