Technical Field

The present disclosure relates to a retroreflective article and a method of manufacturing the retroreflective article.

Background

Retroreflective articles may be used to transfer or apply retroreflective segments onto a garment. Retroreflective segments are used in a variety of applications. For example, the retroreflective segments are often used as high-visibility trims on garments and footwear to increase a visibility of a user wearing the garments and the footwear. The retroreflective segments are often added to garments that are worn by firefighters, rescue personnel, road workers, and the like.

Summary

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 defining a plurality of enclosed openings therebetween, a first mesh major surface, and a second mesh major surface opposite to the first mesh major surface. The plurality of interconnected portions together form the first mesh major surface and the second mesh major surface. The retroreflective article further includes a bond layer including a plurality of bond portions at least partially spaced apart from each other by the mesh layer. Each of the plurality of bond portions is disposed within a corresponding enclosed opening from the plurality of enclosed openings and removably bonded to one or more adjacent interconnected portions from the plurality of interconnected portions of the mesh layer. The second mesh major surface is proximal to the bond layer. The retroreflective article further includes a plurality of sets of optical elements corresponding to the plurality of bond portions of the bond layer. Each of the sets of optical elements includes a plurality of optical elements partially embedded within a corresponding bond portion from the plurality of bond portions of the bond layer. The first mesh major surface is proximal to the sets of optical elements. The sets of optical elements are spaced apart from each other by the one or more interconnected portions of the mesh layer.

In a second aspect, the present disclosure provides a method of manufacturing a retroreflective article. The method includes providing a carrier layer. The method further includes disposing a mesh layer on the carrier layer. The mesh layer includes a plurality of interconnected portions defining a plurality of enclosed openings therebetween, a first mesh major surface, and a second mesh major surface opposite to the first mesh major surface. 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. The method further includes disposing a plurality of optical elements within the plurality of enclosed openings of the mesh layer. The method further includes providing a bond layer adjacent to the plurality of optical elements within the plurality of enclosed openings of the mesh layer opposite to the carrier layer, such that the plurality of optical elements is partially embedded within the bond layer. The bond layer includes a plurality of bond portions at least partially spaced apart from each other by the mesh layer. Each of the plurality of bond portions is at least partially disposed within a corresponding enclosed opening from the plurality of enclosed openings. Each of the plurality of bond portions is spaced apart from the first mesh major surface along a thickness of the mesh layer. The bond layer removably bonds to the plurality of interconnected portions of the mesh layer.

Brief Description of the Drawings

Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. In particular, thicknesses of certain layers in proportion to certain other items are exaggerated for ease of illustration and clarity purposes. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

FIG. 1 is a schematic cross-sectional view of a retroreflective article according to an embodiment of the present disclosure;

FIG. 2 is a schematic perspective view of a mesh layer of the retr or ef ective article according to an embodiment of the present disclosure;

FIG. 3 is a schematic cross-sectional view of a retror effective article according to another embodiment of the present disclosure;

FIG. 4 is a schematic cross-sectional view of a retror effective article according to another embodiment of the present disclosure;

FIG. 5 is a schematic cross-sectional view of a retror effective article according to another embodiment of the present disclosure;

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

FIG. 7 is a flowchart depicting various steps of a method of manufacturing a retroreflective article according to an embodiment of the present disclosure; FIGS. 8A-8G are schematic cross-sectional views depicting various steps of the method of manufacturing the retr or effective according to an embodiment of the present disclosure; and

FIGS. 9A-9C are schematic cross-sectional views of retr or ef ective articles manufactured by the method according to some embodiments of the present disclosure.

Detailed Description

In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

In the following disclosure, the following definitions are adopted.

As recited herein, all numbers should be considered modified by the term “about”. As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within +/- 20 % for quantifiable properties).

The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within +/- 10% for quantifiable properties) but again without requiring absolute precision or a perfect match.

The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within +/- 5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

Terms such as same, equal, uniform, constant, strictly, and the like, are understood to be within the usual tolerances or measuring error applicable to the particular circumstance rather than requiring absolute precision or a perfect match.

As used herein, the terms “first” and “second” are used as identifiers. Therefore, such terms should not be construed as limiting of this disclosure. The terms “first” and “second” when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

As used herein, when a first material is termed as “similar” to a second material, at least 90 weight % of the first and second materials are identical and any variation between the first and second materials comprises less than about 10 weight % of each of the first and second materials. As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

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.

As used herein, the term “adjacent” refers to elements that are in proximity to each other, usually in contact with each other, but may have intervening elements between them.

As used herein, the term “configured to” and like is at least as restrictive as the term “adapted to” and requires actual design intention to perform the specified function rather than mere physical capability of performing such a function.

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 a whole amount. The term “partially” refers to any percentage less than 100%.

As used herein, the term “spaced apart” refers to elements that are disposed at a distance from one another. A plurality of elements spaced apart from each other means that adjacent elements from the plurality of elements are disposed at a distance from one another. A plurality of elements at least partially spaced apart from each other means that at least portions of adjacent elements from the plurality of elements are disposed at a distance from one another.

As used herein, the term “retroreflective” refers to the attribute of reflecting an obliquely incident light ray in a direction antiparallel to its incident direction, or nearly so, such that it returns to the light source or an immediate vicinity thereof.

As used herein, the term “retroreflective segment(s)” refers to one or more segments which include components and layers that impart retroreflective property to the one or more segments.

As used herein, the term “removably bonded” refers to two or more elements being attached to each other such that they can be separated or disconnected when required.

As used herein, the term “fixedly bonded” refers to two or more elements being attached to each other so that they are not intended to be separated or disconnected during normal use.

As used herein, the term “mesh layer” refers to a layer of an apertured material. A mesh layer may include cords, wires, or threads woven into a network defining apertures or openings, or a sheet or a film having apertures or openings cut, punched, or otherwise formed therein.

As used herein, the term “percent open area” refers to a percentage of an area of the mesh layer that is taken up by an open area of the apertures or openings. The term “microsphere” or “microspheres” refers to either a population of micron size particles, or an individual particle, depending upon the context in which the word is used, which has a high sphericity measurement. The sphericity measurement of a population of microspheres may be in the range of about 80% to about 100%, with 95% being typical. The microspheres are substantially spherical, although a microsphere population may include some individual particles that have a lower sphericity measurement.

As used herein, the term “median diameter” refers to a diameter distribution where 50% of the particles are smaller than a given value.

As used herein, the term “garment” refers to an item that, in normal use, is to be donned and worn by a user. The term “garment” excludes any item that is itself to be attached to a garment.

As used herein, the term “external surface” of a garment refers to a surface, much or all of which is visible when the garment is worn.

As used herein, the term “elastomer” is defined as a polymer having an ability to be stretched to at least twice its original length and to retract to approximately its original length when released, (definition taken from “Hawley's Condensed Chemical Dictionary”, R. J. Lewis Sr. Ed., 12th Ed., Van Nostrand Reinhold Co., New York, N.Y. (1993)).

The present disclosure relates to a retr or effective article and a method of manufacturing the retr or ef ective article. The retr or effective article includes a mesh layer. The mesh layer includes a plurality of interconnected portions defining a plurality of enclosed openings therebetween, a first mesh major surface, and a second mesh major surface opposite to the first mesh major surface. The plurality of interconnected portions together form the first mesh major surface and the second mesh major surface. The retr or effective article further includes a bond layer including a plurality of bond portions at least partially spaced apart from each other by the mesh layer. Each of the plurality of bond portions is disposed within a corresponding enclosed opening from the plurality of enclosed openings and removably bonded to one or more adjacent interconnected portions from the plurality of interconnected portions. The second mesh major surface is proximal to the bond layer. The retroreflective article further includes a plurality of sets of optical elements corresponding to the plurality of bond portions of the bond layer. Each of the sets of optical elements includes a plurality of optical elements partially embedded within a corresponding bond portion from the plurality of bond portions of the bond layer. The first mesh major surface is proximal to the sets of optical elements. The sets of optical elements are spaced apart from each other by the one or more interconnected portions of the mesh layer. In some embodiments, the retroreflective article further includes an adhesive layer disposed opposite to the plurality of optical elements. A plurality of retroreflective segments may be formed at least partially within the plurality of enclosed openings of the mesh layer. In other words, at least a portion of each of the plurality of retr or ef ective segments may be formed within the plurality of enclosed openings of the mesh layer. Therefore, the plurality of retr or effective segments may be at least partially spaced apart from each other by the mesh layer. Each of the plurality of retr or effective segments may include one or more of a corresponding bond portion, a corresponding set of optical elements, a portion of a reflective layer, and a portion of an interlayer.

The retr or effective article may be used to transfer or apply the plurality of retr or effective segments onto a garment. Specifically, as the plurality of bond portions is removably bonded to the plurality of interconnected portions of the mesh layer, the plurality of retroreflective segments may be applied to the garment via the adhesive layer. The mesh layer may be subsequently removed.

In some cases, the plurality of bond portions may be completely spaced apart from each other by the mesh layer and the adhesive layer may include a plurality of adhesive portions completely spaced apart from each other by the mesh layer. In such cases, application of the plurality of retroreflective segments on a garment may result in gaps between adjacent retroreflective segments from the plurality of retroreflective segments when the plurality of the interconnected portions of the mesh layer is removed. As a result, the retroreflective article may be used to apply the plurality of retroreflective segments in a discontinuous manner, thereby providing enhanced breathability to a portion of a garment on which the plurality of retroreflective segments is applied.

Referring now to Figures, FIG. 1 illustrates a schematic cross-sectional view of a retroreflective article 100 according to an embodiment of the present disclosure.

The retroreflective article 100 defines mutually orthogonal x, y, and z-axes. The x-axis is defined along a length of the retroreflective article 100, while the y-axis is defined along a breadth of the retroreflective article 100. The z-axis is defined along a thickness of the retroreflective article 100.

The retroreflective article 100 includes a mesh layer 110. The mesh layer 110 is also shown in FIG. 2. Referring to FIGS. 1 and 2, the mesh layer 110 includes a plurality of interconnected portions 112 defining a plurality of enclosed openings 114 (best shown in FIG. 2) therebetween. The mesh layer 110 may include any apertured structure, i.e., a structure including a plurality of apertures (i.e., the plurality of enclosed openings 114).

In some cases, such apertured structure may inherently include the plurality of enclosed openings 114 from a process of manufacturing, and may not necessarily require any kind of post-processing to form the plurality of enclosed openings 114. In some other cases, the plurality of enclosed openings 114 may be formed on a structure by way of a post-process, e.g., mechanical perforation (e.g., by die-cutting), water-jet cutting, laser-cutting, needle-punching, and so forth. In such cases, a shape of the plurality of enclosed openings 114 may be established by a particular method and equipment used, e.g., round, oval, square, hexagonal, and so forth. The mesh layer 110 may include cords, wires, or threads woven into a network defining the plurality of enclosed openings 114. The mesh layer 110 may further include a sheet or a film having the plurality of enclosed openings 114 cut, punched, 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, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymers, and/or vinyl chloride-acrylonitrile copolymers. Perforation may be provided by die punching, needle punching, knife cutting, laser perforating, and slitting as described in U. S. Pat. Nos. 9,168,636 (Wald et al.) and 9,138,031 (Wood et al.), for example, which are incorporated herein in their entirety by reference. Perforation may also be provided by applying a flame, a heat source, or pressurized fluid, as described in U. S. Patent Application No 2016/0009048 Al (Slama et al.) and U. S. Pat. No. 7,037,100 (Strobel et al.), for example, which are incorporated herein in their entirety by reference.

In some embodiments, the mesh layer 110 includes a mesh fabric. For example, the plurality of interconnected portions 112 of the mesh layer 110 may include any suitable bondable yarns, such as spun yarns (e.g., spun yarns composed of cotton fibers and/or polyester fibers). The mesh fabric may include knit fabrics, open weave fabrics, woven meshes/screens (e.g., wire mesh or fiberglass mesh), unitary meshes (e.g., unitary continuous plastic screens), or perforated nonporous (e.g., sealed) fabrics.

As shown in FIG. 2, 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 further include a set of second members 112B oriented in a second direction different from the first direction. The first and second members 112 A, 112B may meet at junctions 113. In the illustrated embodiment of FIG. 2, each of the set of first members 112A is oriented substantially along the y-axis. Further, each of the set of second members 112B is oriented substantially along the x-axis. Consequently, each of the plurality of enclosed openings 114 is substantially rectangular in FIG. 2. However, the plurality of interconnected portions 112 may include any number of members, in any suitable configuration, to define the plurality of enclosed openings 114 that are, for example, circular, lozenge (e.g., diamond shaped), pentagonal, hexagonal, etc. In other words, many variations of the mesh layer 110 are possible, which involve members, such as the first and second members 112A, 112B, that are oriented in more than two directions, members that meet at relatively complex junctions as compared to the junctions 113 of FIG. 2, and so forth.

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 enclosed openings 114 may occupy at least 70% of a total area of the mesh layer 110. In one embodiment, the plurality of enclosed 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.

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

The mesh layer 110 defines a thickness HOT between the first mesh major surface 110A and the second mesh major surface 110B along the z-axis. The thickness HOT may be selected based on desired application attributes. In one embodiment, the thickness HOT may be selected such that the mesh layer 110 may be the thickest layer of the retroreflective article 100. In some embodiments, the thickness HOT may be from about 0.05 (millimeters) mm to about 2.5 mm. The thickness 110T is shown to be uniform in FIGS. 1 and 2, however, the thickness HOT of the mesh layer 110 may vary along a length (along the x-axis) and/or a breadth (along the y-axis) of the mesh layer 110. In some embodiments, the thickness HOT of the mesh layer 110 may vary from about 0.05 mm to about 2.5 mm along the length and/or the breadth of the mesh layer 110.

The retroreflective article 100 further includes a bond layer 120. The bond layer 120 includes a plurality of bond portions 122 at least partially spaced apart from each other by the mesh layer 110. Further, each of the plurality of bond portions 122 is at least partially disposed within a corresponding enclosed opening 114 from the plurality of enclosed openings 114. Specifically, at least portions of adjacent bond portions 122 may be spaced apart from each other by a corresponding interconnected portion 112 from the plurality of interconnected portions 112 of the mesh layer 110. As a result, at least one interconnected portion 112 from the plurality of interconnected portions 112 may be disposed between adjacent bond portions 122 from the plurality of bond portions 122.

Each of the plurality of bond portions 122 is removably bonded to one or more adjacent interconnected portions 112 from the plurality of interconnected portions 112 of the mesh layer 110. In other words, each of the plurality of bond portions 122 may be configured to de-bond or disconnect from the one or more adjacent interconnected portions 112 when desired. The plurality of bond portions 122 is intended to be de-bonded or disconnected from the plurality of interconnected portions 112 during use of the retroreflective article 100. For example, the plurality of bond portions 122 may be de-bonded or disconnected from the plurality of interconnected portions 112 in order to transfer one or more retroreflective segments onto a garment. Retroreflective segments will be discussed in more detail below.

In the illustrated embodiment of FIG. 1, each of the plurality of bond portions 122 is spaced apart from the first mesh major surface 110A along the thickness HOT of the mesh layer 110. As illustrated in FIG. 1, each of the plurality of bond portions 122 is disposed below the first mesh major surface 110A. Further, the second mesh major surface 11 OB is proximal to the bond layer 120. In other words, the second mesh major surface 110B is proximal to each of the plurality of bond portions 122 of the bond layer 120. Further, in the illustrated embodiment of FIG. 1, each of the plurality of bond portions 122 is spaced apart from the second mesh major surface HOB along the thickness HOT of the mesh layer 110. As illustrated in FIG. 1, each of the plurality of bond portions 122 is disposed between the first mesh major surface 110A and the second mesh major surface 110B along the thickness HOT of the mesh layer 110.

In some embodiments, the bond layer 120 may include more than 20 weight percent of a polymeric binder. In some embodiments, the bond layer 120 includes a colorant and the polymeric binder. Specifically, in some embodiments, the bond layer 120 may include a flexible polymeric binder material that is colored in some fashion. The bond layer 120 may further include additives, such as UV stabilizers, antioxidants, UV absorbers, property modifiers, performance enhancers, or combinations thereof.

The polymeric binder of the bond layer 120 may include, but is not limited to, an elastomer. Specifically, the polymeric binder may include a cross-linked or virtually cross-linked elastomer. A cross-linked elastomer means that polymeric chains of the elastomer are chemically cross-linked to form a three dimensional network which is stabilized against molecular flow. A virtually crosslinked elastomer means that the polymeric chain mobility of the elastomer is greatly reduced by chain entanglement and/or by hydrogen bonding, resulting in an increase in the cohesive 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; agent or group coupling such as by vulcanization or reaction with a coupling agent, such as a diol in the case of isocyanate or epoxy functionalized polymers; a diisocyanate or an activated ester in the case of amine and alcohol functionalized polymers; and epoxides and diols in the case of carboxylic acid or anhydride functionalized polymers. Examples of such virtual cross-linking include amide hydrogen bonding as is found in polyamides or crystalline and amorphous region interactions as is found in block copolymers of styrene and acrylonitrile.

Examples of the polymers that may be employed in the polymeric binder include polyolefins, polyesters, polyurethanes, polyepoxides, polyacrylates, natural and synthetic rubbers, and combinations thereof. Examples of cross-linked polymers include the foregoing examples of polymers substituted with cross-linkable groups such as epoxide groups, olefinic groups, isocyanate groups, alcohol groups, amine groups, anhydride groups, or acrylate groups. Multifunctional monomers and oligomers which react with functional groups of the polymers may also be used as cross-linkers.

Specific examples of materials for the bond 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 materials for the bond layer 120 includes one or more flexible polymers having active hydrogen functionalities, such as crosslinked urethane-based polymers (for example, isocyanate cured polyesters or one of two component polyurethanes) and one or more isocyanate- functional silane coupling agents. In the ‘ 101 patent, the materials for the bond layer 120 includes an electron-beam cured polymer selected from the group consisting of chlorosulfonated polyethylenes, ethylene copolymers including at least about 70 weight percent polyethylene, and poly(ethylene-co-propylene-co diene) polymers.

The retroreflective article 100 further includes a plurality of sets 131 of optical elements

130 corresponding to the plurality of bond portions 122 of the bond layer 120. Each of the sets

131 of optical elements 130 includes a plurality of optical elements 130 partially embedded within a corresponding bond portion 122 from the plurality of bond portions 122 of the bond layer 120.

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

Such an arrangement of the retroreflective article 100 may thus be distinguished from, for example, an approach in which the mesh layer 110 is not disposed between the plurality of bond portions 122 and the sets 131 of optical elements 130. Further, the plurality of optical elements 130 are absent on the first mesh major surface 110A of the mesh layer 110.

In the illustrated embodiment of FIG. 1, 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 facing the bond layer 120. The surface 132, adjacent to which the reflective layer 140 is disposed, faces the bond layer 120. Therefore, in some embodiments, the reflective layer 140 is at least partially disposed between the plurality of optical elements 130 and the bond 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 HOB of the mesh layer 110. Alternatively, in some embodiments, reflective particles (such as pearlescent pigments) may be added to the bond layer 120, such as what is 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 bond layer 120.

The plurality of optical elements 130 and the reflective layer 140 may collectively return a substantial quantity of incident light towards a light source. That is, light that passes into and through the plurality of optical elements 130 is reflected by the reflective layer 140 to again reenter the plurality of optical elements 130, such that the light is steered to return toward the light source, in the general manner signified by the term “retroreflection”.

In some embodiments, each of the plurality of optical elements 130 includes a transparent microsphere. In some embodiments, each of the plurality of optical elements 130 may include glass. For example, each of the plurality of optical elements 130 may be a transparent microsphere made substantially of glass. In some embodiments, each of the plurality of optical elements 130 has a diameter I 30D. The diameters BOD of the plurality of optical elements 130 have 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.

In some embodiments, the reflective layer 140 includes a metal mirror or a dielectric mirror. The metal mirror may include elemental metal in pure or alloy form, which 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 in its entirety by reference. 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.

A variety of metals may be used to provide a specularly reflective metal mirror. These include aluminum, silver, chromium, nickel, magnesium, gold, tin, and the like, in elemental form. Aluminum and silver are preferred metals for use in the metal mirror as they tend to provide good retroreflective brightness. In the case of aluminum and silver, some of the metal may be in the form of the metal oxide and/or hydroxide.

The dielectric mirror may also be referred to as a dichroic mirrors, Bragg reflectors, 1-D 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)), which are each generally understood to those of skill in the art to at least partially reflect light within a desired band of wavelengths by employing alternating high and low refractive index layers. The dielectric mirror may be at least partially reflective and at least partially transparent. The term dielectric is used to refer to non-metallic and non-electrically conducting materials.

Typically, the dielectric mirror has a multi-layer construction. For example, the dielectric mirror may include a plurality of layers deposited, e.g., by layer-by-layer self-assembly. The dielectric mirror can include alternating stacks of optical thin films with different refractive indexes (RIs) — e.g., a “high” RI and a “low” RI. The interfaces between stacks with different RIs produce phased reflections, selectively reinforcing certain wavelengths (constructive interference) and cancelling other wavelengths (destructive interference). By selecting certain variables such as stack thickness, refractive indices, and number of the stacks, the band(s) 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.

In the illustrated embodiment of FIG. 1, the retroreflective article 100 further incudes an interlayer 145 at least partially disposed between the plurality of optical elements 130 and the reflective layer 140. In some embodiments, the interlayer 145 may have a thickness (along the z- axis) from about 5 nm to about 0.03 mm. In some embodiments, the interlayer 145 may have various thickness along the length and/or the breadth of the retroreflective article 100, i.e., its thickness may be zero or may approach zero. However, the interlayer 145 may preferably be continuous or substantially continuous.

The interlayer 145 may include a polymeric material. The interlayer 145 may preferably include a polymer that is linked to a silane coupling agent. In some embodiments, the polymer preferably is a crosslinked polymer. Examples of polymers that may be suitable for the interlayer 145 include those that contain units of urethane, ester, ether, urea, epoxy, carbonate, acrylate, acrylic, olefin, vinyl chloride, amide, alkyd, or combinations thereof.

The polymer that is 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 possess such functionality. For example, in producing polyurethanes, the starting materials may possess hydrogen functionalities that are capable of reacting with an isocyanate-functional silane coupling agent; see for example, U.S. Pat. No. 5,200,262 to Li, incorporated herein by reference in its entirety. Preferred polymers are crosslinked poly(urethane-ureas) and crosslinked poly(acrylates).

Poly(urethane-ureas) may be formed by reacting a hydroxy -functional polyester resin with excess polyisocyanate. Alternatively, a polypropylene oxide diol may be reacted with a diisocyanate and then with a triamino-functionalized polypropylene oxide. Crosslinked poly(acrylates) may be formed by exposing acrylate oligomers to electron beam radiation; see for example, U.S. Pat. No. 5,283,101 to Li incorporated herein by reference in its entirety.

In some embodiments, the retroreflective article 100 further includes an adhesive layer 150. In the illustrated embodiment of FIG. 1, the adhesive layer 150 includes a plurality of adhesive portions 152 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 interconnected portions 112 of the mesh layer 110. Further, each of the plurality of adhesive portions 152 is at least partially disposed on a corresponding bond portion 122 from the plurality of bond portions 122 opposite to the plurality of optical elements 130.

Each of the plurality of adhesive portions 152 is at least partially disposed within a corresponding enclosed opening 114 from the plurality of enclosed openings 114 of the mesh layer 110. In the illustrated embodiment of FIG. 1, each of the plurality of adhesive portions 152 is spaced apart from each other and is disposed between the first mesh major surface 110A and the second mesh major surface HOB 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 HOB of the mesh layer 110. The adhesive layer 150 may be applied by, for example, liquidcoating, spraying, extrusion, lamination, and the like.

The adhesive layer 150 includes an adhesive. In some embodiments, the adhesive is one of a pressure sensitive adhesive and a hot-melt adhesive. In some embodiments, the adhesive may include a pressure sensitive adhesive, a heat activated adhesive, a laminating adhesive, or a combination of different types of adhesives. A wide variety of pressure sensitive adhesives are suitable, including tackified natural rubbers, synthetic rubbers, tackified styrene block copolymers, polyvinyl ethers, poly (meth)acrylates, polyurethanes, polyureas, poly-alpha-olefins, and silicones. The pressure sensitive adhesive may be covered with a release liner to protect the adhesive prior to adhesion to a substrate. Heat activated adhesives are similar to pressure sensitive adhesives, but require the application of heat to become tacky. One advantage of heat activated adhesives is that they typically do not require a release liner to protect the adhesive layer prior to adhesion to a substrate because they are not tacky at room temperature. Examples of laminating adhesives include hot-melt adhesives, adhesive dispersions and suspensions, and curing adhesives, such as cyanoacrylates.

A plurality of retr or effective segments 170 may be formed at least partially within the plurality of enclosed openings 114 of the mesh layer 110. In other words, at least a portion of each of the plurality of retr or ef ective segments 170 may be formed within the plurality of enclosed openings 114 of the mesh layer 110. Therefore, the plurality of retr or effective segments 170 may be at least partially spaced apart from each other by the mesh layer 110. Each of the plurality of retr or effective segments 170 may include one or more of a corresponding bond portion 122, a corresponding set 131 of optical elements 130, a portion of the reflective layer 140, and a portion of the interlayer 145.

The retr or effective article 100 may be used to transfer or apply the plurality of retr or effective segments 170 onto a garment. Specifically, as the plurality of bond portions 122 is removably bonded to the plurality of interconnected portions 112, the plurality of retr or effective segments 170 may be applied to the garment via the adhesive layer 150. The mesh layer 110 may be subsequently removed.

In some embodiments, such as illustrated in FIG. 1, the plurality of bond portions 122 may be completely spaced apart from each other by the mesh layer 110 and the plurality of adhesive portions 152 of the adhesive layer 150 may be completely spaced apart from each other by the mesh layer 110. In such embodiments, application of the plurality of retr or effective segments 170 on a garment may result in gaps (due to the removal of the plurality of interconnected portions 112) between adjacent retr or effective segments 170 from the plurality of retr or effective segments 170 when the mesh layer 110 is removed. As a result, the retr or effective article 100 may be used to apply the plurality of retr or effective segments 170 in a discontinuous manner, thereby providing enhanced breathability to a portion of a garment on which the plurality of retr or effective segments 170 is applied. It will be appreciated that in actual industrial production of the retr or effective article 100, small-scale statistical fluctuations may inevitably be present that may result in a small amount of the bond layer 120 and/or the adhesive layer 150 to be present on the second mesh major surface HOB. Such occasional occurrences are to be expected in any real-life production process; however, the bond layer 120 and/or the adhesive layer 150 of the retr or effective article 100, as described above, are distinguished from circumstances in which the bond layer 120 and/or the adhesive layer 150 are purposefully arranged in a continuous manner (i.e., portions thereof are not spaced apart from each other by the mesh layer 110). FIG. 3 illustrates a schematic cross-sectional view of a retroreflective article 101 according to another embodiment of the present disclosure. The retr or ef ective article 101 is similar to the retr or effective article 100 of FIG. 1, with like elements designated by like reference characters. However, the retr or effective article 101 has a different configuration of the bond layer 120 and the adhesive layer 150 as compared to the retr or effective article 100 of FIG. 1. Specifically, in the illustrated embodiment of FIG. 3, each of the plurality of bond 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, in the illustrated embodiment of FIG. 3, the bond layer 120 is further disposed on the second mesh major surface HOB of the mesh layer 110. Further, in the illustrated embodiment of FIG. 3, the adhesive layer 150 is substantially continuous and is disposed on the bond layer 120 opposite to the plurality of optical elements 130.

FIG. 4 illustrates a schematic cross-sectional view of a retr or effective article 200 according to another embodiment of the present disclosure. The retr or effective article 200 is similar to the retr or effective article 100 of FIG. 1, with like elements designated by like reference characters. However, the retror effective article 200 further includes a carrier layer 160. In the illustrated embodiment of FIG. 4, the carrier layer 160 includes a liner 161 and a carrier bonding layer 162 at least removably bonding the liner 161 to the mesh layer 110. In some embodiments, the carrier bonding layer 162 may include a polymer (e.g., polyethylene). Further, the liner 161 may include any suitable material (e.g., a paper material) on which the carrier bonding layer 162 may be disposed.

In some embodiments, a bond strength between the carrier bonding layer 162 and the mesh layer 110 may be greater than a bond strength between the plurality of bond portions 122 and the plurality of interconnected portions 112. As a result, after application of the retr or effective segments 170 onto a garment using the retr or effective article 200, removing the carrier layer 160 may further remove the mesh layer 110.

FIG. 5 illustrates a schematic cross-sectional view of a retr or effective article 300 according to another embodiment of the present disclosure. Elements of the retr or effective article 300 identical to the retror effective article 100 of FIG. 1 are designated by like reference characters.

In the illustrated embodiment of FIG. 5, the retroreflective article 300 includes the carrier layer 160. The retroreflective article 300 further includes the plurality of retroreflective segments 170 removably bonded to the carrier layer 160 and spaced apart from each other. Specifically, as shown in FIG. 5, adjacent retroreflective segments 170 from the plurality of retroreflective segments are spaced apart from each other by a gap G. In this embodiment, a bond strength between the carrier bonding layer 162 and the plurality of retroreflective segments 170 may be greater than either a bond strength between the carrier bonding layer 162 and the mesh layer 110 (shown in FIG. 8G) or a bond strength between the plurality of retr or effective segments 170 and the mesh layer 110. As a result, the mesh layer 110 may be removed from the rest of the retr or ef ective article 300 to form the gap G. In the illustrated embodiment of FIG. 5, each retr or effective segment 170 includes a corresponding set 131 of optical elements 130, a corresponding bond portion 122 of the bond layer 120, the reflective layer 140, the interlayer 145, and a corresponding adhesive portion 152 of the adhesive layer 150. Further, in the illustrated embodiment of FIG. 5, the carrier bonding layer 162 of the carrier layer 160 is removably bonded to the plurality of optical elements 130. As a result, after application of the retr or effective segments 170 onto a garment using the retr or effective article 300, the carrier layer 160 may be removed from the plurality of optical elements 130.

FIGS. 6A-6D schematically illustrate a process of using retr or effective articles of the present disclosure. Specifically, FIGS. 6A-6D schematically illustrate a process of transferring the retr or effective segments 170 onto an external surface 401 of a garment 400. The garment 400 may take form of, e.g., a jacket, a shirt (long-sleeve or short-sleeve), a pair of trousers, a pair of shoes, a coverall, and the like. For explanatory purposes, the process will be described with reference to the retr or effective article 100, however, similar concepts may be applied with the retr or effective article 101 of FIG. 3, the retr or effective article 200 of FIG. 4, and the retror effective article 300 of FIG. 5.

As shown in FIG. 6A, the retr or effective article 100 may be disposed on the external surface 401 of the garment 400, such that the second mesh major surface HOB of the mesh layer 110 may contact or engage the external surface 401, and the adhesive layer 150 may be adjacent to the external surface 401.

As shown in FIG. 6B, the retr or effective article 100 and/or the plurality of retr or effective segments 170 may be pressed against the garment 400, such that the adhesive layer 150 contacts the external surface 401 of the garment 400. Subsequently, the adhesive layer 150 may bond to the external surface 401 of the garment 400. Specifically, each of the plurality of adhesive portions 152 of the adhesive layer 150 may bond to the external surface 401 of the garment 400. In some embodiments, the adhesive layer 150 may bond to the external surface 401 via application of heat, i.e., via heat lamination.

As discussed above, each of the plurality of bond portions 122 is removably bonded to one or more adjacent interconnected portions 112 from the plurality of interconnected portions 112. Therefore, as shown in FIG. 6C, after bonding of the adhesive layer 150 to the external surface 401, the mesh layer 110 may be removed, such that the plurality of retr or effective segments 170 is attached to the external surface 401.

For the retr or effective article 200 of FIG. 4, the carrier layer 160 may be removed prior to, or at the same time of removal of the mesh layer 110, such that the plurality of retr or effective segments 170 is attached to the external surface 401. For the retr or effective article 300 of FIG. 5, the carrier layer 160 may be removed, such that the plurality of retr or effective segments 170 is attached to the external surface 401.

FIG. 6D shows the plurality of retr or effective segments 170 transferred from the retr or effective article 100 to the garment 400. Moreover, the retr or effective segments 170 are spaced apart from each other. In other words, the plurality of retr or effective segments 170 may be transferred in a discontinuous manner, thereby providing enhanced breathability to a portion of the garment 400 on which the plurality of retroreflective segments 170 is applied.

FIG. 7 illustrates a flowchart depicting various steps of a method 500 of manufacturing a retroreflective article. The method 500 may be used to manufacture the retroreflective article 100 of FIG. 1. The method 500 may be further used to manufacture the retroreflective article 101 of FIG. 3. The method 500 may be further used to manufacture the retroreflective article 200 of FIG. 4. The method 500 may further be used to manufacture the retroreflective article 300 of FIG. 5. Various steps of the method 500 are also illustrated in FIGS. 8A-8G. The method 500 will be described with reference to FIGS. 5, 7, and 8A-8G.

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

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

At step 504, the method 500 further includes disposing a mesh layer on the carrier layer. The mesh layer includes a plurality of interconnected portions defining a plurality of enclosed openings therebetween, a first mesh major surface, and a second mesh major surface opposite to the first mesh major surface. 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, as shown in FIG. 8 A, the mesh layer 110 may include the plurality of interconnected portions 112 defining the plurality of enclosed openings 114 therebetween. The mesh layer 110 may include the first mesh major surface 110A and the second mesh major surface HOB 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 HOB. As shown in FIG. 8B, 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.

In some embodiments, disposing the mesh layer on the carrier layer further includes bonding the carrier layer to the mesh layer. The carrier layer may be either removably bonded or fixedly bonded to the mesh layer. For example, disposing the mesh layer 110 on the carrier layer 160 may include bonding the carrier layer 160 to the mesh layer 110. A bond strength between the carrier bonding layer 162 and the mesh layer 110 may be greater than a bond strength between the plurality of bond portions 122 and the plurality of interconnected portions 112.

Specifically, the carrier bonding layer 162 may bond to the mesh layer 110 and prevent unwanted delamination of the mesh layer 110 from the carrier layer 160 during manufacture of the retroreflective article. The mesh layer 110 may bond to the carrier bonding layer 162 by heat lamination.

At step 506, the method 500 further includes disposing a plurality of optical elements within the plurality of enclosed openings of the mesh layer. For example, as shown in FIG. 8C, the method 500 may include disposing the plurality of optical elements 130 within the plurality of enclosed openings 114 of the mesh layer 110.

In some embodiments, disposing the plurality of optical elements within the plurality of enclosed openings further includes disposing the plurality of optical elements on the carrier layer. For example, disposing the plurality of optical elements 130 within the plurality of enclosed openings 114 may include disposing the plurality of optical elements 130 on the carrier layer 160. The carrier bonding layer 162 of the carrier layer 160 may removably bond to the plurality of optical elements 130 and prevent unwanted 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 removably bond to the carrier bonding layer 162 by heat. Advantageously, the mesh layer 110 may protect the plurality of optical elements 130 during manufacturing. Specifically, the mesh layer 110 may prevent delamination and loss of some of the plurality of optical elements 130 due to abrasion/static produced by winding and unwinding during manufacturing.

At step 508, the method 500 further includes providing a bond layer adjacent to the plurality of optical elements within the plurality of enclosed openings of the mesh layer opposite to the carrier layer, such that the plurality of optical elements is partially embedded within the bond layer. The bond layer includes a plurality of bond portions at least partially spaced apart from each other by the mesh layer. Each of the plurality of bond portions is at least partially disposed within a corresponding enclosed opening from the plurality of enclosed openings. Each of the plurality of bond portions is spaced apart from the first mesh major surface along a thickness of the mesh layer. The bond layer removably bonds to the plurality of interconnected portions of the mesh layer.

For example, as shown in FIG. 8F, the method 500 may include providing the bond layer 120 adjacent to the plurality of optical elements 130 within the plurality of enclosed openings 114 of the mesh layer 110 opposite to the carrier layer 160, such that the plurality of optical elements 130 is partially embedded within the bond layer 120. The bond layer 120 may include the plurality of bond portions 122 at least partially spaced apart from each other by the mesh layer 110. Each of the plurality of bond portions 122 may be at least partially disposed within the corresponding enclosed opening 114 from the plurality of enclosed openings 114. Each of the plurality of bond portions 122 may be spaced apart from the first mesh major surface 110A along the thickness HOT (shown in FIG. 1) of the mesh layer 110. The bond layer 120 may removably bond to the plurality of interconnected portions 112 of the mesh layer 110. A thickness of the bond layer 120 may reduce after the bond layer 120 dries.

In some embodiments, the method 500 further includes providing a reflective layer adjacent to a surface of at least some of the plurality of optical elements prior to providing the bond layer, such that the reflective layer is at least partially disposed between the bond layer and the plurality of optical elements. For example, as shown in FIG. 8E, the method 500 may include providing the reflective layer 140 adjacent to the surface of 132 of at least some of the plurality of optical elements 130 prior to providing the bond layer 120, such that the reflective layer 140 is at least partially disposed between the bond layer 120 and the plurality of optical elements 130. The reflective layer 140 may be provided, for example, via vapor deposition. As a result, 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 HOB of the mesh layer 110.

In some embodiments, the method 500 further includes providing an interlayer on at least some of the plurality of optical elements prior to providing the reflective layer. For example, as shown in FIG. 8D, the method 500 may include providing the interlayer 145 on at least some of the plurality of optical elements 130 prior to providing the reflective layer 140. In some embodiments, the bond layer is provided adjacent to the plurality of optical elements, such that each of the plurality of bond portions is spaced apart from the second mesh major surface along a thickness of the mesh layer. For example, the bond layer 120 may be provided adjacent to the plurality of optical elements 130, such that each of the plurality of bond portions 122 is spaced apart from the second mesh major surface HOB along the thickness HOT (shown in FIG. 1) of the mesh layer 110. In such embodiments, the bond layer 120 may be disposed between the first mesh major surface 110A and the second mesh major surface 11 OB of the mesh layer 110.

In some embodiments, the method 500 further includes providing an adhesive layer on at least one of the second mesh major surface of the mesh layer and the bond layer opposite to the plurality of optical elements. For example, as shown in FIG. 8G, the method 500 may further include providing the adhesive layer 150 on at least one of the second mesh major surface 110B of the mesh layer 110 and the bond layer 120 opposite to the plurality of optical elements 130. As a result, as shown in FIG. 9A, the retroreflective article 200 may be manufactured.

In some embodiments, the method 500 further includes adhering (e.g., via the adhesive layer 150) the retroreflective article to a substrate (e.g., a garment), followed by removing the carrier layer and the mesh layer from the rest of the retroreflective article.

In some embodiments, during use of the retroreflective article, the carrier layer 160 and the mesh layer 110 can be removed together. This may occur when the bonding strength between the carrier layer 160 and the mesh layer 110 is greater than either the bonding strength between the carrier layer 160 and the retroreflective segments 170 or the bonding strength between the mesh layer 110 and the retroreflective segments 170. This method is helpful especially after the retroreflective article is laminated to a fabric. After removing the carrier layer 160 and the mesh layer 110 together, the retroreflective segments 170 are left on the fabric.

In some embodiments, the method 500 further includes removing the mesh layer from the rest of the retroreflective article, such that after removal of the mesh layer, the plurality of optical elements and the plurality of bond portions are removably bonded to the carrier layer. The plurality of optical elements and the plurality of bond portions may be removably bonded to the carrier layer after removal of the mesh layer from the rest of the retroreflective article when the plurality of bond portions of the bond layer are completely spaced apart from each other by the mesh layer, and the plurality of adhesive portions of the adhesive layer are completely spaced apart from each other by the mesh layer. Further, the plurality of optical elements and the plurality of bond portions may be removably bonded to the carrier layer when a bond strength between the plurality of optical elements and the carrier layer is greater than either a bond strength between the bond layer and the one or more interconnected portions of the mesh layer, or a bond strength between the carrier layer and the interconnected portions of the mesh layer.

For example, in some embodiments, the method 500 may include removing the mesh layer 110 from the rest of the retroreflective article, such that after removal of the mesh layer 110, the plurality of optical elements 130 and the plurality of bond portions 122 are removably bonded to the carrier layer 160. In such a case, as shown in FIG. 9B, the retroreflective article 300 may be manufactured.

In some other embodiments, the method 500 further includes removing the carrier layer from the rest of the retroreflective article, such that after removal of the carrier layer, the plurality of optical elements and the plurality of bond portions are removably bonded to one or more adjacent interconnected portions from the plurality of interconnected portions of the mesh layer. The plurality of optical elements and the plurality of bond portions may be removably bonded to the one or more adjacent interconnected portions from the plurality of interconnected portions of the mesh layer when a bond strength between the plurality of bond portions and the one or more interconnected portions of the mesh layer is greater than either a bond strength between the plurality of optical elements and the carrier layer, or a bond strength between the interconnected portions of the mesh layer and the carrier layer.

For example, the method 500 may include removing the carrier layer 160 from the rest of the retroreflective article, such that after removal of the carrier layer 160, the plurality of optical elements 130 and the plurality of bond portions 122 are removably bonded to one or more adjacent interconnected portions 112 from the plurality of interconnected portions 112 of the mesh layer 110. In such a case, as shown in FIG. 9C, the retroreflective article 100 may be formed.

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 prior to 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 HOB of the mesh layer 110 prior to 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 intertwining of the mesh layer 110 with the bond layer 120 and/or the adhesive layer 150.

The mesh layer 110 may be thick enough (i.e., the thickness HOT shown in FIG. 1 may be great enough) to block bridging of bond layer 120 and adhesive layer 150 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 low adhesion layer may be used) in order to facilitate separation from the bond layer 120 and the adhesive layer 150 when desired. Suitable material for mesh layer 110 may include plastics, such as polypropylene, polyethylene, and the like, and metals, such as stainless steel, with suitable low adhesion coatings on surfaces thereof, as per requirements.

The method 500 may require use of less material (e.g., the plurality of optical elements 130, the bond layer 120, and the adhesive layer 150) to manufacture the retroreflective articles, and further reduce waste of material. Furthermore, the method 500 may allow reuse of the mesh layer 110 to form the retroreflective articles. Therefore, the method 500 may be more sustainable than conventional methods of manufacturing retroreflective articles.

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

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.