John R. Tumbleston

Continuous liquid interface production of 3D objects

Fast, continuous, 3D printing Although three-dimensional (3D) printing is now possible using relatively small and low-cost machines, it is still a fairly slow process. This is because 3D printers require a series of steps to cure, replenish, and reposition themselves for each additive cycle. Tumbleston et al. devised a process to effectively grow solid structures out of a liquid bath. The key to the process is the creation of an oxygen-containing “dead zone” between the solid part and the liquid precursor where solidification cannot occur. The precursor liquid is then renewed by the upward movement of the growing solid part. This approach made structures tens of centimeters in size that could contain features with a resolution below 100 µm. Science, this issue p. 1349 Solid parts are elevated from a liquid resin pool at a speed of hundreds of millimeters per hour. Additive manufacturing processes such as 3D printing use time-consuming, stepwise layer-by-layer approaches to object fabrication. We demonstrate the continuous generation of monolithic polymeric parts up to tens of centimeters in size with feature resolution below 100 micrometers. Continuous liquid interface production is achieved with an oxygen-permeable window below the ultraviolet image projection plane, which creates a “dead zone” (persistent liquid interface) where photopolymerization is inhibited between the window and the polymerizing part. We delineate critical control parameters and show that complex solid parts can be drawn out of the resin at rates of hundreds of millimeters per hour. These print speeds allow parts to be produced in minutes instead of hours.

Photonic Crystal Geometry for Organic Solar Cells

We report organic solar cells with a photonic crystal nanostructure embossed in the photoactive bulk heterojunction layer, a topography that exhibits a 3-fold enhancement of the absorption in specific regions of the solar spectrum in part through multiple excitation resonances. The photonic crystal geometry is fabricated using a materials-agnostic process called PRINT wherein highly ordered arrays of nanoscale features are readily made in a single processing step over wide areas (approximately 4 cm(2)) that is scalable. We show efficiency improvements of approximately 70% that result not only from greater absorption, but also from electrical enhancements. The methodology is generally applicable to organic solar cells and the experimental findings reported in our manuscript corroborate theoretical expectations.

Mobility-Controlled Performance of Thick Solar Cells Based on Fluorinated Copolymers

Developing novel materials and device architectures to further enhance the efficiency of polymer solar cells requires a fundamental understanding of the impact of chemical structures on photovoltaic properties. Given that device characteristics depend on many parameters, deriving structure-property relationships has been very challenging. Here we report that a single parameter, hole mobility, determines the fill factor of several hundred nanometer thick bulk heterojunction photovoltaic devices based on a series of copolymers with varying amount of fluorine substitution. We attribute the steady increase of hole mobility with fluorine content to changes in polymer molecular ordering. Importantly, all other parameters, including the efficiency of free charge generation and the coefficient of nongeminate recombination, are nearly identical. Our work emphasizes the need to achieve high mobility in combination with strongly suppressed charge recombination for the thick devices required by mass production technologies.

Controlling molecular weight of a high efficiency donor-acceptor conjugated polymer and understanding its significant impact on photovoltaic properties.

The molecular weight (MW) of PBnDT-FTAZ can be precisely controlled by adjusting the stoichiometric ratio of the two monomers, following the Carothers equation. The study of a set of PBnDT-FTAZ polymers with different MWs reveals that the MW significantly influences the morphology and structural order of PBnDTFTAZ in its bulk heterojunction solar cells, with the highest efficiency (over 7%) achieved with the use of a MW of 40 000 g mol(-1) .

Disentangling the impact of side chains and fluorine substituents of conjugated donor polymers on the performance of photovoltaic blends

Side chains and fluorine (F) substituents on conjugated polymers have shown significant impact on the photovoltaic properties of polymer-based bulk heterojunction (BHJ) solar cells, but their respective impact is largely studied independently. In order to disentangle the effect of side chains and F substituents, we comprehensively investigate a series of conjugated polymers with an identical backbone (PNDT–DTBT) but different combinations of side chains and F substituents. Surprisingly, these seemingly marginal changes to the polymer backbone strongly influence the morphology and structure in BHJ thin films (e.g., domain size/purity and the relative orientation of polymer crystallites), as manifested by resonant soft X-ray scattering (R-SoXS) and grazing-incidence wide-angle X-ray scattering (GI-WAXS), thereby exerting significant impact on the photovoltaic properties of these conjugated polymer-based BHJ cells. Devices based on the polymer with long bulky side chains and F substituents (C8,4-C6,2F) simultaneously exhibit large open circuit voltage (Voc), high short circuit current (Jsc) and good fill factor (FF), with an efficiency as high as 5.6% for this series of PNDT–DTBT polymers.

Importance of Domain Purity and Molecular Packing in Efficient Solution-Processed Small-Molecule Solar Cells

Connections are delineated between solar-cell performance, charge-carrier mobilities, and morphology in a highperformance molecular solar cell. The observations show that maximizing the relative phase purity and structural order while simultaneously limiting the domain size may be essential for achieving optimal solar-cell performances in solution-processed small-molecule solar cells .

On the role of intermixed phases in organic photovoltaic blends

Recently, an intermixed phase has been identified within organic photovoltaic (OPV) bulk heterojunction (BHJ) systems that can exist in addition to relatively phase-pure regions, highlighting the need for a refined picture of the solid-state microstructure of donor–acceptor blends and for gaining further understanding of the exact nature and role such intermixed phases play in such devices. Here we manipulate the microstructure of polymer–fullerene systems via processing means and the selection of the molecular weight of the donor polymer. This manipulation is used as a tool to vary the fraction of intermixed phase present and its effects on the structure and subsequently the opto-electronic processes. We find clear relationships between the state of mixing and amount of exciton quenching and number of polarons generated per absorbed photon. Furthermore, we observe that blend systems incorporating higher molecular weight polymer result in a greater yield of dissociated polarons, likely due to the increase of the intermixed fraction.

Absorption and quasiguided mode analysis of organic solar cells with photonic crystal photoactive layers

We analyze optical absorption enhancements and quasiguided mode properties of organic solar cells with highly ordered nanostructured photoactive layers comprised of the bulk heterojunction blend, poly-3-hexylthiophene/[6,6]-phenyl-C61-butyric acid methyl ester (P3HT:PCBM) and a low index of refraction conducting material (LICM). This photonic crystal geometry is capable of enhancing spectral absorption by approximately 17% in part due to the excitation of quasiguided modes near the band edge of P3HT:PCBM. A nanostructure thickness between 200 nm and 300 nm is determined to be optimal, while the LICM must have an index of refraction approximately 0.3 lower than P3HT:PCBM to produce absorption enhancements. Quasiguided modes that differ in lifetime by an order of magnitude are also identified and yield absorption that is concentrated in the P3HT:PCBM flash layer.

On the Efficiency of Charge Transfer State Splitting in Polymer:Fullerene Solar Cells

The field dependence and yield of free charge carrier generation in polymer:fullerene blends with varying energetic offsets is not affected when the excitation energy is varied from above band-gap to direct CT state excitation. Instead, the ability of the CT state to split is dictated by the energetic offset between the relaxed CT state and the charge separated (CS) state.

Electrophotonic enhancement of bulk heterojunction organic solar cells through photonic crystal photoactive layer

We present one- (1D) and two-dimensional (2D) periodic nanostructured designs for organic photovoltaics where a photonic crystal is formed between blended poly-3-hexylthiophene/[6,6]-phenyl-C61-butyric acid methyl ester (P3HT:PCBM) and nanocrystalline zinc oxide. Absorption enhancements over the full absorption range of P3HT:PCBM of 20% (one polarization) and 14% are shown for the 1D and 2D structures, respectively. These improvements result in part from band edge excitation of quasiguided modes. The geometries are also shown to create excitons 26% (1D) and 11% (2D) closer to P3HT:PCBM exit interfaces indicating further photovoltaic improvement.