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For environmentally friendly and cost-effective manufacturing of organic photovoltaic (OPV) cells, it is highly desirable to replace haloarenes with water as the active layer fabrication solvent. Replacing an organic solvent with water requires retooling the device fabrication steps. The optimization studies were conducted using poly(3-hexylthiophene) (P3HT) and [6,6]-phenyl C61 butyric acid methyl ester (PCBM) as active layer materials. These materials were dispersed in water as blend and separate nanoparticles using the miniemulsion method. Topologies of the active layers were investigated using atomic force microscopy and electron microscopy techniques. We have identified two essential steps to fabricate efficient OPVs from aqueous dispersions: (1) treatment of the hole-transport layer with UV-O3 to make the surface hydrophilic and (2) the use of an electron-transporting buffer layer for efficient charge extraction. We have also identified relative humidity and substrate temperature as key fabrication parameters for obtaining uniform active layer films. The OPV devices were fabricated using PEDOT:PSS as the hole-transport layer and PCBM as electron-transport layer with Ca/Al as the counter electrode. Efficiencies of 2.15% with a fill factor over 66% were obtained; the efficiency and the fill-factor is the highest among all aqueous processing of P3HT–PCBM nanoparticle solar cells.

Nanoparticles derived from π-conjugated polymers have gained widespread attention as active layer materials in various organic electronics applications. The optoelectronic, charge transfer, and charge transport properties of π-conjugated polymers are intimately connected to the polymer aggregate structure. Herein we show that the internal aggregate structure of regioregular poly(3-hexylthiophene) (P3HT) within polymer nanoparticles can be tuned by solvent composition during nanoparticle fabrication through the miniemulsion process. Using absorption spectra and single-NP photoluminescence decay properties, we show that a solvent mixture consisting of a low boiling good solvent and a high boiling marginal solvent results in polymer aggregate structure with a higher degree of uniformity and structural order. We find that the impact of solvent on the nature of P3HT aggregation within nanoparticles is different from what has been reported in thin films.

We address here the need for a general strategy to control molecular assembly over multiple length scales. Efficient organic photovoltaics require an active layer comprised of a mesoscale interconnected networks of nanoscale aggregates of semiconductors. We demonstrate a method, using principles of molecular self-assembly and geometric packing, for controlled assembly of semiconductors at the nanoscale and mesoscale. Nanoparticles of poly(3-hexylthiophene) (P3HT) or [6,6]-phenyl-C61-butyric acid methyl ester (PCBM) were fabricated with targeted sizes. Nanoparticles containing a blend of both P3HT and PCBM were also fabricated. The active layer morphology was tuned by the changing particle composition, particle radii, and the ratios of P3HT:PCBM particles. Photovoltaic devices were fabricated from these aqueous nanoparticle dispersions with comparable device performance to typical bulk-heterojunction devices. Our strategy opens a revolutionary pathway to study and tune the active layer morphology systematically while exercising control of the component assembly at multiple length scales.

Charge transport through a semiconducting nanoparticle assembly is demonstrated. The hole mobility of low and high molecular weight and regioreglular poly(3-hexylthiophene) (P3HT) nanoparticles is on the order of 2 × 10(-4) to 5 × 10(-4) cm(2) V(-1) s(-1) , which is comparable to drop-cast thin films of pristine P3HT. Various methods are employed to understand the nature and importance of the nanoparticle packing.