CN1073934C - 网格式反光膜的制造方法 - Google Patents

网格式反光膜的制造方法 Download PDF

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CN1073934C
CN1073934C CN96199854A CN96199854A CN1073934C CN 1073934 C CN1073934 C CN 1073934C CN 96199854 A CN96199854 A CN 96199854A CN 96199854 A CN96199854 A CN 96199854A CN 1073934 C CN1073934 C CN 1073934C
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roller
film
reflective membrane
cube
reflective
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CN1208375A (zh
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W·斯科特·蒂尔曼
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Efri Dennison Co.
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Stimsonite Corp
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00Producing optical elements, e.g. lenses or prisms
    • B29D11/00605Production of reflex reflectors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • B29C66/438Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B29C66/81467General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint arranged in an offset pattern
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B29C66/81469General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint one placed next to the other in a single line transverse to the feed direction, e.g. shoulder to shoulder sonotrodes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411Roller, cylinder or drum types
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45Joining of substantially the whole surface of the articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/003Reflective
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00Optical elements, e.g. lenses, prisms
    • B29L2011/0083Reflectors
    • B29L2011/0091Reflex reflectors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S359/00Optical: systems and elements
    • Y10S359/90Methods
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Abstract

网格式反光膜(40)包括在一个表面上形成有微小立方角式反光单元(12)阵列的热塑材料的第一薄膜(10)。反光单元被薄的第二热塑薄膜(36)所覆盖,两层薄膜一起通过表面带有图案的辊子,在辊子处一组声波焊接触头(24)迅速将薄膜粘接在一起形成与辊子表面图案相同形式的立方角式反光单元(12)的小网格(52)。由于焊接过程产生的热量局限在辊子的图案部位,可以形成壁厚较小的网格侧壁同时保证薄膜的良好的粘接。而且残余的热量不会明显传到相邻的反光单元(12),因此相邻单元的变形可以降到最低,可以得到有优异外观光泽和耐久性并且对较宽角度范围的入射光有最大反光能力的反光膜(40)结构。同时还提出了制造这种反光膜(40)的方法。

Description

网格式反光膜的制造方法
发明领域
本发明涉及一种能反射入射光的膜结构,尤其涉及一种对较宽角度范围的入射光具有增强的反光性能,并且提高了其复合层的粘接强度的网格式反光膜。
现有技术简述
多年来在世界各地反光装置已被用于改善高速公路的安全性。各种不同的可将来自汽车前车灯光束的入射光向汽车司机反射回去的反光装置一直被用来制造各种设施,诸如路面标志,汽车反光器件,邮政设施标志和交通标志,这些设施在环境光线不足的驾驶条件下起到提醒司机注意前方的危险以及其他道路状况。
一种反光装置被称为立方角式反光器。这种装置一般是由一些具有三个互相垂直的表面的“立方”单元排列而成,单元的表面可以接受入射光并将入射光以大约180。平行于入射光的路线向光源反射回去。在本技术领域中,术语“立方角式”一直被用来表示任何具有三个互相垂直的表面的结构,而不考虑各个表面的尺寸和形状或单元的光轴。一个较早的披露立方角式反光器的例子是1933年5月2日公布的Stimson的美国专利No.1,906,655。另一个是1967年7月25日公布的Hennande的美国专利No.3,332,327,这两个专利都是有关路面标识的结构。
在路面标识结构中,立方角式单元的尺寸可以相对较大,因为标识结构比较牢固可以承受车辆的负荷和轮胎的冲击。然而,立方角式反光元件在反光膜的领域中的重要用途也被逐渐开发出。在制造交通公路标志时反光膜尤其有用,例如,在铝制的标志牌上贴上带有适当标识的反光膜以警示司机特定的道路状况。
与立方角式单元在路面标识结构中应用不同,在反光膜的应用中立方角式单元的尺寸要减小以便适应相对较薄的薄膜基础层。反光膜最好应该是柔性的,可以成卷的生产和供货。为此目的,人们开发出了制造带有反光单元的薄膜材料的方法,例如通过模压或铸造的方式。反光膜通常包括透明的丙烯酸基质或薄膜,尽管可以使用许多其他热塑性材料例如,聚碳酸酯,乙烯基树脂,聚乙烯,或者聚氨酯。
一个能够连续模压出带有立方角式反光单元的树脂膜的高效方法和设备的例子是Pricone等人在美国专利No.4,601,861中提出的,在这里引用该专利的内容作为参考。在该方法中,使连续的透明薄膜通过模压设备,在模压设备中薄膜被加热到转变温度用模压模具压制,使树脂膜材料流动变形进入模具的表面图案中。然后薄膜被冷却,硬化,与模具剥离。模具可以根据Montalbano在美国专利No.4,460,449中披露的方法来加工,在这里引用该专利的内容作为参考。该专利的模具能够以每平方英寸薄膜数千个的密度制造非常小且精确成型的立方角式单元。
我们知道立方角式单元具有方向敏感性,对于不同角度的入射光其反光性能亦不同。因而在制造立方角式反光膜时,一个基本方法是制备一些四分之一英寸左右大小的与立方体棱镜呈大约6度角度的标准模具块,然后使用多个各自均以不同旋转角度排布的标准模块就可以在薄膜上加工出多重阵列的或网格的立方角式反光单元,最终得到的反光膜在很宽的方位角范围内具有总体的高反光性能。
在用立方角式结构制造反光膜的技术中,一般认为立方单元的背面必须是金属化的或是在与之靠近的任何背面承托表面之间用气隙支撑。这是因为一般来讲,除与立方单元的背面紧密接触的反光金属涂镀层以外的任何材料都会有反射系数,因而会使立方单元的焦点改变。因此,一直对立方单元的背面采用金属化处理以使单元基础层可以同适宜的背面承托层粘接。在实际中,为保护反光单元并使反光膜可以方便的用粘接方法固定在标志牌或类似物体上,背面承托层是必要的。金属化也是容易实现的,例如可利用已知的银或铝汽相沉积技术。
在反光膜的制造中采用金属化处理的一个缺憾是金属反光层使最终得到的反光膜的颜色明显发灰。反光膜的这种灰色外观被证明用做高速公路标识不够理想,尤其是在白天的光照条件下。另一方面,立方单元与背面层分隔开的气隙结构使得反光膜比金属化的反光膜具有大为改善的光泽。因而,人们一直在试图利用某种形式的气隙结构制造反光膜。
一种形式的气隙结构是Pricone在美国专利No.4,618,518中所披露的,在一卷透明的热塑材料上先模压出立方角式反光单元,用矿油精(mineral spirits),乙醇和疏水性二氧化硅粉末的悬浮液以类似印刷的方式涂覆在单元上,形成覆盖了许多立方角式单元表面上的二氧化硅小岛屿。随后用一层水基丙烯酸覆在二氧化硅之上,由于二氧化硅是防水性的,这样就形成了连续的表面覆盖,并环绕二氧化硅构成所需形式的网格侧壁。只与立方体表面切向接触的二氧化硅颗粒保持着气隙,并使单元被丙烯酸覆盖层密封。这样就得到了合乎要求的反光膜产品,反光膜既利用了所需的气隙结构,同时又有了适宜的背面承托层。网格的尺寸要选择合适,以便在将反光膜剪切成所需尺寸时对单元密封的破坏只会对处于反光膜切块最边缘的反光单元有最小范围的影响,并且避免做边缘密封的步骤。然而这种结构的缺点是,为了获得足够的丙烯酸承托层的机械粘接强度,实际环绕二氧化硅填充物形成的单元侧壁的壁厚必须在0.035英寸(0.9毫米)左右。这一点是由最终的反光膜可能所处的极端工作条件要求的,例如与之相关连的标识牌的迅速和剧烈的膨胀和收缩。而且,已经证实单元侧壁厚度至少为0.035英寸(0.9毫米)的带有二氧化硅背层的反光膜在入射角度等于或大于30度时效率要降低。因此在某些交通标志的应用中这种反光膜不能达到特定的反光性能标准。
另一种用于立方角式反光单元的气隙结构形式中,有加工成的反光单元阵列,网格侧壁环绕着若干立方体单元。用平坦的覆盖膜覆盖网格侧壁,然后用化学的和/或热融的方法将阵列与覆盖膜粘接在一起。结果是反光膜带有许多在反光单元与覆盖膜之间形成气隙的网格。这种结构的一个例子是McGrath的美国专利No.4,025,159。然而这种结构的缺点是在用热处理方法粘接阵列与覆盖膜时,很难对过程进行控制来避免粘接过程中热量使邻近网格侧壁的立方角式单元发生变形。特有的立方角式单元必须令它们的三个反光面的取向互相垂直,且角度误差在几分之内,否则它们就不能反光。将反光阵列与覆盖膜粘接起来所需的温度必须在200~500°F(93℃-260℃),这会毁坏足够多的立方角式单元以至使生产出的反光膜产品中有20~30%完全不能反光。另外,粘接阵列与覆盖膜时所用的化学方法不仅复杂和耗费时间而且如不精心控制还伴有对环境不利的影响。英国专利No.1,476,447披露了另一种形式的柔性反光膜,其中也涉及加热密封。
在1995年4月27日根据专利合作条约发表的序列号为WO95/11464的较近的一个专利申请中,提到了用射频或超声焊接方法在反光膜上加工立方角式反光单元的网格。但是文中所提及的只是预示性的并未提供相关的焊接方法的披露内容。实际上这个专利申请认为最好的方法是热融方法。在实际中,迄今为止确实还没有看到利用射频或超声焊接技术连续地生产商品化的反光膜产品的报道。
因此,希望提供利用气隙结构的立方角式反光膜。还希望在所提供的膜中,网格阵列的每个小网格以密封的结构形式将许多基础薄膜的反光单元封在其中,这样在将反光膜按需要的尺寸剪切后,只有反光膜的边缘很少部分受到破坏。
此外,还希望提供这样的反光膜,覆盖层同基础层牢固地粘接在一起,覆盖层在处于不利条件的情况下也不会与相关的基础层分离,例如用做高速公路标识牌时。
而且,还希望提供这样的反光膜,在光的入射角度增大时不会因基础层和覆盖层的粘接影响立方角式单元的反光性能。还希望基础层和覆盖层的粘接不会造成对立方角式反光单元的明显破坏,因而在反光膜中可发挥作用的单元数量可相对最大。
而且,还希望提供这样的反光膜,它能够以高生产率连续生产,在生产过程中不包含潜在的对环境有不利影响的因素。
发明简述
本发明提出了一种在热塑材料膜的一个表面上用常规方法形成微小的立方角式反光单元构成的反光膜,从而克服了已有技术的缺点。反光单元之上用第二层薄膜覆盖,两层膜同时通过带有表面图案的辊子,在辊子处若干个超声焊头迅速将薄膜粘接在一起,形成与辊子表面图案相同的立方角式反光单元小网格。由于超声焊接过程产生的热量局限在辊子表面图案区域,形成的网格侧壁厚度会减薄而热量不会明显传到相邻的反光单元,因而可以最大限度降低相邻单元的变形,可以获得相当亮丽外观而且对宽角度范围的入射光具有最大反光性能的反光结构。
对附图的简要说明
通过下面结合附图对优选实施例的描述可对本发明上述的和其他特点及优越性有清楚的理解,附图包括:
图1为已有技术中用于制造反光膜的基础膜背面放大的平面图,已经用模压或其他方法加工出立方角式反光单元;
图2为沿图1中2-2线的剖视图;
图3为相应于本发明原理的用于制造密封网格式反光膜的设备的侧视图;
图4为本发明设备的焊接部分的侧视图;
图5为本发明设备的焊接部分的端视图;
图6为沿图4中6-6线的剖视图;
图7为相应于本发明的表面带有图案的辊子端部视图,示出了在辊子上成型的网格式反光膜;
图8为用于制造相应于本发明的网格式反光膜的表面带有图案的辊子的局部放大剖视图;
图9为根据本发明的方法制造的网格式反光膜的局部放大剖视图;
图10为已有技术的二氧化硅衬底反光膜与本发明的反光膜反光率对照曲线。
对优选实施例的详细描述
首先参看图1和图2,图中所示为已有技术中用于制造立方角式反光膜的薄膜10的放大图。薄膜10的一面利用常规方法模压成重复排布的可反光的立方角式反光单元12,且用厚度大约0.006英寸(0.15毫米)的丙烯酸的材料比较合适。立方角式单元的深度,即图中的尺寸A在一个例子中为0.00338英寸(0.08毫米)。相应的尺寸B,即平行沟槽间的距离,对应于上述尺寸A应大约为0.0072英寸(0.18毫米)。然后一卷在模压过程中加上保护性承载膜的反光膜就可供下一步处理,Pricone在美国专利No.4,618,518中披露了与此相关的内容。在这个例子中,薄膜10上的反光单元12的数量大约为每平方英寸22,000个(每平方厘米3,400个)。
图3所示为用于制造相应于本发明的密封网格式反光膜的设备,用序号20表示。设备20包括作为主要部件的表面带有图案的做可转动安装的辊子22,辊子的作用下面将做详细叙述。一组声波焊头24设在辊子22上方,每个焊头都带有靠近辊子22表面设置的焊接触头26。
将具有如前所述结构的事先经过模压的连续薄膜10(仍然由承托膜承托)的卷轴28通过适当的支撑使薄膜10能够通过设在焊接头24前面的张力辊32。薄膜10的宽度大约为48英寸左右(122厘米),薄膜10上的单元数量如前所述大约每平方英寸22,000个(每平方厘米3,400个)。
通过对同样宽度的平坦的衬底膜36的卷轴34做适当的支撑,衬底膜36能够通过设在焊接头24前面的张力辊38。两层薄膜10和36和在一起从焊接触头26和表面带有图案的辊子22中间通过,在其间通过声波焊接将两层薄膜焊接在一起,制造出网格式反光膜40成品。还通过设置适当的驱动辊42,以均恒的速度将成型的反光膜40从设备20中拉出。然后反光膜40可以传送到适宜的卷取辊(图中未示)。
图4-7为设备20的焊接部分的详细结构。如图所示焊接头24的设计最好使焊接触头26沿辊子22的长度方向交错排布,并使焊接触头26的两端稍微重合,这样就可以保证焊缝在反光膜40的整个宽度上不间断。在实际中,制造48英寸(122厘米)宽度的反光膜40时,7个焊头24,每个焊头带有宽度为7英寸(18厘米)的焊接触头26是比较好的配置。这时焊接触头26的两端大约重合1/16英寸(1.6毫米)。
参看图8,图中为表面有图案的辊子22的局部放大剖视图,示出了由直立侧壁46形成的连续排布的封闭网格44。侧壁46的壁厚,即图中的C,最好在0.010英寸(0.25毫米)左右,其高度,即图中的D,最好在0.015英寸(0.38毫米)左右。辊子22可以是表面腐刻有网格44图案的直径为8英寸(20厘米)的钢筒。在一个优选的形式中,网格44的形式为互相毗连的相同尺寸的六角形阵列,每个六角形的面积约为0.015平方英寸(0.1平方厘米),直径约为0.15英寸(3.8毫米)。
图9所示为用设备20制造的网格式反光膜的放大剖视图。从图中可以看出,反光薄膜10的立方角式反光单元12的方向向下,反光膜10由衬底膜36覆盖,形状与辊子22的表面图案相同的焊缝50将薄膜10和36粘接在一起,形成了包含多个立方角式反光单元12的密封的网格52。在实际中,焊缝50会在衬底膜36的表面形成与辊子22表面图案相对应的凹槽54。对于图示的反光膜40,可以在模压时利用本技术领域常用的方法将一层经过强化紫外线稳定处理的丙烯酸层56附在反光薄膜10上,以增加反光膜40在阳光照射下的抗老化性能。可以直接在衬底膜36上施加一层适宜的粘接剂58,粘接剂上再覆一层防粘揭衬60,这样反光膜40就可方便地用在结构上,例如用在标志牌上。实际上防粘揭衬60可以是各种适宜的材料,如聚乙烯,聚酯,或纸。
可以理解,本发明的设备20能够连续生产比已有技术的反光膜结构反光性能更强的网格式反光膜40。也没有必要在基础层材料上加工网格壁。在网格44的图案尺寸大致为0.015平方英寸(0.1平方厘米),每个网格包括大约300个立方角式反光单元12的情况下,为了在基础膜10和衬底膜36之间获得合适的结合强度,表面带有图案的辊子22的壁46厚度不超过0.010英寸(0.25毫米),焊接触头26的超声波焊接可形成形状精确的焊缝50,焊缝50局限在网格46的壁厚范围。这样,靠近焊缝50的反光单元12的残余热变形可以降到最小程度。这样就得到了网格式的带有密封空气隙的反光膜40,它对于相对较宽角度范围内的入射光具有较强的反光性能。
而且由于本发明的网格式反光膜40不涉及化学粘接过程,在其制造中可完全消除对环境的影响因素。并且生产速度也远超过化学过程的速度。利用本发明的技术可以容易地达到至少每分钟20英尺(6米)的生产速度。
用做衬底膜36的材料最好是高韧性的白色透明的丙烯酸共聚物。这种衬底膜36与改进的立方角式反光器的空气隙结构形成了比已有技术的反光膜更具有光泽的反光膜40。例如在一个优选实施例中,本发明以每分钟20英尺(6米)的速度将宽度为48英寸(122厘米)的成卷薄膜10制成反光膜40。在这个例子中基础膜为0.006英寸(0.15毫米)厚的丙烯酸,每平方英寸有大约22,000个立方角式单元(相当于每平方厘米3,400个),与前面的叙述相同。衬底膜36是厚度约为0.002英寸(0.05毫米)的丙烯酸共聚物。网格侧壁46的宽度为0.15英寸(3.8毫米),形状为六边形。这样制成的网格式反光膜40与前面提到的二氧化硅衬底的反光膜相比要好的多。例如,图10给出了本发明的反光膜40与二氧化硅衬底反光膜的反光性能比较,从中可以看出本发明反光膜单位面积的比强度要大许多,尤其是在入射光角度较大时。事实上,由于网格侧壁结构的原因,减少了反光膜的死区面积,故对于所有入射角度的光线都有更好的反光性能。在另一个试验中,用CIE色度坐标确定的白色进行比较,使用了2度观测仪D65,光源几何形式0/45,得到如下结果:
    值                  颜色
    Y     x     y
二氧化硅衬底     55.54  0.3119  0.3324
    声波焊接     48.57  0.3009  0.3287
适宜用于本发明的焊接头24是由Connecticut的BransonUltrasonic Corporation of Banbury制造的900型ao设备,该设备振动频率为每秒20,000次,带有阶梯形的焊接触头26。而且如图3所示,尽管焊接过程不会产生过量的热量,还是可以在靠近辊子22处设置气刀56来冷却焊接后的反光膜40,以避免积累在焊接触头26和辊子22上并可能传导到反光膜40热量产生不利的影响。如果需要进一步控制焊接后的反光膜的温度,还可以将辊子22设计成有恒温流体从辊子中流过的形式。
本发明的一个重要优点是可以更加充分地利用具有不同光学特性的立方角式单元(其特性由立方的形状,尺寸,斜度等所确定),因为无须对基础薄膜的网格侧壁的形式加以限制,侧壁可以是在焊接过程中由辊子表面的侧壁来成型。
尽管本发明是结合优选实施例进行叙述的,本领域的一般技术人员可以理解,不偏离本发明的精神和范围可以做出许多改变和修改。因此,权利要求意在涵盖本发明的精神和范围所包括的所有改变和修改。

Claims (7)

1.一种制造柔性可反光的密封网格式反光膜的方法,该方法包括以下步骤:
制备连续的热塑的第一薄膜,薄膜的一面形成有多个立方角式反光单元;
制备连续的热塑材料的第二衬底薄膜;
将所述的第一和第二薄膜并置在一起,使所述的第二薄膜覆盖在所述的反光单元之上;
使所述的并置在一起的薄膜通过表面带有图案的辊子,所述的第二衬底薄膜与所述的辊子接触,所述的辊子带有形成网格的直立封闭侧壁的连续阵列;以及
当所述的并置在一起的薄膜通过辊子时,在辊子处对所述并置在一起的薄膜施加声波振动,因而在所述的薄膜之间形成与辊子表面图案相同形式的焊缝,所述的焊缝形成了包含多个反光单元的彼此独立的并在所述单元与所述的第二薄膜之间带有气隙的密封网格,从而得到了网格式反光膜。
2.如权利要求1所述的方法,其特征在于,所述的连续的网格侧壁的厚度大约为0.25毫米。
3.如权利要求1所述的方法,其特征在于,所述的振动是由一组沿所述辊子的轴向方向排布的超声焊接触头来施加的。
4.如权利要求3所述的方法,其特征在于,所述的焊接触头沿所述辊子的长度方向交错排布。
5.如权利要求4所述的方法,其特征在于,所述的焊接触头重叠排布以确保连续的焊缝。
6.如权利要求1所述的方法,其特征在于,该方法还包括将空气引向所述的焊接中的反光膜使所述反光膜冷却的步骤。
7.如权利要求1所述的方法,其特征在于,该方法还包括使流体流过所述的辊子以控制所述辊子的温度的步骤。
CN96199854A 1995-12-01 1996-12-02 网格式反光膜的制造方法 Expired - Fee Related CN1073934C (zh)

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EP0874736A1 (en) 1998-11-04
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AU1143597A (en) 1997-06-19
US20030170426A1 (en) 2003-09-11
CN1208375A (zh) 1999-02-17
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US5930041A (en) 1999-07-27
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