Formation of Crystalline Bulk Heterojunctions in Organic Solar Cells: Insights from Phase-Field Simulations

The performance of organic solar cells strongly depends on the bulk-heterojunction (BHJ) morphology of the photoactive layer. This BHJ forms during the drying of the wet-deposited solution, because of physical processes such as crystallization and/or liquid-liquid phase separation (LLPS). However, the process-structure relationship remains insufficiently understood. In this work, a recently developed, coupled phase-field-fluid mechanics framework is used to simulate the BHJ formation upon drying. For the first time, this allows to investigate the interplay between all the relevant physical processes (evaporation, crystal nucleation and growth, liquid demixing, composition-dependent kinetic properties), within a single coherent theoretical framework. Simulations for the model system P3HT-PCBM are presented. The comparison with previously reported in situ characterization of the drying structure is very convincing: The morphology formation pathways, crystallization kinetics, and final morphology are in line with experimental results. The final BHJ morphology is a subtle mixture of pure crystalline donor and acceptor phases, pure and mixed amorphous domains, which depends on the process parameters and material properties. The expected benefit of such an approach is to identify physical design rules for ink formulation and processing conditions to optimize the cell's performance. It could be applied to recent organic material systems in the future.