Organic Photoelectric Conversion Layer Packing to Prevent Electrode Shorts
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Solution Overview
Problem
Organic photoelectric conversion elements face reliability issues due to short circuits between electrodes, primarily caused by voids in the organic photoelectric conversion layer, which affects the efficiency and durability of devices like solar cells and imaging elements.
Innovation Solution
A photoelectric conversion element is designed with an organic photoelectric conversion layer using a mixture of materials with different average particle diameters, including fullerene or its derivatives, to create a dense layer with reduced voids, enhancing the reliability of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an organic photoelectric conversion layer is formed using a single material with uniform particle diameter, then the manufacturing process is simple, but voids occur in the layer leading to short circuits and device failure
Solution Approach 1:
The patent applies parameter changes by varying the particle diameter of organic semiconductor materials in the photoelectric conversion layer. Specifically, it uses a mixture of materials with different average particle diameters (e.g., 50-300 μm as mentioned in PTL 1, or broader ranges like 1 μm to 1 mm in other embodiments). This parameter variation allows smaller particles to fill voids between larger particles, creating a denser layer structure that prevents short circuits while maintaining manufacturing simplicity through solution processing.
Solution Approach 2:
The patent employs composite materials by combining multiple organic semiconductor materials with different particle diameters in the photoelectric conversion layer. This composite approach, where materials with varying sizes are mixed (such as fullerene derivatives with different particle sizes), creates a more compact and void-free structure. The composite material strategy directly addresses the reliability issue by eliminating the pathways for short circuits that would exist in uniform particle structures.
2Reliability
If materials with different particle diameters are mixed in the organic photoelectric conversion layer, then voids are reduced and reliability improves, but the material formulation becomes more complex
Solution Approach 1:
The patent utilizes parameter changes in particle diameter to achieve dense packing. By selecting materials with systematically varied particle sizes (e.g., using fullerene derivatives with controlled particle diameter distributions), the formulation complexity is managed while achieving the desired void reduction. The particle size parameters are optimized to ensure that smaller particles effectively fill the interstices of larger particles without requiring overly complex mixing procedures.
3Reliability
If the organic photoelectric conversion layer contains voids, then the device structure is simpler to form, but short circuits occur between electrodes reducing reliability
Solution Approach 1:
The patent applies parameter changes by controlling the particle diameter distribution of organic semiconductor materials to achieve optimal layer density. Using materials with specific average particle diameters and size distributions (such as the 50-300 μm range mentioned in PTL 1 or broader ranges in other embodiments) enables the formation of dense layers that prevent electrode short circuits while maintaining manufacturability through standard solution processing techniques.
Solution Approach 2:
The patent employs composite materials with different particle sizes to achieve high layer density. By formulating the photoelectric conversion layer with a mixture of organic semiconductor materials having different average particle diameters, the composite structure naturally packs more efficiently, reducing voids and improving electrode insulation without requiring additional manufacturing steps or higher precision equipment.
Data Source
AI summary
A photoelectric conversion element according to an embodiment of the present disclosure include a first electrode, a second electrode opposed to the first electrode, and an organic photoelectric conversion layer provided between the first electrode and the second electrode and formed using a plurality of materials having average particle diameters different from each other, the plurality of materials including at least fullerene or a derivative thereof, and a particle diameter ratio, of a first material having a smallest average particle diameter among the plurality of materials with respect to a second material having a largest average particle diameter among the plurality of materials, is 0.6 or less.