Improved Synthesis for the Production of Ordered Polyblock Copolymers with Controllable Molecular Weight Distribution

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This patent describes a new and efficient method to synthesize well-ordered block copolymers, specifically with tightly controlled molecular weight distribution. The method allows for the sequential and convergent assembly of polymers containing at least one non-polar and one polar block, where the polar block can be very short and is attached in a single step via epoxy functionalization. The precise control enables the creation of copolymers with highly uniform chain lengths, particularly suitable for advanced solid polymer electrolytes in rechargeable alkali metal batteries, such as lithium-ion batteries.

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• Manufacture of high-performance solid polymer electrolytes for lithium-ion and other alkali-ion batteries
• Development of next-generation batteries with improved safety and performance for portable electronics, electric vehicles, and grid storage
• Production of advanced polymeric materials with independently tunable ion-transport and mechanical properties
• Use in flexible and solid-state energy storage devices where stability and uniformity of electrolyte are vital
• Creating new materials for medical devices that require specific electrical and mechanical properties

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• Enables precise and reproducible control over block copolymer molecular weights and compositions
• Allows the scalable and cost-effective synthesis of block copolymers with very uniform chain lengths (low polydispersity)
• Results in polymer electrolytes offering high ionic conductivity over wide temperature ranges, including below 0°C
• Provides materials with decoupled ionic transport and mechanical properties—optimizing both independently
• Improves battery safety compared to liquid electrolyte systems (lower flammability/risk)
• Facilitates the development of batteries with better performance (higher lithium-ion conductivity, more stable cycling)
• Allows for the use of less hazardous chemicals and simplified, easily automatable production processes

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Patent Abstract

The present invention relates to a method for sequential and convergent production of ordered block copolymers which at least comprise a non-polar and a polar polymer block, wherein the non-polar block is constructed by means of living sequential anionic polymerisation from specific monomers using a Li organyl initiator having a pKa value greater than or equal to 45, and the polar block is a polymer block having a molecular weight greater than or equal to 350 g/mol and less than or equal to 5000 g/mol and is selected from monomers from the group consisting of C2-C10 oxacyclo- compounds, derivatives thereof or mixtures of at least two different monomers therefrom, wherein the polar polymer block is convergently covalently bonded in one step to the non-polar block anion by means of epoxy functionalisation of one of the monomers of the polar block, obtained by reacting this monomer with epichlorohydrin, in a non-polar solvent in the presence of free Li ions. The present invention also relates to specific block copolymers having short polar chains of very uniform chain lengths, to polymer electrolytes and to the use of the block copolymers as polymer electrolytes in secondary alkaline batteries.