The development of processing methods to precisely control the solution state properties of semiconducting polymers in situ have remained elusive. Herein, a facile solution seed nucleation processing method is presented in which nucleated poly(3-hexylthiophene) (P3HT) solutions are blended with well-solvated, non-nucleated counterparts as a means to promote the formation of interconnected polymer networks. Nucleation and growth of these networks was induced by preprocessing the solution with UV irradiation and subsequent solution aging prior to deposition via blade-coating. This process was adopted for both batch and continuous flow processing. Superior charge carrier (hole) mobilities were observed in samples with nucleated seeds compared to controls with 0% nucleated P3HT and 100% nucleated P3HT. UV-vis spectral analysis identified that an intermediate degree of solution aggregation (15-20%) is most conducive to enhanced charge transport. The role of intrachain and interchain ordering and alignment on the mesoscale and macroscale is characterized via X-ray scattering, atomic force microscopy, and optical microscopy techniques. The results presented here provide a framework to enable in situ control of the nucleation and growth process to achieve targeted solution state properties resulting in reliable and reproducible performance when the solutions are used for device fabrication.
Keywords: conjugated polymers; crystallization; microfluidics; solution processing; tie-chains.