Predictive modelling of structure formation in semiconductor films produced by meniscus-guided coating

Molecular-dipole oriented universal growth of conjugated polymers into semiconducting single-crystal thin films

Precise control over crystallinity and morphology of conjugated polymers (CPs) is essential for progressing organic electronics. However, manufacturing single-crystal thin films of CPs presents substantial challenges due to their complex molecular structures, distorted chain conformations, and unbalanced crystallization kinetics. In this work, we demonstrate a universal nanoconfined molecular-dipole orientating strategy to craft high-quality single-crystal thin films for a variety of CPs, spanning from traditional thiophene- and theinothiophene-based homopolymers to diketopyrrolopyrrole- (i.e., p-type) and naphthalene-based (i.e., n-type) donor-acceptor copolymers. Central to this strategy is the synergetic manipulations of molecular dipoles, π-π stackings, and alkyl-alkyl interactions of CPs within our rationally-designed spatial-electrostatic confinement capacitor, which facilitates the rotation of conjugated backbones and the alignment of π-π stackings into microscale-sized single-crystal thin films. A minimal energetic disorder of 25 meV that below the thermal fluctuation energy kBT at room temperature, as well as an excellent transistor mobility of 15.5 cm2V-1s-1 are achieved, marking a significant step towards controllable growths of conjugated-polymer single-crystal thin films that hold a cornerstone for high-performance organic electronic devices.

Simulation of perovskite thin layer crystallization with varying evaporation rates

Perovskite solar cells (PSC) are promising potential competitors to established photovoltaic technologies due to their superior efficiency and low-cost solution processability. However, the limited understanding of the crystallization behaviour hinders the technological transition from lab-scale cells to modules. In this work, advanced phase field (PF) simulations of solution-based film formation are used for the first time to obtain mechanistic and morphological information that is experimentally challenging to access. The well-known transition from a film with many pinholes, for a low evaporation rate, to a smooth film, for high evaporation rates, is recovered in simulation and experiment. The simulation results provide us with an unprecedented understanding of the crystallization process. They show that supersaturation and crystallization confinement effects determine the final morphology. The ratio of evaporation to crystallization rates turns out to be the key parameter driving the final morphology. Increasing this ratio is a robust design rule for obtaining high-quality films, which we expect to be valid independently of the material type.

Using a Flexible Fountain Pen to Directly Write Organic Semiconductor Patterns with Crystallization Regulated by the Precursor Film

Organic semiconductor (OSC) films fabricated by meniscus-guided coating (MGC) methods are suitable for cost-effective and flexible electronics. However, achieving crystalline thin films by MGC methods is still challenging because the nucleation and crystal growth processes are influenced by the intertwined interactions among solvent evaporation, stochastic nucleation, and the fluid flow instabilities. Herein, a novel flexible fountain pen with active ink supply is designed and used to print OSCs. This direct-write method allows the flexible pen tip to contact the substrate, maintaining a robust meniscus by eliminating the gap found in conventional MGCs. An in situ optical microscopy observation system shows that the precursor film plays a critical role on the crystallization and the formation of coffee rings and dendrites. The computational fluid dynamics simulations demonstrate that the microstructure of the pen promotes extensional flows, facilitating mass transport and crystal alignment. Highly-aligned ribbon-shaped crystals of a small organic molecule (TIPS-pentacene), as well as a semiconducting polymer (N2200) with highly-ordered orientations, have been successfully printed by the flexible fountain pen. Organic field-effect transistors based on the flexible pen printed OSCs exhibit high performances and strong anisotropic mobility. In addition, the flexible fountain pen is expandable for printing multiple lines or large-area films.

Structuring in thin films during meniscus-guided deposition

We theoretically study the evaporation-driven phase separation of a binary fluid mixture in a thin film deposited on a moving substrate, as occurs in meniscus-guided deposition for solution-processed materials. Our focus is on the limit of rapid substrate motion where phase separation takes place far away from the coating device. In this limit, demixing takes place under conditions mimicking those in a stationary film because substrate and film move at the same speed. We account for the hydrodynamic transport of the mixture within the lubrication approximation. In the early stages of demixing, diffusive and evaporative mass transport predominates, consistent with earlier studies on evaporation-driven spinodal decomposition. In the late-stage coarsening of the demixing process, the interplay of solvent evaporation, diffusive, and hydrodynamic mass transport results in several distinct coarsening mechanisms. The effective coarsening rate is dictated by the dominant mass transport mechanism and therefore depends on the material properties, evaporation rate, and time: slow solvent evaporation results in initially diffusive coarsening that for sufficiently strong hydrodynamic transport transitions to hydrodynamic coarsening, whereas rapid solvent evaporation can preempt and suppress hydrodynamic and diffusive coarsening. We identify a novel hydrodynamic coarsening regime for off-critical mixtures, arising from the interaction of the interfaces between solute-rich and solute-poor regions in the film with the solution-gas interface. This interaction induces a directional motion of solute-rich droplets along gradients in the film thickness, from regions where the film is relatively thick to where it is thinner. The solute-rich domains subsequently accumulate and coalesce in the thinner regions.

One-stop quantification of microplastics and nanoparticles based on meniscus self-assembly technology

Micro-nano plastics (MNPs) pollution is currently a hot topic of global concern. However, there is still a lack of reliable analytical methods for completely quantitative analysis of MNPs, especially nanoplastics. This study proposes meniscus self-assembly enrichment method, which deposits nanoplastics more uniformly in a specific area. The meniscus self-assembly method greatly overcomes the agglomeration or dispersion of nanoplastics caused by traditional enrichments, and facilitates particles counting. This study investigates the effect of key parameters (e.g. time and initial concentration) on meniscus self-assembly enrichment performance. Besides, due to the large size difference between MNPs, it leads to incomplete quantification analysis when MNPs are counted at the same scale. In response to this problem, this study proposes a one-stop method to count MNPs separately through filtering. The plastics (>1 μm) are collected on the filter paper, then plastics (<1 μm) in the filtrate are homogeneously enriched by meniscus self-assembly, and finally statistically counted by scanning electron microscopy (SEM). The migration of MNPs from take-out plastic containers are detected, with microplastics of 460.55 particles/mL and nanoplastics of 4196.61 particles/mL found. The method has the advantages of saving time and effort, economic efficiency and comprehensive statistics compared with the traditional method.

Breaking Fundamental Limitation of Flow-Induced Anisotropic Growth for Large-Scale and Fast Printing of Organic Single-Crystal Films

Advanced organic electronic technologies have put forward a pressing demand for cost-effective and high-throughput fabrication of organic single-crystal films (OSCFs). However, solution-printed OSCFs are typically plagued by the existence of abundant structural defects, which pose a formidable challenge to achieving large-scale and high-performance organic electronics. Here, it is elucidated that these structural defects are mainly originated from printing flow-induced anisotropic growth, an important factor that is overlooked for too long. In light of this, a surfactant-additive printing method is proposed to effectively overcome the anisotropic growth, enabling the deposition of uniform OSCFs over the wafer scale at a high speed of 1.2 mm s-1 at room temperature. The resulting OSCF exhibits appealing performance with a high average mobility up to 10.7 cm2 V-1 s-1, which is one of the highest values for flexible organic field-effect transistor arrays. Moreover, large-scale OSCF-based flexible logic circuits, which can be bent without degradation to a radius as small as 4.0 mm and over 1000 cycles are realized. The work provides profound insights into breaking the limitation of flow-induced anisotropic growth and opens new avenues for printing large-scale organic single-crystal electronics.

Modeling and Fundamental Dynamics of Vacuum, Gas, and Antisolvent Quenching for Scalable Perovskite Processes

Hybrid perovskite photovoltaics (PVs) promise cost-effective fabrication with large-scale solution-based manufacturing processes as well as high power conversion efficiencies. Almost all of today's high-performance solution-processed perovskite absorber films rely on so-called quenching techniques that rapidly increase supersaturation to induce a prompt crystallization. However, to date, there are no metrics for comparing results obtained with different quenching methods. In response, the first quantitative modeling framework for gas quenching, anti-solvent quenching, and vacuum quenching is developed herein. Based on dynamic thickness measurements in a vacuum chamber, previous works on drying dynamics, and commonly known material properties, a detailed analysis of mass transfer dynamics is performed for each quenching technique. The derived models are delivered along with an open-source software framework that is modular and extensible. Thereby, a deep understanding of the impact of each process parameter on mass transfer dynamics is provided. Moreover, the supersaturation rate at critical concentration is proposed as a decisive benchmark of quenching effectiveness, yielding ≈ 10-3 - 10-1s-1 for vacuum quenching, ≈ 10-5 - 10-3s-1 for static gas quenching, ≈ 10-2 - 100s-1 for dynamic gas quenching and ≈ 102s-1 for antisolvent quenching. This benchmark fosters transferability and scalability of hybrid perovskite fabrication, transforming the "art of device making" to well-defined process engineering.

Transient nucleation driven by solvent evaporation

We theoretically investigate homogeneous crystal nucleation in a solution containing a solute and a volatile solvent. The solvent evaporates from the solution, thereby continuously increasing the concentration of the solute. We view it as an idealized model for the far-out-of-equilibrium conditions present during the liquid-state manufacturing of organic electronic devices. Our model is based on classical nucleation theory, taking the solvent to be a source of the transient conditions in which the solute drops out of the solution. Other than that, the solvent is not directly involved in the nucleation process itself. We approximately solve the kinetic master equations using a combination of Laplace transforms and singular perturbation theory, providing an analytical expression for the nucleation flux. Our results predict that (i) the nucleation flux lags slightly behind a commonly used quasi-steady-state approximation. This effect is governed by two counteracting effects originating from solvent evaporation: while a faster evaporation rate results in an increasingly larger influence of the lag time on the nucleation flux, this lag time itself is found to decrease with increasing evaporation rate. Moreover, we find that (ii) the nucleation flux and the quasi-steady-state nucleation flux are never identical, except trivially in the stationary limit, and (iii) the initial induction period of the nucleation flux, which we characterize as a generalized induction time, decreases weakly with the evaporation rate. This indicates that the relevant time scale for nucleation also decreases with an increasing evaporation rate. Our analytical theory compares favorably with results from a numerical evaluation of the governing kinetic equations.

Grain Crystallinity, Anisotropy, and Boundaries Govern Microscale Hydrodynamic Transport in Semicrystalline Porous Media

Polycrystallinity is often an unintended consequence of real manufacturing processes used to produce designer porous media with deterministic and periodic architectures. Porous media are widely employed as high-surface conduits for fluid transport; unfortunately, even small concentrations of defects in the long-range order become the dominant impediment to hydrodynamic transport. In this study, we isolate the effects of these defects using a microfluidic analogy to energy transport in atomic polycrystals by directly tracking capillary transport through polycrystalline inverse opals. We reveal─using high-fidelity florescent microscopy─the boundary-limited nature of flow motions, along with nonlinear impedance elements introduced by the presence of "grain boundaries" that are separating the well-ordered "crystalline grains". Coupled crystallinity, anisotropy, and linear defect density contribute to direction-dominated flow characteristics in a discretized manner rather than traditional diffusive-like flow patterns. Separating individual crystal grains' transport properties from polycrystals along with new probabilistic data sets enables demonstrating statistical predictive models. These results provide fundamental insight into transport phenomena in (poly)crystalline porous media beyond the deterministic properties of an idealized unit cell and bridge the gap between engineering models and the ubiquitous imperfections found in manufactured porous materials.

Rational control of meniscus-guided coating for organic photovoltaics

Meniscus-guided coating exhibiting outstanding depositing accuracy, functional diversity, and operating convenience is widely used in printing process of photovoltaic electronics. However, current studies about hydrodynamic behaviors of bulk heterojunction ink are still superficial, and the key dynamic parameter dominating film formation is still not found. Here, we establish the principle of accurately evaluate the Hamaker constant and reveal the critical effect of precursor film length in determining flow evolution, the polymer aggregation, and final morphology. A shorter precursor film is beneficial to restraining chain relaxation, enhancing molecular orientation and mobility. On the basis of our precursor film-length prediction method proposed in this work, the optimal coating speed can be accurately traced. Last, a 18.39% power conversion efficiency has been achieved in 3-cm2 cell based on bulk heterojunction fabricated by blade coating, which shows few reduce from 19.40% in a 0.04-cm2 cell based on spin coating.

Meniscus-Guided Deposition of Organic Semiconductor Thin Films: Materials, Mechanism, and Application in Organic Field-Effect Transistors

Solution-processable organic semiconductors are one of the promising materials for the next generation of organic electronic products, which call for high-performance materials and mature processing technologies. Among many solution processing methods, meniscus-guided coating (MGC) techniques have the advantages of large-area, low-cost, adjustable film aggregation, and good compatibility with the roll-to-roll process, showing good research results in the preparation of high-performance organic field-effect transistors. In this review, the types of MGC techniques are first listed and the relevant mechanisms (wetting mechanism, fluid mechanism, and deposition mechanism) are introduced. The MGC processes are focused and the effect of the key coating parameters on the thin film morphology and performance with examples is illustrated. Then, the performance of transistors based on small molecule semiconductors and polymer semiconductor thin films prepared by various MGC techniques is summarized. In the third section, various recent thin film morphology control strategies combined with the MGCs are introduced. Finally, the advanced progress of large-area transistor arrays and the challenges for roll-to-roll processes are presented using MGCs. Nowadays, the application of MGCs is still in the exploration stage, its mechanism is still unclear, and the precise control of film deposition still needs experience accumulation.

High throughput processing of dinaphtho[2,3-b:2',3'-f]thieno[3,2-b]thiophene (DNTT) organic semiconductors

The deposition of organic semiconductors (OSCs) using solution shearing deposition techniques is highly appealing for device implementation. However, when using high deposition speeds, it is necessary to use very concentrated OSC solutions. The OSCs based on the family of dinaphtho[2,3-b:2',3'-f]thieno[3,2-b]thiophene (DNTT) have been shown to be excellent OSCs due to their high mobility and stability. However, their limited solubility hinders the processing of these materials at high speed. Here, we report the conditions to process alkylated DNTT and the S-shaped π-core derivative S-DNTT by bar-assisted meniscus shearing (BAMS) at high speed (i.e., 10 mm s^-1). In all the cases, homogeneous thin films were successfully prepared, although we found that the gain in solubility achieved with the S-DNTT derivative strongly facilitated solution processing, achieving a field-effect mobility of 2.1 cm² V^-1 s^-1, which is two orders of magnitude higher than the mobility found for the less soluble linear derivatives.

The Thickness and Structure of Dip-Coated Polymer Films in the Liquid and Solid States

Films formed by dip coating brass wires with dilute and semi-dilute solutions of polyvinyl butyral in benzyl alcohol were studied in their liquid and solid states. While dilute and semi-dilute solutions behaved as Maxwell viscoelastic fluids, the thickness of the liquid films followed the Landau-Levich-Derjaguin prediction for Newtonian fluids. At a very slow rate of coating, the film thickness was difficult to evaluate. Therefore, the dynamic contact angle was studied in detail. We discovered that polymer additives preserve the advancing contact angle at its static value while the receding contact angle follows the Cox–Voinov theory. In contrast, the thickness of solid films does not correlate with the Landau-Levich-Derjaguin predictions. Only solutions of high-molecular-weight polymers form smooth solid films. Solutions of low-molecular-weight polymers may form either solid films with an inhomogeneous roughness or solid polymer domains separated by the dry substrate. In technological applications, very dilute polymer solutions of high-molecular-weight polymers can be used to avoid inhomogeneities in solid films. These solutions form smooth solid films, and the film thickness can be controlled by the experimental coating conditions.

Scalable Growth of Organic Single-Crystal Films via an Orientation Filter Funnel for High-Performance Transistors with Excellent Uniformity

Organic single-crystal films (OSCFs) provide an unprecedented opportunity for the development of new-generation organic single-crystal electronics. However, crystallization of organic films is normally governed by stochastic nucleation and incoherent growth, posing a formidable challenge to grow large-sized OSCFs. Here, an "orientation filter funnel" concept is presented for the scalable growth of OSCFs with well-aligned, singly orientated crystals. By rationally designing solvent wetting/dewetting patterns on the substrate, this approach can produce seed crystals with the same crystallographic orientation and then maintain epitaxial growth of these crystals, enabling the formation of large-area OSCFs. As a result, this unique concept for crystal growth not only enhances the average mobility of organic film by 4.5-fold but also improves its uniformity of electrical properties, with a low mobility variable coefficient of 9.8%, the new lowest record among organic devices. The method offers a general and scalable route to produce OSCFs toward real-word electronic applications.

A Direct Writing Approach for Organic Semiconductor Single-Crystal Patterns with Unique Orientation

Organic semiconductor single-crystal (OSSC) patterns with precisely controlled orientation are of great significance to the integrated fabrication of devices with high and uniform performance. However, it is still challenging to achieve purely oriented OSSC patterns due to the complex nucleation and growth process of OSSCs. Here, a general direct writing approach is presented to readily obtain high-quality OSSC patterns with unique orientation. In specific, a direct writing method is demonstrated wherein the microscale meniscus is manipulated, which makes it possible to precisely control the nucleation and growth process of the OSSC because of its comparable size to the crystal nuclei. The resulting OSSC patterns are highly crystalline and purely oriented, in which each ribbon crystal shows a deviation angle of 33° to the printing direction. The mechanism of orientation purification is revealed experimentally and theoretically, and the results show that the TCL deformation caused by the difference in wettability and adhesive force, as well as the asymmetry of fluid concentration distribution, are the key factors leading to the selective deposition and unique orientation. Moreover, organic field-effect transistors (OFETs) and polarization-sensitive photodetectors are prepared based on the OSSC patterns with unique orientation, which exhibit higher device performance compared to the non-purely oriented crystal-based OFETs.

Precipitation dominated thin films of acetaminophen fabricated by meniscus guided coating

Crystallization above the solvent boiling point facilitates the identification of a new precipitation dominant morphology during meniscus guided coating.

Phase-Field Simulation of Liquid-Vapor Equilibrium and Evaporation of Fluid Mixtures

In solution processing of thin films, the material layer is deposited from a solution composed of several solutes and solvents. The final morphology and hence the properties of the film often depend on the time needed for the evaporation of the solvents. This is typically the case for organic photoactive or electronic layers. Therefore, it is important to be able to predict the evaporation kinetics of such mixtures. We propose here a new phase-field model for the simulation of evaporating fluid mixtures and simulate their evaporation kinetics. Similar to the Hertz-Knudsen theory, the local liquid-vapor (LV) equilibrium is assumed to be reached at the film surface and evaporation is driven by diffusion away from this gas layer. In the situation where the evaporation is purely driven by the LV equilibrium, the simulations match the behavior expected theoretically from the free energy: for evaporation of pure solvents, the evaporation rate is constant and proportional to the vapor pressure. For mixtures, the evaporation rate is in general strongly time-dependent because of the changing composition of the film. Nevertheless, for highly nonideal mixtures, such as poorly compatible fluids or polymer solutions, the evaporation rate becomes almost constant in the limit of low Biot numbers. The results of the simulation have been successfully compared to experiments on a polystyrene-toluene mixture. The model allows to take into account deformations of the liquid-vapor interface and, therefore, to simulate film roughness or dewetting.

Use of Hybrid PEDOT:PSS/Metal Sulfide Quantum Dots for a Hole Injection Layer in Highly Efficient Green Phosphorescent Organic Light-Emitting Diodes

In this study, we have synthesized the molybdenum sulfide quantum dots (MoS2 QDs) and zinc sulfide quantum dots (ZnS QDs) and demonstrated a highly efficient green phosphorescent organic light-emitting diode (OLED) with hybrid poly (3,4-ethylenedioxythiophene)/poly (styrenesulfonate) (PEDOT:PSS)/QDs hole injection layer (HIL). The electroluminescent properties of PEDOT:PSS and hybrid HIL based devices were explored. An optimized OLED based on the PEDOT:PSS/MoS2 QDs HIL exhibited maximum current efficiency (CE) of 72.7 cd A-1, which shows a 28.2% enhancement as compared to counterpart with single PEDOT:PSS HIL. The higher device performance of OLED with hybrid HIL can be attributed to the enhanced hole injection capacity and balanced charge carrier transportation in the OLED devices. The above analysis illustrates an alternative way to fabricate the high efficiency OLEDs with sulfide quantum dots as a HIL.