Single Composition Block Copolymer for Phase-Separated Structures

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Solution Overview

Problem

Current methods for forming finer structure bodies using phase-separated block copolymers require separate compositions for undercoat agent and self-organization layers, leading to increased complexity and material management challenges.

Innovation Solution

A method involving the application of a single composition containing a block copolymer onto a substrate to form both the undercoat agent and self-organization layers, followed by phase separation, simplifying the process and reducing material management efforts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate compositions are used for undercoat agent and self-organization layer, then the functional performance of each layer is optimized, but the complexity of material management and process steps increases

Engineering Contradiction:

Improvefunctional performanceVSAvoidmaterial management complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the undercoat agent and self-organization layer into a single composition containing a block copolymer with specific structural features (Formula 1). This single composition simultaneously provides both the undercoat function and the self-organization function, eliminating the need for separate compositions and reducing material management complexity while maintaining the functional performance of both layers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The block copolymer composition is designed to perform multiple functions: it acts as both an undercoat agent that promotes adhesion and a self-organization layer that forms phase-separated nanostructures. The molecular architecture (Formula 1) with specific blocks and functional groups enables this multi-functionality, allowing one material to replace two separate materials.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple compositions are used for different layers, then each layer can be optimized independently, but the number of process steps and material changes increases

Engineering Contradiction:

Improvelayer optimizationVSAvoidprocess time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges the undercoat agent and self-organization layer applications into a single coating process using one composition. This eliminates the need for separate application steps, drying steps, and material changes, thereby reducing total process time while the block copolymer's molecular design ensures both undercoat and self-organization functions are achieved in the single layer.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If different compositions are used for undercoat and self-organization, then material performance is optimized, but raw material management and inventory complexity increases

Engineering Contradiction:

Improvematerial performanceVSAvoidraw material management

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The single block copolymer composition is designed to fulfill both undercoat and self-organization requirements, meaning only one material needs to be managed, stored, and tracked in inventory. The molecular structure (Formula 1) with its specific blocks and functional groups ensures that this single material delivers the performance previously requiring two separate materials.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 allows for the efficient formation of phase-separated structures with reduced material complexity, improving the ease of production and management of raw materials while maintaining the desired structural properties.

Implementation Method 1

subjecting the self-organization layer to phase separation

Methodology Applied

Scientific EffectPhase separation:

Implementation Method 2

it is considered essential to form self-organized nanostructures, which are formed by micro-phase separation

Methodology Applied

Scientific EffectSelf-organization: Self-Assembly

Implementation Method 3

R1c and R1d each independently represents a substrate adsorptive group-containing group

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS20250011616A1Method for producing structure body including phase-separated structure, and composition

Publication Date: 2025.01.09 TOKYO OHKA KOGYO CO LTD

AI summary

A method for producing a structure body including a phase-separated, the method including (i) applying a composition containing a block copolymer represented by Formula (n1) onto a substrate to form an undercoat agent layer, (ii) applying the composition containing the block copolymer onto the undercoat agent layer to form a self-organization layer, and (iii) subjecting the self-organization layer to phase separation. In General Formula (n1), A represents a first polymer block, B represents a second polymer block, R1c and R1d represent a substrate adsorptive group-containing group, R2c and R2d represent a substituent other than the substrate adsorptive group-containing group, m1 and n1 represent an integer of 0 to 5, m2 and n2 represent an integer of 0 to 5, m1+n1 >1, m1+m2<5, and n1+n2<5