CN102458818A - 包括印刷区域的回射制品 - Google Patents
包括印刷区域的回射制品 Download PDFInfo
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- CN102458818A CN102458818A CN2010800246707A CN201080024670A CN102458818A CN 102458818 A CN102458818 A CN 102458818A CN 2010800246707 A CN2010800246707 A CN 2010800246707A CN 201080024670 A CN201080024670 A CN 201080024670A CN 102458818 A CN102458818 A CN 102458818A
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Abstract
本发明通常涉及包括低折射率材料和印刷区域的回射制品。本发明还通常涉及制备回射制品的方法。
Description
技术领域
本发明通常涉及包括低折射率材料和印刷区域的回射制品。本发明还通常涉及制备回射制品的方法。
背景技术
回射材料的特征在于能够将入射至材料上的光重新导向返回至初始光源。该性能已使回射片材广泛用于多种交通和个人安全应用。回射片材常用于多种制品,例如交通标志、路障、牌照、路面标记和标志带,以及车辆和衣物的反光带。
两种已知类型的回射片材为立体角片材和微球基片材。微球基片材(有时称为“微珠”片材)采用大量微球,所述微球通常至少部分地嵌入粘合剂层中,并具有相关的镜面反射或漫反射材料(例如,颜料粒子、金属薄片或蒸镀层等)以回射入射光。立体角回射片材(有时称为“棱柱”片材)通常包括薄的透明层,该透明层具有基本上平的第一表面和结构化第二表面,该结构化第二表面包括多个几何结构,这些几何结构的一些或全部包括构成立体角元件的三个反射表面。
通常,立体角元件包括在单个顶点相交的三个相互垂直的光学面。通常,从光源入射至立体角元件的光从三个垂直的立体角光学面的每一个发生全内反射,并被重新导向返回至光源。在光学面上的例如灰尘、水和粘合剂的存在可抑制全内反射(TIR)并导致回射光强度的降低。这样,空气界面通常被密封膜所保护,但这种膜通常减少了总活性区域,该总活性区域为其上可以发生回射的区域。金属化立体角不依赖于回射光的TIR,但它们对于例如标记应用的日间观察通常不足够白。此外,金属涂层的耐久性也可能不充分。
发明内容
本发明通常涉及一种回射制品,所述回射制品包括:包括多个立体角元件的回射层,所述多个立体角元件共同形成与主表面相对的结构化表面;与结构化主表面的至少一部分相邻的低折射率材料,所述低折射率材料具有小于约1.3的有效折射率;以及设置于低折射率材料的一部分上的可印刷材料。
本发明通常涉及一种回射制品,所述回射制品包括:包括多个立体角元件的回射层,所述多个立体角元件共同形成与主表面相对的结构化表面;低折射率材料,所述低折射率材料与所述结构化主表面的至少一部分相邻以形成回射入射光的光学活性区域;以及可印刷材料,所述可印刷材料被设置于所述低折射率材料的一部分上以形成基本上不回射入射光的无光学活性的区域。
本发明通常涉及一种形成回射制品的方法,所述方法包括(1)提供包括与主表面相对的结构化表面的回射层;(2)邻近结构化主表面的至少一部分施用低折射率材料,所述低折射率材料具有低于约1.3的有效折射率;以及(3)在低折射率材料的一部分上印刷材料。
附图说明
图1为本发明的示例性回射制品的示意性侧视图。
图2为图1通常所示类型的一个示例性回射制品的示意性俯视图。
图3为图1通常所示类型的另一示例性回射制品的示意性俯视图。
具体实施方式
图1和2分别为本发明的示例性回射制品100的示意性侧视图和示意性俯视图。回射制品100包括回射层110,回射层110包括多个光学元件112,所述多个光学元件112共同形成与主表面116相对的结构化表面114。回射层110还包括覆盖层118。图1所示的实施例包括覆盖层118,且不包括基体层或基体部分。该构造对于灵活的实施例可以是理想的。本领域技术人员将认识到回射层110或者可包括基体层或基体部分。回射制品还包括多个低折射率区域120、多个印刷区域130、粘合剂层140、和基材150。低折射率区域120包括折射率小于1.3、小于1.25、小于1.2、小于1.15、小于1.1的低折射率材料。低折射率区域120还包括孔穴。图1的印刷区域130显示接触结构化表面114,但在其他实施例中印刷区域130不延伸至结构化表面114。在一些实施例中,以足够的厚度施用低折射率涂层材料以有效地将该构造平面化。
在与低折射率区域120相邻的立体角元件112的一部分上入射的光线150被回射返回至观察者102。为此原因,回射制品100的包括低折射率区域120的区域被称为光学活性区域。相反,回射制品100的与印刷区域130相邻的区域被称为无光学活性的区域,因为其基本上不回射入射光。在至少一些实施例中,当印刷区域延伸至结构化表面114时,区域无光学活性。即,其中印刷区域不延伸至结构化表面的与印刷区域相邻的区域仍然为光学活性的。
图1和2的回射制品100可通过如下示例性方法制得。将低折射率材料施用至回射层的结构化主表面。然后,将可印刷材料施用至所述低折射率材料上。可印刷材料至少部分渗透和填充低折射率材料中的至少一些孔穴以形成印刷区域130。可使用接触或非接触方法将可印刷材料施用至该构造。施用方法可包括印刷,包括例如非接触方法,例如使用喷墨打印机印刷。印刷方法可为接触印刷方法,例如柔性版印刷。印刷方法可为连续或非连续的。示例性的连续印刷方法包括覆墨(flood coating)、Mayer棒、和槽式涂布。示例性的非连续印刷方法包括网版印刷、凹版印刷、喷涂。另外的示例性印刷方法包括,例如,喷墨印刷、柔性版印刷、凹版印刷(直接和间接)、网版印刷、转移印花、槽式印刷(slot printing)、刮涂、辊涂或辊印、喷涂或喷印、浸涂、和橡皮版印刷。
在一些实施例中,印刷区域130形成图案或施用印刷区域130以形成图案。图案可为规则的或不规则的。通常,任何所需的图案可通过所述的技术的组合产生,包括例如标记,如字母、单词、字母数字、符号、或甚至图画。图案也可为连续的、不连续的、单调的、螺线型、任何平滑变化的函数、在纵向、横向、或上述两者上变化的条纹;图案可形成图像、徽标、或文字,且图案可包括图案化涂层和/或穿孔。在一些实施例中,印刷区域和/或非印刷区域可形成防伪特征。在一些实施例中,印刷区域用作增强层。可改变印刷密封图案的尺寸以产生较不明显或更明显的图案。可改变可印刷材料的量和类型以及所用的图案以改进持水效率和总层片粘附力。在一些实施例中,回射制品的至少40%、至少50%、或至少60%为回射的。
在一些实施例中,相邻印刷区域130形成封闭单元160,如图3中示意所示。封闭单元可为特别有利的,因为它们受到印刷区域的保护而免于环境暴露于诸如水的材料。当回射制品100在封闭单元160上包括保护层时,单元为封装单元。在一些实施例中,单元尺寸小于1000微米、小于750微米、小于500微米、或小于250微米。多边形单元的尺寸通常为两个相对表面之间的距离。圆形单元的尺寸为单元的直径。不规则形单元的尺寸可通过单元的面积除以周长而测得。微密封单元的几何、形状、尺寸和结构在整个片材上可为均匀的,或可以受控的方式变化。单元几何(如尺寸、形状、和单元宽度)的变化可用于有意引入具有近距离(低于20英尺,优选低于5英尺)的视觉外观上的轻微波动。这种波动可具有间或隐藏缺陷的作用,所述缺陷可无规分布于片材中(污染物、涂层裂纹等),或者可源自模具或产品中的周期结构(例如,成比例放大或焊接线)。
适于在本发明的回射制品中使用的可印刷材料具有大于1.3的折射率。在一些实施例中,可印刷材料为油墨或染料,包括任何彩色油墨(例如透光的、白色、黄色、黑色)。在一些实施例中,可印刷材料为透明的、不透明的、或有色的。在一些实施例中,可印刷材料包括单体、低聚物、和/或聚合物。示例性的可印刷材料包括辐射固化性组合物、溶剂基聚合物溶液、和UV可固化组合物。在一些实施例中,可印刷材料紧密接触结构化表面或与结构化表面直接相邻。在一些实施例中,可印刷材料被设置于结构化表面的至少50%、至少60%、至少70%、至少80%、和至少90%。在一些实施例中,可印刷材料为溶剂,所述溶剂在干燥之后引起孔穴塌缩和/或熔合。在一些实施例中,在特定区域中可选择性地使用热或压力以产生较高折射率的区域。在这种实施例中,孔穴可能被塌缩以形成具有较高折射率的区域。这种实施例将显示改进的粘附力等。
在一些实施例中,如在示例性回射制品100中,每个回射光学元件112为四面体或棱锥的形式,如具有三个平面或边和底部(其中所述边在顶点处会合)的常规的四面体或棱锥。然而,光学元件可具有提供有效反射或回射的任何形状。在任意两个面之间的二面角可根据所需的性质而变化。在一些实施例中,任意两个面之间的二面角为90度。在这种实施例中,所述面基本上彼此垂直(如同房间的角落中),且光学元件可称为立体角元件。在一些实施例中,相邻面之间的二面角可偏离90°,如例如在美国专利No.4,775,219中所述,该专利的公开内容以全文引用的方式并入本文。在一些实施例中,所述光学元件可为截平的立体角。在一些实施例中,所述光学元件可为全立方体(full cube)或为如例如美国专利No.7,422,334中所述的优选几何(PG)立方体,该专利的公开内容以全文引用的方式并入本文。每个回射光学元件包括对称轴,所述对称轴与面形成相等角度。在一些实施例中,如在示例性构造100中,对称轴垂直于底部或前表面。在一些可选择的实施例中,对称轴不垂直于底部或前表面。在这种实施例中,光学元件的顶点可如例如美国专利No.4,588,258中所述为倾斜的,该专利的公开内容以全文引用的方式并入本文。顶点也可称为光学元件顶端。
回射立体角的原理操作是公知的,并描述于例如J.Optical Soc.ofAmerica46(7),496(1958)中。大体上,沿正y方向传播并入射至回射光学元件上的光线被光学元件的每个面TIR,从而产生沿负y方向传播并平行于入射光线的回射光线。在一些实施例中,回射光线偏离y方向,因为回射光线与y轴形成发散角δ。在一些实施例中,如在交通标记的情况中,发散角δ在约0.2度至约2度的范围内。TIR的任何衰减可显著降低回射光线的强度。
回射制品100的回射系数RA(有时称为回射率)可根据在特定应用中所需的性质而变化。在一些实施例中,RA在0度和90度取向角下满足ASTM D4956-07e1标准。在一些实施例中,当根据ASTM E-810测试方法或CIE 54.2;2001测试方法在0.2度观察角和+5度入射角测量时,RA在约5cd/(lux·m2)至约1500cd/(lux·m2)的范围内。在一些实施例中,如在其中回射制品100用于交通控制标志、描绘器或路障的实施例中,如根据ASTM E-810测试方法或CIE 54.2;2001测试方法在0.2度观察角和+5度入射角测得,RA为至少约330cd/(lux·m2),或至少约500cd/(lux·m2),或至少约700cd/(lux·m2)。在一些实施例中,对于约0.2度的观察角和约-4度的入射角,回射结构化主表面显示具有不小于(或大于)约40cd/(lux·m2)、或大于约100cd/(lux·m2)、或大于约150cd/(lux·m2)、或大于约200cd/(lux·m2)、或大于约250cd/(lux·m2)、或大于约300cd/(lux·m2)、或大于约350cd/(lux·m2)、或大于约400cd/(lux·m2)的回射系数RA。
在一些实施例中,如在机动车辆相关的应用中,如根据ASTM E-810测试方法或CIE 54.2;2001测试方法在0.2度观察角和+5度入射角测得,RA为至少约60cd/(lux·m2)、或至少约80cd/(lux·m2)、或至少约100cd/(lux·m2)。
回射制品100的全光返回(Total light return)(TLR)可由了解活性区域百分比和光线强度而确定。光线强度可通过前表面损失和通过从用于回射线的三个立体角表面的每一个反射而被降低。全光返回定义为活性区域百分比和光线强度的乘积,或被回射的全入射光的百分比。对直接加工的立体角阵列的全光返回的讨论描述于例如美国专利No.3,712,706(Stamm)中,该专利以全文引用的方式并入本文。全光返回还描述于2008年10月22日提交的美国临时专利申请号61/107,586中,该专利申请以全文引用的方式并入本文。在一些实施例中,对于入射角为约-4度的入射可见光,回射表面显示具有不小于(或大于)约5%、或大于约10%、或大于约15%、或大于约20%、或大于约25%、或大于约30%的全光返回。
示例性的低折射率材料具有小于1.3的折射率。在一些实施例中,低折射率材料与基本上整个结构化主表面相邻。在其他实施例中,低折射率材料与仅一部分结构化表面相邻。
本发明的回射制品或构造的一些实施例包括一个或多个低折射率层、区域、或部分,所述低折射率层、区域、或部分通过包括多个空隙而支持全内反射(TIR)或增大的内反射(EIR)。当在光学透明的非多孔介质中行进的光在具有高孔隙率的层上入射时,倾斜角度的入射光的反射率比垂直入射的入射光的反射率高得多。在无雾度或低雾度的空隙膜的情况中,在大于临界角度的倾斜角度下的反射率接近约100%。在这种实施例中,入射光发生TIR。在高雾度的空隙膜的情况中,即使光可能不发生TIR,在入射角度的类似范围内,倾斜角度反射率可接近100%。高雾度膜的该增大的反射率类似于TIR,并指定为EIR。本文所用的多孔或有空隙的低折射率层EIR意指对于在膜或膜层合物或层的空隙层和非空隙层的边界处的反射率,具有空隙的比无空隙的大。
本发明的回射制品或构造的一些实施例包括一个或多个低折射率层,所述低折射率层包括分散于粘合剂中的多个空隙。空隙具有折射率nv和介电常数εv,其中nv 2=εv,且粘合剂具有折射率nb和介电常数εb,其中nb 2=εb。通常,低折射率层与光(如在低折射率层上入射或在低折射率层内传播的光)的相互作用取决于多个膜或层特性,例如,膜或层厚度、粘合剂折射率、空隙或孔穴折射率、孔穴形状和尺寸、孔穴的空间分布、和光的波长。在一些实施例中,在低折射率层上入射或在低折射率层内传播的光“看见”或“经历”有效介电常数εeff和有效折射率neff,其中neff可以以空隙折射率nv、粘合剂折射率nb、和空隙孔隙率或体积分数“f”表示。在这种实施例中,低折射率层足够厚且空隙足够小,使得光不能分辨单个或分开的空隙的形状和特征。在这种实施例中,至少大部分空隙(如至少60%或70%或80%或90%的空隙)的尺寸不大于约λ/5、或不大于约λ/6、或不大于约λ/8、或不大于约λ/10、或不大于约λ/20,其中λ为光的波长。在一些实施例中,一些空隙可为足够小,使得它们的主要光学作用为降低有效折射率,而其他一些空隙可降低有效折射率和散射光,而其他另一些空隙可为足够大,使得它们的主要光学作用为散射光。
在一些实施例中,在低折射率层上入射的光为可见光,意味着光的波长在电磁光谱的可见范围内。在这种实施例中,可见光具有在约380nm至约750nm、或约400nm至约700nm、或约420nm至约680nm范围内的波长。在这种实施例中,低折射率层具有有效折射率,并包括多个空隙,如果至少大多数空隙(如至少60%或70%或80%或90%的空隙)的尺寸不大于约70nm、或不大于约60nm、或不大于约50nm、或不大于约40nm、或不大于约30nm、或不大于约20nm、或不大于约10nm。
在一些实施例中,低折射率层足够厚,使得低折射率层具有有效折射率,所述有效折射率可以以空隙和粘合剂的折射率和空隙或孔穴体积分数或孔隙率表示。在这种实施例中,光学膜或低折射率层的厚度不小于约100nm、或不小于约200nm、或不小于约500nm、或不小于约700nm、或不小于约1,000nm。在这种实施例中,低折射率层的有效折射率为空隙和粘合剂的折射率的体积加权平均。在环境条件下,空隙含有空气,因此空隙的折射率nv为大约1.00。例如,空隙体积分数为约50%且具有折射率为约1.5的粘合剂的低折射率层具有约1.25的有效折射率。
低折射率层120可为在与回射层110的界面处促进或保持TIR或提高内反射的任何光学层。低折射率层120具有足够低的折射率以保持或支持TIR,从而得到通过回射层110的有效回射。低折射率层120可由支持这些目标的任何材料制成。在一些实施例中,低折射率层120的有效折射率不大于(或小于)约1.3、或小于约1.25、或小于约1.2、或小于约1.15、或小于约1.1。在一些实施例中,折射率为约1.14至约1.30。低折射率层的一些实施例优选足够多孔以促进或保持TIR或提高内反射。在一些实施例中,低折射率层120包括粘合剂、多个粒子、和多个互连空隙或互连空隙的网络。在其他实施例中,低折射率层120包括粘合剂和多个互连空隙或互连空隙的网络。
多个互连空隙或互连空隙的网络可通过本文公开的两个主要方法之一产生。在一个方法中,在粘合剂混合物中利用高度结构化、高表面积热解法金属氧化物(如热解法二氧化硅)的固有孔隙率以形成结合粘合剂、粒子、空隙和任选的交联剂或其他辅助材料的复合结构。在另一方法中,由粘合剂、交联剂混合物和任选的粒子原位形成空隙,随后固化。该方法“胶凝”溶剂化态的组分以形成饱和凝胶,当所述凝胶完全干燥和交联时得到原位孔隙率的形成。理想的粘合剂与粒子的比率取决于用于形成互连空隙结构的方法类型。
尽管粘合剂树脂不是形成多孔热解法二氧化硅结构的先决条件,但通常理想的是掺入一些类型的聚合物树脂或粘合剂与金属氧化物网络一起,以改进最终构造的加工、涂层品质、粘附力和耐久性。可用的粘合剂树脂的例子为衍生自热固性、热塑性和UV可固化聚合物的那些。例子包括聚乙烯醇(PVA)、聚乙烯醇缩丁醛(PVB)、聚乙烯吡咯烷酮(PVP)、聚乙烯乙酸乙烯酯共聚物(EVA)、乙酸丁酸纤维素(CAB)、聚氨酯(PUR、聚甲基丙烯酸甲酯(PMMA)、聚丙烯酸酯、环氧树脂、有机硅和含氟聚合物。可用于混合物中的市售粘合剂的例子为可得自Kuraray-USA、Wacker Chemical、Dyneon LLC的那些。尽管粘合剂可为聚合物体系,其也可作为可聚合单体体系(如UV可固化或可热固化或可交联体系)加入。这种体系的例子可为UV聚合型丙烯酸酯、甲基丙烯酸酯、多官能丙烯酸酯、氨基甲酸酯丙烯酸酯、和它们的混合物。一些典型例子可为1,6己二醇二丙烯酸酯、三羟甲基丙烷三丙烯酸酯、季戊四醇三丙烯酸酯。这种UV活性体系是公知的,并易于由如Ato-Fina或Sartomers的供应商获得。
聚合物粘合剂也可与交联剂一起配制,所述交联剂可与聚合物粘合剂化学结合以形成交联网络。尽管交联的形成不是形成多孔结构或低折射率光学性质的先决条件,但由于其他功能性原因,交联的形成通常是理想的,所述其他功能性原因例如改进涂层的粘合强度、对基材的粘合或耐湿性、耐热性及耐溶剂性。交联剂的特定类型取决于所用的粘合剂。用于聚合物粘合剂(如PVA)的典型交联剂可为二异氰酸酯、钛酸盐(如TYZOR-LATM(可得自DuPont,Wilmington,DE))、硼酸、二环氧化物二元酸等。
聚合物粘合剂可与粒子聚集体形成分离相,或可以一定方式分散于粒子聚集体之间,所述方式为通过直接共价键的形成或分子相互作用(如离子力、偶极力、范德华力和与金属氧化物的物理缠结)将聚集体“结合”在一起形成与金属氧化粒子连接的结构。
示例性的粒子包括热解法金属氧化物或焦化金属氧化物,例如热解法二氧化硅或氧化铝。在一些实施例中,可使用高度支化或结构化的粒子。这种粒子抑制了在粘合剂基体中的有效堆积,并允许形成空隙或孔穴。包括高度支化或结构化粒子的示例性材料包括Cabo-SilTM热解法二氧化硅或二氧化硅分散体(例如以商品名EH5、TS 520销售的那些),或预分散的热解法二氧化硅粒子(如可以Cabo-SperseTM PG 001、PG 002、PG 022、1020K、1015得到的那些)。尽管由于二氧化硅具有固有的比氧化铝低的骨架折射率而优选二氧化硅,但热解法氧化铝也是可用的结构化粒子以形成低折射率体系。氧化铝的例子可以商品名Cabo-Sperse获得,例如以商品名Carbo-SperseTM PG003或Cabot Spec-AlTM销售的那些。也可使用非白色粒子,例如某些可分散炭黑,例如可以商品名VulcanTM XC72R得自Cabot的那些。非白色粒子可具有透射时显示一种颜色但为高度回射的附加光学益处。在一些实施例中,这些示例性热解法金属氧化物的聚集体包含多个约8nm至约20nm范围内的初级粒子,并形成具有约80nm至大于300nm范围内的广泛尺寸分布的高度支化的结构。在一些实施例中,这些聚集体在涂层的单元体积中无规堆积以形成具有通道、隧道、和孔穴的复杂双连续网络的介孔结构,所述通道、隧道、和孔穴将空气夹带在网络中并由此降低涂层的密度和折射率。
热解法二氧化硅粒子也可用表面处理剂进行处理。金属氧化物粒子的表面处理可提供,例如,改进的在聚合物粘合剂中的分散、改变的表面性质、提高的粒子-粘合剂相互作用、和/或反应性。在一些实施例中,表面处理稳定粒子,使得粒子良好分散于粘合剂中,从而得到基本上更均匀的组合物。可调整表面改性的无机粒子的掺入,例如以提高粒子与粘合剂的共价结合并由此提供更持久和更均匀的聚合物/粒子网络。
优选的处理剂类型部分地由金属氧化物表面的化学性质决定。硅烷对于二氧化硅和其他含硅填料来说是优选的。在硅烷的情况中,可优选的是在掺入至粘合剂之前使硅烷与粒子表面反应。表面改性剂的所需量取决于若干因素,例如粒子尺寸、粒子类型、改性剂分子量、和/或改性剂类型。硅烷改性剂可具有在粒子和粘合剂之间形成共价键的反应性基团,例如,羧基、醇、异氰酸酯、丙烯酰氧基、环氧、硫醇或胺。反之,硅烷改性剂可具有非反应性基团,例如,烷基、烷氧基、苯基、苯氧基、聚醚、或它们的混合物。这种非反应性基团可改性涂层的表面以改进例如防污性和防尘性,或改进静电耗散。表面改性的二氧化硅粒子的市售例子包括,例如,Cabo-SilTM TS 720和TS 530。有时也理想的是在粒子表面上引入官能团和非官能团的混合物以获得这些理想特征的组合。
适合在本发明的组合物中使用的表面处理剂的代表性实施例包括,例如,N-(3-三乙氧基甲硅烷基丙基)甲氧基乙氧基乙氧基乙基氨基甲酸酯、N-(3-三乙氧基甲硅烷基丙基)甲氧基乙氧基乙氧基乙基氨基甲酸酯、3-(甲基丙烯酰氧基)丙基三甲氧基硅烷、3-丙烯酰氧基丙基三甲氧基硅烷、3-(甲基丙烯酰氧基)丙基三乙氧基硅烷、3-(甲基丙烯酰氧基)丙基甲基二甲氧基硅烷、3-(丙烯酰氧基丙基)甲基二甲氧基硅烷、3-(甲基丙烯酰氧基)丙基二甲基乙氧基硅烷、3-(甲基丙烯酰氧基)丙基二甲基乙氧基硅烷、乙烯基二甲基乙氧基硅烷、苯基三甲氧基硅烷、正辛基三甲氧基硅烷、十二烷基三甲氧基硅烷、十八烷基三甲氧基硅烷、丙基三甲氧基硅烷、己基三甲氧基硅烷、乙烯基甲基二乙酰氧基硅烷、乙烯基甲基二乙氧基硅烷、乙烯基三乙酰氧基硅烷、乙烯基三乙氧基硅烷、乙烯基三异丙氧基硅烷、乙烯基三甲氧基硅烷、乙烯基三苯氧基硅烷、乙烯基三叔丁氧基硅烷、乙烯基三异丁氧基硅烷、乙烯基三异丙烯氧基硅烷、乙烯基三(2-甲氧基乙氧基)硅烷、苯乙烯基乙基三甲氧基硅烷、巯丙基三甲氧基硅烷、3-缩水甘油氧基丙基三甲氧基硅烷、丙烯酸、甲基丙烯酸、油酸、硬脂酸、十二烷酸、2-[2-(2-甲氧基乙氧基)乙氧基]乙酸(MEEAA)、β-羧基乙基丙烯酸酯(BCEA)、2-(2-甲氧基乙氧基)乙酸、甲氧基苯基乙酸、和它们的混合物。
粒子体积浓度(PVC)和临界粒子体积浓度(CPVC)可用于表征涂层的孔隙率。术语PVC和CPVC为在油漆和颜料文献中意义明确的术语,并进一步在例如“Paint Flow and Pigment Dispersion”,Patton,T.C.,2nd Edition,J.Wiley Interscience,1978,第5章,第126页和“Modeling Cluster Voids andPigment Distribution to Predict Properties and CPVC in Coatings.Part 1:DryCoating Analysis”和Sudduth,R.D;Pigment andResin Technology,2008,37(6).第375页的参考文章和技术书籍中明确定义。当粒子的体积浓度大于CPVC时,涂层为多孔的,因为不存在足够的粘合剂以填充粒子之间的所有间隙和涂层的空隙区域。所述涂层则变为粘合剂、粒子、和空隙的混合物。发生该情况的体积浓度与粒子尺寸以及粒子结构和/或形状相关。体积浓度在CPVC以上的配制物具有在混合物中树脂的体积缺陷,所述体积缺陷被空气取代。CPVC、PVC和孔隙率之间的关系为:
在CPVC的该讨论中所用的术语“颜料”等同于粒子,术语“树脂”等同于粘合剂。在某些粘合剂-粒子体系中,当粒子的体积浓度超过称为CPVC的临界值时,所述混合物变得多孔。因此,涂层基本上变为粘合剂、粒子、和空气的混合物,因为存在不足的粘合剂以填充粒子之间的所有间隙和涂层的空隙区域。当这发生时,体积浓度与颜料粒子尺寸分布、润湿、和粒子结构或形状的至少一个相关。提供所需低折射率性质的材料具有亚微米孔穴,所述孔穴衍生自高度结构化的配制为它们的CPVC以上的粒子-粘合剂混合物。在一些实施例中,回射制品具有不大于(或小于)约60%、或小于约50%、或小于约40%的CPVC值。
如上所述,高度支化或结构化的粒子抑制了在粘合剂基体中的有效堆积,并允许形成空隙或孔穴。相比之下,在所需CPVC以下的材料组合将不足够多孔。BET法(上文所述)可有助于测定CPVC以及低折射率材料的孔隙率,因为BET法分析直径小于200nm、直径小于100nm、或甚至直径小于10nm的孔穴。BET数据可协助表征满足用于形成多孔结构的最少要求的材料。
通过PVC/CPVC关系描述的粒子的体积浓度也与粒子的重量浓度相关。因此可以确立在CPVC以上的粒子重量范围。重量比或重量百分比的使用为配制具有理想CPVC值的混合物的一种方式。对于本发明的回射制品,1∶1至1∶8的粘合剂与粒子的重量比是理想的。1∶1的重量比为约50wt%的粒子的等同形式,而1∶8等同于约89wt%的粒子。示例性的粘合剂与金属氧化物粒子的比例为小于1∶2(小于33%的粘合剂)、小于1∶3、小于1∶4、小于1∶5、小于1∶6、小于1∶7、小于1∶8、小于1∶9、和小于1∶10(约8-10%的粘合剂)。粘合剂的下限可由所需的折射率决定。粘合剂的下限可由所需的物理性质,例如加工或最终耐用性特性决定。因此粘合剂与粒子的比率将根据所需的最终用途和所需的回射制品性质而变化。
通常,在本文通常称为“胶凝”法的一种方法中,首先,制备包含溶解于溶剂中的多个粒子(如纳米粒子)和可聚合材料的溶液,其中可聚合材料可包括例如一种或多种类型的单体。然后,例如通过施加热或光来聚合可聚合材料,以在溶剂中形成不可溶聚合物基体。随着聚合发生,溶剂溶解度(在已固化基体中)减小,并可从基体中相分离。这产生富基体网络和相分离的富溶剂网络。随后去除所述溶剂而留下孔穴和空隙,这生成多孔涂层。相分离的程度和类型为决定膜的形态和表面特征的主要因素。最终结构也取决于基体网络的机械性质。随着去除溶剂,网络模量和强度应足以保持空隙空间。组合物和固化程度为决定形态的因素。
或者,低折射率层可包括图案化的低折射率层,所述图案化的低折射率层具有包括折射率、雾度、透射率、透明度、或它们的组合的变化的区域。在一些实施例中,低折射率层包括粘合剂和多个纳米空隙。在另一实施例中,光学构造包括基材和设置于基材上的低折射率层。低折射率层包括粘合剂和多个纳米空隙。在又一实施例中,光学构造包括基材和设置于基材上的低折射率层。在又一实施例中,光学构造包括低折射率层,包括将溶液设置于基材上以形成涂层,所述涂层包括可聚合粘合剂和溶剂;选择性地聚合涂层的第一部分以在溶剂中形成不可溶聚合物基体;从涂层去除溶剂的主要部分;以及聚合涂层与第一部分相邻的第二部分。
空隙具有尺寸d1,所述尺寸d1可通常通过选择合适的组合物和制造技术如各种涂布、干燥、和固化条件而进行控制。通常,d1可为在任何所需数值范围内的任何所需的值。例如,在一些实施例中,至少大部分空隙,如至少60%或70%或80%或90%或95%的空隙具有在所需范围内的尺寸。例如,在一些实施例中,至少大部分空隙,如至少60%或70%或80%或90%或95%的空隙具有不大于约10微米、或不大于约7微米、或不大于约5微米、或不大于约4微米、或不大于约3微米、或不大于约2微米、或不大于约1微米、或不大于约0.7微米、或不大于约0.5微米的尺寸。在一些实施例中,多个互连空隙具有不大于约5微米、或不大于约4微米、或不大于约3微米、或不大于约2微米、或不大于约1微米、或不大于约0.7微米、或不大于约0.5微米的平均空隙或孔穴尺寸。
在一些实施例中,粒子的折射率n1可足够接近粘合剂的折射率nb,使得有效折射率不取决于或极小取决于粒子的折射率。在这种实施例中,n1与nb之间的差异不大于约0.01、或不大于约0.007、或不大于约0.005、或不大于约0.003、或不大于约0.002、或不大于约0.001。在一些实施例中,粒子足够小,且它们的折射率足够接近粘合剂的折射率,使得所述粒子不主要散射光或影响折射率。在这种实施例中,粒子的主要作用可例如为提高低折射率层的强度。在一些实施例中,粒子可提高制备低折射率层的方法,尽管低折射率层可不使用粒子制得。
通常,低折射率层可具有在应用中可能理想的任何孔隙率、孔穴尺寸分布、或空隙体积分数。在一些实施例中,在低折射率层中的多个空隙的体积分数不小于约20%、或不小于约30%、或不小于约40%、或不小于约50%、或不小于约60%、或不小于约70%、或不小于约80%、或不小于约90%。
在一些实施例中,即使低折射率层具有高光学雾度和/或漫反射率,低折射率层的部分也可显示一些低折射率性质。例如,在这种实施例中,低折射率层的部分可在对应于小于粘合剂的折射率nb的折射率的角度下支持TIR。
在示例性的低折射率层中,粒子可为固体粒子。在一些实施例中,低折射率层可另外或可选择地包括多个空心或多孔粒子。粒子可为在应用中可能理想的任何类型的粒子。例如,粒子可为有机或无机粒子。例如,粒子可为二氧化硅、氧化锆或氧化铝粒子。粒子可具有在应用中可能理想的或可得的任何形状。例如,粒子可具有规则或不规则形状。例如,粒子可大约为球形。作为另一实例,粒子可为细长的。在这种实施例中,低折射率层包括多个细长粒子。在一些实施例中,细长粒子具有不小于约1.5、或不小于约2、或不小于约2.5、或不小于约3、或不小于约3.5、或不小于约4、或不小于约4.5、或不小于约5的平均纵横比。在一些实施例中,粒子可为珍珠串(如可得自Nissan Chemical,Houston,TX的Snowtex-PS粒子)或球形或无定形粒子的聚集链(如热解法二氧化硅)的形式或形状。
粒子可被官能化或不被官能化。在一些实施例中,粒子未被官能化。在一些实施例中,粒子被官能化,使得它们可分散于所需溶剂或粘合剂中而无聚集或具有极少聚集。在一些实施例中,粒子可进一步被官能化以化学结合至粘合剂。例如,粒子可被表面改性并具有反应性官能团或基团以化学结合至粘合剂。在这种实施例中,至少大部分的粒子被化学结合至粘合剂。在一些实施例中,粒子不具有反应性官能团以化学结合至粘合剂。在这种实施例中,粒子可被物理结合至粘合剂,或粘合剂可封装粒子。
在一些实施例中,一些粒子具有反应性基团,其他粒子不具有反应性基团。例如,在一些实施例中,约10%的粒子具有反应性基团且约90%的粒子不具有反应性基团,或约15%的粒子具有反应性基团且约85%的粒子不具有反应性基团,或约20%的粒子具有反应性基团且约80%的粒子不具有反应性基团,或约25%的粒子具有反应性基团且约75%的粒子不具有反应性基团,或约30%的粒子具有反应性基团且约60%的粒子不具有反应性基团,或约35%的粒子具有反应性基团且约65%的粒子不具有反应性基团,或约40%的粒子具有反应性基团且约60%的粒子不具有反应性基团,或约45%的粒子具有反应性基团且约55%的粒子不具有反应性基团,或约50%的粒子具有反应性基团且约50%的粒子不具有反应性基团。在一些实施例中,一些粒子可使用反应性基团和非反应性基团在相同粒子上进行官能化。
粒子的集合可包括尺寸、反应性和非反应性粒子和不同类型粒子的混合物,不同类型粒子例如,有机粒子,包括聚合物粒子,如丙烯酸类、聚碳酸酯、聚苯乙烯、有机硅等;或无机粒子,如玻璃或陶瓷,包括例如二氧化硅和氧化锆等。
粘合剂可为或包括在应用中可能理想的任何材料。例如,粘合剂可为形成聚合物(如交联聚合物)的固化型材料。通常,粘合剂可为任何可聚合材料,如辐射固化性的可聚合材料,如UV固化型材料。
低折射率层可使用在应用中可能理想的任何方法制得。在一些实施例中,低折射率层可通过描述于如下中的方法制得:题为“PROCESS ANDAPPARATUS FOR A NANOVOIDED ARTICLE”的共同待审的专利申请美国序列号61/169429(代理人档案号65046US002)、题为“PROCESS ANDAPPARATUS FOR COATING WITH REDUCED DEFECTS”的共同待审的专利申请美国序列号61/169427(代理人档案号65185US002)、和题为“PROCESS FOR GRADIENT NANOVOIDED ARTICLE”的共同待审的专利申请美国序列号61/254674(代理人档案号65766US002),所述专利申请的公开内容以全文引用的方式并入本文。
通过控制聚合、干燥、和固化环境,可控制形态。所述方法也可使用在涂布台和聚合装置之间的受控环境区域,如在别处所述。所述区域能够改进对涂布的膜组合物和环境的控制。聚合装置可位于涂布台和干燥器之间的任何位置。在聚合过程中控制环境也是有利的。随后干燥聚合涂层,并可用例如常规UV辐射系统进一步固化材料而进一步后处理聚合涂层。可用于聚合装置的辐射源包括LED、UV激光器、UV灯、和电子束。
在一些实施例中,在聚合步骤之后,溶剂仍可包含一些可聚合材料,尽管可聚合材料具有较低浓度。然后,通过干燥或蒸发溶液而去除溶剂,从而得到低折射率层,所述低折射率层包括分散于聚合物粘合剂中的空隙网络或多个空隙。低折射率层还包括分散于聚合物中的多个粒子。粒子结合至粘合剂(其中结合可为物理的或化学的),或被粘合剂封装。
低折射率层可具有除了粘合剂和粒子之外的其他材料。例如,低折射率层可包括一种或多种添加剂(例如偶联剂)以协助润湿未在本文明确显示的基材的表面,低折射率层在基材上形成。作为另一实例,低折射率层可包括一种或多种着色剂(如炭黑)以赋予低折射率层颜色(如黑色)。在低折射率层中的其他示例性材料可包括引发剂(如一种或多种光引发剂);抗静电剂;增粘剂;表面活性剂;UV吸收剂;脱模剂;或其他,如在别处所述。在一些实施例中,低折射率层可包括能够吸收光并再发射出更长波长的光的下转换材料。示例性的下转换材料包括荧光体。
通常,对于粘合剂与多个粒子的任何重量比,低折射率层可具有广泛的理想孔隙率。因此,通常,重量比可为在应用中可能理想的任何值。在一些实施例中,粘合剂与多个粒子的重量比不小于约1∶2.5、或不小于约1∶2.3、或不小于约1∶2、或不小于(或大于)约1∶1、或不小于约1.5∶1、或不小于约2∶1、或不小于约2.5∶1、或不小于约3∶1、或不小于约3.5∶1、或不小于约4∶1、或不小于约5∶1。在一些实施例中,重量比在约1∶2.3至约4∶1的范围内。
在一些实施例中,可处理低折射率层的顶部主表面以例如改进低折射率层对另一层的粘附力。例如,顶部表面可被电晕处理。
粒子的表面改性可以以多种已知方式实现,如描述于2004年12月30日提交的美国专利申请号11/027,426以及美国专利No.6,376,590中的那些方式,所述专利以引用的方式并入本文。
另外的示例性粒子描述于2009年4月15日提交的题为“OPTICALFILM”的美国专利申请号61/169,466中。在一些实施例中,在低折射率层中的粒子可为大约球形或细长的。
在一些实施例中,低折射率层或材料具有大于约40%(其对应于约50m2/g的通过BET法确定的表面积)的BET孔隙率,大于约50%(其对应于约65-70m2/g的通过BET法确定的表面积)的孔隙率,大于约60%(其对应于约80-90m2/g的通过BET法确定的表面积)的孔隙率,且最优选约65%至约80%(其对应于值大于约100m2/g和约220m2/g的通过BET法确定的表面积)的孔隙率。在一些实施例中,在低折射率层中的多个互连空隙的体积分数不小于(或大于)约20%、或大于约30%、或大于约40%、或大于约50%、或大于约60%、或大于约70%、或大于约90%。BET表面积和孔隙率值百分比将由平衡低折射率和其他关键性能性质(如涂层的粘合强度)的需要所决定。本文所用的术语“BET法”指Brunauer、Emmett、和Teller表面积分析(参见S.Brunauer,P.H.Emmett和E.Teller,J.Am.Chem.Soc.,1938,60,309)。BET法是用于测定固体物质的孔穴尺寸、表面积、和孔隙率百分比的公知的经科学验证的方法。BET理论涉及气体分子在固体表面上的物理吸附,并用作用于获得有关固体表面的表面积和孔隙率的物理信息的基础。
本发明的回射制品可具有任何所需的光学雾度。在一些实施例中,低折射率层960具有不小于(或大于)约20%、或大于约30%、或大于约40%、或大于约50%、或大于约60%、或大于约70%、或大于约80%、或大于约90%、或大于约95%的光学雾度。在一些实施例中,低折射率层具有低光学雾度。例如,在一些实施例中,低折射率层的光学雾度小于约20%、小于约7%、小于约5%、小于约3%、小于约2%、小于约1.5%、或小于约1%。
低折射率层可通过任何合适的方法形成,如槽式涂布、直接和间接凹版涂布、刮涂、Mayer棒涂布、和辊涂,也在例如自动化卷对卷(web-to-web)涂布法中。在一些实施例中,低折射率层120被涂布于结构化表面114上。本文所用的术语“涂布”可意指平面化或保角的。涂布旨在指施用方法(例如,刮涂、压模涂布、凹版涂布、坡流涂布、喷墨印刷等)。
本发明的回射制品显示具有改进的层粘附力和/或改进的耐水性。改进的层粘附力和耐水性通过增加回射制品的耐久性和耐候性而提供回射片材的多孔低折射率的更大效用。优选地,在单元之后添加保护层(例如,粘合剂层)提供了完全封闭和封装的单元。另外,通过适当选择材料、尺寸、和/或间距,本发明的回射制品可具有比使用包括密封膜的常规回射制品所获得外观更均匀的外观。另外,本发明的回射制品不需要包括或使用密封膜,从而降低了它们的成本。在一些实施例中,印刷区域足够小,使得它们不会不利影响工艺品的美观或在回射制品或构造的表面上印刷的设计。这些方法和构造也允许生成具有任意形状和颜色的印刷区域。因此,可形成具有白色外观的回射制品以及具有抗波纹效果和/或防伪特征的制品。最后,制造方法为流线型,因为从方法中去除了蒸汽涂布步骤。在一些实施例中,光的角分布改变。例如,一些实施例在低角度下相比于在较高角度下显示增加的亮度损失,这在一些情况中可为有利的。
此外,当相比于珠状片材时,本发明的回射制品具有改进的性能。当相比于玻璃珠基片材时,通常已知棱柱片材将更高百分比的入射光回射返回至光源。(参见,例如,“Driver-Focused Design of RetroreflectiveSheeting for Traffic Signs”的图2和3,Kenneth Smith,87th Annual Meeting ofTransportation Research Board,2008年1月13-17日,Washington,D.C.)。当回射光相对于观察角适当设置时,结果为具有优异亮度和性能的产品。
本文描述的低折射率层、涂层、和材料和回射制品和构造可被引入回射装置中,如用于反光标记、牌照、和广告显示器中的那些回射装置。当根据本文描述的方法测量时,本文描述的制品和构造制得回射系数(Ra)为40至大于200烛光的高度反射装置。此外,光学漫射低折射率构造也可用于需要高反射和漫射镜面特性的半镜面装置。
如下实例描述了回射片材、形式的各种实施例的一些示例性构造,和制备本申请中所述的回射片材和形式的方法。如下实例旨在为说明性的,但不旨在限制本专利申请的范围。
实例
如下描述用于制备实例1至7。通过将立体角微结构浇铸于覆膜上而制得回射层,如美国专利No.5,691,846(Benson)中所述,该专利以引用的方式并入本文。通过用低折射率组合物或材料涂布至少一些立体角微结构而形成低折射率层来制得回射光学构造。或者,可将低折射率材料层合至立体角微结构。通过印刷至低折射率层的至少一部分上而提供密封层。
低折射率涂层组合物如下描述于涂层溶液1-3中。根据本发明制得的示例性回射光学构造描述于实例1-7中。
通过将乙烯酸丙烯酸酯(EAA)(可以商品名“Primacor 3440”购自Dow Company of Midland,MI)以厚度为0.01cm(4mil)的膜浇铸于大约53in(134.6cm)宽且0.05mm(0.002in)厚的电晕处理的聚对苯二甲酸乙二醇酯(PET)载体上而制得覆膜。将EAA粒料进料至可得自C.W.BrabenderInstruments Inc.,South Hackensack,N.J.的1.9cm(3/4in)单螺杆挤出机中。挤出机温度分布为140℃(284°F)至175℃(347°F),得到约175℃(347°F)的熔融温度。随着熔融树脂离开挤出机,其通过水平模头(可以商品名“Ultraflex-40”购自Extrusion Dies Industries LLC,Chippewa Falls,WI)并被浇铸至上文所述的PET载体上。PET载体以大约36米/min(120ft/min)行进。使PET载体上的所得熔融覆膜在橡胶辊与淬火钢支撑辊之间运动,以将熔融树脂固化成层。EAA表面以1.5J/cm2进行电晕处理。
所得立体角结构具有间距或主槽间距为81.3微米(0.0032英寸)的三组相交的槽。相交的槽形成夹角为61、61、和58度且立体角元件高度为37.6微米(0.00148英寸)的立体角底部三角形。主槽间距定义为在形成底部三角形的两个61度底角的槽之间的槽间距。
使用通过组合25重量%的双酚A环氧二丙烯酸酯(可以商品名“Ebecryl 3720”购自Cytek,Woodland Park,NJ)、12重量%的丙烯酸二甲氨基乙酯(“DMAEA”)、38重量%的TMPTA(三羟甲基丙烷三丙烯酸酯)和25重量%的1,6HDDA(二丙烯酸己二醇酯)而形成的树脂组合物来制备立体角微结构。该配制物含有0.5pph的TPO(2,4,6-三甲基苯甲酰二苯基氧化膦)光引发剂。
在室温下以25fpm将树脂组合物浇铸至加热至77℃(170°F)的金属工具上。通过具有间隙的橡胶轧辊将树脂组合物填满工具中立体角微结构的空穴,所述的间隙被设定为使得树脂组合物填满工具上的压花图案的空穴,并使得位于工具的基体区域上的树脂的量最少。通过使电晕处理的EAA膜/PET载体与树脂的立体角微结构接触而制得回射层。使用12个设定为600W/in的Fusion D UV灯(可得自Fusion Systems,Rockville,MD)通过工具上的PET载体/EAA膜来固化立体角微结构树脂。在紫外灯前面使用二向色性滤波器,以使对构造的红外加热最小化。当完成固化过程并从工具中移出回射层时,利用在50%下运行的Fusion D UV灯照射立体角微结构以提供后UV辐射固化。使回射层经过设定在127℃(260°F)下的烘箱以缓和膜中的应力。
涂布溶液1:
使用非表面改性的碱稳定的二氧化硅分散体(可以商品名“Cabo-Sperse PG002”购自Cabot of Bellerica,MA)和固体聚乙烯醇(PVA)(可以商品名“Poval 235”购自Kuraray USA)制备低折射率组合物。向400ml塑料烧杯中加入138.8g的7.2%固体PVA水溶液、1.0g的非离子型表面活性剂(可以商品名“Tergitol Min-Foam 1X”购自Dow Chemical Company,Midland,Michigan)、和1ml的浓缩NH4OH溶液。使用在低速下运行的气动架空实验室混合机在低剪切下混合溶液。溶液的pH为约10.3。然后将二氧化硅分散体(200g)加入溶液中。使共混物混合大约15分钟,通过缓慢加入5%HCl溶液调节pH直至获得9.5至9.8的pH。然后将包含1份PVA对4份二氧化硅(以干重计)的共混物转移至1L圆底烧瓶中,并置于温度为约40℃且600mmHg真空的旋转蒸发仪上。低折射率涂布组合物的最终固含量被调节至14.5%。
涂布溶液2:
使用可得自Cabot of Bellerica,MA的Cabo-SperseTM2020K二氧化硅分散体制备低折射率涂布溶液。这是非表面改性的碱稳定的M-5二氧化硅分散体。该二氧化硅的特征在于其通常为约120-150m2/g的中等表面积。在典型过程中,将150g的7.2wt%PVA 235溶液装入1000ml塑料烧杯(以干重计10.8g PVA 235),随后加入2.0g的10wt%Tergitiol Min-Foam 1X和1ml浓缩NH4OH溶液。使用搅拌棒彻底混合这些组分。在这些组分完全混合之后,加入486g的Cabo-SperseTM2020K(在水中20wt%),随后加入445g的DI水。使用手动混合机或低转速下的气动混合机在低剪切下混合组分。将最终固体调节至10%wt以制得包含以干重计1份PVA树脂对9份二氧化硅(1∶9PVA-Si比例,20重量%PVA)的混合物。当这些组分混合时,然后将溶液转移至1L单颈圆底烧瓶中并置于40℃和600mmHg下的旋转蒸发仪上。涂布混合物的最终固含量为10.3%。
涂布溶液3:
制备包含硼酸交联体系的低折射率涂布溶液。向安装气动实验室混合机和加热套的400ml塑料烧杯中加入100g二氧化硅分散体(可以商品名“Cabo-Sperse PG 022”购自Cabot,Bellerica,MA)。二氧化硅分散体被轻轻搅拌并温热至45-50℃。当分散体在该温度范围平衡时,将14g预热的5wt%硼酸水溶液(可得自Aldrich,相当于0.7g硼酸或0.035g硼酸/g二氧化硅)加入二氧化硅分散体中并混合约30min。之后,将2g低泡沫表面活性剂(10wt%Tergitiol Min-Foam 1X,可得自Dow Chemical,Midland,MI)加入二氧化硅-硼酸混合物中,随后加入3.36g聚乙烯醇。PVA作为46.3g7.2wt%水溶液加入。当加入PVA溶液时,混合物变得非常粘稠,加入另外87g去离子水以降低粘度并确保充分混合。轻轻搅拌混合物另外20min。之后,将涂布溶液转移至1L单颈圆底烧瓶中并置于40℃和600mmHg真空下的旋转蒸发仪上。溶液的最终固含量为10.2%。最终混合物具有4.2-4.5的pH,并包含以干重计1份PVA树脂对6份PG022二氧化硅(1∶6PVA-Si比例,14.3重量%PVA)。
比较例A:
通过使用安装设定为0.004″(0.10mm)间隙的18in(45.7cm)宽的刀杆的自动化涂布线,将涂布溶液1刮涂至回射层的立体角微结构上而制备回射光学构造。将回射层置于设定为50fpm(15.1m/min)的恒定线速度的移动卷筒上,其中立体角微结构面朝上。将大约250g涂布溶液1手动倒在所述立体角微结构上,湿涂层在5区125英尺(38m)烘箱中逐渐干燥。第一烘箱区域设定在100°F(37.7℃),其余四个区域设定在180°F(82.2℃)。
实例1-2:
如在比较例A中所述制备回射光学构造,其中将低折射率涂布溶液涂布于立体角微结构上。
将回射光学构造转化为9in×14in(22.8×57.9cm)的样品。通过使用UV喷墨打印机(可以商品名“PressVu UV 200printer”购自VUTEk Inc.)和喷墨黑色油墨(可以商品名“3M Piezo Ink Jet Ink Series 2200UV”购自3M Company,St.Paul,MN)将不同图案印刷至低折射率层上以覆盖所述层的不同区域(如图2所示),来制备印刷构造。打印机以分辨率为363×600dpi的双击(double strike)模式运行。
第一印刷图案由竖直线条组成。线条为0.1mm厚,并彼此相等间距1.3mm。第一印刷图案的区域覆盖率为约33%。第二印刷图案类似于第一印刷图案,不同的是线条为0.2mm厚,并间隔1.3mm。第二印刷图案的区域覆盖率为约66%。
将5in×7in(12.7cm×17.8cm)区域印刷于样品上,从印刷样品上切割2in×4in(5cm×10.1cm)的小测试带。使用黑色油墨,然而可以使用可匹配交通标志或牌照的特定背景的任何颜色的油墨。
辐射聚合性压敏粘合剂(PSA)如美国专利No.5,804,610(Hamer)中所述制得,所述专利以引用的方式并入本文。通过混合95重量份丙烯酸异辛酯(IOA)、5重量份丙烯酸(AA)、0.15重量份Irgacure 651(可购自CibaCorporation,现为BASF Company,NJ)、0.05重量份巯基乙酸异辛酯(IOTG)、和0.4重量份Irganox 1076(可购自Ciba Corporation)而制得PSA组合物。将PSA组合物置于由厚度为0.0635mm的乙烯乙酸乙烯酯共聚物膜(可以商品名“VA-24”购自Pliant Corporation,Dallas,TX)制成的包装中并热封,所述膜测得为大约10cm×5cm。聚合PSA组合物。将约25份增粘树脂(可以商品名“Foral 3085”购自Hercules Inc.,Wilmington DE)与75份PSA组合物一起加入挤出机中,并以2mil(0.005cm)的厚度作为膜浇铸于有机硅隔离衬垫上,如美国专利No.5,804,610的实例46通常所述,所述专利以引用的方式并入本文。使PSA膜经受第二聚合过程。然后使用手压辊层合机将PSA膜层合至回射光学构造,其中粘合剂接触图案化立体角微结构以提供密封。
将印刷测试带层合至经阳极化处理的铝板PSA膜。使构造在75°F(23.9C)和50%相对湿度下平衡72小时。使用安装5kg测力传感器的I-MassSP-2000剥离测试机进行粘附力剥离测试。对于1in(2.54cm)的长度使用12in/min(30.5cm/min)的剥离速率。丢弃最初0.5秒的收集数据,平均剩余数据,数值记录于下表1中。
在0.2的观察角,-4度的入射角和0度及90度取向下,根据ASTME810-03测量回射率(RA)。比较例A和实例1-2的粘附力和回射率示于下表2中。
表2:实例1-2的回射率和粘附力
实例3-6
使用美国No.40Meyer棒(设计用以制得约3密耳的湿膜厚度)通过如下方式将涂布溶液2涂布于8in×12in(20cm×30cm)的回射层上:将回射层固定于橡胶垫上,靠近片材一边施用涂层溶液,在溶液上用手缓慢拉延Meyer棒并同时施加略微朝下的压力。在用溶液涂布回射层之后,使湿涂层在室温下干燥,然后将其置于158°F(70℃)下的空气循环烘箱中达10min。
用UV喷墨打印机(可购自Mimaki,Suwanee,GA的“JF-1631”型)印刷涂布的回射层。使用8程单向印刷,用设定为高的灯和600×600dpi分辨率运行打印机。使用黄色喷墨油墨(可购自Mimaki)。使用包含以长棱形平行四边形设置的点的印刷图案,其中每个点集中于平行四边形的顶点,如图3示意性地显示。点的半径为400至600μm,水平相邻的点的中心之间的距离为“S”,竖直相邻的点的中心之间的距离为“S”/2。“S”在1064至1585μm的范围内。覆盖面积(%面积)基于印刷区域和未印刷区域的相对量进行计算。用于印刷涂布的回射光学构造(实例3-6)的图案的细节示于表3,其中R为以微米计的圆的尺寸,且S为以微米计的圆之间的间距。印刷围绕圆的区域,且圆本身不被印刷。使用100%和200%的油墨沉积水平。
表3:实例3-6中所用的印刷图案
图案 | S(μm) | R(μm) | %印刷区域 |
1 | 1064 | 300 | 50% |
2 | 1418 | 400 | 50% |
3 | 1585 | 400 | 60% |
4 | 1294 | 400 | 40% |
PSA膜如实例1-2所述制得,并使用手压辊层合机以约60psi的层合压力将PSA膜层合至印刷样品。在层合压敏粘合剂之后,切割1in(2.54cm)宽的样品测试带。从测试带去除PSA膜的隔离衬垫,使用手压辊将样品层合至铝基材上。使样品平衡过夜。使用安装22.5lbf测力传感器和用于保持90度剥离角的滑动台的测试机(可以Sintech Testing Device购自Sintech)使用90度剥离测试测量粘附力。所用的剥离速率为2in/min。测定剥离样品的平均力,结果列表于下表4中。
表4:实例3-6的平均剥离力
在0.2度的观察角,-4度的入射角和0度及90度取向下测量回射率。回射率作为0度至90度取向的平均回射率示于下表5中。
表5.实例3-6的回射率
观察角/入射角(度) | 0.2/-4 | 1/4 | 2/4 |
比较例A | 201.0 | 88.0 | 16.9 |
实例3 | 65.9 | 62.8 | 26.8 |
实例4 | 52.7 | 43.8 | 17.4 |
实例5 | 63.2 | 37.8 | 9.3 |
实例6 | 60.3 | 54.4 | 21.5 |
比较例B和实例7:
通过涂布回射层样品(8in×12in(20cm×30cm))而制得比较例B和实例7。在涂布之前在0.5mJ/cm2下氮气电晕处理回射层。如实例1-2所述,使用美国No.45Meyer棒将涂布溶液3涂布于回射层上。
如实例1-2所述,使用UV油墨打印机印刷涂布的回射层,不同的是印刷图案包含以网格图案印刷的200μm宽的垂直线条。线条间距700μm(中心至中心)。经计算的%,非印刷区域为大约51%。使用200%的油墨沉淀水平。
在0.2、1和2度的观察角,-4度的入射角和0度及90度取向下测量回射率。回射率作为0度至90度取向的平均回射率示于下表6中。
表6.比较例B和实例7的回射率
观察角/入射角(度) | 0.2/-4 | 1/4 | 2/4 |
比较例B | 177 | 97 | 24 |
实例7 | 90 | 67 | 21 |
实例7
当进行浸水测试时,当与比较例B相比时,实例7显示具有更好的耐水性,比较例B在5分钟水浸泡之后显示明显的水侵。
端值内的所有数值范围的表述旨在包括归入该范围内的所有数字(即,1至10的范围包括例如1、1.5、3.33、和10)。
本领域的技术人员将会知道,可以在不脱离本发明基本原理的前提下对上述实施例和实施方式的细节做出多种更改。此外,在不脱离本发明的精神和范围的前提下,对本发明的各种修改和更改对本领域技术人员将是显而易见的。因此,本专利申请的范围应当仅由以下权利要求书确定。
Claims (40)
1.一种回射制品,包括:
包括多个立体角元件的回射层,所述多个立体角元件共同形成与主表面相对的结构化表面;
与所述结构化主表面的至少一部分相邻的低折射率材料,所述低折射率材料具有小于约1.3的有效折射率;以及
设置于所述低折射率材料的一部分上的可印刷材料。
2.根据权利要求1所述的回射制品,其中所述低折射率材料与基本上全部的所述结构化主表面相邻。
3.根据权利要求1所述的回射制品,其中所述低折射率材料包括孔穴并具有大于约1.1的折射率。
4.根据权利要求3所述的回射制品,其中所述可印刷材料至少部分填充所述低折射率材料中的至少一些孔穴。
5.根据权利要求4所述的回射制品,其中所述可印刷材料紧密接触所述结构化表面。
6.根据权利要求1所述的回射制品,其中所述可印刷材料为如下的一种:透明的、不透明的、和有色的。
7.根据权利要求1所述的回射制品,其中所述可印刷材料为如下的一种:辐射固化性组合物、溶剂基聚合物溶液、和UV可固化组合物。
8.根据权利要求1所述的回射制品,其中通过如下方式的一种将所述可印刷材料设置于所述低折射率材料的部分上:喷墨印刷、柔性版印刷、凹版印刷、网版印刷、转移印花、和橡皮版印刷。
9.根据权利要求1所述的回射制品,其中将所述可印刷材料设置于所述结构化表面的至少50%上。
10.根据权利要求1所述的回射制品,其中以图案设置所述可印刷材料以产生封闭单元。
11.根据权利要求10所述的回射制品,还包括封装所述封闭单元的保护层。
12.根据权利要求10所述的回射制品,其中每个所述封闭单元具有小于1000微米的单元尺寸。
13.根据权利要求1所述的回射制品,其中用另外的保护层封装所述低折射率层。
14.一种回射制品,包括:
包括多个立体角元件的回射层,所述多个立体角元件共同形成与主表面相对的结构化表面;
低折射率材料,所述低折射率材料与所述结构化主表面的至少一部分相邻以形成回射入射光的光学活性区域;以及
可印刷材料,所述可印刷材料被设置于所述低折射率材料的一部分上以形成基本上不回射入射光的无光学活性的区域。
15.根据权利要求14所述的回射制品,其中所述可印刷材料具有大于约1.3的有效折射率。
16.根据权利要求14所述的回射制品,其中所述低折射率材料与基本上全部的所述结构化主表面相邻。
17.根据权利要求14所述的回射制品,其中所述低折射率材料包括孔穴并具有约1.1至约1.3的折射率。
18.根据权利要求17所述的回射制品,其中所述可印刷材料至少部分填充所述低折射率材料中的至少一些孔穴。
19.根据权利要求14所述的回射制品,其中所述可印刷材料与所述结构化表面直接相邻。
20.根据权利要求14所述的回射制品,其中所述可印刷材料为如下的一种:透明的、不透明的、和有色的。
21.根据权利要求14所述的回射制品,其中所述可印刷材料为如下的一种:辐射固化性组合物、溶剂基聚合物溶液、和UV可固化组合物。
22.根据权利要求14所述的回射制品,其中通过如下方式的一种将所述可印刷材料设置于所述低折射率材料的部分上:喷墨印刷、柔性版印刷、凹版印刷、网版印刷、转移印花、和橡皮版印刷。
23.根据权利要求14所述的回射制品,其中将所述可印刷材料设置于所述结构化表面的至少50%上。
24.根据权利要求14所述的回射制品,其中以图案设置所述可印刷材料以产生封闭单元。
25.根据权利要求24所述的回射制品,还包括封装所述封闭单元的保护层。
26.根据权利要求24所述的回射制品,其中每个所述封闭单元具有小于1000微米的单元尺寸。
27.根据权利要求14所述的回射制品,其中用另外的保护层封装所述低折射率层。
28.一种形成回射制品的方法,包括:
提供包括与主表面相对的结构化表面的回射层;以及
邻近结构化主表面的至少一部分施用低折射率材料,所述低折射率材料具有低于约1.3的有效折射率;以及
在所述低折射率材料的一部分上印刷材料。
29.根据权利要求28所述的方法,其中所述印刷材料具有大于约1.3的有效折射率。
30.根据权利要求28所述的方法,其中所述低折射率材料与基本上全部的所述结构化主表面相邻。
31.根据权利要求28所述的方法,其中所述低折射率材料包括孔穴并具有大于约1.1的折射率。
32.根据权利要求31所述的方法,其中所述印刷材料至少部分填充所述低折射率材料中的至少一些孔穴。
33.根据权利要求28所述的方法,其中所述印刷材料与所述结构化表面直接相邻。
34.根据权利要求28所述的方法,其中所述印刷材料为如下的一种:透明的、不透明的、和有色的。
35.根据权利要求28所述的方法,其中所述印刷材料为如下的一种:辐射固化性组合物、溶剂基聚合物溶液、和UV可固化组合物。
36.根据权利要求28所述的方法,其中通过如下方式的一种在所述低折射率材料的部分上印刷所述印刷材料:喷墨印刷、柔性版印刷、凹版印刷、网版印刷、转移印花、和橡皮版印刷。
37.根据权利要求28所述的方法,其中将所述印刷材料印刷在所述结构化表面的至少50%上。
38.根据权利要求28所述的方法,其中以图案印刷所述印刷材料以产生封闭单元。
39.根据权利要求38所述的方法,还包括:
将保护层施用至所述低折射率层以封装所述单元。
40.根据权利要求38所述的方法,其中每个所述封闭单元具有小于1000微米的单元尺寸。
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US61/324,298 | 2010-04-14 | ||
PCT/US2010/031278 WO2010121056A1 (en) | 2009-04-15 | 2010-04-15 | Retroreflective articles including printed areas |
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WO (1) | WO2010121056A1 (zh) |
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CN111194418A (zh) * | 2017-10-12 | 2020-05-22 | 日本电石工业株式会社 | 回归反射片及回归反射片的制造方法 |
CN111201456A (zh) * | 2017-10-12 | 2020-05-26 | 日本电石工业株式会社 | 回归反射片 |
US11280941B2 (en) | 2017-10-12 | 2022-03-22 | Nippon Carbide Industries Co., Inc. | Retroreflective sheet having particles disposed between retroreflective elements and back face layer |
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CN102458818B (zh) | 2015-10-14 |
BRPI1006713A2 (pt) | 2019-06-18 |
WO2010121056A1 (en) | 2010-10-21 |
EP2419267A4 (en) | 2012-12-05 |
EP2419267A1 (en) | 2012-02-22 |
US8746902B2 (en) | 2014-06-10 |
EP2419267B8 (en) | 2016-08-10 |
EP2419267B1 (en) | 2016-06-29 |
US20120037025A1 (en) | 2012-02-16 |
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