Mechanics manipulation in large-area organic solar modules achieving over 16.5 % efficiency

High-efficiency organic solar cells (OSCs) are typically produced through spin-coating, restricting their application to small areas. Blade-coating, however, emerging as a promising method for large-scale production, yet faces challenges in film morphology optimization, which often leads to reduced power conversion efficiency (PCE). This study delves into the influence of both liquid and solid additives on the morphology of active layer in blade-coated OSCs, comparing them with spin-coated counterparts, using the high-efficiency PM6:D18:BTP-eC9 active layer. For the first time, we discovered the distinct impacts of solid versus liquid additives on the film uniformity, phase separation and crystalline regulation in blade-coating technique. Our findings reveal that liquid additives in blade-coating trigger outward Marangoni flow, causing undesirable material aggregation and phase separation, thereby impairing device performances. Conversely, switching to solid additives, like 1,4-Diiodobenzene (DIB), prevents these detrimental changes in fluid mechanics and preserves the desired additive effects. We demonstrate that solid additives can significantly change these inferior behaviors introduced by liquid additives in blade-coating, regulate phase separation, enhance π-π accumulation and delay crystallization, and ultimately boost OSC efficiency. Using DIB solid additive, we achieved a PCE of 18.81 % in blade-coated devices. Scaling up by 252 times, the PCE of large-area OSC module (15.64 cm²) sustained at 16.70 % (certified 16.66 %), ranking among the highest efficiency for OSC modules reported so far. These modules also exhibited exceptional storage stability, retaining 98 % efficiency after 5880 h in a nitrogen atmosphere. This research also provides a comprehensive understanding from various film characterizations and the perspective of fluid mechanics normally lack in the research. This research not only establishes a new framework for high-performance and large-area OSC modules but also extends its findings to other OSC systems with different additives, demonstrating a roll-to-roll compatible technique.