US5691846A
Expired / Lapsed
US
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Ultra-flexible retroreflective cube corner composite sheetings and methods of manufacture
Assignee: 3M Innovative Properties Co
•
Filing: 1995-06-07
•
Granted: 1997-11-25
•
Expires: 2015-06-07
Abstract
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.
Inventors
- 👤 Olester Benson, Jr.
- 👤 Cheryl M. Frey
- 👤 Jeanine M. Shusta
- 👤 Susan K. Nestegard
- 👤 Vera L. Lightle
- 👤 Kenneth L. Smith
- 👤 Chester A. Bacon, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 11:35
CPC Classifications
B; B29; B29C; B29C39/00; B29C39/14; B29C39/148; B29C59/00; B29C59/02; B29C59/04; B29C59/046; G; G02; G02B; G02B5/00; G02B5/12; G02B5/122; G02B5/124; B29C59/022; B29C2059/023; Y; Y10; Y10S; Y10S359/00; Y10S359/90; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24612
Claims Analysis
Total Claims: 51
Claim 1
Independent Claim
201 words
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; then f) 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.
Claim 2
Independent Claim
201 words
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; then f) 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.
Claim 3
Dependent Claim
26 words
The method of claim 1 wherein said microstructure elements are cube corner elements and wherein said curable resin composition is suitable for forming cube corner elements.
Claim 4
Dependent Claim
35 words
The method of claim 1 wherein said curing comprises exposing said resin composition at least one curing treatments selected from the following: actinic radiation from a radiation source, an electron beam, and chemical curing agent.
Claim 5
Dependent Claim
18 words
The method of claim 1 further comprising the step of subjecting said resin to a secondary curing treatment.
Claim 6
Dependent Claim
22 words
The method of claim 1 further comprising the step of subjecting said sheeting to a heat treatment after said applying mechanical stress.
Claim 7
Dependent Claim
19 words
The method of claim 1 wherein said overlay film has an elastic modulus less than about 13×10 8 pascals.
Claim 8
Dependent Claim
28 words
The method of claim 1 wherein the elastic modulus of said microstructure elements is at least 1.0×10 7 pascals more than the elastic modulus of said overlay film.
Claim 9
Dependent Claim
12 words
The method of claim 1 wherein said overlay film is light transmissive.
Claim 10
Dependent Claim
39 words
The method of claim 1 wherein said overlay film is selected from the group consisting of the following: ionomeric ethylene copolymers, plasticized vinyl halide polymers, acid-functional ethylene copolymers, aliphatic polyurethanes, aromatic polyurethanes, other light transmissive elastomer, and combinations thereof.
Claim 11
Dependent Claim
12 words
The method of claim 1 wherein said resin composition shrinks when cured.
Claim 12
Dependent Claim
19 words
The method of claim 1 wherein said resin composition shrinks by at least 5 percent by volume when cured.
Claim 13
Dependent Claim
22 words
The method of claim 1 wherein said resin composition shrinks be between about 5 and about 20 percent by volume when cured.
Claim 14
Dependent Claim
21 words
The method of claim 1 wherein said microstructure elements, after curing, have an elastic modulus greater than about 25×10 8 pascals.
Claim 15
Dependent Claim
20 words
The method of claim 1 wherein said microstructure elements have an elastic modulus of at least about 2.0×10 8 pascals.
Claim 16
Dependent Claim
25 words
The method of claim 1 wherein said microstructure elements, comprise a material selected from the group consisting of the following: monofunctional, difunctional, and polyfunctional acrylates.
Claim 17
Dependent Claim
12 words
The method of claim 1 wherein said microstructure elements are substantially transparent.
Claim 18
Dependent Claim
95 words
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.
Claim 19
Dependent Claim
95 words
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.
Claim 20
Dependent Claim
92 words
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.
Claim 21
Dependent Claim
92 words
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.
Claim 22
Dependent Claim
41 words
The sheeting of claim 18 wherein at least some of said microstructure elements were in connection with adjacent microstructure elements through a land after said curing in situ, said land having been fractured such that said microstructure elements are substantially independent.
Claim 23
Dependent Claim
28 words
The sheeting of claim 19 wherein said land has a thickness of less than about 10 percent of the average height of said microstructure elements of said array.
Claim 24
Dependent Claim
28 words
The sheeting of claim 19 wherein said land has a thickness of less than about 1 percent of the average height of said microstructure elements of said array.
Claim 25
Dependent Claim
21 words
The sheeting of claim 18 wherein said microstructure elements are cube corner elements and wherein said composite is a retroreflective sheeting.
Claim 26
Dependent Claim
29 words
The sheeting of claim 22 wherein the elastic modulus of said cube corner elements is at least 1.0×10 7 pascals more than the elastic modulus of said overlay film.
Claim 27
Dependent Claim
21 words
The sheeting of claim 22 wherein said cube corner elements have an elastic modulus of at least about 2.0×10 8 pascals.
Claim 28
Dependent Claim
21 words
The sheeting of claim 22 wherein said cube corner elements have an elastic modulus of at least about 25×10 8 pascals.
Claim 29
Dependent Claim
36 words
The sheeting of claim 22 wherein said sheeting has a coefficient of retroreflectivity greater than about 50 candelas per lux per square meter, measured at an entrance angle of -4° and an observation angle of 0.2°.
Claim 30
Dependent Claim
23 words
The sheeting of claim 26 wherein said sheeting has a coefficient of retroreflectivity greater than about 250 candelas per lux per square meter.
Claim 31
Dependent Claim
23 words
The sheeting of claim 26 wherein said sheeting has a coefficient of retroreflectivity greater than about 500 candelas per lux per square meter.
Claim 32
Dependent Claim
46 words
The sheeting of claim 22 having a coefficient of retroreflectivity greater than about 50 candelas per lux per square meter, measured at an entrance angle of -4° and an observation angle of 0.2°, when said sheeting has been elongated to 110 percent of its original length.
Claim 33
Dependent Claim
47 words
The sheeting of claim 22 having a coefficient of retroreflectivity, measured at an entrance angle of -4° and an observation angle of 0.2°, after being stretched to at least 110 percent of its original length that is at least 30 percent of it initial coefficient of retroreflectivity.
Claim 34
Dependent Claim
47 words
The sheeting of claim 22 having a coefficient of retroreflectivity, measured at an entrance angle of -4° and an observation angle of 0.2°, after being stretched to at least 110 percent of its original length that is at least 50 percent of it initial coefficient of retroreflectivity.
Claim 35
Dependent Claim
31 words
The sheeting of claim 22 having a retroreflective brightness greater than about 75 percent of its initial retroreflective brightness after being stretched 10 percent in one dimension and allowed to relax.
Claim 36
Dependent Claim
48 words
The sheeting of claim 22 having a coefficient of retroreflectivity of at least 50 candela/lux/meter 2 , measured at an entrance angle of -10° and an observation angle of 0.15° when elongated to 150 percent of its original length over a radius of curvature of about 150 millimeters.
Claim 37
Dependent Claim
28 words
The sheeting of claim 22 having a retroreflective brightness of greater than about 50 percent of its initial brightness after being laundered for twenty five home laundering cycles.
Claim 38
Dependent Claim
28 words
The sheeting of claim 34 having a retroreflective brightness of greater than about 75 percent of its initial brightness after being laundered for twenty five home laundering cycles.
Claim 39
Dependent Claim
26 words
The sheeting of claim 22 having a retroreflective brightness of greater than about 50 percent of its initial brightness after 1000 hours of accelerated UV weathering.
Claim 40
Dependent Claim
25 words
The sheeting of claim 22 having a retroreflective brightness of greater than about 50 percent of its initial brightness after 170 hours at 82° C.
Claim 41
Dependent Claim
29 words
The sheeting of claim 22 having a retroreflective brightness of greater than about 50 percent of its initial brightness after 48 hours in a temperature and humidity cycling chamber.
Claim 42
Dependent Claim
15 words
The sheeting of claim 22 further comprising a reflective layer on said cube corner elements.
Claim 43
Dependent Claim
34 words
The sheeting of claim 22 further comprising a sealing film adhered to the cube corner side of said sheeting in an interconnecting network so as form cells in which cube corner elements are encapsulated.
Claim 44
Dependent Claim
18 words
An article comprising a sheeting of claim 40 bonded thereto wherein said sealing film acts as the bonding.
Claim 45
Dependent Claim
13 words
The sheeting of claim 18 wherein said first polymeric material shrunk while curing.
Claim 46
Dependent Claim
20 words
The sheeting of claim 18 wherein said overlay film has an elastic modulus of less than about 13×10 8 pascals.
Claim 47
Dependent Claim
18 words
The sheeting of claim 18 wherein said first polymeric material is a thermoset material or a thermoplastic material.
Claim 48
Dependent Claim
13 words
The sheeting of claim 18 wherein said overlay film is an elastomeric film.
Claim 49
Dependent Claim
18 words
The sheeting of claim 18 wherein said overlay film is extensible and has substantially no tendency to recover.
Claim 50
Dependent Claim
21 words
The sheeting of claim 18 further comprising a sealing layer adhered to said overlay film through openings between individual microstructure elements.
Claim 51
Dependent Claim
12 words
An article of personally comprising a sheeting of claim 18 attached thereto.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-11-24 | 2001-05-26 | 2001-11-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-11-24 | 2005-05-26 | 2005-11-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-11-24 | 2009-05-26 | 2009-11-25 | $7700.00 | Window Closed / Lapsed |