Lithium-ion batteries are known as the “engine of the modern energy revolution”, from cell phones, drones, home energy storage batteries to electric vehicles, its technology supports the global intelligent process. By 2023, the global lithium-ion battery market size has exceeded $100 billion, with an annual growth rate of more than 15%.
Cathode, as the core of energy, the mainstream materials include lithium cobalt oxide (LiCoO₂), ternary (NCM/NCA) and lithium iron phosphate (LiFePO₄), which directly determines the energy density and cost of the battery, and its function is to release lithium ions from discharging (Li⁺), and to charge and recycle Li⁺; meanwhile, anode is dominating the market with graphite layer structure, and future innovation focuses on silicon, with high efficiency embedding/de-embedding of Li⁺;
At the same time, the anode is dominated by graphite layered structure, highly efficiently embedded/de-embedded Li⁺, and future innovations will focus on silicon-based materials (theoretical capacity increased by 10 times, need to overcome the expansion problem);
Electrolyte consists of lithium hexafluorophosphate (LiPF₆) and carbonate solvent, which serves as an ion transport “highway”, conducts Li⁺ flow and isolates electrons;
Separator adopts PE/PP porous membrane material, which assumes the responsibility of safety “gate”, not only blocking the positive and negative short-circuit but also keeping the ion channel unobstructed;
Shell and collector constitute the physical skeleton of the battery, steel shell or aluminum-plastic film (soft pack battery) to provide protection, copper foil (negative electrode), aluminum foil (positive electrode) as a carrier for current conduction.
The essence of charging and discharging is the reversible conversion of chemical and electrical energy through the synergy of external circuits and ionic circuits.
Discharge process
Lithium ions detach from the graphite negative electrode and migrate through the electrolyte toward the positive electrode; electrons flow to the positive electrode through the external circuit to drive the device; lithium ions and electrons combine in the positive electrode material.
Charging process
The power supply forces lithium ions to detach from the positive electrode and return to the negative electrode; electrons flow back from the positive electrode to the negative electrode via an external circuit; lithium ions are re-embedded in the graphite interlayer, waiting for the next discharge.
The structural design of lithium batteries offers multiple advantages in forklift applications that can significantly improve performance, efficiency and reliability!
1. High energy density: compact and lightweight
Weight reduction: Compared with lead-acid batteries, Li-ion batteries have high energy density (about 3 times), which reduces the dead weight of forklift trucks and improves load efficiency.
Extended range: More power is stored in the same volume, suitable for long time operation.
Space Optimization: Modular design allows flexible layout, adapting to the limited space of the forklift.
2. Long cycle life: electrode stability and structural durability
Long life span of 5-10 years: supports 3500-5000 cycles, far more than lead-acid batteries (500-1000 cycles), reducing replacement frequency and total cost.
Deep discharge without damage: can be discharged to less than 20% without affecting the life, suitable for high-intensity operation.
3. Fast charging capability: low internal resistance and efficient heat dissipation design
1-2 hours fast charging: lead-acid batteries take 8-10 hours, reducing forklift downtime.
Opportunity charging: short breaks can be recharged to improve continuous operation.
4. Safety: multiple protective structures
High temperature/vibration resistance: suitable for complex environment in warehouse, avoiding the risk of liquid leakage and explosion.
Intelligent protection: automatic cut-off in case of overcharging, over-discharging and short-circuiting to ensure operational safety.
5. Maintenance-free and environmentally friendly: sealed structure and non-polluting materials
Zero maintenance cost: saves labor and downtime.
Comply with environmental regulations: easy to recycle and meet green supply chain requirements.
6. Intelligent management: modularization and BMS integration
Accurate power management: extend range and avoid accidental power failure.
Rapid fault diagnosis: reduce maintenance complexity and improve operational efficiency.
The structure and working principle of lithium-ion batteries are inextricably linked, with the positive and negative materials, electrolyte and diaphragm forming the “highway” for lithium-ion migration, while the casing and collector provide a stable operating environment for the battery. Understanding this synergistic mechanism will help us to better utilize lithium-ion battery technology and promote the innovative development of future energy storage.
