目前有机太阳能电池（OSCs）的能量转换效率（PCE）已超过20%,但大面积低成本有机太阳能电池的发展相对滞后。实现有机太阳能电池的低成本化，需要从材料和制备工艺两个方面进行突破；其中材料方面，聚噻吩是一种低成本的给体材料；制备工艺方面，凹版印刷是一种可二维图案化、高速、高精度和低成本的大面积制备方法。
近日，太原理工大学闫翎鹏副教授、华南理工大学段春晖教授、中国科学院苏州纳米技术与纳米仿生研究所骆群研究员和王振国博士等人在Science China Materials发表研究论文，采用低成本的聚噻吩材料为给体材料，通过卷对卷的凹版印刷技术制备了柔性OSCs，实现了低成本的OSCs。
本文要点
1) 通过调节活性层油墨的浓度来调控活性层油墨的粘度，明显减弱了流动条纹，获得了均匀的印刷薄膜。2) 通过温度调节，明显抑制了凹印活性层薄膜微观形貌的过度聚集，获得了较优的微观形貌。3) 通过卷对卷凹版印刷制备1 cm2的柔性OSCs，获得了10.55%的器件效率，与旋涂器件相当。上述结果表明低成本的聚噻吩材料体系可以通过卷对卷凹版印刷的方法制备，且有望大幅降低有机光伏的生产成本。Figure 1. (a) Schematic diagram of the fabrication of PET/AgNWs/ZnO/Active layer films by gravure printing and the three main steps in the gravure process. Insets: i) the doctor blade forces the ink to fill the gravure cavities; ii) the ink is transferred from the cavities of the gravure roller to the substrate; iii) ink droplets level on the substrate. The molecular structure of the active layer donor material P5TCN-F25 and the acceptor material BTP-BO-4Cl. (b) The relationship between shear viscosity and shear rate of active layer inks with different concentrations of P5TCN-F25:BTP-BO-4Cl. (c) The viscosity curve of P5TCN-F25:BTP-BO-4Cl active layer inks with different concentrations (at a shear rate of 1 s−1). (d) The contact angles of the P5TCN-F25 inks on PET/AgNWs/ZnO films at different concentrations. Ink concentrations were 10, 12, 14, and 16 mg mL−1, respectively.![]()
Figure 2. (a) Schematic diagram of the structure of the flexible OSCs. (b) J-V curves, (c) Efficiency statistical distributions, (d) EQE curves, and (e) Jph-Veff intensity curves of P5TCN-F25:BTP-BO-4Cl OSCs fabricated by spin-coated and gravure-printed active layers on PET/AgNWs/ZnO film. The ink concentration of the active layer was 14 mg mL−1, and the line density was 60 lpc.Figure 3. AFM (a–c) height of the active layer gravure-printed on ZnO film with different temperatures of ink. In-situ absorption dynamics of gravure-printed active layers and annealing processes at different temperatures, (d, e) RT, (f, g) 70°C. (h, i) 130°C. Annealing temperature: 120°C. The peak position evolution as a function of time of (j) BTP-BO-4Cl in films. (k) The UV-vis absorption spectra of P5TCN-F25 in CB with a concentration of 0.01 mg mL−1 under varied temperatures.Figure 4. (a) J-V curves, (b) efficiency distribution histograms, and (c) EQE curves of fully gravure-printed (three-layer) OSCs prepared at different solution temperatures. (d) Summary of the device efficiency of OSCs fabricated by gravure printing using polythiophene active layer materials in recent years.Weitao Qi, Xiyue Yuan, Yuanqi Liu, Shutao Yang, Yunsha Chu, Fan Qian, Lingpeng Yan, Zhenguo Wang, Chunhui Duan, Qun Luo, Chang-Qi Ma. Roll-to-roll gravure printed organic solar cells based on low-cost polythiophene donor. Sci. China Mater. (2024).https://doi.org/10.1007/s40843-024-3156-6
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