Block Copolymer Intermediate for DSA Precision

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Solution Overview

Problem

Existing methods for synthesizing block copolymers for Directed Self-Assembly (DSA) techniques face challenges in precisely controlling the molecular weight and dispersion of polymer blocks, making it difficult to achieve consistent pattern size and precision.

Innovation Solution

The development of a block copolymer intermediate with a specific structure, represented by general formulas (1) and (2), which allows for the synthesis of block copolymers with narrow molecular weight distribution, enabling precise control of the molecular weight and dispersion of individual polymer blocks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a simple initiation method using alkyllithium is used to synthesize block copolymer, then the process is simple, but the molecular weight distribution becomes wide and precision is poor due to sensitivity to water and oxygen

Engineering Contradiction:

Improveprocess simplicityVSAvoidmolecular weight control precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces a silyl ether-protected compound as an intermediary protecting group that shields the alkyllithium initiator from water and oxygen. This intermediary allows the simple initiation method to proceed while protecting against harmful factors, enabling both process simplicity and molecular weight precision to be achieved simultaneously.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates an inert environment by using silyl ether protection, which effectively isolates the sensitive alkyllithium initiator from moisture and oxygen in the air. This inert environment approach maintains process simplicity while ensuring precise molecular weight control by preventing side reactions.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Ease of manufacture

If conventional initiation method is used, then the process is straightforward, but selectivity of monomers is limited

Engineering Contradiction:

Improveprocess straightforwardnessVSAvoidmonomer selectivity

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent changes the chemical parameters of the initiation system by introducing silyl ether-protected alkyllithium compounds. This parameter change enables the initiation method to work with a broader range of monomers including styrene derivatives and (meth)acrylic acid esters, thereby increasing monomer selectivity while maintaining process straightforwardness.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If block copolymer is synthesized without specific intermediate structure, then synthesis is simpler, but molecular weight and dispersion cannot be precisely controlled

Engineering Contradiction:

Improvesynthesis complexityVSAvoidmolecular weight and dispersion control

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by introducing the silyl ether protecting group before the polymerization reaction. This preliminary protection ensures that the initiator remains stable and active throughout the synthesis process, enabling precise control of molecular weight and dispersion while keeping the overall synthesis approach relatively simple.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in block copolymers with precise molecular weight control and narrow dispersion, suitable for DSA techniques, and a method that simplifies the synthesis process while maintaining high precision.

Implementation Method 1

a block copolymer intermediate having a silyl ether group at a terminal vinyl group of a diphenylethylene derivative

Methodology Applied

Scientific EffectProtecting group chemistry:

Implementation Method 2

there is a living anionic polymerization method (see, for example, PTL 1)

Methodology Applied

Scientific EffectLiving anionic polymerization:

Implementation Method 3

X represents a halogen atom

Methodology Applied

Scientific EffectNucleophilic substitution reaction:

Data Source

PatentUS12331148B2Block copolymer intermediate, block copolymer, and production methods for same

Publication Date: 2025.06.17 DIC CORP

AI summary

Provided are a block copolymer having a narrow molecular weight distribution such that the copolymer can be used in a DSA technique, a block copolymer intermediate thereof, and methods for producing the same. A block copolymer intermediate represented by the general formula (1) or (2) is used:wherein, in the general formulae (1) and (2), each of R1 and R3 independently represents a polymerization initiator residue, each of R2 and R4 independently represents an aromatic group or an alkyl group, Y1 represents a polymer block of (a)an (meth)acrylic acid ester, Y2 represents a polymer block of styrene or a derivative thereof, L represents an alkylene group having 1 to 6 carbon atoms, X represents a halogen atom, and each of m and n independently represents an integer of 1 to 5.