Article comprising conductive conduit channels

Abstract

Disclosed is a process for preparing an article comprising a layer of nonconductive polymeric material comprising a plurality of integral polymer conduit channels containing a substantially transparent conductive material comprising applying the conductive material to the grooves and applying a protective overcoat within the channels.

1 . A process for forming an article containing a layer of nonconductive polymeric material comprising a plurality of patterned integral conduit channels that contain a transparent electrically conductive polymeric material that are conductive in the plane of the layer and provide pathways for conduction of electricity, which material is overcoated within the channels with a protective overcoat having a resistivity of at least 5000 ohm-meters, wherein the conduit channels comprise grooves in the surface of the polymeric material, wherein the conduits, measured from the surface of the top of the conduit, have a depth of between 0.1 and 100 micrometers,  
       comprising the steps of: 
 a) casting or extrusion molding to form the channeled article;  
 b) coating the surface and grooves of the channeled article with a dispersion containing a transparent electrically conductive polymeric material;  
 c) removing excess dispersion from the surface of the channeled article;  
 d) drying the conductor in the grooves; and  
 e) applying a protective overcoat within the grooves having a resistivity of at least 5000 ohm-meters  
 
     
     
         2 . The process of  claim 1  wherein the protective overcoat is water impermeable.  
     
     
         3 . The process of  claim 1  wherein the protective material is applied by electrophotographic application and fusing or by coating and fusing an aqueous solution or dispersion of protective material.  
     
     
         4 . The process of  claim 3  wherein the protective material is applied by electrophotographic application and fusing.  
     
     
         5 . The process of  claim 3  wherein the protective material is applied by coating and drying an aqueous solution or dispersion of protective material in the grooves.  
     
     
         6 . The process of  claim 5  wherein the protective material is applied as a dispersion of polymer beads in a polymer latex binder.  
     
     
         7 . The process of  claim 6  wherein the protective material is cross-linked during fusing.  
     
     
         8 . The process of  claim 7  wherein the protective material is one curable by the application of UV or heat and is followed by the application of UV or heat to effect fusing.  
     
     
         9 . The process of  claim 1  comprising coating a smoothing layer on the formed article.  
     
     
         10 . The process of  claim 1  wherein said protective overcoat material has a surface energy less than 40 dynes/cm 2 .  
     
     
         11 . The process of  claim 1  wherein the transparent conductive material further comprises a pigment.  
     
     
         12 . The process of  claim 1  wherein said transparent conductive material further comprises a colored dye.  
     
     
         13 . The process of  claim 1  wherein said transparent conductive material wave guides visible light in the channel along the length of the channel.  
     
     
         14 . The process of  claim 1  wherein said article has a light transmission greater than 90%.  
     
     
         15 . The process of  claim 1  wherein said conduits have a depth of between 0.1 and 10 micrometers.  
     
     
         16 . The process of  claim 1  wherein said conduits have a frequency of from 1 to 1000 conduits/cm.  
     
     
         17 . The process of  claim 1  wherein said article has a thickness between 20 and 350 micrometers.  
     
     
         18 . The process of  claim 1  wherein said plurality of conduits have at least one intersection point.  
     
     
         19 . The process of  claim 1  wherein said polymer conduits comprise a nanocomposite material.  
     
     
         20 . The process of  claim 19  wherein said nanocomposite comprises layered particles.