Abstract: Optical structures and methods for manufacturing the same includes, in one embodiment, a substrate and a plurality of two-sided optical components disposed along the substrate. Each component includes optical microstructures on each side. At least a portion of one side of at least some of the components is air-backed and the other side of the at least some of the components is substantially wetted-out by a material. Retroreflective optical structures, threads, or fibers and manufacturing methods for forming same are also provided. Optical structures are provided that include a plurality of microstructures enclosed within an outer layer that is formed from a single substrate. An apparatus and method are also provided for forming an optical structure comprising injecting a material into a mold to form the optical structure, forming the optical structure into a desired geometric shape, and sealing ends of the optical structure.

Abstract: A light-redirecting optical structure includes a first side and a second side, the first side including plurality of linear prisms having a visibly random shaped surface on the prisms and a plurality of cross-cut prisms on first side which are oriented at an angle such that it is greater than zero degrees but less than 180 degrees. A backlight wedge includes a stepped structure on a bottom side that decreases in size traversing the wedge away from a light source which is positioned at an end and having a visibly random shaped surface on said wedge.

Abstract: Optical structures and methods for manufacturing the same includes, in one embodiment, a substrate and a plurality of two-sided optical components disposed along the substrate. Each component includes optical microstructures on each side. At least a portion of one side of at least some of the components is air-backed and the other side of the at least some of the components is substantially wetted-out by a material. Retroreflective optical structures, threads, or fibers and manufacturing methods for forming same are also provided. Optical structures are provided that include a plurality of microstructures enclosed within an outer layer that is formed from a single substrate. An apparatus and method are also provided for forming an optical structure comprising injecting a material into a mold to form the optical structure, forming the optical structure into a desired geometric shape, and sealing ends of the optical structure.

Abstract: A luminaire and method are provided comprising a light source, a plurality of prisms, such as linear prisms, for redirecting light from the light source in a predetermined direction, and a reflector for redirecting light from the light source toward the plurality of prisms. Each of the linear prisms has a longitudinal axis and the light source has a longitudinal axis, wherein the longitudinal axes of the linear prisms are substantially parallel to the longitudinal axis of the light source. Each of the plurality of prisms has an included angle, which can vary as a function of the distance from the light source. The angle can vary stepwise or continuously. In one embodiment, each of the plurality of prisms adjacent the light guide has an included angle in the range of between about 35 and 45 degrees. In another embodiment, the included angle is substantially uniform among the prisms.

Abstract: A retroreflective structure is described in which an array of transparent prisms is formed on a release coating of a sheet. The facet side of the prisms is made reflective and the prisms are either released to form a plurality of individual retroreflective structures or the array is adhered to a supporting substrate and then released from the base sheet. In the latter case, the array can be applied to a pre-existing structure formed of compatible fabrics, such as tarpaulins.

Abstract: A luminaire and method are provided comprising a light source, a plurality of prisms, such as linear prisms, for redirecting light from the light source in a predetermined direction, and a reflector for redirecting light from the light source toward the plurality of prisms. Each of the linear prisms has a longitudinal axis and the light source has a longitudinal axis, wherein the longitudinal axes of the linear prisms are substantially parallel to the longitudinal axis of the light source. Each of the plurality of prisms has an included angle, which can vary as a function of the distance from the light source. The angle can vary stepwise or continuously. In one embodiment, each of the plurality of prisms adjacent the light guide has an included angle in the range of between about 35 and 45 degrees. In another embodiment, the included angle is substantially uniform among the prisms.

Abstract: Retroreflective sheeting for forming orientation free cones of reflected light encompassing a 0.5 degree angle of observation is formed of small metal backed cube corner prisms in an array in which the size of the prisms are in a range between 0.0005 inch to 0.003 inches on center. The array is formed by casting transparent plastic prisms in a mold formed by ruling three sets of grooves which intersect at an angle. The grooves are spaced apart in the range of 0.0005 inch to 0.003 inches on center. Before or after formation, the prisms are coated with a reflective material such as a metal.

Abstract: A retroreflective structure is described in which an array of transparent prisms is formed on a release coating of a sheet. The fact side of the prisms is made reflective and the prisms are either released to form a plurality of individual retroreflective structures or the array is adhered to a supporting substrate and then released from the base sheet. In the latter case, the array can be applied to a pre-existing structure formed of compatible fabrics, such as tarpaulins.

Abstract: A retroreflective structure is described in which an array of transparent prisms is formed on a release coating of a sheet. The facet side of the prisms is made reflective and the prisms are either released to form a plurality of individual retroreflective structures or the array is adhered to a supporting substrate and then released from the base sheet. In the latter case, the array can be applied to a pre-existing structure formed of compatible fabrics, such as tarpaulins.

Abstract: A retroreflective structure is described in which an array of transparent prisms is formed on a release coating of a sheet. The facet side of the prisms is made reflective and the prisms are either released to form a plurality of individual retroreflective structures or the array is adhered to a supporting substrate and then released from the base sheet. In the latter case, the array can be applied to a pre-existing structure formed of compatible fabrics, such as tarpaulins.

Abstract: A retroreflective structure is described in which an array of transparent prisms is formed on a release coating of a sheet. The facet side of the prisms is made reflective and the prisms are either released to form a plurality of individual retroreflective structures or the array is adhered to a supporting substrate and then released from the base sheet. In the latter case, the array can be applied to a pre-existing structure formed of compatible fabrics, such as tarpaulins.

Abstract: A method and apparatus is described for producing a signaling device which uses sunlight or moonlight to signal a target by retroreflecting light through a window provided on the light reflective material of a mirror. A specular light reflective material with an opening coincident with the first opening is provided on the light reflective side of the mirror to aid in alignment of the mirror with the target.

Abstract: A durable reusable polymeric mold for casting a microstructure sheet having an array of prism elements and a method for forming the microstructure sheet are disclosed. A polymeric mold has a facet side and a base side including an array of prism elements upon which an radiation cured sheet can be formed. A protective surface layer can be formed on the facet side of the polymeric mold. The protective surface layer is sufficiently opaque to radiation to protect the polymeric mold from damage when the curable sheet is formed and is sufficiently bonded to the polymeric mold to allow the cured sheet to be removed from the protective surface layer while not substantially removing the protective surface layer from the polymeric mold. The microstructure sheet can be used as a retroreflective structure.

Abstract: Retroreflective sheet material is produced by forming sheet material with closely spaced retroreflective formations on one face and depositing on this face silver and copper atoms having high kinetic energy to provide a reflective metallic deposit comprising a base layer of metallic silver and an overlying layer of metallic copper. An organic protective coating is thereafter applied over the reflective metallic deposit. Light rays passing through the front face of the body enter the retroreflective formations, impinge upon the interface provided by the silver base layer and are retroreflected therefrom. As a result, the sheet material exhibits a bright white appearance in daylight as well as a bright white coloration at night when an incandescent beam impinges thereon.

Abstract: A retroreflective material providing a visual coloration includes a body member with microprisms on its rear surface. Some of the microprisms have a retroreflective interface and the remainder have a colored non-reflective coating thereon. As a result, light rays entering the front face which impinge upon the prisms with the retroreflective interface are redirected so that they exit the material in a parallel path. Light rays which travel to the color coated prisms are refracted from those prisms and impart a visual coloration to the material in daylight and ambient light.

Abstract: A retroreflective laminar sheet assembly comprises base and cover sheets made from flexible synthetic plastic materials, and an array of interposed retroreflective film pieces seated within discrete cells formed therebetween. The sheets and film pieces of different compositions are used to afford a preselected balance of mechanical and optical properties, and the construction is such that distortion is minimized and flexibility of the assembly is maintained. The invention also provides novel methods by which such an assembly can be produced, which may take advantage of inherent or induced cohesive characteristics of the components employed.

Abstract: There are disclosed an apparatus to perform a method for continuously embossing synthetic plastic sheet material with precisely formed embossments in patterns repeating along the length thereof. The apparatus includes a movable polished belt upon which the sheet material is carried, and a series of molds are placed on the sheet material. As the sheet material and molds are advanced in steps through the apparatus, presses clamp the molds and belt against opposite surfaces of the sheet material and raise the temperature of the assembly to embossing temperature for the resin to cause the resin to flow into the mold cavities, and volatiles at the interface are dissolved in the resin. After the embossing step, the clamping pressure is released and this permits limited shrinkage of the mold and sheet material.

Abstract: A retroreflective assembly includes a transparent polycarbonate housing of generally trapezoidal cross section. A channel extends upwardly from the base of the trapezoid, and the channel receives a vertically oriented strip of retroreflective sheet material. Planar side surfaces are provided at an angle with the vertical so that light from oncoming cars impinging on it will be directed downward to the retroreflective strip, whose top is spaced downward from the top of the housing to permit a thickness of material between the top of the channel on the top of the housing that is sufficient to afford structural strength to the housing. As a result, the image of the retroreflective strip is higher than its actual position, permitting relatively high visibility in a small structure of rugged construction.

Abstract: There are disclosed an apparatus and a method for continuously embossing synthetic plastic sheet material with precisely formed embossments in patterns repeating along the length thereof. The apparatus includes a movable polished belt upon which the sheet material is carried, and a series of molds are placed on the sheet material. As the sheet material and molds are advanced in steps through the apparatus, presses clamp the molds and belt against opposite surfaces of the sheet material and raise the temperature of the assembly to embossing temperature for the resin to cause the resin to flow into the mold cavities, and volatiles at the interface are dissolved in the resin. After the embossing step, the clamping pressure is released and this permits limited shrinkage of the mold and sheet material.

Abstract: A composite retroreflective sheet material with controlled stretch is provided by a strip of transparent retroreflective snythetic resin having cube corner formations on one surface thereof bonded to a longitudinally stretched flexible strip of backing material with the cube corners thereadjacent. The composite sheet material is puckered when in a relaxed state and is stretchable on a support surface with the elimination of the puckered condition indicating the proper degree of elongation without distortion of the cube corners. The backing material is stretched 3 - 15% at the time of bonding, and bonding is conveniently only along the longitudinal edges of the two strips. The exposed surface of the backing material may have a high friction or adhesive coating, and the faces of the cube corner formations may have a reflective coating.