Patent Publication Number: US-2004051948-A1

Title: Systems, methods, and apparatus for patterned sheeting

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
     [0001] This United States (US) non-provisional patent application filed by David Reed claims the benefit of U.S. provisional patent application Serial No. 60/410,206, filed by David Reed on Sep. 11, 2002. 
    
    
     
       FIELD OF THE INVENTION  
       [0002] The invention relates generally to the field of patterned sheeting. Particularly, the invention relates to reflective and retro-reflective sheeting. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0003]FIG. 1 is a perspective view of a film squeezed between an embodiment of a patterned roller and another roller.  
     [0004]FIG. 2 is an exploded view of a patterned ring or shim and a pair of spacer rings or shims from the patterned roller of FIG. 1.  
     [0005]FIG. 3 is a magnified view of a portion of FIG. 2.  
     [0006]FIG. 4A is a perspective view of another embodiment of a patterned roller which is partially assembled together.  
     [0007]FIG. 4B is a perspective view of the patterned roller of FIG. 4A with all patterned rings or shims and/or spacer rings or shims assembled together.  
     [0008]FIG. 4C is a magnified view of a portion of the patterned roller of FIG. 4A.  
     [0009]FIG. 5 is a perspective view of a patterned ring or shim of the patterned roller of FIG. 4A.  
     [0010]FIG. 6 is a magnified view of a portion of the patterned roller of FIG. 4A.  
     [0011]FIG. 7 is a magnified view of a portion of FIG. 6.  
     [0012] FIGS.  8 A- 8 B are views of a portion of a reflective film having full corner cubes to reflect incident light.  
     [0013] FIGS.  9 A- 9 B are exploded side views of other layers and their orientation prior to lamination together with the reflective film.  
     [0014]FIG. 10 is a schematic diagram of an exemplary manufacturing system with a roller stack including the patterned roller.  
     [0015]FIG. 11 is a front view of a patterned roller assembly including the patterned roller.  
     [0016]FIG. 12 is a perspective view of an exemplary roll of reflective film.  
     [0017] FIGS.  13 A- 13 G illustrate applications of reflective film. 
    
    
     [0018] Like reference numbers and designations in the drawings indicate like elements providing similar functionality.  
     DETAILED DESCRIPTION OF THE INVENTION  
     [0019] In the following detailed description of the invention, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it is to be understood that the invention may be practiced without these specific details. In other instances well known methods, procedures, elements, components, and equipment have not been described in detail so as not to unnecessarily obscure aspects of the invention.  
     [0020] Reflectors may use an array of ball or spherical lenses formed out of an optical material to reflect radiation. In other cases, a reflector may use an array of half corner cubes formed out of an optical material to reflect radiation. In some cases, half corner cubes may be combined with ball or spherical lenses to reflect radiation. In other instances, a reflector may use an array of full corner cubes formed out of an optical material to reflect radiation.  
     [0021] The present invention includes methods and apparatus for manufacturing reflective sheeting or film that may be used as a reflector or an element of a reflector. The reflective sheeting or film may have a surface of optical material formed with a microstructured array of half corner cubes or full corner cubes in order to reflect the radiation. In one embodiment, the reflective sheeting or film of the present invention may be formed in an extrusion process using a patterned roller.  
     [0022] Half corner cubes have two boundary surfaces where the incident radiation is reflected twice in order to redirect back toward the incident light source. Full corner cubes use three boundary surfaces where the incident radiation is reflected thrice in order to redirect back toward the incident light source. Full corner cubes typically provide larger range of angles over which incident light may be received and redirected back towards the light source. Provided that the losses are low in the optical material, full corner cubes tend to be more reflectively efficient that half corner cubes. However, full corner cubes are more difficult to manufacture. Typically, reflective film is formed out of a thin film that is embossed with a half corner cube pattern that naturally reflects incident light at a pre-determined angle.  
     [0023] Typical methods of manufacturing an array of half corner cubes into a reflective sheeting or film are by molding, machine cutting, and stamping processes.  
     [0024] The molding process typically requires a mold which is fixed for a given pattern. A molten plastic or other similar optical material in liquid form is poured over and into the mold. The optical material requires a curing time in the mold in order to take a shape which has reflective properties. The curing time can be significant. Additionally, a mold does not lend itself to form full corner cubes in the optical material.  
     [0025] The machine cutting process typically requires a machine tool to individually scribe a pattern into a plastic or other optical material. Individually scribing a pattern is very time consuming and is not a cost effective method of manufacturing a continuous sheet of reflective material.  
     [0026] A stamping process typically requires a rectangular stamp which has a fixed pattern. A soft semi-solid or semi-liquid optical material, such as plastic, is stamped by the stamp into a shape which has reflective properties. Stamping a finite area with a rectangular stamp is also slow and less cost effective.  
     [0027] These typical processes oftentimes introduce seams in between reflective patterns in the reflective sheeting or film in order to provide an adequate size. The seams break up the reflective pattern and are non-reflective thereby reducing the reflectivity or intensity efficiency.  
     [0028] Each of these typical processes may form unbroken half corner cube patterns over a limited area—for example, no larger than nine inches by nine inches unbroken pattern (i.e. a “nine inch pattern block”) with thirty-six nine inch pattern blocks within a forty-eight inch by forty-eight inch sheet. In some cases, the nine inch pattern block may limit the application to this size or otherwise require meticulous splicing to create larger patterns.  
     [0029] The present invention can provide a microstructured film on a continuous roll, without seams, to provide customers with a seamless reflective film of nearly any length. By eliminating the seams in the manufacture of reflective sheeting, reflectivity efficiency can be increased and costs can be reduced by the increased density of the reflective pattern.  
     [0030] To provide continuous roll of a reflective film, a microstructured cylindrical die with the optical pattern cut into its surface is provided. The microstructured cylindrical die is referred to herein as a patterned roller. This microstructured cylindrical die presses its pattern into the plastic film, continuously imprinting the pattern into a warm optical material such as a warm plastic. In typical processes, it is difficult to cut a half or a full corner cube pattern into a cylindrical die.  
     [0031] The patterned roller provides the tooling for a manufacturing process that allows for continuous manufacture of a microstructured reflective film, with either and/or both half corner cubes and full corner cubes. Accurate corner cube grooves can be formed on a three dimensional surface. Rather than a solid cylinder or roller, the patterned roller forms a cylindrical pattern out of multiple pieces or subpatterns. The patterned roller uses one or more narrow annular rings or shims packed tightly together to form an overall cylindrical pattern. Each ring or shim is individually cut to make up a portion of the pattern. In one embodiment, the rings are less than one millimeter wide. By using various numbers of rings or shims placed tightly side by side, a cylinder of varying widths with a desired pattern can be formed.  
     [0032] The patterned roller can provide large, unbroken reflective surfaces with full corner cubes. That is, a surface of the reflective film or sheeting can be formed into a wide and infinitely long unbroken reflective surface. By using one or more rings or shims to form the overall cylindrical pattern of the patterned roller, adjustment of the angles of the surfaces of the full corner cubes may be made, including having different angles on each ring. Full corner cubes may be provided by alternating the alignment of subpattern across rings, from ring to ring. As a result, a number of reflective angles and reflective effects may be made into a surface of an optical material to provide the reflective or retro-reflective of incident light or radiation. The cube angles (i.e., wider or narrower) and the depth (i.e., shallower or deeper) of the cube can be readily adjusted varying their orthogonality by changing the rings or shims of the overall cylindrical pattern to change the reflective characteristics of a reflective film and an end product. Larger, deeper cubes can be formed into a surface without sacrificing the reflective quality. The patterned roller is adaptable in that different reflective sheeting or film can be manufactured using different configurations of the same tool. The overall cylindrical pattern need only be modified by changing the configuration of rings or shims over the cylindrical pattern. Over a single patterned roller, there can be many sizes and kinds of corner cubes coincidentally co-existing over the extent of the cylindrical face of the roller to form the overall cylindrical pattern.  
     [0033] The patterned roller includes a base cylinder, serving as a holder for the rings or shims. The base cylinder contains one or more guides lengthwise, that serve to align the rings properly and help hold them securely coupled together. The outside diameter and shape of the base cylinder is similar to the inside diameter and shape of the rings, to retain the positions of the rings/shims and avoid shifting of the pattern.  
     [0034] Referring now to FIG. 1, a first embodiment of a patterned roller  100 A is illustrated. The patterned roller  100 A may also be referred to as a patterned drum or a patterned revolving cylinder. The patterned roller  100 A includes a cylindrical pattern. In the preferred embodiment, the cylindrical pattern is used to form microstructures in a surface of a material layer.  
     [0035] An optical film or layer may be sandwiched between the patterned roller  100 A and another roller  104 . In the preferred embodiment, the pattern of the patterned roller  100 A is formed into a surface of the optical film or layer to generate a continuous pattern of a patterned or reflective film, layer of sheet  102 .  
     [0036] In one embodiment, the optical film or layer is a plastic material heated into a soft state between a liquid and a solid so that the cylindrical pattern of the patterned roller  100 A is imprinted into a surface of the optical film. In another embodiment, the pattern of the patterned roller  100 A is sufficiently sharp to cut into a surface of the optical film in its solid state.  
     [0037] As illustrated in FIG. 1, the patterned roller  100 A may include one or more rotatable axles, shafts, or journals  112 , one or more N patterned shims/rings  114 , M spacer shims/rings (not illustrated in FIG. 1), a pair of end flanges  116 , a pair of rods  118 , a center cylindrical sleeve  120 , and one or more fasteners  122  at each end flange  116 . The center cylindrical sleeve  120  may also be referred to as a cylindrical core  120 . The respective number N and M of the one or more patterned rings and spacer shims/rings depends upon the desired cylindrical pattern of the patterned roller and the optical film. In one embodiment, M=N+1. In another embodiment, M=0 and no spacer shim/ring is used. The patterned shims/rings  114  have a width which is a function of the desired pattern. The spacer shims/rings may not have a pattern cut or formed into them but may be sized appropriately to form a straight line, groove or an indentation pattern in the surface of the film. The spacer shims/rings may be considered to have an edge pattern that forms the straight line, the groove or the indentation pattern in a surface.  
     [0038] The patterned roller  100 A rotates about the one or more axles  112  as one or more material layers of film are pushed and/or pulled through between the patterned roller and the roller  104  to form the reflective film  102 . The cylindrical pattern of the one or more of the N patterned shims and the M spacer shims is formed into a surface of the reflective film  102  as the patterned roller rolls over it. The pattern formed in the surface of the film can be considered a continuous pattern. The one or more of the N patterned shims  114  are located around the center cylindrical sleeve  120 . The pair of rods  118  retain the one or more of the N patterned shims  114  as well as the M spacer shims (not illustrated), if any, in a fixed position on the patterned roller  100 A. The end flanges  116  sandwich the one or more of the N patterned shims  114 ; the M spacer shims, if any; one or more rods  118 ; and the center cylindrical sleeve  120  between them. The fasteners  122 , at each of the end flanges  116 , squeeze the end flanges  116  together and hold the other elements sandwiched between them together as a unit. In one embodiment, the fasteners  122  are each a nut and bolt combination.  
     [0039] The N patterned shims and the M spacer shims, if any, slidingly couple to one or more rods  118 . The one or more rods  118  are located around the patterned roller parallel to the axle  112 . The one or more rods  118  may be located on opposite sides of the patterned roller  100 A as illustrated or spaced apart at angles from each other around the patterned roller  100 A. FIG. 1 illustrates a pair of rods  118  located on opposite sides and spaced equally by one hundred eighty degrees from each other. However, there may be one, two, three, four or more rods  118  located around the patterned roller  100 A to retain the shims.  
     [0040] Referring now to FIG. 2, an exploded view of the patterned shim  114  and a pair of spacer shims  214  is illustrated. When assembled on the patterned roller  100 A, the patterned shim  114  may be sandwiched by the pair of spacer shims/rings  214 . Each of the spacer shims  214  include one or more alignment holes  218  to slide over the one or more rods  118 . Similarly, each of the patterned shims  114  includes one or more alignment holes  218 ′ to slide over the one or more rods  118 . Additionally, each spacer shim  214  and patterned shim  114  include a center opening  220  to slide over the center cylindrical sleeve  120 .  
     [0041] Referring now to FIG. 3, a magnified view of a portion of FIG. 2 is illustrated. Each of the one or more patterned shims  114  includes a subpattern  300  around its outer edge. In the case of one patterned shim  114 , the subpattern  300  of the one patterned shim  114  may be the overall pattern if no spacer shim  214  is used to form part of the overall pattern. Each of the subpatterns  300  of each patterned shim  114  may be similar or unique in order to complete the overall cylindrical pattern of the patterned roller which is rolled into the surface of the reflective film  102 . The subpattern  300  may alternate between odd and even patterned shims  114 . The subpattern  300  of each patterned shim  114  may be the same but the subpattern may be slightly offset from one patterned shim  114  to the next patterned shim on the patterned roller  100 . The overall cylindrical pattern of the patterned roller  100  may be readily changed by replacing the patterned shims  114  and any spacer shims with a different configuration of patterned shims and spacer shims.  
     [0042] Each of the patterned shims includes a thickness  302  which may vary depending on the subpattern selected for a given patterned shim. In comparison, the thickness of the spacer shims  214  is substantially small. For example, in one embodiment the thickness of the spacer shims is twenty five percent of the thickness of the patterned shims. However, the spacer shims  214  do form their own subpattern within the overall pattern. In one case, the spacer shims  214  may form a groove or a line in a surface of the film. While the thickness of the spacer shims  214  are illustrated as being substantially small or nil in FIG. 3, they may be provided with a more substantial thickness to further define a subpattern within the over all pattern.  
     [0043] Referring now to FIG. 4A, a second embodiment of a patterned roller  100 B is illustrated. The patterned roller  100 B may also be referred to as a patterned drum or a patterned revolving cylinder. The patterned roller  100 B includes a number of elements of the patterned roller  100 A. The patterned roller  100 B includes a cylindrical pattern. In the preferred embodiment, the cylindrical pattern is to form microstructures in a surface of a material layer. However, the patterned shims and the spacer shims are retained differently in each of the respective patterned rollers.  
     [0044] Patterned roller  100 B includes one or two shafts, journals or axles  112 , one or more of the N patterned shims  114 ′, M spacer shims  214 ′, a pair of end flanges  116 ′, a center cylindrical sleeve  120 ′, and one or more fasteners  122 . The center cylindrical sleeve  120 ′ may also be referred to as a cylindrical core  120 ′. In the embodiment of the patterned roller  100 B, the center cylindrical sleeve  120 ′ includes a guide slot  418 . The guide slot  418  engages with a guide tab in each patterned shim  114 ′ and each spacer shim  214 ′ to retain the angular orientation of each around the center cylindrical sleeve  120 ′. The end flanges  116 ′ differ slightly from the end flanges  116  of FIG. 1 because the guide slot  418  may be used without the one or more rods  118 .  
     [0045] Referring now to FIG. 4B, all of the patterned shims  114 ′ and/or spacer shims  214 ′ are assembled together on the patterned roller  100 B to form a cylindrical pattern  400 . Due to the micromachined surfaces in the one or more patterned shims  214 ′, details of the cylindrical pattern  400  are not illustrated in FIG. 4B and it may appear to be all black.  
     [0046] Referring now to FIG. 4C, a magnified view of a portion of the patterned roller  100 B is illustrated. The cylindrical pattern  400  may include one or more of the patterned shims  114 ′ and zero or more of the spacer shims  214 ′ between the pair of end flanges  116 ′. The spacer shims  214 ′ may be located on either side of a patterned shim  114 ′. Alternatively, patterned shims  114 ′ may be adjacent each other in some cylindrical pattern  400 . One or more patterned shims  114 ′ may be located on either side of a spacer shim  214 ′. Alternatively, spacer shims  214 ′ may be adjacent each other in another cylindrical pattern  400 .  
     [0047] The subpattern  300  may be formed in each patterned shim  114 ′ around the outside circumference or outer edge of each shim. The subpattern  300  may repeat around the outside circumference of the patterned shim. Alternatively, the subpattern  300  may be unique along any arc or the entire circumference of a given patterned shim  114 ′.  
     [0048] The subpattern  300  may be unique to each shim  114  within the overall cylindrical pattern  400 . That is, no two patterned shims  114 ′ may be alike. Alternatively, a set of patterned shims  114  may each be unique within the set, with the set of patterned shims  114  being repeated across the overall cylindrical pattern  400 . In yet another embodiment, each pattern shim  114 ′ may have the same identical subpattern  300  to form some overall cylindrical pattern  400 . In this manner, the cylindrical pattern  400  is easily adaptable to form a pattern in a surface of a material.  
     [0049] Referring back to FIG. 4B, a drive groove  420  formed into an the one or more axles  112  is illustrated. The drive groove  420  is parallel with and near an end of the one or more axles  112 . On one axle of one or more axles  112  or one side of an axle  112 , the drive groove  420  may be provided to couple to the axle to a drive gear or motor to rotate the patterned roller  100 B. In one embodiment, a key (not shown) may be positioned into the drive groove  420  to couple to a keyway of a gear or other drive coupler. In another embodiment, the gear or other drive coupler may have a tab that slides into the drive groove  420 . In another embodiment, the drive groove  420  may be configured as a drive key extending outward from the cylindrical surface of the axle.  
     [0050] Referring now to FIG. 5, a perspective view of the patterned shim  114 ′ is illustrated. The patterned shim  114 ′ illustrated in FIG. 5 is exemplary of the N patterned shims  114 ′ of the patterned roller  100 B. The patterned shim  114 ′ includes the center opening  220 ′, the guide tab  518 , and the subpattern  300 . The guide tab  518  is located on the inside edge of the patterned shim  114 ′ in the center opening  220 ′. The center opening  220 ′ allows the patterned shim  114 ′ to slide over outside surface of the center cylindrical sleeve  120 ′. The guide tab  518  of the patterned shim  114 ′ slides within the guide slot  418  as the center opening  220 ′ slides over the outside surface of the cylindrical sleeve  120 ′.  
     [0051] The patterned shims  114  and  114 ′ as well as the spacer shims  214  and  214 ′ are generally ring shaped or annular. The patterned shims  114  and  114 ′ as well as the spacer shims  214  and  214 ′ may also be considered to be generally shaped as a hollow cylinder with a finite thickness and height. The outer edge of each of the patterned shims varies around its outer edge or circumference due to the subpattern  300 . The spacer shims may be constant or vary around its outer edge or circumference. The inner edge or surface of the patterned shims and spacer shims is shaped to match the shape of the center cylindrical sleeve  120 . In one embodiment, the center cylindrical sleeve  120  is a circular cylinder such that the inner edge or surface of each of the spacer shims and patterned shims are generally a circular cylindrical shape as well. In other embodiments, the inner edge may be a square, a rectangular, a hexagon or another cylindrical shape to match the shape of the center cylindrical sleeve.  
     [0052] The spacer shims  214  and the patterned shims  114 ′ assemble onto the center cylindrical sleeve  120 ′ with the guide tabs  518  of each being aligned with the guide slot  418 .  
     [0053] Referring now to FIG. 6, a magnified view of another portion of the rings/shims of the patterned roller  100 B is illustrated. As previously discussed, the patterned shim  114 ′ may be sandwiched by a pair of spacer shims  214 ′. The subpattern  300  of each patterned shim  114 ′ is repeated around the outside circumference or outer edge thereof.  
     [0054] Referring now to FIG. 7, a magnified view of a portion of the shims/rings of FIG. 6 is illustrated. The subpattern  300  continues around the outer edge or circumference of the patterned rings  114 ′. The subpattern  300  may form corner-cubes within an area of the reflective film  102 . The space shims or rings  214 ′ may form a groove, slot, or line within the reflective film  102  separating columns of corner-cubes formed by the subpattern  300  of each patterned shim/ring  114 ′.  
     [0055] The subpattern  300  may be machined into the patterned rings  114  or  114 ′ using a precision cutting tool. Alternatively, the patterned rings  114  or  114 ′ may be molded or cast to include the subpattern  300  along the outer edge. A unique subpattern may be formed into each patterned ring. Alternatively, a similar subpattern may be formed into each patterned ring but at different angular positions around the cylindrical sleeve. Alternatively, the subpattern  300  may be periodically similar in shape and position across the patterned rings  114  or  114 ′ assembled onto the patterned roller  100 A and  100 B.  
     [0056] The one or more patterned rings  114  or  114 ′ may each be uniquely numbered to identify positions on the cylindrical sleeve  120  or  120 ′ with respect to each other and any spacer rings. Similarly, the zero or more spacer rings  214  or  214 ′ may each be uniquely numbered to identify their position on the cylindrical sleeve  120  or  120 ′ with respect to each other and the patterned rings  114  or  114 ′.  
     [0057] Referring now to FIGS.  8 A- 8 D, views of a portion of the reflective film  102  is illustrated as a reflective film  102 ′. FIG. 8A illustrates a top view of a reflective film  102 ′. FIG. 8B illustrates a side view of the reflective film  102 ′. FIG. 8C illustrates a perspective view of the reflective film  102 ′. FIG. 8D illustrates a cross section of the reflective film  102 ′. Because either embodiment of the patterned roller  100 A and  100 B can form a pattern in the film, the patterned roller will generally be referred to as patterned roller  100 .  
     [0058] As previously discussed, as the film  102  is pushed or pulled from between the patterned roller  100  and the roller  104 , an overall pattern is formed in a surface of the reflective film  102 . The pattern formed in the reflective film  102  by the patterned roller  100  is not a molding process.  
     [0059] The reflective film  102 ′ includes a plurality of full corner cubes  800 . The reflective film  102 ′ includes a body region  802  and a microstructure region  804 . The plurality of corner cubes  800  are formed in the microstructure region  804  of the reflective film  102 ′. The body region  802  of the reflective film  102 ′ supports the microstructure region  804 .  
     [0060] In an embodiment of the pattern of the patterned roller  100 , the plurality of full corner cubes  800  are arranged into columns  814 A- 814 F. Each column  814 A- 814 F is separated by respective lines, slots or grooves  824 A- 824 G.  
     [0061] Each corner cube  800  has a base edge (B), a tail (T), a head (H), a vertex or apex (A), and three surfaces (S 1 , S 2 , and S 3 ) at which light may be reflected. The apex, where the three surfaces (S 1 , S 2 , and S 3 ) join together at a corner, is nearer the head of each corner cube  800 . The tail of each corner cube  800  is opposite the head. The base edge of each corner cube  800  may be level with a base surface of the reflective film. Along a column, the base edge of one corner cube  800  may join the base edge of the next corner cube. Each corner cube resembles a tetrahedron. That is, each corner cube resembles a triangular pyramid having three triangular sides and a triangular base. The triangular pyramid shape may or may not be symmetrical. That is three triangular sides may have non-equal sides to form an asymmetrical triangular pyramid or a non-regular tetrahedron.  
     [0062] Within each column, each corner cube  800  reverses orientation from the next down the respective column. Each corner cube  800  along a row, (i.e., across columns), has its orientation aligned with the next. For example, in one row the corner cubes  800  are aligned with the tail on the left side and the head on the right side of the reflective film. In the next row adjacent thereto, the corner cubes  800  are aligned with the head on the left side and the tail on the right side of the reflective film  102 .  
     [0063] The reflective film  102 ′ illustrated in FIGS.  8 A- 8 D may only be a portion of an entire sheet or roll of reflective film. For the portion illustrated in FIGS.  8 A- 8 D, the reflective film  102 ′ may be formed by six patterned shims  114  or  114 ′ and seven spacer shims  214  or  214 ′ of the patterned roller  100 . Each column  814 A- 814 F of corner cubes formed in the reflective film is formed by the respective patterned shim  114  or  114 ′. Each of the grooves  824 A- 824 G between columns  814 A- 814 F in the reflective film  102 ′ is formed by the respective spacer shims  214  or  214 ′.  
     [0064] In one embodiment, the corner cubes formed into the surface of the reflective film  102  are male corner cubes. In another embodiment the corner cubes formed in the surface may be female corner cubes. In either case, the overall pattern rolled into the reflective film  102  may be a seamless continuous pattern.  
     [0065] Referring now to FIGS.  9 A- 9 B, the reflective film  102  or  102 ′ may be laminated with other layers of materials depending upon the desired application to form a reflective laminate sheeting. The optical microstructures cut or imprinted into the surface of the reflective film  102  or  102 ′, such as full corner cubes, may be formed therein to reflect light which is incident from a front side of the optical microstructures or from a back side of the optical microstructures.  
     [0066] In FIG. 9A, light rays  910 A are coupled into the back side of the optical microstructures and light rays  910 B are coupled into the front side of the optical microstructures in the reflective layer  102 ′ of the reflective laminate sheeting  900 A.  
     [0067] In FIG. 9B, light rays  910 A are coupled into the back side of the optical microstructures and light rays  910 B are coupled into the front side of the optical microstructures in the reflective layer  102 ′ of the reflective laminated sheeting  900 B.  
     [0068]FIG. 9A further illustrates that one or more layers of other materials may be laminated on either or both top and bottom of the reflective layer  102 ′. The one or more layers  901 A- 901 N may be laminated together with the reflective layer  102 ′ on a first surface. The one or more layers  902 A- 902 N may be laminated together with the reflective layer  102 ′ on a second surface opposite the first surface.  
     [0069]FIG. 9B further illustrates the one or more layers of other materials, which may be laminated together with the reflective layer  102 ′, may have various widths and various thicknesses. For example, layer  911  has a width W1 and a thickness T1. Layer  912  has a width W2 and a thickness T2 each differing respectively from the width W1 and the thickness T1 of layer  911 , for example. The lengths of the layers may also vary along the laminated film. Furthermore, the widths, thicknesses, and lengths of the other material layers need not be uniform across the reflective layer  102 ′.  
     [0070] The differing widths and lengths may be used to alter the reflectivity efficiency to display lettering, for example, or alter the color or frequency of the reflected light back towards a source, for example. The differing thicknesses may similarly be used to alter the reflectivity efficiency or may be related to the amount of material needed to provide a desired effect. The type of material used to form the reflective sheet  102  may alter the reflectivity efficiency of the reflective laminate. The type of the other materials, their index of refraction, and position with respect to the optical microstructures, may also alter the reflectivity efficiency of any reflective laminate. Furthermore, the reflectivity efficiency can be maximized for some frequencies or colors of light and minimized for other frequencies or colors of light by appropriate selection of the other layers of material, their thicknesses, and dimensions. Some of the other material layers may be transparent or opaque to certain desired wavelengths or frequencies of light and not others.  
     [0071] The reflective sheet layer  102  may be a polymer or plastic layer such as a thermoplastic or other material layer having optical properties that can be cut or patterned by the patterned roller  100 . In one embodiment the layer  102  is a transparent semicrystalline polymer.  
     [0072] Examples of the types of other material layers that may be laminated together with the reflective layer  102  are a reflective film coating, color pigments, ink, phosphor, silica, polarizer, sealant, protective coating, binder, substrate, adhesive, and removable release sheet layer. The adhesive layer may be a pressure sensitive adhesive, a heat activated adhesive, or a radiation activated adhesive. The removable release sheet layer may be used to protect the adhesive layer until the reflective laminate is ready to be coupled to a surface.  
     [0073] The silica (silicon-di-oxide) may be used to fill into voids formed by the optical microstructures into an even level surface. One form of silica that may be used is mica.  
     [0074] The protective coating layer may be provided to resist abrasion and stains such as may be experienced by tires running over a pavement marker. The protective coating layer may also provide soil and dew repellency to maintain the original reflectivity efficiency of the laminate after exposure to moisture and dirt or grime.  
     [0075] A substrate may be provided to fix the reflexive laminate to a surface by mechanical means, such as by sewing into a garment or shoe. The binder layer or adhesive layer may be provided to affix the reflective laminate to a surface.  
     [0076] A reflective film, such as a metal foil formed of a thin layer of aluminum, brass, copper, gold, nickel, platinum, silver, or titanium may also be used to reflect light and/or provide a difference in index of refraction. The reflective film may be laminated or alternately sprayed onto the reflective layer  102 . Other materials that may be used to form a reflective film layer such as titania, zirconia, cobalt/iron mixture, zirconia-di-oxide, zinc oxide, white lead, antimony oxide, zinc sulfide, alumina and magnesia.  
     [0077] The other layers may also be multiple alternating layers of two polymers each with a thickness less than one hundred nanometers, selected to have a mismatch in refractive indices to cause constructive interference of light.  
     [0078] The layers may be laminated together by pressure and heating in the extrusion process. Alternatively and/or conjunctively, the layers may be laminated together by pressure and the use of a thin layer of glue, binder, or epoxy selectively used between the layers to hold multiple layers together.  
     [0079] Referring now to FIG. 10, an exemplary schematic of a processing line, production line, or manufacturing system  1000  is illustrated. In one embodiment, the manufacturing system  1000  is a coextrusion system to extrude a reflective film. The flow of materials in the exemplary manufacturing system  1000  proceeds from left to right across the page. The manufacturing system  1000  receives as in an input a plurality of pellets, beads, pulverized, chunks, or other forms of raw materials  1001  in order to form a roll of reflective film  1002  as its output.  
     [0080] The exemplary manufacturing system  1000  includes an extruder  1014 , an extrusion die  1016 , a patterned roller stack  1020 , an idler roller (“idler”)  1030 , a pair of nip rollers  1032 , and a wind-up roller  1034 . The exemplary manufacturing system  1000  may further include a feeder, a blender, a screen pack filter, a gear pump, a feed block, a thickness gauge, a slitter, and a dancer in various positions of the manufacturing system. Additionally, the exemplary manufacturing system  1000  may have one or more flows of molten or liquefied material that can be combined by a feedblock for multiple layers of the reflective film. Alternatively, a laminating machine may be used to laminate multiple layers of materials together including a reflective film layer  102 . In another case, a vacuum former may be used to apply additional material layers to the reflective film layer  102 .  
     [0081] The patterned roller stack  1020  includes a first roller  1022 , the patterned roller  100 , and a second roller  1024 . The patterned roller  100  is driven by a motor to pull the extruded film into the patterned roller stack  1020  for patterning. A first surface of the extruded film makes intimate contact with the patterned roller  100  so that the cylindrical pattern of the roller  100  may be imprinted or cut into the first surface. The first roller  1022  at the top of the stack presses against a second surface of the extruded film to squeeze the film between the patterned roller  100  and the first roller  1022 . The first roller  1022  can also partially cool the extruded film. Thus, the first roller  1022  may also be referred to as a top chill roller. The second roller  1024  at the bottom of the stack may be driven by a motor to pull the reflective film out through the patterned roller stack  1020 . The second roller  1024  can also cool the extruded reflective film into a solid state. Thus, the second roller  1024  may also be referred to as a bottom chill roller. The patterned roller stack  1022  may further include a chassis, stand, or frame  1026  to which the first roller  1022 , the patterned roller  100 , and the second roller  1024  may be rotatably coupled. The frame  1026  supports the positions of the rollers therein and may move one or more rollers together in order to squeeze and apply pressure to the extruded film.  
     [0082] To begin manufacturing of the extruded reflective film, raw materials  1001  of appropriate proportions are coupled into the extruder  1014 . The extruder  1014  heats up the raw material from a solid state into a liquefied or molten state, mixes the raw materials together, and pushes the molten raw materials out as liquefied or molten raw materials  1004 .  
     [0083] It is desirable to modify the cross section of the liquefied raw materials  1004  into a cross section of a layer or a sheet of material. The liquefied raw materials  1004  are coupled into the extrusion die  1016 . The extrusion die  1016  converts a first cross section of the liquefied raw materials into a thin wide cross section of a sheet, film or layer of extruded film  1006 . The extruded film  1006  has a pair of side edges and a top surface and a bottom surface. The side edges of the extruded film  1006  are relatively thin and the top and bottom surface of the extruded film  1006  are relatively wide.  
     [0084] The flattened sheet, film, or layer of extruded film  1006  is coupled into the patterned roller stack  1020  between the first roller  1022  and the patterned roller  100 .  
     [0085] As discussed previously, the patterned roller  100  includes the cylindrical pattern  400  formed by the one or more patterned rings  114  or  114 ′ and/or the zero or more spacers  214  or  214 ′. The continuous cylindrical pattern  400  of the patterned roller  100  is imprinted, pressed or cut into a surface of the sheet of extruded film  1006  to form a microstructure therein as the film  102 . In one embodiment, the microstructures in the film are full corner cubes and the film  102  is an extruded reflective film or layer. The continuous cylindrical pattern  400  of the patterned roller  100  forms the continuous pattern  800  in the surface of the reflective layer  102 .  
     [0086] The reflective layer  102  wraps around a portion of the second roller  1024  of the patterned roller stack  1026  to re-orient the film  102 . The second roller  1024  further provide a means for added cooling of the sheet of material into a solid state from a soft state. The sheet of material output from the patterned roller stack  1020  is then coupled towards the wind-up roller  1034 .  
     [0087] The film  102  wraps over the idle roller  1030  to alter the angle over which the film flows in the manufacturing system. The film  102  is pulled over the idle roller  1030  by the pair of nip rollers  1032 . Each of the nip rollers  1032  are rollers driven by a motor. The film  102  is squeezed between the pair of nip rollers  1032  and flows through towards the wind-up roller  1034 .  
     [0088] The wind-up roller  1034  receives the sheet of the film  102  and winds it up into a roll  1002 . In the case that the film  102  is extruded reflective film, the roll  1002  is a reflective film roll of extruded reflective sheeting or film. The wind up roller  1034  is driven in order to tightly wind the extruded film into a spiral roll. The wind up roller  1034  may include a spool having edges to maintain alignment of the film  102  as its wound up into the spiral roll.  
     [0089] In summary, the manufacturing system  1000  includes an extrusion or liquefaction process, a flattening process, a patterning process, and a wind-up process. The extrusion or liquefaction process is performed by the extruder  1014 . The flattening process is performed by the extrusion die  1016 . The patterning process is performed by the patterned roller stack  1020 . The wind-up process is performed by the nip rollers  1032  and the wind-up roller  1034 .  
     [0090] Referring now to FIG. 11, an exemplary patterned roll assembly  1100  is illustrated. The patterned roll assembly  1100  includes the patterned roller  100 , a pair of bearings  1102 , a gear box  1104 , and an AC motor  1106  coupled together as illustrated in FIG. 11. The pair of bearings  1102  provide support points to the patterned roller  100  coupled to the axle or journal  112  on the inside. The outside of the pair of bearings  1102  may couple to the frame of the patterned roller stack  1020  in order to support the patterned roll assembly  1100  therein. The pair of bearings  1102  allow the patterned roller  100  to rotate within the patterned roller stack. Each of the pair of bearings  1102  may be a roller bearing.  
     [0091] The motor  1106  includes a rotating shaft to drive the gear box  1104 . The gear box  1104  includes gears to ratio the rotations of the rotating shaft to rotations of the patterned roller. In one embodiment, the ratio of the gearbox reduces the number of rotations of the motor that are transferred to the patterned roller. In another embodiment, the ratio of the gearbox  1104  increases the number of rotations of the motor that are transferred to the patterned roller  100 . In yet another embodiment, the ratio of the gearbox  1104  is one and the same number of rotations of the motor  1106  are transferred to the patterned roller  100 . The ratio of the gearbox  1104  may be selective similar to a transmission to vary the rotational speed of the patterned roller  100 .  
     [0092] Referring now to FIG. 12, a roll  1002  including the reflective sheeting  120  is illustrated. As previously discussed other layers of materials may be laminated around the reflective sheeting  102  to form a reflective laminate  1200 . The reflective laminate includes the reflective sheeting  102  and one or more other layers of other materials, such as layers  1201 - 1204  for example. As previously discussed and illustrated in FIGS.  9 A- 9 B, the one or more layers of other materials may be sized differently and located on either side of the reflective sheeting.  
     [0093] Thus, the roll  1002  may be a roll of reflective sheeting  102  alone, without other layers. Alternatively the roll  1002  may be a roll of a reflective laminate  1200  including other layers laminated together with the reflective sheeting  102 . The roll  1002  may further include a center cylinder core  1210  upon which the reflective sheeting  102  or reflective laminate  1200  may be spiral wound. The center cylinder core  1210  may be a spool including edges to align the reflective sheeting  102  or reflective laminate  1200  as its wound around by the wide up roller.  
     [0094] Referring now to FIGS.  13 A- 13 G, exemplary applications of the reflective film  102  are illustrated. The reflective film  102  can be used in a broad range of reflector applications including but not limited to reflective signage, pavement markers, sportswear, and safety clothing. Reflectors and reflective film can be incorporated into articles of manufacture in a number of ways. The reflector can be formed as a part of the article, such as in a spoke reflector for a bicycle or a tail reflector for a vehicle. Alternatively, the reflector can be formed into a sheet or a strip of material layers and then applied or coupled to the article. Reflective tape can be applied to clothing, for example. Reflective sheeting or film may be applied to highway signage or markers. The reflective film  102  or reflective laminate may be spooled or wound off of the roll  1002  and applied to the article during manufacturing.  
     [0095] In FIG. 13A, the reflective film  1002 A representing a portion of the roll  1002  is embodied in a license plate  1300 A. The letters and numbers may be formed by including one or more different colored ink layers to a reflective laminate  1200 .  
     [0096] In FIG. 13B, the reflective film  1002 B representing a portion of the roll  1002  is embodied in a shoe  1300 B. The reflective film  1002 B may include a substrate to be sewn to the shoe  1300 B and/or an adhesive to be glued thereto.  
     [0097] In FIG. 13C, the reflective film  1002 C representing a portion of the roll  1002  is embodied in a highway sign  1300 C, such a stop sign.  
     [0098] In FIG. 13D, the reflective film  1002 D representing a portion of the roll  1002  is embodied in an article of clothing  1300 D, such as a vest.  
     [0099] In FIG. 13E, the reflective film  1002 E representing a portion of the roll  1002  is embodied in a pavement marker  1300 E. The pavement marker  1300 E is affixed to pavement  1352  by an adhesive  1354  as illustrated in FIG. 13E.  
     [0100] In FIG. 13F, the reflective film  1002 F representing a portion of the roll  1002  is embodied in reflectors  1300 F and  1300 F′ of an automobile  1360 . Reflectors  1300 F are side markers or side reflectors of the automobile  1360 . The reflectors  1300 F′ are rear reflectors or front reflectors of the automobile  1360 .  
     [0101] In FIG. 13G, the reflective film  1002 G representing a portion of the roll  1002  is embodied in reflectors  1300 G and  1300 G′ and  1300 G″ of a bicycle  1370 . The reflectors  1300 G are spoke or wheel reflectors. The reflectors  1300 G′ are front or rear bicycle reflectors. Reflector  1300 G″ are pedal reflectors.  
     [0102] Because the patterned roller acts as a printing or cutting roller and not a mold, there is little to no curing time needed for the optical reflective sheeting—providing a high speed method of forming extruded reflective sheeting. The patterned roller allows a continuous sheet of full corner cubes to be formed into a surface of a sheet of optical material. By using the patterned roller, the pattern over the continuous sheet is seamless. The patterned roller is adaptable. That is, the pattern formed by the patterned roller can be altered by changing the patterned rings and the spacer rings with another configuration of patterned rings and spacer rings.  
     [0103] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art after reading the disclosure. For example, the patterned roller is described herein as being used to manufacture an extruded reflective film. However, the patterned roller may also be used to form other types of structures or microstructures in the surface of a film or sheet of material. Rather than limiting the invention to the specific constructions and arrangements shown and described herein, the invention should be construed according to the following claims.