High fidelity nano-structures and arrays for photovoltaics and methods of making the same

• US 9,214,590 B2
• Filed: 03/06/2013
• Issued: 12/15/2015
• Est. Priority Date: 12/19/2003
• Status: Active Grant

• Current Assignee: University of North Carolina At Chapel Hill (University of North Carolina System)
• Original Assignee: University of North Carolina At Chapel Hill (University of North Carolina System)
• Inventors: DeSimone, Joseph M., Rothrock, Ginger Denison, Zhou, Zhilian, Samulski, Edward T., Earl, Meredith, Williams, Stuart
• Primary Examiner(s): THEISEN, MARY LYNN F
• Application Number:
  US13/787,134
• Publication Number:
  US 20130249138A1
• Time in Patent Office: 1,014 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B29C 37/0003 Discharging moulded articles from the mould constructions for removing the articles B29C33/44
• CPC Class Codes: B29C 39/36 Removing moulded articles
• CPC Class Codes: B81C 1/00031 Regular or irregular arrays of nanoscale structures, e.g. etch mask layer photomechanical, e.g. photolithographic, production of textured or patterned surfaces G03F7/00; lithographic processes for making patterned surfaces using printing and stamping G03F7/0002
• CPC Class Codes: B81C 1/00214 Processes for the simultaneaous manufacturing of a network or an array of similar microstructural devices
• CPC Class Codes: B81C 2201/034 Moulding
• CPC Class Codes: B81C 99/0085 using moulds and master templates, e.g. for hot-embossing
• CPC Class Codes: B82Y 10/00 Nanotechnology for information processing, storage or transmission, e.g. quantum computing or single electron logic
• CPC Class Codes: B82Y 20/00 Nanooptics, e.g. quantum optics or photonic crystals
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: G03F 7/0002 Lithographic processes using patterning methods other than those involving the exposure to radiation, e.g. by stamping
• CPC Class Codes: H01L 31/0352 characterised by their shape or by the shapes, relative sizes or disposition of the semiconductor regions
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H10K 30/15 Sensitised wide-bandgap semiconductor devices, e.g. dye-sensitised TiO2 photo-electrochemical devices comprising a liquid electrolyte or a solid electrolyte H01G9/20
• CPC Class Codes: H10K 30/30 comprising bulk heterojunctions, e.g. interpenetrating networks of donor and acceptor material domains
• CPC Class Codes: H10K 30/35 comprising inorganic nanostructures, e.g. CdSe nanoparticles
• CPC Class Codes: H10K 30/50 Photovoltaic [PV] devices
• CPC Class Codes: H10K 71/13 using printing techniques, e.g. ink-jet printing or screen printing
• CPC Class Codes: H10K 85/113 Heteroaromatic compounds comprising sulfur or selene, e.g. polythiophene
• CPC Class Codes: H10K 85/215 comprising substituents, e.g. PCBM
• CPC Class Codes: Y02E 10/549 : Organic PV cells

Abstract

A photovoltaic device includes an electron accepting material and an electron donating material. One of the electron accepting or donating materials is configured and dimensioned as a first component of a bulk heterojunction with a predetermined array of first structures, each first structure is substantially equivalent in three dimensional shape, has a substantially equivalent cross-sectional dimension, and where each first structure of the array of first structures has a substantially equivalent orientation with respect to adjacent first structures of the predetermined array forming a substantially uniform array.

Claims

1. A method for harvesting micro- and/or nano-particles, comprising:

a) contacting a harvesting layer and one or more of the micro- and/or nano-particles, wherein the harvesting layer is associated with a surface of the one or more micro- and/or nano-particles, wherein prior to said contacting, each of the one or more micro- and/or nano-particles resides in a discrete recess of a polymer mold, and wherein the harvesting layer has an affinity for the particles greater than the affinity of the particles for the polymer mold;

b) dissociating the harvesting layer from the polymer mold, wherein the one or more micro- and/or nano-particles are removed from the recess of the polymer mold to prepare harvested particles, wherein the harvested particles are in communication with the harvesting layer;

wherein the harvested particles are a plurality of monodisperse particles.

2. The method of claim 1, further comprising:

c) dissociating the harvested particles from the harvesting layer.

3. The method of claim 2, wherein dissociating the harvested particles comprises scraping the particles under dry conditions.

4. The method of claim 2, wherein dissociating the harvested particles comprises dissolving at least a portion of the harvesting layer.

5. The method of claim 1, wherein the surface energy of the harvesting layer is greater than the surface energy of the polymer mold.

6. The method of claim 1, wherein the harvesting layer comprises a surface that has a surface energy greater than the surface energy of the polymer mold.

7. The method of claim 1, wherein the harvesting layer is a sheet or a film.

8. The method of claim 1, wherein the harvesting layer comprises a material selected from the group consisting of a carbohydrate, an epoxy, a wax, polyvinyl alcohol, polyvinyl pyrrolidone, polybutyl acrylate, a polycyano acrylate and polymethyl methacrylate or combinations thereof.

9. The method of claim 1, wherein the harvested particles are in an array, wherein the distance between each particle is between about 1 nm and about 100 nm.

10. The method of claim 9, wherein the distance is between about 5 nm and about 20 nm.

11. The method of claim 1, wherein at least one of the harvested particles is a nanoparticle having a size between about 1 nm about 200 nm.

12. The method of claim 1, wherein at least one of the harvested particles is a nanoparticle having a size between about 1 nm about 50 nm.

13. The method of claim 1, wherein at least one of the harvested particles is a nanoparticle having a size between about 1 nm about 20 nm.