In Situ Printing: Insights into the Morphology Formation and Optical Property Evolution of Slot‐Die‐Coated Active Layers Containing Low Bandgap Polymer Donor and Nonfullerene Small Molecule Acceptor

Printing of active layers for high‐efficiency organic solar cells with the slot‐die coating technique can overcome the challenge of upscaling, which will be needed for organic photovoltaics on its way to marketability. The morphology of a bulk‐heterojunction organic solar cell has a very high impact on its power conversion efficiency. Therefore, it is of particular importance to understand the mechanisms of structure formation during printing of active layers to enable further optimization of the solar cell performance and upscaling of the production process. Meniscus‐guided slot‐die coating of the blend of a low bandgap conjugated polymer donor with benzodithiophene units PBDB‐T‐SF and the nonfullerene small molecule acceptor IT‐4F is studied in situ with optical microscopy, Ultraviolet–visible spectroscopy, and grazing incidence small angle X‐ray scattering. The structure formation is followed from the liquid to the final dry film state. Thereby, five regimes of morphology formation are determined. The morphological evolution in the printed active layer is correlated to changing optical properties of the thin film. In the final dry film, polymer domains of several tens of nanometers are observed, which will be favorable for application in high‐efficiency organic solar cells. Meniscus‐guided slot‐die coating of the blend of a low bandgap conjugated polymer donor with benzodithiophene units PBDB‐T‐SF and the nonfullerene small molecule acceptor IT‐4F is studied in situ using optical microscopy, UV–vis spectroscopy, and grazing incidence small angle X‐ray scattering. The structure formation is followed from the liquid to the final dry film state.