Retroreflective article

Abstract

A retroreflective article includes a mesh layer including a plurality of interconnected portions defining a plurality of surrounded openings therebetween, an adhesive layer, and a plurality of sets of optical elements. The adhesive layer includes a plurality of adhesive portions that are at least partially spaced apart from each other by the mesh layer. Each bonding portion is at least partially disposed within a corresponding surrounded opening and removably bonded to an adjacent one or more interconnection portions of the mesh layer. The plurality of groups of optical elements correspond to the plurality of bonding portions of the bonding layer. Each of the plurality of sets of optical elements includes a plurality of optical elements partially embedded within a corresponding one of the plurality of bond portions of the bond layer. The sets of optical elements are spaced apart from each other by the one or more interconnection portions of the mesh layer.

Description

Technical Field

[0001] The present disclosure relates to retroreflective articles and methods of making retroreflective articles. Background Art

[0002] Retroreflective articles can be used to transfer or apply retroreflective segments to clothing. Retroreflective segments are used in a variety of applications. For example, retroreflective segments are often used as high-visibility decorative pieces on clothing and footwear to increase the visibility of the user wearing the clothing and footwear. Retroreflective segments are often added to clothing worn by firefighters, emergency rescue personnel, road workers, etc. Summary of the invention

[0003] In a first aspect, the present disclosure provides a retroreflective article. The retroreflective article includes a mesh layer. The mesh layer includes a plurality of interconnected portions, a first mesh main surface, and a second mesh main surface opposite to the first mesh main surface, wherein a plurality of interconnected portions define a plurality of surrounded openings. The plurality of interconnected portions together form the first mesh main surface and the second mesh main surface. The retroreflective article also includes a bonding layer, which includes a plurality of bonding portions, which are at least partially spaced apart from each other by the mesh layer. Each of the plurality of bonding portions is disposed in a corresponding surrounded opening of the plurality of surrounded openings, and is removably bonded from the plurality of interconnected portions of the mesh layer to one or more adjacent interconnected portions. The second mesh main surface is adjacent to the bonding layer. The retroreflective article also includes a plurality of groups of optical elements corresponding to the plurality of bonding portions of the bonding layer. Each group of optical elements in each group of optical elements includes a plurality of optical elements, which are partially embedded in a corresponding bonding portion of the plurality of bonding portions of the bonding layer. The first mesh main surface is adjacent to each group of optical elements. Each group of optical elements is spaced apart from each other by one or more interconnected portions of the mesh layer.

[0004] In a second aspect, the present disclosure provides a method for manufacturing a retroreflective article. The method includes providing a carrier layer. The method also includes disposing a mesh layer on the carrier layer. The mesh layer includes a plurality of interconnected portions, a first mesh main surface, and a second mesh main surface opposite to the first mesh main surface, wherein a plurality of interconnected portions define a plurality of surrounded openings therebetween. The plurality of interconnected portions together form the first mesh main surface and the second mesh main surface. The first mesh main surface is disposed on the carrier layer. The method also includes disposing a plurality of optical elements within the plurality of surrounded openings of the mesh layer. The method also includes providing a bonding layer adjacent to the plurality of optical elements opposite to the carrier layer within the plurality of surrounded openings of the mesh layer, such that the plurality of optical elements are partially embedded within the bonding layer. The bonding layer includes a plurality of bonding portions, which are at least partially spaced apart from each other by the mesh layer. Each of the plurality of bonding portions is at least partially disposed within a corresponding surrounded opening of the plurality of surrounded openings. Each of the plurality of bonding portions is spaced apart from the first mesh main surface along the thickness of the mesh layer. The bonding layer is removably bonded to the plurality of interconnected portions of the mesh layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The exemplary embodiments disclosed herein may be more fully understood in view of the following detailed description in conjunction with the accompanying drawings. The accompanying drawings are not necessarily drawn to scale. In particular, the thickness of certain layers that are proportional to certain other items are exaggerated for ease of illustration and simplicity. Like numbers used in the figures refer to like parts. However, it should be understood that the use of numbers to refer to parts in a given figure is not intended to limit the parts marked with the same number in another figure.

[0006] Figure 1 is a schematic cross-sectional view of a retroreflective article according to an embodiment of the present disclosure;

[0007] Figure 2 is a schematic perspective view of a mesh layer of a retroreflective article according to an embodiment of the present disclosure;

[0008] Figure 3 is a schematic cross-sectional view of a retroreflective article according to another embodiment of the present disclosure;

[0009] Figure 4 is a schematic cross-sectional view of a retroreflective article according to another embodiment of the present disclosure;

[0010] Figure 5 is a schematic cross-sectional view of a retroreflective article according to another embodiment of the present disclosure;

[0011] FIG. 6A to FIG. 6D are schematic cross-sectional views depicting various steps of a process for using a retroreflective article according to an embodiment of the present disclosure;

[0012] Figure 7 is a flow chart depicting various steps of a method of making a retroreflective article according to an embodiment of the present disclosure;

[0013] FIG. 8A to FIG. 8G is a schematic cross-sectional view depicting various steps of a method of manufacturing a retroreflective according to an embodiment of the present disclosure; and

[0014] 9A to 9C is a schematic cross-sectional view of a retroreflective article made by a method according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0015] In the following description, reference is made to the accompanying drawings which form a part thereof, and in which various embodiments are shown by way of illustration. It should be understood that other embodiments can be envisioned and made without departing from the scope or essence of the present disclosure. Therefore, the following specific embodiments should not be considered to have a limiting meaning.

[0016] In the following disclosure, the following definitions apply.

[0017] As used herein, all numbers should be considered to be modified by the term "about". As used herein, "a", "an", "said", "at least one" and "one or more" are used interchangeably.

[0018] As used herein, as a modifier of a characteristic or property, unless otherwise specifically defined, the term "substantially" means that the characteristic or property will be readily discernible by a person of ordinary skill without requiring absolute precision or a perfect match (e.g., within + / - 20% for quantifiable characteristics).

[0019] Unless specifically defined otherwise, the term "substantially" means a high degree of approximation (eg, within + / - 10% for a quantifiable characteristic), but again does not require an absolutely precise or perfect match.

[0020] Unless specifically defined otherwise, the term "about" means a close approximation (eg, within + / - 5% for a quantifiable property), but again does not require absolute precision or a perfect match.

[0021] Terms such as same, equal, uniform, constant, exact, etc. should be understood to mean within normal tolerances, or within measurement errors applicable to the particular circumstances, rather than requiring absolute precision or a perfect match.

[0022] As used herein, the terms "first" and "second" are used as identifiers. Therefore, such terms should not be understood as limitations on the present disclosure. Throughout the embodiments of the present disclosure, the terms "first" and "second" are interchangeable when used in conjunction with a feature or element.

[0023] As used herein, when a first material is referred to as being "similar" to a second material, at least 90 weight percent of the first and second materials are identical, and any variation between the first and second materials is less than about 10 weight percent of each of the first and second materials.

[0024] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0025] Unless specified or limited otherwise, the terms "attached," "connected," and variations thereof are used broadly and encompass both direct and indirect attachments, connections, and couplings.

[0026] As used herein, the term "adjacent" refers to elements that are close to each other, generally contacting each other, but may have intervening elements between them.

[0027] As used herein, the term "configured to" and similar terms are at least as restrictive as the term "adapted to" and require actual design intent to perform the specified function, not just the physical ability to perform such function.

[0028] As used herein, the term "at least partially" refers to any percentage greater than 1%. In other words, the term "at least partially" refers to any amount of a whole. For example, "at least partially" may refer to a small portion, half, or a selected portion of a whole. In some cases, "at least partially" may refer to the whole amount. The term "partially" refers to any percentage less than 100%.

[0029] As used herein, the term "spaced apart" refers to elements that are disposed at a distance from one another. A plurality of elements that are spaced apart from one another means that adjacent elements of the plurality of elements are disposed at a distance from one another. A plurality of elements that are at least partially spaced apart from one another means that at least portions of adjacent elements of the plurality of elements are disposed at a distance from one another.

[0030] As used herein, the term "retroreflective" refers to the property of reflecting oblique incident light in a direction antiparallel or nearly antiparallel to the incident direction of the oblique incident light such that the light returns to the light source or a location immediately adjacent to the light source.

[0031] As used herein, the term "retroreflective segment" refers to one or more segments that include components and layers that impart retroreflective properties to the one or more segments.

[0032] As used herein, the term "removably bonded" means that two or more elements are attached to each other so that they can be separated or disconnected when desired.

[0033] As used herein, the term "fixedly bonded" means that two or more elements are attached to each other such that they are not intended to be separated or disconnected during normal use.

[0034] As used herein, the term "mesh layer" refers to a layer of porous material. The mesh layer may include strings, wires or threads woven into a network defining apertures or openings, or a sheet or film having apertures or openings cut, punched or otherwise formed therein.

[0035] As used herein, the term "percent open area" refers to the percentage of the area of ​​the mesh layer that is occupied by the open area of ​​the apertures or openings.

[0036] The term "microsphere" or "plurality of microspheres" refers to a population of micron-sized particles or individual particles having a high sphericity measurement, depending on the context in which the word is used. The sphericity measurement of a population of microspheres may range from about 80% to about 100%, with 95% being typical. The microspheres are substantially spherical, although a population of microspheres may include some individual particles having a lower sphericity measurement.

[0037] As used herein, the term "median diameter" refers to a distribution of diameters in which 50% of the particles are smaller than a given value.

[0038] As used herein, the term "garment" refers to an article that is put on and worn by a user in normal use. The term "garment" does not include any article that is itself attached to the garment.

[0039] As used herein, the term "exterior surface" of a garment refers to the surface that is mostly or completely visible when the garment is worn.

[0040] As used herein, the term "elastomer" is defined as a polymer having the ability to be stretched to at least twice its original length and to contract substantially to its original length when released (this definition is taken from "Haw's Concise Chemical Dictionary", RJ Lewis Sr. ed., 12th ed., Van Nostrand Reinhold Publishing Company, New York, 1993).

[0041] The present disclosure relates to retroreflective articles and methods for manufacturing retroreflective articles. The retroreflective article includes a mesh layer. The mesh layer includes a plurality of interconnected portions, a first mesh main surface, and a second mesh main surface opposite to the first mesh main surface, wherein a plurality of interconnected portions define a plurality of surrounded openings. The plurality of interconnected portions together form the first mesh main surface and the second mesh main surface. The retroreflective article also includes a bonding layer, which includes a plurality of bonding portions, which are at least partially spaced apart from each other by the mesh layer. Each bonding portion of the plurality of bonding portions is disposed in a corresponding surrounded opening of the plurality of surrounded openings, and is removably bonded from the plurality of interconnected portions to one or more adjacent interconnected portions. The second mesh main surface is adjacent to the bonding layer. The retroreflective article also includes a plurality of groups of optical elements corresponding to the plurality of bonding portions of the bonding layer. Each group of optical elements in each group of optical elements includes a plurality of optical elements, which are partially embedded in a corresponding bonding portion of the plurality of bonding portions of the bonding layer. The first mesh main surface is adjacent to each group of optical elements. Each group of optical elements is spaced apart from each other by one or more interconnected portions of the mesh layer. In some embodiments, the retroreflective article further includes an adhesive layer disposed opposite the plurality of optical elements.

[0042] The plurality of retroreflective segments may be at least partially formed within the plurality of encircled openings of the mesh layer. In other words, at least a portion of each of the plurality of retroreflective segments may be formed within the plurality of encircled openings of the mesh layer. Thus, the plurality of retroreflective segments may be at least partially separated from each other by the mesh layer. Each of the plurality of retroreflective segments may include one or more of a corresponding bonding portion, a set of corresponding optical elements, a portion of a reflective layer, and a portion of an interlayer.

[0043] The retroreflective article can be used to transfer or apply a plurality of retroreflective segments to clothing. Specifically, since a plurality of bonding portions are removably bonded to a plurality of interconnected portions of a mesh layer, a plurality of retroreflective segments can be applied to clothing via an adhesive layer. The mesh layer can then be removed.

[0044] In some cases, the plurality of bonding portions may be completely separated from each other by the mesh layer, and the adhesive layer may include a plurality of adhesive portions that are completely separated from each other by the mesh layer. In such cases, applying the plurality of retroreflective segments to a garment may result in gaps between adjacent ones of the plurality of retroreflective segments when the plurality of interconnected portions of the mesh layer are removed. Thus, the retroreflective article may be used to apply the plurality of retroreflective segments in a discontinuous manner, thereby providing enhanced breathability to the portion of the garment to which the plurality of retroreflective segments are applied.

[0045] Now refer to the figure, Figure 1 A schematic cross-sectional view of a retroreflective article 100 according to an embodiment of the present disclosure is illustrated.

[0046] Retroreflective article 100 defines mutually orthogonal x-, y-, and z-axes. The x-axis is defined along the length of retroreflective article 100, while the y-axis is defined along the width of retroreflective article 100. The z-axis is defined along the thickness of retroreflective article 100.

[0047] Retroreflective article 100 includes mesh layer 110. Mesh layer 110 is also shown in Figure 2 Reference Figure 1 and Figure 2 The mesh layer 110 includes a plurality of interconnected portions 112 defining a plurality of encircled openings 114 therebetween (in Figure 2 ). The mesh layer 110 may include any porous structure, ie, a structure including a plurality of apertures (ie, a plurality of surrounded openings 114).

[0048] In some cases, such a porous structure may inherently include a plurality of encircled openings 114 of the manufacturing process, and may not necessarily require any kind of post-processing to form the plurality of encircled openings 114. In some other cases, the plurality of encircled openings 114 may be formed on the structure by post-processing, such as mechanical perforation (e.g., by die cutting), water jet cutting, laser cutting, needle punching, etc. In such cases, the shape of the plurality of encircled openings 114 may be determined by the specific method and equipment used, such as circular, oval, square, hexagonal, etc. The mesh layer 110 may include a string, wire, or thread woven into a network defining a plurality of encircled openings 114. The mesh layer 110 may also include a sheet or film having a plurality of encircled openings 114 cut, stamped, or otherwise formed therein. For example, the mesh layer 110 may include a perforated polymer film, including, for example, polyester (e.g., polyethylene terephthalate), polyamide (e.g., hexamethylene adipamide, polycaprolactam), polypropylene, acrylic acid, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer and / or vinyl chloride-acrylonitrile copolymer. Perforation can be provided by die punching, needle punching, knife cutting, laser perforation and cutting, such as described in U.S. Patent Nos. 9,168,636 (Wald et al.) and 9,138,031 (Wood et al.), which are incorporated herein by reference in their entirety. Perforation can also be provided by applying a flame, a heat source or a pressurized fluid, such as described in U.S. Patent Application No. 2016 / 0009048A1 (Slama et al.) and U.S. Patent No. 7,037,100 (Strobel et al.), which are incorporated herein by reference in their entirety.

[0049] In some embodiments, the mesh layer 110 comprises a mesh fabric. For example, the plurality of interconnected portions 112 of the mesh layer 110 may comprise any suitable bondable yarn, such as a spun yarn (e.g., a spun yarn composed of cotton fibers and / or polyester fibers). The mesh fabric may comprise a knitted fabric, an open weave fabric, a woven mesh / screen (e.g., a wire mesh or a fiberglass mesh), an integral mesh (e.g., an integral continuous plastic screen), or a perforated impermeable (e.g., sealed) fabric.

[0050] like Figure 2 As shown, in some embodiments, the plurality of interconnected portions 112 may include a set of first members 112A oriented in a first direction. The plurality of interconnected portions 112 may also include a set of second members 112B oriented in a second direction different from the first direction. The first members 112A and the second members 112B may meet at the junction 113. Figure 2 In the illustrated embodiment, each first member in the set of first members 112A is oriented substantially along the y-axis. In addition, each second member in the set of second members 112B is oriented substantially along the x-axis. Thus, each of the plurality of surrounded openings 114 is oriented substantially along the x-axis. Figure 2 However, the plurality of interconnected portions 112 may include any number of members in any suitable configuration to define a plurality of encircled openings 114 that are, for example, circular, rhombic (e.g., diamond-shaped), pentagonal, hexagonal, etc. In other words, many variations of the mesh layer 110 are possible, involving members oriented in more than two directions, such as the first member 112A and the second member 112B, in a direction with Figure 2 The joint 113 is relatively complex compared to the components that meet at the joint.

[0051] In some embodiments, the mesh layer 110 may have a percent open area of ​​at least 70%. In other words, in some embodiments, the plurality of encircled openings 114 may occupy at least 70% of the total area of ​​the mesh layer 110. In one embodiment, the plurality of encircled openings 114 may occupy 75% of the total area of ​​the mesh layer 110, and the plurality of interconnected portions 112 may occupy 25% of the total area of ​​the mesh layer 110.

[0052] The mesh layer 110 further includes a first mesh main surface 110A and a second mesh main surface 110B opposite to the first mesh main surface 110A. Specifically, a plurality of interconnected portions 112 together form the first mesh main surface 110A and the second mesh main surface 110B. In other words, the first mesh main surface 110A and the second mesh main surface 110B are formed by a plurality of interconnected portions 112.

[0053] The mesh layer 110 defines a thickness 110T along the z-axis between the first mesh major surface 110A and the second mesh major surface 110B. The thickness 110T can be selected based on the desired application properties. In one embodiment, the thickness 110T can be selected so that the mesh layer 110 can be the thickest layer of the retroreflective article 100. In some embodiments, the thickness 110T can be about 0.05 (millimeter) mm to about 2.5 mm. The thickness 110T can be about 0.05 (millimeter) mm to about 2.5 mm. Figure 1 and Figure 2 10 is shown as uniform, however, the thickness 110T of the mesh layer 110 may vary along the length (along the x-axis) and / or the width (along the y-axis) of the mesh layer 110. In some embodiments, the thickness 110T of the mesh layer 110 may vary from about 0.05 mm to about 2.5 mm along the length and / or width of the mesh layer 110.

[0054] The retroreflective article 100 also includes a bonding layer 120. The bonding layer 120 includes a plurality of bonding portions 122 that are at least partially spaced apart from each other by the mesh layer 110. In addition, each of the plurality of bonding portions 122 is at least partially disposed within a corresponding surrounded opening 114 of the plurality of surrounded openings 114. Specifically, at least portions of adjacent bonding portions 122 may be spaced apart from each other by corresponding interconnecting portions 112 of the plurality of interconnecting portions 112 of the mesh layer 110. Therefore, at least one interconnecting portion 112 of the plurality of interconnecting portions 112 may be disposed between adjacent bonding portions 122 of the plurality of bonding portions 122.

[0055] Each of the plurality of bonding portions 122 is removably bonded to an adjacent one or more interconnected portions 112 of the plurality of interconnected portions 112 of the mesh layer 110. In other words, each of the plurality of bonding portions 122 can be configured to be debonded or broken from the adjacent one or more interconnected portions 112 when desired. During use of the retroreflective article 100, the plurality of bonding portions 122 are intended to be debonded or broken from the plurality of interconnected portions 112. For example, the plurality of bonding portions 122 can be debonded or broken from the plurality of interconnected portions 112 in order to transfer one or more retroreflective segments to a garment. Retroreflective segments will be discussed in more detail below.

[0056] exist Figure 1 In the illustrated embodiment, each of the plurality of bonding portions 122 is spaced apart from the first mesh major surface 110A along the thickness 110T of the mesh layer 110. Figure 1 As shown, each of the plurality of bonding portions 122 is disposed below the first mesh main surface 110A. In addition, the second mesh main surface 110B is adjacent to the bonding layer 120. In other words, the second mesh main surface 110B is adjacent to each of the plurality of bonding portions 122 of the bonding layer 120. In addition, Figure 1 In the illustrated embodiment, each of the plurality of bonding portions 122 is spaced apart from the second mesh major surface 110B along the thickness 110T of the mesh layer 110. Figure 1 As shown, each of the plurality of bonding portions 122 is disposed along the thickness 110T of the mesh layer 110 between the first mesh major surface 110A and the second mesh major surface 110B.

[0057] In some embodiments, the bonding layer 120 may include greater than 20% by weight of a polymer binder. In some embodiments, the bonding layer 120 includes a colorant and a polymer binder. Specifically, in some embodiments, the bonding layer 120 may include a flexible polymer binder material that is colored in some manner. The bonding layer 120 may also include additives such as UV stabilizers, antioxidants, UV absorbers, property modifiers, performance enhancers, or combinations thereof.

[0058] The polymer binder of the bonding layer 120 may include but is not limited to elastomers. Specifically, the polymer binder material includes cross-linked or virtual cross-linked elastomers. Cross-linked elastomers mean that the polymer chains of the elastomer are chemically cross-linked to form a three-dimensional network that becomes stable when encountering molecular flow. Virtual cross-linked elastomers mean that the mobility of the polymer chains of the elastomer is greatly reduced via chain entanglement and / or via hydrogen bonding, resulting in an increase in the cohesive strength or internal strength of the polymer. Examples of such polymer cross-linking include carbon-carbon bond formation, such as: free radical bonding between vinyl groups between chains; reagent or group coupling, such as by vulcanization or reaction with a coupling agent, the coupling agent such as diols for isocyanate or epoxy functionalized polymers; diisocyanates or activated esters for amine and alcohol functionalized polymers; and epoxides and diols for carboxylic acid or anhydride functionalized polymers. Examples of such virtual cross-linking include amide hydrogen bonding as found in polyamides, or crystalline and amorphous regions as found in block copolymers of styrene and acrylonitrile.

[0059] Examples of polymers that can be used in polymer binders include polyolefins, polyesters, polyurethanes, polyepoxides, polyacrylates, natural and synthetic rubbers, and combinations thereof. Examples of crosslinked polymers include the aforementioned examples of polymers substituted with crosslinkable groups such as epoxy groups, olefin groups, isocyanate groups, alcohol groups, amine groups, anhydride groups, or acrylic acid groups. Multifunctional monomers and oligomers that react with the functional groups of polymers can also be used as crosslinking agents.

[0060] Specific examples of materials for bonding layer 120 are disclosed in U.S. Pat. Nos. 5,200,262 and 5,283,101, the disclosures of which are incorporated herein in their entirety. In the '262 patent, the material for bonding layer 120 comprises one or more flexible polymers having active hydrogen functional groups such as a cross-linked urethane-based polymer (e.g., one of an isocyanate-cured polyester or a two-component polyurethane) and one or more isocyanate-functional silane coupling agents. In the '101 patent, the material for bonding layer 120 comprises an electron beam cured polymer selected from the group consisting of chlorosulfonated polyethylene, an ethylene copolymer comprising at least about 70% by weight polyethylene, and a poly(ethylene-co-propylene-co-diene) polymer.

[0061] Retroreflective article 100 also includes a plurality of groups 131 of optical elements 130 corresponding to the plurality of bonding portions 122 of bonding layer 120. Each of groups 131 of optical elements 130 includes a plurality of optical elements 130 partially embedded within a corresponding bonding portion 122 of the plurality of bonding portions 122 of bonding layer 120.

[0062] The groups 131 of optical elements 130 are spaced apart from each other by one or more interconnecting portions 112 of the mesh layer 110. Therefore, each of the groups 131 of optical elements 130 is discrete and disposed between adjacent interconnecting portions 112. The groups 131 of optical elements 130 are disposed proximate to the first mesh major surface 110A. In other words, the first mesh major surface 110A is proximate to the groups 131 of optical elements 130.

[0063] This arrangement of retroreflective article 100 is therefore distinguishable from, for example, approaches in which mesh layer 110 is not disposed between plurality of bonding portions 122 and group 131 of optical elements 130. Additionally, plurality of optical elements 130 are not present on first mesh major surface 110A of mesh layer 110.

[0064] exist Figure 1In the illustrated embodiment, the retroreflective article 100 further includes a reflective layer 140 disposed adjacent to a surface 132 of at least some of the plurality of optical elements 130 that faces the bonding layer 120. The surface 132 to which the reflective layer 140 is disposed adjacent faces the bonding layer 120. Thus, in some embodiments, the reflective layer 140 is at least partially disposed between the plurality of optical elements 130 and the bonding layer 120. In one embodiment, the reflective layer 140 may be disposed adjacent to the surface 132 via vapor deposition. During vapor deposition, in some cases, the reflective layer 140 may be further disposed on the second mesh major surface 110B of the mesh layer 110. Alternatively, in some embodiments, reflective particles (such as pearlescent pigments) may be added to the bonding layer 120, such as described in U.S. Pat. No. 32,28,897 (Nellessen), which is incorporated herein in its entirety. In these embodiments, the reflective layer 140 is located within the bonding layer 120.

[0065] The plurality of optical elements 130 and the reflective layer 140 can collectively return a large amount of incident light toward the light source. That is, the light entering and passing through the plurality of optical elements 130 is reflected by the reflective layer 140 to re-enter the plurality of optical elements 130 again, so that the light is guided in a general manner represented by the term "retroreflection" to return toward the light source.

[0066] In some embodiments, each optical element in the plurality of optical elements 130 comprises a transparent microsphere. In some embodiments, each optical element in the plurality of optical elements 130 may comprise glass. For example, each optical element in the plurality of optical elements 130 may be a transparent microsphere substantially made of glass. In some embodiments, each optical element in the plurality of optical elements 130 has a diameter 130D. The diameter 130D of the plurality of optical elements 130 has a median diameter (D50). In some embodiments, the median diameter of the plurality of optical elements may be from about 0.015 mm to about 0.2 mm. In some embodiments, the median diameter is about 0.05 mm, about 0.06 mm, about 0.07 mm, about 0.08 mm, about 0.09 mm, about 0.1 mm, about 0.12 mm, about 0.14 mm, about 0.16 mm, or about 0.18 mm.

[0067] In some embodiments, the reflective layer 140 includes a metal mirror or a dielectric mirror. The metal mirror may include an elemental metal in pure or alloy form that is capable of reflecting light, preferably specularly reflecting light. The metal may be a continuous coating produced by vacuum deposition, vapor coating, chemical deposition, or electroless plating. In some embodiments, the metal mirror may be printed or transferred, as disclosed in U.S. Patent Application Publication No. 20200264349 (Chen-Ho et al.), which is incorporated herein by reference in its entirety. The metal mirror of the reflective layer 140 may have a thickness (along the z-axis) ranging from about 10 nanometers (nm) to about 500 nm.

[0068] A variety of metals can be used to provide specularly reflective metal mirrors. These metals include aluminum, silver, chromium, nickel, magnesium, gold, tin, etc. (in elemental form). Aluminum and silver are preferred metals for metal mirrors because they tend to provide good retroreflective brightness. In the case of aluminum and silver, some metals may be in the form of metal oxides and / or metal hydroxides.

[0069] Dielectric mirrors may also be referred to as dichroic mirrors, Bragg reflectors, one-dimensional photonic crystals, or visible light reflectors (VLRs, i.e., when tuned to partially transmit and partially reflect light in the visible spectrum (i.e., from 400 nm to 700 nm), each of which is generally understood by those skilled in the art to at least partially reflect light within a desired wavelength band by employing alternating high and low refractive index layers. Dielectric mirrors may be at least partially reflective and at least partially transparent. The term dielectric is used to refer to non-metallic materials and non-conductive materials.

[0070] Typically, the dielectric mirror has a multilayer construction. For example, the dielectric mirror may include multiple layers deposited, for example, by layer-by-layer self-assembly. The dielectric mirror may include alternating optical thin film stacks with different refractive indices (RI) (e.g., "high" RI and "low" RI). The interface between the stacks with different RIs produces a step-by-step reflection, selectively enhancing certain wavelengths (constructive interference) and canceling other wavelengths (destructive interference). By selecting certain variables such as stack thickness, refractive index, and number of layers, the spectral band of reflected and / or transmitted wavelengths can be tuned and made as wide or as narrow as desired. The dielectric mirror of the reflective layer 140 may have a thickness (along the z-axis) ranging from about 10 nanometers nm to about 500 nm.

[0071] exist Figure 1In the illustrated embodiment, retroreflective article 100 further includes an interlayer 145 at least partially disposed between the plurality of optical elements 130 and the reflective layer 140. In some embodiments, interlayer 145 can have a thickness (along the z-axis) of about 5 nm to about 0.03 mm. In some embodiments, interlayer 145 can have varying thicknesses along the length and / or width of retroreflective article 100, i.e., its thickness can be zero or can approach zero. However, interlayer 145 can preferably be continuous or substantially continuous.

[0072] Interlayer 145 may include a polymer material. Interlayer 145 may preferably include a polymer linked to a silane coupling agent. In some embodiments, the polymer is preferably a cross-linked polymer. Examples of polymers that may be suitable for interlayer 145 include those containing units of urethane, ester, ether, urea, epoxy, carbonate, acrylate, acrylic acid, olefin, vinyl chloride, amide, alkyd resin, or a combination thereof.

[0073] The polymer used in interlayer 145 may have functional groups that allow the polymer to be linked to the silane coupling agent, or the reactants that form the polymer may have such functional groups. For example, in the preparation of polyurethanes, the starting materials may have hydrogen-containing functional groups that are capable of reacting with isocyanate-functional silane coupling agents; see, for example, U.S. Patent No. 5,200,262 to Li, which is incorporated herein by reference in its entirety. Preferred polymers are cross-linked poly(urethane-ureas) and cross-linked poly(acrylates).

[0074] Poly(urethane-ureas) can be formed by reacting a hydroxyl-functional polyester resin with an excess of polyisocyanate. Alternatively, a polyoxypropylene glycol can be reacted with a diisocyanate and then with a functionalized triaminopolypropylene oxide. Crosslinked poly(acrylates) can be formed by exposing acrylate oligomers to electron beam radiation; see, e.g., U.S. Pat. No. 5,283,101 to Li, which is incorporated herein by reference in its entirety.

[0075] In some embodiments, retroreflective article 100 further includes adhesive layer 150. Figure 1 In the illustrated embodiment, the adhesive layer 150 includes a plurality of adhesive portions 152 that are at least partially spaced apart from each other by the mesh layer 110. Specifically, the plurality of adhesive portions 152 may be at least partially spaced apart from each other by one or more interconnecting portions 112 of the mesh layer 110. In addition, each adhesive portion of the plurality of adhesive portions 152 is at least partially disposed on a corresponding bonding portion 122 of the plurality of bonding portions 122 opposite the plurality of optical elements 130.

[0076] Each adhesive portion of the plurality of adhesive portions 152 is at least partially disposed within a corresponding encircled opening 114 of the plurality of encircled openings 114 of the mesh layer 110. Figure 1 In the illustrated embodiment, each adhesive portion of the plurality of adhesive portions 152 is spaced apart from one another and disposed between the first mesh major surface 110A and the second mesh major surface 110B of the mesh layer 110. However, in some other embodiments, some of the plurality of adhesive portions 152 may extend beyond the second mesh major surface 110B of the mesh layer 110. The adhesive layer 150 may be applied, for example, by liquid coating, spraying, extrusion, lamination, and the like.

[0077] Adhesive layer 150 comprises adhesive.In some embodiments, adhesive is one of pressure-sensitive adhesive and hot-melt adhesive.In some embodiments, adhesive can comprise the combination of pressure-sensitive adhesive, heat-activated adhesive, laminating adhesive or different types of adhesive.Various pressure-sensitive adhesives are suitable, comprise tackifying natural rubber, synthetic rubber, tackifying styrene block copolymer, polyvinyl ether, poly (methyl) acrylate, polyurethane, polyurea, poly-alpha-olefin and silicone.Pressure-sensitive adhesive can be covered with release liner, to protect adhesive before being adhered to substrate.Heat-activated adhesive is similar to pressure-sensitive adhesive but needs to apply heat to become tacky.An advantage of heat-activated adhesive is that they do not need release liner usually to protect adhesive layer before being adhered to substrate, because they can not be tacky at room temperature.The example of laminating adhesive comprises hot-melt adhesive, adhesive dispersion and suspension, and curing adhesive such as cyanoacrylate.

[0078] The plurality of retroreflective segments 170 may be at least partially formed within the plurality of encircled openings 114 of the mesh layer 110. In other words, at least a portion of each of the plurality of retroreflective segments 170 may be formed within the plurality of encircled openings 114 of the mesh layer 110. Thus, the plurality of retroreflective segments 170 may be at least partially spaced apart from one another by the mesh layer 110. Each of the plurality of retroreflective segments 170 may include one or more of a corresponding bonding portion 122, a corresponding group 131 of optical elements 130, a portion of the reflective layer 140, and a portion of the interlayer 145.

[0079] Retroreflective article 100 can be used to transfer or apply multiple retroreflective segments 170 to clothing. Specifically, since multiple bonding portions 122 are removably bonded to multiple interconnecting portions 112, multiple retroreflective segments 170 can be applied to clothing via adhesive layer 150. Mesh layer 110 can then be removed.

[0080] In some embodiments, such as Figure 1As shown, the plurality of bonding portions 122 may be completely separated from each other by the mesh layer 110, and the plurality of adhesive portions 152 of the adhesive layer 150 may be completely separated from each other by the mesh layer 110. In such embodiments, when the mesh layer 110 is removed, the application of the plurality of retroreflective segments 170 to the garment may create gaps between adjacent ones of the plurality of retroreflective segments 170 (due to the removal of the plurality of interconnecting portions 112). Thus, the retroreflective article 100 may be used to apply the plurality of retroreflective segments 170 in a discontinuous manner, thereby providing enhanced breathability to the portion of the garment on which the plurality of retroreflective segments 170 are applied. It should be understood that in the actual industrial production of the retroreflective article 100, there may be unavoidable small-scale statistical fluctuations, which may result in a small amount of bonding layer 120 and / or adhesive layer 150 being present on the second mesh major surface 110B. In any actual life production process, such occasional occurrences would be expected; however, as described above, the bonding layer 120 and / or adhesive layer 150 of the retroreflective article 100 is different from the case where the bonding layer 120 and / or adhesive layer 150 are purposefully arranged in a continuous manner (i.e., portions of them are not separated from each other by the mesh layer 110).

[0081] Figure 3 A schematic cross-sectional view of a retroreflective article 101 according to another embodiment of the present disclosure is illustrated. Retroreflective article 101 is similar to Figure 1 Retroreflective article 100, wherein like elements are represented by like reference numerals. Figure 1 Compared to the retroreflective article 100 of FIG. 1 , the retroreflective article 101 has a different configuration of the bonding layer 120 and the adhesive layer 150. Specifically, in Figure 3 In the illustrated embodiment, each of the plurality of bonding portions 122 extends beyond the second mesh major surface 110B of the mesh layer 110 along the thickness 110T of the mesh layer 110. In other words, Figure 3 In the embodiment shown, the bonding layer 120 is further disposed on the second mesh major surface 110B of the mesh layer 110. Figure 3 In the illustrated embodiment, the adhesive layer 150 is substantially continuous and is disposed on the bonding layer 120 opposite the plurality of optical elements 130 .

[0082] Figure 4 A schematic cross-sectional view of a retroreflective article 200 according to another embodiment of the present disclosure is illustrated. Retroreflective article 200 is similar to Figure 1 1, wherein like elements are denoted by like reference numerals. However, the retroreflective article 200 further includes a carrier layer 160. Figure 4In the illustrated embodiment, the carrier layer 160 includes a liner 161 and a carrier bonding layer 162 that removably bonds the liner 161 to at least the mesh layer 110. In some embodiments, the carrier bonding layer 162 may include a polymer (e.g., polyethylene). In addition, the liner 161 may include any suitable material (e.g., a paper material) on which the carrier bonding layer 162 may be disposed.

[0083] In some embodiments, the bond strength between carrier bonding layer 162 and mesh layer 110 can be greater than the bond strength between plurality of bonding portions 122 and plurality of interconnecting portions 112. Thus, after retroreflective segments 170 are applied to a garment using retroreflective article 200, removing carrier layer 160 can further remove mesh layer 110.

[0084] Figure 5 0 illustrates a schematic cross-sectional view of a retroreflective article 300 according to another embodiment of the present disclosure. Figure 1 Elements of retroreflective article 300 that are identical to retroreflective article 100 are represented by the same reference numerals.

[0085] exist Figure 5 In the illustrated embodiment, the retroreflective article 300 includes a carrier layer 160. The retroreflective article 300 also includes a plurality of retroreflective segments 170 that are removably bonded to the carrier layer 160 and spaced apart from one another. Figure 5 As shown, adjacent retroreflective segments 170 of the plurality of retroreflective segments are spaced apart from each other by a gap G. In this embodiment, the bonding strength between the carrier bonding layer 162 and the plurality of retroreflective segments 170 may be greater than the bonding strength between the carrier bonding layer 162 and the mesh layer 110 (eg, Figure 8G The bonding strength between the retroreflective segments 170 and the mesh layer 110 can be increased by 10%. Therefore, the mesh layer 110 can be removed from the rest of the retroreflective article 300 to form the gap G. Figure 5 In the illustrated embodiment, each retroreflective segment 170 includes a corresponding group 131 of optical elements 130, a corresponding bonding portion 122 of bonding layer 120, a reflective layer 140, an interlayer 145, and a corresponding adhesive portion 152 of adhesive layer 150. Figure 5 In the illustrated embodiment, carrier bonding layer 162 of carrier layer 160 is removably bonded to plurality of optical elements 130. Thus, after retroreflective segments 170 are applied to a garment using retroreflective article 300, carrier layer 160 can be removed from plurality of optical elements 130.

[0086] FIG. 6A to FIG. 6D The process of using the retroreflective article of the present disclosure is schematically illustrated. Specifically, FIG. 6A to FIG. 6DThe process of transferring retroreflective segments 170 to an outer surface 401 of a garment 400 is schematically illustrated. The garment 400 may take the form of, for example, a jacket, a shirt (long sleeve or short sleeve), a pair of pants, a pair of shoes, work clothes, etc. For purposes of explanation, the process will be described with reference to retroreflective article 100, however, similar concepts may be applied to Figure 3 Retroreflective products 101, Figure 4 Retroreflective article 200 and Figure 5 Retroreflective article 300.

[0087] like Fig. 6A As shown, retroreflective article 100 may be disposed on exterior surface 401 of garment 400 such that second mesh major surface 110B of mesh layer 110 may contact or engage exterior surface 401 and adhesive layer 150 may be adjacent exterior surface 401 .

[0088] like Figure 6B As shown, retroreflective article 100 and / or plurality of retroreflective segments 170 may be pressed onto garment 400 such that adhesive layer 150 contacts exterior surface 401 of garment 400. Subsequently, adhesive layer 150 may be bonded to exterior surface 401 of garment 400. Specifically, each of plurality of adhesive portions 152 of adhesive layer 150 may be bonded to exterior surface 401 of garment 400. In some embodiments, adhesive layer 150 may be bonded to exterior surface 401 via application of heat, i.e., via heat lamination.

[0089] As discussed above, each of the plurality of bonding portions 122 is removably bonded to an adjacent one or more interconnecting portions 112 of the plurality of interconnecting portions 112. Figure 6C As shown, after bonding the adhesive layer 150 to the outer surface 401 , the mesh layer 110 may be removed such that the plurality of retroreflective segments 170 are attached to the outer surface 401 .

[0090] for Figure 4 For a retroreflective article 200, the carrier layer 160 may be removed before or simultaneously with the removal of the mesh layer 110, so that the plurality of retroreflective segments 170 are attached to the outer surface 401. Figure 5 In the retroreflective article 300 , the carrier layer 160 may be removed such that the plurality of retroreflective segments 170 are attached to the outer surface 401 .

[0091] Fig.6D A plurality of retroreflective segments 170 are shown transferred from retroreflective article 100 to garment 400. In addition, retroreflective segments 170 are spaced apart from one another. In other words, a plurality of retroreflective segments 170 may be transferred in a discontinuous manner, thereby providing enhanced breathability to the portion of garment 400 on which the plurality of retroreflective segments 170 are applied.

[0092] Figure 7A flow chart depicting various steps of a method 500 for making a retroreflective article is illustrated. The method 500 may be used to make Figure 1 The method 500 can be further used to manufacture a retroreflective article 100. Figure 3 The method 500 can be further used to manufacture a retroreflective article 101. Figure 4 The method 500 can be further used to manufacture a retroreflective article 200. Figure 5 The various steps of method 500 are also FIG. 8A to FIG. 8G Reference will be made to Figure 5 , Figure 7 , FIG. 8A to FIG. 8G Method 500 is described.

[0093] At step 502 , method 500 includes providing a carrier layer. For example, method 500 may include providing carrier layer 160 .

[0094] like Fig. 8A As shown, in some embodiments, the carrier layer 160 includes a liner 161 and a carrier bonding layer 162. The carrier bonding layer 162 can be disposed on the liner 161. The carrier bonding layer 162 can be configured to at least temporarily bond with the mesh layer 110. In some embodiments, the carrier bonding layer 162 can include a polymer (e.g., polyethylene). In addition, the liner 161 can include any suitable material (e.g., a paper material) on which the carrier bonding layer 162 can be disposed.

[0095] At step 504, method 500 further includes disposing a mesh layer on a carrier layer. The mesh layer includes a plurality of interconnected portions, a first mesh major surface, and a second mesh major surface opposite the first mesh major surface, wherein the plurality of interconnected portions define a plurality of surrounded openings therebetween. The plurality of interconnected portions together form the first mesh major surface and the second mesh major surface. The first mesh major surface is disposed on the carrier layer. For example, Fig. 8A As shown, the mesh layer 110 may include a plurality of interconnected portions 112, wherein a plurality of surrounding openings 114 are defined between the plurality of interconnected portions. The mesh layer 110 may include a first mesh major surface 110A and a second mesh major surface 110B opposite to the first mesh major surface 110A. The plurality of interconnected portions 112 may together form the first mesh major surface 110A and the second mesh major surface 110B. Figure 8B As shown, the method 500 may include disposing the mesh layer 110 on the carrier layer 160. Specifically, the method 500 may include disposing the first mesh major surface 110A of the mesh layer 110 on the carrier layer 160.

[0096] In some embodiments, disposing the mesh layer on the carrier layer further comprises bonding the carrier layer to the mesh layer. The carrier layer can be removably bonded or fixedly bonded to the mesh layer. For example, disposing the mesh layer 110 on the carrier layer 160 may comprise bonding the carrier layer 160 to the mesh layer 110. The bond strength between the carrier bonding layer 162 and the mesh layer 110 may be greater than the bond strength between the plurality of bonding portions 122 and the plurality of interconnecting portions 112.

[0097] Specifically, the carrier bonding layer 162 can be bonded to the mesh layer 110 and prevent undesirable delamination of the mesh layer 110 from the carrier layer 160 during the manufacturing process of the retroreflective article. The mesh layer 110 can be bonded to the carrier bonding layer 162 by heat lamination.

[0098] At step 506, method 500 further includes placing a plurality of optical elements within the plurality of enclosed openings of the mesh layer. Figure 8C As shown, the method 500 may include disposing a plurality of optical elements 130 within a plurality of encircled openings 114 of the mesh layer 110 .

[0099] In some embodiments, disposing the plurality of optical elements within the plurality of encircled openings further comprises disposing the plurality of optical elements on a carrier layer. For example, disposing the plurality of optical elements 130 within the plurality of encircled openings 114 may comprise disposing the plurality of optical elements 130 on a carrier layer 160. The carrier bonding layer 162 of the carrier layer 160 is capable of removably bonding to the plurality of optical elements 130 and preventing undesired delamination of the plurality of optical elements 130 from the carrier layer 160 during manufacture of the retroreflective article. The plurality of optical elements 130 may be removably bonded to the carrier bonding layer 162 by heat. Advantageously, the mesh layer 110 may protect the plurality of optical elements 130 during manufacture. Specifically, the mesh layer 110 may prevent delamination and loss of some of the plurality of optical elements 130 due to abrasion / static electricity generated by winding and unwinding during manufacture.

[0100] At step 508, method 500 also includes providing a bonding layer adjacent to the plurality of optical elements in the plurality of encircled openings of the mesh layer opposite the carrier layer, such that the plurality of optical elements are partially embedded in the bonding layer. The bonding layer includes a plurality of bonding portions that are at least partially spaced apart from each other by the mesh layer. Each of the plurality of bonding portions is at least partially disposed within a corresponding encircled opening of the plurality of encircled openings. Each of the plurality of bonding portions is spaced apart from the first mesh major surface along the thickness of the mesh layer. The bonding layer is removably bonded to the plurality of interconnected portions of the mesh layer.

[0101] For example, Fig.8FAs shown, the method 500 may include providing a bonding layer 120 adjacent to the plurality of optical elements 130 in the plurality of encircled openings 114 of the mesh layer 110 opposite the carrier layer 160, such that the plurality of optical elements 130 are partially embedded in the bonding layer 120. The bonding layer 120 may include a plurality of bonding portions 122 that are at least partially spaced apart from each other by the mesh layer 110. Each bonding portion of the plurality of bonding portions 122 may be at least partially disposed in a corresponding encircled opening 114 of the plurality of encircled openings 114. Each bonding portion of the plurality of bonding portions 122 may be disposed along a thickness 110T ( Figure 1 The bonding layer 120 can be removably bonded to the plurality of interconnected portions 112 of the mesh layer 110. After the bonding layer 120 is dried, the thickness of the bonding layer 120 can be reduced.

[0102] In some embodiments, method 500 further includes providing a reflective layer adjacent to surfaces of at least some of the plurality of optical elements prior to providing the bonding layer, such that the reflective layer is at least partially disposed between the bonding layer and the plurality of optical elements. Fig. 8E As shown, the method 500 may include providing a reflective layer 140 adjacent to the surface 132 of at least some of the plurality of optical elements 130 before providing the bonding layer 120, such that the reflective layer 140 is at least partially disposed between the bonding layer 120 and the plurality of optical elements 130. The reflective layer 140 may be provided, for example, via vapor deposition. Thus, in some embodiments, the method 500 further includes providing the reflective layer on the second mesh major surface of the mesh layer. For example, the method 500 may further include providing the reflective layer 140 on the second mesh major surface 110B of the mesh layer 110.

[0103] In some embodiments, method 500 further includes providing an interlayer on at least some of the plurality of optical elements before providing the reflective layer. Fig.8D As shown, the method 500 may include providing an interlayer 145 on at least some of the plurality of optical elements 130 prior to providing the reflective layer 140 .

[0104] In some embodiments, the bonding layer is disposed adjacent to the plurality of optical elements such that each of the plurality of bonding portions is spaced apart from the second mesh major surface along the thickness of the mesh layer. For example, the bonding layer 120 can be disposed adjacent to the plurality of optical elements 130 such that each of the plurality of bonding portions 122 is spaced apart from the second mesh major surface along the thickness 110T ( Figure 1 In such embodiments, the bonding layer 120 may be disposed between the first mesh major surface 110A and the second mesh major surface 110B of the mesh layer 110.

[0105] In some embodiments, method 500 further includes providing an adhesive layer on at least one of the second mesh major surface of the mesh layer and the bonding layer opposite the plurality of optical elements. Figure 8G As shown, the method 500 may further include providing an adhesive layer 150 on at least one of the second mesh major surface 110B of the mesh layer 110 and the bonding layer 120 opposite to the plurality of optical elements 130. Fig. 9A As shown, a retroreflective article 200 can be manufactured.

[0106] In some embodiments, method 500 further includes adhering the retroreflective article (eg, via adhesive layer 150) to a substrate (eg, a garment) prior to removing the carrier layer and the mesh layer from the remainder of the retroreflective article.

[0107] In some embodiments, during use of the retroreflective article, the carrier layer 160 and the mesh layer 110 may be removed together. This may occur when the bond strength between the carrier layer 160 and the mesh layer 110 is greater than the bond strength between the carrier layer 160 and the retroreflective segments 170 or the bond strength between the mesh layer 110 and the retroreflective segments 170. This method is particularly useful after the retroreflective article is laminated to a fabric. After the carrier layer 160 and the mesh layer 110 are removed together, the retroreflective segments 170 remain on the fabric.

[0108] In some embodiments, method 500 further includes removing the mesh layer from the remainder of the retroreflective article such that after the mesh layer is removed, the plurality of optical elements and the plurality of bonding portions are removably bonded to the carrier layer. When the plurality of bonding portions of the bonding layer are completely separated from each other by the mesh layer and the plurality of adhesive portions of the adhesive layer are completely separated from each other by the mesh layer, after the mesh layer is removed from the remainder of the retroreflective article, the plurality of optical elements and the plurality of bonding portions can be removably bonded to the carrier layer. Additionally, when the bond strength between the plurality of optical elements and the carrier layer is greater than the bond strength between the bond layer and one or more interconnected portions of the mesh layer or the bond strength between the carrier layer and the interconnected portions of the mesh layer, the plurality of optical elements and the plurality of bonding portions can be removably bonded to the carrier layer.

[0109] For example, in some embodiments, method 500 may include removing mesh layer 110 from the remainder of the retroreflective article such that after mesh layer 110 is removed, plurality of optical elements 130 and plurality of bonding portions 122 are removably bonded to carrier layer 160. In such cases, as Fig. 9B As shown, a retroreflective article 300 can be manufactured.

[0110] In some other embodiments, the method 500 further includes removing the carrier layer from the remainder of the retroreflective article such that after the carrier layer is removed, the plurality of optical elements and the plurality of bonding portions are removably bonded to adjacent one or more interconnected portions of the plurality of interconnected portions of the mesh layer. The plurality of optical elements and the plurality of bonding portions are removably bonded to adjacent one or more interconnected portions of the plurality of interconnected portions of the mesh layer when the bonding strength between the plurality of bonding portions and the one or more interconnected portions of the mesh layer is greater than the bonding strength between the plurality of optical elements and the carrier layer or the bonding strength between the interconnected portions of the mesh layer and the carrier layer.

[0111] For example, method 500 may include removing carrier layer 160 from the remainder of the retroreflective article such that after removing carrier layer 160, plurality of optical elements 130 and plurality of bonding portions 122 are removably bonded to adjacent one or more interconnected portions 112 of plurality of interconnected portions 112 of mesh layer 110. In this case, as Fig. 9C As shown, a retroreflective article 100 can be formed.

[0112] In some embodiments, the method 500 further includes flattening at least one of the first mesh major surface and the second mesh major surface of the mesh layer before disposing the mesh layer on the carrier layer. For example, the method 500 may further include flattening at least one of the first mesh major surface 110A and the second mesh major surface 110B of the mesh layer 110 before disposing the mesh layer 110 on the carrier layer 160. The mesh layer 110 may be flattened by heat / pressure or by extrusion to prevent the mesh layer 110 from entangled with the bonding layer 120 and / or the adhesive layer 150.

[0113] The mesh layer 110 may be thick enough (ie, Figure 1 The thickness 110T shown may be large enough) to prevent the bonding layer 120 and the adhesive layer 150 from bridging over the second mesh major surface 110B during manufacturing. The mesh layer 110 may have a low surface energy (e.g., a nylon monofilament mesh or other mesh coated with a low adhesion layer may be used) to facilitate separation from the bonding layer 120 and the adhesive layer 150 when desired. Suitable materials for the mesh layer 110 may include plastics such as polypropylene, polyethylene, etc. and metals such as stainless steel, with a suitable low adhesion coating on its surface as needed.

[0114] Method 500 may require the use of less material (e.g., multiple optical elements 130, bonding layer 120, and adhesive layer 150) to manufacture a retroreflective article, and further reduce material waste. In addition, method 500 may allow the mesh layer 110 to be reused to form a retroreflective article. Therefore, method 500 may be more sustainable than conventional methods of manufacturing retroreflective articles.

[0115] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and the appended claims are approximations that may vary depending upon the desired properties sought to be obtained by one skilled in the art utilizing the teachings disclosed herein.

[0116] Although specific embodiments have been illustrated and described herein, it will be appreciated by those skilled in the art that the specific embodiments shown and described may be replaced with a variety of alternative and / or equivalent implementations without departing from the scope of the present disclosure. The present application is intended to cover any modifications or variations of the specific embodiments discussed herein. Therefore, the present disclosure is intended to be limited only by the claims and their equivalents.

Claims

1. A retroreflective article, comprising: a mesh layer, the mesh layer comprising a plurality of interconnected portions, a first mesh major surface, and a second mesh major surface opposite the first mesh major surface, the plurality of interconnected portions defining a plurality of surrounded openings therebetween, the plurality of interconnected portions together forming the first mesh major surface and the second mesh major surface; a bonding layer comprising a plurality of bonding portions at least partially spaced apart from one another by the mesh layer, wherein each bonding portion of the plurality of bonding portions is disposed within a corresponding one of the plurality of encircled openings and is removably bonded to an adjacent one or more interconnected portions of the plurality of interconnected portions of the mesh layer, and wherein the second mesh major surface is proximate to the bonding layer; and A plurality of groups of optical elements, the plurality of groups of optical elements corresponding to the plurality of bonding portions of the bonding layer, wherein each group of optical elements in the plurality of groups of optical elements comprises a plurality of optical elements partially embedded within corresponding bonding portions of the plurality of bonding portions of the bonding layer, wherein the first mesh major surface is adjacent to the plurality of groups of optical elements, and wherein the plurality of groups of optical elements are spaced apart from each other by the one or more interconnecting portions of the mesh layer.

2. The retroreflective article of claim 1, wherein each of the plurality of bonding portions is spaced apart from the first mesh major surface along a thickness of the mesh layer.

3. The retroreflective article of claim 1, further comprising: A carrier layer includes a liner and a carrier bonding layer, wherein the carrier bonding layer bonds the liner to the mesh layer.

4. The retroreflective article of claim 1, further comprising: An adhesive layer includes a plurality of adhesive portions at least partially separated from each other by the mesh layer, wherein each adhesive portion of the plurality of adhesive portions is at least partially disposed on a corresponding bonding portion of the plurality of bonding portions opposite the plurality of optical elements.

5. The retroreflective article of claim 1, further comprising: A reflective layer is disposed adjacent to surfaces of at least some of the plurality of optical elements that face the bonding layer, wherein the reflective layer is at least partially disposed between the plurality of optical elements and the bonding layer.

6. The retroreflective article of claim 1, wherein the tie layer comprises a colorant.

7. The retroreflective article of claim 4, wherein the adhesive layer comprises an adhesive, and wherein the adhesive is a pressure sensitive adhesive or a hot melt adhesive.

8. The retroreflective article of claim 1, wherein each optical element of the plurality of optical elements comprises transparent microspheres.

9. The retroreflective article of claim 5, wherein the reflective layer comprises a metal mirror or a dielectric mirror.

10. The retroreflective article of claim 5, further comprising: An interlayer is at least partially disposed between the plurality of optical elements and the reflective layer.

11. A method of making a retroreflective article, the method comprising: providing a carrier layer; Disposing a mesh layer on the carrier layer, the mesh layer comprising a plurality of interconnected portions, a first mesh main surface, and a second mesh main surface opposite to the first mesh main surface, the plurality of interconnected portions defining a plurality of surrounded openings therebetween, the plurality of interconnected portions together forming the first mesh main surface and the second mesh main surface, wherein the first mesh main surface is disposed on the carrier layer; disposing a plurality of optical elements within the plurality of encircled openings of the mesh layer; as well as A bonding layer is provided adjacent to the plurality of optical elements within the plurality of encircled openings of the mesh layer opposite to the carrier layer, such that the plurality of optical elements are partially embedded within the bonding layer, wherein the bonding layer comprises a plurality of bonding portions at least partially spaced apart from each other by the mesh layer, wherein each of the plurality of bonding portions is at least partially disposed within a corresponding encircled opening of the plurality of encircled openings, wherein each of the plurality of bonding portions is spaced apart from the first mesh major surface along the thickness of the mesh layer, and wherein the bonding layer is removably bonded to the plurality of interconnected portions of the mesh layer.

12. The method according to claim 11, further comprising: A reflective layer is provided adjacent to surfaces of at least some of the plurality of optical elements prior to providing the bonding layer, such that the reflective layer is at least partially disposed between the bonding layer and the plurality of optical elements.

13. The method according to claim 12, further comprising: An interlayer is provided on at least some of the plurality of optical elements before providing the reflective layer.

14. The method according to claim 11, further comprising: An adhesive layer is provided on at least one of the second mesh major surface of the mesh layer and the bonding layer opposite to the plurality of optical elements.

15. The method according to claim 14, further comprising: The retroreflective article is adhered to a substrate, and then the carrier layer and the mesh layer are removed from the remainder of the retroreflective article.

16. The method of claim 11, wherein disposing the plurality of optical elements within the plurality of encircled openings further comprises disposing the plurality of optical elements on the carrier layer.

17. The method according to claim 11, further comprising: At least one of the first mesh major surface and the second mesh major surface of the mesh layer is flattened prior to disposing the mesh layer on the carrier layer.

18. The method of claim 11, wherein the bonding layer is disposed adjacent to the plurality of optical elements such that each of the plurality of bonding portions is spaced apart from the second mesh major surface along a thickness of the mesh layer.

19. The method according to claim 18, further comprising: The mesh layer is removed from the remainder of the retroreflective article such that the plurality of optical elements and the plurality of bonding portions are removably bonded to the carrier layer after the mesh layer is removed.

20. The method according to claim 11, further comprising: The carrier layer is removed from the remainder of the retroreflective article such that, after the carrier layer is removed, the plurality of optical elements and the plurality of bonding portions are removably bonded to adjacent one or more of the plurality of interconnected portions of the mesh layer.

21. The method of claim 11, wherein disposing the mesh layer on the carrier layer further comprises bonding the carrier layer to the mesh layer.

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