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Upcycling plastic waste into reprocessable materials with performance-advantaged properties would contribute to the development of a circular plastics economy. Here, we modify branched polyolefins and postconsumer polyethylene through a versatile C–H functionalization approach using thiosulfonates as a privileged radical group transfer functionality. Cross-linking the functionalized polyolefins with polytopic amines provided dynamically cross-linked polyolefin networks enabled by associative bond exchange of diketoenamine functionality. A combination of resonant soft X-ray scattering and grazing incidence X-ray scattering revealed hierarchical phase morphology in which diketoenamine-rich microdomains phase-separate within amorphous regions between polyolefin crystallites. The combination of dynamic covalent cross-links and microphase separation results in useful and improved mechanical properties, including a ∼4.5-fold increase in toughness, a reduction in creep deformation at temperatures relevant to use, and high-temperature structural stability compared to the parent polyolefin. The dynamic nature of diketoenamine cross-links provides stress relaxation at elevated temperatures, which enabled iterative reprocessing of the dynamic covalent polymer network with little cycle-to-cycle property fade. The ability to convert polyolefin waste into a reprocessable thermoformable material with attractive thermomechanical properties provides additional optionality for upcycling to enable future circularity.

Morphological and mechanical stabilities of organic solar cells (OSCs) are of paramount importance to ensure long-lived devices. However, the fundamental drivers of these stability metrics and their competing relationship have yet to be well defined. Here, several high-performance polymers and small molecule acceptors (SMAs) are considered to assist in the development of a comprehensive view of the molecular drivers of, and interrelationships between, morphological and mechanical stabilities. We find that the SMAs drive much of the embrittlement and diffusion characteristics in the blend films. However, the heterointeraction of the SMA and polymer, probed through dynamic mechanical analysis, is a key contributing factor to the film toughness. The heterointeraction energy is ideally maximally negative (i.e., repulsive), deviating from the geometric mean of the homointeraction energy. These findings assist in introducing a framework to understand the active layer stability and highlight material properties that lead to morphologically stable and physically robust OSCs.

We report on the use of molecular acceptors (MAs) and donor polymers processed with a biomass-derived solvent (2-methyltetrahydrofuran, 2-MeTHF) to facilitate bulk heterojunction (BHJ) organic photovoltaics (OPVs) with power conversion efficiency (PCE) approaching 15%. Our approach makes use of two newly designed donor polymers with an opened ring unit in their structures along with three molecular acceptors (MAs) where the backbone and sidechain were engineered to enhance the processability of BHJ OPVs using 2-MeTHF, as evaluated by an analysis of donor–acceptor (D–A) miscibility and interaction parameters. To understand the differences in the PCE values that ranged from 9–15% as a function of composition, the surface, bulk, and interfacial BHJ morphologies were characterized at different length scales using atomic force microscopy, grazing-incidence wide-angle X-ray scattering, resonant soft X-ray scattering, X-ray photoelectron spectroscopy, and 2D solid-state nuclear magnetic resonance spectroscopy. Our results indicate that the favorable D–A intermixing that occurs in the best performing BHJ film with an average domain size of ∼25 nm, high domain purity, uniform distribution and enhanced local packing interactions – facilitates charge generation and extraction while limiting the trap-assisted recombination process in the device, leading to high effective mobility and good performance.

It has been reported recently that conjugated polymer:small molecule systems might exhibit complex, re-entrant phase behavior with hourglass or closed-loop miscibility gaps due to an ‘apparent’ lower critical solution temperature branch. However, the study did not firmly establish if the observations were reflecting equilibrium or not. To assure that the observed shapes of the binodals viaa mixing experiment represent local near-equilibrium conditions that capture complex molecular interactions or equation-of-state effects, we present here the liquidus and the binodal for the exact same systems, i.e., PTB7-Th:PC61BM, PffBT4T-C9C13:PC71BM and PTB7-Th:EH-IDTBR, with the liquidus measured viaa demixing experiment with long annealing time of days to weeks. We observe that the binodal displayed consistent trends with the liquidus, revealing an underlying thermodynamic and not microstructural or kinetic cause behind the complex phase behavior. Our results highlight the need for a novel, sufficiently complex physical model for understanding these non-trivial phase diagrams of semi-conducting materials. We also discover that the composition difference (Δ) between liquidus and binodal reflects the crystalline–amorphous interaction, exhibiting a linear relationship with the binodal composition (b,polymer), i.e., Δincreases as χaadecreases. This possibly provides a new approach for obtaining the crystalline–amorphous interaction parameter χca(T) beyond the commonly used melting point depression method, which estimates χcanear the melting temperature Tmof the crystalline component. The capability of obtaining χca(T) over a more extended temperature range may encourage more extensive studies and facilitate the understanding of χcain general, but particularly for all the novel non-fullerene acceptors that are able to crystallize.

In organic solar cells (OSCs), a thick active layer usually yields a higher photocurrent with broader optical absorption than a thin active layer. In fact, a ∼300 nm thick active layer is more compatible with large-area processing methods and theoretically should be a better spot for efficiency optimization. However, the bottleneck of developing high-efficiency thick-film OSCs is the loss in fill factor (FF). The origin of the FF loss is not clearly understood, and there a direct method to identify photoactive materials for high-efficiency thick-film OSCs is lacking. Here, we demonstrate that the mobility field-dependent coefficient is an important parameter directly determining the FF loss in thick-film OSCs. Simulation results based on the drift–diffusion model reveal that a mobility field-dependent coefficient smaller than 10–3(V/cm)−1/2is required to maintain a good FF in thick-film devices. To confirm our simulation results, we studied the performance of two ternary bulk heterojunction (BHJ) blends, PTQ10:N3:PC71BM and PM6:N3:PC71BM. We found that the PTQ10 blend film has weaker field-dependent mobilities, giving rise to a more balanced electron–hole transport at low fields. While both the PM6 blend and PTQ10 blend yield good performance in thin-film devices (∼100 nm), only the PTQ10 blend can retain a FF = 74% with an active layer thickness of up to 300 nm. Combining the benefits of a higher JSCin thick-film devices, we achieved a PCE of 16.8% in a 300 nm thick PTQ10:N3:PC71BM OSC. Such a high FF in the thick-film PTQ10 blend is also consistent with the observation of lower charge recombination from light-intensity-dependent measurements and lower energetic disorder observed in photothermal deflection spectroscopy.

Molecular packing and texture of semiconducting polymers are often critical to the performance of devices using these materials. Although frameworks exist to quantify the ordering, interpretations are often just qualitative, resulting in imprecise use of terminology. Here, we reemphasize the significance of quantifying molecular ordering in terms of degree of crystallinity (volume fractions that are ordered) and quality of ordering and their relation to the size scale of an ordered region. We are motivated in part by our own imprecise and inconsistent use of terminology in the past, as well as the need to have a primer or tutorial reference to teach new group members. We strive to develop and use consistent terminology with regards to crystallinity, semicrystallinity, paracrystallinity, and related characteristics. To account for vastly different quality of ordering along different directions, we classify paracrystals into 2D and 3D paracrystals and use paracrystallite to describe the spatial extent of molecular ordering in 1–10 nm. We show that a deeper understanding of molecular ordering can be achieved by combining grazing-incidence wide-angle X-ray scattering and differential scanning calorimetry, even though not all aspects of these measurements are consistent, and some classification appears to be method dependent. We classify a broad range of representative polymers under common processing conditions into five categories based on the quantitative analysis of the paracrystalline disorder parameter (g) and thermal transitions. A small database is presented for 13 representative conjugated and insulating polymers ranging from amorphous to semi-paracrystalline. Finally, we outline the challenges to rationally design more perfect polymer crystals and propose a new molecular design approach that envisions conceptual molecular grafting that is akin to strained and unstrained hetero-epitaxy in classic (compound) semiconductors thin film growth.

As the power conversion efficiency of organic photovoltaic has been dramatically improved to over 18%, achieving long-term stability is now crucial for applications of this promising photovoltaic technology. Among the high-efficiency systems, most are using BTP-4F and its analogs as acceptors. Herein, we determine the thermal transition temperatures (Tg) of seven BTP analogs to develop a structure-Tgframework. Our results point out an unresolved molecular design conundrum on how to simultaneously achieve high performance and intrinsic stability with BTP-based acceptors. We also show that PC71BM has miscibility above the percolation threshold in PM6 and can maintain local charge percolation and improved stability in ternary devices. However, PC71BM is not miscible with BTP-C3-4F and unfavorable vertical gradients that develop during aging still degrade performance. This points to a second thermodynamic conundrum. A compound with differential miscibility in the donor polymer can only impact percolation, and a compound with differential miscibility with the BTP only impacts diffusion.

While there are numerous approaches to functionalize conjugated polymers for organic solar cells (OSCs), one widely adopted approach is fluorination. Of the many different locations for fluorination, one of the least studied is the conjugated linker which connects the donor and acceptor moieties; further, all existing reports primarily explore monofluorinated thiophene units. Herein, we synthesize and compare two conjugated polymers, HTAZ and dFT-HTAZ, which have different thiophene linkers. In HTAZ, a bare thiophene unit connects the donor and acceptor moieties, while dFT-HTAZ utilizes difluorinated thiophene (dFT) linkers. These polymers serve as the model system to explore the impact of dFT units in OSCs; additionally, this is the first publication to investigate polymers containing dFT units paired with non-fullerene acceptors. Compared to HTAZ, the incorporation of the dFT units maintained the optical properties while lowering the energy levels by ∼0.4 eV, which allowed for a much improved Vocvalue of ∼1 V. Importantly, when compared with the appropriate non-fullerene acceptor, dFT-HTAZ:ITIC-Th1 blends reached an efficiency of ∼10%, which is nearly 3× that of the nonfluorinated HTAZ. As most OSC polymers have thiophene linkers, using dFT units could serve as a proficient method to increase OSC performance in many polymer systems, especially those that do not have locations for functionalization on the acceptor moiety.

Rapid increase in the power conversion efficiency of organic solar cells (OSCs) has been achieved with the development of non-fullerene small-molecule acceptors (NF-SMAs). Although the morphological stability of these NF-SMA devices critically affects their intrinsic lifetime, their fundamental intermolecular interactions and how they govern property–function relations and morphological stability of OSCs remain elusive. Here, we discover that the diffusion of an NF-SMA into the donor polymer exhibits Arrhenius behaviour and that the activation energy Eascales linearly with the enthalpic interaction parameters χHbetween the polymer and the NF-SMA. Consequently, the thermodynamically most unstable, hypo-miscible systems (high χ) are the most kinetically stabilized. We relate the differences in Eato measured and selectively simulated molecular self-interaction properties of the constituent materials and develop quantitative property–function relations that link thermal and mechanical characteristics of the NF-SMA and polymer to predict relative diffusion properties and thus morphological stability.

Multi-component organic solar cells (OSCs) comprising more than two donor and acceptor materials have attracted significant research attention, as they can offer broader and better absorption, hence increasing solar cell performance. However, the morphology of multi-component OSCs is exceptionally complicated and challenging to control. Here, we develop a highly efficient (near 17.7%) quaternary OSC (q-OSC) using two polymer donors (namely PM6 and PTQ10) along with a fullerene (PC71BM) and a non-fullerene acceptor (N3). Our quaternary system demonstrates a new type of “rivers and streams” functional hierarchical (multi-length scale) morphology, where small domains of PTQ10 and PC71BM act as separators that spatially separate PM6 and N3, which effectively suppressed charge recombination, enhanced hole transport, and balanced charge transportation. These improvements in the quaternary system contribute to the increased internal quantum efficiency (IQE) and, thus, lead to an excellent JSCand device performance, which surpass their respective binary and ternary OSCs.

Conjugated polymers have proven to be an important class of materials for flexible and stretchable electronics. To ensure long-term thermal and mechanical stability of associated devices, there is a need to determine the origin of the polymer ductility and toughness. In this work, we investigate a variety of high-performance conjugated polymers and relate their thermomechanical behavior to film toughness. Dynamic mechanical analysis (DMA) is used to probe thermomechanical relaxations of the conjugated polymers. Film ductility is measured as a function of temperature to determine the temperature that corresponds to a significant loss in film toughness. We systematically study polymers with changes to the side-chain structure, backbone structure, and crystallinity. We also compare polymers that have a clear glass transition (Tg) to those that do not. It is found that secondary thermal relaxations (sub-Tg) play a critical role in film toughness. This sub-Tgis found to be a local molecular relaxation that appears to relate to side-chain and backbone mobility. We also find that many of the polymers considered continue to show moderate ductility below their sub-Tg, which is attributed to crystallites or aggregates that have active slip systems. These results provide new insights into how conjugated polymer structure and related thermal relaxations influence film toughness that will assist in realizing mechanically robust devices.

The field of organic solar cells has seen rapid developments after the report of a high-efficiency (15.7%) small molecule acceptor (SMA) named Y6. In this paper, we design and synthesize a family of SMAs with an aromatic backbone identical to that of Y6 but with different alkyl chains to investigate the influence of alkyl chains on the properties and performance of the SMAs. First, we show that it is beneficial to use branched alkyl chains on the nitrogen atoms of the pyrrole motif of the Y6. In addition, the branching position of the alkyl chains also has a major influence on material and device properties. The SMA with 3rd-position branched alkyl chains (named N3) exhibits optimal solubility and electronic and morphological properties, thus yielding the best performance. Further device optimization using a ternary strategy allows us to achieve a high efficiency of 16.74% (and a certified efficiency of 16.42%).

Although non-fullerene small molecular acceptors (NF-SMAs) are dominating current research in organic solar cells (OSCs), measurements of thermodynamics drivers and kinetic factors determining their morphological stability are lacking. Here, we delineate and measure such factors in crystallizable NF-SMA blends and discuss four model systems with respect to their meta-stability and degree of vitrification. We determine for the first time the amorphous-amorphous phase diagram in an NF-SMA system and show that its deep quench depth can result in severe burn-in degradation. We estimate the relative phase behavior of four other materials systems. Additionally, we derive room-temperature diffusion coefficients and conclude that the morphology needs to be stabilized by vitrification corresponding to diffusion constants below 10−22cm2/s. Our results show that to achieve stability via rational molecular design, the thermodynamics, glass transition temperature, diffusion properties, and related structure-function relations need to be more extensively studied and understood.

Developing effective methods to make efficient bulk-heterojunction polymer solar cells at roll-to-roll relevant active layer thickness is of significant importance. We investigate the effect of fullerene content in polymer:fullerene blends on the fill factor (FF) and on the performance of thick-film solar cells for four different donor polymers PTB7-Th, PDPP-TPT, BDT-FBT-2T, and poly[5,5′-bis(2-butyloctyl)-(2,2′-bithiophene)-4,4′-dicarboxylate-alt-5,5′-2,2′-bithiophene] (PDCBT). At a few hundreds of nanometers thickness, increased FFs are observed in all cases and improved overall device performances are obtained except for PDCBT upon increasing fullerene content in blend films. This fullerene content effect was studied in more detail by electrical and morphological characterization. The results suggest enhanced electron mobility and suppressed bimolecular recombination upon increasing fullerene content in thick polymer:fullerene blend films, which are the result of larger fullerene aggregates and improved interconnectivity of the fullerene phases that provide continuous percolating pathways for electron transport in thick films. These findings are important because an effective and straightforward method that enables fabricating efficient thick-film polymer solar cells is desirable for large-scale manufacturing via roll-to-roll processing and for multijunction devices.

Side-chain engineering of conjugated polymer donor materials is an important way for improving photovoltaic performances of polymer solar cells (PSCs). On the basis of the polymer J61 synthesized in our group, here, we design and synthesize three new 2D-conjugated polymers J62, J63, and J64 with different types of side chains to further investigate the effect of side chain on their physicochemical and photovoltaic properties. With the narrow bandgap n-type organic semiconductor (n-OS) ITIC as acceptor, the optimized PSCs based on polymer donor of J62 with linear octyl, J63 with linear unsaturated hexylene, and J64 with cyclohexane side chains display power conversion efficiency (PCE) of 10.81%, 8.13%, and 8.59%, respectively. After thermal treatment at 200 °C for 2 h on the active layer,the PCE of the PSC based on J63 still keeps 92% of the original value, which verifies that the cross-linking of the polymer can improve the thermal stability of PSCs. Morphological studies show that the active layer based on J63 displays strong lamellar packing with RMS 1.26, and the active layer based on J64 shows little phase separation with RMS 0.65. The RMS of the active layer based on J62 is 0.900, and the size of phase separation is between that of J63 and J64, which indicates the excessive high lamellar packing or low phase separation is harmful to the performance of PSCs. These results indicate that the side-chain engineering is an effective way to adjust the aggregation of polymers and the morphology of blend films, which are key factors to influence the performance of PSCs.

Inner side-chain engineering on Y6 has been proven successful in improving short-circuit current density (JSC) through fine-tuning aggregated structures of acceptors. However, it fails in tuning the lowest unoccupied molecular orbital level (LUMO) and open-circuit voltage (VOC). In this paper, we turn to focus on engineering the outer side chains on the flanking thienothiophene units with 4-hexylphenyl (PhC6) and 6-phenylhexyl (C6Ph) chains. Use of PhC6 enhances the steric effect between the attached phenyl and the ending group, which in combination with the additional conjugation effect provided by the linking phenyl leads to upshifted energy levels and increased VOCas a result. Again, substitution with the bulkier PhC6 unprecedentedly improves film-morphology with reduced paracrystalline disorder and long period and increased root-mean-square composition variations as well, leading to increased electron and hole mobilities and suppressed monomolecular recombination with JSCand fill-factor (FF) simultaneously enhanced. The PM6:BTP-PhC6-based devices yield a higher efficiency value of 16.7% than the PM6:BTP-C6Ph-based one (15.5%). Therefore, this study shows a conceptual advance in materials design towards reducing the conflict between VOCand JSCin binary blended organic solar cells, which can be achieved by introducing bulkier chains to twist the backbone and simultaneously enhance the packing order.