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资讯 固态电解质膜的稳定制备，已成为固态电池前段制造的关键瓶颈。但高质量电解质膜的制备并非简单的成膜问题。
粉体易团聚、超薄成膜难度大、气氛控制要求严苛、溶剂回收易结霜堵塞、电解质膜转印效率低——五大难点交织叠加，构成固态电解质膜规模化制造的共性挑战。
在实际生产中，这些问题进一步转化为良率提升慢、验证周期长等现实压力。不仅推高试产与制造成本，也进一步拉长从中试到量产的爬坡周期。
因此，解决问题的关键不在于单一设备性能的提升，而在于覆盖全链路的系统性解决方案，实现各工序间的稳定衔接。
针对上述痛点，曼恩斯特依托十余年涂布工艺积累与精密设备集成经验，以双螺杆连续制浆、涂布干燥与溶剂回收、热转印复合三大子系统为核心，将五大共性挑战分别贯穿到对应工艺环节，形成可落地、可量产的系统解决方案。
01
三大子系统协同
破解量产关键难题
陶瓷双螺杆连续制浆
从源头抑制团聚与水氧侵蚀
硫化物电解质粉体因粒径细、表面能高，极易发生团聚沉降，而常规搅拌工艺无法从微观层面彻底打散团聚体，一旦进入涂布环节，将导致颗粒点、膜厚不均等缺陷。
曼恩斯特采用陶瓷双螺杆强剪切捏合工艺，以微观尺度的强剪切力粉碎团聚体；同时，以陶瓷螺杆元件与机筒内衬构建全陶瓷接触界面，从根本上阻断了浆料腐蚀与金属异物的引入路径。面对硫化物材料的高水氧敏感性，系统全程密闭惰气保护，并集成自动计量、连续制浆与即配即用功能，制浆计量精度达±2‰。
这一强剪切分散与连续制浆的深度融合，不仅保障了浆料的高均一性与稳定供料，更为电解质层的精密成型和电池的长期循环安全奠定了制浆端的关键防线。
双螺杆连续制浆子系统
高精度涂布与溶剂回收
成膜精度与安全回收协同
随着电解质膜向薄层化发展，超薄成膜对设备精度要求更高。在长循环或高倍率工况下，膜厚偏差会放大局部过充与析锂风险，严重威胁电池安全性与循环寿命。
对此，曼恩斯特采用高精度闭环挤压涂布系统，配合CCD、光谱共焦尺寸检测或面密度检测，可以实现涂布面密度的闭环控制，将双面面密度偏差控制在≤±1.0%，膜厚覆盖10—80μm，保障了超薄电解质层的厚度一致性与均匀性。
针对脆性电解质膜在加工过程中的稳定性问题，曼恩斯特引入骨架膜预贴合工艺，形成“电解质层—骨架膜—电解质层”的三明治式复合结构。
骨架膜显著增强复合膜的抗拉强度与柔韧性，同时为抑制锂枝晶穿透构筑额外的物理屏障，提升了电解质膜的加工稳定性与界面安全性，为长循环固态电池的结构可靠性提供了有效保障。
对于湿法工艺而言，溶剂处理与制造环境同样决定着产线能否稳定运行。针对水氧敏感材料，曼恩斯特将涂布设备与手套箱、集装箱干房等气氛控制系统深度集成，以模块化"堆积木"式架构缩小环境管控体积、提升自动化水平，实现涂布全程水氧≤10ppm的全密闭惰气保护。
同时在溶剂回收环节引入深冷热氟化霜工艺，通过多级冷凝叠加高密防爆设计，实现不停机融霜排液，解决了结霜堵塞难题，在保障连续生产的同时大幅降低溶剂损耗与废气排放，降低生产与制造成本。
涂布干燥与溶剂回收子系统
热转印复合
工序集成保障转印良率
转印复合是电解质膜进入极片制造的关键工序，相比单纯成膜，转印还需要同时攻克膜层剥离、位置精度、复合状态与裁切质量等多重挑战。
曼恩斯特推出电解质转印-压实-裁断一体机，集成放卷纠偏、预热、热转印复合、在线压实、激光测厚、精密裁断与CCD视觉检测于一体，以工序集成消除多设备转序的精度损耗。
针对固-固界面无法自然浸润，设备采用伺服控制的恒间隙/恒压力双模式辊压：恒间隙模式保障膜厚均匀一致，恒压力模式适配不同电解质体系的形变特性，可按工艺切换；配合极性变换胶粘剂与热响应界面技术，提高电解质膜转移效率并增强界面结合，材料转移率≥95%，实现界面致密、低阻抗稳定接触。
热转印复合子系统
全程激光在线测厚与CCD对位闭环调控，工艺参数可追溯、支持MES对接；相比传统分散工序方案，综合效率提升50%以上，达到行业领先水平。
设备兼容硫化物、氧化物、聚合物等电解质体系及多种正负极材料，满足了不同工艺路线的验证与量产需求，为固态电池极片制造的高效、精密、柔性化生产奠定了核心装备基础。
02
从单点设备到整线协同
以工程实践驱动量产落地
目前，曼恩斯特固态电解质膜系统解决方案已与多家客户开展深度技术对接，部分订单项目进入交付环节。
在固态电池技术路线尚未完全收敛的关键窗口期，设备方案的确定性，直接决定客户的验证效率。曼恩斯特正以工程实践，推动工艺方案加速验证与产业化落地。 ?
未来，曼恩斯特将持续围绕薄层化、高一致性、工序集成与在线检测推进技术迭代，同步布局干法成膜等前沿工艺，深化装备与工艺协同能力，携手材料厂商与电池企业，以高端装备制造能力推动固态电池从实验室向量产线过渡。
The stable production of solid-state electrolyte membranes has become a critical bottleneck in the front-end manufacturing of solid-state batteries. However, producing high-quality electrolyte membranes is far more than a simple film-forming process.
Fine powders are prone to agglomeration, ultra-thin film formation is highly challenging, stringent atmosphere control is required, solvent recovery is susceptible to frosting and clogging, and electrolyte membrane transfer efficiency remains low. These five challenges are interconnected, creating common obstacles to the large-scale manufacturing of solid-state electrolyte membranes.
In actual production, these challenges translate into practical pressures such as slow yield improvement and long validation cycles. They not only increase pilot-production and manufacturing costs, but also extend the ramp-up period from pilot scale to mass production.
Therefore, the key to addressing these challenges lies not in improving the performance of a single piece of equipment, but in developing a systematic, end-to-end solution that enables stable integration and coordination across processes.
To address these challenges, MANST leverages more than a decade of experience in coating processes and precision equipment integration. Centered on three core subsystems—continuous twin-screw slurry preparation, coating, drying and solvent recovery, and thermal transfer and lamination—MANST integrates the five common challenges into their corresponding process stages, forming a practical and mass-production-ready system solution.
01 Three Core Subsystems Working in Synergy to Address Key Challenges in Mass Production
Ceramic Twin-Screw Continuous Slurry Preparation: Suppressing Agglomeration and Moisture/Oxygen Attack at the Source
Sulphide electrolyte powders have fine particle sizes and high surface energy, making them highly prone to agglomeration and sedimentation. Conventional mixing processes cannot completely break down agglomerates at the microscopic level. Once these agglomerates enter the coating process, they can lead to defects such as particle spots and uneven film thickness.
MANST adopts a ceramic twin-screw high-shear kneading process, using intense shear forces at the microscopic level to break down powder agglomerates. At the same time, ceramic screw elements and a ceramic barrel liner form a fully ceramic contact interface, fundamentally reducing the pathways for slurry corrosion and metal contamination. Given the high sensitivity of sulphide materials to moisture and oxygen, the system operates under fully enclosed inert-gas protection throughout the process and integrates automatic metering, continuous slurry preparation, and just-in-time slurry supply, achieving a metering accuracy of ±2‰.
The deep integration of high-shear dispersion and continuous slurry preparation not only ensures high slurry uniformity and stable material supply, but also establishes a critical safeguard at the slurry-preparation stage for precision electrolyte-layer formation and the long-term cycling safety of solid-state batteries.
High-Precision Coating and Solvent Recovery: Coordinating Film-Formation Precision with Safe Solvent Recovery
As electrolyte membranes become increasingly thinner, ultra-thin film formation places higher demands on equipment precision. Under long-cycle or high-rate operating conditions, variations in film thickness can increase the risk of localized overcharging and lithium plating, posing a serious threat to battery safety and cycle life.
To address this challenge, MANST employs a high-precision closed-loop slot-die coating system, combined with CCD, spectral confocal dimensional inspection, or areal-density measurement, to enable closed-loop control of coating areal density. The double-sided areal-density deviation can be controlled within ≤±1.0%, with film thickness ranging from 10–80 μm, ensuring the thickness consistency and uniformity of ultra-thin electrolyte layers.
To improve the stability of brittle electrolyte membranes during processing, MANST introduces a supporting-film pre-lamination process, forming a sandwich-like composite structure of “electrolyte layer–supporting film–electrolyte layer.”
The supporting film significantly enhances the tensile strength and flexibility of the composite membrane. It also provides an additional physical barrier against lithium dendrite penetration, improving the processing stability and interfacial safety of the electrolyte membrane and providing effective structural support for the long-cycle reliability of solid-state batteries.
For wet-process manufacturing, solvent handling and the production environment are equally critical to stable line operation. For moisture- and oxygen-sensitive materials, MANST deeply integrates coating equipment with atmosphere-control systems such as gloveboxes and containerized dry rooms. Using a modular, “building-block” architecture, the system reduces the volume required for environmental control while increasing the level of automation, enabling fully enclosed inert-gas protection throughout coating with moisture and oxygen levels maintained at ≤10 ppm.
At the same time, the solvent recovery process incorporates a deep-cooling fluorinated defrosting process. Through multi-stage condensation combined with a high-sealing, explosion-proof design, the system enables defrosting and liquid discharge without stopping the line, addressing frosting and clogging issues. This supports continuous production while significantly reducing solvent loss and exhaust emissions, thereby lowering production and manufacturing costs.
Thermal Transfer and Lamination: Process Integration for Higher Transfer Yield
Thermal transfer and lamination is a critical process for integrating electrolyte membranes into electrode manufacturing. Compared with film formation alone, the transfer process must simultaneously address challenges such as membrane delamination, positional accuracy, lamination quality, and cutting precision.
MANST has developed an electrolyte transfer–compaction–cutting integrated machine, integrating unwinding and web alignment, preheating, thermal transfer and lamination, online compaction, laser thickness measurement, precision cutting, and CCD visual inspection. By integrating multiple processes into a single system, the equipment minimizes precision losses associated with transferring materials between separate machines.
To address the poor natural wetting at solid–solid interfaces, the equipment adopts a servo-controlled constant-gap/constant-pressure dual-mode roll pressing system. The constant-gap mode ensures uniform and consistent membrane thickness, while the constant-pressure mode accommodates the deformation characteristics of different electrolyte systems and can be selected according to process requirements. Combined with polar adhesive technology and thermally responsive interface technology, the system improves electrolyte membrane transfer efficiency and interfacial bonding. With a material transfer rate of ≥95%, it enables dense interfaces and stable, low-resistance contact.
Full-process online laser thickness measurement and CCD alignment provide closed-loop process control. Process parameters are traceable, and the system supports MES integration. Compared with conventional solutions using separate process equipment, overall efficiency can be increased by more than 50%, reaching an industry-leading level.
The equipment is compatible with sulphide, oxide, polymer, and other electrolyte systems, as well as various cathode and anode materials. It meets the validation and mass-production requirements of different process routes, providing a core equipment foundation for efficient, precise, and flexible solid-state battery electrode manufacturing.
02 From Standalone Equipment to Integrated Line Coordination: Driving Mass-Production Implementation Through Engineering Practice
At present, MANST’s solid-state electrolyte membrane system solution has entered in-depth technical discussions with multiple customers, with some projects already progressing to the delivery stage.
At this critical stage, when solid-state battery technology routes have yet to fully converge, the certainty of equipment solutions directly affects customers’ validation efficiency. Through engineering practice, MANST is accelerating process validation and industrial-scale implementation.
Looking ahead, MANST will continue to advance technology in thinner membranes, higher consistency, process integration, and online inspection, while also developing emerging processes such as dry film formation. By deepening equipment–process integration capabilities, MANST will work together with material suppliers and battery manufacturers to leverage advanced equipment manufacturing capabilities and accelerate the transition of solid-state batteries from the laboratory to mass-production lines.
编辑 | 阿聪
审核 | 小熊
终审 | 魏小姐
#固态电池 #固态电解质膜 #热转印
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