# US 11,112,544 B2 · Truncated beadfilm constructions and methods of making the same

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- Number: US 11,112,544 B2
- Document ID: US11112544B2
- Status: Granted
- Kind: B2
- Application number: 16/323,281
- Filed: 2017-08-03
- Published: 2020-06-18
- Granted: 2021-09-07
- Earliest claimed: 2016-08-12
- Assignees: 3M Innovative Properties Company
- Applicants: 3M Innovative Properties Company
- Inventors: John C. Clark; John J. Gagliardi; Kevin W. Gotrik; Alexander J. Kugel; Jean A. Tangeman; Christopher B. Walker, Jr.
- Web page: https://patentgrep.com/patent/US11112544B2

## CPC

- G02B 5/128: transparent spheres being embedded in matrix
- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/043: {of natural rubber or synthetic rubber}
- B32B 9/045: {of synthetic resin}
- B32B 9/048: {made of particles}
- B32B 9/06: of paper or cardboard
- B32B 15/06: of {natural rubber or synthetic} rubber
- B32B 15/08: of synthetic resin
- B32B 15/12: of paper or cardboard
- B32B 15/16: next to a particulate layer
- B32B 17/06: comprising glass as the main or only constituent of a layer, next to another layer of a specific {material}
- B32B 17/10018: {comprising only one glass sheet}
- B32B 25/04: comprising rubber as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046)}
- B32B 25/042: {of natural rubber or synthetic rubber}
- B32B 25/047: {of particles}
- B32B 25/08: of synthetic resin
- B32B 25/12: comprising natural rubber
- B32B 25/14: comprising {synthetic rubber copolymers (B32B25/18 and B32B25/20 take precedence)}
- B32B 25/16: comprising polydienes {homopolymers} or poly-halodienes {homopolymers (B32B25/12 takes precedence)}
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/14: next to a particulate layer
- B32B 27/18: characterised by the use of special additives
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 27/283: {comprising polysiloxanes}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- B32B 29/002: {as the main or only constituent of a layer, which is next to another layer of the same or of a different material (next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10)}
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 29/007: {next to a foam layer}
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 29/04: next to a particulate layer
- B32B 33/00: Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
- G02B 5/0226: {having particles on the surface}
- G02B 5/0268: {characterized by the fabrication or manufacturing method}
- G02B 5/136: plural reflecting elements forming part of a unitary body (G02B5/124 takes precedence)
- B32B 2038/0016: {Abrading}
- B32B 2260/025: Particulate layer
- B32B 2260/046: Synthetic resin
- B32B 2260/048: Natural or synthetic rubber
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2264/0278: Polyester particles
- B32B 2264/101: Glass
- B32B 2264/105: Metal
- B32B 2264/107: Ceramic
- B32B 2266/0207: Materials belonging to B32B25/00
- B32B 2266/025: Polyolefin
- B32B 2266/06: Open cell foam
- B32B 2266/08: Closed cell foam
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes
- B32B 2307/41: Opaque
- B32B 2307/412: Transparent
- B32B 2307/414: Translucent
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/584: Scratch resistance
- B32B 2307/71: Resistive to light or to UV
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2307/738: Thermoformability
- B32B 2437/00: Clothing
- B32B 2437/02: Gloves, shoes
- B32B 2457/00: Electrical equipment
- B32B 2509/00: Household appliances
- B32B 2535/00: Medical equipment, e.g. bandage, prostheses or catheter
- B32B 2605/003: Interior finishings
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

Described herein is a construction comprising a microsphere layer comprising a plurality of microspheres, wherein the microspheres comprise glass, ceramic, and combinations thereof; a bead bonding layer, wherein the plurality of microspheres is partially embedded in the bead bonding layer forming a first surface comprising exposed microspheres, wherein the plurality of microspheres on the first surface are truncated. Also disclosed herein are articles comprising the construction and methods of making thereof.

## Claims

### Claim 1

A construction comprising:
a microsphere layer comprising a plurality of microspheres, wherein the plurality of microspheres consists essentially of glass, ceramic, or glass-ceramic; and
a bead bonding layer, wherein the plurality of microspheres is partially embedded in the bead bonding layer forming a first outermost surface of the construction, the first outermost surface comprising exposed microspheres embedded in the bead bonding layer, wherein at least a portion of the exposed microspheres on the first outermost surface are truncated at the first outermost surface.

### Claim 2 (depends on 1)

The construction of claim 1, wherein the plurality of microspheres are substantially planarized across the first outermost surface.

### Claim 3 (depends on 2)

The construction of claim 2, wherein the plurality of microspheres are truncated by a latitudinal plane parallel to the bead bonding layer.

### Claim 4 (depends on 1)

The construction of claim 1, wherein a difference between the refractive index of the bead bonding layer and the refractive index of the plurality of microspheres is less than 0.05.

### Claim 5 (depends on 1)

The construction of claim 1, wherein only a portion of the plurality of microspheres on the first surface are truncated.

### Claim 6 (depends on 1)

The construction of claim 1, wherein the difference in height of the apex of each microsphere in the plurality of microspheres is within 20 micrometers.

### Claim 7 (depends on 1)

The construction of claim 1, wherein the average height difference along the first outermost surface between the surface of the bead bonding layer and the top of the truncated microspheres in the plurality of microspheres is at least 0.1 micrometers.

### Claim 8 (depends on 1)

The construction of claim 1, wherein the plurality of microspheres are embedded no more than 80% of their average diameter in the bead bonding layer.

### Claim 9 (depends on 1)

The construction of claim 1, wherein the plurality of microspheres are transparent.

### Claim 10 (depends on 1)

The construction of claim 1, wherein the plurality of microspheres have a refractive index of less than 1.60.

### Claim 11 (depends on 1)

The construction of claim 1, wherein the microsphere layer is a monolayer of microspheres.

### Claim 12 (depends on 1)

The construction of claim 1, wherein the first outermost surface is substantially free of a coating.

### Claim 13 (depends on 1)

The construction of claim 1, wherein the bead bonding layer comprises at least one of: a polyurethane, polyesters, (meth)acrylic acid ester polymers, an epoxy, a (meth)acrylate, polyvinylchloride polymer, polyvinyl acetate polymer, polyamides, a urethane/(meth)acrylate, a silicone, polyolefin, acrylobutadiene polymers, fluoropolymers, and blends thereof.

### Claim 14 (depends on 1)

An article comprising the construction of claim 1.

### Claim 15

A method of making a construction comprising:
(i) obtaining a microsphere layer comprising a plurality of microspheres, wherein the plurality of microspheres consists essentially of glass, ceramic, or glass-ceramic; and a bead bonding layer, wherein the plurality of microspheres is partially embedded in the bead bonding layer forming a first outermost surface of the construction, the first outermost surface comprising exposed microspheres embedded in the bead bonding layer; and
(ii) abrading the first outermost surface to truncate at least a portion of the plurality of microspheres at the first outermost surface.

### Claim 16 (depends on 15)

The method of claim 15, wherein abrading is performed with an abrasive particle selected from diamond, silicon carbide, and cubic boron nitride.

### Claim 17 (depends on 15)

The method of claim 15, wherein a lubricant is used during the abrading step.

### Claim 18 (depends on 15)

The method of claim 15, wherein the first outermost surface is contacted with diamond lapping film.

### Claim 19 (depends on 15)

The method of claim 15, wherein the first outermost surface is contacted with a 3D abrasive construction.

### Claim 20 (depends on 15)

The method of claim 15, wherein the abrading step comprises a plurality of abrading steps with an increasing degree of polish.