NZ593730A

NZ593730A - Hot punch process for producing a perforated retroreflective trim

Info

Publication number: NZ593730A
Application number: NZ59373011A
Authority: NZ
Inventors: Christopher John Brennan
Original assignee: Video Taped Transcripts Pty Ltd
Priority date: 2010-06-24
Filing date: 2011-06-24
Publication date: 2011-10-28
Also published as: AU2011203099A1; AU2011203099B2

Abstract

A method for producing a perforated retroreflective trim is disclosed, wherein the method includes the steps of: providing a retroreflective trim comprising a retroreflective material and having first and second sides; forcing a plurality of rigid members through the retroreflective trim to remove a plurality of portions of the retroreflective trim to provide a plurality of openings through the retroreflective trim extending between the sides of the retroreflective trim, thereby forming a perforated retroreflective trim, wherein the rigid members are heated when forced through the retroreflective trim. The disclosed perforated retroreflective trim includes: a retroreflective film of material including opposite first and second sides;a plurality of holes or openings through the retroreflective film of material and extending entirely through the film of material between the first and second sides formed by the removal of a plurality of portions of the retroreflective film,wherein in the process a portion of the retroreflective film around the openings formed in the retroreflective film through melting or softening is partially drawn through and into the openings.

Description

Patent Form No. 5 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION TITLE: PERFORATED RETROREFLECTIVE TRIM AND A METHOD OF PRODUCING PERFORATED RETROREFLECTIVE TRIM We Video Taped Transcripts Pty. Ltd., an Australian company of 34 Murdock Street, South Clayton, Victoria, 3169, Australia, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: 4003q 2 PERFORATED RETROREFLECTIVE TRIM AND A METHOD OF PRODUCING PERFORATED RETROREFLECTIVE TRIM FIELD OF THE INVENTION The present invention relates to perforated retro reflective trim, perforated 5 retrorefiective fabric and perforated retro reflective tape and to a method for producing a perforated retrorefiective trim, fabric or tape. For the sake of convenience, the term perforated retrorefiective trim is used in the foregoing discussion of the invention, however, it is to be appreciated that the reference to perforated retrorefiective trim includes perforated retrorefiective fabric or perforated retrorefiective tape and may 10 also be a reference to other perforated flexible retrorefiective materials, that would benefit from incorporating the principles of the invention.

BACKGROUND OF THE INVENTION Retrorefiective trim is often used in or provided on the outer layer of garments such as fire fighter garments, construction worker garments, road and rail worker 15 garments and jogging suits. Such garments may be referred to as high visibility safety garments. The reason for providing the retrorefiective trim is to reflect available light in dark environments so as to enhance the visibility of the garment to which the trim is applied as well as the wearer of the garment.

In some circumstances law mandates that individuals must wear high visibility 20 garments incorporating retrorefiective trim material when engaged in certain activities in adverse light conditions or even in light conditions that are not adverse. Such laws often require high visibility safety garments be worn by people in situations where they may be exposed to hazards from moving plant or equipment, motor vehicles, trains etc. For example, it is often mandatory for fire fighter garments to include a 25 retrorefiective component to increase the visibility of the garment, and the wearer of the garment, in hazardous and low light conditions.

National and international standards are applicable to retrorefiective trim used in relation to the aforementioned garments. Such standards specify various minimum requirements for high visibility safety garments and for trim material used in relation to 30 such garments. For example, retrorefiective trim applied used in relation to high SPEC-893079 3 visibility garments or other objects may be required to meet minimum threshold requirements for visibility, reflectivity, retroreflectivity and other physical performance properties such as heat resistance, abrasion resistance and wear resistance. This is particularly the case in relation to fire fighter garments in respect of which the wearer, 5 namely a fire fighter, will often confront and have to enter hazardous situations and in which high levels of heat, a high likelihood of abrasion and low levels of light can be encountered.

The stringent requirements of the standards applicable to garments such as fire fighting garments including retrorefiective trim have meant that existing 10 retrorefiective trim is formed as a continuous non-permeable, non-perforated sheet which is not breathable. A problem with existing retrorefiective trim is that it does not easily permit the transfer of heat or vapour from perspiration emanating from the wearer of a garment incorporating the retrorefiective trim. Accordingly, the wearer of the garment is subjected to a build up of heat and vapour within the garment resulting 15 in stress to the wearer. This problem is significant given that while wearing high visibility retrorefiective garments the wearers are frequently engaged in strenuous physical activity or are subjected to warm and abrasive environments.

Another crucial requirement of retrorefiective trim is that the retrorefiective component, which is usually a retrorefiective coating applied to a substrate, must be 20 strongly bound to the underlying substrate. This is so that the retrorefiective trim can meet standards requiring the retrorefiective component to be resistant to abrasion resulting from when a garment incorporating the retrorefiective trim is worn or washed and from general wear and tear. In fact, this property of the retrorefiective trim is crucial to its ability to meet standards applicable to such materials. This is because 25 although a retrorefiective trim may initially meet the reflectivity requirements after a number of wash cycles the adherence of the retrorefiective component to the substrate may degrade to the extent that the retrorefiective component may separate from the substrate such that the retrorefiective trim no longer meets the minimum threshold standards for heat resistance, abrasion resistance and reflectivity.

The above discussion of acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any of these matters are SPEC-3&3079 RECEIVED at IPONZ on 17 August 2011 4 known, form part of the prior art base or are common general knowledge in the field relevant to the present invention at the priority date of each claim of this application.

Accordingly, there is a need for a breathable retrorefiective trim for use with high visibility garments, such as fire fighting garments, that is sufficient to meet the 5 standards for retrorefiective trim such as reflectivity and other physical performance properties such as heat resistance, abrasion resistance and wear resistance. Furthermore, there is a need for a breathable retrorefiective trim that is efficient to produce and that has superior appearance and quality characteristics. There is yet furthermore a need for a method of producing such breathable retrorefiective trims.

For the sake of convenience, the terms "retrorefiective" and "retroreflectivity" are used throughout the specification to describe the nature of material to which the present invention is applicable, however, it is to be appreciated that for the purposes of this specification the terms "retrorefiective" and "retroreflectivity" respectively could include "reflective" and "reflectivity" within their scope. That is, the present invention 15 could be suitable for the purpose of providing perforated reflective trim from unperforated reflective trim.

SUMMARY OF THE INVENTION Accordingly, in a first aspect, the present invention provides a method for producing a perforated retrorefiective trim that includes the steps of: providing a retrorefiective trim comprising a retrorefiective material and having first and second sides forcing a plurality of rigid members through the retrorefiective trim to remove one or more portions of the retrorefiective trim to provide a plurality of openings through the retrorefiective trim extending between the sides of the retrorefiective trim, 25 thereby forming a perforated retrorefiective trim, In one form, the rigid members are heated when forced through the retrorefiective trim.

In another form, the rigid members are heated to a temperature sufficient to soften or melt the retrorefiective trim upon contact between the rigid members and the 30 retrorefiective trim.

SPEC493079 The above embodiments are particularly advantageous in that the heat enables the rigid members to soften or melt the retrorefiective trim and thereby enable openings to be formed in the retrorefiective trim with the application of less force to the rigid members. Furthermore, it has been discovered that the edges of the retrorefiective trim around the openings formed in the retrorefiective trim are smoother and more rounded than without the application of heat. A beneficial result of more smooth and rounded edges around the openings in the retrorefiective trim is that the perforated trim is more durable and resistant to abrasion and other forms of wear and tear. Another benefit is that the reflectivity of the perforated trim is enhanced over trim perforated by rigid members that are not heated.

In yet another form, the rigid members include male punch members or female die members.

The method can further include a step of positioning the retrorefiective trim between the male punch members and the female die members before the step of 15 forcing one or more rigid members through the retrorefiective trim.

In one form of the method, the step of forcing one or more rigid members through the retrorefiective trim includes pressing the male punch members and the female die members together with the retrorefiective trim therebetween.

In one form, at least one of the male punch members and the female die 20 members has a cutting edge.

In another form, the male punch members are sized to closely fit within the female die members. !n yet another form, a portion of the retrorefiective material around the one or more openings formed in the retrorefiective trim is softened or melted and is partially 25 drawn through and into the openings.

In still yet another form, the softened or melted retrorefiective material is drawn through and into the openings at least part the way, or completely through, the thickness of the retrorefiective trim.

SPEC-893079 RECEIVED at IPONZ on 17 August 2011 6 In yet another form of the method, the retrorefiective trim is provided continuously from a roll and the rigid members are forced through a section of the retrorefiective trim at a time.

In one embodiment, the retrorefiective trim comprises a retrorefiective layer 5 adhered to a substrate.

In another embodiment, the retrorefiective trim comprises a retrorefiective film that is capable of being adhered to a substrate.

The method of any one of the preceding claims, wherein a sheet of paper or 10 cardboard material is applied to one of the sides of the retrorefiective trim as the one or more rigid members are forced through the retrorefiective trim and at least part of the way through the paper sheet or cardboard material.

In another aspect, the invention provides perforated retrorefiective trim produced by the above method.

In yet another aspect, the invention provides a garment incorporating the perforated retrorefiective trim produced by the above method.

In another aspect, the present invention provides perforated retrorefiective trim including: a retrorefiective film of material including opposite first and second sides; a plurality of holes or openings through the retrorefiective film of material and extending entirely through the film of material between the first and second sides formed by the removal of a plurality of portions of the retrorefiective film, wherein in the process a portion of the retrorefiective film around the openings formed in the retrorefiective film through melting or softening is partially drawn through and into the 25 openings.

Preferably, the softened or melted retrorefiective film or material is drawn through and into the openings completely through the thickness of the film from the first side to the second side of the film.

SPEC-893079 7 retrorefiective film of material and the substrate and extending entirely through the film of material and the substrate between the first and second sides of the substrate, wherein a portion of the retrorefiective film around the one or more openings formed in the retrorefiective film and the substrate which through melting or softening is 5 partially drawn through and into the openings in the substrate.

The present invention is advantageous in that it may provide a perforated retrorefiective trim that is porous, breathable and suitable for use with garments and that allows or enhances the transport of heat and water vapour emanating from the wearer from within the garment to the external environment outside the garment so as 10 to enhance the comfort of the wearer.

In addition, the invention has resulted in the surprising discovery that the perforated retrorefiective trim produced in accordance with the invention exhibits a high degree of effectiveness in the areas of reflectivity, abrasion resistance and wear resistance despite the disruptiveness of the openings to the continuity of the 15 retrorefiective trim. Furthermore, the invention may result in a perforated retrorefiective trim having superior appearance and quality characteristics.

Furthermore, the present invention may enable perforated retrorefiective trim to be produced that when incorporated into garments, such as high visibility garments and firefighting garments, provides such garments with an enhanced ability to meet 20 standards applicable thereto.

The present invention will now be described in more detail with reference to the following preferred embodiments. However, it is to be appreciated that the present invention is not limited to the embodiments described in the foregoing as other methods and products incorporating the principles of the invention outlined above 25 may fall within the scope of the invention also.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be further explained with reference to the drawings, wherein: Figure 1 is a perspective view of a first example of perforated trim formed from 30 an embodiment of the method of the invention.

SPEC-H93D79 8 Figure 2 is a side view of the reflective trim of Figure 1 being fed from a roll of the trim into a machine in accordance with a preferred form of the method of the invention.

Figure 3 is a side view of the perforated retrorefiective trim of Figure 2 being 5 fed onto rolls after exiting from the machine of Figure 2 in accordance with a preferred form of the method of the invention.

Figure 4 is a side view of a punch and die arrangement and a section of retrorefiective trim positioned between the punch and die wherein the punch and die have been pressed together to remove a portion of the retrorefiective trim to form an 10 opening therethrough.

Figure 5 is a perspective view of a second example of perforated trim formed from an embodiment of the method of the invention.

Figure 6 is a side view of a punch and anvil or plate arrangement of the machine involved in another embodiment of the method and a section of retrorefiective trim positioned between the punch and anvil wherein the punch and anvil before being pressed together.

Figure 7 is a side view of the punch and anvil or plate arrangement of Figure 6 and a section of retrorefiective trim positioned between the punch and anvil wherein the punch and anvil have been pressed together to remove a portion of the 20 retrorefiective trim to form an opening therethrough.

Figure 8 is a side view of the reflective trim being fed from a roll of the trim into the machine of Figure 6 in accordance with a preferred form of the method of the invention.

Figure 9 is a side view of the perforated retrorefiective trim being fed onto rolls 25 after exiting from the machine of Figure 6 in accordance with a preferred form of the method of the invention.

DETAILED DESCRIPTION Referring to Figure 1 there is shown a section of a first example of perforated retrorefiective trim 20 produced by an embodiment of the method of the present SPEC-893079 9 invention. The perforated retrorefiective trim 20 is formed from an imperforated retrorefiective trim 15, as illustrated in Figures 2 to 9, including a substrate 30 and a retrorefiective layer 40. The perforated retrorefiective trim 20 includes holes or openings 25 through the perforated retrorefiective trim 20 which provide the 5 perforated retrorefiective trim 20 with the characteristic of being perforated.

Figures 2 to 9 particularly illustrate the method of the invention. As particularly illustrated in Figures 2 to 9 the method includes providing the retrorefiective trim 15, which has a first side 35 and a second side 37, and that is formed out of a substrate 30 and a retrorefiective layer 40 adhered to one side of the substrate 30. Accordingly, 10 the reflective layer 40 is on the first side 35 of the retrorefiective trim 15 while the substrate is on the second side 37 of the retrorefiective trim 15.

In an embodiment of the method of the invention the substrate 30 is a 20 material such as a woven material or fabric that may be of a material that is heat resistant and/or fire resistant. Examples of such woven material or fabric may include 15 woven synthetic fibres such as polyester fibres or aramid fibres. The retrorefiective layer 40 on the first side 35 of the retrorefiective trim 15 is a retrorefiective film that may be adhered to the substrate 30 by an adhesive or that may be a heat transfer retrorefiective film that is adhered to the substrate 30 by heating the film and/or the substrate 30 and then applying the film to the substrate 30 with or without pressure. 20 The retrorefiective layer 40 on the first side 35 of the retrorefiective trim 15 may be of a material that is heat resistant and/or fire resistant. The retrorefiective trim 15, which includes the substrate 30 with the retrorefiective layer 40 adhered thereto, is flexible and in particularly preferred embodiments of the invention is heat resistant and/or fire resistant.

Figures 2 to 4 illustrate a preferred means of carrying out the method of the invention in which the retrorefiective trim 15 including the substrate 30 with the retrorefiective layer 40 adhered thereto is fed from a roll 140 of the retrorefiective trim 15 into a machine 110. The machine 110 includes a guide 115 on which the retrorefiective trim 15 is fed into the machine 110. The machine 110 includes a set of 30 rigid members 60, of which an embodiment is illustrated in Figure 4. In the embodiment illustrated in Figure 4 one of the rigid members 60 is illustrated in which the rigid member 60 is a male member, in particular a male punch member 62, that is SPEC-S93079 mounted to a first plate member (not shown). Each one of the punch members 62 has a sharpened edge 64. The machine 110 also includes a female member, in the form of a female die member 70, for each male punch member 62. Each female die member 70 is mounted to a second plate member (not shown). The die member 70 5 includes an opening 72 surrounded by an opening edge 74 that is configured to receive the punch member 62 therethrough. The edge 74 of the opening 72 in the die member 70 is sized to enable the punch member to just fit therewithin. In a preferred form, the edge 74 of the opening 72 in the die member is circular in shape and the sharpened edge 64 of the punch member 62 is also circular. The punch member also 10 has a circular cross section and, therefore, an outer surface 65 that is curved. However, it is to be appreciated that the circular shapes of the edge 74 of the opening 72 in the die member 70 and the sharpened edge 64 of the punch member 62 could be any other suitable shape such as square, hexagonal, trapezoidal, rectangular or any other polyhedral shape. In a preferred form, the diameter of the sharpened 15 edges 64 of the punch members is 0.8mm whereas the diameter of the edge 74 of the opening 72 in the die member 70 is substantially larger at 2.0mm.

The machine is configured to force the rigid members 60 through the retrorefiective trim 15 as will be described in more detail below. An array of the male punch members 62 are mounted to the first plate and a corresponding array of the 20 female die members 70 are mounted to the second plate. The first and second plates each could have both male punch members 62 and female die members 70 mounted thereto. The retrorefiective trim 15 is fed from the roll 140 into the machine 110 where the machine 110 places the retrorefiective trim 15 between the first and second plates and thereby between the male punch members 62 and the female die members 70. 25 The machine 110 then presses the first and second plates together thereby pressing the male punch members 62 and the female die members 70 together with the retrorefiective trim therebetween. The machine 110 continues to press the male punch members 62 and the female die members 70 together until, as illustrated in Figure 4, for each of the male punch members 62 that penetrate the retrorefiective 30 trim 15 a portion 17 of the retrorefiective trim 15 is removed to form an opening 25 therethrough that extends between the first side 35 and the second side 37 of the retrorefiective trim 15. Each one of the male punch members 62, and the removed portions 17 of the retrorefiective trim 15, then enter a corresponding female die SPEC-893079 11 member 70 through the opening 72 of the die member 70. The process of the male punch member 62 penetrating the retrorefiective trim 15 and removing a portion 17 of the retrorefiective trim 15 and forming an opening 25 therethrough occurs in respect of each of the male punch members 62 mounted to the first plate. Thus, upon 5 pressing the plurality of male punch members 62 and the female die members 70 together a plurality of the openings 25 is formed within the retrorefiective trim 15 thus forming the perforated retrorefiective trim 20. Preferably, the openings 25 formed in the perforated retrorefiective trim by the method are approximately 0.8mm in diameter. It has been discovered that openings 25 of approximately 0.8mm in 10 diameter provide a perforated retrorefiective trim 20 for use in garments having superior breathability characteristics.

In a preferred form of the invention, the rigid members 60, which may be the male punch members 62 or the female die members 70 or both are heated by any suitable means. Thus, when the rigid members 60 are forced through the 15 retrorefiective trim 15 such as in the manner described above the rigid members 60, upon contact with the retrorefiective trim 15, soften or melt the material forming the retrorefiective trim 15, namely the substrate 30 or the retrorefiective layer 40 or both. By softening or melting the substrate 30 or the retrorefiective layer 40 or both upon contacting the retrorefiective trim 15 the rigid members 60 are able to penetrate the 20 retrorefiective trim 15 with the application of less force to the rigid members 60 than would be the case if the rigid members 60 were not heated, in a preferred form, the male punch members 62 or the female die members 70 or both are heated to a temperature sufficient to soften or meit the retrorefiective trim 15 upon contact between the male punch members 62, the female die members 70 and the 25 retrorefiective trim 15. The temperature may be varied depending on the nature of the materials forming the substrate 30 and the retrorefiective layer 40 of the retrorefiective trim such as their respective melting points.

As mentioned above, heating the rigid members 60, namely the male punch members 62 or the female die members 70 or both, upon penetration through the 30 retrorefiective trim 15 enables the rigid members 60 to soften or melt the retrorefiective trim 15 and thereby penetrate the retrorefiective trim 15 with the application of less force to the rigid members 60. Another advantage of embodiments of the method and product of the invention is that the reflectivity of the perforated SPEC-393079 12 retrorefiective trim 20 is enhanced over trim perforated by rigid members that are not heated. The softened or melted retrorefiective layer 40 at edges 26 immediately surrounding the openings 25 formed in the resulting perforated retrorefiective trim 20 is deformed and partially drawn through and into the openings 25. The softened or 5 melted retrorefiective layer 40 is drawn through and into the openings 25 at least part the way, or completely through, the thickness of the substrate 30. As the diameter of the sharpened edges 64 of the punch members 62 are substantially smaller, at 0.8mm, than the diameter of the edges 74 of the openings 72 in the die members 70, at 2.0mm, sufficient clearance is provided between the punch members 62 and the 10 die members 70 to enable the softened or melted retrorefiective layer to be drawn through and into the openings 25. As a result, the edges 26 around the openings 25 formed in the resulting perforated retrorefiective trim 20 are smoother and more rounded than without the application of heat. In particular, the retrorefiective layer 40 at the edges 26 around the openings 25 is formed into a smooth, round edge that has 15 a number of advantages. One such advantage of the method and product of the present invention is that the retroreflectivity performance of the resulting perforated trim 20 is superior than an article formed from identical materia! where the edges 26 around the openings 25 are mechanically sheared without heating of the punch members 62 or die members 70. Yet another surprising advantage of the method and 20 product of the present invention is that the when retroreflectivity of the perforated retrorefiective trim 20 is measured at an entrance angle of 5 degrees and observation angle of 0.2 degrees the retrorefiective readings indicate a substantial increased brightness when compared to continuous retrorefiective trim without perforations. Another beneficial result of more smooth and rounded edges 26 around the openings 25 25 in the perforated retrorefiective trim 20 is that the perforated retrorefiective trim 20 is more durable and resistant to abrasion and other forms of wear and tear. One reason for this is that it has been discovered that where the openings 25 in the perforated retrorefiective trim 20 are formed with heated rigid members 60 the edges 26 around the openings 25 in the retrorefiective trim 15 are less likely to provide a 30 location at which separation of the retrorefiective layer 40 from the substrate 30 can occur or be initiated.

Figure 3 illustrates the operation of the machine 110 wherein after the retrorefiective trim 15 is provided with the openings 25 the resulting perforated SPEC-893079 13 retrorefiective trim 20 is fed out of the machine 110 and onto a roll 150. Accordingly, embodiments of the invention described above provide for continuous production of the perforated retrorefiective trim 20 into a roll 150 which may be conveniently and efficiently stored, packaged and transported. Another step in the method may involve 5 providing layers and/or coatings to the perforated retrorefiective trim 20 for providing the perforated retrorefiective trim 20 with further resistance to abrasion and wear and tear; providing an adhesive layer for providing a perforated retrorefiective trim 20 in a form that is capable of being adhered to a surface or object; and providing a porous lining in face to face contact with the exposed first side 37 of the substrate 30 of the 10 perforated retrorefiective trim 20.

Figures 6 to 9 illustrate another preferred means of carrying out the method of the invention in which the retrorefiective trim 215 including the substrate 30 with the retrorefiective layer 40 adhered thereto is fed from a roll 245 of the retrorefiective trim 215 into a machine 210. A backing sheet 250 which may be of any suitable material, 15 but which in a preferred embodiment is a cardboard material, is fed from a roll 240 into the machine 210 so as to come into contact with a surface of the substrate 30 opposite to the surface to which the retrorefiective layer 40 is adhered. The machine 210 includes a guide 115 on which the retrorefiective trim 215 and the backing sheet 250 is fed into the machine 210. The machine 210 includes a set of rigid members 60, 20 of which an embodiment is illustrated in Figure 4. The embodiment illustrated in Figures 6 to 8 differs from the previously described embodiment illustrated in Figures 2 to 5 in that the female member in the form of a female die member 70 is replaced by an anvil member in the form of a metal plate 170.

As shown in Figures 6 and 7, the machine 210 for use in the embodiment 25 illustrated in Figures 6 to 9 includes one or more rigid members 160 in the form of one or more punch members 162, that are each mounted to a first plate member (not shown). Each one of the punch members 162 has a central substantially cylindrically shaped opening 161 extending axially within the punch member 162 and defined at one end by a sharpened edge 164 and at an opposite end by an exit opening 163. As 30 mentioned above, the machine 210 also includes the metal plate 170. The metal plate 170 includes a substantially flat upper surface 172 that is configured to support a section of the backing sheet 250 and a section of the retrorefiective trim 215 thereon. The punch member 162 has a circular cross section and, therefore, an outer surface SPEC-893079 14 165 that is curved. However, it is to be appreciated that the cross section of the punch member 162 and the sharpened edge 164 of the punch member 162 could be any other suitable shape such as ellipsoidal, oval, square, hexagonal, trapezoidal, rectangular or any other polyhedral shape. In a preferred form, the diameter of the 5 sharpened edges 164 of the punch member is 0.8mm, however, it is to be appreciated that the diameter of the sharpened edge 164 of the punch member 162 could be any diameter up to 5mm.

The machine is configured to force the rigid members 160 through the retrorefiective trim 215 as will be described in more detail below. An array of the 10 punch members 162 are mounted to a plate. The retrorefiective trim 215 is fed from the roll 245 and the backing sheet 250 is fed from the roll 240 into the machine 210 where the machine 210 places the retrorefiective trim 215 between the plate of mounted punch members 162 and the upper surface 172 of the metal piate 170 as illustrated in Figure 6. The machine 210 then presses the plate of mounted punch 15 members 162 and the upper surface 172 of the metal plate 170 together thereby pressing the punch members 162 and the upper surface 172 of the metal plate 170 together with the retrorefiective trim 215 therebetween. The machine 210 continues to press the plate of punch members 162 and the upper surface 172 of the metal plate 170 together until, as illustrated in Figure 7, the sharpened edge 164, which may be a 20 straight or serrated edge, of each of the punch members 162 penetrates the retrorefiective trim. Each one of the punch members 162 penetrates the retrorefiective trim 215 such that a portion 117 of the retrorefiective trim 215 is removed to form an opening 25 therethrough that extends between the first side 235 and the second side 237 of the retrorefiective trim 15. The punch members 162 are 25 pressed towards the upper surface 172 of the metal plate 170 to the extent that the sharpened edge 164 of each of the punch members 162 penetrates completely through the retrorefiective trim 215 and penetrates through part of the thickness of the backing sheet 320. Each of the removed portions 117 of the retrorefiective trim 215 then enters the opening 161 within the punch member 162 and is ejected through the 30 exit opening 163. The process of the punch member 162 penetrating the retrorefiective trim 215 and removing a portion 117 of the retrorefiective trim 215 and forming an opening 25 therethrough occurs in respect of each of the punch members 62 mounted to the plate. Thus, upon pressing the plurality of punch members 162 SPEC-893079 towards the upper surface 172 of the metal plate 170 a plurality of the openings 25 are formed within the retrorefiective trim 215 thus forming the perforated retrorefiective trim 20. Preferably, the openings 25 formed in the perforated retrorefiective trim by the method are approximately 0.8mm in diameter. However, 5 opening of diameters up to 5mm are envisaged.

In a preferred form of the invention, the rigid members 160, which in the illustrated embodiment are the punch members 162, are heated by any suitable means. Thus, when the rigid members 160 are forced through the retrorefiective trim 215 such as in the manner described above the rigid members 160, upon contact with 10 the retrorefiective trim 15, soften or melt the material forming the retrorefiective trim 15, namely the substrate 30 or the retrorefiective layer 40 or both. By softening or melting the substrate 30 or the retrorefiective layer 40 or both upon contacting the retrorefiective trim 215 the rigid members 160 are able to penetrate the retrorefiective trim 215 with the application of less force to the rigid members 160 than would be the 15 case if the rigid members 160 were not heated. In a preferred form, the punch members 162 are heated to a temperature sufficient to soften or melt the retrorefiective trim 215 upon contact between the punch members 162 and the retrorefiective trim 215. The temperature may be varied depending on the nature of the materials forming the substrate 30 and the retrorefiective layer 40 of the 20 retrorefiective trim such as their respective melting points. The rigid members 160 may be heated to a temperature anywhere between 40 degrees celcius and 160 degrees ceicius.

As mentioned above, heating the rigid members 160, namely the punch members 162, upon penetration through the retrorefiective trim 215 enables the rigid 25 members 160 to soften or melt the retrorefiective trim 215 and thereby penetrate the retrorefiective trim 215 with the application of less force to the rigid members 160. Another advantage of embodiments of the method and product of the invention is that the reflectivity of the perforated retrorefiective trim 220 is enhanced in comparison to when the retrorefiective trim 215 is perforated by the rigid members 160 at room or 30 ambient temperature (i.e. when the rigid members 160 are not heated). The softened or melted retrorefiective layer 40 at edges 26 immediately surrounding the openings 25 formed in the resulting perforated retrorefiective trim 220 formed from employing heated rigid members 160 is deformed and partially drawn through and into the SPEC-893079 16 openings 25. The softened or melted retrorefiective layer 40 is drawn through and into the openings 25 at least part the way, or completely through, the thickness of the substrate 30. As a result, the edges 26 around the openings 25 formed in the resulting perforated retrorefiective trim 220 are smoother and more rounded than 5 without the application of heat to the rigid members 160. In particular, the retrorefiective layer 40 at the edges 26 around the openings 25 is formed into a smooth, round edge that has a number of advantages. One such advantage of the method and product of the present invention is that the retroreflectivity performance of the resulting perforated trim 220 is superior to an article formed from identical material 10 where the edges 26 around the openings 25 are mechanically sheared without heating of the punch members 162. Yet another surprising advantage of the method and product of the present invention is that the when retroreflectivity of the perforated retrorefiective trim 220 is measured at an entrance angle of 5 degrees and observation angle of 0.2 degrees the retrorefiective readings indicate a substantial 15 increased brightness when compared to continuous retrorefiective trim without perforations. Another beneficial result of more smooth and rounded edges 26 around the openings 25 in the perforated retrorefiective trim 220 is that the perforated retrorefiective trim 220 is more durable and resistant to abrasion and other forms of wear and tear. One reason for this is that it has been discovered that where the 20 openings 25 in the perforated retrorefiective trim 220 are formed with heated rigid members 160 the edges 26 around the openings 25 in the retrorefiective trim 215 are less likely to provide a location at which separation of the retrorefiective layer 40 from the substrate 30 can occur or be initiated.

Figure 9 illustrates the operation of the machine 210 wherein after the 25 retrorefiective trim 215 is provided with the openings 25 the resulting perforated retrorefiective trim 220 is fed out of the machine 210 and onto a roll 150. Also, the backing sheet 250 is fed out of the machine and onto a roll 255 for reuse in the above method. Accordingly, embodiments of the invention described above provide for continuous production of the perforated retrorefiective trim 220 into the roll 150 which 30 may be conveniently and efficiently stored, packaged and transported. Another step in the method may involve providing layers and/or coatings to the perforated retrorefiective trim 220 for providing the perforated retrorefiective trim 220 with further resistance to abrasion and wear and tear. Yet another step in the method may SPEC-893079 17 involve providing an adhesive layer for providing a perforated retrorefiective trim 220 in a form that is capable of being adhered to a surface or object. Still yet another step in the method may include providing a porous lining in face to face contact with the exposed first side 237 of the substrate 30 of the perforated retrorefiective trim 20.

In another embodiment of the method and of the product of the invention, the retrorefiective trim is composed only of a film of retrorefiective material and does not include a substrate to which the retrorefiective film is adhered. Thus, the perforated retrorefiective trim produced by the method includes only a film of retrorefiective material including a plurality of perforations. In all other respects, the method with 10 which the retrorefiective trim, which is composed only of a retrorefiective film, is perforated is the same as the method with which the retrorefiective trim 215 is perforated in the embodiment described above and illustrated in Figures 6 to 9. The perforated retrorefiective trim produced by this embodiment which may be a retrorefiective heat transfer film with a plurality of perforations that can be adhered to 15 a substrate such as an article of fabric, or an article of resiliently stretchable fabric. The provision of perforations in the retrorefiective heat transfer film means that when the film is adhered to a fabric, such as a stretchable fabric, the perforated retroreflctive heat transfer film can be resiliently deformed along with the stretchable substrate and then return to its original configuration when the substrate returns to its 20 resting or unstretched state. Accordingly, in the present embodiment the method involves continuously feeding the retrorefiective film from the roll 245 into the machine 210 along with the backing sheet 250 of a cardboard material which is fed from the roll 240 into the machine 210 so as to come into contact with a surface of the film. The rigid members 160 of Figures 6 and 7 are used in the manner described above to 25 remove portions of the retrorefiective film to provide a plurality of openings or perforations in the retrorefiective film. The rigid members 160 may be heated to a temperature anywhere between 40 degrees celcius and 160 degrees celcius. Preferably, the openings 25 formed in the perforated retrorefiective film by the present embodiment of the method are approximately 5mm in diameter.

The above embodiments of the method of the invention enable: continuous formation of the perforated retrorefiective trim 20, 220 by enabling continuous provision of the retrorefiective trim 15, 215 and providing the openings 25 in sections of the retrorefiective trim 15, 215 at a time. In one form, the machine 110, 210 may SPEC-893079 18 feed a length of the retrorefiective trim 15, 215 from the roller 140, 240 to a position between the first and second plates of male punch members 62 and female die members 70 or between a plate with attached punch members 162 and the metal plate member 170 and stopped so that the plates can be pressed together to 5 perforate the length of retrorefiective trim 15, 215 and form a length of the perforated retrorefiective trim 20, 220. The machine 110, 210 may then feed another similar length of the retrorefiective trim 215 from the roller 140, 240 to a position between the first and second plates of male punch members 62 and female die members 70 or between the plate with attached punch members 162 and the metal plate member 10 170 and stopped so that the plates can be pressed together to perforate the another length of retrorefiective trim 15, 215. This process is repeated by the machine 110, 210 in a continuous process until a desired length of the perforated retrorefiective trim 20, 220 is obtained.

It is envisaged that the machine 110, 210 may be configured to produce 15 perforated retrorefiective trim with various characteristics as desired. For example, Figure 5 illustrates a section of a second example of perforated retrorefiective trim 20' produced by an embodiment of the method of the present invention. For ease of referencing, features of the perforated retrorefiective trim 20' illustrated in Figure 5 are labelled with the same numeral reference as their corresponding features illustrated in 20 Figure 1 and are suffixed with an apostrophe (').

Similar to the first example of perforated retrorefiective trim 20, this second example of perforated retrorefiective trim 20' is formed from an unperforated retrorefiective trim (not shown) including a substrate 30' and a retrorefiective layer 40'. The perforated retrorefiective trim 20' includes holes or openings 25' through the 25 perforated retrorefiective trim 20' which provide the perforated retrorefiective trim 20' with the characteristic of being perforated.

As seen in both Figures 1 and 5, the openings are arranged in columns (in a substantially lengthwise or longitudinal direction of the trim) and/or rows (in a substantially crosswise or transverse direction of the trim). However unlike the first 30 example of perforated retrorefiective trim 20, the second example of perforated retrorefiective trim 20' is produced with adjacent columns of openings 25' offset in the longitudinal direction by approximately half the separation distance between adjacent SPEC-893079 19 columns. Similarly adjacent rows of openings 25' may be offset in the transverse direction by approximately half the separation distance between adjacent rows. Such an offset alignment of the openings 25' may be achieved, for example, by appropriately mounting the array of male punch members to the first plate in a similar 5 pattern to the positions of the openings 25' as illustrated in Figure 5. The offset openings 25' provides a different appearance to the perforated retrorefiective trim 20'. Furthermore the offset openings 25' may modify the structural characteristics of the perforated retrorefiective trim 20'by allowing it to better withstand breakage along the longitudinal and transverse directions of the perforated retrorefiective trim 20'.

Another difference between the two examples above is that the second example of perforated retrorefiective trim 20' is produced to include one or more unperforated regions 28a and 28b. In one form, as illustrated in Figure 5, the unperforated regions 28a and 28b are in the form of strips of 3mm to 5mm in width located along either longitudinal edge of the perforated retrorefiective trim 20'. The 15 unperforated regions 28a and 28b may be produced, for example, by the absence of one or more column-arrays of male punch members in a corresponding part of the first plate. Advantageously the unperforated regions 28a and 28b provide regions of continuous substrate for attachment of the perforated retrorefiective trim 20' on to a garment. For example, if the perforated retrorefiective trim 20' is to be sewn on to a 20 garment, the perforated retrorefiective trim 20' is preferably stitched through the unperforated regions 28a and 28b and not a perforated region so as to avoid damage or breakage of the perforated retrorefiective trim 20' by the stitches. in another embodiment of the perforated retrorefiective trim 20, 20', the retrorefiective trim is composed only of a film of retrorefiective material and does not 25 include a substrate to which the retrorefiective film is adhered. Thus, the perforated retrorefiective trim produced by the method includes only a film of retrorefiective material including a plurality of perforations.

In another embodiment, a sheet of material, such as paper, can be applied to the exposed surface of the substrate 30 is on the second side 37 of the retrorefiective 30 trim 15, 215 prior to feeding the retrorefiective trim 15, 215 into the machine 110, 210. This can be achieved by providing another roll (not shown) of paper sheet (not shown) in addition to the roll 140, 240 of the retrorefiective trim 15, 215 and SPEC-893079 simultaneously feeding paper sheet and the retrorefiective trim 15, 215 into the machine 110. Thus, when the rigid members 60 are forced through the retrorefiective trim 15, 215 they are also force through the paper sheet on the second side 37 of the retrorefiective trim 15. In particular, the female die members 70 are applied to the 5 paper sheet on the second side 37 of the retrorefiective trim 15, 215 as the male punch members 62 are forced through the retrorefiective trim 15, 215 and enter openings 72 of corresponding female die members 70, It has been discovered that the application of a sheet of paper to the second side 37 of the retrorefiective trim 15, 215 where the substrate 30 is exposed results in a cleaner cut of the material of the 10 retrorefiective trim 15, including the substrate 30 and the retrorefiective layer 40, upon penetration therethrough of the rigid members 60, namely the male punch members 62. As a result, the edges 26 around the openings 25 formed in the resulting perforated retrorefiective trim 20 are smoother and more cleanly cut or sheared than without the application of the paper sheet to the second surface 37 of the 15 retrorefiective trim 20.

In another embodiment, the machine 110 may include a vacuum assembly (not shown) that is arranged to apply a vacuum through each one of the openings 72 of each one of the die members 70, Where the female die members 70 are mounted to a plate member (not shown) the vacuum may be applied throught the plate to each of 20 the openings 72 of each of the die members 70. Thus, when the openings 72 of the die members 70 receive the punch members 62 and the removed portions 17 of the retrorefiective trim 15, 215 therewithin the vacuum removes the portions 17 from within the openings 72 in the die members 70. Removing the portions 17 from within the openings 72 in the die members 70 clears the openings 72 to receive 25 subsequently removed portions 17 of the retrorefiective trim 15. In another embodiment, the machine 210 may include a blowing and/or vacuum assembly (not shown) that is arranged to apply a flow of air and a vacuum to an area within the machine 210 where the rigid members 160, which in the illustrated embodiment are the punch members 162, are forced through the retrorefiective trim 215 to thereby 30 remove the portions 117 of the retrorefiective trim 215 and form openings 25 therethrough. Thus the extraneous portions 117 of the retrorefiective trim 215 that are removed to the form perforated retrorefiective trim 220 are removed for disposal and do not impede operation of the machine 210.

SPEC-893079 21 While the above detailed description of the invention details various preferred and envisaged embodiments of the invention it is to be appreciated that there may be other embodiments that incorporate the principles and/or spirit of the invention that have not been described either because they are not preferred or have not been 5 envisaged and that such embodiments ought to be considered to be within the scope of the invention disclosed herein.

SPEC-S93079

Claims

RECEIVED at IPONZ on 17 August 2011 22 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1. A method for producing a perforated retrorefiective trim that includes the steps of: providing a retrorefiective trim comprising a retrorefiective material and having first and second sides forcing a plurality of rigid members through the retrorefiective trim to remove a plurality of portions of the retrorefiective trim to provide a plurality of openings through the retrorefiective trim extending between the sides of the retrorefiective trim, thereby forming a perforated retrorefiective trim, wherein the rigid members are heated when forced through the retrorefiective trim.
2. The method of claim 1, wherein the rigid members are heated to a temperature sufficient to soften or melt the retrorefiective trim upon contact between the rigid members and the retrorefiective trim.
3. The method of claim 1 or claim 2, wherein the rigid members include male punch members or female die members.
4. The method of claim 3, the method further includes positioning the retrorefiective trim between the male punch members and the female die members before the step of forcing the rigid members through the retrorefiective trim.
5. The method of claim 4, wherein the step of forcing the rigid members through the retrorefiective trim includes pressing the male punch members and the female die members together with the retrorefiective trim therebetween.
6. The method of any one of claims 3 to 5, wherein at least one of the male punch members and the female die members has a cutting edge.
RECEIVED at IPONZ on 17 August 2011 23 7.
The method of any one of claims 3 to 6, wherein the male punch members are sized to closely fit within the female die members.
9. The method of any one of claims 3 to 7, wherein a portion of the retrorefiective material around the openings formed in the retrorefiective trim is softened or melted and is partially drawn through and into the openings.
10. The method of claim 9, wherein the softened or melted retrorefiective material is drawn through and into the openings at least part the way, or completely through, the thickness of the retrorefiective trim.
11. The method of any one of the preceding claims, wherein the retrorefiective trim is provided continuously from a roll and the rigid members are forced through a section of the retrorefiective trim at a time.
12. The method of any one of the preceding claims, wherein a sheet of paper or cardboard material is applied to one of the sides of the retrorefiective trim as the rigid members are forced through the retrorefiective trim and at least part of the way through the paper sheet or cardboard material.
13. The method of any one of the preceding claims, wherein the rigid members are arranged in columns or rows.
14. The method of claim 13, wherein adjacent columns or adjacent rows are offset from one another.
15. The method of claim 14, wherein the adjacent columns or the adjacent rows are offset from one another by approximately half the separation between the adjacent columns or the adjacent rows.
16. The method of any one of the preceding claims, wherein the step of forcing the rigid members through the retrorefiective trim includes the step of RECEIVED at IPONZ on 17 August 2011 24 forcing the rigid members through a portion of the retrorefiective trim resulting in one or more unperforated regions.
17. The method of claim 16, wherein the one or more unperforated regions are located along one or more longitudinal edges of the retrorefiective trim.
18. The method of any one of the preceding claims, wherein the retrorefiective trim comprises a retrorefiective layer adhered to a substrate.
19. The method of any one of claims 1 to 18, wherein the retrorefiective trim comprises a retrorefiective film that is capable of being adhered to a substrate.
20 Perforated retrorefiective trim including: a retrorefiective film of material including opposite first and second sides; a plurality of holes or openings through the retrorefiective film of material and extending entirely through the film of material between the first and second sides formed by the removal of a plurality of portions of the retrorefiective film, wherein in the process a portion of the retrorefiective film around the openings formed in the retrorefiective film through melting or softening is partially drawn through and into the openings.
21. The perforated retrorefiective trim of claim 20, wherein the softened or melted retrorefiective film or material is drawn through and into the openings completely through the thickness of the film from the first side to the second side of the film.
22. The perforated retrorefiective trim of claim 20, wherein the retrorefiective film of material is adhered to a substrate including first and second RECEIVED at IPONZ on 17 August 2011 25 sides, holes or openings provided through the retrorefiective film of material and the substrate and extending entirely through the film of material and the substrate between the first and second sides of the substrate, wherein a portion of the retrorefiective film around the openings formed in the retrorefiective film and the substrate which through melting or softening is partially drawn through and into the openings in the substrate.
23. The perforated retrorefiective trim of claim 22, wherein the substrate is a woven material.