Methods for producing polymer gels, and uses thereof
View Patent ↗Embodiments of the invention include methods for producing polymer gels useful in the fabrication of organic cells. The method includes mixing poly(3-hexylthiophene) with phenyl-C61 butyric acid methyl ester and solvent to form a first solution, where the poly(3-hexylthiophene) includes at least some regioregular poly(3-hexylthiophene). The first solution is then cooled to a specified temperature to induce gelation to form an at least partially gelled solution that can be deposited onto a surface to form a coated surface. At least one or more steps of the method can occur as an extrusion process carried out in a twin-screw or single-screw extruder.
1. A method comprising the steps of:
i) at least partially mixing poly(3-hexylthiophene) with phenyl-C61 butyric acid methyl ester and at least one solvent to form a first solution which comprises said poly(3-hexylthiophene), said phenyl-C61 butyric acid methyl ester, and said at least one solvent, wherein said poly(3-hexylthiophene) includes at least some regioregular poly(3-hexylthiophene);
ii) cooling said first solution to a specified temperature to induce gelation of at least a portion of said first solution to form an at least partially gelled solution;
iii) depositing at least a portion of said at least partially gelled solution onto at least a portion of a surface to form an at least partially coated surface; and
iv) at least partially drying said at least partially coated surface by removing at least a portion of said at least one solvent from at least a portion of said at least partially coated surface.
2. The method of claim 1 , wherein said specified temperature is between −5° C. and −15° C.
3. The method of claim 1 , wherein at least one of step i) and step ii) is performed in an extruder.
4. The method of claim 3 , wherein said extruder is a twin-screw extruder.
5. The method of claim 1 , wherein step iii) is performed using one or more of a slit-die, a doctor-blade, or a blade-coater.
6. The method of claim 1 , wherein said surface of said at least a portion of a surface comprises an outer surface of a solar cell precursor material.
7. The method of claim 6 , wherein said solar cell precursor material comprises indium tin oxide.
8. The method of claim 1 , wherein said at least one solvent includes ortho-dichlorobenzene.
9. The method of claim 1 , further comprising a step of annealing said at least partially coated surface by passing said at least partially coated surface through an oven.
10. The method of claim 9 , wherein said oven is an environmentally-controlled oven configured to control temperature and humidity.
11. The method of claim 1 , wherein at least two or more of the steps i) to at least step iii) occur simultaneously.
12. The method of claim 1 , wherein said at least partially gelled solution includes a semi-crystalline gel network.
13. The method of claim 1 , wherein said at least partially gelled solution is a thermo-reversible gel.
14. The method of claim 1 , wherein said poly(3-hexylthiophene) includes at least some regiorandom poly(3-hexylthiophene).
15. An extrusion process comprising the steps of:
i) providing an extruder including at least one mixing zone;
ii) feeding poly(3-hexylthiophene), phenyl-C61 butyric acid methyl ester, and at least one solvent into said at least one mixing zone of said extruder, wherein said poly(3-hexylthiophene) includes at least some regioregular poly(3-hexylthiophene);
iii) operating said extruder to form a first solution which comprises said poly(3-hexylthiophene), said phenyl-C61 butyric acid methyl ester, and said at least one solvent;
iv) cooling said first solution to a specified temperature to induce gelation of at least a portion of said first solution to form an at least partially gelled solution;
v) depositing at least a portion of said at least partially gelled solution onto at least a portion of a surface to form an at least partially coated surface; and
vi) at least partially drying said at least partially coated surface by removing at least a portion of said at least one solvent from at least a portion of said at least partially coated surface.
16. The extrusion process of claim 15 , wherein step iv) occurs in said extruder.
17. The extrusion process of claim 15 , wherein step v) occurs by operating said extruder to force at least a portion of said solution out of said extruder and through a die.
18. The extrusion process of claim 17 , wherein said die includes one or more of a slit-die, a doctor-blade, or a blade-coater.
19. The extrusion process of claim 15 , wherein said extruder comprises a twin-screw extruder.
20. The extrusion process of claim 15 , wherein said poly(3-hexylthiophene) includes at least some regiorandom poly(3-hexylthiophene).