Classifications

• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B5/00—Optical elements other than lenses
  • G02B5/12—Reflex reflectors
  • G02B5/122—Reflex reflectors cube corner, trihedral or triple reflector type
  • G02B5/124—Reflex reflectors cube corner, trihedral or triple reflector type plural reflecting elements forming part of a unitary plate or sheet
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/007—After-treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
  • B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
  • B05D5/061—Special surface effect
  • B05D5/063—Reflective effect
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D11/00—Producing optical elements, e.g. lenses or prisms
  • B29D11/00865—Applying coatings; tinting; colouring
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
  • C23C16/06—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
  • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
  • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
  • G02B1/14—Protective coatings, e.g. hard coatings
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B5/00—Optical elements other than lenses
  • G02B5/20—Filters
  • G02B5/208—Filters for use with infrared or ultraviolet radiation, e.g. for separating visible light from infrared and/or ultraviolet radiation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D2201/00—Polymeric substrate or laminate
  • B05D2201/02—Polymeric substrate
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D2252/00—Sheets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING 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
  • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material

Definitions

• This disclosure relates generally to retroreflective sheeting including a topcoat and to methods of making such sheeting.
• Retroreflective articles are characterized by the ability to redirect light incident on the material back toward the originating light source. This property has led to the widespread use of retroreflective articles in sheeting used in, for example, traffic and personal safety uses. Retroreflective sheeting is commonly employed in a variety of traffic control articles, for example, road signs, barricades, license plates, pavement markers and marking tape, as well as retroreflective tapes for vehicles and clothing.
• Cube corner sheeting is one type of retroreflective sheeting, and it typically includes a multitude of cube corner elements to retroreflect incident light.
• Cube corner retroreflectors typically include a sheet having a generally planar front surface and an array of cube corner elements protruding from the back surface.
• Cube corner reflecting elements include generally trihedral structures that have three approximately mutually perpendicular lateral faces meeting in a single corner— a cube corner.
• the retroreflector is arranged with the front surface disposed generally toward the anticipated location of intended observers and the light source. Light incident on the front surface enters the sheet and passes through the body of the sheet to be reflected by each of the three faces of the elements, so as to exit the front surface in a direction substantially toward the light source.
• Some exemplary polymers for use in making cube corner sheeting include poly(carbonate), poly(methyl methacrylate), poly(ethylene terephthalate), aliphatic polyurethanes, as well as ethylene copolymers and ionomers thereof.
• Cube corner sheeting may be prepared by casting directly onto a film, such as described in U.S. Patent No. 5,691,846, incorporated in its entirety herein.
• Polymers for radiation-cured cube corners include cross-linked acrylates such as multifunctional acrylates or epoxies and acrylated urethanes blended with mono-and multifunctional monomers.
• cube corners may be cast on to plasticized polyvinyl chloride film for more flexible cast cube corner sheeting. These polymers are often employed for one or more reasons including thermal stability, environmental stability, clarity, excellent release from the tooling or mold, and capability of receiving a reflective coating.
• Prismatic retroreflective sheeting typically includes a thin transparent layer having a substantially planar first surface and a second structured surface including a plurality of geometric structures, some or all of which include three reflective faces configured as a cube corner element. Prismatic retroreflective sheeting is known for returning a large portion of the incident light towards the source.
• prismatic cube corner microstructures to meet high retroreflectance specifications (e.g., retroreflectance (RA) or brightness in the range of 300 to 1000 candela per lux per meter square (cpl) for 0.2 degree observation angle and -4 entrance angle), such as ASTM types III, VII, VIII, IX, and X, as described in ASTM D 4956-04, and type XI, as described in ASTM D 4956-09.
• high retroreflectance specifications e.g., retroreflectance (RA) or brightness in the range of 300 to 1000 candela per lux per meter square (cpl) for 0.2 degree observation angle and -4 entrance angle
• ASTM types III, VII, VIII, IX, and X candela per lux per meter square
• type XI as described in ASTM D 4956-09.
• prismatic retroreflective sheeting includes truncated cube corner elements and is described in, for example, U.S. Patent Nos.
• topcoat layer that gives protection to the underlying cube corner layer and may add other functionality such as improved ink receptivity, dirt resistance, flexibility or rigidity, coloration, etc.
• Existing topcoats are typically either extruded films or waterborne acrylic compositions (see, e.g., U.S. Patent No. 7,048,989).
• extruded films Some exemplary drawbacks of extruded films are that they are relatively thick and can impair sheeting flexibility and that they are expensive to manufacture.
• waterborne acrylic polymer compositions are that they are expensive and time-consuming to manufacture because they take extended periods of time and energy to remove the water by drying.
• topcoat materials for use with prismatic retroreflective sheeting are typically either (1) extruded or (2) water-based or aqueous-based.
• the inventors of the present disclosure recognized that improved retroreflective sheeting, and an improved method of making retroreflective sheeting, includes a solvent-based topcoat.
• solvent-based topcoat compositions provide a low cost and equally performing alternative to the use of water-based urethane or water-based acrylic topcoats.
• the use of a solvent-based topcoat composition on retroreflective sheeting results in sheeting with at least one of sufficient adhesion to a retroreflective core sheet, a sheeting with high retroreflective brightness, excellent surface protection, good toner/ink adhesion properties, and/or decreased incidence of crazing and/or hazing. Also, the manufacturing process for making the sheeting is improved by at least one of efficiency, decreased cost, decreased solvent waste requirements, and the like.
• the inventors of the present application also discovered methods of effectively and efficiently applying a solvent-based topcoat onto a polycarbonate-based retroreflective sheeting without creating significant craze or haze in the resulting retroreflective sheeting.
• Some embodiments of the present disclosure relate to retroreflective sheeting, comprising: a first major surface that is a structured surface having a structure imparted by a plurality of prismatic cube comer elements; a second major surface opposite the first major surface, the second major surface being substantially planar and including a polycarbonate; and a topcoat adjacent to at least a portion of the second major surface, wherein the topcoat includes a solvent-based composition.
• the solvent-based composition includes at least one of (1) a solvent-borne acrylic or (2) a solvent-borne vinyl.
• Some embodiments of the present disclosure relate to a method of making retroreflective sheeting, comprising: providing a sheeting having (1) a first major surface that is a structured surface having a structure imparted by a plurality of prismatic cube corner elements; and (2) a second major surface opposite the first major surface, the second major surface being substantially planar and including a polycarbonate; and placing a topcoat composition adjacent to at least a portion of the second major surface, wherein the topcoat includes a solvent-based composition.
• the solvent- based composition includes at least one of (1) a solvent-borne acrylic or (2) a solvent-borne vinyl.
• the method further comprises removing the solvent from the solvent-borne topcoat composition.
• the method further includes removing substantially all of the solvent from the topcoat composition within 15 seconds of placing the topcoat composition adjacent to the second major surface. In some embodiments, the method further includes removing substantially all of the solvent from the topcoat composition within 12 seconds of placing the topcoat composition adjacent to the second major surface. In some embodiments, the method further includes removing substantially all of the solvent from the topcoat composition within 10 seconds of placing the topcoat composition adjacent to the second major surface. In some embodiments, the method further includes removing substantially all of the solvent from the topcoat composition within 8 seconds of placing the topcoat composition adjacent to the second major surface. In some embodiments, the method further includes removing substantially all of the solvent from the topcoat composition within 5 seconds of placing the topcoat composition adjacent to the second major surface.
• the topcoat includes a UV absorber. In some embodiments, the topcoat includes at least 10% by weight UV absorber. In some embodiments, the topcoat includes multiple layers and the layers are the same as one another. In some embodiments, the topcoat includes multiple layers and the layers differ from one another. In some embodiments, the topcoat includes a solvent-borne vinyl chloride copolymer.
• the plurality of prismatic cube corner elements include at least one of truncated cube corner elements, full cube corner elements, or preferred geometry cube corner elements. In some embodiments, the plurality of prismatic cube corner elements includes a thermoplastic polymer.
• the thermoplastic polymer is at least one of an acrylic polymer, a polycarbonate, a polyester, a polyimide, a fluoropolymer, a polyamide, a polyetherketone; a poly(etherimide); a polyolefin; a poly(phenylene ether); a poly(styrene); a styrene copolymer; a silicone modified polymer; a cellulosic polymer; a fluorine modified polymer; and mixtures of the above polymers.
• the second major surface is part of at least one of (1) a land layer or (2) a body layer.
• the land layer or body layer includes a polycarbonate.
• Some embodiments further comprise a seal film.
• the seal film includes a polyester.
• the amount of one or more of crazing or haze reduces retroreflective brightness by less than 90%.
• Some embodiments further comprise a specular reflective coating.
• the specular reflective coating includes a metal.
• the metal is aluminum.
• Some embodiments further comprise a seal film. Some methods further include placing a seal film adjacent to the structured surface. In some embodiments, the seal film is a polyester.
• Fig. 1 is a cross-sectional side view of an exemplary embodiment of retroreflective sheeting consistent with the teachings herein.
• Fig. 2 is a cross-sectional side view of an exemplary embodiment of retroreflective sheeting consistent with the teachings herein.
• FIGs. 3A and 3B are cross-sectional side views of an exemplary embodiment of retroreflective sheeting consistent with the teachings herein.
• the present invention generally relates to retroreflective sheeting comprising prismatic cube corner element sheeting including a viewing surface on which incoming light is incident. A topcoat is disposed on the viewing surface. The topcoat includes a solvent-borne composition.
• topcoat refers to a layer disposed on the viewing surface (e.g.
• topcoats described herein can, for example, assist in protecting the front surface of the retroreflective sheeting.
• solvent-borne or “solvent-based” refers to a polymer or composition that is dispersed or emulsified in a solvent.
• water-borne As used herein, the term “water-borne,” “water-based,” “aqueous-borne,” or “aqueous-based” refers to a polymer or composition that is dispersed or emulsified in water.
• PG cube corner elements or "preferred geometry cube corner elements” refers to a cube corner element that has at least one non-dihedral edge that: (1) is nonparallel to the reference plane; and (2) is substantially parallel to an adjacent non-dihedral edge of a neighboring cube corner element.
• a cube corner element whose three reflective faces comprise rectangles (inclusive of squares), trapezoids or pentagons are examples of PG cube corner elements.
• Reference plane with respect to the definition of a PG cube corner element refers to a plane or other surface that approximates a plane in the vicinity of a group of adjacent cube corner elements or other geometric structures, the cube corner elements or geometric structures being disposed along the plane.
• the group of adjacent cube corner elements consists of a single row or pair of rows.
• the group of adjacent cube corner elements includes the cube corner elements of a single lamina and the adjacent contacting laminae.
• the group of adjacent cube corner elements In the case of sheeting, the group of adjacent cube corner elements generally covers an area that is discernible to the human eye (e.g. , preferably at least 1 mm 2 ) and preferably the entire dimensions of the sheeting.
• FIG. 1 shows an exemplary embodiment of retroreflective sheeting consistent with the teachings herein.
• Retroreflective sheeting 100 includes a prismatic cube corner element-based sheeting 1 10 and a topcoat 120 adjacent thereto. More specifically, prismatic cube corner element-based sheeting 110 includes a first major surface 130 that is structured by a plurality of cube corner elements 140 and an opposite, second major surface 150 that is substantially planar. Topcoat 120 is adjacent to second major surface 150.
• Fig. 2 shows the retroreflective sheeting of Fig. 1 further including a seal film.
• retroreflective sheeting 200 includes a prismatic cube corner element-based sheeting 1 10 and a topcoat 120 adjacent thereto.
• prismatic cube corner element-based sheeting 1 10 includes a first major surface 130 that is structured by a plurality of cube corner elements 140 and an opposite second major surface 150 that is substantially planar.
• Topcoat 120 is adjacent to second major surface 150.
• a seal film 220 is adjacent to and forms an air interface 225 with structured surface 130 of cube corner elements 140. Adjacent to seal film 220 is an adhesive layer 230 and an optional release liner 235.
• the prismatic cube corner sheeting of the present disclosure includes a plurality of
• microreplicated retroreflective elements there are various types of prismatic retroreflective elements that can be used in the embodiments and inventions described and claimed herein.
• One such type includes truncated cube corner elements including, for example, those described in U.S. Patent Nos. 3,712,706; 4,202,600; 4,243,618; and 5,138,488, all of which are incorporated herein in their entirety.
• Other types includes full cube corner elements and preferred geometry cube corner elements, as are described in, for example, U.S. Patent Nos. 7, 156,527; 7, 152,983; and 8,251,52, all of which are incorporated herein in their entirety. Additional illustrative examples of cube corner-based retroreflective sheeting are disclosed in U.S. Patent Nos. 4,588,258; 4,775,219; 4,895,428; 5,387,458; 5,450,235;
• the cube corner elements include, for example, those described in U.S. Patent No. 7,862, 187, incorporated herein in its entirety.
• the cube corner elements include light transmitting or transparent polymeric materials.
• the cube corner prismatic elements include polycarbonate.
• the prismatic cube corner elements have a height ranging from 20 to 500 micrometers ( ⁇ ).
• the term "body layer” refers to a separate material to which the microreplicated elements are attached, adhered, or adjacent (see, for example, Fig. 2).
• a body layer is optional.
• microreplicated retroreflective elements of the types described herein are adhered, attached, or adjacent to a body layer.
• Some exemplary body layers have a thickness between about 20 and 1 ,000 ⁇ .
• both the body layer and microreplicated retroreflective elements include the same material.
• the material is one or more light transmitting or transparent polymeric materials.
• the body layer is a different material(s) than the microreplicated retroreflective elements.
• the body layer may itself include more than one layer. In some embodiments where the body layer includes multiple layers, these layers can include more than one composition, and the composition can vary by layer.
• Some exemplary body layers are described in, for example, U. S. Patent No. 7,611 ,251 , incorporated by reference herein in its entirety. These materials include, for example, poly(ethylene-co-acrylic acid) and poly(ethylene-co-vinylacetate).
• the body layer includes a polyolefin, typically comprising at least 50 weight percent (wt-%) of alkylene units having 2 to 8 carbon atoms (e.g., ethylene and propylene).
• the term "land layer” refers to a material adjacent to and integral with the microreplicated elements.
• a land layer is optional. Some embodiments include a land layer (not shown) integral with cube corner elements 12 which includes the same polymeric material as the cube corner elements. Cube corner retroreflective sheeting having a land layer is shown, for example, in U.S. Patent 5,450,235, which is incorporated herein in its entirety.
• the land layer is thin by comparison to the microrep Heated retroreflective elements, typically having a thickness no greater than 10 percent of the height of the cube corner elements. In some embodiments, land layer thickness is in the range of 1 - 150 ⁇ . In some embodiments, land layer thickness is in the range of 10 - 100 ⁇ .
• Some embodiments include microreplicated retroreflective elements and a body layer without a land layer. Some embodiments include microreplicated retroreflective elements and a land layer without a body layer. Some embodiments include microreplicated retroreflective elements adjacent to a land layer which is adjacent to a body layer. In this latter instance, the body layer is often referred to as a top film or overlaminate.
• retroreflective sheeting include a specular reflective coating, such as a metallic coating, on the backside of the prismatic cube corner elements. These embodiments are often referred to as "metalized retroreflective sheeting.”
• specular reflective coating can be applied by known techniques such as vapor depositing or chemically depositing a metal such as aluminum, silver, or nickel.
• a primer layer may be applied to the backside of the cube corner elements to promote the adherence of the metallic coating. Additional information about metalized sheeting, including materials used to make metalized sheeting and methods of making it can be found, for example, in U.S. Patent Nos. 4,801, 193 and 4,703,999, both of which are incorporated herein in their entirety.
• topcoats can be used in the embodiments described herein.
• Some exemplary compositions include those described in, for example, US 5,514,441 and 4,725,494, both of which are incorporated herein in their entirety.
• Some exemplary topcoat compositions include, for example, transparent polymer-based material such as methyl methacrylate resin, acrylic resin, alkyd resin, polyurethane resin, epoxy resin, polyester resin, polycarbonate resin, polyvinyl butyral, cellulose acetate butyrate, and the like. These resins may be applied from solution or dispersion or from liquids that contain no volatiles. The materials may be nonreactive or may react to a cross-linked relatively insoluble and infusible state.
• the topcoat includes a solvent-based vinyl polymer.
• the vinyl polymer can be polymerized from a single vinyl monomer.
• the vinyl polymer is a copolymer made from two or more vinyl monomers.
• the vinyl polymers may have a core-shell structure.
• Core-shell polymers typically comprise a different copolymer with regard to either the base monomers or proportions thereof in the surrounding shell layer in comparison to the core.
• Core-shell polymers are generally described as two phase or multi phase polymers and may optionally contain a third phase incorporated into the same particle or as a separate particle. Other morphologies are also possible such as micro-phases, phase separated, bi-modal, multi-lobed, or inverted-core shell.
• the vinyl polymer is a copolymer made from two or more vinyl monomers in combination with one or more monomers.
• the weight average molecular weight (Mw) of the solvent-borne vinyl polymer(s) is generally at least about 14,000 g/mole, more typically at least about 22,000 g/mole, more typically at least 27,000 g/mole.
• the topcoat includes a blend of solvent-based vinyl polymer and at least one modifying polymer.
• the modifying polymer may comprise one or more solvent-based polymer(s).
• the topcoat composition includes a totality of up to about 50 wt-% solids of modifying polymer(s).
• the modifying polymer and/or copolymer may be commercially available in a powdered form that may be emulsified or dispersed in solvent.
• Some embodiments of the present disclosure are made by the following method: providing a sheeting having (a) a first major surface including a plurality of prismatic cube corner elements including a polycarbonate and forming a structured surface; and (b) a second major surface opposite the first major surface, the second major surface being substantially planar; and coating on at least a portion of the second major surface a topcoat having at least one of (a) a thickness of less than 0.5 mil (when dry); or (b) at least one of a solvent-borne acrylic or a solvent-borne vinyl. Coating may be effected by, for example, processes described in U.S. Patent Nos. 7,048,989; 4,844,976; 5,508, 105; and European Patent No.
• Topcoats can be coated directly onto the cube corner sheeting or alternately preformed and heat laminated either during the manufacturing of the cube corner layer or in a subsequent operation.
• the topcoat has a minimal contribution to the physical properties of the sheeting, and polymer selection can be made based on the adhesion to the polycarbonate, dirt resistance, resistance to surface impression, etc.
• the topcoat includes a solvent-based acrylic polymer.
• the acrylic polymers may be polymerized from a single acrylate monomer.
• the acrylic polymer is a copolymer made from two or more acrylate monomers.
• the acrylic polymers may have a core-shell structure. Core-shell polymers typically comprise a different copolymer with regard to either the base monomers or proportions thereof in the surrounding shell layer in comparison to the core. Core-shell polymers are generally described as two phase or multi phase polymers and may optionally contain a third phase incorporated into the same particle or as a separate particle. Other morphologies are also possible such as micro-phases, phase separated, bi-modal, multi-lobed, or inverted-core shell.
• the acrylic polymer is a copolymer made from two or more acrylate monomers in combination with styrene monomers.
• the styrene content of the copolymer is typically less than about 50 wt-%, more typically less than about 30 wt-%, and most typically less than about 20 wt-%.
• the weight average molecular weight (Mw) of the solvent-borne acrylic polymer(s) is generally at least about 20,000 g/mole. , more typically at least about 50,000 g/mole, more typically at least 70,000 g/mole.
• the topcoat includes a blend of solvent-based acrylic polymer and at least one modifying polymer.
• the modifying polymer is a solvent-borne polymer.
• the topcoat composition includes a totality of up to about 50 wt-% solids of modifying polymer(s).
• the modifying polymer and/or copolymer may be commercially available in a powdered form that may be emulsified or dispersed in solvent.
• the topcoat includes additives, such as, for example, UV stabilizers.
• UV stabilizers are used to prevent or terminate oxidation of polymers by UV light.
• Suitable UV stabilizers for use in the topcoat compositions of the present disclosure are UV absorbers, quenchers and/or scavengers, and include, for example, at least one of hindered amine light stabilizers (HALS), benzophenones, benzotriazoles, triazines, and combinations thereof.
• HALS hindered amine light stabilizers
• benzophenones benzotriazoles
• triazines triazines
• certain thicknesses of solvent-borne coating compositions provide a low cost alternative to the use of thick (e.g., greater than 0.5 mil when dry) topcoats.
• a thinner coating composition thick e.g., less than 0.5 mil when dry
• a sealing layer in the sheeting prevents or limits entry of soil or moisture into the sheeting.
• Some exemplary methods of applying of a sealing layer are described in U.S. Patent Nos. 7,329,447; 7,611,251 ; 5,784, 197; 4,025,159 (disclosing use of electron beam radiation); 5,706,132 (use of thermal bonding or radio frequency welding); PCT Publication WO 2011/152977 (describing multi-layer sealing films for prismatic retroreflective sheeting); and. 6,224,792 (hermetic encapsulation by the sealing layer).
• Some embodiments include a structured sealing layer.
• An exemplary structured sealing layer is described in, for example, in PCT Patent Publication No. WO 201 1/129832, incorporated herein in its entirety.
• the retroreflective sheeting lacks either a sealing films and/or a specular reflective or metal coating on the cube corner elements.
• Exemplary sheeting constructions are described in, for example, in PCT Patent Publication No. WO 201 1/129832, incorporated herein in its entirety.
• FIGS. 3A and 3B show one exemplary embodiment of a retroreflective article 300 that faces viewer 302.
• Retroreflective article 300 includes a retroreflective layer 310 including multiple cube corner elements 312 that collectively form a structured surface 314 opposite a major surface 316.
• Retroreflective layer 310 also includes a topcoat / overlay layer 318.
• a pressure sensitive adhesive layer 330 is adjacent to retroreflective layer 310.
• Pressure sensitive adhesive layer 330 includes a pressure sensitive adhesive 332, one or more barrier layers 334, and a liner 336.
• Barrier layer 334 has sufficient structural integrity to prevent pressure sensitive adhesive 332 from flowing into a low refractive index layer 338 that is between structured surface 314 and barrier layer 334.
• Barrier layer 334 can directly contact or be spaced apart from or can push slightly into the tips of cube corner elements 312.
• barrier layers 334 form a physical "barrier" between pressure sensitive adhesive 330 and cube corner elements 312. Barrier layers may prevent wetting of cube tips or surfaces by the pressure sensitive either initially during fabrication of the retroreflective article or over time due to the to viscoelastic nature of the adhesive.
• a trapped layer between barrier layers 334 (where present) and cube corner elements 312 is low refractive index layer 338. Low refractive index layer is thereby enclosed. If a protective layer is applied thereto, the low refractive index layer is encapsulated. Encapsulation of the low refractive index layer maintains and/or protects the integrity of the low refractive index layer.
• barrier layer permits the portions of structured surface 314 adjacent to low refractive index layer 338 and/or barrier layers 334 to retroreflect incident light 350.
• Barrier layers 334 may also prevent pressure sensitive adhesive 330 from wetting out the cube sheeting. Pressure sensitive adhesive 330 that is not in contact with a barrier layer 334 adheres to the cube corner elements, thereby effectively sealing the retroreflective areas to form optically active areas or cells. Pressure sensitive adhesive 330 also holds the entire retroreflective construction together, thereby eliminating the need for a separate sealing film and sealing process. In some embodiments, the pressure sensitive adhesive is in intimate contact with or is directly adjacent to the structured surface or the cube corner elements.
• a light ray 350 incident on a cube corner element 312 that is adjacent to low refractive index layer 338 is retroreflected back to viewer 302.
• an area of retroreflective article 300 that includes low refractive index layer 338 is referred to as an optically active area.
• an area of retroreflective article 300 that does not include low refractive index layer 338 is referred to as an optically inactive area because it does not substantially retroreflect incident light.
• Low refractive index layer 338 includes a material that has a refractive index that is less than about 1.30, less than about 1.25, less than about 1.2, less than about 1.15, less than about 1.10, or less than about 1.05.
• Exemplary low refractive index materials include air and low index materials (e.g., low refractive index materials described in U.S. Patent Application No. 61/324,249, which is hereby incorporated herein in its entirety.
• barrier layer 334 any material that prevents the pressure sensitive adhesive from contacting cube corner elements 312 or flowing or creeping into low refractive index layer 338 can be used in barrier layer 334.
• Exemplary materials for use in barrier layer 334 include resins, polymeric materials, dyes, inks, vinyl, inorganic materials, UV-curable polymers, pigment, particle, and bead.
• the size and spacing of the barrier layers can be varied.
• the barrier layers may form a pattern on the retroreflective sheeting. In some embodiments, one may wish to reduce the visibility of the pattern on the sheeting.
• any desired pattern can be generated by combinations of the described techniques, including, for example, indicia such as letters, words, alphanumerics, symbols, or even pictures.
• the patterns can also be continuous, discontinuous, monotonic, serpentine, any smoothly varying function, stripes, varying in the machine direction, the transverse direction, or both; the pattern can form an image, logo, or text, and the pattern can include patterned coatings and/or perforations.
• the printed areas and/or unprinted areas can form a security feature.
• the pattern can include, for example, an irregular pattern, a regular pattern, a grid, words, graphics, images lines, and intersecting zones that form cells.
• the pressure sensitive adhesive layer includes a first region and a second region.
• the second region is in direct or intimate contact with the structured surface.
• the first and second regions have sufficiently different properties to form and separate the low refractive index layer between and from the pressure sensitive adhesive layer and the structured surface of the
• the second region includes a pressure sensitive adhesive and the first region differs in composition from the second region.
• the first region and the second region have different polymer morphology.
• the first region and the second region have different flow properties.
• the first region and the second region have different viscoelastic properties.
• the first region and the second region have different adhesive properties.
• the retroreflective article includes a plurality of second regions that form a pattern.
• the pattern is one of an irregular pattern, a regular pattern, a grid, words, graphics, and lines.
• Exemplary pressure sensitive adhesives for use in the retroreflective articles of the present disclosure include those described in PCT Patent Publication No. WO 201 1/129832, incorporated herein in its entirety.
• Solvent-based topcoats have not been used until the present disclosure because solvent coating a polycarbonate typically causes crazing or haze.
• the terms "craze” or “crazing” relate generally to macroscopic tension failure in a thermoplastic polymer. Crazing occurs before total tension failure of the thermoplastic polymer. The crazes appear stochastically depending on the distribution of microscopic defects within and at the surface of a material. Crazes include voids that typically extend perpendicular to the tensile strain. Often, the tip of the craze will contain fibrils of polymer chains that extend from one surface to the other across the tip parallel to the tension. Once a craze reaches a critical state, it typically either (1) propagates into a crack that grows to a macroscopic fracture or (2) the material yields. Crazing causes an increase in whiteness and an undesirable increase in haze of the sheeting.
• haze refers to cloudiness in the sheeting caused by scattering of incident light. Haze can occur in addition to or separate from crazing, and is an undesirable property in retroreflective sheeting because it decreases the retroreflectivity of the sheeting and/or can cause yellowing of the sheeting. Without being limited by theory, it is thought that solvents penetrate into the polycarbonate of the retroreflective sheeting and cause the polycarbonate to crystallize, which may cause undesirable hazing. Small amounts of either or both haze or craze result in significant decrease in retroreflectivity. For at least this reason, solvent-based topcoats have not been used until the present disclosure.
• a solvent-based topcoat could be used with minimal to no crazing if at least one of the following conditions was present: (1) the topcoat layer is very thin (e.g., less than 0.5 mils when dry); (2) the exposure time of the topcoat coating on the polycarbonate is very minimal (e.g., less than 15 seconds, or less than 12 seconds, or less than 10 seconds, or less than 9 seconds, or less than 7 seconds, or less than 5 seconds, etc).
• the solvent molecules are largely prevented from diffusing into the polycarbonate, which is thought to contribute to the creation of haze and/or crazing. It was highly unexpected that a polycarbonate sheeting could be stabilized with a coating of such a minimal thickness.
• the retroreflective sheeting of the present disclosure has numerous advantages over existing sheeting and methods of making the sheeting.
• One advantage is that solvent coating directly onto a polycarbonate is achieved with minimal to no crazing and/or without sacrificing durability and/or weatherability.
• the retroreflective sheeting described herein may be used for a variety of uses such as traffic signs, license plates, pavement marking (e.g. raised pavement markings), personal safety, vehicle decoration, and commercial graphics such as retroreflective advertising displays, bus wraps, etc.
• major surface and “major surfaces” refer to the surface(s) with the largest surface area on a three-dimensional shape having three sets of opposing surfaces.
• phrases "at least one of and “comprises at least one of followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

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• Physics & Mathematics (AREA)
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• Optics & Photonics (AREA)
• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Health & Medical Sciences (AREA)
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• 2014
  • 2014-06-26 SG SG11201510810QA patent/SG11201510810QA/en unknown
  • 2014-06-26 JP JP2016524201A patent/JP6694812B2/ja active Active
  • 2014-06-26 KR KR1020167002442A patent/KR102217293B1/ko active Active
  • 2014-06-26 EP EP14819302.2A patent/EP3017327B1/en active Active
  • 2014-06-26 CN CN201480037971.1A patent/CN105359008B/zh active Active
  • 2014-06-26 WO PCT/US2014/044365 patent/WO2015002814A1/en not_active Ceased
  • 2014-06-26 US US14/901,969 patent/US20160370514A1/en not_active Abandoned
• 2018
  • 2018-11-30 JP JP2018225783A patent/JP2019066863A/ja active Pending
• 2020
  • 2020-06-18 US US16/905,177 patent/US20200319384A1/en not_active Abandoned

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