Design rules are presented for significantly expanding sequential processing (SqP) into previously inaccessible polymer:fullerene systems by tailoring binary solvent blends for fullerene deposition. Starting with a base solvent that has high fullerene solubility, 2‐chlorophenol (2‐CP), ellipsometry‐based swelling experiments are used to investigate different co‐solvents for the fullerene‐casting solution. By tuning the Flory‐Huggins χ parameter of the 2‐CP/co‐solvent blend, it is possible to optimally swell the polymer of interest for fullerene interdiffusion without dissolution of the polymer underlayer. In this way solar cell power conversion efficiencies are obtained for the PTB7 (poly[(4,8‐bis[(2‐ethylhexyl)oxy]benzo[1,2‐b:4,5‐b′]dithiophene‐2,6‐diyl)(3‐fluoro‐2‐[(2‐ethylhexyl)carbonyl]thieno[3,4‐b]thiophenediyl)]) and PC61BM (phenyl‐C61‐butyric acid methyl ester) materials combination that match those of blend‐cast films. Both semicrystalline (e.g., P3HT (poly(3‐hexylthiophene‐2,5‐diyl)) and entirely amorphous (e.g., PSDTTT (poly[(4,8‐di(2‐butyloxy)benzo[1,2‐b:4,5‐b′]dithiophene‐2,6‐diyl)‐alt‐(2,5‐bis(4,4′‐bis(2‐octyl)dithieno[3,2‐b:2′3′‐d]silole‐2,6‐diyl)thiazolo[5,4‐d]thiazole)]) conjugated polymers can be processed into highly efficient photovoltaic devices using the solvent‐blend SqP design rules. Grazing‐incidence wide‐angle x‐ray diffraction experiments confirm that proper choice of the fullerene casting co‐solvent yields well‐ordered interdispersed bulk heterojunction (BHJ) morphologies without the need for subsequent thermal annealing or the use of trace solvent additives (e.g., diiodooctane). The results open SqP to polymer/fullerene systems that are currently incompatible with traditional methods of device fabrication, and make BHJ morphology control a more tractable problem.

Polymer:fullerene bulk heterojunction (BHJ) solar cell active layers can be created by traditional blend casting (BC), where the components are mixed together in solution before deposition, or by sequential processing (SqP), where the pure polymer and fullerene materials are cast sequentially from different solutions. Presently, however, the relative merits of SqP as compared to BC are not fully understood because there has yet to be an equivalent (composition-and thickness-matched layer) comparison between the two processing techniques. The main reason why matched SqP and BC devices have not been compared is because the composition of SqP active layers has not been accurately known. In this paper, we present a novel technique for accurately measuring the polymer:fullerene film composition in SqP active layers, which allows us to make the first comparisons between rigorously composition-and thickness-matched BHJ organic solar cells made by SqP and traditional BC. We discover that, in optimal photovoltaic devices, SqP active layers have a very similar composition as their optimized BC counterparts (≈44−50 mass % PCBM). We then present a thorough investigation of the morphological and device properties of thickness-and composition-matched P3HT:PCBM SqP and BC active layers in order to better understand the advantages and drawbacks of both processing approaches. For our matched devices, we find that small-area SqP cells perform better than BC cells due to both superior film quality and enhanced optical absorption from more crystalline P3HT. The enhanced film quality of SqP active layers also results in higher performance and significantly better reproducibility in larger-area devices, indicating that SqP is more amenable to scaling than the traditional BC approach. X-ray diffraction, UV−vis absorption, and energy-filtered transmission electron tomography collectively show that annealed SqP active layers have a finer-scale blend morphology and more crystalline polymer and fullerene domains when compared to equivalently processed BC active layers. Charge extraction by linearly increasing voltage (CELIV) measurements, combined with X-ray photoelectron spectroscopy, also show that the top (nonsubstrate) interface for SqP films is slightly richer in PCBM compared to matched BC active layers. Despite these clear differences in bulk and vertical morphology, transient photovoltage, transient photocurrent, and subgap external quantum efficiency measurements all indicate that the interfacial electronic processes occurring at P3HT:PCBM heterojunctions are essentially identical in matched-annealed SqP and BC active layers, suggesting that device physics are surprisingly robust with respect to the details of the BHJ morphology.

Although it is known that evaporated metals can penetrate into films of various organic molecules that are a few nanometers thick, there has been little work aimed at exploring the interaction of the common electrode metals used in devices with fullerene derivatives, such as organic photovoltaics (OPVs) or perovskite solar cells that use fullerenes as electron transport layers. In this paper, we show that when commonly used electrode metals (e.g., Au, Ag, Al, Ca, etc.) are evaporated onto films of fullerene derivatives (such as [6,6]-phenyl-C61-butyric acid methyl ester (PCBM)), the metal penetrates many tens of nanometers into the fullerene layer. This penetration decreases the effective electrical thickness of fullerene-based sandwich structure devices, as measured by the device's geometric capacitance, and thus significantly alters the device physics. For the case of Au/PCBM, the metal penetrates a remarkable 70 nm into the fullerene, and we see penetration of similar magnitude in a wide variety of fullerene derivative/evaporated metal combinations. Moreover, using transmission electron microscopy to observed cross-sections of the films, we show that when gold is evaporated onto poly(3-hexylthiophene) (P3HT)/PCBM sequentially processed OPV quasi-bilayers, Au nanoparticles with diameters of ∼3-20 nm are formed and are dispersed entirely throughout the fullerene-rich overlayer. The plasmonic absorption and scattering from these nanoparticles are readily evident in the optical transmission spectrum, demonstrating that the interpenetrated metal significantly alters the optical properties of fullerene-rich active layers. This opens a number of possibilities in terms of contact engineering and light management so that metal penetration in devices that use fullerene derivatives could be used to advantage, making it critical that researchers are aware of the electronic and optical consequences of exposing fullerene-derivative films to evaporated electrode metals.

Poly(fluorene-alt-thiophene) (PFT) is a conjugated polyelectrolyte that self-assembles into rod-like micelles in water, with the conjugated polymer backbone running along the length of the micelle. At modest concentrations (∼10 mg/mL in aqueous solutions), PFT forms hydrogels, and this work focuses on understanding the structure and intermolecular interactions in those gel networks. The network structure can be directly visualized using cryo electron microscopy. Oscillatory rheology studies further tell us about connectivity within the gel network, and the data are consistent with a picture where polymer chains bridge between micelles to hold the network together. Addition of tetrahydrofuran (THF) to the gels breaks those connections, but once the THF is removed, the gel becomes stronger than it was before, presumably due to the creation of a more interconnected nanoscale architecture. Small polymer oligomers can also passivate the bridging polymer chains, breaking connections between micelles and dramatically weakening the hydrogel network. Fits to solution-phase small-angle X-ray scattering data using a Dammin bead model support the hypothesis of a bridging connection between PFT micelles, even in dilute aqueous solutions. Finally, time-resolved microwave conductivity measurements on dried samples show an increase in carrier mobility after THF annealing of the PFT gel, likely due to increased connectivity within the polymer network.

The efficiency of bulk heterojunction (BHJ) organic photovoltaics is sensitive to the morphology of the fullerene network that transports electrons through the device. This sensitivity makes it difficult to distinguish the contrasting roles of local electron mobility (how easily electrons can transfer between neighboring fullerene molecules) and macroscopic electron mobility (how well‐connected is the fullerene network on device length scales) in solar cell performance. In this work, a combination of density functional theory (DFT) calculations, flash‐photolysis time‐resolved microwave conductivity (TRMC) experiments, and space‐charge‐limit current (SCLC) mobility estimates are used to examine the roles of local and macroscopic electron mobility in conjugated polymer/fullerene BHJ photovoltaics. The local mobility of different pentaaryl fullerene derivatives (so‐called ‘shuttlecock’ molecules) is similar, so that differences in solar cell efficiency and SCLC mobilities result directly from the different propensities of these molecules to self‐assemble on macroscopic length scales. These experiments and calculations also demonstrate that the local mobility of phenyl‐C60 butyl methyl ester (PCBM) is an order of magnitude higher than that of other fullerene derivatives, explaining why PCBM has been the acceptor of choice for conjugated polymer BHJ devices even though it does not form an optimal macroscopic network. The DFT calculations indicate that PCBM's superior local mobility comes from the near‐spherical nature of its molecular orbitals, which allow strong electronic coupling between adjacent molecules. In combination, DFT and TRMC techniques provide a tool for screening new fullerene derivatives for good local mobility when designing new molecules that can improve on the macroscopic electron mobility offered by PCBM.