Long-Wavelength Instabilities Impact Alignment during Blade Coating of a Stretchable Organic Transistor Blend

The use of polymer-polymer blends to tailor mechanical properties and improve electrical performance is becoming widespread in the field of printed electronics. Similarly, meniscus-guided coating can be used to tailor electrical properties through alignment of the semiconducting material. We report on a long-wavelength instability during blade coating of a semiconducting polymer/elastomer blend for organic transistor applications that results in significant variation of the semiconducting polymer nanofibril alignment across the instability period. By correlating measurements over diverse (nm to mm) length scales, we can directly relate the charge transport in top-gate transistors to the local polymer nanofibril alignment. Hole mobility is directly correlated to the local alignment and shows an ≈2 × variation across the instability for devices aligned with the coating direction. The potential for long-wavelength instabilities to create device-relevant morphology variations should be considered when optimizing coating conditions. These results reveal considerable potential for error in assuming that smooth films are necessarily structurally uniform; material structure may spatially vary for some coating methods, leading to a correlated, spatially varying device performance.