A selective solvent vapor, i.e., cyclohexanone or isopropyl benzene, which is a poor solvent for poly(3-hexylthiophene-2,5-diyl) (P3HT) and a good solvent for fullerene derivative [6,6]-phenyl-C61-butyric acid methyl ester (PCBM), was employed to reduce the size of PCBM aggregates and prolong the formation time of big PCBM aggregates in P3HT/PCBM film. PCBM nucleates and aggregates of 10-20 nm scale form in the first few minutes annealing. Then the size of PCBM aggregates kept unchanged until annealing for 60 min. Finally, larger PCBM aggregates of micron-size formed hours later. On the contrary, the growth rate of PCBM aggregates was faster and their size was larger when treated with a good solvent vapor for both components. The P3HT crystallinity was the same with different types of annealing solvents, although the rate of P3HT self-organization was decreased after a selective solvent vapor annealing. Because of the smaller size of phase separation, the device annealed in a selective solvent vapor for 30 min had a higher PCE than that annealed in a good solvent vapor. Recent years, polymer solar cells have attracted lots of interests due to their advantages compared with inorganic solar cells such as easy processability, light weight, low cost, flexible and so on. Regioregular poly(3-hexyl-thiophene-2,5-diyl) (rr-P3HT) and fullerene derivative [6,6]-phenyl-C61-butyric acid methyl ester (PCBM) are respectively one of the most important donor and acceptor materials in polymer solar cells. The power conversion efficiency of devices based on them has been up to 5%-6% [1-3]. A great deal of research has proved that the morphology of the photoactive layer is crucial for highly efficient performance. Ideally, the donor and acceptor materials should form interpenetrated networks of 10-20 nm-scale on account of the typical exciton diffusion length which is about 10 nm for conjugated polymers [4,5]. When represented by a two-dimensional model, it showed that a phase separated morphology with feature sizes smaller than ~50 nm could improve charge transport within and between the two phases and reduce bimolecular charge recombination [6]. In the case of P3HT/PCBM, the molecular ordering of rr-P3HT is concerned with photon absorption and hole transport [7][8][9], and the suitable size of phase separation is related to charge separation. In order to achieve an optimum morphology, many methods have been employed, including thermal annealing [10,11], solvent vapor annealing [12][13][14], mixed solvent [15,16], introduction of additives [17,18] and so on. Most of these methods can induce P3HT to self-organize into ordered structure. In fact, the crystallization of P3HT is always faster than the aggregation of PCBM [19,20]. When the crystallinity of P3HT is enhanced, crystallization-driven phase separation will happen [21,22]. As a result, big (even micron-sized) PCBM aggregates often appear. The scale of them was obviously much greater than the exciton diffusion length. Meanwhile, the diffusion of PCBM out of the polymer matri...