Resin Composition Phase Separation Defect Control
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Solution Overview
Problem
The existing resin compositions for forming phase-separated structures face a trade-off between improving process margin and suppressing defects, with the current compositions either providing a large process margin but risking surface defects, or reducing defects at the cost of process margin.
Innovation Solution
A resin composition comprising a first and second block copolymer, along with homopolymers A and B, where the number-average molecular weight of the second block copolymer is higher than the first, and the constitutional units within the blocks are the same, allowing for improved phase separation and defect suppression while enhancing process margin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a resin composition containing multiple specific homopolymers is used to improve process margin, then the process margin is improved, but surface defects are likely to occur
Solution Approach 1:
The patent changes the compositional parameters by specifying precise ratios of block copolymers and homopolymers (first homopolymer: second homopolymer ratio matching first block: second block ratio), and controlling the total homopolymer content within 1-50 mass%. This parameter optimization resolves the contradiction by achieving both improved process margin and reduced surface defects through balanced composition design
Solution Approach 2:
The patent creates a composite resin composition system combining two types of block copolymers (first and second block copolymers with different molecular weights) and two types of homopolymers. This composite structure allows the different components to work synergistically - the block copolymers provide phase separation while the controlled homopolymer content suppresses defects, resolving the trade-off between process margin and defect occurrence
2Manufacturing precision
If the compositional ratio of homopolymers matches the block ratio to improve phase separation, then phase separation is enhanced, but defect occurrence increases
Solution Approach 1:
The patent optimizes the total content of homopolymers within a specific range (1-50 mass% of total resin composition) while maintaining the compositional ratio match. This parameter control ensures sufficient phase separation while preventing excess homopolymer from causing defects, resolving the contradiction between phase separation quality and defect suppression
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 improves the process margin for forming phase-separated structures while minimizing defects, enabling more precise control over the phase separation pattern and orientation, thus achieving a balance between process efficiency and defect reduction.
Implementation Method 1
The block copolymer is separated (phase-separated) in micro regions due to repulsion between blocks incompatible with each other
Implementation Method 2
there has been developed a technology for forming a finer pattern by utilizing a phase-separated structure formed by self-organization of a block copolymer
Implementation Method 3
subjected to a heat treatment or the like to form a structure body having a regular periodic structure
Data Source
AI summary
A resin composition for forming a phase-separated structure, the resin composition containing a first block copolymer having a first a block and a first b block, a second block copolymer having a second a block and a second b block, a homopolymer A compatible with the first a block and the second a block, and a homopolymer B compatible with the first b block and the second b block, in which a constitutional unit constituting the first a block and a constitutional unit constituting the second a block are the same, a constitutional unit constituting the first b block and a constitutional unit constituting the second b block are the same, and a number-average molecular weight of the second block copolymer is larger than a number-average molecular weight of the first block copolymer.