Perforated retroreflective film

• US 6,481,857 B2
• Filed: 12/05/2000
• Issued: 11/19/2002
• Est. Priority Date: 12/16/1997
• Status: Active Grant

• Current Assignee: Orafol Americas Inc. (Orafol Europe GmbH)
• Original Assignee: Reflexite
• Inventors: Smith, Peter R.
• Primary Examiner(s): Spyrou, Cassandra
• Assistant Examiner(s): BOUTSIKARIS, LEONIDAS
• Application Number:
  US09/730,522
• Publication Number:
  US 20010017731A1
• Time in Patent Office: 714 Days
• Field of Search: 359/530, 359/529, 359/531, 359/532, 359/533, 359/833, 359/834, 428/137, 428/913.3
• US Class Current: 359/530
• CPC Class Codes: G02B 5/124 plural reflecting elements forming part of a unitary plate or sheet
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24479 including variation in thickness

Abstract

A see-through retroreflective structure includes a transparent polymeric film, an array of retroreflective elements attached to the polymeric film, and an array of apertures through the retroreflective structure within the array of retroreflective elements. In one embodiment, the retroreflective structure includes a metalized reflective layer formed on the transparent prism elements and a support layer, such as a fabric, is attached to the metalized reflective layer.

The method includes providing a transparent polymeric film. An array of retroreflective elements is attached to the polymeric film. The array of retroreflective elements and the transparent polymeric film are perforated through the retroreflective structure to form an array of apertures, thereby forming a retroreflective structure. The apertures are of sufficient size and spacing to provide a see-through capability. In one embodiment, a metalized reflective layer can be applied to the retroreflective elements and a support layer, such as a fabric, is attached to the metalized reflective layer.

Claims

1. A retroreflective structure comprising:

a) a film having a first side and a second side;

b) a first array of retroreflective cube-corner elements attached to the first side of the film; and

c) an array of apertures through the retroreflective structure within the array of retroreflective cube-corner elements, the apertures formed by removing a portion of the film and the elements.

2. The retroreflective structure of claim 1 further comprising a second array of retroreflective cube-corner elements attached to the second side of the film.

3. The retroreflective structure of claim 2 wherein the retroreflective cube-corner elements of the first array and the second array of retroreflective cube-corner elements include a metalized reflective layer.

4. The retroreflective structure of claim 1 wherein both sides of the film retroreflect incoming light.

5. The retroreflective structure of claim 2 further comprising a first polymer layer attached to the first array of retroreflective cube-corner elements and a second polymer layer attached to the second array of retroreflective cube-corner prisms.

6. The retroreflective structure of claim 5 wherein the first polymer layer and the second polymer layer include a transparent polymer.

7. The retroreflective structure of claim 1 further comprising a polymer layer attached to the first array of retroreflective cube-corner elements and a barrier film covering at least some of the apertures for providing stiffness to the retroreflective structure while an ink or paint is applied to the polymer layer.

8. The retroreflective structure of claim 1 wherein the retroreflective structure is attached to a window.

9. The retroreflective structure of claim 8 further comprising an adhesive disposed between the cube-corner elements and an outer surface of the window.

10. The retroreflective structure of claim 1 further comprising a polyvinyl film attached to the first array of retroreflective cube-corner elements and further comprising a carrier film disposed on the polyvinyl film opposite the cube-corner elements.

11. The retroreflective structure of claim 10 further comprising an ink or paint applied to the carrier film.

12. The retroreflective structure of claim 11 wherein the retroreflective structure is applied to an outer surface of a window.

13. The retroreflective structure of claim 1 further comprising a polymer layer attached to the first array of retroreflective cube-corner elements, wherein an ink or paint applied to the polymer layer.

14. The retroreflective structure of claim 13 wherein the retroreflective structure is attached to an inner surface of a window.

15. A retroreflective particle comprising:

a) a film having a first side and a second side;

b) a first array of retroreflective cube-corner elements attached to the first side of the film; and

c) a second array of retroreflective cube-corner elements attached to the second side of the film.

16. The retroreflective particle of claim 15 wherein a plurality of the retroreflective particles are attached to an adhesive coated substrate.

17. The retroreflective particle of claim 16 wherein a top film is laminated over the retroreflective particles on the adhesive coated substrate.

18. The retroreflective particle of claim 15, wherein the retroreflective particles are mixed with a gel.

19. A method for forming a retroreflective structure, comprising:

a) providing a film having a first side and a second side;

b) attaching a first array of retroreflective cube-corner elements to the first side of the film; and

c) perforating the array of retroreflective cube-corner elements and the film to remove a portion of the retroreflective cube-corner elements and the film to form an array of apertures through the retroreflective structure.

20. The method of claim 19 further comprising the step of attaching a second array of retroreflective cube-corner elements to the second side of the film.

21. The method of claim 19 wherein the array of retroreflective cube-corner elements is made retroreflective by applying a metalized reflective layer to the array of prismatic elements.

22. The method of claim 19 further including the step of:

d) collecting retroreflective particles formed by perforating the array of retroreflective elements and the film.

23. A transflector comprising:

a) a film;

b) an array of retroreflective cube-corner elements attached to a first side of the film;

c) an array of apertures through the retroreflective structure within the array of retroreflective cube-corner elements, the apertures formed by removing a portion of the film and the elements; and

d) a printed sheet attached to a second side of the film.

24. The transflector of claim 23 wherein the retroreflective cube-corner elements include a metalized reflective layer.

25. The transflector of claim 23 wherein a diffuse film is attached to the metalized reflective layer.

26. A retroreflective structure comprising:

a) a film;

b) an array of retroreflective cube-corner elements attached to the film;

c) an array of apertures through the retroreflective structure within the array of retroreflective cube-corner elements; and

d) a plurality of beads within the array of apertures.

27. The retroreflective structure of claim 26 further comprising an ink receptive system disposed on the film.

28. The retroreflective structure of claim 26 wherein the retroreflective cube-corner elements include a metalized reflective layer.

29. The retroreflective structure of claim 26 wherein the apertures are formed by removing a portion of the film and the elements.

30. A retroreflective structure comprising:

a) a film having a first side and a second side;

b) an array of retroreflective cube-corner elements attached to the first side of the film;

c) an array of apertures through the retroreflective structure within the array of retroreflective cube-corner elements, the apertures formed by removing a portion of the film and the elements; and

d) an ultraviolet light resistant layer disposed on the second side of the film.

31. The retroreflective structure of claim 30 further comprising colored polyethylene terepthalate pieces disposed between the second side of the film and the ultraviolet light resistant layer.

32. The retroreflective structure of claim 31 wherein the retroreflective cube-corner elements include a metalized reflective layer.

33. A retroreflective structure comprising:

a) a film;

b) an array of retroreflective cube-corner elements attached to the film;

c) an array of apertures through the retroreflective structure within the array of retroreflective cube-corner elements; and

d) a plurality of retroreflective particles within the array of apertures.

34. The retroreflective structure of claim 33 wherein the retroreflective particles include a film having a first side and a second side and a first array of retroreflective cube-corner elements attached to the first side of the film.

35. The retroreflective structure of claim 34 wherein the retroreflective particles further include a second array of retroreflective cube-corner elements attached to the second side of the film.

36. A retroreflective structure comprising:

a) a first film having a first side and a second side;

b) a first array of retroreflective cube-corner elements attached to the first side of the first film;

c) an array of apertures through the retroreflective structure within the first array of retroreflective cube-corner elements;

d) a second film having a first side and a second side, the second side being disposed adjacent to the first array of retroreflective cube-corner elements; and

e) a second array of retroreflective cube-corner elements attached to the first side of the second film.

37. The retroreflective structure of claim 36 further comprising a backing layer disposed between the first array of retroreflective cube-corner elements and the second array of retroreflective cube-corner elements.

38. The retroreflective structure of claim 36 further comprising a backing layer attached to the second array of retroreflective cube-corner elements.

39. The retroreflective structure of claim 36 wherein the apertures are formed by removing a portion of the film and the elements.

40. The retroreflective structure of claim 36 wherein the second array of retroreflective cube-corner elements is made retroreflective by applying a metalized reflective layer to the elements.

41. A retroreflective structure comprising:

a) a first film having a first side and a second side;

b) a first array of retroreflective cube-corner elements attached to the first side of the first film;

c) an array of apertures through the retroreflective structure within the first array of retroreflective cube-corner elements;

d) a second film having a first side and a second side; and

e) a second array of retroreflective cube-corner elements attached to the first side of the second film, the second array of retroreflective cube-corner elements being attached to the second side of the first film.

42. The retroreflective structure of claim 41 further comprising a backing layer attached to the first array of retroreflective cube-corner elements.

43. The retroreflective structure of claim 41 wherein at least some of the cube-corner elements of the second array cover the at least some of the apertures such that the at least some of the cube-corner elements are air-backed.

44. The retroreflective structure of claim 41 wherein the second array of retroreflective cube-corner elements is attached to the second side of the first film by a substantially clear adhesive.