Positively operating radiation-sensitive mixture containing a polyfunctional .alpha.-diazo-.beta.-keto ester and radiation-sensitive recording material containing this mixture

BACKGROUND OF THE INVENTION
The invention relates to a positively operating radiation-sensitive mixture containing a photoactive component and a binder which is insoluble in water but soluble or at least swellable in aqueous-alkaline solution.
Radiation-sensitive mixtures which contain photoactive diazo derivatives and are suitable for irradiation with high-energy UV radiation have been described in the literature for some time.
Positively operating radiation-sensitive mixtures which contain a diazo derivative of Meldrum's acid as the photoactive compound are mentioned in U.S. Pat. No. 4,339,522. This compound is said to be suitable for exposure to high-energy UV radiation in the range from 200 to 300 nm. However, it has been found that when these mixtures are used, the photoactive compound is exuded under the relatively high processing temperatures frequently employed in practice; the radiation-sensitive mixture loses its original activity, so that reproducible structurings are not possible.
EP-A-0,198,674 and 0,262,864, U.S. Pat. No. 4,622,283 and SU-A-1,004,359 provide 2-diazo-cyclohexane-1,3-dione or -cyclopentane-1,3-dione derivatives as photoactive compounds for radiation-sensitive mixtures of the type described. These compounds have a lower volatility, but instead, depending on the substitution pattern present, exhibit a poor compatibility in the radiation-sensitive mixture. This manifests itself in particular by crystallization of the photoactive compound during drying of the layers, by insolubility thereof in solvents used in practice or by a layer inhomogeneity caused by phase separation.
Other positively operating photoactive compounds which are sensitive in the low UV range are known from EP-A-0,129,694 and U.S. Pat. No. 4,735,885. The compounds described in these documents have the disadvantage that the carbenes formed from them during exposure do not have a stability in the matrix which is adequate for the desired carboxylic acid formation. This leads to an inadequate solubility difference between the exposed and non-exposed areas in the developer and therefore to an undesirably high removal rate of the non-exposed areas. A possible explanation for this phenomenon is given by C. G. Willson et al. in SPIE Vol. 771, "Advances in Resist Technology and Processing IV", 2 (1987).
EP-A-0,195,986 therefore proposes .alpha.-phosphoryl-substituted diazocarbonyl compounds as photoactive compounds, since these have an increased carbene stability. In practice, however, such compounds probably find only minor use, since atoms which can potentially be used as doping agents, such as, for example, the phosphorus contained in these compounds, must be very meticulously excluded during the processing processes.
In their paper "Positive Excimer Laser Resist Prepared with Aliphatic Diazoketones" (SPIE Proc., 920, 51 (1988)), H. Sugiyama, E. Ebata, A. Mizushima and K. Nate introduce novel .alpha.-diazoacetoacetates which are employed as photoactive compounds in positively operating radiation-sensitive mixtures, in particular for use with radiation in the low UV range. Since these are derivatives of aceto-acetic acid, the keto group in the .beta.-position relative to the ester group is directly adjacent to a terminal methyl group. Radiation-sensitive mixtures which contain the compounds mentioned as photoactive components exhibit good bleaching properties, but their properties in respect of image differentiation are poor.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a positive operating radiation-sensitive mixture which comprises a photoactive compound of high sensitivity in the UV range, which does not have the numerous disadvantages described and which allows good differentiation between the exposed and non-exposed layer areas.
Another object of the present invention is to provide a mixture comprising a photoactive compound which is readily compatible with the most diverse polymers which can be used in practice, and which is not exuded from the radiation-sensitive mixture so formed.
An additional object of the present invention is to provide a mixture comprising a photoactive compound which has a high thermal stability as well as a photosensitivity which meets the requirements in practice.
A further object of the present invention is to provide a positively operating recording material employing the foregoing mixture.
Yet another object of the present invention is to provide a process for producing the above-described recording material.
In accomplishing the foregoing objectives, there has been provided, in accordance with one aspect of the present invention, a positively operating radiation-sensitive mixture which comprises a binder which is insoluble in water but soluble or at least swellable in aqueous alkaline solution, and as a photoactive component a polyfunctional .alpha.-diazo-.beta.-keto ester of the general formula I ##STR6## in which R.sup.1 denotes an aliphatic, cycloaliphatic or araliphatic or aromatic radical having 4 to 20 carbon atoms, in which individual CH.sub.2 groups can be replaced by oxygen or sulfur atoms or by ##STR7## NH groups and/or contain keto groups, X denotes an aliphatic, cycloaliphatic, carbocyclic, heterocyclic or araliphatic radical having 2 to 22 carbon atoms, in which individual CH.sub.2 groups can be replaced by oxygen or sulfur atoms or by the groups --NR.sup.2 --, --C(O)--O--, --C(O)--NR.sup.2 --, ##STR8## or --O--C(O)--O--, or CH groups can be replaced by --N--, in which R.sup.2 and R.sup.3 independently of one another represent hydrogen or an aliphatic, carbocyclic or araliphatic radical,
m denotes an integer from 2 to 10 and
n denotes an integer from 0 to 2,
with the proviso that
m-n is .gtoreq.2.
In accordance with another aspect of the present invention there is provided a positively operating recording material which comprises a carrier and the foregoing mixture applied thereto.
In accordance with still another aspect of the present invention, there is provided a process for preparing the foregoing recording material, which comprises the steps of coating the carrier with the radiation-sensitive mixture by spraying, rolling, knife-coating, pouring, flow-coating, whirler coating or dip-coating or by means of a slot die, and removing the solvent by evaporation, so that a layer thickness of about 0.1 to 100 .mu.m is formed.
Other objects, features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the preferred embodiment, R.sub.2 and R.sub.3 denote hydrogen, (C.sub.1 -C.sub.3)alkyl, (C.sub.6 -C.sub.12)aryl or (C.sub.6 -C.sub.11)aralkyl, in which the radicals--in particular aryl or aralkyl--can likewise be substituted on the nucleus by alkyl, alkoxy, halogen or amino. R.sub.2 and R.sub.3 particularly preferably represent hydrogen or (C.sub.1 -C.sub.3)alkyl, but in particular hydrogen.
The radicals R.sup.1 and X can be optionally substituted, in particular by (C.sub.1 -C.sub.3)alkyl, (C.sub.1 - C.sub.3)alkoxy, halogen, amino or nitro. Radicals R.sup.1 and X which are substituted by (C.sub.1 -C.sub.3)alkyl or (C.sub.1 -C.sub.3)alkoxy are preferred. In particular, if R.sup.1 and X represent an alkyl radical the unsubstituted derivatives are preferred.
The aliphatic radicals R.sup.1 can be either straight-chain or branched. The number of chain members here is preferably about 4 to 10, in particular 4 to 8. These include the particularly preferred pure carbon chains and also the substituted chains in which up to 3 CH.sub.2 groups are replaced by oxygen atoms or --NH-- groups and/or contain keto groups which includes ether, keto, ester, amido or imido groups, that is to say also esters of carbamic acid. In the pure aliphatic radicals R.sup.1, ether groups particularly preferably occur twice per radical R.sup.1. If the chains are pure, in particular straight-chain, carbon chains, limitation of the number of carbons is not essential; it is entirely possible to employ aliphatic radicals having up to about 20 carbon atoms. Nevertheless, the t-butyl radical is preferred.
If R.sup.1 denotes a cycloaliphatic radical, the number of ring members is preferably 4, 5, 6 or 12, in particular 4, 5 or 6. The unsubstituted variants are particularly preferred. Examples are the cyclobutyl, cyclopentyl and cyclohexyl radical. The cyclohexyl radical is particularly preferred.
If R.sup.1 is an araliphatic radical, the number of members of the aliphatic part is about 2 to 11, in particular 2 to 5. If the carbon chain in the aliphatic part is a pure carbon chain, the number of C atoms is preferably 1 or 2. If CH.sub.2, groups are replaced by oxygen atoms, these can occur as a bridge member between the aromatic and aliphatic part of the radical R.sup.1, and also in the aliphatic part. In both cases, it is particularly preferable for the remaining total number of carbon atoms as chain members in the aliphatic part of this radical to be 1 or 2, the ether oxygen atom being positioned in the case of 2 carbon atoms as chain members such that it is adjacent to both CH.sub.2 groups. Amongst these there may be mentioned the benzyl, the phenoxymethylene and the benzyloxymethylene radical. If still further CH.sub.2 groups in the aliphatic part of the araliphatic radical R.sup.1 are additionally replaced by hetero atoms and/or substitutions are undertaken on these, the total number of chain members of the aliphatic part is 2 to 5, wherein up to 3 chain members are substituted by hetero atoms. This includes, inter alia, phenyl or benzyl radicals bonded via ester groups, but also the benzyl or phenyl esters of carbamic acid. However, the aliphatic part can also be the imido group of an aromatic dicarboxylic acid. The aromatic part of such a radical consists, in particular, of 6 carbon atoms. If the aromatic part of the araliphatic radical is directly adjacent to the keto group, that is to say is bonded as an arylene radical, there are no limitations in respect of the minimum number of carbon atoms present for the aliphatic part occurring therein.
The aromatic radicals R.sup.1 preferably contain no hetero atoms, such as, for example, oxygen, in their ring system. If R.sup.1 is an aromatic radical, it preferably contains 6 to 12 carbon atoms, in particular 6 carbon atoms, that is to say corresponds to a phenyl radical. However, aromatic radicals R.sup.1 are not preferred.
Overall, t-butyl, n-hexyl, nonyl, octadecyl, 2,5-dioxahexyl, cyclopentyl, cyclohexyl, benzyl, phenoxymethyl and benzyloxymethyl may be mentioned as particularly preferred radicals R.sup.1. The t-butyl, phenoxymethyl and cyclohexyl radical are particularly preferred.
X represents an aliphatic or cycloaliphatic radical which can be saturated or unsaturated, or a carbocyclic, heterocyclic or araliphatic radical having 2 to 22 carbon atoms, in particular 2 to 17 carbon atoms. In addition, at least one CH.sub.2 group in these radicals can be replaced by hetero atoms, such as oxygen or sulfur, or by groups such as --NR.sup.2 --, --C(O)--O--, --C(CO)--NR.sup.2 --, ##STR9## or --O--C(CO)--O-- or CH groups can be replaced by --N--. Those variants in which not more than two CH.sub.2 groups have been replaced by one type of the abovementioned groups are particularly preferred in the aliphatic or araliphatic radicals. If CH.sub.2 groups are replaced by hetero atoms, the number of these can preferably be not more than 5, in particular not more than 3. It is particularly preferable in this case if all the CH.sub.2 groups to be replaced are replaced by hetero atoms of one type.
If the radical X is an unsubstituted saturated or unsaturated aliphatic radical, in the preferred variant this contains not more than 6 carbon atoms. Unsaturated aliphatic radicals X 5 include, in particular, those in which the CH.sub.2 or CH groups are not replaced by hetero atoms or the abovementioned groups. In their particular embodiment, they contain not more than one C--C multiple bond; the number of chain members in such a radical is particularly preferably 4. The radicals X mentioned can be either di- or trivalent, but it is preferable for X to be divalent. If CH.sub.2 groups in the aliphatic radicals X are replaced by hetero atoms, these are preferably bonded in alkylene radicals having in each case at least 2 CH.sub.2 groups. If sulfur is the hetero atom in the aliphatic radical X, this particularly preferably occurs only once per radical. It is surrounded in particular by alkyl radicals having in each case not more than 3 CH.sub.2 groups. If oxygen is employed as the hetero atom in the aliphatic radical, this can occur more frequently per radical, in particular 2 to 4 times. In this case, the alkylene radicals into which two oxygen atoms are bonded contain at least three CH.sub.2 groups.
If the number of carbon atoms in the unsubstituted aliphatic radical is greater than 3, this alkylene radical is, in particular, in the form of the branched isomer. The t-butyl or t-pentyl radical is particularly preferred.
In the radical X, it is also possible for several alkyl radicals, in particular the t-butyl or t-pentyl radical, to be bonded via groups, which are mentioned above, which replace hetero atoms or CH.sub.2 groups. This is particularly preferable if these radicals are more than divalent.
If the t-butyl or t-pentyl radicals are trivalent, m is at least 3. Preferably, m =4 is achieved by a divalent t-pentyl or t-butyl radical being present twice in the radical X. In addition, m=4 is achieved by a divalent propyl radical occurring twice on the radical X.
Preferably, m =6 is achieved by two trivalent radicals (t-butyl or t-pentyl) or three divalent propyl radicals being present in the radical X. Additionally, m =8 is achieved, for example, by the combination of 4 divalent radicals or 2 trivalent radicals with one divalent radical.
A radical X which is more than divalent can also be achieved by the radical containing hetero atoms which are more than divalent: if a CH group is replaced by ##STR10## m values of 2 to 3 can be achieved. If two CH groups are replaced by ##STR11## m can reach a maximum of 4; if this is part of a cycloaliphatic ring, m is not more than 2.
In all cases where CH groups in the radical X are replaced by ##STR12## no replacement of a CH.sub.2 group by a further hetero atom or by one of the groups described above preferably takes place. The number of CH.sub.2 groups which lie between the oxygen hetero atom and the radical bonded to the radical X, according to the general formula I, is at least 2; this is particularly the number 2.
Pure cycloaliphatic radicals, that is to say unsubstituted radicals, as a variant of the radical X are not preferred. The cyclohexyl radical is mentioned in particular as the cycloaliphatic radical. However, this can be substituted, in particular by hydroxyl and/or alkyl or alkylene, the valency thereof (that is to say m) preferably being determined by the number of alkylene substituents on the cycloaliphatic radical. A cyclohexyl radical which contains four methylene groups as substituents, which at the same time ensures bonding of the .alpha.-diazo-.beta.-keto ester units, in accordance with the general formula I (m=4) is especially preferred. It is particularly preferred for this radical X also to contain a hydroxyl group, in particular a secondary hydroxyl group, so that n=1.
The cycloaliphatic radicals as variants of the radical X are usually rather a combination of a cycloaliphatic and a chain-like aliphatic part. In this case, the cycloaliphatic part is preferably not substituted such that CH.sub.2 groups from this part are replaced by hetero atoms or by groups from the abovementioned series.
An exception is a six-membered ring (heterocyclic radical) of three carboxylic acid amide units in which the coupling of the .alpha.-diazo-.beta.-keto ester units of the general formula I is via ethylene groups to the amidonitrogen. Therefore m is 3 and n is 0.
However, if X is a combination of a pure cycloaliphatic part and one or more chain-like aliphatic parts having 2 or more carbon atoms, the cycloaliphatic part is, in particular, directly adjacent to a CH.sub.2 group which is replaced by one of the abovementioned hetero atoms or groups. Those variants in which the cycloaliphatic part is directly adjacent to a nitrogen atom, in particular to the groups ##STR13## are particularly preferred. In this case, a cyclohexyl radical is preferably employed as the cycloaliphatic part and can be either monovalent or divalent, the latter preferably being in the 1,4-position. In both cases, linking of one of the free valencies of the radicals ##STR14## with the .alpha.-diazo-.beta.-keto ester unit in accordance with the general formula I is via an alkylene radical having at least 2 CH.sub.2 units. If the radical is a ##STR15## a t-butylene radical is preferably formulated as the linking group. If the radical is a ##STR16## radical, that is to say the linking in question is via the oxygen atom of this group, an ethylene radical is preferably employed as the linking group.
If the variant of group X is an araliphatic radical, the aromatic part, in particular a phenyl or, if divalency exists, a phenylene radical, can be bonded both via a nitrogen atom and via an oxygen atom. However, here also--if both atoms are available--the nitrogen atom is preferred. An example in which the aromatic part is bonded directly via an oxygen atom is an ether oxygen atom bonded via an ethylene group to the .alpha.-diazo-.beta.-keto ester unit. A third variant in this case is also the possibility that the aromatic radical, especially if it is monovalent, is bonded via the keto group of a radical ##STR17## In this case, the nitrogen atom carries, in particular, an ethylene radical.
If an araliphatic radical X is present, the aliphatic part of the radical X which is bonded via the nitrogen atom of a radical ##STR18## replacing a CH.sub.2 group is in particular a t-butylene or an ethylene radical; if the aliphatic part is bonded via the oxygen atom, this is particularly preferably an ethylene radical.
The fact that an ethylene group is preferably bonded via the oxygen atom of the abovementioned groups which are to replace a CH.sub.2 group in the radical X can also be applied in general to aliphatic radicals, whereas both ethylene radicals and higher aliphatic radicals, in particular of hydrocarbon chains having more than 3 carbon atoms, are bonded via the nitrogen atom. The t-butylene radical is preferred.
If the radicals X are araliphatic and aliphatic, preferably not more than 2 CH.sub.2 groups are replaced by radicals such as ##STR19## In the particularly preferred embodiment, the radical ##STR20## as a replacement for a CH group is present only once in a radical X.
In the variants described above for radicals R.sup.1 and X, m is preferably an integer from 2 to 8 and n an integer from 0 to 2.
Particularly preferably, m is an integer from 2 to 6 and n=0.
The .alpha.-diazo-.beta.-keto esters of the general formula I characterized in more detail above and employed in the positively operating radiation-sensitive mixture according to the invention are outstandingly suitable as photoactive components. In particular, these compounds exhibit a high absorption when exposed to radiation of a wavelength of 190 to 350 nm, preferably 200 to 300 nm. The polyfunctional compounds according to the general formula I and their preparation are described in German Patent Application P 39 00 735.9, corresponding to U.S. Application No. 07/464,003, now U.S. Pat. No. 4,996,301 issued Feb. 26, 1991 filed at the same time.
In the process for the preparation of the .alpha.-diazo-.beta.-keto ester, it has proved particularly advantageous first to synthesize suitable precursors for .beta.-keto esters of the general formula II and to convert these into the .alpha.-diazo-.beta.-keto esters of the formula I by a so-called diazo transfer in a subsequent reaction (compare M. Regitz et al., Org. Prep. Proced., 1, 99 (1969)): ##STR21## For this purpose, a .beta.-keto ester of the general formula II (in which R.sup.1 and X have the meaning given in formula I) are dissolved in about 5 to 50 times, preferably 10 times, the amount (based on the mixture) of a suitable solvent and the solution is cooled to a temperature between about -15.degree. C. and +15.degree. C., preferably between -5.degree. C. and +5.degree. C. Suitable solvents are alcohols, such as methanol and ethanol, alcohol ethers, such as ethylene glycol monomethyl ether, chlorinated hydrocarbons, such as methylene chloride or chloroform, or, preferably, aliphatic nitriles, such as acetonitrile, or mixtures of these solvents. Those which have a boiling point between about 30.degree. C. and 140.degree. C. are particularly preferred here. The actual reaction according to the invention can be carried out by 3 variants.
Variant A
An about 1- to 1.3-fold excess (based on the number of activated methylene groups to be reacted) of a diazo transfer reagent is added to the cooled solution. Aromatic and aliphatic sulfonyl azides, such as toluenesulfonyl azide, 4-carboxyphenylsulfonyl azide, 2-naphthalenesulfonyl azide or methylsulfonyl azide, have proved to be particularly suitable transfer reagents. The equimolar amount, based on the sulfonyl azide, of a base, preferably a tertiary amine, is then added to the solution. The temperature of the mixture must be kept constant here. Examples of preferred amines are triethylamine, triisopropylamine and diazabicyclo[2.2.2]octane. The use of triethylamine as the base is particularly preferred. The resulting mixture is stirred at the given temperature for about 5 to 50 minutes, preferably 10 to 15 minutes, warmed to room temperature and stirred at this temperature for a further about 1 to 24 hours, preferably 2 to 4 hours. The sulfonamide thereby formed may precipitate, depending on the nature of the sulfonyl azide employed, so that it is filtered off, if appropriate, when the reaction has ended.
Variant B
Alternatively to variant A, the .beta.-keto ester of the general formula II and the amine can be initially introduced into the reaction vessel under the conditions described above and the sulfonyl azide can then be metered in, while maintaining the temperature.
Variant C
However, it has proved to be particularly advantageous to use a modified variant A, in which only about a 0.7- to 0.9-fold excess (based on the number of activated methylene groups to be reacted) of a sulfonyl azide, preferably toluenesulfonyl azide, is added to the solution of the .beta.-keto ester of the general formula II and the total amount of the amine is added, while maintaining the given temperature. The mixture is then stirred, if appropriate while warming to room temperature. After about 10-120 minutes, the toluenesulfonyl azide can no longer be detected by chromatography. The mixture is then cooled again, if appropriate, and about a 0.6- to 0.1-fold excess of 4-carboxyphenylsulfonyl azide is this time added, so that a total excess of sulfonyl azide corresponding to variant A results. The crude products prepared by this variant have a high purity.
The mixture obtained according to variants A to C is freed from the solvent and excess reagents and taken up in an inert water-immiscible solvent, in particular methylene chloride or diethyl ether. The mixture is washed twice with 5% strength potassium hydroxide solution to remove sulfonylamide residues and then washed neutral with water, dried over a suitable desiccant and freed from the solvent again. The residue which remains, which, especially if variant C is used, consists almost exclusively of pure .alpha.-diazo-.beta.-keto ester of the general formula I, can be worked up by known methods, for example by means of crystallization or chromatography.
The preparation of the .beta.-keto esters of the general formula II required for conversion into the .alpha.diazo-.beta.-keto esters of the general formula I can be carried out by various procedures which are known in the literature:
1. In accordance with equation 2, a monofunctional 5-acyl-2,2-dialkyl-1,3-dioxane-4,6-dione (5-acyl-Meldrum's acid) of the general formula III is reacted with a polyhydric alcohol of the general formula IV to give the polyfunctional .alpha.-keto ester of the general formula II. The preparation of 5-acyl-Meldrum's acid derivatives of the general formula III and reaction thereof to give .beta.-keto esters of the general formula II is known for monofunctional compounds and can be carried out, for example, analogously to the procedure of Y. Oikawa et al., J. Org. Chem., 43, 2087 (1987) by reaction of acid or chlorides with Meldrum's acid, or analogously to the procedure of P. Houghton and D. J. Lapham, Synthesis, 1982. 451 et seq. The products are isolated in their enol form. ##STR22##
2. In accordance with equation 3, a monofunctional .beta.-keto ester, preferably a methyl or ethyl ester of the general formula V, is reacted with a polyhydric alcohol of the general formula IV to give the polyfunctional .beta.-keto ester of the general formula II. The transesterification reaction for the preparation of monofunctional .beta.-keto esters of the general formula II is known and is described by A. R. Bader et al. in J. Amer. Chem. Soc., 73, 4195 et seq. (1951). ##STR23##
In the reaction sequence according to equation 2, the amount of the mono- or polyfunctional alcohol in question of the general formula IV required for the desired degree of conversion is added to the derivative in question of 5-acyl-Meldrum's acid of the general formula III and the mixture is then dissolved in about 5 to 20 times, preferably 10 times, the amount of a solvent which does not react with alcohols or Meldrum's acid, for example of a ketone, such as acetone or ethyl methyl ketone, or an ether, such as 1,2-dimethoxyethane or dioxane, if necessary with warming. The clear solution is heated to a temperature of about 60.degree. C. to 120.degree. C., preferably from 80.degree. C. to 100.degree. C. The start of the reaction manifests itself by vigorous evolution of carbon dioxide. The mixture is stirred at the given temperature for about 1 to 6 hours, preferably 2 to 3 hours, until no further evolution of CO.sub.2 can be observed.
The solvent is then removed in vacuo. Although the .beta.-keto ester in question of the general formula II is obtained in a high purity, the product can be further purified, if appropriate, by methods known to one skilled in the art.
Particularly suitable derivatives of 5-acyl-Meldrum's acid of the general formula III are those in which R.sup.1 denotes cyclobutyl, butyl, pentyl, cyclopentyl, hexyl, cyclohexyl, heptyl, octyl, nonyl or higher alkyl radicals having up to about 22 carbon atoms, which are optionally substituted by further alkyl radicals, alkoxyalkyl radicals, aryl radicals, alkoxyaryl radicals, aryloxyaryl radicals or halogen atoms or by other functional groups, for example by terminal acid ester functions, or in which individual CH.sub.2 groups can be replaced by oxygen or sulfur atoms or by groups such as --C(O)--O--, --C(O)--NR.sup.2 --, --NR.sup.2 --C(O)--NR.sup.3 --, --O--C(O)--NR.sup.2 --, --O--C(O)--O--or --NR.sup.2 --, in which R.sup.2 and R.sup.3 have the meaning described above.
Particularly preferred radicals R.sup.1 which may be mentioned are t-butyl, n-hexyl, 2,5-dioxahexyl, cyclopentyl, cyclohexyl, benzyl, phenoxymethyl and nonyl. The t-butyl, cyclohexyl and phenoxymethyl radicals are particularly preferred.
Alcohols of the general formula IV which can be used are alcohols which are di- or trifunctional or of higher functionality; alcohols which contain 2 to 6 OH groups per molecule are preferred. Difunctional alcohols of the general formula IV include, for example, ethylene glycol, propane-1,2-diol,propane-1,3-diol,2,2-dimethylpropane-1,3-diol, 3-chloropropane-1,2-diol, butane-1,2-diol, butane-1,3-diol, butane-2,3-diol, butane-1,4-diol, 2,3-dimethylbutane-2,3-diol, pentane-1,2-diol, pentane-1,5-diol, pentane-2,4-diol, 2-methylpentane-2,4-diol, hexane-1,6-diol, hexane-2,5-diol, 2,5-dimethylhexane-2,5-diol, 2-ethylhexane-1,3-diol, octane-1,8-diol, decane-1,10-diol, dodecane-1,2-diol, dodecane-1,12-diol and phenylethylene glycol, or higher optionally substituted and branched alkanediols, such as tartaric acid, dimethyl tartrate, diethyl tartrate, diisopropyl tartrate, 3-allyloxy-1,2-propane, dihydroxyacetone or tetraphenyl-1,2-ethanediol, in which one or more methylene groups can optionally be replaced by radicals containing oxygen atoms, such as, for example, in diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol or 2,3-benzylidenethreitol, by radicals containing sulfur atoms, such as in 2,2-thiodiethanol or 1,8 -dihydroxy-3,6-dithiooctane, or by radicals containing nitrogen atoms, such as, for example, in N-methyl-2,2'-iminodiethanol, N-butyl-2,2'-iminodiethanol,N-tert.-butyl-2,2'-iminodiethanol or N-phenyl-2,2'-diiminodiethanol, or by the groups described above. Unsaturated diols, such as, for example, 2-butene-1,4-diol, 2-butyne-1,4-diol, 3-hexyne-2,5-diol or 2,5-dimethyl-3-hexyne-2,5-diol, or cyclic diols, which can in turn be substituted by oxygen, sulfur or nitrogen atoms, such as cyclohexane-1,2-diol, cyclohexane-1,4-diol, 1,4-bis(hydroxymethyl)cyclohexane or 1,4-bis(2-hydroxyethyl)-piperazine, can moreover also advantageously be employed. Such diols are in general commercially available. Other diols can be prepared, for example, by reaction of diols containing primary amino groups, for example 2-amino-2-methyl-1,3-propanediol, with monofunctional acid derivatives, such as carboxylic acid chlorides or sulfonic acid chlorides, or monofunctional isocyanates, and also with difunctional acid derivatives or corresponding isocyanates.
Trifunctional alcohols are preferably derived from glycerol, from higher .alpha.,.beta.,.omega.-triols or from triethanolamine. It is also possible for higher-chain derivatives, in particular ethoxylated compounds and heterocyclic compounds, such as, for example, 1,3,5-tris(2-hydroxyethyl)-cyanuric acid, similarly to be used. Glycerol, 2-hydroxymethyl-2-methylpropane-1,3-diol, 2-ethyl-2-hydroxymethylpropane-1,3-diol, 2,3-isopropylidene-erythruronic acid, hexane-1,2,6-triol, 1,1,1-triethanolamine, 1,1,1-tripropanolamine and partly acetalized or ketalized sugar derivatives are mentioned.
Reaction products of tetrafunctional alcohols or aminotriols with acid derivatives, isocyanates or cyclic carbonates can moreover also be used. Alcohols of higher functionality of the general formula III are derived, for example, from condensation products of glycerol or pentaerythritol or from reaction products of difunctional acid derivatives or isocyanates with alcohols or amino-alcohols of higher functionality. The list of alcohols which can be used is thus by no means complete; practically all alcohols which contain no other group which reacts with acid esters or which react homogeneously under the reaction conditions described to form esters can be used.
In the preparation of .beta.-keto esters of the general formula II by transesterification in accordance with equation 3, monofunctional .beta.-keto esters of the general formula V are employed with alcohols of the general formula IV such that about a 5 to 200% excess, preferably a 10 to 50% excess, of a .beta.-keto ester esterified with a low molecular weight alcohol, for example a methyl or ethyl ester, is reacted at about 100.degree. to 160.degree. C, preferably at 120.degree. to 140.degree. C. If appropriate, a solubilizing agent, such as dimethylformamide or N-methylpyrrolidone, can be added to increase the solubility of the alcohol of the general formula IV in the .beta.-keto ester of the general formula V. By applying a weak vacuum of about 800 to 20 mm Hg, preferably 400 to 100 mm Hg, the equilibrium is shifted continuously in the desired direction by distilling off the lower alcohol formed. When the theoretical amount of lower alcohol has distilled off, the excess .beta.-keto ester of low degree of esterification of the general formula V and if appropriate the solubilizing agent added are distilled off under a high vacuum. The .beta.-keto ester of the general formula II, which is often obtained as an oil, remains as the residue usually in a very high purity, so that it can be used for the diazo transfer without further purification.
The .beta.-keto esters of the general formula V of low degree of esterification required in this reaction sequence are in some cases commercially available or can be prepared by numerous methods which are known from the literature. Their preparation from the corresponding derivatives of 5-acyl-Meldrum's acid according to the general formula III is particularly preferred here. Although an additional reaction step is taken in this procedure in comparison with process variant 1, improved yields and/or purer .beta.-keto esters of the general formula II can be achieved with this variant.
The radiation-sensitive mixture according to the invention can contain one or more .alpha.-diazo-.beta.-keto esters of the general formula I, in particular in equal proportions. Preferably, however, the mixture contains only one photoactive compound. The concentration of the .alpha.-diazo-.beta.-keto esters of the general formula I in the radiation-sensitive mixture according to the invention can vary within wide limits. However, the concentration thereof is in general in the range from about 4 to 40% strength by weight, in particular 6 to 30% strength by weight, based on the non-volatile constituents of the radiation-sensitive mixture.
The radiation-sensitive mixture according to the invention furthermore contains at least one polymeric binder which is insoluble in water but soluble or at least swellable in aqueous alkaline solutions. The binder is particularly distinguished by the fact that it readily dissolves the constituents of the radiation-sensitive mixture according to the invention and has the lowest possible intrinsic absorption, in particular about .epsilon.<0.25 per .mu.m of layer thickness, that is to say a high transparency, especially in the wavelength range from about 190 to 300 nm. This does not include, in particular,those binders based on novolak condensation resins, which have as a rule been employed as photoactive components in combination with naphthoquinone diazides. Although novolak condensation resins, also in combination with the .alpha.-diazo-.beta.-keto esters mentioned, reveal a reduction in solubility, compared with aqueous-alkaline developers, in the non-exposed areas following imagewise exposure, their intrinsic absorption in the wavelength range required for the exposure is undesirably high.
However, the novolak condensation resins mentioned can be employed as a mixture with other resins of higher transparency which are suitable as binders. The mixing ratios here depend mainly on the nature of the binder to be mixed with the novolak resin. In particular, its degree of intrinsic absorption in the wavelength range mentioned, and also the miscibility with the other constituents of the radiation-sensitive mixture play a decisive role. However, the binder of the radiation-sensitive mixture according to the invention can in general contain up to about 30% by weight, in particular up to 20% by weight, of a novolak condensation resin.
Suitable binders are homo- or copolymers of p-hydroxystyrene and its alkyl derivatives, for example 3-methylhydroxystyrene, and homo- or copolymers of other polyvinylphenols, for example 3-hydroxystyrene, or the esters or amides of acrylic acid with aromatics containing phenolic groups. Comonomers which can be employed in the copolymer are polymerizable compounds, such as styrene, methacrylic acid methacrylate, acrylic acid methacrylate or similar compounds.
Mixtures of increased plasma stability are obtained if vinyl monomers containing silicon, for example vinyltrimethylsilane, are used to prepare copolymers of the above type. The transparency of these binders in the range of interest is generally higher, so that improved structuring is possible.
Homo- or copolymers of maleimide can also be used with the same success. These binders also exhibit a high transparency in the wavelength range described. The comonomers employed here are also preferably styrene, substituted styrenes, vinyl ethers, vinyl esters, vinyl-silyl compounds or (meth)acrylic esters.
Finally, copolymers of styrene with comonomers which cause an increase in solubility in aqueous-alkaline solutions can be used. These include, for example, maleic anhydride, maleic acid half-esters or the like.
The binders mentioned can occur in mixtures, as long as they are miscible and do not impair the optical qualities of the radiation-sensitive mixture. However, binders containing one type of the abovementioned species are preferred.
The radiation-sensitive mixture according to the invention contains about 60 to 96% by weight, in particular 70 to 94% by weight, of a binder, based on the content of nonvolatile constituents of the radiation-sensitive mixture.
Dyestuffs, pigments, wetting agents, adhesion promoters and flow control agents can furthermore be added to the radiation-sensitive mixture according to the invention, if appropriate, in order to improve specific requirements, such as flexibility, adhesion and gloss.
The photosensitive mixture according to the invention is preferably dissolved in solvents, such as ethylene glycol, glycol ethers, such as glycol monomethyl ether, glycol dimethyl ether, glycol monoethyl ether or propylene glycol monoalkyl ethers, in particular propylene glycol methyl ether; aliphatic esters, such as ethyl acetate, hydroxyethyl acetate, alkoxyethyl acetate, .gamma.-butyl acetate, propylene glycol monoalkyl ether acetate, in particular propylene glycol methyl ether acetate, or amyl acetate; ethers, such as dioxane; ketones, such as methyl ethyl ketone, methyl isobutyl ketone, cyclopentanone and cyclohexanone; dimethylformamide, dimethylacetamide, hexamethylphosphoric acid amide, N-methylpyrrolidone, butyrolactone or tetrahydrofuran or in mixtures thereof. Glycol ethers, aliphatic esters and ketones are particularly preferred. Solvent mixtures which also contain, inter alia, aromatic hydrocarbons or xylene, can moreover be used. The choice of solvents finally depends on the coating process used, the desired layer thickness and the drying conditions. The solvents must likewise be chemically neutral, that is to say they should not react irreversibly with the other components of the layer.
The solutions formed with the other constituents of the radiation-sensitive mixture as a rule have a solids content of about 5 to 60% by weight, preferably up to 50% by weight.
The invention furthermore relates to a radiation-sensitive recording material which essentially consists of a substrate and the radiation-sensitive mixture applied thereon.
Possible substrates are all materials of which condensers, semiconductors, multilayered printed circuits or integrated circuits consist or from which they can be produced. Surfaces of pure silicon layers and thermally oxidized and/or aluminum-coated silicon material, which can optionally also be doped, including all the other substrates which are customary in semiconductor technology, such as, for example, silicon nitride, gallium arsenide and indium phosphide, may be mentioned in particular. The substrates known from the production of liquid crystal displays, such as glass and indium/tin oxide; and furthermore metal sheets and foils, for example of aluminum, copper or zinc; bimetallic and trimetallic foils, but also foils which are not electrically conductive and which are vapor-deposited using metals, if appropriate aluminum-coated SiO, materials and paper are furthermore possible. These substrates can be subjected to heat pretreatment, roughened on the surface, etched or treated with chemicals to achieve desirable properties, such as, for example, an increase in hydrophilicity.
In a particular embodiment, the radiation-sensitive mixture can contain an adhesion promoter for better adhesion in the resist or between the resist and the substrate. Possible adhesion promoters here for silicon or silicon dioxide substrates are those of the aminosilane type, such as, for example, 3-aminopropyltriethoxysilane or hexamethyldisilazane.
Examples of carriers which can be used for production of photomechanical recording layers, such as printing forms for letterpress printing, planographic printing, screen printing and gravure printing, and of relief copies are aluminum sheets, if appropriate anodized, grained and/or silicated aluminum sheets, zinc sheets, steel sheets, which have been worked with chromium if appropriate, and films of plastics or paper.
The recording material according to the invention is exposed imagewise. Sources of actinic radiation are: metal halide lamps, carbon arc lamps, xenon lamps and mercury vapor lamps. Exposure can also be performed with high-energy radiation, such as laser beam, electron beam or X-ray. However, lamps which can emit light of a wavelength of 190 to 260 nm, that is to say, in particular, xenon and/or mercury vapor lamps, are particularly preferred. Laser light sources can also be used, for example excimer lasers, in particular KrF or ArF lasers, which emit light at 249 and 193 nm respectively. The radiation sources must have an adequate emission in the wavelength ranges mentioned, but on the other hand they must also be sufficiently transparent to actinic light of the range mentioned.
The invention furthermore relates to a process for the preparation of a radiation-sensitive recording material. The radiation-sensitive mixture can be applied to the substrate by spraying, rolling, knife-coating, pouring, flow-coating, whirler-coating and dip-coating or by means of slot dies. The solvent is then removed by evaporation, so that the radiation-sensitive layer remains on the surface of the substrate. If appropriate, the removal of the solvent can be promoted by heating the layer at temperatures of up to about 140.degree. C. However, it is also possible first to apply the mixture to the intermediate carrier in the abovementioned manner, and to transfer it from this to the final carrier material under pressure and at elevated temperature.
The layer thickness varies according to its field of use. It is between about 0.1 and 100 .mu.m, in particular between 0.3 and 10 .mu.m.
The layer is then exposed imagewise. Actinic radiation is usually employed UV lamps which emit light of a wavelength of about 190 to 300 nm are preferably used for the irradiation. An image pattern is then exposed in the radiation-sensitive layer by development, by treating the layer with a development solution which dissolves or removes the irradiated areas of the material.
Solutions of reagents such as, for example, silicates, metasilicates, hydroxides, hydrogen phosphates and dihydrogen phosphates, carbonates and bicarbonates of alkali metals and/or alkaline earth metals, and in particular of ammonium ions, or ammonia and the like, are used as developers. Developers which are free from metal ions are described in U.S. Pat. No. 4,729,941, EP-A-0,062,733, U.S. Pat. Nos. 4,628,023, 4,141,733, EP-A-0 097 282 and EP-A-0,023,758. The content of these substances in the developer solution is in general about 0.1 to 15% by weight, preferably 0.5 to 5% by weight, based on the weight of the developer solution. Developers which are free from metal ions are used in particular. If appropriate, relatively small amounts of a wetting agent may be added to the developers in order to facilitate detachment of the exposed areas in the developer.
If appropriate, the developed resist structures are postcured. This is in general effected by heating the resist structure on a hotplate up to a temperature below the flow point and then exposing the entire area to UV light from a xenon-mercury vapor lamp (range from 200 to 250 nm). As a result of this after-hardening, the resist structures are crosslinked, so that the structures in general have a flow stability up to temperatures of more than 200.degree. C. The postcuring can also be carried out without increasing the temperature under irradiation by UV light. This applies in particular if high-energy radiation is used, for example electron beams.
The radiation-sensitive mixture according to the invention is preferably used in lithographic processes for the production of integrated circuits or discrete electrical units. The recording material prepared from the mixture is used here as a mask for the subsequent process steps. These include, for example, etching of the layer carrier, implantation of ions into the layer carrier or deposition of metals or other materials onto the layer carrier.
Under the conditions customary in practice, when exposed to light in the DUV range the mixtures according to the invention exhibit a high photo-sensitivity which is comparable to that of known materials (for a comparison example, see below) when it is irradiated with light of a wavelength of about 190 to 300 nm. However, the advantages they exhibit are a higher heat stability than the known materials and an outstanding compatibility.
The following examples illustrate the preparation of the .alpha.-diazo-.beta.-keto esters according to the general formula I.
PREPARATION EXAMPLES
Preparation of a difunctional .alpha.-diazo-.beta.-keto ester of the general formula I: bis-2,9-diazo-1,10-dicyclohexyl-4,7-dioxa-1,3,8,10-tetraoxodecane (3)
Stage 1
5-(1-Cyclohexyl-1-hydroxymethylidene)-2,2-dimethyl-1,3-dioxane-4,6-dione (1)
A solution consisting of 144.1 g (1.0 mol) of 2,2-dimethyl-1,3-dioxane-4,6-dione and 158.2 g (2.0 mol) of pyridine in 500 ml of methylene chloride is cooled to 10.degree. C. 146.6 g (1.0 mol) of cyclohexanecarbonyl chloride are added dropwise at this temperature, while stirring. The reaction mixture is then warmed to room temperature, and after 4 hours a mixture of 500 g of ice, 500 ml of water and 100 ml of concentrated hydrochloric acid is added. The organic phase is washed twice with 400 ml of water, dried over magnesium sulfate and then freed from the solvent.
An oily red residue remains which is boiled up twice with 600 ml of n-hexane each time, with addition of active charcoal. On cooling, fine, pale yellow-colored crystals of the desired compound (1) precipitate out of the n-hexane solution. After further recrystallization from n-hexane, white crystals of the compound (1) of melting point 82.degree. C. are obtained in a yield of 57%.
Stage 2
1,10-Dicyclohexyl-4,7-dioxa-1,3,8,10-tetraoxo-decane (2)
12.4 g (0.2 mol) of ethylene glycol and 101.8 g (0.4 mol) of the compound (1) described above are introduced into 800 ml of ethyl methyl ketone and the mixture is heated slowly. From about 60.degree. C., vigorous evolution of carbon dioxide starts. The solution is kept under reflux for 2.5 hours. After the reaction mixture has cooled, the solvent is stripped off in vacuo. An oily residue which consists virtually exclusively of the desired difunctional .beta.-keto ester (2) remains. It is used as the starting product for the next stage without further purification.
Stage 3
Bis-2,9-diazo-1,10-dicyclohexyl-4,7-dioxa-1,3,8,10-tetraoxo-decane (3)
11.5 g (30 mmol) of the .beta.-keto ester (2) are dissolved in 130 ml of acetonitrile and the solution is cooled to 0.degree. C. 9.85 g (50 mmol) of tosyl azide are added to the cooled solution, while stirring, and 6.6 g (65 mmol) of triethylamine are then added dropwise so that the temperature does not rise above 5.degree. C. The mixture is stirred at this temperature for 10 minutes; it is then warmed to room temperature. After two hours, no further tosyl azide is detectable in the reaction mixture by thin layer chromatography (silica gel, mobile phase: CH.sub.2 Cl.sub.2). 3.4 g (15 mmol) of 4-carboxyphenylsulfonyl azide are added to the mixture, while cooling. After further reaction at room temperature for a further 2 hours, a precipitate forms. The mixture is concentrated on a rotary evaporator, the residue is taken up in diethyl ether, the mixture is extracted twice with in each case 5% strength aqueous potassium hydroxide solution and the extract is washed neutral with water. The organic phase is separated off and dried over magnesium sulfate. After concentration thereof, 12.2 g of a pale yellowish oil, which is freed from solvent residues by application of a high vacuum, remain. Chromatography on silica gel using methylene chloride as the mobile phase yields the colorless product (3), which has the following composition.
C.sub.22 H.sub.18 N.sub.4 O.sub.6 (molecular weight 434.41):
calculated: C 60.8%; H 4.2%; N 12.9%.
found: C 60.7%; H 4.3%; N 13.0%.
IR (film): 2,140.7 cm.sup.-1 (C.dbd.N.sub.2)
Example 2
Preparation of an unsaturated difunctional .alpha.-diazo-.beta.-keto ester of the general formula I: bis-4,13-diazo-6,11-dioxa-2,2,15,15-tetramethyl-3,5,12,14-tetraoxo-hexadec-8-yne (5)
Stage 1
6,11-Dioxa-2,2-15,15-tetramethyl-3,5,12,14-tetraoxo-hexadec-8-yne (4)
8.6 g (0.1 mol) of 2-butyne-1,4-diol are heated to 120.degree. C. together with 47.5 g (0.3 mol) of methyl 4,4-dimethyl-3-oxovalerate, while stirring. The methyl alcohol formed during this procedure is distilled off into a cooled receiver. After about 4 hours, the theoretically calculated amount of methyl alcohol is distilled off. The homogeneous solution is heated at 140.C for 1 hour and excess 4,4-dimethyl-3-oxovaleric acid is distilled off by applying a vacuum (10 mm Hg). The residue which remains virtually corresponds to the pure compound (4) and is further processed without additional purification.
Stage 2
Bis-4,13-diazo-6,11-dioxa-2,2,15,15-tetramethyl-3,5,12,14-tetraoxo-hexadec-8-yne (5)
30.4 g (90 mmol) of the product (4) described above are dissolved in 250 ml of acetonitrile and the solution is cooled to 0.degree. C. 33.6 g (170 mmol) of tosyl azide are added dropwise in portions, while stirring, so that the temperature does not exceed 5.degree. C. The mixture is warmed to room temperature. After about 2 hours, no further tosyl azide can be detected by thin layer chromatography. 4.5 g (20 mmol) of 4-carboxybenzenesulfonyl azide are added to the mixture. After two hours, the solvent is distilled off on a rotary evaporator, the solid residue is taken up in methylene chloride and the mixture is washed with 2.times.200 ml of 4% strength potassium hydroxide solution and then with 200 ml of water. After drying and removal of the solvent, an oil remains, which starts to crystallize in the refrigerator. The crystal cake (29.8 g=85% of theory) is recrystallized from n-hexane. 22.2 g of colorless crystals of the compound (5) of melting point 69.degree.-70.degree. C. are obtained.
C.sub.18 H.sub.22 N.sub.4 O.sub.6 (molecular weight 390.40)
calculated: C 55.38; H 5.68; N 14.35.
found: C 55.4; H 5.6; N 14.4.
IR (KBR): 2,137.9 cm.sup.-1, 2,160.0 cm.sup.-1 (shoulder) (C.dbd.N.sub.2).
Example 3
Preparation of a trifunctional .alpha.-diazo-.beta.-keto ester of the general formula I: tris-[(5-diazo-3,8-dioxa-4,6-dioxo-8-phenyl)-octyl]-amine (8)
Stage 1
5-(1-Hydroxy-2-phenoxyethylidene)-2,2-dimethyl-1,3-dioxane-4,6-dione (6)
93.8 g (0.55 mol) of phenoxyacetyl chloride are added dropwise to a solution, cooled to 8.degree. C., of 72.1 g (0.5 mol) of 2,2-dimethyl-1,3-dioxane-4,6-dione and 79.1 g (1.0 mol) of pyridine in 250 ml of methylene chloride so that the temperature does not rise above 10.degree. C. The mixture is subsequently stirred at room temperature for 2.5 hours, a mixture of 250 g of ice, 250 ml of water and 30 ml of concentrated hydrochloric acid is added and the mixture is extracted by shaking. The organic phase is washed twice with 100 ml of water each time and dried over magnesium sulfate. The solvent is distilled off, a solid remaining, which is recrystallized from t-butyl methyl ether. 72 g (52% of theory) of white crystals of the compound (6), which melt at 85.degree.-87.degree. C., with decomposition, are obtained.
Stage 2
Tris-[(3,8-dioxa-4,6-dioxo-8-phenyl)-octyl] -amine (7)
3.6 g (20 mmol) of triethanolamine and 18 g (64 mmol) of the compound (6) described above are heated under reflux in 140 ml of methyl ethyl ketone. When the evolution of carbon dioxide has ended, the mixture is heated under reflux for a further hour and the solvent is then distilled off. A highly viscous reddish oil of the compound (7) remains, which is employed for the subsequent reaction stage without further purification.
Stage 3
Tris-[(5-diazo-3,8-dioxa-4,6-dioxo-8-phenyl)-octyl]-amine (8)
The total amount of the oil (7) formed in stage 2 (about 20 mmol) is dissolved in 120 mol of acetonitrile and the solution is cooled to 0.degree. C. 6.5 g (65 mmol) of triethylamine are added to the cooled solution, while stirring, and 12.8 g (65 mmol) of tosyl azide are then added dropwise in a manner such that the temperature does not rise above 5.degree. C. The mixture is stirred at this temperature for 10 minutes and then warmed to room temperature. After three hours, the clear solution is evaporated to dryness on a rotary evaporator, the residue is taken up in diethyl ether, the mixture is extracted twice with 100 ml of 5% strength aqueous potassium hydroxide solution each time and the extract is then washed neutral with water. The organic phase is separated off and dried over magnesium sulfate. After concentration on a rotary evaporator, 15.4 g of a pale brownish oil remain, which is freed from solvent residues by applying a high vacuum. During this procedure, crystals start to separate out. The crystal slurry is recrystallized from toluene to form 12.1 g of colorless crystals of the compound (8), which melt at 104.degree. C. with the start of decomposition.
C.sub.36 H.sub.33 N.sub.7 O.sub.12 (molecular weight 707.70):
calculated: C 61.10%; H 4.70%; N 13.85%.
found: C 61.0%; H 4.7%; N 14.1%.
IR (KBr): 2,142 cm.sup.-1 (C.dbd.N.sub.2)
Example 4
Preparation of a trifunctional .alpha.-diazo-.beta.-keto ester of the general formula I: tris-[(5-diazo-7,7-dimethyl-4,6-dioxo-3-oxa)-octyl]-amine (10)
Stage 1
Tris-[(7,7-dimethyl-4,6-dioxo-3-oxa)-octyl]-amine (9)
7.5 g (50 mmol) of triethanolamine and 30 g (189 mmol) of methyl 4,4-dimethyl-3-oxovalerate are heated at 130.C for 5 hours, while stirring. The methyl alcohol formed during this procedure is distilled off. The excess monofunctional .beta.-keto ester is then distilled off in vacuo. A pale yellow oil remains, which proves to be an almost pure compound (9), so that it can be used for the subsequent reaction stage without further purification.
Stage 2
Tris-[(5-diazo-7,7-dimethyl-4,6-dioxo-3-oxa)-octyl]-amine (10)
18 g (34 mmol) of the compound (9) from stage 1 are dissolved in 180 ml of acetonitrile and the solution is cooled to 0.degree. C. 11.4 g (112 mmol) of triethylamine are added to the cooled solution, while stirring, and 22.4 g (112 mmol) of tosyl azide are then added dropwise so that the temperature does not rise above 5.degree. C. The mixture is stirred at this temperature for 10 minutes and then warmed to room temperature. After two hours, the clear solution is concentrated to dryness on a rotary evaporator, the residue is taken up in diethyl ether, the mixture is extracted twice with 100 ml of 5% strength aqueous potassium hydroxide solution each time and the extract is washed neutral with water. The organic phase is separated off and dried over magnesium sulfate. After concentration on a rotary evaporator, 18.4 g of a pale brownish oil remain, which is freed from solvent residues by applying a high vacuum. During this procedure, crystals start to separate out. The crystal slurry is recrystallized from cyclohexane to give 15.4 g of colorless crystals of the compound (10), which melt at 101.degree. C., with slow decomposition.
C.sub.27 H.sub.39 N.sub.7 O.sub.9 (molecular weight 605.65)
calculated: C 53.55%; H 6.49%; N 16.19%.
found: C 53.5%; H 6.7%; N 16.1%.
IR (KBr): 2,171 cm.sup.-1, 2,134 cm.sup.-1 : (shoulder) (C.dbd.N.sub.2)
Example 5
Preparation of a trifunctional .alpha.-diazo-.beta.-keto ester of the general formula I: N-phenyl-N'-[1,1-bis-(5-cyclohexyl-4-diazo-3,5-dioxo-2-oxapentyl)-6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl]-urea (13)
Stage 1
N-Phenyl-N'-[1,1-bis-hydroxymethyl-2-hydroxyethyl]-urea (11)
66.6 g (0.55 mol) of tris(hydroxymethyl)aminomethane are dissolved in 200 ml of distilled water, and 400 ml of acetone are added. 59.6 g (0.5 mol) of phenyl isocyanate are added dropwise, while stirring, whereupon a heavy white precipitate forms. When the addition has ended, the mixture is stirred for a further 2 hours and the precipitate is filtered off with suction. It is then digested successively with in each case 150 ml of water, acetone and diethyl ether. Finally, the compound (11), which is obtained in virtually analytically pure form, is dried at 75.degree. C.
Stage 2
N-Phenyl-N,-[1,1-bis-(5-cyclohexyl-3,5-dioxo-2-oxa-pentyl)-6-cyclohexyl-4,6-dioxo-3-oxahexyl]-urea (12)
8.4 g (35 mmol) of the compound (11) and 22.0 g (119 mmol) of methyl 3-cyclohexyl-3-oxo-propionate are heated at 130.degree. C. in a Claisen apparatus for 4 hours under application of a weak vacuum, the methyl alcohol formed being distilled off. The excess methyl 3-cyclohexyl-3-oxo-propionate (boiling point 75.degree.-76.degree. C./0.05 mm Hg) is then distilled off from the mixture. A brownish highly viscous oil of N-phenyl-N'-1,1-bis-(5-cyclohexyl-3,5-dioxo-2-oxa-pentyl)-6-cyclohexyl-4,6-dioxo-3-oxa-hexyl-urea (12) remains and can be further used without additional purification.
Stage 3
N-Phenyl-N,-[1,1-bis-(5-cyclohexyl-4-diazo-3,5-dioxo-2-oxa-pentyl-6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl]-urea (13)
13.72 g (20 mmol) of the compound (12) described above and 6.6 g (65 mmol) of triethylamine are dissolved in 140 ml of acetonitrile and the solution is cooled to 0.degree. C. 12.8 g (65 mmol) of toluenesulfonyl azide are added dropwise to this solution so that the temperature does not rise above 5.degree. C. The mixture is warmed to room temperature and subsequently stirred for 4 hours. The clear solution is then evaporated to dryness on a rotary evaporator, the residue is taken up in methylene chloride, the mixture is extracted twice with 100 ml of 5% strength aqueous potassium hydroxide solution each time and the extract is washed neutral with water. The organic phase is separated off and dried over magnesium sulfate. After concentration on a rotary evaporator, 12.4 g of a pale brownish oil remain, which is freed from solvent residues by applying a high vacuum. The oil is taken up again in a small amount of methylene chloride and eluted over a silica gel column. By using methylene chloride/ethyl acetate 5:1 as the mobile phase and after concentration of the solvent, 8.5 g (55.6% of theory) of a pale yellowish oil of the compound (13) is obtained.
C.sub.38 H.sub.48 N.sub.8 O.sub.10 (molecular weight 764.76):
calculated: C 58.91%; H 5.98%; N 14.46%.
found: C 59.2%; H 6.0%; N 14.5%.
IR (KBr): 2,141.2 cm.sup.-1 : (C.dbd.N.sub.2)
Example 6
Preparation of a trifunctional .alpha.-diazo-.beta.-keto ester of the general formula I: 2,2,2-tris-[4-(7-cyclohexyl-6-diazo-1,4-dioxa-5,7-dioxoheptyl)-phenyl]-ethane (15)
Stage 1
2,2,2-Tris-[4-(7-cyclohexyl-1,4-dioxa-5,7-dioxo-heptyl)-phenyl]-ethane (14)
8.77 g (20 mmol) of 2,2,2-tris-[4-(2-hydroxyethoxy)-phenyl]-ethane (prepared by reaction of tris-(4-hydroxyphenyl)-ethane with 2-chloroethanol) are heated at 130.degree. C. with 18.4 g (100 mmol) of methyl 3-cyclohexyl-3-oxo-propionate in a Claisen apparatus for 4 hours with application of a weak vacuum. The methyl alcohol formed is distilled off, as is the excess methyl 3-cyclohexyl-3-oxo-propionate (boiling point 75.degree.-76.degree. C./0.05 mm Hg). A pale brownish-colored highly viscous oil of the compound (14) remains and is further used without additional purification.
Stage 2
2,2,2-Tris-[4-(7-cyclohexyl-6-diazo-1,4-dioxa-5,7-dioxo-heptyl)-phenyl]-ethane (15)
8.95 g (10 mmol) of the compound (14) described above and 3.5 g (35 mmol) of triethylamine are dissolved in 100 ml of acetonitrile and the solution is cooled to 0.degree. C. 6.9 g (35 mmol) of toluenesulfonyl azide are added dropwise to this solution so that the temperature does not rise above 5.degree. C. The mixture is warmed to room temperature and subsequently stirred for 4 hours. The clear solution is then evaporated to dryness on a rotary evaporator, the residue is taken up in methylene chloride, the mixture is extracted twice with 100 ml of 5% strength aqueous potassium hydroxide solution each time and the extract is washed neutral with water. The organic phase is separated off and dried over magnesium sulfate. After concentration on a rotary evaporator, 9.4 g of a pale brownish oil remain, which is freed from solvent residues by applying a high vacuum. The oil starts to crystallize immediately. The crystal slurry is recrystallized from t-butyl methyl ether. The compound (15) is obtained in the form of a white powder in virtually quantitative yield and has a melting point of 96.degree. C.
C.sub.53 H.sub.60 N.sub.6 O.sub.12 (molecular weight 973.09):
calculated: C 65.42%; H 6.22%; N 8.64%.
found: C 65.4%; H 6.3%; N 8.4%.
IR (KBr): 2,141.2 cm.sup.-1 (C.dbd.N.sub.2)
Example 7
Preparation of a tetrafunctional .alpha.-diazo-.beta.-keto ester of the general formula I: N-[1,1-bis-(5-cyclohexyl-4-diazo-3,5-dioxo-2-oxa-pentyl)-6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl]-0-(6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl)-urethane (18)
Stage 1
N-(Bis-1,1-hydroxymethyl-2-hydroxyethyl)-0-(2-hydroxyethyl)-urethane (16)
88.6 g (1 mol) of ethylene carbonate and 21.2 g of tris-(hydroxymethyl)-aminomethane are mixed with one another. The mixture heats up and is kept at not more than 70.degree. C. by external cooling. When the exothermic reaction has ended, the mixture is stirred at this temperature for a further 6 hours. On cooling, a melt forms, which is recrystallized from acetone. 198 g of white crystals of melting point 112.degree. C. are obtained.
Stage 2
N-[1,1-Bis-(5-cyclohexyl-3,5-dioxo-2-oxapentyl)-6-cyclohexyl-4,6-dioxo-3-oxa-hexyl]-0-(6-cyclohexyl-4,6-dioxo-3-oxa-hexyl)-urethane (17)
6.27 g (30 mmol) of the compound (16) from stage 1 are heated at 140.degree. C. with 25.0 g (136 mmol) of methyl cyclohexylacetoacetate. The theoretical amount of methyl alcohol is distilled off from the mixture in the course of 4 hours. The excess methyl cyclohexylacetoacetate is then distilled off in vacuo and the pale brownish residue of the compound (17) is further processed without additional purification.
Stage 3
N-[1,1-Bis-(5-cyclohexyl-4-diazo-3,5-dioxo-2-oxa-pentyl)-6-cyclohexyl-5-diazo-4,6-dioxo-3-oxahexyl]-0-(6-cyclohexyl-5-diazo-4,6-dioxo-3-oxahexyl)-urethane (18)
24.5 g (30 mmol) of the compound (17) are dissolved in 250 ml of acetonitrile and the solution is cooled to 0.degree. C. 13.4 g (130 mmol) of triethylamine are added to the cooled solution, while stirring. 25.6 g (130 mmol) of tosyl azide are then added dropwise so that the temperature does not rise above 5.degree. C. The mixture is stirred at this temperature for 10 minutes and then warmed to room temperature. After 3 hours, the clear reddish-brown solution is concentrated to dryness on a rotary evaporator, the residue is taken up in methylene chloride, the mixture is extracted twice with 100 ml of 5% strength aqueous potassium hydroxide solution each time and the extract is washed neutral with 5% strength aqueous sodium chloride solution. The organic phase is then separated off and dried over magnesium sulfate. After concentration of the solution on a rotary evaporator, 26.7 g of a brownish oil remain, which is freed from solvent residues by application of a high vacuum. By addition of diethyl ether, small amounts of pale yellowish crystals start to separate out. These are separated off and prove to be N-[1,1-bis-(5-cyclohexyl-4-diazo-3,5-dioxo-2-oxapentyl)-6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl]-O-(6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl)-urethane (18). The solution which remains is chromatographed on silica gel using methylene chloride in order to isolate residual traces of the compound (18). Excess tosyl azide is eluted during this procedure. The main fraction is eluted with a mixture of methylene chloride/ethyl acetate (75% of the amount employed), crystallization of the compound (I8) starting after the solvent has been distilled off.
C.sub.43 H.sub.55 N.sub.9 O.sub.14 (molecular weight 921.96):
calculated: C 56.02%; H 6.01%; N 13.62%.
found: C 56.1%; H 5.8%; N 13.4%.
IR (KBr): 2,140.6 cm.sup.-1 (C.dbd.N.sub.2)
Example 8
Preparation of a tetrafunctional .alpha.-diazo-.beta.-keto ester of the general formula I: N,N,N',N'-tetrakis-[6-cyclohexyl-5-diazo-4,6-dioxo-3-oxahexyl]-ethylenediamine (20)
Stage 1
N,N,N',N'-Tetrakis-6-cyclohexyl-4,6-dioxo-3-oxa-hexyl-ethylenediamine (19)
5.9 g (25 mmol) of N,N,N',N'-tetrakis-(2-hydroxyethyl)-ethylenediamine are heated at 130.degree. C. with 33.1 g (180 mmol) of methyl 3-cyclohexyl-3-oxo-propionate for 7.5 hours, during which the methyl alcohol formed is distilled off. The excess methyl 3-cyclohexyl-3-oxo-propionate is then distilled off in vacuo. An orange-yellow viscous oil of the very pure compound (19) is obtained in quantitative yield. This is employed in the next reaction stage without further purification.
Stage 2
N,N,N',N'-Tetrakis-[6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa-hexyl]-ethylenediamine (20)
19.8 g (23 mmol) of the compound described above are dissolved in 200 ml of acetonitrile. 20.6 g (104 mmol) of tosyl azide are added to the solution, which has been cooled to 0.degree. C., and 10.8 g (107 mmol) of triethylamine are then added dropwise so that the temperature does not rise above 50.degree. C. After three hours, the clear reddish solution is evaporated to dryness on a rotary evaporator, the residue is taken up in an ether/methylene chloride (3:1) mixture, the mixture is extracted twice with 100 ml of 5% strength aqueous potassium hydroxide solution each time and the extract is washed neutral with 5% strength aqueous sodium chloride solution. The organic phase is separated off and dried over magnesium sulfate. On concentration on a rotary evaporator, the almost pure product (20) is already obtained as crystals in a yield of 95%. An analytically pure sample is prepared by recrystallization from ethanol, yielding white crystals of melting point 112.degree.-114.degree. C.
C.sub.46 G.sub.64 N.sub.10 O.sub.12 (molecular weight 949.07):
calculated: C 58.22%; H 6.80%; N 14.76%.
found: C 58.1%; H 7.0%; N 14.5%.
IR (KBr): 2,140.6 cm.sup.-1 (C.dbd.N.sub.2)
Example 9
Preparation of a hexafunctional .alpha.-diazo-.beta.-keto ester of the general formula I: 1,19-bis-cyclohexyl-2,18-bis-diazo-6,14-[bis-(4-cyclohexyl-3-diazo-2,4-dioxo-1-oxa)-butyl]-10-[8-(cyclohexyl-7-diazo-1,5-dioxa-6,8-dioxo-3-(3-cyclohexyl-3-diazo-2,4-dioxo-1-oxa-butyl))-1,5-dioxa-6,8-dioxooctyl]-4,8,12,16-tetraoxa-1,3,17,19-tetraoxononadecane (22)
Stage 1
1,19-Bis-cyclohexyl-6,14-[bis-(4-cyclohexyl-2,4-dioxo-1-oxa)-butyl]-10-[8-(cyclohexyl-1,5-dioxa-6,8-dioxo-3-(3-cyclohexyl-2,4-dioxo-1-oxabutyl))-1,5-dioxa-6,8-dioxo-octyl]-4,8,12,16-tetraoxa-1,3,17,19-tetraoxo-nonadecane (21)
6.32 g (20 mmol) of tetraglycerol are heated at 130.degree. C. with 33.1 g (180 mmol) of methyl 3-cyclohexyl-3-oxo-propionate for 7.5 hours, the methyl alcohol formed being distilled off. The excess methyl 3-cyclohexyl-3-oxo-propionate is then distilled off in vacuo. A virtually colorless vitreous product of very pure 1,19-bis-cyclo-hexyl-6,14-[bis-(4-cyclohexyl-2,4-dioxo-1-oxa)-butyl]-10-[8-(cyclohexyl-1,5-dioxa-6,8-dioxo-3-(3-cyclohexyl-2,4-dioxo-1-oxa-butyl))-1,5-dioxa-6,8-dioxo-octyl]-4,8,12,16-tetraoxa-1,3,17,19-tetraoxo-nonadecane (21) is obtained in a quantitative yield. This is employed in the next reaction stage without further purification.
Stage 2
1,19-Bis-cyclohexyl-2,18-bis-diazo-6,14-[bis-(3-diazo-4-cyclohexyl-2,4-dioxo-1-oxa)-butyl]-10-[8-(cyclohexyl-7-diazo-1,5-dioxa-6,8-dioxo-3-(3-cyclohexyl-3-diazo-2,4-dioxo-1-oxa-butyl))-1,5-dioxa-6,8-dioxo-octyl]-4,8,12,16-tetraoxa-1,3,17,19-tetraoxo-nonadecane (22)
12.3 g (10 mmol) of the compound (21) are dissolved in 150 ml of acetonitrile, and 11.8 g (60 mmol) of tosyl azide and 6.1 g (60 mmol) of triethylamine are added, as described above. After warming to room temperature, the mixture is stirred for 8 hours and worked up as described above. Half of the product mixture is eluted over a silica gel column, a pale yellow fraction being isolated by using the mobile phase methylene chloride/ethyl acetate (6:1). After concentration, a yellowish oil remains.
C.sub.66 H.sub.86 N.sub.12 O.sub.21 (molecular weight 1383.48): calculated: C 57.30%; H 6.27%; N 12.15%. found: C 56.7% ; H 6.5%; N 11.9%.
IR (film): 2,138.4 cm.sup.-1 (C.dbd.N.sub.2)
Example 10
As described in Example 7, 10 g (73.5 mmol) of pentaerythritol are reacted with 55.2 g of methyl 3-cyclohexyl-3-oxo-propionate and the mixture is worked up. A tetrafunctional ester (compound 23) in which R.sup.1 denotes C.sub.6 H.sub.11 can be isolated. It is obtained as a viscous oil in virtually quantitative yield.
The ester (23) is then reacted with 59.1 g (300 mmol) of toluenesulfonyl azide and 30.6 g (300 mmol) of triethylamine in 200.0 g of acetonitrile to give the corresponding tetrafunctional .alpha.-diazo-.beta.-keto ester of the general formula I. The compound (25) is purified by recrystallization from ethanol. It has a melting point of 123.degree.-125.degree. C.
C.sub.14 H.sub.52 N.sub.8 O.sub.12 (molecular weight 848.91): calculated: C 58.01%; H 6.17%; N 13.20%. found: C 58.2% ; H 6.2% ; N 13.2%.
Example 11 (Comparison Example)
As described in Example 10, 10 g of pentaerythritol are converted into a tetrafunctional ester (compound 24), but in this case using 39.0 g of methyl acetoacetate, so that R.sup.1 denotes CH.sub.3.
The compound (24) is then converted, as described in Example 10, into the corresponding tetrafunctional .alpha.-diazo-.beta.-keto ester (26) of the general formula I and the compound (26) is recrystallized from ethanol. It has a melting point of 108.degree.-120.degree. C.
C.sub.21 H.sub.20 N.sub.8 O.sub.12 (molecular weight 576.43): calculated: C 43.76%; H 3.50%; N 19.44%. found: C 43.9%; H 3.6%; N 19.5%.
As demonstrated in German Patent Application P 39 00 735.9, corresponding to U.S. application Ser. No. 07/464,003, filed at the same time, it is true that photosensitive mixtures which contain the compound according to Example 11 as the photoactive component show comparable bleaching properties in comparison with the compound of the general formula I according to the invention, but the image differentiating properties are not satisfactory.
Examples 12 to 67
Further compounds of the general formula I are listed, which have been prepared analogously to the examples described so far. Because of the large number of compounds, these are characterized in the following tables in respect of the possible variations described in the general formula I. Quantitative determination of the nitrogen is sufficiently conclusive as an analytical value.
No. R.sup.1 m X n calc./found N % 12 C.sub.6 H.sub.5CH.sub.2 2 C.sub.2 H.sub.4 0 12.90/13.0 13 CH.sub.3 C O(O)C.sub.2 H.sub.4 2 " 0 12.22/12.5 14 CH.sub.3C(O)C.sub.2 H.sub.4 2 " 0 19.80/20.1 15 C.sub.6 H.sub.5CH.sub.2OCH.sub.2 2 " 0 11.24/11.2 16 n-C.sub.4 H.sub.9 2 CH.sub.2 CH.sub.2 CH.sub.2 0 14.73/14.8 17 ##STR24## 2 ##STR25## 0 14.33/14.2 18 i-C.sub.4 H.sub.9 2 ##STR26## 0 14.20/14.3 19 n-C.sub.14 H.sub.29 2 ##STR27## 0 8.30/8.3 20 n-C.sub.6 H.sub.13 2 C.sub.2 H.sub.4OC.sub.2 H.sub.4 0 12.44/12.6 21 t-C.sub.4 H.sub.9 2 C.sub.2 H.sub.4SC.sub.2 H.sub.4 0 13.14/13.1 22 C.sub.6 H.sub.11 2 CH.sub.3N(C.sub.2 H.sub.4).sub.2 0 15.51/15.3 23 C.sub.6 H.sub.5OCH.sub.2 2 CH.sub.2(CH.sub.2).sub.4CH.sub.2 0 10.72/10.8 24 n-C.sub.4 H.sub.9 2 CH.sub.2CHCHCH.sub.2 0 14.28/14.1 25 C.sub.6 H.sub.11 2 CH.sub.2CCCH.sub.2 0 12.66/12.6 26 C.sub.6 H.sub.5CH.sub.2 2 " 0 12.22/12.5 27 n-C.sub.8 H.sub.17 2 " 0 11.15/11.2 28 CH.sub.3 OC(O)C.sub.2 H.sub.4 2 " 0 11.22/11.2 29 C.sub.6 H.sub.11 2 ##STR28## 0 14.18/13.9 30 CH.sub.3 OC.sub.2 H.sub.4 OCH.sub.2 2 ##STR29## 0 12.84/12.5 31 ##STR30## 2 ##STR31## 0 13.89/14.1 32 C.sub.6 H.sub.11 2 ##STR32## 0 15.84/16.0 33 C.sub.6 H.sub.5CH.sub.2 2 " 0 15.38/15.8 34 C.sub.6 H.sub.11 2 ##STR33## 0 15.94/16.2 35 t-C.sub.4 H.sub.9 3 ##STR34## 0 15.32/15.3 36 C.sub.6 H.sub.11 3 " 0 13.41/13.2 37 " 3 " 1 12.49/12.2 38 " 3 N(C.sub.2 ) H.sub.4.sub.3 0 14.34/14.5 39 CH.sub.3(CH.sub.2).sub.7 3 " 0 12.67/12.4 40 C.sub.6 H.sub.5CH.sub.2 3 " 0 13.85/13.9 41 CH.sub.3(CH.sub.2).sub.16 3 " 0 8.51/8.2 42 ##STR35## 3 " 0 12.57/12.3 43 t-C.sub.4 H.sub.9 3 ##STR36## 0 15.94/16.1 44 i-C.sub.4 H.sub.9 3 " 0 15.94/16.0 45 C.sub.6 H.sub.11 3 " 0 14.35/14.5 46 t-C.sub.4 H.sub.9 3 ##STR37## 0 16.08/15.8 47 C.sub.6 H.sub.5CH.sub.2 3 " 0 14.03/14.6 48 n-C.sub.10 H.sub.21 3 " 0 11.81/12.0 49 C.sub.6 H.sub.11 3 ##STR38## 0 15.84/15.7 50 C.sub.6 H.sub.5CH.sub.2 3 " 0 15.30/15.6 51 t-C.sub.4 H.sub.9 3 ##STR39## 0 9.39/9.1 52 C.sub.6 H.sub.5OCH.sub.2 3 " 0 8.04/8.5 53 t-C.sub.4 H.sub.9 4 C(CH.sub.2).sub.4 0 15.05/14.9 54 C.sub.6 H.sub.5CH.sub.2 4 " 0 12.72/13.0 55 C.sub.6 H.sub.11 4 ##STR40## 0 15.11/15.0 56 C.sub.6 H.sub.5CH.sub.2 4 " 0 14.70/15.1 57 t-C.sub.4 H.sub.9 4 ##STR41## 0 16.43/16.8 58 C.sub.6 H.sub.11 4 " 0 15.04/15.2 59 C.sub.6 H.sub.11 4 ##STR42## 0 13.98/14.2 60 t-C.sub.4 H.sub.9 4 ##STR43## 0 16.58/16.5 61 n-C.sub.6 H.sub.13 4 " 0 14.63/15.0 62 t-C.sub.4 H.sub.9 5 ##STR44## 0 14.28/14.5 63 t-C.sub.4 H.sub.9 5 " 1 13.52/12.8 64 t-C.sub.4 H.sub.9 6 ##STR45## 0 14.40/14.7 65 C.sub.6 H.sub.11 6 " 0 12.70/12.4 66 i-C.sub.4 H.sub.9 6 ##STR46## 0 13.70/13.2 67 C.sub.4 H.sub.7 6 " 0 13.52/13.2 68 t-C.sub.4 H.sub.9 8 ##STR47## 0 14.10/13.8 69 C.sub.6 = cyclohexyl. cyclobutyl; C.sub.6 H.sub.11
USE EXAMPLES
The following examples show some possible possible uses of the radiation-sensitive mixtures according to the invention. These are intended merely to be of illustrating character, and not to limit the invention. In the examples, the ratio of parts by weight (pw) to pars by volume (pv) or g:cm.sup.3 is 1:1.
Example 1
A radiation-sensitive micture containing
0.19 Gt 2,2,2-tris-[4-(7-cyclohexyl-6-diazo-1,4-dioxa-7,5-dioxo-heptyl)-phenyl]-ethane (Example 6) and
0.75 Gt poly-(3-methyl-4-hydroxystyrene) in
4.25 Gt propylene glycol monomethyl ether acetate
is prepared.
1.5 ml of this solution is filtered through a filter of pore diameter 0.2 .mu.m and applied to a silicon wafer having a diameter of 7.62 cm. A homogeneous layer is produced by rotating the wafer at 2,000 revolutions per minute for 40 seconds, and after drying in a circulating air oven at 90.degree. C. for 30 minutes has a thickness of 0.87 .mu.m.
The wafer coated in this manner is irradiated imagewise through a photomask with UV radiation from a xenon-mercury vapor lamp at 260 nm with an energy of 112 mJ/cm.sup.3.
The layer which has been irradiated imagewise is then developed with a 0.3 N aqueous solution of tetramethylammonium hydroxide for 120 seconds. The removal of the layer in the non-exposed areas (dark area removal) was less than 20 nm. Structures, including those having dimensions of less than 1.0 .mu.m, were cleanly resolved with a good edge stability.
Example 2
A radiation-sensitve mixture containing
0.19 pw N-cyclohexyl-N'-tris-[(5-cyclohexyl-4-diazo-3,5-dioxo-2-oxa)-pentyl]-methylurea (Example 45) and
0.75 pw poly-(3-methyl-4-hydroxystyrene) in 4.25 pw propylene glycol monomethyl ether acetate is prepared.
A radiation-sensitive mixture is prepared from this solution using the information from Example 1. Exposure and development are carried out analogously to Example 1. However, an exposure energy of 60 mJ/cm.sup.2 is used for the exposure. Structures with sharp edges could be obtained.
Example 3
A radiation-sensitive mixture containing
0.19 pw tris-[(5-diazo-4,6-dioxo-3-oxa-7-phenyl)-heptyl]-amine (Example 40) and
0.75 pw poly-(3-methyl-4-hydroxystyrene) in 4.25 pw propylene glycol monomethyl ether acetate is prepared and is further processed in accordance with Example 2. Structures with sharp edges were to be obtained on imagewise irradiation with an energy of 71 mJ/cm.sup.2.
Example 4
A radiation-sensitive mixture containing
0.19 pw tris-[(5-diazo-4,6-dioxo-3-oxa-7-phenyl)-heptyl]-amine and
0.55 pw poly-(styrene-co-maleimide) (1:1) in 4.45 pw cyclohexanone is prepared.
1.5 ml of this solution are filtered by means of a filter of pore diameter 0.2 .mu.m and applied to a silicon wafer rotating at 2,000 revolutions per minute and having a diameter of 7.62 cm. After 40 seconds, a homogeneous layer can be obtained. After the layer has been dried at 90.degree. C. for 30 minutes, the layer thickness of the homogeneous radiation-sensitive layer is 0.891 .mu.m.
The coated wafer is then exposed imagewise through a photomask at a wavelength of 260 nm. A xenon-mercury vapor lamp is used as the UV radiation source. The exposure energy is 200 mJ/cm.sup.2.
The layer could then be developed perfectly within 60 seconds using a 0.02 N aqueous solution of tetramethylammonium hydroxide. The dark area removal was less than 10 nm; structures 1.0 .mu.m wide showed a good resolution with a good edge gradient.
Examples 5 to 14
Radiation-sensitive mixtures were prepared and processed analogously to Example 4 but using the photoactive compounds listed below. In all cases, a high resolution was achieved using the exposure energy stated.
______________________________________ Exposure Photoactive energyExample component [mJ/cm.sup.2 ]______________________________________5 Bis-[N,N'-(5-diazo-6-cyclohexyl-4,6-dioxo- 60 3-oxa)-hexyl]piperazine (Example 32)6 Bis-4,13-diazo-6,11-dioxa-2,2,15,15-tetra- 45 methyl-3,5,12,14-tetraoxo-hexadec-8-yne (Example 2)7 Tris-[(5-diazo-7,7-dimethyl-4,6-dioxo-3-oxa)- 70 octyl]-amine (Example 4)8 Tris-[(6-cyclohexyl-5-diazo-4,6-dioxo-3-oxa)- 110 hexyl]-amine (Example 38)9 Tris-[(5-diazo-3,11-dioxa-4,6,10-trioxo)- 130 tridecyl]-amine (Example 42)10 Tris-[(5-diazo-4,6-dioxo-3-oxa-7-phenyl)- 200 heptyl]-amine (Example 40)11 Tris-[(5-diazo-3,8-dioxa-4,6-dioxo-8- 230 phenyl)-octyl]-amine12 N-[1,1-bis-(5-cyclohexyl-4-diazo-3,5-dioxo-2- 60 oxa-pentyl)-6-cyclohexyl-5-diazo-4,6-dioxo-3- oxa-hexyl]-O-(6-cyclohexyl-5-diazo 4,6- dioxo-3-oxa-hexyl)-urethane (Example 7)13 1,19-Bis-cyclohexyl-2,18-bis-diazo-6,14-[bis- 96 (4-cyclohexyl-3-diazo-2,4-dioxo-1-oxa)- butyl]-10-[8-(cyclohexyl-7-diazo-1,5-dioxa- 6,8-dioxo-3-(3-cyclohexyl-3-diazo-2,4-dioxo- 1-oxa-butyl))-1,5-dioxa-6,8-dioxo-octyl]- 4,8,12,16-tetraoxa-1,3,17,19-tetraoxo- nonadecane (Example 9)14 Mixture of equal parts by weight of tris-[(5- 164 diazo-7,7-dimethyl-4,6-dioxo-3-oxa)-octyl]- amine (Example 4) and 2,2,2-tris-[4-(7- cyclohexyl-6-diazo-1,4-dioxa-5,7-dioxo- heptyl)-phenyl]-ethane (Example 6)______________________________________
Example 15
A radiation-sensitive mixture containing
0.19 pw of the compound (25) from Preparation Example 10 and
0.55 pw of poly-(styrene-co-maleimide) (1:1) in 4.45 pw of cyclohexanone is prepared.
1.5 ml of the solution is whirler-coated through a filter of pore diameter 0.2 .mu.m onto a silicon wafer of 7.62 cm diameter and a homogeneous layer is produced within 40 seconds by rotating the wafer at 4000 revolutions per minute. The layer thickness after drying at 90.degree. C. for 30 minutes in a circulating air oven is 0.87 .mu.m.
The coated wafer is irradiated through a photomask with UV radiation from a xenon-mercury vapor lamp in the range of 260 nm with an exposure energy of 200 mJ/cm.sup.2. The layer is then developed with a 0.3 N aqueous solution of tetraethylammonium hydroxide in the course of 60 seconds. The dark area removal was less than 2 nm/minute. 1 .mu.m structures were to be resolved cleanly and with sharp edges by using an exposure energy of 116 mJ/cm.sup.2.
Example 16 (Comparison Example)
A radiation-sensitive mixture containing
0.19 pw of the compound (26) from Comparison Example 11 and
0.55 pw of poly-(styrene-co-maleimide) (1:1) in 4.45 pw of cyclohexanone is prepared.
The mixture is processed analogously to Example 15. However, it was to be found that after a development time of 60 seconds using the same developer from Example 15, both the exposed and the non-exposed areas had been completely removed. The removal of the non-exposed areas (dark area removal) at 1,660 nm/minute was comparable to the removal rate of the exposed areas (2,360 nm/minute). Only if a development time of 20 seconds was used were structures to be produced, but with very flat edges.

Number	Name	Date
4339522	Balanson et al.	Jul 1982
4622283	Gray	Nov 1986
4624908	Schwartzkopf	Nov 1986
4626491	Gray	Dec 1986
4735885	Hopf et al.	Apr 1988
4996301	Wilharm et al.	Feb 1991

Number	Date	Country
0129694	Jan 1985	EPX
0195986	Oct 1986	EPX
0198674	Oct 1986	EPX
0262864	Apr 1988	EPX
3841571	Jun 1989	DEX

Positively operating radiation-sensitive mixture containing a polyfunctional .alpha.-diazo-.beta.-keto ester and radiation-sensitive recording material containing this mixture

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Entry
Patent Abstracts, vol. 99, 1983, 99:53746y Bicycle diazodiketocyclopentanes U.S.S.R. SU 1,004,359.
Willson et al., "New Diazoketone Dissolution Inhibitors for Deep U.V. Photolithography," Advances in Resist Technology and Processing IV, Mar. 2-3, 1987, pp. 2-10.
Sugiyama et al., "Positive Excimer Laser Resists Prepared with Aliphatic Diazoketones," SPIE Proc., 920, 51, 1988, pp. 51-61.