CA2156266C - Retroreflective structure - Google Patents

Retroreflective structure Download PDF

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Publication number
CA2156266C
CA2156266C CA002156266A CA2156266A CA2156266C CA 2156266 C CA2156266 C CA 2156266C CA 002156266 A CA002156266 A CA 002156266A CA 2156266 A CA2156266 A CA 2156266A CA 2156266 C CA2156266 C CA 2156266C
Authority
CA
Canada
Prior art keywords
prisms
substrate
transparent
free
standing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA002156266A
Other languages
French (fr)
Other versions
CA2156266A1 (en
Inventor
David C. Martin
Edward D. Phillips
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Reflexite Corp
Original Assignee
Reflexite Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Reflexite Corp filed Critical Reflexite Corp
Publication of CA2156266A1 publication Critical patent/CA2156266A1/en
Application granted granted Critical
Publication of CA2156266C publication Critical patent/CA2156266C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/12Reflex reflectors
    • G02B5/122Reflex reflectors cube corner, trihedral or triple reflector type
    • G02B5/124Reflex reflectors cube corner, trihedral or triple reflector type plural reflecting elements forming part of a unitary plate or sheet
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1052Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1052Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1084Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
    • Y10T156/1087Continuous longitudinal slitting
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1089Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina

Abstract

A retroreflective structure is described in which an easy of free-standing retroreflective prisms is formed on a suitable substrate for application of the structure to pre-existing structure formed of compatible fabrics, such as tarpaulins.

Description

R~TRO~ CTIVE STRUCTURE
gackyround of the Invention Retroreflective materiaie are commonly employed for safety and decorative purposes. One type of retroreflective material is formed of molded members having very small prisms or cube-corner formations. (See, for example, U.S. Patent 3,810,804 and French Patent 2,662,268.) It is often desirable to apply these materials to pre-existing structures; in which case, the retroreflective material may not be compatible with the material of the pre-existing structure or the method of application may be destructive of the retroreflective properties.
A need exists, therefore, for a retroreflective system and process in which the retroreflective material may be fabricated to facilitate permanent transfer to existing structures of different material without damaging the retroreflective material.
Surnmaryr of the Invention A method and apparatus for forming retroreflective material on a substrate is described in which a release coating is formed on a base material and an array o~ solid light transparent prisms are formed on the coating by casting the prism array in a plastic oligomer which is adhered to the coating, The prisms are then made reflective by forming a metal layer on the prisms. An adhe$ive is then applied to the reflective metal layer. A substrate is then applied to the adhesive and the base material is removed at the release coating, leaving an exposed array of Free-standing prisms, i.e., prisms with a reflective metal backin~_g affixed to the substrate.
A ~9E~JDED SNEET

The substrate i.s preferably formed of the same material a:~ the str~.~cture upon which the retroreflective material i.:~ to be sc_~cured or is compatible with such structure. For example, the substrate may comprise a sheet of synthetic resin, such as polyvinylchloride (PVC) , pol~ramide, pc~>l.ypropyl.ene, polycarbonate, or fabrics such as polyester, nylon, or the like, coated with a suitable res:u~ .
Preferably, the substrate with the exposed prism layer may then be ccv;rered with a transparent protective layer on the exposed. side and the substrate may then be bonded by various well-known tec:~zniques to a pre-existing structure of the sar::e or similar material as the substrate.
Brief Description of_t,he -Drawings Figures l1a-1F crrw process f Low schematic cross-sectional views showing the main steps in the fabrication of the retr~oreflecti;r~s material of the invention on a substrate.
Figure 2 is a ~rc;rlematic cro:~s-sec~vion showing further modification to the Figs. la-if embodiment.
Figure 3 is a ~~ckoematic perspective showing a tape formed in accordance with the invention.
Figure 4 _i_s a ~.ect:ion showing an alternate tape embodiment of the invention.
Figure 5 is a clet~:~iled sect:'~onal ~~~iew showing the prism orientat~.on.

~'TIUS94/01681 -3_ 2156266 Detailed Description of the Invention The invention will now be described in detail in connection with the drawings. Referring to Figs. la-lf, a preferred embodiment will be described in which the substrate comprises tarpaulin material. This is a . particularly appropriate example, since a need exists for a simple and inexpensive method of attaching retroreflective material to truck tarpaulins for safety reasons.
As shown in Figure 1A, the starting structure consists of base sheet 10 of material, such as a polyester sheet with an acrylic print treatment on one side (sold by DuPont under the name J Film). A release coating 12 formed of a polyester solvent borne tie cast is applied to the treated side of a 1-4 mils thick sheet 10.
Next, as shown in Figure 1B, an array of mircoprisms 14, about 2.8 mils high, are formed on the release coating by casting the present array onto an epoxy or urethane oligomer and adhering it to the coating.
Preferably, the prisms are of the type formed of cube corners in which the 3 faces intersect at 90° angles and in which the optical and prism axis are coincident, although non-perfect cube corner prisms to achieve special optical effects are within the contemplation of this invention.
The prisms 14 are made reflective by coating the exposed prisms surface with a metal layer 16, such as aluminum, gold or silver of about 500-800 A (Figure 1C).
The structure of Figure 1C is inverted and an adhesive, such as a one component moisture curing reactive poly-urethane adhesive 18 (sold by MACE Corp.) is applied to the metallized prism side in a continuous stripe format of about 50 mm stripe length (Figure 1D).

The substrate a:0, shown here as a tarpaulin material formed of a polyester cloth 22 encapsulated by a plastic material 24, is then laminated to the adhesive 18 (Figure 1E) and the base sheep :LO i.s str=~~pped away (1 figure 1F) .
This :leaves stripes of an array o~ exposed (free) retroreflective pri~cms 14 adhered to the substrate 20 by adhesive 18 (Figure L1'?. Fight rays E incident upon the face of the prism 19 are retroreflected back by surface 16.
The resultant s.tiucture shown in L~'igure 1F may be further processed, as shown in Figure 2, by coating the free prism side with an adhesive 30 and lamiruating a clear protective sheet 32 of material, such as polyvinyl, to the str;zcture. 'fhf: structure shown in Figure 2 may then be slit into strips to form tapes, as shown in Figure 3.
Alternately, as :~rnown in Figure 4, the free prism side shown in Figure 1F may be coated with a material 36 adapted to form a go~_>d bond with both t:he substrate 20 and the free prisms 14.
For example, if tale substrate :is formed of tarpaulin with an acrylic lacquer coating, then an elastomeric urethane coating wou:Ld be a good choice for material 36.
Other substrate materials may corlprise fabric reinforced and embossed vinyl, coated vinyl, urethanes, polypropyle::les and the like.
As shown in Figure 5, an important feature of the present inz~~~ntion is that the prisms 7.4, because they are relatively Free to mc;vre:, become somewhat oriented by the shape of the substrate material 20, which improves the retroreflec:eted light c:li.stributi.on.

Claims (18)

The invention claimed is:
1. A method for forming a retroreflective structure having free-standing prisms, comprising the steps of:

a) forming an array of transparent prisms having a facet side and a window side on a sheet of base material on the window side of said prisms;

b) forming a reflective layer on the facet side of said prisms;

c) adhering a substrate to the reflective layer on the facet side of the prisms; and d) removing the sheet of base material leaving the window side of the array of the transparent prisms formed on the substrate exposed, thereby forming the retroreflective structure having free-standing prisms.
2. The method of Claim 1 wherein the method further includes the step of applying a light-transparent protective sheet on the window side of the array of the transparent free-standing prisms.
3. The method of Claim 2 wherein the light-transparent protective sheet is adhered to the array of prisms by an adhesive.
4. The method of Claim 1 wherein the transparent prisms are cube-corner prisms.
5. The method of Claim 1 wherein the substrate is a tarpaulin.

CLAIMS,
6. The method of claim 1 wherein the substrate is a fabric reinforced plastic.
7. The method of claim 2 wherein the protective sheet includes a thermoplastic.
8. The method of claim 7 wherein the thermoplastic includes a polyvinyl chloride.
9. The method of claim 2 wherein the protective sheet includes an elastomeric.
10. The method of claim 1 wherein the formed retroreflective structure is formed into a tape.
11. A retroreflective structure having free-standing transparent prisms comprising:

a) a substrate;

b) a layer of free-standing transparent prisms having a facet side and window side formed on said substrate, wherein the facet side of the prisms adheres to the substrate and the window side is exposed; and c) a reflective layer formed on the facet side of the free-standing transparent prisms.
12. The structure of claim 11 wherein the retroreflective structure further includes a fabric reinforced with plastic attached to the facet side of the prisms.
13. The structure of claim 11 wherein the retroreflective structure further includes a tarpaulin attached to the facet side of the prisms.
14. The structure of claim 11 wherein the structure is formed into a tape.
15. the structure of claim 11 wherein the prisms are bonded to the substrate with an adhesive.
16. The structure of claim 11 wherein the reflective layer includes a metal.
17. The structure of claim 16 wherein the metal is selected from the group consisting of aluminum, gold and silver.
18. The structure of claim 11 further comprising a light-transparent protective sheet on the window side of the layer of free-standing transparent prisms.
CA002156266A 1993-02-17 1994-02-15 Retroreflective structure Expired - Fee Related CA2156266C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US1876693A 1993-02-17 1993-02-17
US08/018,766 1993-02-17
US08/088,252 US5637173A (en) 1993-02-17 1993-07-07 Method for forming a retroreflective structure having free-standing prisms
US08/088,252 1993-07-07
PCT/US1994/001681 WO1994019711A1 (en) 1993-02-17 1994-02-15 Retroreflective structure

Publications (2)

Publication Number Publication Date
CA2156266A1 CA2156266A1 (en) 1994-09-01
CA2156266C true CA2156266C (en) 2004-05-25

Family

ID=26691478

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002156266A Expired - Fee Related CA2156266C (en) 1993-02-17 1994-02-15 Retroreflective structure

Country Status (7)

Country Link
US (1) US5637173A (en)
EP (1) EP0690995B1 (en)
JP (1) JP3701967B2 (en)
AU (1) AU6241594A (en)
CA (1) CA2156266C (en)
DE (1) DE69413677T2 (en)
WO (1) WO1994019711A1 (en)

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US5549962A (en) * 1993-06-30 1996-08-27 Minnesota Mining And Manufacturing Company Precisely shaped particles and method of making the same
WO1995003558A1 (en) * 1993-07-19 1995-02-02 Reflexite Corporation Retroreflective structure
US5691846A (en) * 1993-10-20 1997-11-25 Minnesota Mining And Manufacturing Company Ultra-flexible retroreflective cube corner composite sheetings and methods of manufacture
US5450235A (en) 1993-10-20 1995-09-12 Minnesota Mining And Manufacturing Company Flexible cube-corner retroreflective sheeting
BR9507585A (en) * 1994-05-02 1997-09-23 Minnesota Mining & Mfg Process for producing an oven and a retro-reflective fabric material and retro-reflective material
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CA2236603C (en) * 1995-11-02 2005-12-27 Minnesota Mining And Manufacturing Company Microstructured articles with backing and methods of manufacture
US5706132A (en) * 1996-01-19 1998-01-06 Minnesota Mining And Manufacturing Company Dual orientation retroreflective sheeting
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US6036322A (en) * 1997-12-01 2000-03-14 Reflexite Corporation Multi-orientation retroreflective structure
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US20050185279A1 (en) * 1999-01-21 2005-08-25 Reflexite Corporation Durable, open-faced retroreflective prismatic construction
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KR101896935B1 (en) * 2011-12-22 2018-09-12 엘지이노텍 주식회사 Retro-reflection structure for improving luminance and durability and process method
CN103513310A (en) * 2013-10-28 2014-01-15 福建省晋江市夜光达反光材料有限公司 Process for producing microprism reflective crystal lattice strip and microprism reflective crystal lattice strip
CN103963382B (en) * 2014-04-23 2017-01-04 福建夜光达科技股份有限公司 A kind of PET glistening bead sheet and manufacture method thereof
CN109322004A (en) * 2018-10-08 2019-02-12 福建夜光达科技股份有限公司 A kind of microprism monomer fully-jewelled Reflect light line and preparation method thereof

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Also Published As

Publication number Publication date
CA2156266A1 (en) 1994-09-01
US5637173A (en) 1997-06-10
AU6241594A (en) 1994-09-14
JPH08507161A (en) 1996-07-30
WO1994019711A1 (en) 1994-09-01
DE69413677D1 (en) 1998-11-05
EP0690995A1 (en) 1996-01-10
JP3701967B2 (en) 2005-10-05
EP0690995B1 (en) 1998-09-30
DE69413677T2 (en) 1999-06-10

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