Numerical Simulations and In Situ Optical Microscopy Connecting Flow Pattern, Crystallization, and Thin‐Film Properties for Organic Transistors with Superior Device‐to‐Device Uniformity

Abstract

Currently, due to the lack of precise control of flow behavior and the understanding of how it influences thin‐film crystallization, strict tuning of thin‐film properties during solution‐based coating is difficult. In this work, a continuous‐flow microfluidic‐channel‐based meniscus‐guided coating (CoMiC) is introduced, which is a system that enables manipulation of flow patterns and analysis connecting flow pattern, crystallization, and thin‐film properties. Continuous supply of a solution of an organic semiconductor with various flow patterns is generated using microfluidic channels. 3D numerical simulations and in situ microscopy allow the tracking of the flow pattern along its entire path (from within the microfluidic channel to near the liquid–solid boundary), and enable direct observation of thin‐film crystallization process. In particular, the generation of chaotic flow results in unprecedented device‐to‐device uniformity, with coefficient of variation (CV) of 7.3% and average mobility of 2.04 cm² V⁻¹ s⁻¹ in doped TIPS‐pentacene. Furthermore, CV and average mobility of 9.6% and 11.4 cm² V⁻¹ s⁻¹ are achieved, respectively, in a small molecule:polymer blend system. CoMiC can serve as a guideline for elucidating the relation between flow behavior, liquid‐to‐solid phase transition, and device performance, which has thus far been unknown.