Slot‐Die Coating of a High Performance Copolymer in a Readily Scalable Roll Process for Polymer Solar Cells

Copolymers based on dithieno[3,2‐b:2′,3′‐d]silole (DTS) and dithienylthiazolo[5,4‐d]thiazole (TTz) are synthesized and tested in an all‐solution roll process for polymer solar cells (PSCs). Fabrication of polymer:[6,6]‐phenyl‐C₆₁‐butyric acid methyl ester (PCBM) solar cells is done on a previously reported compact coating/printing machine, which enables the preparation of PSCs that are directly scalable with full roll‐to‐roll processing. The positioning of the side‐chains on the thiophene units proves to be very significant in terms of solubility of the polymers and consequently has a major impact on the device yield and process control. The most successful processing is accomplished with the polymer, PDTSTTz‐4, that has the side‐chains situated in the 4‐position on the thiophene units. Inverted PSCs based on PDTSTTz‐4 demonstrate high fill factors, up to 59%, even with active layer thicknesses well above 200 nm. Power conversion efficiencies of up to 3.5% can be reached with the roll‐coated PDTSTTz‐4:PCBM solar cells that, together with good process control and high device yield, designate PDTSTTz‐4 as a convincing candidate for high‐throughput roll‐to‐roll production of PSCs.