Abstract: A method for tooling a pattern of retroreflective microcubes, which pattern can be subdivided into smaller increments within which there are straight line tooling paths, none of which pass through an otherwise solid part of the incremental pattern. The tooling paths within the various increments need not be parallel to a common plane. Various adaptions of the method enable the tooling of a number of specific microcube shapes and for modifying such optical properties of the microcubes as entrance angularity, incidence angularity, orientation angularity, observation angularity, percent active aperture and retroreflectance. Specific techniques govern the pre-selection of cube parameters such as cube axis cant, cube apex decentration, and cube boundary proportions, which parameters can be adjusted independently of each other. Designs tooled by the method can have 100% active aperture at near zero degrees entrance angle.

Abstract: A pavement marker comprising a base member and a signal device for sending a light signal to a driver of an oncoming vehicle further includes a longitudinally extending tire directing hood member that directs tire contact away from the upper edge, upper portion, and upper generally corner portions of the signal device front face, while allowing tire contact with the lower portion of the signal device front face. The signal device front face is at a predetermined recess depth in said pavement marker, and is at a predetermined angle with respect to the roadway surface. The marker can be either a snowplowable marker or a sun country marker. The signal device optionally can be mounted on a base member by a mechanical interlock. Optional drainage channels can be provided in the base member to allow drainage of fluid from in front of the lower portion of the signal device.

Abstract: A method for tooling a pattern of retroreflective microcubes, which pattern can be subdivided into smaller increments within which there are straight line tooling paths, none of which pass through an otherwise solid part of the incremental pattern. The tooling paths within the various increments need not be parallel to a common plane. Various adaptions of the method enable the tooling of a number of specific microcube shapes and for modifying such optical properties of the microcubes as entrance angularity, incidence angularity, orientation angularity, observation angularity, percent active aperture and retroreflectance. Specific techniques govern the pre-selection of cube parameters such as cube axis cant, cube apex decentration, and cube boundary proportions, which parameters can be adjusted independently of each other. Designs tooled by the method can have 100% active aperture at near zero degrees entrance angle.

Abstract: An optically precise endless embossing belt for making retroreflection materials having projections with 90.degree. corners is provided by the instant invention.

Abstract: A pavement marker base is provided having a generally planar bottom support surface with an array of downwardly facing open chambers molded therein. Deformations are formed on the bottom surfaces of at least some of the walls dividing the chambers, and also preferably in the peripheral support surface of the marker base to provide additional downwardly facing surface area to mate with an adhesive material used to adhere the marker base to a roadway surface. These deformations may be characterized by a variety of surface shapes, such as arcs, rectangular notches, and dovetails. In the preferred embodiment, chamber walls include outwardly directed lips to engage the adhesive material. In another embodiment of the invention, a wire mesh covers at least some of the bottom surface of the marker base, and is imbedded within the bottom surface of the chamber walls and peripheral support surface. The mesh engages with the adhesive to provide a strong means of anchorage.

Abstract: A tool for producing a pattern of highly accurate optical quality surfaces and the method of making same from a series of bi-metallic pins. A high strength metal pin is coupled to a slug of metal of lesser strength capable of being accurately scribed. The supporting pin blank preferably is magnetic stainless steel and the slug is of copper. A group of such bi-metallic pins then is placed in an appropriate fixture after which an optical configuration, such as the three faces of a cube-corner element, are scribed into the copper ends. A completed tool may then be electroformed to produce an electroformed tool from an array of the like or different pins, arranged in various patterns.

Abstract: Cylindrical embossing tools are constructed from one or more masters formed by accurately scribing the face of a substrate along three axes in the face to produce a pattern of tetrahedrons. The plurality of masters, or replicated copies made from a single master, are assembled in a fixture and seamless copies are made by electrodeposition of nickel using various shielding and grinding methods to provide replicated copies of uniform thickness. The replicated copies are assembled and used to form larger electroforms until a generally cylindrical embossing tool of the correct width and circumference is created. Novel processes and apparatus are provided for removing the electroformed cylindrical tool from its mother cylinder.

Abstract: A tool for producing a pattern of highly accurate and optical quality surfaces and the method of making same from a series of bi-metallic pins. A high strength metal pin is coupled to a slug of metal of lesser strength capable of being accurately scribed. The supporting pin blank preferably is magnetic stainless steel and the slug is of copper. A group of such bi-metallic pins then is placed in an appropriate fixture after which an optical configuration, such as the three faces of a cube-corner element, are scribed into the copper ends. A completed tool may then be electroformed to produce an electroformed tool from an array of like or different pins, arranged in various patterns.