Air-Knife-Assisted Spray Coating of Organic Solar Cells

The power conversion efficiencies (PCEs) of organic solar cells (OSCs) have risen dramatically since the introduction of the "Y-series" of non-fullerene acceptors. However, the demonstration of rapid scalable deposition techniques to deposit such systems is rare. Here, for the first time, we demonstrate the deposition of a Y-series-based system using ultrasonic spray coating─a technique with the potential for significantly faster deposition speeds than most traditional meniscus-based methods. Through the use of an air-knife to rapidly remove the casting solvent, we can overcome film reticulation, allowing the drying dynamics to be controlled without the use of solvent additives, heating the substrate, or heating the casting solution. The air-knife also facilitates the use of a non-halogenated, low-toxicity solvent, resulting in industrially relevant, spray-coated PM6:DTY6 devices with PCEs of up to 14.1%. We also highlight the obstacles for scalable coating of Y-series-based solar cells, in particular the influence of slower drying times on blend morphology and crystallinity. This work demonstrates the compatibility of ultrasonic spray coating, and use of an air-knife, with high-speed, roll-to-roll OSC manufacturing techniques.

High Sensitivity of Non-Fullerene Organic Solar Cells Morphology and Performance to a Processing Additive

Although solvent additives are used to optimize device performance in many novel non-fullerene acceptor (NFA) organic solar cells (OSCs), the effect of processing additives on OSC structures and functionalities can be difficult to predict. Here, two polymer-NFA OSCs with highly sensitive device performance and morphology to the most prevalent solvent additive chloronaphthalene (CN) are presented. Devices with 1% CN additive are found to nearly double device efficiencies to 10%. However, additive concentrations even slightly above optimum significantly hinder device performance due to formation of undesirable morphologies. A comprehensive analysis of device nanostructure shows that CN is critical to increasing crystallinity and optimizing phase separation up to the optimal concentration for suppressing charge recombination and maximizing performance. Here, domain purity and crystallinity are highly correlated with photocurrent and fill factors. However, this effect is in competition with uncontrolled crystallization of NFAs that occur at CN concentrations slightly above optimal. This study highlights how slight variations of solvent additives can impart detrimental effects to morphology and device performance of NFA OSCs. Therefore, successful scale-up processing of NFA-based OSCs will require extreme formulation control, a tuned NFA structure that resists runaway crystallization, or alternative methods such as additive-free fabrication.