Block Copolymer Resin Composition for Vertical Phase Separation

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Solution Overview

Problem

Existing block copolymers struggle to form phase-separated structures with excellent vertical orientation, which is necessary for creating fine patterns in advanced technologies such as LSI processing.

Innovation Solution

A resin composition comprising a block copolymer with a specific structure, including a first block composed of a polymer with a repeating unit represented by formula (b1) and a second block composed of a random copolymer with units represented by formulas (b2a) and (b2b), is used to achieve a phase-separated structure with improved vertical orientation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If a block copolymer with high interaction parameter (χ) is used to increase structural period (L0), then the mutual repulsion between different blocks increases and phase separation tendency becomes stronger, but the block copolymer becomes difficult to form a phase-separated structure with vertical orientation

Engineering Contradiction:
Improvestructural period (L0)VSAvoidvertical orientation formation
Core Design Contradiction:
Length of stationary objectVSEase of operation

Solution Approach 1:

The patent changes the chemical composition parameters of the block copolymer by introducing fluorinated groups with specific electron-withdrawing capabilities. This modifies the interaction parameter (χ) and degree of polymerization (N) to achieve an optimal χ·N product that provides both sufficient phase separation strength and vertical orientation capability. The fluorinated monomer units (Formula 1) with specific R1 alkyl groups and oxygen/silicon atoms create the desired balance between repulsion force and orientational order.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite block copolymer structure combining hydrocarbon blocks (Formula 2) with fluorinated blocks (Formula 1). This composite material approach allows the hydrocarbon portion to provide structural framework while the fluorinated portion enhances phase separation through strong dipole-dipole interactions and electron-withdrawing effects, achieving both large structural period and vertical orientation simultaneously.

Inventive Principle:
Principle #40Composite materials

2Length of stationary object

If the degree of polymerization (N) is increased to increase structural period (L0), then the structural period increases proportionally, but the manufacturing complexity and difficulty of controlling phase separation pattern increase

Engineering Contradiction:
Improvestructural period (L0)VSAvoidphase separation pattern control
Core Design Contradiction:
Length of stationary objectVSDevice complexity

Solution Approach 1:

Instead of increasing N proportionally to increase L0, the patent changes the interaction parameter (χ) by introducing fluorinated monomer units. This allows achieving larger structural periods through enhanced χ values rather than simply increasing polymer chain length, thereby reducing the complexity associated with controlling high molecular weight block copolymers.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the mechanical approach of increasing chain length (N) with a chemical approach of enhancing intermolecular interactions (χ) through fluorinated groups. This replacement of physical scaling with chemical modification simplifies the control of phase separation patterns while achieving the desired structural period.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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

The proposed resin composition effectively forms phase-separated structures with excellent vertical orientation, enabling the creation of fine patterns suitable for advanced technological applications.

Implementation Method 1

a technique for forming a finer pattern utilizing a phase-separated structure formed by self-organization of a block copolymer in which blocks incompatible with each other are bonded

Methodology Applied
Scientific EffectPhase separation:

Implementation Method 2

formed by self-organization of a block copolymer

Methodology Applied
Scientific EffectSelf-organization: Self-Assembly

Implementation Method 3

chemical epitaxy for controlling a phase separation pattern based on a difference in a chemical state of a substrate

Methodology Applied
Scientific EffectEpitaxy: Epitaxy

Data Source

PatentUS20250197550A1Resin composition for forming phase-separated structure, method for producing structure having phase-separated structure, and block copolymer
Publication Date: 2025.06.19 TOKYO OHKA KOGYO CO LTD
  • US20250197550A1 patent drawing
  • US20250197550A1 patent drawing
  • US20250197550A1 patent drawing

AI summary

A resin composition for forming a phase-separated structure, the resin composition including a block copolymer having a first block and a second block, the first block including a polymer having a repeating structure of a constituent unit represented by the following formula (b1), the second block including a random copolymer having a structure in which a constituent unit represented by the following formula (b2a) and a constituent unit represented by the following formula (b2b) are randomly arranged, and a ratio of a volume of the first block is 20% by volume or more and 80% by volume or less