Crystallization-sequence engineering enables organic solar cell modules with efficiencies exceeding 18%
Authors: CAI Yunhao, HUANG Hui
Organic solar cells (OSCs) offer mechanical flexibility, low density, and solution processability, enabling wearable electronics, portable energy systems, and building-integrated photovoltaics. Despite laboratory power conversion efficiencies (PCEs) exceeding 20%, scaling to large-area modules remains impeded by the thickness constraint of the photoactive layer. High-performance bulk heterojunction (BHJ) devices typically require active layers of 80–120 nm to ensure efficient exciton dissociation and charge extraction. Such thin films are incompatible with industrially relevant coating methods (blade coating, slot-die coating, printing) because minor thickness variations generate pinholes, shunts, and nonuniform electric fields, reducing manufacturing yield and operational reliability. Increasing thickness enhances light harvesting and processing tolerance but conventionally causes sharp PCE losses due to limited carrier mobility, trap-assisted recombination, and uncontrolled phase separation that disrupts percolation networks and vertical composition profiles. This fundamental contradiction between scalable fabrication and efficient operation demands kinetic control over film formation. The final BHJ morphology is governed not only by thermodynamics but also by the kinetic pathway during solvent removal. In conventional blends, donor and acceptor solidify simultaneously, freezing suboptimal morphologies, especially in thick films. Crystallization-sequence engineering—manipulating the temporal order of crystallization and phase separation—offers a route to reshape the internal structure. The referenced study (Chen et al., Nat. Mater. 2025, 24(3): 444) demonstrates that such manipulation yields OSCs with 20.82% efficiency and high tolerance to active layer thickness, and the present work extends this strategy to modules exceeding 18% efficiency, bridging the gap between laboratory performance and industrial-scale manufacturing.