Microstructured material and process for its manufacture

Abstract

A micro-structured article is disclosed comprising a free-standing network of interconnected traces surrounding randomly-shaped cells wherein the interconnected traces comprise at least partially-joined nanoparticles. In a preferred embodiment, the nanoparticles comprise a conductive metal. The article is preferably formed by coating a nanoparticle-containing emulsion onto a substrate and drying the emulsion. The nanoparticles self-assemble into the network pattern which is subsequently removed from the substrate. A preferred method of removing the network from the substrate comprises the steps of electroplating the traces and subsequently exposing the traces to acid to release the network from the substrate.

1 .- 11 . (canceled) 
     
     
         12 . A process for making the microstructured article of claim  1  comprising:
 a) forming a network of interconnected traces comprising nanoparticles surrounding randomly-shaped cells on the surface of a substrate by self assembly of the nanoparticles from an emulsion; 
 b). electroplating the network; 
 c) exposing the network to an acid to release the network from the substrate; and 
 d) removing the network from the substrate. 
 
     
     
         13 . The process of  claim 12  wherein the emulsion comprises a water-in-oil emulsion and the oil phase comprises an organic solvent having nanoparticles dispersed therein. 
     
     
         14 . The process of  claim 12  wherein the network is transferred to a second substrate after removal from the substrate on which it was formed. 
     
     
         15 . A process for making the microstructured article of claim  1  comprising:
 a) forming a network of interconnected traces comprising nanoparticles surrounding randomly-shaped cells on the surface of a substrate by self assembly of the nanoparticles from an emulsion; 
 b) separating the network from the substrate by mechanical means; and 
 c) collecting the separated network on a roll.