Blade-Cast Nonfullerene Organic Solar Cells in Air with Excellent Morphology, Efficiency, and Stability

Blade-coating serving as a prototype tool for slot-die coating can be very compatible with large-area roll-to-roll coating. Using blade-coating in an ambient environment, an average power conversion efficiency (PCE) of 10.03% is achieved in nonfullerene organic solar cells, which is higher than that of the optimal spin-coated device with a PCE of 9.41%. It is demonstrated that blade-coating can induce a higher degree of molecular packing for both conjugated polymer donors and small-molecular acceptors as it helps to produce a seeding film containing numerous crystal grains, subsequently providing nucleation sites for the residual solution when the motion of the blade exposes a liquid front. Due to this effect, blade-coating can partially replace the role of the additive 1,8-diiodooctane (DIO) and thus achieves the optimized morphology with fewer additives. Moreover, it is found that the blade-coated film with 0.25% DIO possesses not only a smaller domain size but also higher domain purity, suggesting more D/A (donor/acceptor) interfaces and a purer phase domain as compared to the spin-coated film with 1% DIO. Encouragingly, the blade-coated device with less DIO (0.25%) exhibits much better stability than the spin-coated device with 1% DIO, showing excellent prospects.