Air-knife-assisted spray coating of organic solar cells

The power conversion efficiencies (PCEs) of organic solar cells (OSCs) have risen dramatically since the introduction of the “Y-series” of non-fullerene acceptors. However, the demonstration of rapid scalable deposition techniques to deposit such systems is rare. Here, for the first time, we demonstrate the deposition of a Y-series-based system using ultrasonic spray coating─a technique with the potential for significantly faster deposition speeds than most traditional meniscus-based methods. Through the use of an air-knife to rapidly remove the casting solvent, we can overcome film reticulation, allowing the drying dynamics to be controlled without the use of solvent additives, heating the substrate, or heating the casting solution. The air-knife also facilitates the use of a non-halogenated, low-toxicity solvent, resulting in industrially relevant, spray-coated PM6:DTY6 devices with PCEs of up to 14.1%. We also highlight the obstacles for scalable coating of Y-series-based solar cells, in particular the influence of slower drying times on blend morphology and crystallinity. This work demonstrates the compatibility of ultrasonic spray coating, and use of an air-knife, with high-speed, roll-to-roll OSC manufacturing techniques.