Composite micro-prismatic reflective film integrating multiple triangular pyramids and mold manufacturing method thereof

Abstract

The present invention relates to a composite microprismatic reflective film integrating multiple triangular pyramids and a mold manufacturing method thereof. The surface of the microprismatic reflective film is formed by an array of identical parallelogram units. Each parallelogram unit is composed of three identical triangular pyramids A, three identical triangular pyramids B, one triangular pyramid C, and one triangular pyramid D. The bases of triangular pyramids A, B, C, and D are all identical equilateral triangles. The three pyramidal surfaces of triangular pyramid A are inclined at angles of α / 2, α / 2, and β / 2+△, respectively. The three pyramidal surfaces of triangular pyramid B are inclined at angles of α / 2, α / 2, and β / 2-△, respectively. The three pyramidal surfaces of triangular pyramid C are inclined at angles of β / 2+△, and the three pyramidal surfaces of triangular pyramid D are inclined at angles of β / 2-△, with △ greater than zero. The present invention can rationally optimize performance for different application conditions, thereby achieving improved wide-angle performance and optimizing and balancing overall comprehensive performance.

Description

Technical Field

[0001] The invention relates to a composite micro-prismatic reflective film integrating multiple triangular pyramids and a method for manufacturing a mold thereof. Background Art

[0002] Design of micro-prismatic reflective film based on triangular pyramid unit structure: use one tool to process the three pyramidal surfaces of the triangular pyramid, and the inclination angles (angles with the vertical plane) of the three pyramidal reflective surfaces are the same, such as Figure 1 As shown. This type of micro-prismatic reflective film design is mainly used for Class III and IV reflective films with low performance requirements. When used for Class V reflective film, the retroreflection coefficient cannot meet the standard requirements under conditions of large observation angles and large incident angles. In order to achieve the performance requirements of Class V reflective film, different design or manufacturing solutions have been proposed at home and abroad. 3M Company of the United States proposed a reflective film optical design using a full prism structure. However, this design has a complex structure and requires very high mold manufacturing precision. In addition, the manufacturing error has a great impact on the performance of the reflective film, which has limited its promotion and application in China.

[0003] Specifically, the above Figure 1 There is only one optical design variable for the microprismatic reflective film, and it is difficult to obtain a balance between the retroreflective performance at different incident angles and observation angles (especially wide angles), that is, at different azimuth angles, as well as a balance between the retroreflective performance at different incident angles and observation angles (especially wide angles and small incident angles), and at different azimuth angles (such as 0 degrees, 90 degrees, and 180 degrees).

[0004] In the prior art, to achieve isotropic uniformity in the retroreflective performance of reflective sheeting at different azimuth angles, four types of reflective sheeting nickel molds are typically manufactured by mechanically interlocking and splicing two reflective sheeting nickel molds with different orientations, one at 0 degrees and the other at 90 degrees, to create a roller master mold. This method achieves control of the retroreflective performance of the reflective sheeting (e.g., improving wide-angle performance) by slightly adjusting an angle to deviate from the standard corner cone reflector structure. However, this method is very cumbersome to manufacture and is subject to mechanical splicing errors, making it difficult to achieve the desired effect.

[0005] Although the retroreflective performance of the microprismatic reflective film using full prisms (US 3M) is 50% higher than that of the microprismatic reflective film using triangular pyramids (or the effective reflection area of ​​the triangular pyramid reflective film is 66.67% of the effective reflection area of ​​the full pyramid reflective film), the mold structure of the full pyramid reflective film (such as Chinese patent No. 2015107772604 and 201811202555.9) is very complex and difficult to manufacture. In addition, the reflective performance is much lower than expected due to mold manufacturing errors, which limits its promotion and application.

[0006] In response to the above-mentioned shortcomings, the applicant applied for "Retro-reflective microprism array structure and its manufacturing method" (Announcement No. CN 117930406 A) in March 2024 and "Manufacturing method of microprismatic reflective film with double triangular pyramid combination structure and its mold" (Announcement No. CN118759624B) in September 2024.

[0007] Among them, although the "retro-reflective micro-prism array structure and its manufacturing method" is more convenient to manufacture than patents 2015107772604 and 201811202555.9, avoids the difficulty of secondary clamping and special-shaped surface processing, and ensures the quality of the finished product, when making through holes on the second substrate in the processing process, it is necessary to drill holes one by one and then process them by wire cutting. The processing process is still relatively cumbersome, and the corner cones formed by the processing are all regular triangular pyramids with the same inclination angle of the corner cone surface. The optical design variable of the micro-prismatic reflective film produced therefrom is only one, and it is difficult to obtain different incident angles and observation angles. That is, such a micro-prismatic reflective film design can meet the performance requirements of Class IV reflective film. When used for Class V reflective film, the retroreflection coefficient cannot meet the standard requirements under the conditions of large observation angles and large incident angles;

[0008] Among them, the "Manufacturing method of micro-prismatic reflective film with a double triangular pyramid combination structure and its mold" proposes using two tools with tool design angles of α and β to process two micro-prismatic reflective films with a triangular pyramid combination structure on the same mold substrate. After using the first tool with a tool angle of α to process the large triangular pyramid, the second tool with a tool angle of β is used for processing. According to the design requirements, the tool orientation is adjusted so that the inclination angles of the three corner cone surfaces of the central triangular pyramid are all β / 2. At this time, the inclination angles of the two corner cone surfaces of the corner triangular pyramid are α / 2, and the inclination angle of the third corner cone surface in the middle is β / 2. Although the wide-angle performance of the reflective film can be optimized to a certain extent by adjusting the angle variables of the triangular pyramid located in the center, or the performance of the reflective film at 0 degrees and 90 degrees can be optimized to a certain extent, the micro-prismatic reflective film obtained therefrom still has the disadvantage of insufficient freedom in optical design optimization. Summary of the Invention

[0009] In view of the above-mentioned problems, the purpose of the present invention is to propose a method for manufacturing a composite microprismatic reflective film integrating multiple triangular pyramids and a mold thereof. The method for manufacturing a composite microprismatic reflective film integrating multiple triangular pyramids and a mold thereof is rationally designed, can further increase the degree of freedom of optical design, facilitate optimized design, and obtain better performance indicators under different application conditions.

[0010] The technical solutions of the present invention are as follows:

[0011] A composite microprismatic reflective sheeting integrating multiple triangular pyramids, characterized in that: the surface of the microprismatic reflective sheeting is formed by an array of identical parallelogram units, each parallelogram unit being composed of three identical triangular pyramids A, three identical triangular pyramids B, one triangular pyramid C, and one triangular pyramid D, the bases of the triangular pyramids A, B, C, and D being identical equilateral triangles, the base areas of the triangular pyramids A, B, C, and D accounting for 37.5%, 37.5%, 12.5%, and 12.5%, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid A are α / 2, α / 2, and β / 2+△, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid B are α / 2, α / 2, and β / 2-△, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid C are β / 2+△, and the inclination angles of the three pyramidal surfaces of the triangular pyramid D are β / 2-△, where △ is greater than zero.

[0012] A composite microprismatic reflective sheeting integrating multiple triangular pyramids, characterized in that: the surface of the microprismatic reflective sheeting is formed by an array of identical parallelogram units, each parallelogram unit being composed of three identical triangular pyramids A, three identical triangular pyramids B, one triangular pyramid C, and one triangular pyramid D, the bases of the triangular pyramids A, B, C, and D being identical equilateral triangles, the base areas of the triangular pyramids A, B, C, and D accounting for 37.5%, 37.5%, 12.5%, and 12.5%, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid A are α / 2, α / 2, and βL, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid B are α / 2, α / 2, and βR, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid C are βL, and the inclination angles of the three pyramidal surfaces of the triangular pyramid D are βR, where βL is not equal to βR.

[0013] A composite microprismatic reflective sheeting integrating multiple triangular pyramids, characterized in that: the surface of the microprismatic reflective sheeting is formed by an array of identical parallelogram units, each parallelogram unit being composed of two identical triangular pyramids A, two identical triangular pyramids B, two triangular pyramids C, one triangular pyramid D, and one triangular pyramid E, the bottom surfaces of the triangular pyramids A, B, C, D, and E are all identical equilateral triangles, and the bottom surfaces of the triangular pyramids A, B, C, D, and E are all identical equilateral triangles. The base area accounts for 25%, 25%, 25%, 12.5% ​​and 12.5% ​​respectively; the inclination angles of the three pyramidal surfaces of triangular pyramid A are all α / 2, the inclination angles of the three pyramidal surfaces of triangular pyramid B are α / 2, α / 2 and β / 2+△ respectively, the inclination angles of the three pyramidal surfaces of triangular pyramid C are α / 2, α / 2 and β / 2-△ respectively, the inclination angles of the three pyramidal surfaces of triangular pyramid D are α / 2, β / 2+△ and β / 2+△ respectively, and the inclination angles of the three pyramidal surfaces of triangular pyramid E are α / 2, β / 2-△ and β / 2-△ respectively, and △ is greater than zero.

[0014] A composite micro-prismatic reflective film integrating multiple triangular pyramids, characterized in that: the surface of the micro-prismatic reflective film is formed by an array of identical parallelogram units, each parallelogram unit is composed of two identical triangular pyramids A, two identical triangular pyramids B, two triangular pyramids C, one triangular pyramid D and one triangular pyramid E, the bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles, and the triangular pyramids A, B, C, D and E are all identical equilateral triangles. The base area proportions of D and triangular pyramid E are 25%, 25%, 25%, 12.5% ​​and 12.5% ​​respectively; the inclination angles of the three pyramidal surfaces of triangular pyramid A are all α / 2, the inclination angles of the three pyramidal surfaces of triangular pyramid B are α / 2, α / 2 and βL respectively, the inclination angles of the three pyramidal surfaces of triangular pyramid C are α / 2, α / 2 and βR respectively, the inclination angles of the three pyramidal surfaces of triangular pyramid D are α / 2, βL and βL respectively, and the inclination angles of the three pyramidal surfaces of triangular pyramid E are α / 2, βR and βR respectively, and βL is not equal to βR.

[0015] A method for manufacturing a mold for a composite microprismatic reflective film integrating multiple triangular pyramids, used to manufacture the mold for the aforementioned microprismatic reflective film integrating a combination structure of three triangular pyramids, characterized by:

[0016] The mold base is installed horizontally on a workbench. The workbench can drive the mold base to move along the horizontal X-axis and Y-axis. The B-axis turntable on the workbench can drive the mold base to rotate around the normal B-axis of the mold base. Above the mold base is a spindle parallel to the upper surface of the mold base and a flying cutter disk fixedly connected to the spindle. The flying cutter disk is equipped with a tool that can rotate around the Y-axis driven by the spindle. The specific steps of manufacturing are as follows:

[0017] Step 1: Rotate the mold base on the B-axis turntable to 0 degrees. Use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two side cone surfaces of the parallelogram unit, namely the cone surface γ1-1 and the cone surface γ1-2. The inclination angle is α / 2. The first type of tool is a symmetrical tool with the same inclination angle on both sides.

[0018] Step 2: Rotate the mold base on the B-axis turntable to 120 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the other two cone surfaces of the parallelogram unit body, the cone surface γ2-1 and the cone surface γ2-2, with an inclination angle of α / 2;

[0019] Step 3: Rotate the mold base on the B-axis turntable to 60 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two diagonal cone surfaces of the parallelogram unit, namely, the cone surface γ3-1 and the cone surface γ3-2, with an inclination angle of α / 2;

[0020] Step 4: Based on the structure processed in step 3, rotate the mold substrate to the 0 degree position, and use a tool to process the pyramidal surface γ4-1 and the pyramidal surface γ4-2;

[0021] Step 5: Rotate the mold substrate 120 degrees in sequence and use a tool to form the pyramidal surface γ5-1 and the pyramidal surface γ5-2;

[0022] Step 6: Rotate the mold substrate 60 degrees and use a tool to form the pyramidal surface γ6-1 and the pyramidal surface γ6-2;

[0023] The second tool is used in at least two of steps 4, 5, and 6, and the first tool is used in the remaining steps. The second tool is a symmetrical tool with a tool angle of β. The second tool is mounted on a tool holder of a working spindle. The tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the cutting edges on both sides of the second tool are β / 2+△ and β / 2-△, so that the inclination angles of the cone surfaces machined on the left and right sides of the cutting edge are β / 2+△ and β / 2-△, respectively.

[0024] Alternatively, the second type of tool is an asymmetric tool with a tool angle of β, and the left and right blade inclination angles of the second type of tool are βL and βR respectively, so that the inclination angles of the cone surfaces machined on the left and right sides of the blade are βL and βR respectively.

[0025] Preferably, in steps 4, 5 and 6, step 4 uses the first tool, and steps 5 and 6 use the second tool. The second tool is installed on the tool holder of the working spindle, and the tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the blades on both sides of the second tool are β / 2+△ and β / 2-△, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are β / 2+△ and β / 2-△ respectively; the processing obtains a triangular pyramid A with three cone surfaces with an inclination angle of α / 2 and an area accounting for 25%, and the inclination angles of the three cone surfaces are α / 2, α / 2 and β / 2+△ respectively, and the surface The triangular pyramid B has an area accounting for 25%, the triangular pyramid C has an area accounting for 25% and the inclination angles of the three pyramid surfaces are α / 2, α / 2 and β / 2-△, respectively, the triangular pyramid D has an area accounting for 12.5% ​​and the inclination angles of the three pyramid surfaces are α / 2, β / 2+△ and β / 2+△, respectively, and the triangular pyramid E has an area accounting for 12.5% ​​and the inclination angles of the three pyramid surfaces are α / 2, β / 2-△ and β / 2-△, respectively. The triangular pyramid A, triangular pyramid B, triangular pyramid C, triangular pyramid D and triangular pyramid E constitute five microprismatic reflective film molds with different triangular pyramid combination structures.

[0026] Preferably, in steps 4, 5 and 6, step 4 uses the first type of tool, and steps 5 and 6 use the second type of tool, the second type of tool is an asymmetric tool with a tool angle β, and the left and right blade inclination angles of the second type of tool are βL and βR respectively, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are βL and βR respectively; the processing obtains a triangular pyramid A in which the inclination angles of the three cone surfaces are all α / 2 and the area accounts for 25%, and the inclination angles of the three cone surfaces are α / 2, α / 2 and βL respectively, and the area accounts for 25%. The triangular pyramid B has three pyramidal surfaces with inclination angles of α / 2, α / 2 and βR, and an area accounting for 25%, the triangular pyramid C has three pyramidal surfaces with inclination angles of α / 2, βL and βL, and an area accounting for 12.5%, and the triangular pyramid E has three pyramidal surfaces with inclination angles of α / 2, βR and βR, and an area accounting for 12.5%. The triangular pyramid A, triangular pyramid B, triangular pyramid C, triangular pyramid D and triangular pyramid E constitute five microprismatic reflective film molds with different triangular pyramid combination structures.

[0027] Preferably, steps 4, 5 and 6 all use the second type of tool, which is installed on the tool holder of the working spindle. The tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the blades on both sides of the second type of tool are β / 2+△ and β / 2-△, so that the inclination angles of the cone surfaces machined on the left and right sides of the blade are β / 2+△ and β / 2-△ respectively; the three cone surfaces with inclination angles of α / 2, α / 2 and β / 2+△ and an area ratio of 37.55% are obtained by processing. Triangular pyramid A, triangular pyramid B with three pyramidal surfaces with inclination angles of α / 2, α / 2 and β / 2-△ and an area accounting for 37.5%, triangular pyramid C with three pyramidal surfaces with inclination angles of β / 2+△ and an area accounting for 12.5%, and triangular pyramid D with three pyramidal surfaces with inclination angles of β / 2-△ and an area accounting for 12.5%. Triangular pyramid A, triangular pyramid B, triangular pyramid C and triangular pyramid D constitute four microprismatic reflective film molds with different triangular pyramid combination structures.

[0028] Preferably, steps 4, 5 and 6 all use the second type of tool, which is an asymmetric tool with a blade angle of β. The left and right blade inclination angles of the second type of tool are βL and βR, respectively, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are βL and βR, respectively; the processing obtains three triangular pyramids A with inclination angles of α / 2, α / 2 and βL, respectively, and an area share of 37.55%, a triangular pyramid B with inclination angles of α / 2, α / 2 and βR, respectively, and an area share of 37.5%, a triangular pyramid C with three cone surfaces with inclination angles of βL and an area share of 12.5%, and a triangular pyramid D with three cone surfaces with inclination angles of βR and an area share of 12.5%. Triangular pyramid A, triangular pyramid B, triangular pyramid C and triangular pyramid D constitute four microprismatic reflective film molds with different triangular pyramid combination structures.

[0029] The present invention has the following technical advantages.

[0030] From the perspective of optical design, the increase in optical design freedom means that the optical system is expected to simultaneously meet the performance indicators of more different application conditions. For Class V reflective sheeting with high performance requirements, improving its wide-angle performance at large observation angles and large incident angles, and the performance of 90-degree and 0-degree azimuth orientations, as well as their optimization and balance, has always been the focus of Class V reflective sheeting technology research and development.

[0031] The performance under different application conditions can be reasonably optimized, thereby achieving wide-angle performance improvement that cannot be achieved by micro-prismatic reflective film with traditional triangular pyramid unit structure and double triangular pyramid combination structure, as well as optimization and balance of overall comprehensive performance; the performance of reflective film can be further improved while maintaining the simplicity of the reflective film structure and effectively controlling the complexity of reflective film mold manufacturing.

[0032] The present invention selects different deflection angle Δ values ​​of the second tool with a blade angle design of β (or an asymmetric tool design with different inclination angles βL and βR of the left and right blades) and makes different combinations of tool selections for the fourth to sixth tools to obtain a micro-prismatic reflective sheeting design composed of a combination of multiple different triangular pyramids (with varying inclination angles of the pyramidal surfaces), thereby improving the overall performance of the reflective sheeting and optimizing wide-angle performance, small-angle performance, and 90-degree and 0-degree orientation performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The present invention will be further described below with reference to the accompanying drawings;

[0034] Figure 1 This is the main view of a traditional triangular pyramid;

[0035] Figure 2 It is a three-dimensional schematic diagram of the mold substrate placed on the workbench for processing;

[0036] Figure 3 It is a schematic diagram of the cross-sectional structure of a flying cutter tool processing a mold substrate;

[0037] Figure 4 It is a schematic diagram of the cross-sectional structure of another flying cutter tool for processing a mold substrate;

[0038] Figure 5 This is a schematic diagram of the main structure of the microprismatic reflective film and the finished mold of the present invention;

[0039] Figure 6 This is a schematic diagram of the three-dimensional structure of the mold base material when it is not processed;

[0040] Figure 7 yes Figure 6 The main view;

[0041] Figure 8 yes Figure 7 The front view of the mold substrate after being processed in step 1;

[0042] Figure 9 yes Figure 8 The front view of the mold substrate after processing in step 2;

[0043] Figure 10 yes Figure 9 The front view of the mold substrate after processing in step 3;

[0044] Figure 11 yes Figure 10 Stereoscopic image of

[0045] Figure 12 yes Figure 10 The front view of the mold substrate after processing in step 4;

[0046] Figure 13 yes Figure 12 Schematic diagram of the three-dimensional structure;

[0047] Figure 14 yes Figure 12 The front view of the mold substrate after processing in step 5;

[0048] Figure 15 yes Figure 14 Schematic diagram of the three-dimensional structure;

[0049] Figure 16 yes Figure 15 Front view of the mold substrate after processing in step 6. DETAILED DESCRIPTION

[0050] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0051] The present invention integrates a micro-prismatic reflective film with a plurality of triangular pyramid combination structures. The reflective film is composed of four or more different triangular pyramid structures. Specific embodiments are as follows:

[0052] In one embodiment, the surface of the microprismatic reflective film is formed by an array of identical parallelogram units 1, each parallelogram unit 1 being composed of three identical triangular pyramids A, three identical triangular pyramids B, one triangular pyramid C, and one triangular pyramid D. The bases of the triangular pyramids A, B, C, and D are all identical equilateral triangles, and the base areas of the triangular pyramids A, B, C, and D account for 37.5%, 37.5%, 12.5%, and 12.5%, respectively. The inclination angles of the three pyramidal surfaces of the triangular pyramid A are α / 2, α / 2, and β / 2+△, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid B are α / 2, α / 2, and β / 2-△, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid C are β / 2+△, and the inclination angles of the three pyramidal surfaces of the triangular pyramid D are β / 2-△, where △ is greater than zero.

[0053] In one embodiment, the surface of the microprismatic reflective film is formed by an array of identical parallelogram units 1, each parallelogram unit 1 being composed of three identical triangular pyramids A, three identical triangular pyramids B, one triangular pyramid C, and one triangular pyramid D. The bases of the triangular pyramids A, B, C, and D are all identical equilateral triangles, and the base areas of the triangular pyramids A, B, C, and D account for 37.5%, 37.5%, 12.5%, and 12.5%, respectively. The inclination angles of the three pyramidal surfaces of the triangular pyramid A are α / 2, α / 2, and βL, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid B are α / 2, α / 2, and βR, respectively; the inclination angles of the three pyramidal surfaces of the triangular pyramid C are all βL, and the inclination angles of the three pyramidal surfaces of the triangular pyramid D are all βR, and βL is not equal to βR.

[0054] In one embodiment, the surface of the microprismatic reflective film is formed by an array of identical parallelogram units 1, each parallelogram unit 1 is composed of two identical triangular pyramids A, two identical triangular pyramids B, two triangular pyramids C, one triangular pyramid D and one triangular pyramid E. The bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles, and the bottom areas of the triangular pyramids A, B, C, D and E account for 2 5%, 25%, 25%, 12.5% ​​and 12.5%; the inclination angles of the three pyramidal surfaces of triangular pyramid A are all α / 2, the inclination angles of the three pyramidal surfaces of triangular pyramid B are α / 2, α / 2 and β / 2+△, the inclination angles of the three pyramidal surfaces of triangular pyramid C are α / 2, α / 2 and β / 2-△, the inclination angles of the three pyramidal surfaces of triangular pyramid D are α / 2, β / 2+△ and β / 2+△, and the inclination angles of the three pyramidal surfaces of triangular pyramid E are α / 2, β / 2-△ and β / 2-△, and △ is greater than zero.

[0055] One embodiment: The surface of the microprismatic reflective film is formed by an array of identical parallelogram units 1, each parallelogram unit 1 is composed of two identical triangular pyramids A, two identical triangular pyramids B, two triangular pyramids C, one triangular pyramid D and one triangular pyramid E, the bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles, and the bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles. The inclination angles of the three pyramidal surfaces of triangular pyramid A are α / 2, the inclination angles of the three pyramidal surfaces of triangular pyramid B are α / 2, α / 2 and βL, the inclination angles of the three pyramidal surfaces of triangular pyramid C are α / 2, α / 2 and βR, the inclination angles of the three pyramidal surfaces of triangular pyramid D are α / 2, βL and βL, the inclination angles of the three pyramidal surfaces of triangular pyramid E are α / 2, βR and βR, and βL is not equal to βR.

[0056] The specific method for manufacturing a mold for a composite microprismatic reflective film integrating multiple triangular pyramids of the present invention is as follows (i.e., a mold for manufacturing the aforementioned microprismatic reflective film integrating a combination structure of three triangular pyramids, wherein the mold corresponds one-to-one with the aforementioned reflective film structure. The mold for the reflective film of the present invention integrating multiple triangular pyramid structures is formed by an array of identical parallelogram units, wherein each parallelogram unit is formed by six cuts of a cutting tool, wherein the two side pyramidal surfaces formed by the first cut are labeled γ1-1 and γ1-2, respectively, the two side pyramidal surfaces formed by the second cut are labeled γ2-1 and γ2-2, respectively, and so on, wherein the two side pyramidal surfaces formed by the sixth cut are labeled γ6-1 and γ6-2, respectively, as shown in FIG. Figure 6 As shown, the following microprismatic reflective films are obtained by the above processing:

[0057] When the 1st to 3rd tool arrays are used for forming, the first tool with a tool angle designed to be α is used. When the 4th to 6th tool arrays are used for forming, the first tool with a tool angle designed to be α or the second tool with a tool angle designed to be β and a deflection angle Δ (or the left and right blade inclination angles are βL and βR respectively) is selectively used.

[0058] 1. Four types of triangular pyramid structures: When the 4th, 5th and 6th tools are all processed by the second tool β with a deflection angle Δ, it consists of three triangular pyramids A with inclination angles of α / 2, α / 2 and β / 2+△ (or βL) and an area accounting for 37.55%, three triangular pyramids B with inclination angles of α / 2, α / 2 and β / 2-△ (or βR) and an area accounting for 37.5%, three triangular pyramids C with inclination angles of β / 2+△ (or βL) and an area accounting for 12.5%, and three triangular pyramids D with inclination angles of β / 2-△ (or βR) and an area accounting for 12.5%.

[0059] 2. Five triangular pyramid structures: When the 4th, 5th or 5th, 6th or 4th, 6th tool is formed by the second tool β with a deflection angle Δ, it consists of three triangular pyramid A with the inclination angles of the three pyramid surfaces all at α / 2 and an area accounting for 25%, three triangular pyramid B with the inclination angles of the three pyramid surfaces being α / 2, α / 2 and β / 2+△ (or βL) and an area accounting for 25%, three triangular pyramid C with the inclination angles of the three pyramid surfaces being α / 2, β / 2+△ (or βL) and β / 2+△ (or βL) and an area accounting for 25%, three triangular pyramid C with the inclination angles of the three pyramid surfaces being α / 2, β / 2+△ (or βL) and β / 2+△ (or βL) and an area accounting for 12.5%, and three triangular pyramid E with the inclination angles of the three pyramid surfaces being α / 2, β / 2-△ (or βR) and β / 2-△ (or βR) and an area accounting for 12.5%.

[0060] These two new designs increase the optical design freedom of triangular pyramid reflective films. When only the 4th, 5th or 6th cutter (only one of the 4th-6th cutters) is processed using the second cutter with a design cutter angle of β and a deflection angle Δ (or the left and right blade inclination angles are βL and βR respectively), a micro-prismatic reflective film with a combination structure of three triangular pyramids is obtained.

[0061] The specific processing equipment and processing methods are as follows:

[0062] The mold base K1 used to process the mold is horizontally mounted on a workbench K2. The workbench can drive the mold base to move along the horizontal X-axis and Y-axis. The B-axis turntable on the workbench can drive the mold base to rotate around the normal B-axis of the mold base. Above the mold base is a spindle K3 parallel to the upper surface of the mold base and a flying cutter disk K4 fixedly connected to the spindle. A tool K5 is mounted on the flying cutter disk. The tool can rotate around the Y-axis driven by the spindle. The specific steps during manufacturing are as follows:

[0063] Step 1: Rotate the mold base on the B-axis turntable to 0 degrees. Use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two side cone surfaces of the parallelogram unit, namely the cone surface γ1-1 and the cone surface γ1-2. The inclination angle is α / 2. The first type of tool is a symmetrical tool with the same inclination angle on both sides.

[0064] Step 2: Rotate the mold base on the B-axis turntable to 120 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the other two cone surfaces of the parallelogram unit body, the cone surface γ2-1 and the cone surface γ2-2, with an inclination angle of α / 2;

[0065] Step 3: Rotate the mold base material on the B-axis turntable to 60 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two diagonal conical surfaces of the parallelogram unit 1, namely, the conical surface γ3-1 and the conical surface γ3-2, with an inclination angle of α / 2;

[0066] Step 4: Based on the structure processed in step 3, rotate the mold substrate to the 0 degree position, and use a tool to process the pyramidal surface γ4-1 and the pyramidal surface γ4-2;

[0067] Step 5: Rotate the mold substrate 120 degrees in sequence and use a tool to form the pyramidal surface γ5-1 and the pyramidal surface γ5-2;

[0068] Step 6: Rotate the mold substrate 60 degrees and use a tool to form the pyramidal surface γ6-1 and the pyramidal surface γ6-2;

[0069] The second tool is used in at least two of steps 4, 5, and 6, and the first tool is used in the remaining steps. The second tool is a symmetrical tool with a tool angle of β. The second tool is mounted on a tool holder of a working spindle. The tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the cutting edges on both sides of the second tool are β / 2+△ and β / 2-△, respectively, so that the inclination angles of the cone surfaces machined on the left and right sides of the cutting edge are β / 2+△ and β / 2-△, respectively (as shown in the figure);

[0070] The other type is an asymmetric tool with a cutting angle of β. The left and right cutting edge inclination angles of the second tool are βL and βR respectively. The second tool is installed on the tool holder of the working spindle. The tool holder mechanical axis is adjusted to be vertical so that the inclination angles of the cone surfaces processed on the left and right sides of the cutting edge are βL and βR respectively (as shown in the figure).

[0071] Specific embodiment 1: Steps 4, 5 and 6 all use the second type of tool, which is installed on the tool holder of the working spindle. The tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the blades on both sides of the second type of tool are β / 2+△ and β / 2-△, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are β / 2+△ and β / 2-△ respectively; the three cone surfaces obtained by processing have inclination angles of α / 2, α / 2 and β / 2+△ respectively, and the area accounts for 37.55 %, triangular pyramid A with an inclination angle of α / 2, α / 2 and β / 2-△ and an area accounting for 37.5%, triangular pyramid B with an inclination angle of β / 2+△ and an area accounting for 12.5%, and triangular pyramid D with an inclination angle of β / 2-△ and an area accounting for 12.5%. Triangular pyramid A, triangular pyramid B, triangular pyramid C and triangular pyramid D constitute four microprismatic reflective film molds with different triangular pyramid combination structures.

[0072] Specific embodiment 2: Steps 4, 5 and 6 all use the second type of tool, which is an asymmetric tool with a blade angle of β. The left and right blade inclination angles of the second type of tool are βL and βR, respectively, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are βL and βR, respectively; three triangular pyramids A with inclination angles of α / 2, α / 2 and βL and an area accounting for 37.55% are obtained by processing; three triangular pyramids B with inclination angles of α / 2, α / 2 and βR and an area accounting for 37.5% are obtained; three triangular pyramids C with inclination angles of βL and an area accounting for 12.5% ​​are obtained; and three triangular pyramids D with inclination angles of βR and an area accounting for 12.5% ​​are obtained. Triangular pyramids A, B, C and D constitute four microprismatic reflective film molds with four different triangular pyramid combination structures.

[0073] The above-mentioned Examples 1 and 2 obtained four microprismatic reflective film molds with different triangular pyramid combination structures.

[0074] Specific embodiment 3: In steps 4, 5 and 6, step 4 uses the first type of tool, and steps 5 and 6 use the second type of tool. The second type of tool is installed on the tool holder of the working spindle, and the tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the blades on both sides of the second type of tool are β / 2+△ and β / 2-△, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are β / 2+△ and β / 2-△ respectively; the processing obtains a triangular pyramid A with three cone surfaces with an inclination angle of α / 2 and an area accounting for 25%, and the inclination angles of the three cone surfaces are α / 2, α / 2 and β / 2+△ respectively. Triangular pyramid B with an area share of 25%, triangular pyramid C with three pyramidal surfaces with inclination angles of α / 2, α / 2 and β / 2-△ and an area share of 25%, triangular pyramid D with three pyramidal surfaces with inclination angles of α / 2, β / 2+△ and β / 2+△ and an area share of 12.5%, and triangular pyramid E with three pyramidal surfaces with inclination angles of α / 2, β / 2-△ and β / 2-△ and an area share of 12.5%. Triangular pyramid A, triangular pyramid B, triangular pyramid C, triangular pyramid D and triangular pyramid E constitute five microprismatic reflective film molds with different triangular pyramid combination structures.

[0075] Specific embodiment 4: In steps 4, 5 and 6, step 4 uses the first tool, and steps 5 and 6 use the second tool. The second tool is an asymmetric tool with a tool angle β. The left and right blade inclination angles of the second tool are βL and βR respectively, so that the inclination angles of the cone surfaces processed on the left and right sides of the blade are βL and βR respectively; the processing obtains a triangular pyramid A with three cone surfaces with inclination angles of α / 2 and an area accounting for 25%, and the inclination angles of the three cone surfaces are α / 2, α / 2 and βL respectively, and the area accounting for 25 %, a triangular pyramid B with an inclination angle of α / 2, α / 2 and βR respectively and an area accounting for 25%, a triangular pyramid C with an inclination angle of α / 2, βL and βL respectively and an area accounting for 12.5%, and a triangular pyramid E with an inclination angle of α / 2, βR and βR respectively and an area accounting for 12.5%. Triangular pyramid A, triangular pyramid B, triangular pyramid C, triangular pyramid D and triangular pyramid E constitute microprismatic reflective film molds with five different triangular pyramid combination structures.

[0076] The above-mentioned Examples 3 and 4 obtained five micro-prismatic reflective film molds with different triangular pyramid combination structures.

[0077] The mold obtained by the above processing is then processed by conventional technical means to obtain a reflective film (which is existing technology and will not be described here).

[0078] The "Method for Manufacturing Microprismatic Reflective Sheeting with a Double Triangular Pyramid Combination Structure and Its Mold" (Publication No. CN118759624B) uses a first tool with a knife angle of α to machine the large triangular pyramid, and then uses a second tool with a knife angle of β to machine the large triangular pyramid (a total of six cuts, six steps). Although adjusting the angle variables of the triangular pyramid at the center can optimize the wide-angle performance of the reflective sheeting to a certain extent, or achieve a certain degree of optimization of the 0-degree and 90-degree performance of the reflective sheeting, under the same processing steps (this application also uses six cuts, six steps), the microprismatic reflective sheeting produced by this patent still lacks the design freedom of the two triangular pyramids and lacks the freedom of optical design optimization.

[0079] In summary, the present invention has the following technical advantages.

[0080] From the perspective of optical design, the increase in optical design freedom means that the optical system is expected to simultaneously meet the performance indicators of more different application conditions. For Class V reflective sheeting with high performance requirements, improving its wide-angle performance at large observation angles and large incident angles, and the performance of 90-degree and 0-degree azimuth orientations, as well as their optimization and balance, has always been the focus of Class V reflective sheeting technology research and development.

[0081] The performance under different application conditions can be reasonably optimized, thereby achieving wide-angle performance improvement that cannot be achieved by micro-prismatic reflective film with traditional triangular pyramid unit structure and double triangular pyramid combination structure, as well as optimization and balance of overall comprehensive performance; the performance of reflective film can be further improved while maintaining the simplicity of the reflective film structure and effectively controlling the complexity of reflective film mold manufacturing.

[0082] The present invention selects different deflection angle Δ values ​​of the second tool with a blade angle design of β (or an asymmetric tool design with different inclination angles βL and βR of the left and right blades) and makes different combinations of tool selections for the fourth to sixth tools to obtain a micro-prismatic reflective sheeting design composed of a combination of multiple different triangular pyramids (with varying inclination angles of the pyramidal surfaces), thereby improving the overall performance of the reflective sheeting and optimizing wide-angle performance, small-angle performance, and 90-degree and 0-degree orientation performance.

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention and not to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or some technical features can be replaced by equivalents without departing from the spirit of the technical solution of the present invention. They should all be included in the scope of the technical solution for protection of the present invention.

Claims

1. A composite microprismatic reflective sheeting integrating multiple triangular pyramids, characterized by: The surface of the micro-prismatic reflective film is formed by an array of identical parallelogram units (1), each parallelogram unit (1) is composed of two identical triangular pyramids A, two identical triangular pyramids B, two identical triangular pyramids C, one triangular pyramid D and one triangular pyramid E, the bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles, and the bottom areas of the triangular pyramids A, B, C, D and E account for 2 5%, 25%, 25%, 12.5% ​​and 12.5%; the inclination angles of the three pyramidal surfaces of triangular pyramid A are all α / 2, the inclination angles of the three pyramidal surfaces of triangular pyramid B are α / 2, α / 2 and β / 2+△, the inclination angles of the three pyramidal surfaces of triangular pyramid C are α / 2, α / 2 and β / 2-△, the inclination angles of the three pyramidal surfaces of triangular pyramid D are α / 2, β / 2+△ and β / 2+△, and the inclination angles of the three pyramidal surfaces of triangular pyramid E are α / 2, β / 2-△ and β / 2-△, and △ is greater than zero.

2. A method for manufacturing a mold for a composite microprismatic reflective sheeting integrating multiple triangular pyramids, wherein the mold is used to manufacture the composite microprismatic reflective sheeting integrating multiple triangular pyramids according to claim 1, characterized in that: The mold base (K1) is horizontally mounted on a workbench (K2). The workbench can drive the mold base to move along the horizontal X-axis and Y-axis, and the B-axis turntable on the workbench can drive the mold base to rotate around the normal B-axis of the mold base. A spindle (K3) parallel to the upper surface of the mold base and a flying cutter disc (K4) fixedly connected to the spindle are provided above the mold base. A tool (K5) is mounted on the flying cutter disc. The tool can rotate around the Y-axis driven by the spindle. The specific steps of manufacturing are as follows: Step 1: Rotate the mold base on the B-axis turntable to 0 degrees. Use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two side cone surfaces of the parallelogram unit, namely the cone surface γ1-1 and the cone surface γ1-2. The inclination angle is α / 2. The first type of tool is a symmetrical tool with the same inclination angle on both sides. Step 2: Rotate the mold base material on the B-axis turntable to 120 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter head to machine the other two cone surfaces of the parallelogram unit, namely, the cone surface γ2-1 and the cone surface γ2-2, with an inclination angle of α / 2; Step 3: Rotate the mold base material on the B-axis turntable to 60 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two diagonal cone surfaces of the parallelogram unit, namely, the cone surface γ3-1 and the cone surface γ3-2, with an inclination angle of α / 2; Step 4: Based on the structure processed in step 3, rotate the mold substrate to the 0 degree position, and use a tool to process the pyramidal surface γ4-1 and the pyramidal surface γ4-2; Step 5: Rotate the mold substrate 120 degrees in sequence and use a tool to form the pyramidal surface γ5-1 and the pyramidal surface γ5-2; Step 6: Rotate the mold substrate 60 degrees and use a tool to form the pyramidal surface γ6-1 and the pyramidal surface γ6-2; In the steps 4, 5 and 6, the first tool is used in step 4, and the second tool is used in steps 5 and 6. The second tool is installed on the tool holder of the main spindle. The tool holder mechanical axis has an adjustable deflection angle △, so that the inclination angles of the blades on both sides of the second tool are β / 2+△ and β / 2-△, so that the inclination angles of the cone surfaces machined on the left and right sides of the blade are β / 2+△ and β / 2-△ respectively; the three triangular pyramids A with inclination angles of α / 2 and an area accounting for 25% are obtained by processing, and the inclination angles of the three cone surfaces are α / 2, α / 2 and β / 2+△ respectively, and the area accounts for The triangular pyramid B has a triangular pyramid ratio of 25%, the triangular pyramid C has three pyramid surfaces with inclination angles of α / 2, α / 2 and β / 2-△ and an area accounting for 25%, the triangular pyramid D has three pyramid surfaces with inclination angles of α / 2, β / 2+△ and β / 2+△ and an area accounting for 12.5%, and the triangular pyramid E has three pyramid surfaces with inclination angles of α / 2, β / 2-△ and β / 2-△ and an area accounting for 12.5%. Triangular pyramid A, triangular pyramid B, triangular pyramid C, triangular pyramid D and triangular pyramid E constitute five microprismatic reflective film molds with different triangular pyramid combination structures.

3. A composite microprismatic reflective sheeting integrating multiple triangular pyramids, characterized by: The surface of the micro-prismatic reflective film is formed by an array of identical parallelogram units (1), each parallelogram unit (1) is composed of two identical triangular pyramids A, two identical triangular pyramids B, two identical triangular pyramids C, one triangular pyramid D and one triangular pyramid E, the bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles, and the bottom surfaces of the triangular pyramids A, B, C, D and E are all identical equilateral triangles. The inclination angles of the three pyramidal surfaces of triangular pyramid A are α / 2, the inclination angles of the three pyramidal surfaces of triangular pyramid B are α / 2, α / 2 and βL, the inclination angles of the three pyramidal surfaces of triangular pyramid C are α / 2, α / 2 and βR, the inclination angles of the three pyramidal surfaces of triangular pyramid D are α / 2, βL and βL, the inclination angles of the three pyramidal surfaces of triangular pyramid E are α / 2, βR and βR, and βL is not equal to βR.

4. A method for manufacturing a mold for a composite microprismatic reflective sheeting integrating multiple triangular pyramids, wherein the mold is used to manufacture the composite microprismatic reflective sheeting integrating multiple triangular pyramids according to claim 3, characterized in that: The mold base (K1) is horizontally mounted on a workbench (K2). The workbench can drive the mold base to move along the horizontal X-axis and Y-axis, and the B-axis turntable on the workbench can drive the mold base to rotate around the normal B-axis of the mold base. A spindle (K3) parallel to the upper surface of the mold base and a flying cutter disc (K4) fixedly connected to the spindle are provided above the mold base. A tool (K5) is mounted on the flying cutter disc. The tool can rotate around the Y-axis driven by the spindle. The specific steps of manufacturing are as follows: Step 1: Rotate the mold base on the B-axis turntable to 0 degrees. Use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two side cone surfaces of the parallelogram unit, namely the cone surface γ1-1 and the cone surface γ1-2. The inclination angle is α / 2. The first type of tool is a symmetrical tool with the same inclination angle on both sides. Step 2: Rotate the mold base material on the B-axis turntable to 120 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter head to machine the other two cone surfaces of the parallelogram unit, namely, the cone surface γ2-1 and the cone surface γ2-2, with an inclination angle of α / 2; Step 3: Rotate the mold base material on the B-axis turntable to 60 degrees, and use the first type of tool with a tool angle of α installed on the fly cutter disc to machine the two diagonal cone surfaces of the parallelogram unit, namely, the cone surface γ3-1 and the cone surface γ3-2, with an inclination angle of α / 2; Step 4: Based on the structure processed in step 3, rotate the mold substrate to the 0 degree position, and use a tool to process the pyramidal surface γ4-1 and the pyramidal surface γ4-2; Step 5: Rotate the mold substrate 120 degrees in sequence and use a tool to form the pyramidal surface γ5-1 and the pyramidal surface γ5-2; Step 6: Rotate the mold substrate again at 60 degrees in sequence, and use a tool to process the pyramidal surface γ6-1 and the pyramidal surface γ6-2; in the steps 4, 5 and 6, step 4 uses the first tool, and steps 5 and 6 use the second tool. The second tool is an asymmetric tool with a tool angle β, and the left and right blade inclination angles of the second tool are βL and βR respectively, so that the inclination angles of the pyramidal surfaces processed on the left and right sides of the blade are βL and βR respectively; the three pyramidal surfaces are processed to obtain a triangular pyramid A with an inclination angle of α / 2 and an area ratio of 25%, and the inclination angles of the three pyramidal surfaces are respectively The triangular pyramid A, triangular pyramid B, triangular pyramid C, triangular pyramid D and triangular pyramid E constitute five microprismatic reflective film molds with different triangular pyramid combination structures.

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