The embodiments discussed herein are related to a photoelectric conversion device and a fabrication method therefor.
In an organic thin film type solar cell, a photoelectric conversion layer configured from a combination of a p-type organic semiconductor polymer and an n-type organic semiconductor whose example is fullerene is used such that charge separation is performed when an exciton generated by incident light reaches a boundary between the p-type organic semiconductor polymer and the n-type organic semiconductor.
In such an organic thin film type solar cell as just described, a bulk heterojunction (BHJ) type photoelectric conversion layer is frequently used. This is referred to as bulk heterojunction type organic thin film type solar cell.
A bulk heterojunction type photoelectric conversion layer is formed by applying mixed solution, which consists of a p-type organic semiconductor polymer, an n-type organic semiconductor and suitable solvent, and drying the mixed solution. Then, during the course of drying the mixed solution, the p-type organic semiconductor material and the n-type organic semiconductor material individually aggregate spontaneously to cause phase separation, and as a result, a pn junction having a great specific surface area is formed.
It is to be noted that a technology is available wherein a p-type organic semiconductor material and an n-type organic semiconductor material have a double-layered structure or a p-type organic semiconductor material and an n-type organic semiconductor material are structured so as to have a complicated interface therebetween in order to enhance the fill factor to enhance the photoelectric conversion efficiency.
Further, research is being carried out to seek an ideal structure using a numerical simulation in order to enhance the short-circuit current density to enhance the photoelectric conversion efficiency. As an example, also a structure that exhibits superiority is available wherein pillars of a p-type organic semiconductor material and pillars of an n-type organic semiconductor material individually having a width on the order of nanometers are formed perpendicularly to a film plane of a photoelectric conversion film and juxtaposed alternately so as to form a checkered pattern in an in-plane direction.
Further, a technology is available wherein a crystalline organic semiconductor material whose transportability of carriers in the inside thereof enhances by crystallization is used for at least one of a p-type organic semiconductor material and an n-type organic semiconductor material in order to enhance the transportability of carriers to enhance the photoelectric conversion efficiency.
A photoelectric conversion device includes a positive electrode, a negative electrode, and a photoelectric conversion layer including a p-type organic semiconductor material and an n-type organic semiconductor material that configure a bulk heterojunction, including an amorphous polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main chain as the p-type organic semiconductor material, and including an amorphous fullerene derivative as the n-type organic semiconductor material, wherein the photoelectric conversion layer has a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile.
A fabrication method for a photoelectric conversion device includes applying and drying mixed liquid including an amorphous polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main chain as a p-type organic semiconductor material and an amorphous fullerene derivative as an n-type organic semiconductor material, the p-type organic semiconductor material and the n-type organic semiconductor material configuring a bulk heterojunction, exposing the dried substance into an atmosphere including vapor of a solvent that preferentially dissolves the n-type organic semiconductor material rather than the p-type organic semiconductor material, and forming a photoelectric conversion layer having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention.
Incidentally, in an organic thin film type solar cell, a high photoelectric conversion efficiency is obtained in a low-illuminance indoor light environment. Therefore, organic thin film type solar cells can coexist well together with Si solar cells, which form a mainstream of solar cells at present, and have high future prospects.
However, in order to obtain a high photoelectric conversion efficiency in a low-illuminance indoor light environment, it is preferable to raise the light absorption efficiency using a photoelectric conversion layer having a great thickness. On the other hand, if only the film thickness of the photoelectric conversion layer is increased simply, the photoelectric conversion efficiency drops by a drop of the fill factor (FF) especially in a high-illuminance solar light environment. Therefore, it is difficult to obtain a high photoelectric conversion efficiency in both of a low-illuminance indoor light environment (low-illuminance condition) and a high-illuminance solar light environment (high-illuminance condition).
Therefore, it is demanded to obtain a high photoelectric conversion efficiency in both of a low-illuminance indoor light environment (low-illuminance condition) and a high-illuminance solar light environment (high-illuminance condition).
In the following, a photoelectric conversion device and a fabrication method therefor according to an embodiment are described with reference to
The photoelectric conversion device according to the present embodiment is used, for example, as an organic thin film solar cell, particularly, a bulk heterojunction type organic thin film solar cell. Since such a bulk heterojunction type organic thin film solar cell as just described can be fabricated in a printing process, the fabrication cost can be decreased significantly in principle in comparison with a solar cell that forms a mainstream of solar cells at present and in which an inorganic semiconductor is used by stacking in a vacuum process.
As depicted in
Here, the substrate 1 is a transparent substrate that transmits incident light therethrough and is, for example, a glass substrate.
The positive electrode 2 is a transparent electrode that is provided on the substrate 1 and transmits incident light therethrough, and is, for example, an ITO (Indium Tin Oxide) electrode.
The positive electrode side buffer layer 3 is provided on the positive electrode 2, namely, between the positive electrode 2 and the photoelectric conversion layer 4, and functions as a hole transportation layer. It is to be noted that the positive electrode side buffer layer 3 is referred to also as p-type buffer layer. The positive electrode side buffer layer 3 may be configured so as to include a material in which the energy of the lowest unoccupied molecular orbital (LUMO) is shallower than that of the n-type organic semiconductor material that configures the bulk heterojunction of the photoelectric conversion layer 4 (namely, is near to the vacuum level) and energy of the highest occupied molecular orbital (HOMO) is shallower than that of the p-type organic semiconductor material that configures the bulk heterojunction of the photoelectric conversion layer 4. Here, the positive electrode side buffer layer 3 is a layer including, for example, MoO3, namely, a layer including molybdenum oxide (VI). It is to be noted that the positive electrode side buffer layer 3 may not be provided. However, where the positive electrode side buffer layer 3 is provided, a more superior characteristic such as, for example, enhancement of the short-circuit current density is obtained.
The photoelectric conversion layer 4 is provided on the positive electrode side buffer layer 3. In particular, the photoelectric conversion layer 4 is provided between the positive electrode side buffer layer 3 and the negative electrode side buffer layer 5.
The negative electrode side buffer layer 5 is provided on the photoelectric conversion layer 4, namely, between the photoelectric conversion layer 4 and the negative electrode 6, and functions as an electron transport layer. It is to be noted that the negative electrode side buffer layer 5 is referred to also as n-type buffer layer. The negative electrode side buffer layer 5 may be configured so as to include a material in which the energy of the highest occupied molecular orbital is deeper than that of the p-type organic semiconductor material that configures the bulk heterojunction of the photoelectric conversion layer 4 (namely, is far from the vacuum level) and energy of the lowest occupied molecular orbital is deeper than that of the n-type organic semiconductor material that configures the bulk heterojunction of the photoelectric conversion layer 4. Here, the negative electrode side buffer layer 5 is a layer including, for example, TiOx. It is to be noted that the negative electrode side buffer layer 5 may not be provided. However, where the negative electrode side buffer layer 5 is provided, a more superior characteristic such as, for example, enhancement of the short-circuit current density is obtained.
It is to be noted that a hole block layer may be provided in place of the negative electrode side buffer layer 5. In particular, a hole block layer may be provided between the photoelectric conversion layer 4 and the negative electrode 6. For example, the hole block layer may be configured from a layer including lithium fluoride. It is to be noted that the hole block layer is referred to also as insulating hole block layer. While the hole block layer may not be provided, by providing the hole block layer, a more superior characteristic such as, for example, enhancement of the short-circuit current density or the fill factor (FF) is obtained.
The negative electrode 6 is a metal electrode provided on the negative electrode side buffer layer 5 and is, for example, an aluminum electrode.
In the present embodiment, the photoelectric conversion layer 4 is a bulk heterojunction type photoelectric conversion layer that includes a p-type organic semiconductor material 4A and an n-type organic semiconductor material 4B that configure a bulk heterojunction, includes an amorphous (non-crystalline) polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main chain as the p-type organic semiconductor material 4A, and includes an amorphous (non-crystalline) fullerene derivative as the n-type organic semiconductor material 4B.
Especially, it is preferable to configure the photoelectric conversion layer 4 so as to include, as the amorphous p-type organic semiconductor material 4A in a non-crystalized state (amorphous state), poly-[N-9′-heptadecanyl-2,7-carbazole-alt-5,5-(4′,7′-di-2-thienyl-2′,1′,3′-benzothiadiazole) (hereinafter referred to as PCDTBT) represented by the chemical formula (1) given below and include, as the amorphous n-type organic semiconductor material 4A in a non-crystalized state (amorphous state), any one or a mixture (which are hereinafter referred to as PCBM) of [6,6]-phenyl-C71 butyric acid methyl ester (PC71BM produced from C70) represented by the chemical formula (2) given below, [6,6]-phenyl-C61 butyric acid methyl ester (PC61BM produced from C60) represented by the chemical formula (3) given below and [6,6]-Phenyl-C85 butyric acid methyl ester (PC85BM produced from C84) represented by the chemical formula (4) given below. In this case, the photoelectric conversion layer 4 is configured from a mixture of an amorphous PCDTBT and an amorphous PCBM. Here, the reason why a PCDTBT is included as the p-type organic semiconductor material 4A is that the energy level of the highest occupied molecular orbital is comparatively low and a high open voltage is easily obtained. Further, the reason why a PCBM is included as the n-type organic semiconductor material 4B is that it is soluble in various organic solvents.
It is to be noted that the photoelectric conversion layer 4 may include, as the amorphous p-type organic semiconductor material 4A in a non-crystalized state, an amorphous polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main chain. Since an amorphous polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring is a main chain is likely to twist at portions in the front and rear of the rings and the main chain twists spontaneously, the amorphous polymer compound is low in planarity and less likely to form a lamella structure and therefore is liable to cause degradation in crystallinity and is not very high in crystallinity. Such an amorphous polymer compound that is low in trend to spontaneously form crystal as just described may be used for the p-type organic semiconductor material 4A. The reason why such a material having low crystallinity as described above is used is that it is difficult for a material having high crystallinity to cooperate with such an n-type organic semiconductor material 4B as hereinafter described to form a fine stacked structure on the order of nanometers. On the other hand, different from a crystalline p-type organic semiconductor material that forms crystal, an amorphous polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main chain has a conductivity also in a main chain direction. Therefore, even if the crystallinity is low, the transportation of carriers is maintained, and consequently, the amorphous polymer compound can be used as the p-type organic semiconductor material 4A of the photoelectric conversion layer 4.
In particular, the photoelectric conversion layer 4 may include, as the amorphous p-type organic semiconductor material 4A in a non-crystalized state, any one material selected from the group consisting of poly-[N-9′-heptadecanyl-2,7-carbazole-alt-5,5-(4′,7′-di-2-thienyl-2′,1′,3′-benzothiadiazole)], poly-[(9,9-dioctylfluorenyl-2,7-diyl)-alt-co-(1,4-benzo-{2,1′,3 }-thiadiazole)] represented by the chemical formula (5) given below, poly[(9,9-dihexylfluoreny-2,7-diyl)-alt-co-(bithophene)] represented by the chemical formula (6) given below, poly[2,6-(4,4-bis-(2-ethylhexyl)-4H-cyclopenta[2,1-b;3,4-b′]-dithiophene)-alt-4,7-(2,1,3-benzothiadiazole)] represented by the chemical formula (7) given below, poly[2,7-(9-(2′-ethykhexyl)-9-hexyl-fluorene)-alt-5,5-(4′-7′-di-2-thienyl-2′,1′,3′-benzothiadiazole] represented by the chemical formula (8) given below, and poly[2,7-(9,9)-dioctylfluorene]-alt-5,5-(4′,7′-di-2-thienyl-2′,1′,3′-benzothiadiazole) represented by the chemical formula (9) given below. It is to be noted that the p-type organic semiconductor material 4A is hereinafter referred to also as p-type polymer compound or p-type polymer material.
Further, the photoelectric conversion layer 4 may be configured so as to include, as the amorphous n-type organic semiconductor material 4B in a non-crystalized state, an amorphous fullerene derivative soluble in an organic solvent and compatible with the p-type organic semiconductor material 4A. It is to be noted that, although the fullerene derivative can be crystalized in a single substance by performing heat treatment at a high temperature (for example, such a temperature as exceeds 100° C.), it does not crystalize and remains amorphous when it coexists with the p-type organic semiconductor material 4A and besides heat treatment at a high temperature is not performed when to form the photoelectric conversion layer 4 as in an example hereinafter described.
In particular, the photoelectric conversion layer 4 may include, as the amorphous n-type organic semiconductor material 4B in a non-crystalized state, any one material selected from the group consisting of [6,6]-phenyl-C71 butyric acid methyl ester, [6,6]-phenyl-C61 butyric acid methyl ester, [6,6]-Phenyl-C85butyric acid methyl ester, indene-C60bisadduct (ICBA) represented by the chemical formula (10) given below, [6,6]diphenyl C62bis(butyric acid methyl ester) represented by the chemical formula (11) given below, [6,6]diphenyl C72bis(butyric acid methyl ester), [6,6]-phenyl-C61 butyric acid (3-ethylthiophene) ester presented by the chemical formula (12) given below, 1-(3-methoxycarbonyl) propyl-1-thienyl-6,6-methanofullerene (ThCBM) represented by the chemical formula (13) given below, and [6,6]-phenyl-C61 butyric acid (2,5-dibromo-3-ethylthiophene) ester represented by the chemical formula (14) given below.
Further, in the present embodiment, the photoelectric conversion layer 4 has an n-type organic semiconductor region 4X in which the non-crystalized amorphous n-type organic semiconductor material 4B is a main constituent and a p-type organic semiconductor region 4Y in which the non-crystalized amorphous p-type organic semiconductor material 4A is a main constituent, and the p-type organic semiconductor region 4Y is formed so as to fill up a gap of the n-type organic semiconductor region 4X. It is to be noted that the n-type organic semiconductor region 4X in which the n-type organic semiconductor material 4B is a main constituent is referred to also as n-type organic semiconductor material domain. Further, the p-type organic semiconductor region 4Y in which the p-type organic semiconductor material 4A is a main constituent is referred to also as p-type organic semiconductor material domain. In the n-type organic semiconductor region 4X, the n-type organic semiconductor material 4B has a substantially spherical aggregate shape. Meanwhile, the p-type organic semiconductor region 4Y has a stacked structure 4Z in which the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A are stacked alternately. In the photoelectric conversion layer 4 having such a stacked structure 4Z as just described, the non-crystalized amorphous n-type organic semiconductor material 4B and the non-crystalized amorphous p-type organic semiconductor material 4A configure a bulk heterojunction. It is to be noted that such a stacked structure 4Z as described above is referred to also as periodically ordered structure or fine stacked structure.
In particular, the photoelectric conversion layer 4 in the present embodiment has, in the inside thereof, a fine structure in which phase separation between the p-type organic semiconductor material 4A and the n-type organic semiconductor material 4B has proceeded.
Especially, the photoelectric conversion layer 4 in the present embodiment has the stacked structure 4Z in which the layered n-type organic semiconductor material 4B penetrates in the inside of the photoelectric conversion layer 4, namely, the inside of the p-type organic semiconductor region 4Y. In particular, the photoelectric conversion layer 4 in the present embodiment has the stacked structure 4Z in which the layered n-type organic semiconductor material 4B is inserted in a matrix of the p-type organic semiconductor material 4A. In this case, since charge separation occurs also in the p-type organic semiconductor region 4Y, the charge separation efficiency enhances. Consequently, not only the short-circuit current density but also the photoelectric conversion efficiency enhances. Especially, the charge separation efficiency in a low-illuminance indoor light environment (low-illuminance condition) in which the density of excitons and charge generated in the inside of the photoelectric conversion layer 4 is low enhances. Consequently, not only the short-circuit current density but also the photoelectric conversion efficiency enhances.
Further, in the n-type organic semiconductor region 4X of the photoelectric conversion layer 4 in the present embodiment, molecules of the n-type organic semiconductor material 4B in the inside thereof are arranged in accordance with a high regularity, and a state in which electrons are more likely to move is established. Meanwhile, in the p-type organic semiconductor region 4Y, electrons can pass through the layered n-type organic semiconductor material 4B and reach the n-type organic semiconductor region 4X. Therefore, the transportability of electrons in the inside of the photoelectric conversion layer 4 enhances. On the other hand, while the p-type organic semiconductor region 4Y has the stacked structure 4Z, since the p-type organic semiconductor material 4A exists by an overwhelmingly large amount, portions of the p-type organic semiconductor material 4A contact sufficiently with each other. Therefore, in comparison with an alternative p-type organic semiconductor region that has a structure in which the p-type organic semiconductor material 4A and the n-type organic semiconductor material 4B are jumbled disorderly, namely, does not have the stacked structure 4Z, the movability of holes in the inside of the photoelectric conversion layer 4 differs little, and the transportability of holes is secured. In this manner, in comparison with a p-type organic semiconductor region that does not have the stacked structure 4Z, the routes along which electrons and holes move to the negative electrode 6 and the positive electrode 2 are simplified and the probability with which electrons and holes are recombined with each other can be decreased. Especially, recombination of carriers generated by a great amount in a high-illuminance solar light environment (high-illuminance condition) can be prevented. Therefore, also where the film thickness of the photoelectric conversion layer 4 is made comparatively great in order to obtain a high photoelectric conversion efficiency in a low-illuminance indoor light environment, the fill factor in a high-illuminance solar light environment can be improved. Consequently, the photoelectric conversion efficiency can be enhanced. As a result, a high photoelectric conversion efficiency can be obtained in both of a low-illuminance indoor light environment and a high-illuminance solar light environment.
In this manner, since the photoelectric conversion layer 4 of the present embodiment uses an amorphous material for both of the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A, in comparison with an alternative case in which a crystalline material is used and crystalized as described in an example hereinafter described, the photoelectric conversion layer 4 can be formed at a low temperature such as, for example, a room temperature. Therefore, growth of the domain structure in the organic semiconductor materials 4A and 4B is reduced and mixture of the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A along the interface between them on the level of molecules is promoted, and the stacked structure 4Z is formed by an interaction among molecules. Consequently, the transportability of the carriers enhances and the charge separation efficiency and the photoelectric conversion efficiency enhance.
Here, the stacked structure 4Z provided in the photoelectric conversion layer 4 described above does not have any of materials of the amorphous n-type organic semiconductor material 4B and the amorphous p-type organic semiconductor material 4A as simple substances.
Therefore, the photoelectric conversion layer 4 that has the stacked structure 4Z described above has a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile as described in detail in the description of an example given hereinbelow. In particular, a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile appears arising from the stacked structure 4Z that is provided in the p-type organic semiconductor region 4Y of the photoelectric conversion layer 4 and in which the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A are stacked alternately. Therefore, the diffraction peak corresponding to the plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile is a diffraction peak arising from the stacked structure 4Z in which the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A are stacked alternately.
Further, the photoelectric conversion layer 4 having the n-type organic semiconductor region 4X in which molecules of the n-type organic semiconductor material 4B described above are arranged with a high regularity has, in the X-ray diffraction profile, a diffraction peak between a diffraction peak corresponding to a (111) plane and a different diffraction peak corresponding to a (11-1) plane in an X-ray diffraction profile of a simple substance of the n-type organic semiconductor material 4B as described in detail in the description of an example given hereinbelow.
Incidentally, the photoelectric conversion layer 4 having such a configuration as described above can be obtained in the following manner.
In particular, mixed liquid (mixed solution) is applied and dried first which includes an amorphous polymer compound including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main as the p-type organic semiconductor material 4A and an amorphous fullerene derivative as the n-type organic semiconductor material 4B, the p-type organic semiconductor material 4A and the n-type organic semiconductor material 4B configuring a bulk heterojunction.
Then, the intermediate product is exposed in an atmosphere including vapor of a solvent (here, an organic solvent) that preferentially dissolves the n-type organic semiconductor material 4B rather than the p-type organic semiconductor material 4A. In particular, vapor process (organic solvent vapor process) for causing vapor of a solvent that preferentially dissolves the n-type organic semiconductor material 4B rather than the p-type organic semiconductor material 4A to act on the intermediate product is performed for the intermediate product. Here, as the solvent for the vapor process (here, an organic solvent), a solvent may be used which is high in solubility of the n-type organic semiconductor material 4B and is low in solubility of the p-type organic semiconductor material 4A in comparison with the solubility of the n-type organic semiconductor material 4B. For example, dichloromethane or chloroform may be used, and especially, it is preferable to use dichloromethane.
The photoelectric conversion layer 4 having such a stacked structure 4Z as described above, namely, the photoelectric conversion layer 4 having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile, is obtained in this manner. Further, the photoelectric conversion layer 4 having the n-type organic semiconductor region 4X in which molecules of the n-type organic semiconductor material 4B described above are arranged with a high regularity, namely, the photoelectric conversion layer 4 having, in an X-ray diffraction profile, a diffraction peak between a diffraction peak corresponding to a (111) plane and another diffraction peak corresponding to a (11-1) plane in an X-ray diffraction profile of a simple substance of the n-type organic semiconductor material 4B, is obtained.
A process capable of obtaining the photoelectric conversion layer 4 having such a configuration as described above by performing the vapor process described above is further described.
First, before the vapor process described above is performed, a mixture solid of the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A (namely, a photoelectric conversion layer for which the vapor process described above is not performed) has a bulk heterojunction structure having a low structure regularity as depicted in
On the other hand, by performing the vapor process described above, molecules of a solvent (here, an organic solvent) that preferentially dissolves the n-type organic semiconductor material 4B rather than the p-type organic semiconductor material 4A penetrate the mixture solid of the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A. As a result, movement of the molecules of the n-type organic semiconductor material 4B becomes easy. Consequently, the photoelectric conversion layer 4 having such a configuration as described above, namely, the photoelectric conversion layer 4 having the stacked structure 4Z described above and having the n-type organic semiconductor region 4X in which molecules of the n-type organic semiconductor material 4B described above are arranged with a high regularity as depicted in
In particular, if molecules of a solvent (here, an organic solvent) that preferentially dissolves the n-type organic semiconductor material 4B rather than the p-type organic semiconductor material 4A penetrate the mixture solid of the n-type organic semiconductor material 4B and the p-type organic semiconductor material 4A, then the n-type organic semiconductor material 4B is dissolved and discharged from a matrix formed by the p-type organic semiconductor material 4A. As a result, the n-type organic semiconductor material 4B aggregates itself in order to minimize the surface energy thereby to form the n-type organic semiconductor region 4X (n-type domain). Here,
While the formation of the phase separation structure progresses in such a manner as described above, not all of the n-type organic semiconductor material 4B fetched in the matrix of the p-type organic semiconductor material 4A aggregate to the n-type organic semiconductor region 4X but a small amount of the n-type organic semiconductor materials 4B remains in the matrix of the p-type organic semiconductor material 4A. Then, the small amount of the n-type organic semiconductor materials 4B remaining in the matrix of the p-type organic semiconductor material 4A moves so that the potential energy thereof is minimized until a regular arrangement is formed. At this time, since molecules of the solvent (here, organic solvent) that preferentially dissolves the n-type organic semiconductor material 4B rather than the p-type organic semiconductor material 4A are weak in dissolution action on the p-type organic semiconductor material 4A, the p-type organic semiconductor material 4A are not movable by a great distance. Therefore, growth of the arrangement structure of the n-type organic semiconductor material 4B is restricted so that it progresses in such a direction and with such a size that the movement amount of the p-type organic semiconductor material 4A may be minimum.
As a result, the photoelectric conversion layer 4 having such a configuration as described above, namely, the photoelectric conversion layer 4 having the stacked structure 4Z described above and besides having the n-type organic semiconductor region 4X in which molecules of the n-type organic semiconductor material 4B described above are arranged with a high regularity as depicted in
Now, a fabrication method for the photoelectric conversion device according to the present embodiment is described in detail.
First, a positive electrode 2 (transparent electrode) is formed on a substrate 1 (transparent substrate).
Then, a positive electrode side buffer layer (here, a layer including MoO3) 3 is formed on the positive electrode 2.
Then, a photoelectric conversion layer 4 is formed on the positive electrode side buffer layer 3.
In particular, mixed liquid that includes an amorphous polymer compound (here, PCDTBT) including a carbazole ring, a fluorene ring or a cyclopentadithiopene ring in a main chain as the p-type organic semiconductor material 4A and includes an amorphous fullerene derivative (here, PCBM) as the n-type organic semiconductor material 4B is applied (applying step), and the resulting intermediate product is dried at a temperature, for example, lower than approximately 60° C. (preferably, at a room temperature of approximately 25° C.) (drying step).
Then, the intermediate product (the dried substance) is exposed in an atmosphere including vapor of a solvent that preferentially dissolves the n-type organic semiconductor material 4B rather than the p-type organic semiconductor material 4A (here, dichloromethane as an organic solvent). The process just described is called vapor process, organic solvent vapor process or dichloromethane process.
As a result, a photoelectric conversion layer 4 having such a stacked structure 4Z as described above, namely, a photoelectric conversion layer 4 having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile, is obtained. Further, the photoelectric conversion layer 4 having the n-type organic semiconductor region 4X in which molecules of the n-type organic semiconductor material 4B are arranged with a high regularity, namely, the photoelectric conversion layer 4 having, in an X-ray diffraction profile, a diffraction peak between a diffraction peak corresponding to a (111) plane and another diffraction peak corresponding to a (11-1) plane in an X-ray diffraction profile of a simple substance of the n-type organic semiconductor material 4B, is obtained.
It is to be noted here that, while the photoelectric conversion layer 4 having such a stacked structure 4Z as described above, namely, the photoelectric conversion layer 4 having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in the X-ray diffraction profile, is obtained by performing the vapor process after the intermediate product is dried at a temperature, for example, lower than approximately 60° C. (preferably, at a room temperature of approximately 25° C.), the method for obtaining the photoelectric conversion layer 4 is not limited to this. In particular, although the vapor process here is performed after the intermediate product is dried, for example, at a temperature lower than approximately 60° C. (preferably, at room temperature of approximately 25° C.) in order that such a stacked structure 4Z as described above is developed and a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm appears conspicuously in an X-ray diffraction profile, the method for obtaining the photoelectric conversion layer 4 is not limited to this. For example, even if the photoelectric conversion layer 4 is formed by drying the intermediate product at a temperature, for example, lower than approximately 60° C. (preferably, at a room temperature of approximately 25° C.) but without performing the vapor process, the photoelectric conversion layer 4 having such a stacked structure 4Z as described above, namely, the photoelectric conversion layer 4 having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile, can be obtained. However, in order to develop such a stacked structure 4Z as described above so that a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm may appear conspicuously in an X-ray diffraction profile, it is preferable to further perform the vapor process. In contrast, if the photoelectric conversion layer is formed by drying the intermediate product at a temperature equal to or higher than approximately 60° C. but without performing the vapor process, then it is difficult to obtain the photoelectric conversion layer 4 having such a stacked structure 4Z as described above, namely, the photoelectric conversion layer 4 having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile. This is because, where the intermediate product is dried at a temperature equal to or higher than approximately 60° C., it is difficult to obtain the photoelectric conversion layer 4 having such a stacked structure 4Z as described above, namely, the photoelectric conversion layer 4 having a diffraction peak corresponding to a plane spacing d=1.6 nm to 2.0 nm in an X-ray diffraction profile.
Then, a hole block layer (here, a layer including lithium fluoride) that functions also as the negative electrode side buffer layer 5 is formed on the photoelectric conversion layer 4.
Thereafter, a negative electrode 6 (metal electrode) is formed on the hole block layer 5.
Then, the intermediate product is encapsulated, for example, in a nitrogen atmosphere, and a photoelectric conversion device is completed thereby.
Accordingly, with the photoelectric conversion device and the fabrication method therefor according to the present embodiment, there is an advantage that a high photoelectric conversion efficiency is obtained in both of a low-illuminance indoor light environment (low-illuminance condition) and a high-illuminance solar light environment (high-illuminance condition). Further, with the fabrication method for the photoelectric conversion device according to the present embodiment, a photoelectric conversion device with which a high photoelectric conversion efficiency is obtained in both of a low-illuminance indoor light environment and a high-illuminance solar light environment can be fabricated easily.
It is to be noted that the present invention is not limited to the embodiment specifically described above, and variations and modifications can be made without departing from the spirit and scope of the present invention.
For example, while, in the embodiment described above, the drying step (drying process) is performed after the applying step (applying process), the present invention is not limited to this, and, for example, the applying step and the drying step may be performed in parallel by a single step. In particular, while, in the embodiment described above, the applied mixed liquid is dried in the step after the mixed liquid is applied, for example, applying and drying of mixed liquid may be performed in parallel by a single step.
Further, while the embodiment described above is described taking a case in which a photoelectric conversion device is used for an organic thin film type solar cell as an example, the embodiment is not limited to this, and, for example, a photoelectric conversion device can be used for a sensor of an image apparatus such as a camera.
In the following, the embodiment is described in more detail in connection with an example. It is to be noted that the present invention is not limited by the example described below.
In the present example, the photoelectric conversion device was fabricated in the following manner.
First, an ITO electrode (positive electrode) having a width of approximately 2 mm and a film thickness of approximately 200 nm was formed on a glass substrate.
Then, a MoO3 layer (positive electrode side buffer layer) having a thickness of approximately 6 nm was formed by vacuum deposition on the overall area of the ITO electrode as the positive electrode.
Then, the glass substrate on which the ITO electrode and the MoO3 layer were formed was placed into a globe box in which nitrogen was filled. Then, a film of monochlorobenzene solution (mixed solution; density: approximately 2% by weight) including the PCDTBT as the p-type organic semiconductor material and the PCBM (here, [6,6]-phenyl-C71 butyric acid methyl ester; hereinafter referred to as PC71BM) as the n-type organic semiconductor material by a weight ratio of 1:3 was formed, at approximately 25° C. (room temperature), by spin coating under a condition of approximately 500 rpm. Then, the resulting intermediate product was dried.
Thereafter, at approximately 25° C., the dried intermediate product was left (exposed) in a saturation atmosphere including vapor of dichloromethane as a solvent that preferentially dissolves the n-type organic semiconductor material rather than the p-type organic semiconductor material.
In short, a dichloromethane process (vapor process) was performed.
A photoelectric conversion layer having a thickness of approximately 80 nm was formed in this manner.
Then, a lithium fluoride (hole block layer) having a thickness of approximately 1 nm was formed on the photoelectric conversion layer formed and exposed in such a manner as described above without performing heat treatment.
Thereafter, an aluminum electrode (negative electrode) having a width of approximately 2 nm and a thickness of approximately 150 nm was formed by vacuum deposition on the lithium fluoride layer as the hole block layer.
Then, the intermediate product was encapsulated in a nitrogen atmosphere to fabricate a photoelectric conversion device.
Here, a plurality of photoelectric conversion devices (samples; film thickness of the photoelectric conversion layer: approximately 80 nm; subjected to the drying process at approximately 25° C.) were fabricated changing the time period (dichloromethane processing time period) within which the intermediate product was to be left in a dichloromethane saturation atmosphere. The photoelectric conversion devices just described are hereinafter referred to as samples of an example 1. Further, a photoelectric conversion device was manufacture similarly to the samples of the example 1 described above but without performing the dichloromethane process. The photoelectric conversion device just described is hereinafter referred to as sample of an example 2. Further, a photoelectric conversion device in which the thickness of the photoelectric conversion layer was changed from that of the samples of the example 1 and set to approximately 170 nm, namely, a photoelectric conversion device in which the thickness of the photoelectric conversion layer was set to approximately 170 nm and for which the dichloromethane process was performed for approximately two minutes, was fabricated. The photoelectric conversion device just described is hereinafter referred to as sample of an example 3. Further, also a photoelectric conversion device in which the thickness of the photoelectric conversion layer was changed from that of the sample of the example 2 and set to approximately 170 nm, namely, a photoelectric conversion device in which the thickness of the photoelectric conversion layer was set to approximately 170 nm and for which the dichloromethane process was not performed, was fabricated. The photoelectric conversion device just described is hereinafter referred to as sample of an example 4. Further, a photoelectric conversion device was produced by performing the drying process at approximately 60° C. in place of the drying process at approximately 25° C. but without performing the dichloromethane process similarly to the samples of the example 1 described above. The photoelectric conversion device just described is hereinafter referred to as sample of a comparative example 1.
Here,
As depicted in
Further,
In the mapping image depicted in
In contrast,
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Further,
In contrast,
The STEM image depicted in
Further,
It is to be noted here that the X-ray diffraction profiles are those obtained by scanning by a detector in an in-plane direction of the sample (namely, in a direction parallel to a film surface) at an incidence position of a very small angle and measuring a lattice plane perpendicular to the surface, and the wavelength of the X-ray is 1.54 Å and corresponds to CuKα. Further, since the film thickness of the photoelectric conversion layers of the samples has a variation, the X-ray diffraction profiles are in a state standardized with the thickness. Thus, the axis of ordinate of
Further, while both of the X-ray diffraction profiles with regard to simple films of the PCDTBT and the PC71BM individually have a diffraction peak as indicated by the solid line D and E in
Particularly, as indicated by the solid lines A and B in
Here,
As depicted in
On the other hand, as indicated by the solid line C in
In this manner, while, in the sample of the comparative example 1, a peak little exists at 2θ=4° to 5°, namely, at the plane spacing d=1.6 nm to 2.0 nm, in the sample of the example 2, a peak exists at 2θ=4 to 5°, namely, at the plane spacing d=1.6 nm to 2.0 nm as indicated by the solid line B in
Then, the peak existing at 2θ=4° to 5°, namely, at the plane spacing d=1.6 nm to 2.0 nm, in the sample of the example 2 is observed more intensely and clearly on the samples of the example 1. In particular, by performing the drying process at approximately 25° C. and further performing the dichloromethane process, the peak appearing at 2θ=4 to 5°, namely, at the peak appearing in the plane spacing d=1.6 nm to 2.0 nm, appears more intensely and clearly. This indicates that, by performing the drying process, for example, at a lower temperature than approximately 60° C. and further performing the dichloromethane process (vapor process), the stacked structure described above is developed.
Further, as indicated by the solid lines A and B in
Further,
As depicted in
As depicted in
As depicted in
By performing the dichloromethane process for two minutes in this manner, the short-circuit current density (Jsc) and the fill factor (FF) enhanced in both of a high-illuminance condition and a low-illuminance condition, and as a result, the photoelectric conversion efficiency enhanced.
Further,
As depicted in
As depicted in
In this manner, by performing the dichloromethane process for two minutes, also where the thickness of the photoelectric conversion layer was increased, the short-circuit current density (Jsc) and the fill factor (FF) enhanced in both of a high-illuminance condition and a low-illuminance condition, and as a result, the photoelectric conversion efficiency enhanced.
Further,
As depicted in
As depicted in
In this manner, even if the thickness of the photoelectric conversion layer was increased, the short-circuit current density (Jsc) enhanced without a drop of the fill factor (FF) under both of a high-illuminance condition and a low-illuminance condition, and as a result, the photoelectric conversion efficiency enhanced.
All examples and conditional language provided herein are intended for the pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although one or more embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
This application is a continuation application of International Application PCT/JP2012/076930 filed on Oct. 18, 2012 and designated the U.S., the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2012/076930 | Oct 2012 | US |
Child | 14684903 | US |