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WO2003012492A1 - Stratifie reflecteur a microprismes, et procede de fabrication - Google Patents

Stratifie reflecteur a microprismes, et procede de fabrication Download PDF

Info

Publication number
WO2003012492A1
WO2003012492A1 PCT/IT2002/000386 IT0200386W WO03012492A1 WO 2003012492 A1 WO2003012492 A1 WO 2003012492A1 IT 0200386 W IT0200386 W IT 0200386W WO 03012492 A1 WO03012492 A1 WO 03012492A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
reflector
laminate
multilayer film
structured surface
Prior art date
Application number
PCT/IT2002/000386
Other languages
English (en)
Inventor
Giorgio Corradi
Original Assignee
Giorgio Corradi
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 Giorgio Corradi filed Critical Giorgio Corradi
Publication of WO2003012492A1 publication Critical patent/WO2003012492A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/12—Reflex reflectors
    • G02B5/122—Reflex reflectors cube corner, trihedral or triple reflector type
    • G02B5/124—Reflex reflectors cube corner, trihedral or triple reflector type plural reflecting elements forming part of a unitary plate or sheet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0083—Reflectors

Definitions

  • the invention relates to a reflector laminate with micro-prisms and a process for manufacturing it. Specifically, though not exclusively, the reflector laminate can be usefully applied in the field of horizontal road signals.
  • the present invention concerns a laminate with micro-prisms having a high reflecting power.
  • An advantage of the invention is to provide a reflector laminate having characteristics of brightness, colour precision and high reflecting qualities, responding to norms and standards in the field of road signals.
  • a further advantage consists in the fact that the laminate is resistant to wear and has a long working lifetime.
  • the invention also proposes a simple reliable, economical and high-production process for manufacturing a reflector laminate.
  • figure 1 is a plan view from above of a laminate made according to the invention
  • figure 2 is section II-II of figure 1.
  • 1 denotes in its entirety a reflector laminate, used in particular to make horizontal road signals, which comprises a multi-layer film 2 comprising in turn an upper layer 21 made of heat-formable plastic material, either transparent or coloured transparent, for example a methacrylate such as ethyl methacrylate, which on a bottom side exhibits a structured surface 21a having a distribution of micro-prisms in relief, a layer 22 of reflector material underlying the structured surface 21a with the micro-prisms, and one or more layers 23 and 24 of protective material underlying the reflector layer 22.
  • a reflector laminate used in particular to make horizontal road signals
  • a multi-layer film 2 comprising in turn an upper layer 21 made of heat-formable plastic material, either transparent or coloured transparent, for example a methacrylate such as ethyl methacrylate, which on a bottom side exhibits a structured surface 21a having a distribution of micro-prisms in relief, a layer 22 of reflector material underlying the structured surface 21a
  • the reflector layer 22 is metallic (for example, aluminium) and is inferiorly covered with a thin layer 23 of protective material constituted by a preferably polyurethane-based metal primer, which has the function of improving grip with a layer 24 of material for filling the microprisms.
  • the layer 24 is made for example with a high-weight polyurethane resin and fills the "valleys" of the structured surface 21a and covers the "peaks” thereof so as to protect the micro-prisms, and especially to avoid the risk that the micro-prisms deform (damaging their reflective properties) during the heat- forming stage of manufacture of the reliefs 4 and the cells 5, as will be better explained herein below.
  • a thin light-coloured opaque (preferably white) outline 3 is printed on the structured surface 21a of the transparent or coloured transparent layer 21.
  • the outline can be designed as a wording or a figure (perhaps a trade mark, or a geometric figure), and is distributed over the surface 21a of the transparent layer 21 in such a way as to form a sort of lattice which in part (to a predetermined percentage of the layer 21) covers the underlying reflector layer 22, with the aim of modifying the colour characteristics and luminosity of the laminate without excessively reducing its reflective qualities.
  • the outline 3 covers a total area percentage of about 15% of the total area of the structured surface 21a.
  • the percentage is in accordance with the colour and luminosity characteristics required, especially the characteristics required by law in relation to visibility of the laminate by day during normal light conditions.
  • the multi-layer film 2 is shaped to form a distribution of macroscopic reliefs 4 on the upper side of the film 2.
  • the macroscopic reliefs 4 are accompanied, on the bottom layer of the film 2, by cells 5.
  • the height of the macroscopic reliefs 4 is about 1-4 mm. , i.e. at least twice as big as the size of the micro-prisms, so that the lateral surface of each relief 4 exhibits a multiplicity of micro-prisms. This is due to the fact that the lateral surface of the reliefs 4 is the most responsible part for the reflective effect when the laminate is used as a horizontal signal.
  • the reliefs 4 (and the cells 5 on the other side), seen in plan view (figure 1), preferably exhibit a hexagonal shape and are distributed in a regular and ordered fashion. In the illustrated embodiment they are trunco-pyramidal with a hexagonal base. It would however be possible to have other shapes, though it is preferable that the reliefs 4 each exhibit a top surface which is flat and parallel to the laminate, as well as an inclined lateral surface with respect to the laminate. At least a part of the micro-prisms is situated on the inclined lateral surface of the reliefs (4).
  • micro-prisms are protected against wear (by traffic passing over the laminates) and are also the most exposed to light beams coming from the headlights of vehicles, so that reflective capacity is optimised, as is visibility of the horizontal road surface, in all atmospheric and road surface conditions and for all possible angles of incidence of the light beam emitted by the headlights of a vehicle.
  • the laminate also comprises a filler base layer 6 which fills the cells 5 and also functions as a covering for the bottom side of the shaped multi-layer film 2.
  • the base layer 6 is thicker than the depth of the cells 5, so as to obtain a total covering and form a continuous base surface over the whole of the bottom side of the laminate opposite the upper reflecting surface.
  • the material used for the base layer 6 is preferably a plastic spreadable layer, for example a polyurethane resin or synthetic rubber.
  • the material can contain additives, such as a percentage of pigments, for example white or variously coloured according to needs.
  • the material can also contain a percentage (for example, about 0.5%) of a bleach (preferably of the type used in the textile or paper industries) for improving visibility of the film when used as a road signal.
  • the material also preferably contains particles of relatively hard abrasive material, which particles give the base layer 6 high resistance to both mechanical and atmospheric wear, thanks to which the rehefs on the external reflector side keep their shape over a long period of time even where subjected to high wear situations.
  • the abrasive particles can be granular or sharp scales having a very irregular structure, of the type normally used for making glass-paper, mills, emery paper and so on; in the illustrated embodiment, the particles are mostly constituted by grains or scales of corundum or other abrasive substances having a hardness of about the same or even greater than corundum (i.e.
  • laminates for high-quality horizontal signals can be made with abrasive particles having a hardness of less than 8 in the Mohs scale, but preferably harder than silica glass (which is between 6 and 7 in the Mohs scale) such as for example garnet or quartz in very fine grains.
  • abrasive materials are, for example, the following: pumice, sepia, tripoli powder, fossil powder, tantalum carbide, tungsten carbide, sandstone, very fine glass powder, granular and powder emery, iron oxide and/or chrome oxide in powder form.
  • a mixture of powders can also be used, made of various abrasive materials, reduced to granular or powder form and having different hardnesses and granulometries.
  • the abrasive particles can be mixed up together with the other ingredients of the base layer 6 (for example polyurethane resin, white pigment and bleach), after which the mixture obtained can be spread on the side exhibiting the cells, advancing the laminate towards a base layer 4 forming device, comprising a feeder which distributes the mixture and a doctor which fills the cells and scrapes and smooths the mixture.
  • the base layer 6 for example polyurethane resin, white pigment and bleach
  • the process for manufacturing the reflector laminates comprises the following stages: a) printing on a lower side of a heat-formable material, either transparent or coloured transparent, an thin outline 3 of a wording or repeated design, in white or coloured opaque material, according to the desired characteristics or colour scheme and the desired luminosity of the laminate; b) forming (for example by embossing) on the lower printed side a structured surface 21a exhibiting a distribution of micro-prisms in relief.
  • the micro-prisms are conformed in a known way to provide reflecting characteristics; c) treating the structured surface 21a in order to increase the ability thereof to grip and anchor to the next-applied layer of material, for example using a treatment increasing the surface tension and roughness of the structured surface 21a; d) distributing a layer 22 of reflecting material on the treated structured surface with the micro-prisms; the reflecting material is preferably metallic (for example, almninium) and is applied using a known metallizing process under vacuum; e) distributing on the reflecting material at least one thin layer 23 of material, preferably constituted by a metal primer, for example a bicomponent polyurethane, which enables a firm anchoring of the following layer 24 of covering and protective material.
  • a metal primer for example a bicomponent polyurethane
  • the metallized surface can be surface-treated to improve its gripping capacity on the next covering and protective layer 24.
  • a second, filler layer 24 of protective material is laid on the primer layer 23 (or surface-treated layer).
  • This second, filler layer 24 can be for example a high-weight polyurethane resin which flattens the bottom side of the film 2, filling the "valleys" and covering the "peaks" of the micro-prisms in relief on the structured surface 21a; the filler layer 24 is thicker than the depth of the valleys on the structured surface, so that the micro-prisms are fully protected; f). Heat-forming the film 2 to obtain a distribution of macroscopic reliefs 4 to which an equal number of cells 5 corresponds.
  • the filler layer 24 has the function of protecting the micro-prisms so that they keep their conformation and reflective properties.
  • the reliefs 4 project on the upper side of the film 2, i.e. the side bearing the transparent material, while the cells 5 are on the lower side, i.e. the side filled by the filler layer 24.
  • the film is heat-formed by being passed between two opposed embossing cylinders (not illustrated) which are peripherally provided with two matrices (one male, one female) which cooperate to obtain the reliefs 4 on one side of the film and the cells 5 on the other side.
  • one of the two matrices preferably the male matrix
  • the male matrix can be made of silicone rubber while the female matrix can be made of a metal (e.g. steel, nickel, etc).
  • the film 2 is pre-heated, for example by batteries of infra-red rays and/or heating rollers; then the heat-forming is performed by the two embossing rollers (cooled) which operate synchronously to produce a fihn 2 in which each relief (male) on one side corresponds to a cell (female) on the other side.
  • the heat-formable layer 21 guarantees good-quality heat-forming; g). Distributing, as previously described, a filler layer 6 of material to fill the cells 5 and cover the bottom side of the film, 2, the same side as the protective layer 24.
  • a layer of adhesive or self-adhesive is deposited in a known way on the base layer 6, which serves to fix the laminate 1 to an external surface (for example a road surface), protected by a film of paper or silicone.
  • Application of the laminate 1 on a road surface is done in known ways.
  • the laminate is particularly useful for horizontal road signals, has a high back- reflecting power, and can maintain a high reflective capacity over a long period of time, even where subject to wear and stress, such as for example atmospheric agents or passage of motor vehicles.
  • the laminate provides a horizontal signal which will last over a long period of time and which does not require any particular maintenance.
  • the horizontal signal offers very high visibility for drivers even in very bad weather, such as for example at night or when it is foggy or raining, thus improving road safety.
  • the laminate has excellent anti-skid surface characteristics, especially for vehicle tyres.
  • the laminate has colour and luminosity characteristics which satisfy the requirements of the laws, while mamtaining a high degree of reflection.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un film multicouche (2) définissant sur le recto des reliefs macroscopiques (4) obtenus par thermoformage en regard d'autant de cuvettes (5) au verso. Une couche de base en matériau de comblement (6) remplissant les cuvettes recouvre le verso du film multicouche (2). Ce film multicouche (2) est constitué d'une couche supérieure (21) en matière transparente thermoformable, une couche inférieure structurée (21a) présentant des microprismes aux propriétés de réflexion, et d'autres couches en matériaux protecteurs placés sous une couche réfléchissante (22). Ce stratifié au pouvoir réfléchissant élevé, se distingue par ses qualités de luminosité, par une gamme de couleurs et des propriétés de réflexion respectant les dispositions légales et réglementaires.
PCT/IT2002/000386 2001-08-03 2002-06-12 Stratifie reflecteur a microprismes, et procede de fabrication WO2003012492A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT2001MO000162A ITMO20010162A1 (it) 2001-08-03 2001-08-03 Laminato retroriflettente con microprismi e metodo per fabbricarlo
ITMO2001A000162 2001-08-03

Publications (1)

Publication Number Publication Date
WO2003012492A1 true WO2003012492A1 (fr) 2003-02-13

Family

ID=11450848

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IT2002/000386 WO2003012492A1 (fr) 2001-08-03 2002-06-12 Stratifie reflecteur a microprismes, et procede de fabrication

Country Status (2)

Country Link
IT (1) ITMO20010162A1 (fr)
WO (1) WO2003012492A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004011234A1 (fr) * 2002-07-31 2004-02-05 Giorgio Corradi Procede pour produire un stratifie reflechissant
WO2006067573A1 (fr) * 2004-12-22 2006-06-29 Giorgio Corradi Procede permettant d'obtenir un film multicouche retroreflechissant, a support de microprismes et film obtenu par ce procede

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3190178A (en) * 1961-06-29 1965-06-22 Minnesota Mining & Mfg Reflex-reflecting sheeting
US3973342A (en) * 1971-04-19 1976-08-10 Gubela Hans Erich Light reflector plate and method of fabrication
GB1580725A (en) * 1976-04-30 1980-12-03 Amerace Corp Road marker
US4486363A (en) * 1982-09-30 1984-12-04 Amerace Corporation Method and apparatus for embossing a precision optical pattern in a resinous sheet
EP0171975A2 (fr) * 1984-08-10 1986-02-19 Amerace Corporation Procédé et appareil pour former un motif optique de précision par gaufrage dans une feuille ou un stratifié en matière plastique
US5376431A (en) * 1993-05-12 1994-12-27 Reflexite Corporation Retroreflective microprism sheeting with silver/copper reflecting coating and method of making same
US6139158A (en) * 1995-07-26 2000-10-31 Reflexite Corporation Retroreflective articles with multiple size prisms in multiple locations
US6258443B1 (en) * 1994-09-28 2001-07-10 Reflexite Corporation Textured retroreflective prism structures and molds for forming same

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3190178A (en) * 1961-06-29 1965-06-22 Minnesota Mining & Mfg Reflex-reflecting sheeting
US3973342A (en) * 1971-04-19 1976-08-10 Gubela Hans Erich Light reflector plate and method of fabrication
GB1580725A (en) * 1976-04-30 1980-12-03 Amerace Corp Road marker
US4486363A (en) * 1982-09-30 1984-12-04 Amerace Corporation Method and apparatus for embossing a precision optical pattern in a resinous sheet
EP0171975A2 (fr) * 1984-08-10 1986-02-19 Amerace Corporation Procédé et appareil pour former un motif optique de précision par gaufrage dans une feuille ou un stratifié en matière plastique
US5376431A (en) * 1993-05-12 1994-12-27 Reflexite Corporation Retroreflective microprism sheeting with silver/copper reflecting coating and method of making same
US6258443B1 (en) * 1994-09-28 2001-07-10 Reflexite Corporation Textured retroreflective prism structures and molds for forming same
US6139158A (en) * 1995-07-26 2000-10-31 Reflexite Corporation Retroreflective articles with multiple size prisms in multiple locations

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004011234A1 (fr) * 2002-07-31 2004-02-05 Giorgio Corradi Procede pour produire un stratifie reflechissant
WO2006067573A1 (fr) * 2004-12-22 2006-06-29 Giorgio Corradi Procede permettant d'obtenir un film multicouche retroreflechissant, a support de microprismes et film obtenu par ce procede

Also Published As

Publication number Publication date
ITMO20010162A0 (it) 2001-08-03
ITMO20010162A1 (it) 2003-02-03

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