Exploring the ultrasonic nozzle spray-coating technique for the fabrication of solution-processed organic electronics

Abstract

The ultrasonic nozzle (US) spray method was investigated for its utility in fabricating organic electrodes composed of poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS), a standard conductive polymer material used to produce large-area low-cost OFETs. The US spray technique involves generating a solution spray by first passing the solution through a head and nozzle subjected to ultrasonic vibrations that induce atomization. This method is advantageous in that the resulting spray comprises extremely small solution droplets a few micrometers in diameter, unlike the spray produced using conventional air spray methods. The PEDOT:PSS US solution spraying process was optimized by controlling the flow rate of the N2 carrier gas and the substrate temperature while monitoring the quality of the resulting PEDOT:PSS electrode films. The pentacene field-effect transistors prepared using the US spray method displayed a maximum field-effect mobility of 0.47 cm2V−1s−1 (with an average value of 0.31 cm2V−1s−1), 35% better than the mobilities achieved using the conventional air spray method. In addition, the device-to-device reproducibility was improved, as indicated by a decrease in the standard deviation of the mobility values from 30% for the air spray devices to 24% for the US spray devices. These results indicated that the US spray technique is efficient and superior to the conventional air spray method for the development of low-cost large-area organic electronics.