Thermoformable three dimensional retroreflective article and method of manufacture

A thermoformable, high intensity retroreflective laminate, comprising:

• a base sheet of thermoformable plastic;
• a layer of retroreflective microbeads having a variation in diameter adhered over one surface of the base sheet;
• a protective sheet of clear thermoformable plastic laminated over said layer of retroreflective beads, wherein said protective sheet engages a top surface of some of the microbeads to form airspaces and create infrequent tangential point contact between at least a portion of said protective sheet and said some of the microbeads,
• wherein said laminate is thermoformable into a contoured, three dimensional article having an encapsulated bead surface with a reflectivity of at least 200 lux,
• wherein the protective sheet comprises glycol-modified polyethylene terephthalate (PETG);
• and
• wherein the protective sheet has a thickness of 20 mils to 30 mils.

A thermoformable, high intensity retroreflective laminate, comprising:

• a base sheet of thermoformable plastic;
• a layer of retroreflective microbeads adhered over one surface of the base sheet by way of a thermoformable cushion coat, each of said beads having a semisilvered side engaging the cushion coat;
• a protective sheet of clear thermoformable plastic laminated over and in contact with said layer of retroreflective beads, wherein said protective sheet engages a top surface of some of the microbeads to form airspaces and create infrequent tangential point contact between at least a portion of said protective sheet and said some of the microbeads,
• wherein said laminate is capable of being formed into a contoured, three dimensional article having an encapsulated bead surface with a reflectivity of at least 200 lux, said base layer of sheet material has a thickness of between about 4 and 12 times an average diameter of the microbeads, and the thickness of the protective sheet is between about 2 to 10 times an average diameter of the microbeads;
• wherein the protective sheet comprises glycol-modified polyethylene terephthalate (PETG);
• and
• wherein the protective sheet has a thickness of 20 mils to 30 mils.

A thermoformable retroreflective laminate for substantially non-planar articles, comprising;

• a first thermoformable layer having first and second sides;
• a plurality of non-uniformly sized microbeads disposed randomly on said first side of said first layer, said microbeads having a reflectivity of at least about 200 lux and being disposed substantially over said first side;
• a second thermoformable layer having first and second sides, said second thermoformable layer contacting at least some of said microbeads;
• an airspace formed between at least a part of said second thermoformable layer and said microbeads,
• wherein said first and second layer with said microbeads disposed therebetween is formed in-situ creating a substantially non-planar article having at least a partially retroreflective surface,
• wherein said second thermoformable layer comprises glycol-modified polyethylene terephthalate (PETG);
• and
• wherein the protective sheet has a thickness of 20 mils to 30 mils.

A thermoformable, high intensity retroreflective laminate, comprising:

• a base sheet of thermoformable plastic;
• a layer of retroreflective microbeads adhered over one surface of the base sheet by way of a thermoformable cushion coat, each of said beads having a semisilvered side engaging the cushion coat;
• a protective sheet of clear thermoformable plastic laminated over and in contact with said layer of retroreflective beads, wherein said protective sheet engages a top surface of some of the microbeads to form airspaces and create infrequent tangential point contact between at least a portion of said protective sheet and said some of the microbeads,
• wherein said laminate is capable of being formed into a contoured, three dimensional article having an encapsulated bead surface with a reflectivity of at least 200 lux, said base layer of sheet material has a thickness of between about 4 and 12 times an average diameter of the microbeads, and the thickness of the protective sheet is between about 4 to 8 times an average diameter of the microbeads,
• wherein the protective sheet comprises glycol-modified polyethylene terephthalate (PETG),
• wherein the cushion coat comprises a polyvinyl copolymer, a thermoplastic polyurethane, and an aminoplast resin;
• and
• wherein the protective sheet has a thickness of 20 mils to 30 mils.