Push-coating
is a simple process that can be employed for extremely
low-cost polymer electronic device production. Here, we demonstrate
its application to the fabrication of poly(2,7-carbazole-alt-dithienylbenzothiadiazole) (PCDTBT):[6,6]-phenyl-C71-butyric
acid methyl ester (PC71BM) active layers processed in air,
yielding similar photovoltaic performances as thermally annealed spin-coated
thin films when used in inverted polymer solar cells (PSCs). During
push-coating, the polydimethylsiloxane layer temporarily traps the
deposition solvent, resulting in simultaneous film formation and solvent
annealing effect. This removes the necessity for a postdeposition
thermal annealing step which is required for spin-coated PSCs to produce
high photovoltaic performances. Optimized PSC active layers are produced
with a push-coating time of 5 min at room temperature with 20 times
less hazardous solvent and 40 times less active material than spin-coating.
Annealed spin-coated active layers and active layers push-coated for
5 min both produce average power conversion efficiencies (PCEs) of
5.77%, while those push-coated for a shorter time of 1 min yield a
slightly lower value of 5.59%. We demonstrate that, despite differences
in their donor:acceptor vertical concentration gradients, unencapsulated
PCDTBT:PC71BM active layers push-coated for 1 min produce
PSCs with similar operational stability and upscaling capacity as
thermally annealed spin-coated ones. As fast device fabrication can
be achieved with short-time push-coating, we further demonstrate the
potential of this deposition technique by manufacturing push-coated
PSC-based semitransparent photovoltaic devices with a PCE of 4.23%,
relatively neutral colors and an average visible transparency of 40.2%.
Our work thus confirms that push-coating is not limited to the widely
employed poly(3-hexylthiophene-2,5-diyl) but can also be used with
low band gap copolymers and opens the path to low-cost and eco-friendly,
yet efficient and stable PSCs.