Solution-processed organic semiconductor thin films with
high charge
carrier mobility are necessary for development of next-generation
electronic applications, but the rapid processing speed demanded for
the industrial-scale production of these thin films poses a challenge
to control of their thin-film properties, such as crystallinity, morphology,
and film-to-film uniformity. Here, we show a new solution coating
method that is compatible with a roll-to-roll printing process at
a rate of 2 mm s–1 by using a gap-controllable wire
bar, motion-programming strategy, and blended active inks. We demonstrate
that the coating bar, the horizontal motion of which is repeatedly
brought to an intermittent standstill, results in an improved vertically
self-stratified structure and a high crystallinity for organic active
inks comprising a semiconducting small molecule and a semiconducting
polymer. Furthermore, organic transistors prepared by the developed
method show superior hole mobility with high operational stability
(hysteresis and kink-free transfer characteristics), high uniformity
over a large area of a 4 in. wafer, good reproducibility, and superior
electromechanical stabilities on a flexible plastic substrate. The
bar-coating approach demonstrated here will be a step toward developing
industrial-scale practical organic electronics applications.