DPP with branched alkyl-chain or (and) fused thiophene with branched alkyl-chain and the related designing strategy to increase the molecular weight of their semi-conducting copolymers

Abstract

Described herein are compositions including hereocyclic fused thiophene based compounds, polymers based on fused thiophene compounds, and methods for making the monomer and polymer along with uses in thin film-based and other devices.

Claims

1. A polymer chosen from compounds of formula 1AA or 2AA: ##STR00036## wherein m is an integer greater than or equal to one, a and b are equal and are chosen from integers greater than or equal to 3, wherein c and d are equal and are chosen from integers greater than or equal to 5, n is 1 or 2, A=B=O, R.sub.9=R.sub.10=H, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.3 may be, independently, hydrogen, substituted or unsubstituted C.sub.4 or greater alkyl, substituted or unsubstituted C.sub.4 or greater alkenyl, substituted or unsubstituted C.sub.4 or greater alkynyl, or C.sub.5 or greater cycloalkyl; and with the provisos that: i) at least one of R.sub.1 or R.sub.2; one of R.sub.3 or R.sub.4; one of R.sub.5 or R.sub.6; and one of R.sub.7 or R.sub.8 is a substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, or cycloalkyl; ii) if any of R.sub.1, R.sub.2, R.sub.3, or R.sub.4 is hydrogen, then none of R.sub.5, R.sub.6, R.sub.7, or R.sub.8 are hydrogen; iii) if any of R.sub.5, R.sub.6, R.sub.7, or R.sub.8 is hydrogen, then none of R.sub.1, R.sub.7, R.sub.3, or R.sub.4 are hydrogen; and iv) the polymer has a molecular weight, wherein the molecular weight of the polymer is greater than 10,000.

2. The polymer of claim 1, wherein a and b are 3, 4, 5, or 6, c and d are 5, 6, or 7, and each of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, and R.sub.7 is an optionally substituted alkyl group comprising from 8 to 40 carbon atoms and R.sub.6 and R.sub.3 each are hydrogen.

3. The polymer of claim 1, wherein a and b are 3, 4, 5, or 6, c and d are 5, 6, or 7, and all of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8, are an optionally substituted alkyl group comprising from 8 to 40 carbon atoms.

4. The polymer of claim 1, wherein a and b are 3, 4, 5, or 6, c and d are 5, 6, or 7 and each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.1, and R.sub.3 is an optionally substituted alkyl group comprising from 8 to 40 carbon atoms and R.sub.2 and R.sub.4 each are hydrogen.

5. A polymer comprising the repeat unit: ##STR00037## wherein m is an integer greater than or equal to 1, the polymer having a molecular weight, wherein the molecular weight of the polymer is greater than 10,000.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings are included to provide a further understanding of the description, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) and together with the description serve to explain the principles and operation of the embodiments.

(2) FIG. 1 shows a reaction scheme for forming fused thiophene with branched alkyls.

(3) FIG. 2 describes the reaction scheme to produce 3,6-bis(5-bromothiophen-2-yl)-2,5-diheptadecylpyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (bis-bromothienyl-DC17DPP) (diketopyrrolopyrrole=DPP).

(4) FIG. 3 describes the reaction scheme for coupling bis-tin-substituted FT4 (FT4=four-membered fused thiophene) to bis-bromothienyl-DC17DPP via a palladium-catalyzed Stille-type coupling.

(5) FIG. 4 describes the reaction scheme for coupling bis-tin-substituted FT4 to 3,6-bis(5-bromothiophen-2-yl)-2,5-bis(2-octyldodecyl)pyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione (bis-bromothienyl-DC2BC8C10DPP) via a palladium-catalyzed Stille-type coupling.

(6) FIG. 5 illustrates a reaction scheme for coupling a bis-tin-substituted FT4 to 3,6-bis(5-bromothiophen-2-yl)-2,5-dihexadecylpyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione (bis-bromothienyl-DC16DPP) via a palladium-catalyzed Stille-type coupling.

(7) FIG. 6 illustrates a reaction scheme for coupling a bis-tin-substituted FT4 to bis-bromothienyl-DC16DPP via a palladium-catalyzed Stille-type coupling.

(8) FIG. 7 describes a reaction scheme for forming a monomer 3,6-bis(5-bromothiophen-2-yl)-2,5-bis(6-octylhexadecyl)pyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione (bis-bromothienyl-DC6BC8C10DPP).

(9) FIG. 8 illustrates a reaction scheme for forming 2,6-bis-trimethylstannyl-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (bis-trimethylstannyl-DC5BC8C10FT4) according to one embodiment.

(10) FIG. 9 illustrates a reaction scheme for coupling bis-tin-substituted FT4 to bis-bromothienyl-DC6BC8C10DPP via a palladium-catalyzed Stille-type coupling.

(11) FIG. 10 illustrates a reaction scheme for forming a monomer 2,6-bis(5-trimethylstannylthiophen-2-yl)-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DSnTDC5BC8C10FT4).

(12) FIG. 11 illustrates a reaction scheme for coupling bis-tin-substituted FT4 to bis-bromothienyl-DC6BC8C10DPP via a palladium-catalyzed Stille-type coupling.

DETAILED DESCRIPTION

(13) Before the present materials, articles, and/or methods are disclosed and described, it is to be understood that the aspects described below are not limited to specific compounds, synthetic methods, or uses as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

(14) In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings:

(15) Throughout this specification, unless the context requires otherwise, the word comprise, or variations such as comprises or comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

(16) It must be noted that, as used in the specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a carrier includes mixtures of two or more such carriers, and the like.

(17) Optional or optionally means that the subsequently described event or circumstance may or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

(18) Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about, it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

(19) The term alkyl group as used herein may be a branched or unbranched saturated hydrocarbon group of 1 to 40 carbon atoms (or with a number of carbon atoms as defined by the nomenclature C.sub.-C.sub., where and are a numerical values with <), such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, pentyl, hexyl, heptyl, octyl, decyl, or tetradecyl, and the like. The alkyl group may be substituted or unsubstituted. The term unsubstituted alkyl group is defined herein as an alkyl group composed of just carbon and hydrogen. The term substituted alkyl group is defined herein as an alkyl group with one or more hydrogen atoms substituted with a group including, but not limited to, an aryl group, cycloalkyl group, aralkyl group, an alkenyl group, an alkynyl group, an amino group, an ester, an aldehyde, a hydroxyl group, an alkoxy group, a thiol group, a thioalkyl group, or a halide, an acyl halide, an acrylate, or a vinyl ether. For example, the alkyl groups may be an alkyl hydroxy group, where any of the hydrogen atoms of the alkyl group are substituted with a hydroxyl group.

(20) The term alkyl group as defined herein also includes cycloalkyl groups. The term cycloalkyl group as used herein is a non-aromatic carbon-based ring composed of at least three carbon atoms, and in some embodiments from three to 20 carbon atoms. Examples of cycloalkyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, etc. The term cycloalkyl group also includes a heterocycloalkyl group, where at least one of the carbon atoms of the ring may be substituted with a heteroatom such as, but not limited to, nitrogen, oxygen, sulfur, or phosphorus.

(21) The term aryl group as used herein may be any carbon-based aromatic group, fused carbon-based aromatic group, including, but not limited to, benzene, naphthalene, etc. The term aryl group also includes heteroaryl group, meaning an aromatic ring composed of at least three carbon atoms that has at least one heteroatom incorporated within the ring of the aromatic group. Examples of heteroatoms include, but are not limited to, nitrogen, oxygen, sulfur, and phosphorus. The aryl group may be substituted or unsubstituted. The aryl group may be substituted with one or more groups including, but not limited to, alkyl, alkynyl, alkenyl, aryl, halide, nitro, amino, ester, ketone, aldehyde, hydroxy, carboxylic acid, or alkoxy as defined herein. In some embodiments, the term aryl group may be limited to substituted or unsubstituted aryl and heteroaryl rings having from three to 30 carbon atoms.

(22) The term aralkyl as used herein may be an aryl group having an alkyl group as defined above attached to the aryl group. An example of an aralkyl group may be a benzyl group.

(23) The term alkenyl group is defined as a branched or unbranched hydrocarbon group of 2 to 40 carbon atoms and structural formula containing at least one carbon-carbon double bond.

(24) The term alkynyl group is defined as a branched or unbranched hydrocarbon group of 2 to 40 carbon atoms and a structural formula containing at least one carbon-carbon triple bond.

(25) The term conjugated group is defined as a linear, branched or cyclic group, or combination thereof, in which p-orbitals of the atoms within the group are connected via delocalization of electrons and wherein the structure may be described as containing alternating single and double or triple bonds and may further contain lone pairs, radicals, or carbenium ions. Conjugated cyclic groups may comprise one of or both aromatic and non-aromatic groups, and may comprise polycyclic or heterocyclic groups, such as diketopyrrolopyrrole. Ideally, conjugated groups are bound in such a way as to continue the conjugation between the thiophene moieties they connect. In some embodiments, conjugated groups may be limited to conjugated groups having three to 30 carbon atoms.

(26) Disclosed are compounds, compositions, and components that may be used for, may be used in conjunction with, may be used in preparation of, or are products of the disclosed methods and compositions. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds may not be explicitly disclosed, each may be specifically contemplated and described herein. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D may be disclosed, then even if each is not individually recited, each may be individually and collectively contemplated. Thus, in this example, each of the combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. Likewise, any subset or combination of these may be also specifically contemplated and disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods of making and using the disclosed compositions. Thus, if there are a variety of additional steps that may be performed it may be understood that each of these additional steps may be performed with any specific embodiment or combination of embodiments of the disclosed methods, and that each such combination may be specifically contemplated and should be considered disclosed.

(27) The fused thiophene moieties described herein are substituted with optionally substituted alkyl groups at the -positions of the fused thiophene ring system. As used herein, an -position of a fused thiophene ring system may be a non-fused carbon center that may be directly adjacent to the sulfur of a fused thiophene, while a -position may be a non-fused carbon center that may be separated from the sulfur of the fused thiophene by an -position. In the structures 1-4 and 7-8, the -positions are shown as being connected to the rest of the composition, while the -positions are substituted with R.sub.1, R.sub.2, R.sub.3, R.sub.4 linked to the -positions by alkyl chains.

(28) One aspect comprises a polymer comprising a repeat unit of formula 1 or 2:

(29) ##STR00006##
wherein, in the structure 1 and 2, n and m may be integers, greater than or equal to one; R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 may be, independently, hydrogen, substituted or unsubstituted C.sub.4 or greater alkyl, substituted or unsubstituted C.sub.4 or greater alkenyl, substituted or unsubstituted C.sub.4 or greater alkynyl, or C.sub.5 or greater cycloalkyl; a, b, c, and d, independently, may be integers greater than or equal to 3; e and f may be integers greater than or equal to zero; X and Y are, independently a covalent bond, an optionally substituted aryl group, an optionally substituted heteroaryl, an optionally substituted fused aryl or fused heteroaryl group, an alkyne or an alkene; and A and B may be, independently, either S or O, with the provisos that: i. at least one of R.sub.1 or R.sub.2; one of R.sub.3 or R.sub.4; one of R.sub.5 or R.sub.6; and one of R.sub.7 or R.sub.8 is a substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, or cycloalkyl; ii. if any of R.sub.1, R.sub.2, R.sub.3, or R.sub.4 is hydrogen, then none of R.sub.5, R.sub.6, R.sub.7, or R.sub.8 are hydrogen; and iii. if any of R.sub.5, R.sub.6, R.sub.7, or R.sub.8 is hydrogen, then none of R.sub.1, R.sub.2, R.sub.3, or R.sub.4 are hydrogen. iv. e and f cannot both be 0; v. if either e or f is 0, then c and d, independently, are integers greater than or equal to 5; and vi. the polymer having a molecular weight, wherein the molecular weight of the polymer is greater than 10,000.

(30) In one aspect, at least one of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 may be a substituted or unsubstituted C.sub.4 or greater alkyl group. For example, at least one of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 may be an unsubstituted C.sub.4 or greater alkyl group. In this aspect, the unsubstituted C.sub.4 or greater alkyl group may be a straight-chain alkyl group (e.g. butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl or hexadecyl), a branched alkyl group (e.g. sec-butyl, neo-pentyl, 4-methylpentyl), or a substituted or unsubstituted C.sub.5 or greater cycloalkyl group (e.g. cyclopentyl, cyclohexyl). In one aspect, at least one of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 comprises a substituted C.sub.4 or greater alkyl. At least one of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 may be substituted with amino, ester, aldehyde, hydroxyl, alkoxy, thiol, thioalkyl, halide, acyl halide, acrylate, or vinyl ether moieties or any combination of two or more of these. The selection of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 will depend on the end use of the fused thiophene moiety-containing composition. The methods described herein permit the synthesis of fused thiophene moieties having a wide variety of R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 substituents. Any functionality on a substituted alkyl group may be protected in order to survive subsequent reaction steps

(31) In some embodiments, each R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 is, independently, a substituted or unsubstituted C.sub.4 or greater alkyl. In some embodiments, each R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 is, independently, a substituted or unsubstituted C.sub.6 or greater alkyl. In some embodiments, R.sub.1 and R.sub.3 are hydrogen, R.sub.4 and R.sub.2 are each a substituted or unsubstituted C.sub.6 or greater alkyl, and each R.sub.5, R.sub.6, R.sub.7, and R.sub.8 is, independently, a substituted or unsubstituted C.sub.8 or greater alkyl. In some embodiments, R.sub.5 and R.sub.7 are hydrogen, R.sub.6 and R.sub.8 are each a substituted or unsubstituted C.sub.6 or greater alkyl, and each R.sub.1, R.sub.2, R.sub.3, and R.sub.4 is, independently, a substituted or unsubstituted C.sub.8 or greater alkyl.

(32) In some embodiments, n is an integer of 1 or greater. In some embodiments, n is an integer from 1 to 4, or 1 to 3. In one aspect, m may be from 1 to 10,000, 1 to 9,000, 1 to 8,000, 1 to 7,000, 1 to 6,000, 1 to 5,000, 1 to 4,000, 1 to 3,000, 1 to 2,000, 1 to 1,000, 1 to 500, 1 to 250, 1 to 100, 1 to 50, 1 to 25, 1 to 10, 25 to 1000, 25 to 500, 25 to 250, 50 to 1000, 50 to 500, or 50 to 250. In some embodiments, at least one of A or B is O. In other embodiments, at least one of A or B is S.

(33) In some embodiments, a, b, c, and d are each independently an integer of 3 or more. In some embodiments, a and b are each integers of 3 or more and c and d are integers of 4 or more. In some embodiments, a and b are each integers of 4 or more and c and d are integers of 5 or more. In some embodiments, f=1 and e=0 and c and d are integers of 5 or more. In some embodiments, a and b are each integers of from 3 to 7, and c and d are integers from 3 to 7.

(34) In one aspect, each X and Y, is individually a conjugated group. In some embodiments, the conjugated group is a substituted or unsubstituted aryl, heteroaryl, or a double or triple bond. In some embodiments, each X and Y, is individually substituted or unsubstituted aryl or heteroaryl. In some embodiments, each X and Y, is individually substituted or unsubstituted heteroaryl. In some embodiments, each X and Y, is individually substituted or unsubstituted thiophene or fused thiophene. In some embodiments, each X and Y, is individually an unsubstituted thiophene. In some embodiments, each X and Y, is individually one of:

(35) ##STR00007##
wherein each R.sub.9 and R.sub.10 is independently, hydrogen, substituted or unsubstituted alkyl having from 1 to 30 carbon atoms, substituted or unsubstituted alkenyl having from 1 to 30 carbon atoms, substituted or unsubstituted alkynyl, having from 1 to 30 carbon atoms, substituted or unsubstituted aryl having from 4 to 30 carbon atoms, substituted or unsubstituted cycloalkyl, substituted or unsubstituted aralkyl. In one embodiment, at least one of R.sub.9, and R.sub.10, independently, may be an alkyl group comprising from 2 to 30 carbon atoms. In one aspect, at least one of R.sub.9, and R.sub.10, comprises a substituted or unsubstituted alkyl. When at least one of R.sub.9 and R.sub.10 comprises a substituted alkyl, one or more substituents may be selected from amino, ester, aldehyde, hydroxyl, alkoxy, thiol, thioalkyl, halide, acyl halide, acrylate, or vinyl ether moieties or any combination of two or more of these.

(36) The fused thiophene moieties described in 1 and 2 may have any number of fused rings above 3. For example, the fused thiophene moieties may be tetracyclic (2, n=1); pentacyclic (1, n=1), hexacyclic (2, n=2); or heptacyclic (1, n=2). The methods described herein permit the construction of fused thiophene moieties having any desired number of rings. In one aspect, for 1 and 2, n may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15.

(37) An unexpected advantage of the embodied compounds as shown in structures 1 and 2, is that the presence of at least four long alkyl chains on the polymer, with at least two alkyl chains with branching points at the C.sub.4 position or greater provide improved mobility and processability properties. In one aspect, one or both of the fused thiophene unit and the DPP unit contain branched alkyl chains where the branch point is at least four carbons away from the polymer backbone. In such embodiments, the multiple branched side chains in one polymer repeat unit significantly increase the solubility of the polymer, allowing for the polymer to be synthesized with an increased molecular weight without sacrificing other device properties, such as solution processability and - stacking. Additionally, the embodied polymers shown in 1 and 2 have higher field effect hole mobility than current high performance polymers, such as shown in the below structure (from U.S. application Ser. No. 13/665,055, filed Oct. 31, 2012, herein incorporated by reference):

(38) ##STR00008##

(39) Previous work has been done to increase the solubility of OTFT polymers with the goal of improving the resulting polymer properties. However, polymers containing branched DPP units where the branched alkyl chains are only two carbons away from the nitrogen atom on the DPP showed decreased molecular weight and mobility over previous polymers. Similarly, modification of the thiophene unit to attach an alkyl chain resulted in polymer backbones that lack the planarity of earlier, high performance polymers. These results showed that for fused thiophene based systems, there was an unmet need to find a structural solution that provided highly soluble polymers with increased molecular weight without sacrificing the it stacking or -conjugation of the polymer backbones.

(40) It has unexpectedly been found that the best way to achieve improved mobilities and processibility properties exceeding current high performance polymers is via modification of both FT4 units and DPP units in the polymers, wherein both groups contain two large alkyl chains, with at least two alkyl chains with branching points at the C.sub.4 position or greater. These embodiments result in the availability of at least two branched side chains in one polymer repeat unit. While it was expected that the large, branched alkyl chains would inhibit stacking or structured organization of the polymer, these potential issues were not observed. Rather, it is hypothesized that the embodied polymers provide superior properties because 1) since all branched alkyl chains are at least four carbons away from the main polymer backbone, there is no or very low steric effect from them to cause the twisting of the original planarity of the polymer backbone, which would interfere with the -stacking of the polymer backbones, and 2) the existence of four large, nonpolar branched side chains in one polymer repeat unit significantly increases the solubility of these polymers and thus allow for an increase in the molecular weight of the polymers, which may result in an enhanced mobility over current high performance polymers.

(41) One advantage of the increased solubility of the specific polymers disclosed herein is that they can be synthesized by advanced flow reactor techniques, which often can produce higher molecular weight polymers with tighter weight distribution. Additionally, in some non-limiting embodiments, the fused thiophenes (FT4) may be in liquid form at temperatures as low as 10 C., 5 C., 0 C., 5 C., or 10 C. Previously made polymers generally have limited solubility in various solvents and may be difficult to process, e.g., when preparing printed electronics, without negatively impacting electronic performance. The embodied FT4 monomers may satisfy these requirements since branched side-chain FT4 may be used to construct a larger conjugation system with less worry about solubility limitations.

(42) In certain aspects of 1 and 2, R.sub.1R.sub.2CH(CH.sub.2).sub.a+1 and R.sub.3R.sub.4CH(CH.sub.2).sub.b+1 may be identical alkyl groups and/or R.sub.5R.sub.6CH(CH.sub.2).sub.c+1 and R.sub.7R.sub.8CH(CH.sub.2).sub.d+1 may be identical alkyl groups. When R.sub.1R.sub.2CH(CH.sub.2).sub.a+1 and R.sub.3R.sub.4CH(CH.sub.2).sub.b+1 and/or R.sub.5R.sub.6CH(CH.sub.2).sub.c+1 and R.sub.7R.sub.8CH(CH.sub.2).sub.d+1 are identical, regioregular polymers may be easily constructed because the problems of regioselectivity (i.e. head-to-tail vs. head-to-head coupling) of polymerization reactions disappear. In other aspects, R.sub.1R.sub.2CH(CH.sub.2).sub.a+1 and R.sub.3R.sub.4CH(CH.sub.2).sub.b+1 and/or R.sub.5R.sub.6CH(CH.sub.2).sub.c+1 and R.sub.7R.sub.8CH(CH.sub.2).sub.d+1 may be different. For example, one set of R groups (e.g., R.sub.1R.sub.2) may be at least four carbons in size, with the other set of R groups (e.g., R.sub.3R.sub.4) being less than four carbons in size (e.g., a methyl group). Alternatively, in another aspect, all R.sub.1-R.sub.8, while optionally different, may be at least four carbons in length.

(43) As noted above with respect to moieties 1 and 2, X and Y may be attached to the -position of the fused thiophene moiety. In some embodiments, each X and Y may independently have one of the structures:

(44) ##STR00009##
as well as mirror images of such structures. For instance,

(45) ##STR00010##
can include the following structures, without limitation:

(46) ##STR00011##

(47) In one respect, each X or Y may independently be one of the structures:

(48) ##STR00012##
wherein g, R.sub.9 and R.sub.10 are as described above.

(49) According to various non-limiting embodiments, the polymer may be chosen from those of formula 1 or 2, in which X=Y=substituted or unsubstituted thiophene, and e=f=1. For example, the polymer may be chosen from those of formula 1A or 2A below:

(50) ##STR00013##
wherein a, b, c, d, n, m, R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9, R.sub.10, A, and B are as defined above for formulas 1 and 2. According to further embodiments, A=B=O. In still further embodiments, R.sub.1=R.sub.3; R.sub.2=R.sub.4; R.sub.5=R.sub.7; and R.sub.6=R.sub.8. In still other embodiments, R.sub.1=R.sub.3=R.sub.2=R.sub.4; R.sub.5=R.sub.7=R.sub.6=R.sub.8. In some embodiments of 1A and 2A above, the thiophene groups are unsubstituted:

(51) ##STR00014##

(52) Alternatively, in other non-limiting embodiments, the polymer compound may be chosen from those of formula 1 or 2, in which X=substituted or unsubstituted thiophene, f=1, and (Y).sub.e=null. For example, the polymer compound may be chosen from those of formula 1AA or 2AA below:

(53) ##STR00015##
wherein a, b, c, d, n, m, R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9, R.sub.10, A, and B are as defined above for formulas 1 and 2. According to further embodiments, A=B=O. In still further embodiments, R.sub.1=R.sub.3; R.sub.2=R.sub.4; R.sub.5=R.sub.7; and R.sub.6=R.sub.8. In still other embodiments, R.sub.1=R.sub.3=R.sub.2=R.sub.4; R.sub.5=R.sub.7=R.sub.6=R.sub.8. In some embodiments of 1A and 2A above, the thiophene groups are unsubstituted:

(54) ##STR00016##

(55) In certain embodiments, in formula 1, 2, 1A, 2A, 1AA, 2AA, a, b, c, or d, independently, may be integers of 3 or greater. For example, in some embodiments, a=b3 and/or c=d5. In some embodiments, a=b=3 and c=d=3, 4, 5 or 6. According to additional embodiments, at least one of X and Y may be a substituted or unsubstituted thiophene group.

(56) In some embodiments, the compositions disclosed herein may comprise at least one moiety comprising the formula 1B, 2B, 1C, or 2C:

(57) ##STR00017##
wherein, in the structures 1B, 2B, 1C, and 2C, wherein a, b, c, d, e, f, n, m, R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9, R.sub.10, X, Y, A, and B are as defined above for formulas 1 and 2; and each Q.sub.1, Q.sub.2, Q.sub.3, and Q.sub.4 may be, independently, an optionally substituted linear (i.e., unbranched) alkyl, optionally substituted linear alkenyl, or optionally substituted linear alkynyl.

(58) In certain embodiments, in formula 1B, 2B, 1C, or 2C, a, b, c, or d, independently, may be integers greater than 3, 4, 5, or 6. According to additional embodiments, at least one of X and Y may be a substituted or unsubstituted thiophene group. In further embodiments, Q.sub.1, Q.sub.2, Q.sub.3, and Q.sub.4, independently, may be substituted or unsubstituted linear alkyl groups.

(59) In another embodiment, a compound may comprise the formula 7 or 8

(60) ##STR00018##

(61) In the formula 7 and 8, a, b, e, n, R.sub.1, R.sub.2, R.sub.3, R.sub.4, and Y, are as defined above for formulas 1 and 2, and W may be, independently, hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, aryl, cycloalkyl, aralkyl, amino, ester, aldehyde, hydroxyl, alkoxy, thiol, thioalkyl, halide, acyl halide, acrylate, or vinyl ether, or a substituted or unsubstituted tri-alkyl tin or a boronic ester group or alternative group useful for Suzuki or Stille coupling.

(62) According to certain non-limiting embodiments, in formula 7 or 8, Y=substituted or unsubstituted thiophene, and e=1. Additionally, a and b, independently, may be integers greater than 3. For example, the compound may be chosen from those of formula 7A or 8A below:

(63) ##STR00019##
wherein a, b, e, n, R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.9, R.sub.10, W, and Y, are as defined above for formula 7 and 8. According to further embodiments, R.sub.1=R.sub.3 and R.sub.2=R.sub.4. According to further embodiments, A=B=O. In still further embodiments, R.sub.1=R.sub.3; R.sub.2=R.sub.4; R.sub.5=R.sub.7; and R.sub.6=R.sub.8. In still other embodiments, R.sub.1=R.sub.3=R.sub.2=R.sub.4; R.sub.5=R.sub.7=R.sub.6=R.sub.8. In some embodiments of 7A and 8A above, the thiophene groups are unsubstituted:

(64) ##STR00020##

(65) Another aspect comprises methods of making the compounds, monomers, and polymers described herein. Methods of making fused thiophene-based structures may be found in U.S. application Ser. No. 13/665,055, filed Oct. 31, 2012, U.S. application Ser. No. 12/905,667, filed Oct. 15, 2010, U.S. application. Ser. No. 12/935,426, filed Sep. 29, 2010, U.S. application Ser. No. 12/851,998, filed Aug. 6, 2010, U.S. application. Ser. No. 13/397,021, filed Feb. 15, 2012, U.S. application Ser. No. 13/660,529, filed Oct. 25, 2012, and U.S. Pat. Nos. 7,705,108, 7,838,623, 8,389,669, 7,893,191, 8,349,998, 7,919,634, 8,278,410, and 8,217,183, all of which are incorporated herein by reference in their entirety.

(66) In one aspect, compounds comprising the moiety 1 or 2 may be produced by reacting a compound comprising 6 with a compound comprising 7 or 8. In one embodiment, the method for making a compound, such as 1 or 2, may be carried out by providing a diketopyrrolopyrrole (DPP) based monomer comprising a moiety of structure 6:

(67) ##STR00021##
wherein A, B, c, d, X, f, R.sub.5, R.sub.6, R.sub.7, and R.sub.8 are as listed above for 1 and 2 and Z may be a halogen, such as Cl, Br, I, for example. In embodiments where e=0 in 7 or 8 and f=1 in 6, c and d are each independently, integers greater than or equal to 5.

(68) The method of making the compound may be further carried out by providing a fused thiophene ditin or diboron compound comprising a moiety of structure 7 or 8:

(69) ##STR00022##
wherein a, b, e, n, R.sub.1, R.sub.2, R.sub.3, R.sub.4, and Y, are as defined above for formulas 1 and 2, and W may be tri-alkyl tin, such as Sn(Alk).sub.3, where Alk is an optionally substituted alkyl group, or a boronic ester group, such as Alk-B(OAlk).sub.2, where each Alk is an optionally substituted alkyl group. Each W may also be an alternative group, known or unknown, useful for Suzuki or Stille coupling.

(70) Compounds comprising the moiety 1B or 2B may be produced by reacting a compound comprising 6 and 7B or 8B. In one aspect, the method for making a compound, such as 1B or 2B, may be carried out by providing a diketopyrrolopyrrole (DPP) based monomer comprising a moiety of structure 6 and a fused thiophene ditin or diboron compound comprising a moiety of structure 7B or 8B:

(71) ##STR00023##
wherein e, n, Y, Q.sub.1 and Q.sub.2, are as defined above for formulas 1B and 2B and W may be tri-alkyl tin, such as Sn(Alk).sub.3, where Alk is an optionally substituted alkyl group, or a boronic ester group, such as Alk-B(OAlk).sub.2, where each Alk is an optionally substituted alkyl group. Each W may also be an alternative group, known or unknown, useful for Suzuki or Stille coupling.

(72) In a further aspect, compounds comprising the moiety 1C or 2C may be produced by reacting a compound comprising 6C and 7 or 8. In one aspect, the method for making a compound, such as 1C or 2C, may be carried out by providing a diketopyrrolopyrrole (DPP) based monomer comprising a moiety of structure 6C below and reacting this monomer with a compound of 7 or 8 as defined above.

(73) ##STR00024##
wherein Z, X, f, A, and B are as defined in 6 and Q.sub.3 and Q.sub.4 are as defined in 1C and 2C.

(74) The methods may be further carried out by forming a polymer in presence of a metal catalyst. In one aspect, the metal catalyzed reaction may be a Stille-type reaction or Suzuki coupling reaction.

(75) In another aspect, compounds comprising the moiety 1 or 2 may be produced through a series of synthetic steps. The fused thiophene core may be synthesized and brominated as described herein. The dibromo-fused thiophene may then be sequentially reacted with butyllithium and trimethyltinchloride to form the bis-tin-substituted fused thiophene as shown in FIG. 1. The formation of the dipyrrolopyrole moiety may be done via the reaction scheme shown in Tieke et al., Beilstein, J. ORG. CHEM. 830 (2010), herein incorporated by reference in its entirety, and may be described in FIG. 2 for example compound 3,6-bis(5-bromothiophen-2-yl)-2,5-diheptadecylpyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione. The fused thiophene moiety and the dipyrrolopyrrole moiety may be combined to form 1 or 2 via any standard coupling reaction. In some aspects, the fused thiophene moiety and the dipyrrolopyrrole moiety may be combined via a Stille-type coupling reaction as shown in FIG. 3. The reaction in FIG. 3 uses palladium(II) catalyst as it showed good reliability, but palladium(O=0) based catalysts such as tetrakistriphenylphosphine palladium(0) could also be used. Similar synthesis schemes may be used to produce the compounds of formula 1A, 1AA, 1B, 1BB, 1C, 2A, 2B, or 2C.

(76) Fused thiophene and oxidized fused thiophene oligomers and polymers may be prepared using methodologies similar to those used in making oligo- and poly(thiophenes) described above. For example, ,-dihydro fused thiophene moieties may be oxidatively oligomerized or polymerized using iron (III) compounds (e.g., FeCl.sub.3, Fe(acac).sub.3), or may be brominated and coupled in an organomagnesium mediated reaction. The fused thiophene moieties and oxidized fused thiophene moieties described herein may be incorporated into other conjugated polymers such as, for example phenylene, vinylene, and acetylene copolymers, using coupling reactions familiar to the skilled artisan. The fused thiophene moieties and oxidized fused thiophene moieties described herein may be incorporated into other main chain and side chain polymers using techniques known in the art. It is contemplated that the fused thiophene compound may be oxidized prior to incorporation into an oligomer or polymer. In the alternative, the fused thiophene compound may be incorporated into the oligomer or polymer followed by oxidation.

EXAMPLES

(77) The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the materials, articles, and methods described and claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the scope of the description. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in C. or is at ambient temperature, and pressure is at or near atmospheric. There are numerous variations and combinations of reaction conditions, e.g., component concentrations, desired solvents, solvent mixtures, temperatures, pressures and other reaction ranges and conditions that may be used to optimize the product purity and yield obtained from the described process. Only reasonable and routine experimentation will be required to optimize such process conditions.

Synthesis of an OSC Copolymer, PTDC2BC8C10DPPTDC17FT4

(78) ##STR00025##

(79) As shown in FIG. 4, to a 35 mL microwave reaction vessel equipped with a magnetic stir bar are added 2,6-bis(trimethylstannyl)-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DSnDC17FT4) (101.9 mg, 0.100 mmol), 3,6-bis(5-bromothiophen-2-yl)-2,5-bis(2-octyldodecyl)pyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione (bis-bromothienyl-DC2BC8C10DPP) (105.5 mg, 0.100 mmol), tris(dibenzylideneacetone)dipalladium(0) (1.8 mg, 0.002 mmol) and o-tolyl phosphine (2.4 mg, 0.0079 mmol). The reaction vessel and cap are introduced into a nitrogen glovebox, where toluene (10 mL) is added and the cap affixed to the vessel. The vessel is then removed from the glovebox and the reaction microwaved at 160 C. for 2 h. The mixture is cooled to 50 C. before release from the microwave reactor, then poured into a stirring mixture of methanol and acetylacetone (100 mL+100 mL). Hydrochloric acid (1 mL, 35% aq) is added and the mixture is stirred for 16 h. The mixture is filtered and the polymer placed into a glass with glass frit Soxhlet thimble. The polymer is extracted in a Soxhlet apparatus with acetone (250 mL) for 24 h, then hexanes (250 mL) for 24 h. The polymer is then extracted from the Soxhlet apparatus into chloroform (250 mL). The chloroform solution is poured into methanol (400 mL) with rapid stirring, followed by moderate stirring for 20 min. The polymer is then filtered from the mixture and dried under vacuum to give the product, Poly[(3,7-diheptadecylthieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene-2,6-diyl)(3,6-bis(thiophen-2-yl)-2,5-bis(2-octyldodecyl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione-5,5-diyl)] (PTDC2BC8C10DPPTDC17FT4) (0.136 g, 86%) as a purple solid. GPC (1,2,4-trichlorobenzene, 200 C.): Mn=32,000; Mw=55,600; PDI=1.73.

Synthesis of a New OSC Copolymer, PC12(o)TTDC16DPPTC12(o)TDC17FT4

(80) ##STR00026##

(81) As shown in FIG. 5, to a 35 mL microwave reaction vessel equipped with a magnetic stir bar are added 2,6-bis(4-dodecyl-5-trimethylstannylthiophen-2-yl)-3,7-diheptadecylthieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DSnC12(o)TDC17FT4) (400 mg, 0.257 mmol), 3,6-bis(5-bromothiophen-2-yl)-2,5-dihexadecylpyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione (DBrTDC16DPP) (223 mg, 0.257 mmol), tris(dibenzylideneacetone)dipalladium(0) (4.7 mg, 0.0051 mmol) and o-tolyl phosphine (6.3 mg, 0.021 mmol). The reaction vessel and cap are introduced into a nitrogen glovebox, where toluene (10 mL) is added and the cap affixed to the vessel. The vessel is then removed from the glovebox and the reaction microwaved at 160 C. for 2 h. The mixture is cooled to 50 C. before release from the microwave reactor, then poured into a stirring mixture of methanol and acetylacetone (100 mL+100 mL). Hydrochloric acid (1 mL, 35% aq) is added and the mixture stirred for 16 h. The mixture is filtered and the polymer placed into a glass with glass frit Soxhlet thimble. The polymer is extracted in a Soxhlet apparatus with acetone (250 mL) for 24 h. The polymer is soluble in hexane so no hexane extraction is carried out. The polymer is extracted into chloroform and the chloroform solution is poured into methanol (400 mL) with rapid stirring, followed by moderate stirring for 20 min. The polymer is then filtered from the mixture and dried under vacuum to give the product, Poly[(2,6-bis(4-dodecylthiophen-2-yl)-3,7-diheptadecylthieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene-5,5-diyl)(3,6-bis(thiophen-2-yl)-2,5-dihexadecylpyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione-5,5-diyl)] (PC12(o)TTDC16DPPTC12(o)TDC17FT4) (0.407 g, 80%) as a purple solid.

Synthesis of a New OSC Copolymer, PC12(i)TTDC16DPPTC12(i)TDC17FT4

(82) ##STR00027##

(83) As shown in FIG. 6, to a 35 mL microwave reaction vessel equipped with a magnetic stir bar are added 2,6-bis(3-dodecyl-5-trimethylstannylthiophen-2-yl)-3,7-diheptadecylthieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DSnC12(i)TDC17FT4) (1000 mg, 0.643 mmol), DBrTDC16DPP (655 mg, 0.643 mmol), tris(dibenzylideneacetone)dipalladium(0) (11.9 mg, 0.013 mmol) and o-tolyl phosphine (15.8 mg, 0.052 mmol). The reaction vessel and cap are introduced into a nitrogen glovebox, where toluene (20 mL) is added and the cap affixed to the vessel. The vessel is then removed from the glovebox and the reaction microwaved at 160 C. for 2 h. The mixture is cooled to 50 C. before release from the microwave reactor, then poured into a stirring mixture of methanol and acetylacetone (100 mL+100 mL). Hydrochloric acid (1 mL, 35% aq) is added and the mixture stirred for 16 h. The mixture is filtered and the polymer placed into a glass with glass frit Soxhlet thimble. The polymer is extracted in a Soxhlet apparatus with acetone (250 mL) for 24 h. The polymer is very soluble in hexane so no hexane extraction is carried out. The polymer is extracted into chloroform and the chloroform solution is poured into methanol (400 mL) with rapid stirring, followed by moderate stirring for 20 min. The polymer is then filtered from the mixture and dried under vacuum to give the product, Poly[(2,6-bis(3-dodecylthiophen-2-yl)-3,7-diheptadecylthieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene-5,5-diyl)(3,6-bis(thiophen-2-yl)-2,5-dihexadecylpyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione-5,5-diyl)] (PTDC16DPPTC12(i)TDC17FT4) (0.879 g, 69%) as a blue solid.

Synthesis of Monomer DBrTDC6BC8C10DPP

(84) ##STR00028##

(85) (1) Synthesis of DC6BC8C10DPP: As shown in FIG. 7, in a three-neck round-bottom flask, a solution of DTDPP (2.50 g, 8.3 mmol) and anhydrous K.sub.2CO.sub.3 (4.49 g, 32.5 mmol) in 100 mL of anhydrous N,N-dimethylformamide (DMF) is vigorously stirred and heated to 120 C. under N.sub.2 for 30 minutes. 6-octyl-1-hexadecyl bromide (8.69 g, 20.8 mmol) is then added dropwise. The reaction mixture is further stirred and heated at 120 C. (oil bath temperature) for 24 hours. This reaction solution is then allowed to cool down and was poured into ice water, and the resulting suspension is stirred at room temperature for 1 h. Chloroform (400 mL) is used to extract the product. Then 200 mL of hexane is used to extract the aqueous residue. The organic layers are combined and washed by water twice and then dried over anhydrous magnesium sulfate. All solvents are removed and the resulting dark reddish oily product is redissolved in hexane and shot path silica chromatography is carried out using 1:1 hexane/methylene chloride as the eluent. Solvents hexane/methylene chloride are removed to yield a dark red waxy solid that is dissolved in about 80 mL of acetone with gentle heating. The solution is then cooled and kept at 18 C. for three hours where a dark red solid forms in the bottom. Solvent acetone is removed by decanting and the residual pure dark reddish solid product, 3,6-bis(5-bromothiophen-2-yl)-2,5-bis(6-octylhexadecyl)pyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione (DTDC6BC8C10DPP), is dried under vacuum overnight (6.18 g, 76%). 1H NMR (300 MHz, CDCl3, ppm) =8.94 (d, 2H), 7.66 (d, 2H), 7.28 (t, 2H), 4.07 (t, 4H), 1.76 (p, 4H), 1.49-1.21 (m, 78H), 0.88 (t, 12H).

(86) (2) Synthesis of monomer DBrTDC6BC8C10DPP:

(87) ##STR00029##

(88) In a 250 mL three-neck round-bottom flask under N.sub.2 protection, to a stirred solution of DTDC6BC8C10DPP (3.89 g, 4.0 mmol) in 80 mL of chloroform at 0 C., 1.50 g of NBS (8.4 mmol) is added in one portion. The reaction mixture is then warmed to RT slowly and stirred at RT for overnight. The reaction mixture is poured into water (100 mL) and more chloroform (300 mL) is used to extract the desired product. The chloroform extract is washed by brine (2100 mL). The chloroform solution is dried over anhydrous magnesium sulfate. After the filtration to remove magnesium sulfate, solvent chloroform is removed under reduced pressure to yield a dark reddish solid that is dried under vacuum at 50 C. This solid is then recrystallized from acetone (200 mL). The dark reddish solid product, DBrTDC6BC8C10DPP (3,6-bis(5-bromothiophen-2-yl)-2,5-bis(6-octylhexadecyl)pyrrolo[3,4-c]pyrrole-1,4(2H, 5H)-dione), is collected by filtration and dried under vacuum overnight (4.21 g, 93%). 1H NMR (300 MHz, CDCl.sub.2CDCl.sub.2, ppm) =8.55 (d, 2H), 7.20 (d, 2H), 3.88 (t, 4H), 1.67 (p, 4H), 1.38-1.07 (m, 78H), 0.80 (t, 6H).

Synthesis of Monomer Bis-Trimethylstannyl-DC5BC8C10FT4

(1) Synthesis of DC5BC8C10FT4

(89) ##STR00030##

(90) As shown in FIG. 8, in a 250 mL flask fitted with a condenser, dicarboxylic acid-DC5BC8C10FT4 (6.89 g, 6.99 mmol), Cu.sub.2O (200 mg, 1.40 mmol), glycine (157 mg, 2.10 mmol), and 60 mL of tetraethyleneglycol dimethylether are added. Under nitrogen protection, this stirred solution is heated at 250 C. for four hours. The hot reaction mixture is filtered quickly through a hot frit to remove the copper oxide and other solid residue. After the addition of 250 mL of methanol, the filtrate is cooled in a freezer to yield a grey precipitate. The supernatant liquid is removed by decanting since the solid becomes a liquid quickly at RT. This solid is re-dissolved in 60 mL of hexane and is washed by aqueous 2M HCl.sub.(aq) solution (2150 mL), then is washed by water (2190 mL). This hexane solution is then dried over anhydrous magnesium sulfate. After a filtration, solvent hexane is removed to yield an oily product. A silica column chromatography is carried out using hexane as the eluent. Under reduced pressure, solvent hexane is removed to yield a light yellowish oily product that is dried under vacuum overnight to yield pure 3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DC5BC8C10FT4) (5.55 g, 88%). 1H NMR (300 MHz, CD.sub.2Cl.sub.2, ppm) =7.03 (s, 2H), 2.79 (t, 4H), 1.79 (p, 4H), 1.49-1.16 (m, 74H), 0.98-0.82 (m, 12H).

(91) (2) Synthesis of Monomer DSnDC5BC8C10FT4:

(92) ##STR00031##

(93) To a solution of DC5BC8C10FT4 (1.02 g, 1.14 mmol) in 25 mL of anhydrous THF in a 100 mL three neck flask at 0 C., n-BuLi (2.0 M in hexane) (1.99 mL, 3.98 mmol) is added dropwise by using a syringe. The resulting solution is stirred at RT for several hours. A Me.sub.3SnCl solution (1.0 M in THF) (4.55 mL, 4.55 mmol) is then added dropwise. The reaction solution is stirred overnight. This reaction solution is quenched by adding ice-water. After removing most of THF in this solution under reduced pressure, 150 mL of water and 40 mL of hexane are added. After vigorously shaking, the hexane layer is collected. This hexane layer is then washed by water and then dried over anhydrous sodium sulfate. Solvent hexane is then removed to yield a light yellowish oily product that is dried under vacuum for three hours. This oily product is then dissolved in hot acetone and cooled to 18 C. in a freezer and acetone is then decanted. The resulting oily product 2,6-bis-trimethylstannyl-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3: 4,5]thieno[2,3-d]thiophene (bis-trimethylstannyl-DC5BC8C10FT4) is dried under vacuum overnight (1.27 g, 91% in 98% purity). 1H NMR (300 MHz, CD.sub.2Cl.sub.2, ppm) =2.75 (t, 4H), 1.71 (p, 4H), 1.49-1.12 (m, 74H), 0.94-0.78 (m, 12H), 0.44 (s, 18H).

Synthesis of a Designed OSC Copolymer PTDC6BC8C10DPPTDC5B8C10FT4

(94) As shown in FIG. 9, to a three neck flask equipped with a magnetic stir bar are added bis-trimethylstannyl-DC5BC8C10FT4 (710 mg, 0.74 mmol), bis-bromothienyl-DC6BC8C10DPP (820 mg, 0.74 mmol), tris(dibenzylideneacetone)dipalladium(0) (13.6 mg, 0.0148 mmol) and o-tolyl phosphine (18.0 mg, 0.059 mmol). The flask is introduced into a nitrogen glovebox, where chlorobenzene (10 mL) is added and the septa are capped to the flask. The flask is then removed from the glovebox. Under nitrogen protection, the reaction solution is heated at 120 C. for 2 h. The reaction solution is then cooled to RT and then poured into a stirring mixture of methanol and acetylacetone (100 mL+20 mL). Hydrochloric acid (1 mL, 35% aq) is added and the mixture stirred for 16 h. The mixture is filtered and the polymer placed into a Soxhlet thimble. The polymer is extracted in a Soxhlet apparatus with acetone (250 mL) for 24 h. The polymer is very soluble in hexane so no hexane extraction is carried out. The polymer is extracted into chloroform and the chloroform solution is poured into methanol (400 mL) with rapid stirring, followed by moderate stirring for 20 min. The polymer is then filtered from the mixture and dried under vacuum to give the product, Poly[(3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene-2,6-diyl)(3,6-bis(thiophen-2-yl)-2,5-bis(6-octylhexadecyl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione-5,5-diyl)] (PTDC6BC8C10DPPTDC5B8C10FT4) (1.17 g, 85%) as a blue-green solid.

Synthesis of Monomer Bis-Trimethylstannyl-DC5BC8C10FT4

(1) Synthesis of DBrDC5BC8C10FT4

(95) ##STR00032##

(96) Referring to the reaction scheme shown in FIG. 10, in a 250 mL flask fitted with a condenser and protected with aluminum foil at 0 C., DC5BC8C10FT4 (1.00 g, 1.11 mmol) and 50 mL of CHCl.sub.3 (anhydrous) are added. Under nitrogen protection, a solution of NBS (0.46 g, 2.56 mmol) in 20 mL DMF (anhydrous) is added dropwise to the flask. The resulting solution is stirred at 0 C. and warmed to room temperature overnight. The mixture is further stirred at room temperature for two days. The aluminum foil is removed, revealing that a clear solution is formed. This reaction solution is quenched by adding water and subsequently adding aqueous HCl solution into the flask, followed by 300 mL of hexane. After vigorous shaking, the organic layer is collected. The organic portion thus collected is then washed with water and dried over anhydrous sodium sulfate. The solvents are removed to yield an oily product. Silica column chromatography is carried out using hexane as the eluent. Under reduced pressure, solvent hexane is removed to yield an oily product that is dried under vacuum overnight to yield 2,6-dibromo-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DBrDC5BC8C10FT4) (1.16 g, 98%). 1H NMR (300 MHz, CD.sub.2Cl.sub.2, ppm) =2.76 (t, 4H), 1.71 (p, 4H), 1.43-1.12 (m, 74H), 0.92-0.81 (m, 12H).

(97) (2) Synthesis of DTDC5BC8C10FT4:

(98) ##STR00033##

(99) To DBrDC5BC8C10FT4 (1.00 g, 0.95 mmol) in a 35 mL microwave reaction test tube fitted with a stir bar, 0.813 g (2.18 mmol) of 2-(tributylstannyl)thiophene and 0.126 g (0.109 mmol) of (Pd(PPh.sub.3).sub.4 are added. The tube is pump filled with nitrogen several times. The sealed tube is then placed into a nitrogen glovebox. In the glovebox, 10 mL of anhydrous toluene is added to the tube. The tube is resealed, removed from the glovebox, and placed in a microwave reactor. The tube is heated to 120 C. for a reaction time of 2 h. The resulting reaction mixture is then purified by silica column chromatography using hexane as the eluent. Under reduced pressure, solvent hexane is removed to yield a yellowish solid, which is subsequently heated in 30 mL of ethanol at 70 C. with agitation for 20 minutes. After cooling to room temperature, ethanol is removed by decanting to yield a yellowish solid product. This product is then dissolved in ethyl acetate and recrystallized after cooling to room temperature and further cooling in the refrigerator to 4 C. The resulting light yellowish solid product is collected and dried under vacuum to yield 2,6-dithienyl-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DTDC5BC8C10FT4) (0.84 g, 83% yield). 1H NMR (300 MHz, CD.sub.2Cl.sub.2, ppm) =7.38 (dd, 2H), 7.22 (dd, 2H), 7.11 (dd, 2H), 2.93 (t, 4H), 1.76 (p, 4H), 1.52-1.00 (m, 74H), 0.93-0.76 (m, 12H).

(100) (3) Synthesis of bis-trimethylstannyl-DC5BC8C10FT4:

(101) ##STR00034##

(102) To a solution of 2,6-dithienyl-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (DTDC5BC8C10FT4) (0.94 g, 0.89 mmol) in 22 mL of anhydrous THF in a 100 mL three neck flask at 78 C. under nitrogen protection, n-BuLi (2.0 M in hexane (1.55 mL, 3.10 mmol) is added dropwise by syringe. The resulting solution is stirred at 78 C. for four hours. The reaction temperature is warmed to 12 C. and a Me.sub.3SnCl solution (1.0 M in THF) (3.54 mL, 3.54 mmol) is then added dropwise. The reaction solution is warmed to room temperature and stirred overnight. This reaction solution is quenched by adding ice-water. After removing most of the THF under reduced pressure, 150 mL of water and 40 mL of hexane are added. After vigorously shaking, the hexane layer is collected, washed by water and then dried over anhydrous sodium sulfate. To this oily product, 30 mL of ethanol is added, followed by washing with hot ethanol (71 C.). Solvent ethanol is then decanted while still hot and the resulting oily product is dried under vacuum to yield 2,6-bis-trimethylstannyl-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene (bis-trimethylstannyl-DC5BC8C10FT4) (1.10 g, 89% yield). 1H NMR (300 MHz, CD.sub.2Cl.sub.2, ppm) =2.97 (t, 4H), 1.81 (p, 4H), 1.58-1.03 (m, 74H), 0.97-0.82 (m, 12H), 0.45 (s, 18H).

Synthesis of a designed OSC copolymer P2TDC6BC8C10DPP2TDC5BC8C10FT4

(103) ##STR00035##

(104) Referring to the reaction scheme shown in FIG. 1, to a 100 mL three neck flask are added DSnTDC5BC8C10FT4 (900 mg, 0.65 mmol, MW 1387.2), DBrTDC6BC8C10DPP (734 mg, 0.65 mmol, MW 1131.4) (synthesized according to the reaction scheme illustrated in FIG. 7), tris(dibenzylideneacetone)dipalladium(0) (11.9 mg, 0.013 mmol) and o-tolyl phosphine (15.8 mg, 0.052 mmol). The flask is introduced into a nitrogen glovebox, where chlorobenzene (10 mL) is added and the septa are capped to the flask. The flask is then removed from the glovebox. Under nitrogen protection, the reaction solution is heated at 120 C. in an oil bath for 1 h. The reaction solution is then cooled to RT and poured into a stirring mixture of methanol and acetylacetone (200 mL+200 mL). Hydrochloric acid (2 mL, 35% aq) is added and the mixture stirred for 16 h. The mixture is filtered and the polymer placed into a Soxhlet thimble. The polymer is extracted in a Soxhlet apparatus with acetone (250 mL) for 24 h. The polymer is extracted into chloroform (250 mL) and the chloroform solution is poured into methanol (400 mL) with rapid stirring, followed by moderate stirring for 20 min. The polymer is then filtered from the mixture and dried under vacuum to give the product, poly[(2,6-bis(thiophen-2-yl)-3,7-bis(5-octylpentadecyl)thieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene-5,5-diyl)alt(3,6-bis(thiophen-2-yl)-2,5-bis(6-octylhexadecyl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione-5,5-diyl)] (P2TDC6BC8C10DPP2TDC5BC8C10FT4) (1.27 g, 96.9% yield). GPC (1,2,4-trichlorobenzene, 200 C.): Mn=20,700; Mw=98,400; PDI=4.75. The molecular weight Mw of this polymer is much higher than that of poly[(3,7-diheptadecylthieno[3,2-b]thieno[2,3:4,5]thieno[2,3-d]thiophene-2,6-diyl)(3,6-bis(thiophen-2-yl)-2,5-dihexadecylpyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione-5,5-diyl)] (PTDC16DPPTDC17FT4) (Mn=16,200; Mw=30,000; PDI=1.85). Despite their higher molecular weight, the polymers disclosed herein may still exhibit high solubility, e.g., in various organic solvents such as xylene, toluene, tetrahydronaphthalene, cyclooctane, and the like. Moreover, the polymers may be dissolved in such solvents at room temperature or at relatively low temperatures (e.g., about 100 C. or less).

(105) Organic Transistor Performance

(106) Organic field-effect transistors (OFETs) are fabricated by depositing solutions of P2TDC6BC8C10DPP2TDC5BC8C10FT4 (inventive) or PTDC16DPPTDC17FT4 (comparative) (5 mg/mL in p-xylene) on a highly doped silicon wafer with thermally grown oxide layer substrate in a nitrogen glovebox and annealing at 160 C. Various parameters of these fabricated devices are measured, including average charge carrier mobility (.sub.h), average current On/Off ratio (I.sub.ON/I.sub.OFF), and average threshold voltage (V.sub.th). The results of these tests are presented in Table I below.

(107) TABLE-US-00001 TABLE I OFET Device Performance Polymer .sub.h.sup.ave (cm.sup.2V.sup.1s.sup.1) I.sub.ON/I.sub.OFF.sup.ave V.sub.th.sup.ave (V) P2TDC6BC8C10DPP2TDC5BC8C10FT4 1.82 0.44 2.1 10.sup.6 19.7 (inventive) PTDC16DPPTDC17FT4 0.79 0.21 6.1 10.sup.2 22.0 (comparative)
As can be appreciated from Table I, the polymers disclosed herein exhibit higher charge carrier mobility, while also exhibiting higher current on/off ratios and lower threshold voltages, generally indicating that a transistor incorporating such polymers can have a higher conductivity. Furthermore, such an increased carrier mobility can be achieved while annealing at relatively lower temperatures (e.g., as low as 160 C.), as compared to higher annealing temperatures, which are often necessary and were previously used to improve carrier mobility of known OSC polymers (e.g., 190 C. or greater).

(108) Additionally, while the polymers disclosed herein may have relatively high molecular weight and/or molecular volume (due to longer side chains), such polymers may still exhibit the unexpected advantage of a decreased - stacking distance, e.g., these polymers may have improved packing ability. The lamellar spacing and in-plane stacking distance of the deposited inventive and comparative organic films are presented below in Table II.

(109) TABLE-US-00002 TABLE II Molecular Spacing In-Plane Lamellar Stacking Spacing Distance Polymer () () P2TDC6BC8C10DPP2TDC5BC8C10FT4 29.6 3.69 (inventive) PTDC16DPPTDC17FT4 26.0 3.71 (comparative)
As can be appreciated from Table II, while the overall molecular volume of the polymers disclosed herein is larger due to the presence of the four branched alkyl chains (as evidenced by a higher lamellar spacing), the branching in these chains is sufficiently far from the main polymer backbone (e.g., at least three carbons away), such that there is little or no steric effect on the polymer due to these chains. Because of the reduced steric effect imparted by the extra thiophene between the two major units (FT4 and DPP), the polymer may benefit from improved planarity and/or reduced twisting, such that the polymer can stack more efficiently (as evidenced by the reduced in-plane stacking distance). Thus, the polymers disclosed herein may benefit from the branched side chains in terms of improved solubility, while also exhibiting a good packing ability, which can result in a higher charge carrier mobility.

(110) It will be apparent to those skilled in the art that various modifications and variations can be made to the present description without departing from the spirit and scope. Thus, it is intended that the present description cover modifications and variations of embodiments herein provided they come within the scope of the appended claims and their equivalents.