Ultra-flexible retroreflective cube corner composite sheetings and methods of manufacture
First Claim
1. A method of manufacturing microstructured composite sheeting comprising the steps of:
- a) providing a tool having a molding surface with a plurality of cavities opening thereon suitable for forming desired microstructures;
b) applying to said molding surface a volume of a flowable curable resin composition suitable for forming desired microstructure elements;
c) contacting said resin composition with a first major surface of a transparent overlay film having first and second major surfaces; and
d) minimizing excess resin composition extending above said cavitites and tool;
then e) curing said resin composition while in contact with said overlay film to form a sheeting comprising an array of microstructure elements bonded to said overlay film;
thenf) removing said sheeting from said tool; and
g) applying mechanical stress to said sheeting so as to cause a fractured separation of substantially each individual microstructure element from surrounding microstructure elements;
wherein said resin composition and said overlay film are such that said resin composition penetrates said overlay film when contacted thereto such that after said curing said array of cube corner elements are bonded to said overlay film through as interpenetrating network between the material of said microstructure elements and the material of said overlay film.
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Accused Products
Abstract
A method for manufacturing flexible cube corner retroreflective sheeting comprising the steps of:
a) providing a tool having a molding surface;
b) applying to the molding surface a volume of a flowable resin composition;
c) contacting the resin composition with a first major surface of an overlay film;
d) minimizing excess resin composition;
e) curing the resin composition to form a sheeting comprising an array of cube corner elements bonded to the overlay film;
f) removing the sheeting from the tool; and
g) applying mechanical stress to the sheeting so as to cause a fractured separation of substantially each individual cube corner element from surrounding cube corner elements. Also, flexible retroreflective sheetings comprising: a) a two dimensional array of substantially independent cube corner elements, the array comprising a first polymeric material, and b) an overlay film having two major surfaces and comprising of a second polymeric material, the array being bonded to the first major surface of the overlay film. Also safety devices incorporating such sheetings.
444 Citations
48 Claims
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1. A method of manufacturing microstructured composite sheeting comprising the steps of:
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a) providing a tool having a molding surface with a plurality of cavities opening thereon suitable for forming desired microstructures; b) applying to said molding surface a volume of a flowable curable resin composition suitable for forming desired microstructure elements; c) contacting said resin composition with a first major surface of a transparent overlay film having first and second major surfaces; and d) minimizing excess resin composition extending above said cavitites and tool;
then e) curing said resin composition while in contact with said overlay film to form a sheeting comprising an array of microstructure elements bonded to said overlay film;
thenf) removing said sheeting from said tool; and g) applying mechanical stress to said sheeting so as to cause a fractured separation of substantially each individual microstructure element from surrounding microstructure elements; wherein said resin composition and said overlay film are such that said resin composition penetrates said overlay film when contacted thereto such that after said curing said array of cube corner elements are bonded to said overlay film through as interpenetrating network between the material of said microstructure elements and the material of said overlay film. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A microstructured composite sheeting comprising:
- (a) a two dimensional array of cured microstructure elements, said array comprising a first polymeric material, and (b) an overlay film having two major surfaces and comprising a second polymeric material, said array being bonded to the first major surface of said overlay film with a fractured land and wherein the material of said microstructure elements and the material of said overlay film form an interpenetrating network, said microstructure elements being substantially independent from adjacent microstructure elements, said microstructure elements having been cured while in contact with said overlay film.
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18. A microstructured composite sheeting comprising:
- (a) a two dimensional array of cured microstructure elements, said microstructure elements being substantially independent from adjacent microstructure elements, said array comprising a first polymeric material, and (b) an overlay film having two major surfaces and comprising a second polymeric material, said array being bonded to the first major surface of said overlay film wherein said array of microstructure elements was cured in situ on said overlay film and wherein the material of said microstructure elements and the material of said overlay film form an interpenetrating network.
- View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48)
Specification