Slot‐Die Coating of a High Performance Copolymer in a Readily Scalable Roll Process for Polymer Solar Cells

Copolymers based on dithieno[3,2‐b:2′,3′‐d]silole (DTS) and dithienylthiazolo[5,4‐d]thiazole (TTz) are synthesized and tested in an all‐solution roll process for polymer solar cells (PSCs). Fabrication of polymer:[6,6]‐phenyl‐C₆₁‐butyric acid methyl ester (PCBM) solar cells is done on a previously reported compact coating/printing machine, which enables the preparation of PSCs that are directly scalable with full roll‐to‐roll processing. The positioning of the side‐chains on the thiophene units proves to be very significant in terms of solubility of the polymers and consequently has a major impact on the device yield and process control. The most successful processing is accomplished with the polymer, PDTSTTz‐4 , that has the side‐chains situated in the 4‐position on the thiophene units. Inverted PSCs based on PDTSTTz‐4 demonstrate high fill factors, up to 59%, even with active layer thicknesses well above 200 nm. Power conversion efficiencies of up to 3.5% can be reached with the roll‐coated PDTSTTz‐4 :PCBM solar cells that, together with good process control and high device yield, designate PDTSTTz‐4 as a convincing candidate for high‐throughput roll‐to‐roll production of PSCs.     

Slot‐Die and Roll‐to‐Roll Processed Single Junction Organic Photovoltaic Cells with the Highest Efficiency

The record efficiency of the state‐of‐the‐art polymer solar cells (PSCs) is rapidly increasing, due to the discovery of high‐performance photoactive donor and acceptor materials. However, strong questions remain as to whether such high‐efficiency PSCs can be produced by scalable processes. This paper reports a high power conversion efficiency (PCE) of 13.5% achieved with single‐junction ternary PSCs based on PTB7‐Th, PC₇₁BM, and COi8DFIC fabricated by slot‐die coating, which shows the highest PCE ever reported in PSCs fabricated by a scalable process. To understand the origin of the high performance of the slot‐die coated device, slot‐die coated photoactive films and devices are systematically investigated. These results indicate that the good performance of the slot‐die PSCs can be due to a favorable molecule‐structure and film‐morphology change by introducing 1,8‐diiodooctane and heat treatment, which can lead to improved charge transport with reduced carrier recombination. The optimized condition is then used for the fabrication of large‐area modules and also for roll‐to‐roll fabrication. The slot‐die coated module with 30 cm² active‐area and roll‐to‐roll produced flexible PSC has shown 8.6% and 9.6%, respectively. These efficiencies are the highest in each category and demonstrate the strong potential of the slot‐die coated ternary system for commercial applications.     

All‐Polymer Solar Cells with over 12% Efficiency and a Small Voltage Loss Enabled by a Polymer Acceptor Based on an Extended Fused Ring Core

Although the field of all‐polymer solar cells (all‐PSCs) has seen rapid progress in device efficiencies during the past few years, there are limited choices of polymer acceptors that exhibit strong absorption in the near‐IR region and achieve high open‐circuit voltage (V_OC) at the same time. In this paper, an all‐PSC device is demonstrated with a 12.06% efficiency based on a new polymer acceptor (named PT‐IDTTIC) that exhibits strong absorption (maximum absorption coefficient: 2.41 × 10⁵ cm^?1) and a narrow optical bandgap (1.49 eV). Compared to previously reported polymer acceptors such as those based on the indacenodithiophene (IDT) core, the indacenodithienothiophene (IDTT) core has further extended fused ring, providing the polymer with extended absorption into the near‐IR region and also increases the electron mobility of the polymer. By blending PT‐IDTTIC with the donor polymer, PM6, a high‐efficiency all‐PSC is achieved with a small voltage loss of 0.52 V, without sacrificing J_SC and FF, which demonstrates the great potential of high‐performance all‐PSCs.     

Photoactive Blend Morphology Engineering through Systematically Tuning Aggregation in All‐Polymer Solar Cells

Polymer aggregation plays a critical role in the miscibility of materials and the performance of all‐polymer solar cells (APSCs). However, many aspects of how polymer texturing and aggregation affect photoactive blend film microstructure and photovoltaic performance are poorly understood. Here the effects of aggregation in donor–acceptor blends are studied, in which the number‐average molecular weights (M_ns) of both an amorphous donor polymer, poly[4,8‐bis(5‐(2‐ethylhexyl)thiophen‐2‐yl)benzo[1,2‐b;4,5‐b′]dithiophene‐2,6‐diyl‐alt‐(4‐(2‐ethylhexyl)‐3‐fluorothieno[3,4‐b]thiophene‐)‐2‐carboxylate‐2‐6‐diyl)] ( PBDTT‐FTTE ) and a semicrystalline acceptor polymer, poly{[N,N′‐bis(2‐octyldodecyl)naphthalene‐1,4,5,8‐bis(dicarboximide)‐2,6‐diyl]‐alt‐5,5′‐(2,2′‐bithiophene)} ( P(NDI2OD‐T2) ) are systematically varied. The photovoltaic performance is correlated with active layer microstructural and optoelectronic data acquired by in‐depth transmission electron microscopy, grazing incidence wide‐angle X‐ray scattering, thermal analysis, and optical spectroscopic measurements. Coarse‐grained modeling provides insight into the effects of polymer aggregation on the blend morphology. Notably, the computed average distance between the donor and the acceptor polymers correlates well with solar cell photovoltaic metrics such as short‐circuit current density (J_sc) and represents a useful index for understanding/predicting active layer blend material intermixing trends. Importantly, these results demonstrate that for polymers with different texturing tendencies (amorphous/semicrystalline), the key for optimal APSC performance, photovoltaic blend morphology can be controlled via both donor and acceptor polymer aggregation.     

Green‐Solvent‐Processed All‐Polymer Solar Cells Containing a Perylene Diimide‐Based Acceptor with an Efficiency over 6.5%

To realize high power conversion efficiencies (PCEs) in green‐solvent‐processed all‐polymer solar cells (All‐PSCs), a long alkyl chain modified perylene diimide (PDI)‐based polymer acceptor PPDIODT with superior solubility in nonhalogenated solvents is synthesized. A properly matched PBDT‐TS1 is selected as the polymer donor due to the red‐shifted light absorption and low‐lying energy level in order to achieve the complementary absorption spectrum and matched energy level between polymer donor and polymer acceptor. By utilizing anisole as the processing solvent, an optimal efficiency of 5.43% is realized in PBDT‐TS1/PPDIODT‐based All‐PSC with conventional configuration, which is comparable with that of All‐PSCs processed by the widely used binary solvent. Due to the utilization of an inverted device configuration, the PCE is further increased to over 6.5% efficiency. Notably, the best‐performing PCE of 6.58% is the highest value for All‐PSCs employing PDI‐based polymer acceptors and green‐solvent‐processed All‐PSCs. The excellent photovoltaic performance is mainly attributed to a favorable vertical phase distribution, a higher exciton dissociation efficiency (P_diss) in the blend film, and a higher electrode carrier collection efficiency. Overall, the combination of rational molecular designing, material selection, and device engineering will motivate the efficiency breakthrough in green‐solvent‐processed All‐PSCs.     

8.0% Efficient All‐Polymer Solar Cells with High Photovoltage of 1.1 V and Internal Quantum Efficiency near Unity

In very recent years, growing efforts have been devoted to the development of all‐polymer solar cells (all‐PSCs). One of the advantages of all‐PSCs over the fullerene‐based PSCs is the versatile design of both donor and acceptor polymers which allows the optimization of energy levels to maximize the open‐circuit voltage (V_oc). However, there is no successful example of all‐PSCs with both high V_oc over 1 V and high power conversion efficiency (PCE) up to 8% reported so far. In this work, a combination of a donor polymer poly[4,8‐bis(5‐(2‐octylthio)thiophen‐2‐yl)benzo[1,2‐b:4,5‐b′]dithiophene‐2,6‐diyl‐alt‐(5‐(2‐ethylhexyl)‐4H‐thieno[3,4‐c]pyrrole‐4,6(5H)‐dione)‐1,3‐diyl] (PBDTS‐TPD) with a low‐lying highest occupied molecular orbital level and an acceptor polymer poly[[N,N′‐bis(2‐octyldodecyl)‐naphthalene‐1,4,5,8‐bis(dicarboximide)‐2,6‐diyl]‐alt‐thiophene‐2,5‐diyl] (PNDI‐T) with a high‐lying lowest unoccupied molecular orbital level is used, realizing high‐performance all‐PSCs with simultaneously high V_oc of 1.1 V and high PCE of 8.0%, and surpassing the performance of the corresponding PC₇₁BM‐based PSCs. The PBDTS‐TPD:PNDI‐T all‐PSCs achieve a maximum internal quantum efficiency of 95% at 450 nm, which reveals that almost all the absorbed photons can be converted into free charges and collected by electrodes. This work demonstrates the advantages of all‐PSCs by incorporating proper donor and acceptor polymers to boost both V_oc and PCEs.     

Unraveling the Morphology of High Efficiency Polymer Solar Cells Based on the Donor Polymer PBDTTT‐EFT

The microstructure of the polymer PBDTTT‐EFT and blends with the fullerene derivative PC₇₁BM that achieve solar conversion efficiencies of over 9% is comprehensively investigated. A combination of synchrotron techniques are employed including surface‐sensitive near‐edge X‐ray absorption fine structure (NEXAFS) spectroscopy and bulk‐sensitive grazing‐incidence wide angle X‐ray scattering (GIWAXS). A preferential “face‐on” orientation of PBDTTT‐EFT is observed in the bulk of both pristine and blend thin films, with π–π stacking largely normal to the substrate, which is thought to be beneficial for charge transport. At the surface of the blend, a slight “edge‐on” structure of the polymer is observed with side‐chains aligned normal to the substrate. The effect of the solvent additive 1,8‐diiodooctane (DIO) on solar cell efficiency and film microstructure is also investigated, where the addition of 3 vol% DIO results in an efficiency increase from ≈6.4% to ≈9.5%. GIWAXS studies indicate that the addition of DIO improves the crystallization of the polymer. Furthermore, atomic force microscopy and transmission electron microscopy are employed to image surface and bulk morphology revealing that DIO suppresses the formation of large PC₇₁BM aggregates.     

Delicate Morphology Control Triggers 14.7% Efficiency All‐Small‐Molecule Organic Solar Cells

Morphology is a critical factor to determine the photovoltaic performance of organic solar cells (OSCs). However, delicately fine‐tuning the morphology involving only small molecules is an extremely challenging task. Herein, a simple, generic, and effective concentration‐induced morphology manipulation approach is demonstrated to prompt both the state‐of‐the‐art thin‐film BTR‐Cl:Y6 and thick‐film BTR:PC₇₁BM all‐small‐molecule (ASM) OSCs to a record level. The morphology is delicately controlled by subtly altering the prepared solution concentration but maintaining the identical active layer thickness. The remarkable performance enhancement achieved by this approach mainly results from the enhanced absorption, reduced trap‐assistant recombination, increased crystallinity, and optimized phase‐separated network. These findings demonstrate that a concentration‐induced morphology manipulation strategy can further propel the reported best‐performing ASM OSCs to a brand‐new level, and provide a promising way to delicately control the morphology towards high‐performance ASM OSCs.     

High‐Performance and Stable All‐Polymer Solar Cells Using Donor and Acceptor Polymers with Complementary Absorption

To explore the advantages of emerging all‐polymer solar cells (all‐PSCs), growing efforts have been devoted to developing matched donor and acceptor polymers to outperform fullerene‐based PSCs. In this work, a detailed characterization and comparison of all‐PSCs using a set of donor and acceptor polymers with both conventional and inverted device structures is performed. A simple method to quantify the actual composition and light harvesting contributions from the individual donor and acceptor is described. Detailed study on the exciton dissociation and charge recombination is carried out by a set of measurements to understand the photocurrent loss. It is unraveled that fine‐tuned crystallinity of the acceptor, matched donor and acceptor with complementary absorption and desired energy levels, and device architecture engineering can synergistically boost the performance of all‐PSCs. As expected, the PBDTTS‐FTAZ:PNDI‐T10 all‐PSC attains a high and stable power conversion efficiency of 6.9% without obvious efficiency decay in 60 d. This work demonstrates that PNDI‐T10 can be a potential alternative acceptor polymer to the widely used acceptor N2200 for high‐performance and stable all‐PSCs.     

Controlling Molecular Orientation of Naphthalenediimide‐Based Polymer Acceptors for High Performance All‐Polymer Solar Cells

Molecular orientation, with respect to donor/acceptor interface and electrodes, plays a critical role in determining the performance of all‐polymer solar cells (all‐PSCs), but is often difficult to rationally control. Here, an effective approach for tuning the molecular crystallinity and orientation of naphthalenediimide‐bithiophene‐based n‐type polymers (P(NDI2HD‐T2)) by controlling their number average molecular weights (M_n) is reported. A series of P(NDI2HD‐T2) polymers with different M_n of 13.6 ( P_L ), 22.9 ( P_M ), and 49.9 kg mol^?1 ( P_H ) are prepared by changing the amount of end‐capping agent (2‐bromothiophene) during polymerization. Increasing the M_n values of P(NDI2HD‐T2) polymers leads to a remarkable shift of dominant lamellar crystallite textures from edge‐on ( P_L ) to face‐on ( P_H ) as well as more than a twofold increase in the crystallinity. For example, the portion of face‐on oriented crystallites is dramatically increased from 21.5% and 46.1%, to 78.6% for P_L , P_M, and P_H polymers. These different packing structures in terms of the molecular orientation greatly affect the charge dissociation efficiency at the donor/acceptor interface and thus the short‐circuit current density of the all‐PSCs. All‐PSCs with PTB7‐Th as electron donor and P_H as electron acceptor show the highest efficiency of 6.14%, outperforming those with P_M (5.08%) and P_L (4.29%).     

Improved Tandem All‐Polymer Solar Cells Performance by Using Spectrally Matched Subcells

All‐polymer solar cells (all‐PSCs) are attractive as alternatives to fabricate thermally and mechanically stable solar cells, especially with recent improvements in their power conversion efficiency (PCE). In this work, efficient all‐PSCs with near‐infrared response (up to 850 nm) are developed using newly designed regioregular polymer donors with relatively narrow optical gap. These all‐PSCs systems achieve PCEs up to 6.0% after incorporating fluorine into the polymer backbone. More importantly, these polymers exhibit absorbance that is complementary to previously reported wide bandgap polymer donors. Thus, the superior properties of the newly designed polymers afford opportunities to fabricate the first spectrally matched all‐polymer tandem solar cells with high performance. A PCE of 8.3% is then demonstrated which is the highest efficiency so far for all‐polymer tandem solar cells. The design of narrow bandgap polymers provides new directions to enhance the PCE of emerging single‐junction and tandem all polymer solar cells.     

Making Ends Meet: Flow Synthesis as the Answer to Reproducible High‐Performance Conjugated Polymers on the Scale that Roll‐to‐Roll Processing Demands

Continuous flow methods are employed for the controlled polymerization of the roll‐to‐roll (R2R) compatible polymer PBDTTTz‐4 including optimization and upscaling experiments. The polymerization rate and materials’ quality can be increased significantly with the continuous flow method where reaction times down to 10 min afforded PBDTTTz‐4 with high molecular weight and a constant quality. The flow method enables full control of the molecular weight via tuning of the flow speed, catalyst loading, and temperature and avoids variation in materials’ quality associated with conventional batch synthesis. Upscaling from 300 mg batch synthesis to 10 g flow synthesis affords PBDTTTz‐4 with a production rate of up to 120 g day^?1 for a very simple in‐house build flow reactor. An average power conversion efficiency (PCE) of 3.5% is achieved on a small scale (1 cm²) and an average PCE of 3.3% is achieved on a large scale (29 cm²). This shows that small device efficiencies can be scaled when using full R2R processing of flexible and encapsulated carbon‐based modules without the use of vacuum, indium‐tin‐oxide, or silver, with the best achieving a PCE of 3.8% PCE.