U.S. patent number RE29,396 [Application Number 05/649,594] was granted by the patent office on 1977-09-13 for pin having nonaligned cube axis and pin axis and bundle of such pins.
This patent grant is currently assigned to Amerace Corporation. Invention is credited to Sidney A. Heenan.
United States Patent |
RE29,396 |
Heenan |
September 13, 1977 |
Pin having nonaligned cube axis and pin axis and bundle of such
pins
Abstract
A pin for use in making the reflector includes an elongated
.[.snank.]. .Iadd.shank .Iaddend.of regular polygon outline and a
cube-corner formation at one end. The cube axis of the cube-corner
formation is at an angle other than zero degrees with respect to
the pin axis. A group of such pins are assembled into a pin bundle
for use in making a mold insert for the reflector.
Inventors: |
Heenan; Sidney A. (Park Ridge,
IL) |
Assignee: |
Amerace Corporation (New York,
NY)
|
Family
ID: |
27069469 |
Appl.
No.: |
05/649,594 |
Filed: |
January 16, 1976 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
354153 |
Apr 24, 1973 |
3923378 |
|
|
Reissue of: |
550475 |
Feb 18, 1975 |
03926402 |
Dec 16, 1975 |
|
|
Current U.S.
Class: |
204/281;
249/114.1; 249/117; 359/530; 425/DIG.3; 425/DIG.30; 425/808 |
Current CPC
Class: |
G02B
5/124 (20130101) |
Current International
Class: |
G02B
5/124 (20060101); G02B 5/12 (20060101); C25D
001/00 (); C25D 001/06 (); B29C 001/00 (); B29D
011/00 () |
Field of
Search: |
;204/281,7 ;249/117,141
;350/102 ;425/808,DIG.30 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Mack; John H.
Assistant Examiner: Valentine; D. R.
Attorney, Agent or Firm: Bender; S. Michael Sandler; Ronald
A.
Parent Case Text
This is a division of application Ser. No. 354,153, filed Apr. 24,
1973.Iadd., now U.S. Patent No. 3,923,378. .Iaddend.
Claims
What is claimed is:
1. A pin for use in making cube-corner reflectors capable of
reflecting light back to the source thereof said pin comprising an
elongated shank being of regular polygon outline and having a
longitudinally extending pin axis, and a cube-corner formation at
one end of said shank and having a cube axis at an angle to said
pin axis of other than zero degrees, said cube-corner formation
having three mutually perpendicular faces symmetrically arranged
with respect to said cube axis and respectively intersecting in
three mutually perpendicular edges.
2. The pin set forth in claim 1, wherein said elongated shank is
square in outline.
3. The pin set forth in claim 1, wherein said pin is constructed of
stainless steel.
4. The pin set forth in claim 1, wherein said predetermined angle
is in the range of about 6.degree. to 13.degree..
5. A pin for use in making cube-corner reflectors capable of
reflecting light back to the source thereof said pin comprising an
elongated shank being of rectangular outline and having a
longitudinally extending pin axis, and a cube-corner formation at
one end of said shank and having a cube axis at an angle to said
pin axis of other than zero degrees, said cube-corner formation
having three mutually perpendicular faces symmetrically arranged
with respect to said cube axis and respectively intersecting in
three mutually perpendicular edges, said cube-corner formation
having a given side which is rectilinear and is contained by one of
said faces and lies in a plane perpendicular to said pin axis.
6. The pin set forth in claim 5, wherein one of said one edges lies
in the plane containing said pin axis and said cube axis.
7. The pin set forth in claim 5, wherein none of said edges lies in
the plane containing said pin axis and said cube axis.
8. A pin for use in making cube-corner reflectors capable of
reflecting light back to the source thereof said pin comprising an
elongated shank being of rectangular outline and having a
longitudinally extending pin axis, a cube-corner formation at one
end of said shank and having a cube axis at an angle to said pin
axis of other than zero degrees, said cube-corner formation having
three mutually perpendicular faces symmetrically arranged with
respect to said cube axis and respectively intersecting in three
mutually perpendicular edges, said cube-corner formation having one
of said edges thereof terminating at a corner of the associated
outline.
9. The pin set forth in claim 8, wherein said one edge lies in a
plane containing said cube axis and said pin axis.
10. A pin bundle for use in making cube-corner reflectors capable
of reflecting light back to the source thereof over a wide angle,
said pin bundle comprising a plurality of pins each including an
elongated shank and a cube-corner formation at one end thereof and
a cube axis, said elongated shank being of regular polygon outline
and having a longitudinally extending pin axis, said cube-corner
formation having a cube axis at an angle to said pin axis of other
than zero degrees, said cube-corner formation having three mutually
perpendicular faces symmetrically arranged with respect to said
cube axis and respectively intersecting in three mutually
perpendicular edges, the pin axes respectively of said pins being
disposed substantially parallel to one another.
11. The pin bundle set forth in claim 10, wherein said elongated
shank has a square outline.
12. A pin bundle for use in making cube-corner reflectors capable
of reflecting light back to the source thereof over a wide angle,
said pin bundle comprising a plurality of pins each including an
elongated shank and a cube-corner formation at one end thereof and
a cube axis, said elongated shank being of regular polygon outline
and having a longitudinally extending pin axis, each of said
cube-corner formations having three mutually perpendicular faces
symmetrically arranged with respect to said cube axis and
respectively intersecting in three mutually perpendicular edges,
the pin axes respectively of said pins being disposed substantially
parallel to one another, the cube axes of a first group of said
pins being inclined with respect to the associated pin axes at a
first angle as measured in a predetermined plane, the cube axes of
a second group of said pins being inclined with respect to the
associated pin axes at a second different angle as measured in said
predetermined plane.
13. The pin bundle set forth in claim 12, wherein the cube axes of
the pins in said first group are substantially parallel to one
another, and the cube axes of the pins in said second group are
substantially parallel to one another.
14. The pin bundle set forth in claim 12, wherein said first and
second groups of pins are interspersed.
15. A pin bundle for use in making cube-corner reflectors capable
of reflecting light back to the source thereof over a wide angle,
said pin bundle comprising a plurality of pins each including an
elongated shank and a cube-corner formation at one end thereof and
a cube axis, said elongated shank being of regular polygon outline
and having a longitudinally extending pin axis, said cube-corner
formation having three mutually perpendicular faces symmetrically
arranged with respect to said cube axis and respectively
intersecting three mutually perpendicular edges, said cube-corner
formation having a given side which is rectilinear and is contained
by one of said faces and lies in a plane perpendicular to said pin
axis, one edge of said cube-corner formation being substantially
perpendicular to said one face and lying in a predetermined plane,
the pin axes respectively of said pins being disposed substantially
parallel to one another, said pins being arranged in said first and
second rows, the cube axes of the pins in said first rows being
inclined with respect to the associated pin axes at a first angle
as measured in said predetermined plane, the cube axes of the pins
in said second rows being inclined with respect to the associated
pin axes at a second different angle as measured in said
predetermined plane.
16. The pin bundle set forth in claim 15, wherein all of said one
edges are parallel.
17. The pin bundle set forth in claim 15, wherein said first and
second rows of pins alternate.
18. A pin bundle for use in making cube-corner reflectors capable
of reflecting light back to the source thereof over a wide angle,
said pin bundle comprising a plurality of pins each including an
elongated shank and a cube-corner formation at one end thereof and
a cube axis, said elongated shank being of regular polygon outline
and having a longitudinally extending pin axis, said cube-corner
formation having three mutually perpendicular faces symmetrically
arranged with respect to said cube axis and respectively
intersecting in three mutually perpendicular edges, said
cube-corner formation having a given side which is rectilinear and
is contained by one of said faces and lies in a plane perpendicular
to said pin axis, one edge of said cube-corner formation being
substantially perpendicular to said one face, the pin axes
respectively of said pins being disposed substantially parallel to
one another, said pins being arranged in units each having first
and second and third and fourth pins respectively clockwise
situated in the four quadrants of a rectangle, the cube axes of
said first and second and third and fourth pins being inclined with
respect to the associated pin axes respectively at first and second
and third and fourth angles as measured respectively in first and
second and third and fourth planes.
19. The pin bundle set forth in claim 18, wherein said first pin is
a mirror image of said second pin, and said third pin is the mirror
image of said fourth pin.
20. The pin bundle set forth in claim 18, wherein said first and
third planes are substantially parallel, and said second and fourth
planes are substantially parallel.
21. The pin bundle set forth in claim 18, wherein said one edges of
said first and second pins lie in a common plane and said one edges
of said third and fourth pins lie in a common plane.
22. The pin bundle set forth in claim 18, wherein said one edges of
said first and fourth pins are not parallel, and said one edges of
said second and third pins are not parallel.
23. The pin bundle set forth in claim 18, wherein said third pin is
rotated 180.degree. with respect to said first pin, and said fourth
pin is rotated 180.degree. with respect to said second pin.
24. The pin bundle set forth in claim 18, wherein said first pin is
the mirror image of said fourth pin, and said third pin is the
mirror image of said second pin.
25. The pin bundle set forth in claim 18, wherein said given side
of said first pin is in common with said given side of said second
pin so as to provide a rectilinear boundary between said first and
second pins, and said given side of said third pin is in common
with said given side of said fourth pin so as to provide a
rectilinear boundary between said third and fourth pins.
26. The pin bundle set forth in claim 18, wherein said unit is
substantially square in outline when projected in a plane
perpendicular to the associated pin, and each of said pins is
substantially square in outline when projected in a plane
perpendicular to the associated pin axes.
27. A pin bundle for use in making cube-corner reflectors capable
of reflecting light back to the source thereof over a wide angle,
said pin bundle comprising a plurality of pins each including an
elongated shank and a cube-corner formation at one end thereof and
a cube axis, said elongated shank being of regular polygon outline
and having a longitudinally extending pin axis, said cube-corner
formation having three mutually perpendicular faces symmetrically
arranged with respect to said cube axis and respectively
intersecting in three mutually perpendicular edges, said
cube-corner formation having one of said edges thereof terminating
at a corner of the associated outline, the pin axes respectively of
said pins being disposed substantially parallel to one another,
said pins being arranged into rectangular units having four pins
respectively situated in the four quadrants of a rectangle, the
cube axes respectively of said first and second and third and
fourth pins being inclined with respect to the associated pin axes
respectively at first and second and third and fourth angles as
measured respectively in first and second and third and fourth
planes.
28. The pin bundle set forth in claim 27, wherein said first and
third planes are substantially coplanar, and said second and fourth
planes are substantially coplanar.
29. The pin bundle set forth in claim 27, wherein said unit is
substantially square in outline when projected in a plane
perpendicular to the associated pin axes, and each of said
reflector elements is substantially square in outline when
projected in a plane perpendicular to the asociated pin axis.
30. The pin bundle set forth in claim 27, wherein said one edges
respectively of said reflector elements extend respectively to the
corners of said unit. .Iadd. 31. A pin for use in making
cube-corner reflectors capable of reflecting light back to the
source thereof, said pin comprising an elongated shank being of
polygon outline and having a longitudinally extending pin axis, and
a cube-corner formation at one end of said shank and having a cube
axis at an angle to said pin axis of other than zero degrees, said
cube-corner formation having three mutually perpendicular faces
symmetrically arranged with respect to said cube axis and
respectively intersecting in three mutually perpendicular edges.
.Iaddend..Iadd. 32. The pin set forth in claim 31, wherein said
predetermined angle is in the range of about 6.degree. to
13.degree.. .Iaddend..Iadd. 33. A pin bundle for use in making
cube-corner reflectors capable of reflecting light back to the
source thereof, said pin bundle comprising a plurality of pins each
including an elongated shank and a cube-corner formation at one end
thereof, said elongated shank being of polygon outline and having a
longitudinally extending pin axis, said cube-corner formation
having a cube axis at an angle to said pin axis of other than zero
degrees, said cube-corner formation having three mutually
perpendicular faces symmetrically arranged with respect to said
cube axis and respectively intersecting in three mutually
perpendicular edges, the pin axes respectively of said pins being
disposed substantially parallel to one another. .Iaddend..Iadd. 34.
The pin bundle set forth in claim 33, wherein said elongated shank
has a rectangular outline. .Iaddend. .Iadd. 35. A pin bundle for
use in making cube-corner reflectors capable of reflecting light
back to the source thereof over a wide angle, said pin bundle
comprising a plurality of pins each including an elongated shank
and a cube-corner formation at one end thereof and a cube axis,
said elongated shank being of polygon outline and having a
longitudinally extending pin axis, each of said cube-corner
formations having three mutually perpendicular faces symmetrically
arranged with respect to said cube axis and respectively
intersecting in three mutually perpendicular edges, the pin axes
respectively of said pins being disposed substantially parallel to
one another, the cube axes of a first group of said pins being
inclined with respect to the associated pin axes at a first angle
as measured in a predetermined plane, the cube axes of a second
group of said pins being inclined with respect to the associated
pin axes at a second different angle as measured in said
predetermined plane. .Iaddend..Iadd. 36. The pin bundle set forth
in claim 35, wherein said first and second groups of pins are
interspersed. .Iaddend..Iadd. 37. A pin bundle for use in making
cube-corner reflectors capable of reflecting light back to the
source thereof over a side angle, said pin bundle comprising a
plurality of pins each including an elongated shank and a
cube-corner formation at one end thereof and a cube axis, said
elongated shank being of polygon outline and having a
longitudinally extending pin axis, said cube-corner formation
having three mutually perpendicular faces symmetrically arranged
with respect to said cube axis and respectively intersecting three
mutually perpendicular edges, said cube-corner formation having a
given side which is rectilinear and is contained by one of said
faces and lies in a plane perpendicular to said pin axis, one edge
of said cube-corner formation being substantially perpendicular to
said one face and lying in a predetermined plane, the pin axes
respectively of said pins being disposed substantially parallel to
one another, said pins being arranged in said first and second
rows, the cube axes of the pins in said first rows being inclined
with respect to the associated pin axes at a first angle as
measured in said predetermined plane, the cube axes of the pins in
said second rows being inclined with respect to the associated pin
axes at a second different angle as measured in said predetermined
plane. .Iaddend..Iadd. 38. The pin bundle set forth in claim 37,
wherein all of said one edges are parallel. .Iaddend..Iadd. 39. The
pin bundle set forth in claim 37, wherein said first and second
rows of pins alternate. .Iaddend..Iadd. 40. A pin bundle for use in
making cube-corner reflectors capable of reflecting light back to
the source thereof over a wide angle, said pin bundle comprising a
plurality of pins each including an elongated shank and a
cube-corner formation at one end thereof and a cube axis, said
elongated shank being of polygon outline and having a
longitudinally extending pin axis, said cube-corner formation
having three mutually perpendicular faces symmetrically arranged
with respect to said cube axis and respectively intersecting in
three mutually perpendicular edges, said cube-corner formation
having a given side which is rectilinear and is contained by one of
said faces and lies in a plane perpendicular to said pin axis, one
edge of said cube-corner formation being substantially
perpendicular to said one face, the pin axes respectively of said
pins being disposed substantially parallel to one another, said
pins being arranged in units each having a first and second and
third and fourth pins respectively clockwise situated in the four
quadrants of a rectangle, the cube axes of said first and second
and third and fourth pins being inclined with respect to the
associated pin axes respectively at first and second and third and
fourth angles as measured respectively in first and second and
third and fourth planes. .Iaddend..Iadd. 41. The pin bundle set
forth in claim 40, wherein said one edges of said first and second
pins lie in a common plane and said one edges of said third and
fourth pins lie in a common plane. .Iaddend..Iadd. 42. The pin
bundle set forth in claim 40, wherein said one edges of said first
and fourth pins are not parallel, and said one edges of said second
and third pins are not parallel. .Iaddend..Iadd. 43. The pin bundle
set forth in claim 40, wherein said third pin is rotated
180.degree. with respect to said first pin, and said fourth pin is
rotated 180.degree. with respect to said second pin.
.Iaddend..Iadd. 44. The pin bundle set forth in claim 40, wherein
said first pin is the mirror image of said fourth pin, and said
third pin is the mirror image of said second pin. .Iaddend..Iadd.
45. The pin bundle set forth in claim 40, wherein said given side
of said first pin is in common with said given side of said second
pin so as to provide a rectilinear boundary between said first and
second pins, and said given side of said third pin is in common
with said given side of said fourth pin so as to provide a
rectilinear boundary between said third and fourth pins.
.Iaddend..Iadd. 46. A pin bundle for use in making cube-corner
reflectors capable of reflecting light back to the source thereof
over a wide angle, said pin bundle comprising a plurality of pins
each including an elongated shank and a cube-corner formation at
one end thereof and a cube axis, said elongated shank being of
polygon outline and having a longitudinally extending pin axis,
said cube-corner formation having three mutually perpendicular
faces symmetrically arranged with respect to said cube axis and
respectively intersecting in three mutually perpendicular edges,
said cube-corner formation having one of said edges thereof
terminating at a corner of the associated outline, the pin axes
respectively of said pins being disposed substantially parallel to
one another, said pins being arranged into rectangular units each
having four pins respectively situated in the four quadrants of a
rectangle, the cube axes respectively of said first and second and
third and fourth pins being inclined with respect to the associated
pin axes respectively at first and second and third and fourth
angles as measured respectively in first and second and third and
fourth planes. .Iaddend..Iadd. 47. A pin bundle set forth in claim
46, wherein said first and third planes are substantially coplanar,
and said second and fourth planes are substantially coplanar.
.Iaddend. .Iadd. 48. The pin bundle set forth in claim 46, wherein
said one edges respectively of said cube-corner formation of each
pin extend respectively to the corners of said unit.
Description
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,541,606, issued to S. A. Heenan and R. I. Nagel,
discloses a reflector in which the cube corners of the reflector
elements thereof are arranged in two or more groups, the elements
of one group having aligned cube-corner and element axes inclined
at one angle and the elements of the other group having aligned
cube-corner and element axes inclined at another angle. Because of
the dual-angle configuration, the reflector is visible over a
greater zone than would a reflector having all elements similarly
directed.
In a cube-corner reflector, the angle between the cube axis and
each face of each cube-corner reflector element is nominally
35.degree.16', and the angle between the cube axis and each edge of
each reflector element is nominally 54.degree.44'. In a nonangled
reflector, in which the cube axes of all the reflector elements are
parallel (and perpendicular to the front face of the reflector if
it is flat), the angle between all of the cube-corner faces and the
front face of the reflector is nominally 54.degree.44', and the
angle between the cube-corner edges and the front face is nominally
35.degree.16'. In the angled reflector disclosed in the
above-mentioned patent, the cube axes of all the reflector elements
are not all parallel, but, rather are angled in different
directions. Thus one cube-corner face of some reflector elements is
"more nearly parallel" to the front face of the reflector; and one
cube-corner edge of the rest of the elements is "more nearly
parallel" to such front face. For example, if the angle of
inclination were 10.degree. the angle between one cube-corner face
of one-half of the reflector elements and the front face would
decrease to 44.degree.44', and such angle in respect to the rest of
the elements would increase to 64.degree.44'. In the latter
elements, a cube-corner edge of each is "more nearly parallel" to
the front face of the reflector.
It has been found desirable in certain situations, that one face of
all of the cube-corner reflector elements be "more nearly parallel"
to the front face of an angled reflector. While there has been a
previous attempt at providing a reflector in which each reflector
element has one face "more nearly parallel" to the front face of
the reflector, such attempt has not been entirely satisfactory. In
that reflector rows of cube-corner elements are diamond-shaped in
outline. The elements in every other row are angled in one
direction, and the reflector elements in the rest of the rows are
angled in the other direction. Although each reflector element has
a face which is more nearly parallel to the front face of the
reflector, it has "shadowing" or "slippage" losses. Also, apparatus
used in making such a reflector is cumbersome.
SUMMARY OF THE INVENTION
An object is to provide a pin for use in making a wide angle
cube-corner reflector, in which the pin axes and cube axes are not
aligned.
A still further object is to provide a pin bundle incorporating a
plurality of such pins.
In summary, there is provided a pin for use in making cube-corner
reflectors capable of reflecting light back to the source thereof
over a wide angle, the pin comprising an elongated shank being of
regular polygon outline and having a longitudinally extending pin
axis, and a cube-corner formation at one end of the shank, and
having a cube axis at an angle to the pin axis of other than zero
degrees, the cube-corner formation having three mutually
perpendicular faces symmetrically arranged with respect to the cube
axis and respectively intersecting in three mutually perpendicular
edges.
Moreover, there is provided a pin bundle for use in making
cube-corner reflectors capable of reflecting light back to the
source thereof over a wide angle, the pin bundle comprising a
plurality of pins each including an elongated shank and a
cube-corner formation at one end thereof and a cube axis, the
elongated shank being of regular polygon outline and having a
longitudinally extending pin axis, the cube-corner formation having
a cube axis at an angle to the pin axis of other than zero degrees,
each of the cube-corner formations having three mutually
perpendicular faces symmetrically arranged with respect to the cube
axis and respectively intersecting in three mutually perpendicular
edges, the pin axes respectively of the pins being disposed
substantially parallel to one another.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention together with further objects and advantages thereof,
will best be understood by reference to the following specification
taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic, fragmentary, top plan view of a reflector
incorporating the features of the present invention;
FIG. 2 is a rear elevational view, on a smaller scale, of the
reflector in FIG. 1;
FIG. 3 is a greatly enlarged view of a square reflector element
forming part of the reflector of FIGS. 1 and 2, taken in a plane
perpendicular to the element axis of such element;
FIG. 4 is a view in cross section, taken along the line 4--4 of
FIG. 3;
FIG. 5 is a view in cross section, taken along the line 5--5 of
FIG. 3;
FIG. 6 is a fragmentary view, on an enlarged scale, of the portion
of the rear surface of the reflector within the circle 6 of FIG.
2;
FIG. 7 is a fragmentary view, in an enlarged scale, of a portion of
the rear surface of the reflector within the ellipse 7 of FIG.
6;
FIG. 8 is a view in section, taken along the line 8--8 of FIG.
6;
FIG. 9 is a view in section, taken along the line 9--9 of FIG.
8;
FIG. 10 is a greatly enlarged plan view of a square pin used in
making the reflector of FIGS. 1-9, as projected in a plane
perpendicular to the pin axis of such pin;
FIG. 11 is a side elevational view of the square pin viewed from
beneath FIG. 10;
FIG. 12 is a side elevational view of the square pin, viewed from
the right-hand side of FIG. 10;
FIG. 13 is a fragmentary, plan view of a portion of a pin bundle
using a plurality of pins of FIGS. 10-12;
FIG. 14 is a view in cross section, taken along the line 14--14 of
FIG. 13;
FIG. 15 is a greatly enlarged view of a square reflector element
taken in a plane perpendicular to its element axis and forming part
of a reflector comprising a second embodiment of the present
invention;
FIG. 16 is a view in cross section, taken along the line 16--16 of
FIG. 15;
FIG. 17 is a view in cross section taken along the line 17--17 of
FIG. 15;
FIG. 18 is a fragmentary view, on an enlarged scale, of a portion
of the rear surface of a reflector incorporating the element shown
in FIGS. 15 to 17;
FIG. 19 is a fragmentary view, on an enlarged scale, of one unit in
the rear surface of the reflector within the circle 19 of FIG.
18;
FIG. 20 is a view in section, taken along the line 20--20 of FIG.
18;
FIG. 21 is a view in section, taken along the line 21--21 of FIG.
20;
FIG. 22 is a greatly enlarged plan view of a square pin used in
making the reflector of FIGS. 15-21, as projected in a plane
perpendicular to the pin axis of such pin;
FIG. 23 is a side-elevational view of a square pin viewed from
beneath FIG. 22;
FIG. 24 is a side-elevational view of a square pin viewed from the
right-hand side of FIG. 22;
FIG. 25 is a fragmentary plan view of a portion of a pin bundle
with a plurality of the pins of FIGS. 22-24;
FIG. 26 is a view in cross section, taken along the line 26--26 of
FIG. 25;
FIG. 27 is a greatly enlarged view of a square reflector element
taken in a plane perpendicular to its element axis and forming part
of a reflector comprising a third embodiment of the present
invention;
FIG. 28 is a view in cross section, taken along the line 28--28 of
FIG. 27;
FIG. 29 is a view in cross section, taken along the line 29--29 of
FIG. 27;
FIG. 30 is a fragmentary view, on an enlarged scale, of a portion
of the rear surface of a reflector incorporating the element shown
in FIGS. 27 to 29;
FIG. 31 is a fragmentary view, on an enlarged scale, of one unit in
the rear surface of the reflector within the circle 31 of FIG.
30;
FIG. 32 is a view in section, taken along the line 32--32 of FIG.
30;
FIG. 33 is a view in section, taken along the line 33--33 of FIG.
32;
FIG. 34 is a greatly enlarged plan view of a square pin used in
making the reflector of FIGS. 27 to 33, projected in a plane
perpendicular to the pin axis of such pin;
FIG. 35 is an elevational view of a square pin, taken along the
line 35--35 of FIG. 34;
FIG. 36 is a side-elevational view of the square pin, viewed from
the right-hand side of FIG. 34;
FIG. 37 is a fragmentary plan view of a portion of a pin bundle
with a plurality of the pins of FIGS. 34 to 36; and
FIG. 38 is a view in cross section, taken along the line 38--38 of
FIG. 37.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, and more particularly FIGS. 1 and 2
thereof, there is shown a reflector 50 incorporating therein the
features made by the mold of the present invention. The reflector
50 comprises a body 51 of transparent material formed of a
synthetic organic plastic resin, the preferred resin being methyl
methacrylate. The body 51 has a smooth front face 52 which is also
flat in the embodiment shown. The body 51 is also provided with a
configurated rear 53 schematically shown in FIG. 2. The reflector
50 is so designed that it will be visible to a viewer who is within
a combined zone of reflectorization 54, which is 52.degree., for
example.
The "zone of reflectorization" is measured in a predetermined plane
and means a zone throughout which the reflector will reflect at
least a predetermined quantity of light to a viewer in response to
a predetermined quantity of incident light from a light source,
both the source of light and the viewer being within such zone.
Thus, if a source of light and a viewer are both within the zone of
reflectorization 54, the reflector 50 will return light rays from
the source back to the viewer to cause the reflector 50 to be
visible. If the light source and the viewer are without the zone of
reflectorization 54, the reflector 50 will appear dark or not
visible. The term "visible" means at least a predetermined quantity
of light is reflected to the viewer. If the reflector is used on an
automobile, for example, the reflector is designed so that it has
the desired wide angle response in a "predetermined plane" which is
horizontal. It is to be understood that the reflector will have a
response for light rays at an angle to the predetermined plane.
However, it is in such plane that it has the optimum response.
Although the measurement of the zone of reflectorization is in a
plane, such optimum response will occur in all planes parallel to
such predetermined plane approximately within the height of the
reflector.
The manner in which the reflector 50 operates is schematically
shown in FIG. 1. An incoming ray 55a is derived from a source of
light within the zone of reflectorization 54. Specifically, such
ray 55a is at an angle of 0.degree., that is, it is directed
substantially perpendicular to the front face 52 of the reflector
50. The incoming ray 55a is assumed to lie in the predetermined
plane, and, because it strikes the front face 52 substantially
normal thereto, it is not refracted. It strikes the configurated
rear 53 which reflects the light to provide an outgoing ray 55b
parallel to the incoming ray 55a. Although the rays 55a and 55b are
shown to be aligned, it is to be understood that the properties of
the reflector elements themselves cause a slight divergence between
the rays 55a and 55b. Thus, the ray 55a will be returned
retrodirectively by way of a ray of light 55b to an observer
located substantially at the light source. Rays 56a are also in the
predetermined plane, but are directed at an angle with respect to
the flat front face 52 of the reflector 50. Thus, the rays 56a are
refracted by such front face 52, are retrodirectively reflected by
the configurated rear 53, again refracted by the front face 52 and
emerge as outgoing rays 56b. The configurated rear 53 is designed
to cause the outgoing rays 56b to be returned substantially to the
observer who is located at the source of light. Thus, as long as
the source of light and the observer are within the zone of
reflectorization 54, the outgoing rays 56b will be returned back to
the observer, to cause the reflector to be visible.
Reference is now made to FIGS. 3, 4 and 5, which illustrate the
details of each of the reflector elements that make up the
configurated rear 53 of the reflector 50. The reflector element is
designated by the number 60 and includes three faces 61, 62, and 63
which intersect along edges 64, 65, and 66. The faces 61, 62, and
63 are inclined away from a common peak or apex 67. Each of the
faces is substantially perpendicular to the other faces, that is,
the face 61 is perpendicular to the faces 62 and 63; the face 63 is
perpendicular to the faces 61 and 62, etc. The cube axis 68a is an
imaginary line which passes through the apex 67, and, with respect
to which axis, each of the faces 61, 62, and 63 is symmetrically
arranged. In other words the same angle is formed between the cube
axis 68a and each of the faces 61, 62, and 63. Similarly, the cube
axis 68a is symmetrically arranged with respect to the edges 64,
65, and 66, the angle between each of the edges and the cube axis
68a being the same.
Although the reflector element 60 is referred to as being of the
"cube corner" type and the optical axis is referred to as a "cube"
axis, it is to be understood that the term "cube" has reference to
the fact that the three faces of the element are substantially
perpendicular to each other, as are the three edges. The term does
not suggest that the faces are congruent or equal in area. For
example, one face can be larger than the other two faces.
Each reflector element 60 has one side 69 of the square boundary
which is rectilinear and is contained by the face 61. Also, there
is a plane normal to the cube axis 68 that contains the side 69,
and therefore the side 69 is sometimes hereafter characterized as
being "right angle, rectilinear". It should be noted that none of
the other three sides of the square outline of the reflector
element 60 is rectilinear. Specifically, the end of the edge 64
divides the upper (as viewed in FIG. 3) side 70 into shorter and
longer side portions. The edge 65 intersects the left (as viewed in
FIG. 3) side 71 at the center thereof. Finally, the edge 66
intersects the lower (as viewed in FIG. 3) side 72 to provide
longer and shorter side portions. The faces 62 and 63 are mirror
images of each other, but each has a different shape and area than
the face 61. The faces 62 and 63 are symmetrical and symmetrically
disposed on opposite sides of their intersection or edge 65, while
the face 61 is symmetrical with respect to an extension of the edge
65.
The reflector element 60 also has an element axis 68b (FIG. 2),
which, in FIG. 3, would be perpendicular to the plane of the paper.
The reflector element 60 has a rectangular outline when projected
in a plane perpendicular to the element axis 68b; the outline is
square in the embodiment illustrated. Although the element axis 68b
is shown to pass through the apex 67, it can intersect the element
60 at any point such as the geometric center of the outline. It
should be noted that the cube axis 68a is not aligned with the
element axis 68b. The angle between these two axes is in the range
of about 6.degree. to 13.degree.; in the particular form
illustrated the angle is 6.degree.. This is in distinction to the
usual reflector element wherein the cube axis and the element axis
are aligned. The arrangement of the standard reflector element is
depicted by the dotted lines in FIG. 3. The three mutually
perpendicular edges are designated 64a, 65a, and 66a intersecting
in an apex 67a. The apex 67a is located at the geometric center of
the square outline depicted. With such an arrangement, the cube
axis and the element axis are in alignment. In the modified form
illustrated by the solid lines, the entire cube-corner formation
has been tilted to the left, as viewed in FIG. 4, so as to cause
the angle between the face 61 and the element axis 68b to increase
from its nominal value of 35.degree.16'. Such tilt is performed in
a plane which contains the edge 65 and the cube axis 68a and the
element axis 68b. It is in this predetermined plane that a wide
angle response is desired. Assuming a 6.degree. angle between the
axes 68a and 68b, the angle between the face 61 and the element
axis 68b increases to 41.degree.16'. Of course, the edge 65 remains
perpendicular to the face 61, so that the angle between the edge 65
and the element axis 68b decreases from its nominal value of
54.degree.44' to 48.degree.44', in the example described. It is to
be noted that, despite the modification to the cube-corner
formation, the side 69 continues to be right angle rectilinear.
Turning now to FIGS. 6-9, further details of the reflector 50 will
be described. The reflector elements 60 are arranged in alternating
rows, each having a width of one reflector element. The faces 61 of
the reflector elements 60 in every other row are directed to the
right, and the faces 61 of the reflector elements 60 in the rest of
the rows are directed to the left. FIG. 7 illustrates laterally
adjacent reflector elements 60 in two adjacent rows. The two
reflector elements 60 are arranged into a rectangular unit in which
the length is twice as great as the width. The reflector elements
60 in the unit are contiguous and oriented 180.degree. with respect
to each other. The side 69 of one element 60 is in common with the
side 69 of the adjacent element 60. Similarly, the side 71 of one
element 60 is in common with the side 71 of the laterally adjacent
element 60. The side 70 of one reflector element 60 is in common
with the side 72 of the longitudinally adjacent element 60.
All of the element axes 68b in the reflector 50 are parallel to one
another. Because laterally adjacent elements 60 are rotated
180.degree. with respect to each other, the cube axes 68a of
reflector elements 60 in one row are inclined to the left with
respect to the associated element axis 68b, and the cube axes 68a
of the reflector elements 60 in laterally adjacent rows are
directed to the right. In the example illustrated, the angle
between the element axis 68b and the cube axis 68a is the same
throughout the reflector 50, although this is not necessary.
However, for the purpose of this application, the following
convention will be adopted. An angle on one side of a line
perpendicular to the front face 52 bears a plus sign, and an angle
on the other side of that line bears a minus sign. In such case,
the angle between the cube axis 68a and the element 68b of the
reflector elements 60 in one row bears a plus sign, and the
corresponding angle in respect to reflector elements 60 in
laterally adjacent rows bears a minus sign. Thus, while all of the
element axes 68b are parallel, the cube axes 68a are at two
different angles throughout the reflector 60.
Each row of reflector elements is bounded by a pair of parallel
planes defined respectively by the sides 69 and 71. The side 69 of
one reflector element 60 is a rectilinear continuation of the
corresponding side 69 of the two longitudinally adjacent elements
60. The side 71 of each element 60 is a continuation of the
corresponding sides 71 of the two longitudinally adjacent elements
60. Also the face 61 of each element 60 is a planar continuation of
the faces 61 of the two longitudinally adjacent reflector elements
60. The boundaries of the reflector elements are defined by
laterally extending parallel planes, and by longitudinally
extending parallel planes which intersect the lateral planes,
despite the fact that the angle of inclination of the cube axes 68a
is not the same throughout the reflector 50. In the embodiment
shown, the rows of reflector elements 60 alternate, so that in one
row the cube axes 68a are directed to the left, and, in laterally
adjacent rows, the cube axes 68a are directed to the right.
Each reflector element 60 is capable of reflecting light back
toward the source thereof as long as such source is within a zone
of reflectorization centered about the associated cube axis 68a of
the element 60. Thus, those reflector elements with cube axes 68a
directed to the left have a first zone of reflectorization defined
by such cube axes, while the reflector elements with cube axes 68a
directed to the right, will have a second zone reflectorization
centered about the associated cube axes 68a.
The response curve of a cube-corner reflector shows that the
percentage of light returned, or efficiency, drops off very rapidly
beyond entrance angles (angle between rays of incident light and
cube axis) of approximately 17.degree.. In such case the zone of
reflectorization is .+-.17.degree., centered about the cube axis
68a. Because of refraction at the front face 52, a 6.degree.
internal angle in plastic corresponds approximately at a 9.degree.
external angle in air. Using the example of a 6.degree. angle
between the cube axis 68a and the element axis 68b, the zone of
reflectorization would be -26.degree. to +8.degree. for the
reflector elements 60 having cube axes 68a directed to the left.
For those reflector elements 60 having cube axes 68a directed to
the right, the zone of reflectorization would extend from
-8.degree. to +26.degree.. Thus, the combined zone of
reflectorization in this example, is .+-.26.degree. with
substantial overlap. As long as incoming rays are angles within
such combined zone of reflectorization 54 (see FIG. 1) they will be
returned to the source.
One feature derived from the mold of the present invention is the
ability of the reflector 50 to appear uniformly lit when observed
at any point within the combined zone of reflectorization. A
generally accepted rule of thumb is that the eye is unable to
resolve an angle less than 1 minute, so that as 23 feet, areas
spaced part no more than .08 inches would appear unitary. In one
form of the invention, each reflector element 60 has a side-to-side
dimension of .04 inches, so that the width of a row is .04 inches.
Thus, the eye would be unable to detect the spacing between the
rows, as long as the observer was more than about 12 feet from the
reflector 59. As long as the observer is more than 12 feet from the
reflector, it will appear fully illuminated throughout its area to
a viewer who is within the combined zone of reflectorization.
A particular advantage in the reflector described above is the
absence of "slippage" and resultant "shadowing" between
.[.adajcent.]. .Iadd.adjacent .Iaddend.reflector elements 60. A
slippage loss results when there is a discontinuity or axial
displacement between adjacent reflector elements, with the result
that a portion of one element is blocked by a portion of another
element to rays at more than a predetermined inclination to the
cube axes. All of the element axes 68b are parallel, and therefore
each element 60 has a square outline in the same plane; i.e., the
elements 60 are bounded by a set of laterally extending parallel
planes intersecting a set of longitudinally extending parallel
planes. Accordingly, there is no slippage between the reflecting
elements. Although the reflector 50 is comprised of reflector
elements having cube axis in two different directions, all the
faces 61 have been arranged more nearly parallel to the front face
52.
In a wide angle reflector in which the cube axes of some reflector
elements are inclined in one direction and the cube axes of other
reflector elements are inclined in another direction, it is often
desirable that all of the reflector elements have one face which is
more parallel to the front face of the reflector. Examination of
the response characteristics of cube corner reflector elements
shows that, if the entrance angle formed by incident light in a
plane containing the cube axes and one edge of the cube-corner
formation increases, the percentage of reflected light decreases in
such plane. Moreover, as the angle between a ray of incident light
and such plane increases, there is a further decrease in the
percentage of reflected light. However, the loss in specific
intensity for light rays out of such plane is much less when the
face is more nearly parallel to the front face of the reflector. It
is desirable that the reflector have not only wide angle response
in a given plane, it is also desirable that the response not
deteriorate substantially for light rays out of such plane.
Turning now to FIGS. 10 and 14, the method of making the reflector
shown in FIGS. 1 to 9 will be described. There is shown in FIGS. 10
to 12 a pin 98 (the pin 98 is shown very much enlarged and may have
side-to-side dimension of .04 inches or less) having a square
outline, which pin has an elongated shank 99 and a cube-corner
formation 100 at one end thereof. The cube-corner formation 100 has
three mutually-perpendicular faces 101, 102, and 103, adjacent
pairs of faces respectively meeting at edges 104, 105, and 106. The
faces 101, 102, and 103 are inclined away from a common peak or
apex 107. Each of the faces is substantially perpendicular to the
other faces, that is, the face 101 is perpendicular to the faces
102 and 103; the face 103 is perpendicular top the faces 101 and
102; etc. The pin 98 has one side 109 of the square boundary which
is right angle, rectilinear and is contained by the face 101. It
should be noted that none of the other three sides of the square
outline of the pin 98 is rectilinear. Specifically, the end of the
edge 104 divides the lower (as viewed in FIG. 10) side 112 into a
shorter side portion and a longer side portion. The edge 105
intersects the right (as viewed in FIG. 10) side at the center
thereof to provide equal side portions. Finally, the edge 106
intersects the upper (as viewed in FIG. 10) side to provide a
longer side portion and a shorter side portion. The faces 102 and
103 are mirror images of each other but each has a different shape
and area than the face 101. The faces 102 and 103 are symmetrical
and symmetrically disposed on opposite sides of their intersection
or edge 105, while the face 101 is symmetrical with respect to an
extension of the edge 105.
The pin 98 has a cube axis which is an imaginary line passing
through the apex 107 and with respect to which each of the faces
101, 102, and 103 are symmetrically arranged. In other words, the
same angle 34.degree.16' is formed between the cube axis 108a and
each of the faces 101, 102, and 103. Similarly the cube axis 108a
is symmetrically arranged with respect to the edges 104, 105, and
106, the angle between each of the edges and the cube axes 108a
being the same.
The pin 98 also has a pin axis 108b which, in FIG. 10, is
perpendicular to the plane of the paper. Thus, the pin 98 and the
cube-corner formation 100 have a square outline when projected in a
plane perpendicular to the element axis 108b. It should be noted
that the cube 108a is not aligned with the pin axis 108b. In the
particular form illustrated, there is an angle of 6.degree. between
these two axes. This is in distinction to the usual pin wherein the
cube axis and the pin axis are aligned. The arrangement of the
standard pin is depicted by the dotted lines in FIG. 10. The three
mutually perpendicular edges are respectively designated 104a,
105a, and 106a intersecting in an apex 107a. The apex 107a is
located at the geometric center of the square outline depicted.
With such an arrangement, the cube axis and the pin axis would be
in alignment. In the modified form illustrated by the solid lines,
the entire cube-corner formation 100 has been tilted to the right,
as viewed in FIG. 10, so as to cause the angle between the face 101
and the axis 108a to increase from its nominal value of
35.degree.16'. Assuming a 6.degree. angle between the axes 108a and
108b, the angle between the face 101 and the pin axis 108b would
increase to 41.degree.16'. Of course the edge 105 remains
perpendicular to the face 101 so that the nominal value of the
angle between the edge 105 and the pin axis 108b decreases from its
nominal value of 54.degree.44' to 48.degree.44', in the example
described. It is to be noted that despite the modification to the
cube-corner formation 100, the side 69 continues to be right angle
rectilinear.
Thus, the cube-corner formation 100 at the end of the pin 98 is
identical to the reflector element 60 illustrated in FIGS. 3 to 5.
Also the relationship of the pin 98 to its axes 108a and 108b is
the same as the relationship between the element 60 and its axes
68a and 68b.
A number of the pins 98 are arranged into a pin bundle as
illustrated in FIGS. 13 and 14. In plan view, the pin bundle has
the same appearance as the rear of the reflector illustrated in
FIG. 6. The longitudinally extending pin axes 108b of the pins 98
are parallel to each other so that the flat sides of each pin can
respectively abut against the flat sides of adjacent pins.
Accordingly, the pin bundle will have the same compact arrangement
achieved with non-angled pins, despite the fact that the
cube-corner formations 100 are skewed. In the interest of brevity,
the details of the manner in which the pins 98 are assembled into
the pin bundle will not be described further, except to point out
that the parts of the pin bundle correspond to the reflector 50 and
similar reference numerals having been applied; for example, the
element axis is marked 68b and the corresponding pin axis is marked
108b.
The pin bundle is placed in a plating tank in which nickel or the
like is deposited or electroformed onto the faces 101, 102, and 103
of the pins 98. After a period of time, a sufficient thickness of
material has been electroformed onto the faces to render the
electroform self-supporting. At that time, it is pried off the pins
98, and the electroform that is separated therefrom is further
processed, and after being cut and otherwise treated, becomes a
mold part. Of course, the steps of electroforming are known in the
art, whereby the above description is a sketchy one, simply to
describe the over-all process. It is to be understood that there
may be a great many steps in the process of forming the pins into
the desired array, all the way up to obtaining an electroform for
use as a mold. The electroform may be used in an injection molding
process to furnish the reflector of FIGS. 1 to 9.
Turning now to FIGS. 15 to 26 of the drawings, a second embodiment
of the present invention will be described. The reflector
illustrated in FIGS. 1 to 9 responded to light rays in a combined
zone of reflectorization in a plane parallel to planes containing
the edges 65 of the reflector elements 60. The instant embodiment
has a zone of reflectorization in two planes which may be
perpendicular. The reflector elements have cube axes inclined at
two different angles in each of two planes as opposed to the first
embodiment in which the reflector elements 60 had cube axes at two
different angles in a single plane.
The reflector incorporating the features of the second embodiment
is designated generally 150 and has a construction generally
similar to the reflector 50. The reflector 150 operates in the same
manner to reflect light rays back to the source within
predetermined zones of reflectorization which are defined by the
various cube axes.
The reflector 150 comprises a plurality of reflector elements 160,
each including three faces 161, 162, and 163 which intersect along
edges 164, 165, and 166. The faces 161, 162, and 163 are inclined
away from a common peak or apex 167. Each of the faces is
substantially perpendicular to the other faces, that is, the face
161 is perpendicular to the faces 162 and 163; the face 163 is
perpendicular to the faces 161 and 162, etc. The cube axis 168a is
an imaginary line which passes through the apex 167 and with
respect to which axis each of the faces 161, 162, and 163 are
symmetrically arranged. In other words, the same angle is formed
between the cube axis 168a and each of the faces 161, 162 and 163.
Similarly, the cube axis 168a is symmetrically arranged with
respect to the edges 164, 165 and 166, the angle between each of
the edges and the cube axis 168a being the same.
The reflector element 160 also has an element axis 168b which in
FIG. 15, is perpendicular to the plane of the paper. The reflectory
element 150 has a rectangular outline when projected in a plane
perpendicular to the element axis 168b; the outline is square in
the embodiment illustrated. It should be noted that the cube axis
168a is not aligned with the element axis 168b. The arrangement of
a reflector element in which these axes are aligned is depicted by
the dotted lines in FIG. 15. The three mutually perpendicular edges
are designated 164a, 165a, and 166a, intersecting in an apex 167a.
The apex 167a is located at the geometric center of the square
outline depicted. Although not apparent from the drawings, the ends
of the edges 166 and 166a do not intersect the side 170 at a common
point; similarly the edges 164 and 164a do not intersect the side
172 at a common point.
In the modified form illustrated by the solid lines, the entire
cube-corner formation has been tilted to the right and upwardly, as
viewed in FIG. 15. In this second embodiment, such tilt is
performed in a diagonal plane 175, which contains the cube axis
168a and the element axis 168b. It is in this predetermined plane
that a wide angle response is attained. The angle between the cube
axis 168a and the element axis 168b, measured in such predetermined
plane, is preferably in the range of about 6.degree. to 13.degree..
In the particular form illustrated, such angle is 6.degree..
Each reflector element 160 has one side 169 of the square outline
which is rectilinear, although no longer right angle, and is
contained by the face 161. The end of the edge 164 divides the
lower (as viewed in FIG. 15) side 172 into shorter and longer side
portions; the edge 165 intersects the right side 171 to divide it
into longer and shorter side portions; and the edge 166 intersects
the upper side 170 to divide it into longer and shorter
portions.
Turning now to FIGS. 18 to 20, further details of the reflector 150
will be described. The reflector elements are arranged into
rectangular units, each having four elements situated in the four
quadrants of a rectangle. The unit shown in FIG. 19 includes two
reflector elements 160 and two additional elements 180 each of
which differs from the element 160, in that they are mirror images
of each other. It is to be understood, however, that the element
180 is in all other respects essentially identical to the element
160. For convenience, the parts of the element 180 are identified
by numbers which correspond to those used with respect to the
corresponding parts of the element 160.
The cube axis 168a of the first reflector element 160 (in the upper
left quadrant, as viewed in FIG. 19) lies in a diagonal plane 175
and is inclined downwardly and to the left, as viewed in FIG. 19.
The cube axis 188a of the second reflector element 180 (upper right
quadrant) lies in a diagonal plane 195 and is directed downwardly
and to the right; the cube axis 168a of the third reflector element
160 (lower right quadrant) lies in a diagonal plane 175 and is
directed upwardly and to the right; and the cube axis 188a of the
fourth reflector element 180 (lower left quadrant) lies in a
diagonal plane 195 and is directed upwardly and to the left. In all
four elements, the associated cube axis is assumed to extend in the
specified direction from behind FIG. 19; i.e., from the front face
152 to the rear surface 153.
The first reflector element 160 is the mirror image of the second
reflector element 180, and the third reflector element 160 is the
mirror image of the fourth reflector element 180. The edge 165 of
one reflector element 160 and the edge 185 of a laterally adjacent
reflector element 180 lie in a common plane. In the form
illustrated, the angle of the cube axis of the third element 160 is
substantially equal to the angle of the first element 160, but is
opposite in sign; similarly, the angle of the cube axis of the
fourth element 180 is substantially equal to the angle of the
second element 180, but is opposite in sign. All of the element
axes of the elements 160 and 180 are parallel throughout the
reflector 150.
The sides 170 of the reflector elements 160 are respectively in
common with the sides 190 of the longitudinally adjacent reflector
elements 180. The sides 169 of the reflector elements 160 are
respectively in common with the sides 189 of the laterally adjacent
elements. Thus, each mating pair of sides within the unit is
substantially identical, so that each juncture is substantially
perfect.
Each lateral side of the unit, as outlined in FIG. 19, is defined
by the sides 171 and 191 respectively of the reflector elements 160
and 180. The sides 171 and 191 of the reflector elements 160 and
180 in one unit respectively mate with the sides 191 and 171 of the
reflector elements 180 and 160 of laterally adjacent units. Each
longitudinal side of the unit is defined by the sides 172 and 192
respectively of the reflector elements 160 and 180. The sides 172
and 192 of the reflector elements 160 and 180 in one unit
respectively mate with the sides 192 and 172 of the reflector
elements 180 and 160 in longitudinally adjacent units. Each mating
pair of adjoining units is identical, so that each juncture is
substantially perfect; i.e., no axial displacement of one element
with respect to an adjacent element. Each unit is bounded by one
set of two parallel planes defined by the sides 172 and 192 and by
another set of two parallel planes defined by the sides 171 and
191. The faces 161 and 181 are planar continuations respectively of
longitudinally adjacent faces 161 and 181.
Each reflector element is capable of reflecting light back toward
the source thereof within a zone of reflectorization defined by the
associated cube axis and in a predetermined plane containing the
associated cube axis and element axis. In the first reflector
element 160, for example, the zone of reflectorization is in the
diagonal plane 175. Assuming the same exemplary values used in
respect to the first embodiment, the reflector 150 has a zone of
reflectorization of -26.degree. to +8.degree. in one of the planes
175, and -8.degree. to +26.degree. in the other one of the planes
175. The combined zone of reflectorization resulting from the
individual zones of reflectorization in the two planes 175 is
measured in a single plane parallel thereto and is equal to
.+-.26.degree.. Similarly, the reflector 150 has a zone of
reflectorization of -26.degree. to +8.degree. in one of the planes
195, and -8.degree. to +26.degree. in the other one of the planes
195. The combined zone of reflectorization resulting from the
individual zones of reflectorization in the two planes 195 would be
measured in a single plane parallel thereto and is equal to .+-.
26.degree.. Thus, it can be seen that the reflector 150 furnishes
zones of reflectorization in two perpendicular planes. By a
suitable modification of the inclination of the cube axes, the
reflector 150 may have zones of reflectorization in two planes
which are not perpendicular.
The units illustrated in FIG. 19 are interspersed throughout the
reflector 150, so that it will appear fully illuminated throughout
its area to a vehicle which is in the combined zones of
reflectorization.
A particular advantage achieved by the reflector 150 is the absence
of "slippage" and resultant "shadowing" between adjacent reflector
elements 160 and 180, whether in a unit or between units. No
slippage loss is present since there is no discontinuity or axial
displacement between adjacent reflector elements. All of the
element axes 168b and 188b are parallel, and, therefore, each
element 160 and 180 has a square outline in the same plane.
Accordingly, there is no "slippage" between the reflector
elements.
Turning now to FIGS. 22 to 26, the method of making the reflector
150 shown in FIGS. 15 to 21 will be described. There is shown in
FIG. 22 a pin 198 (the pin 198 is shown very much enlarged and may
have side-to-side dimension of .04 inches or less) having a square
outline, which pin has an elongated shank 199 and a cube-corner
formation 200 at one end thereof. The cube-corner formation 200 has
three mutually perpendicular faces 201, 202, and 203, adjacent
pairs of faces respectively meeting at edges 204, 205, and 206. The
faces 201, 202 and 203 are inclined away from a common peak or apex
207. Each of the faces is substantially perpendicular to the other
faces, that is, the face 201 is perpendicular to the faces 202 and
203; the face 203 is perpendicular to the faces 201 and 202, etc.
The pin 198 has one side 209 of the square outline which is
rectilinear and is contained by the face 201. It should be noted
that none of the other three sides of the square outline of the pin
198 is rectilinear. Specifically, the end of the edge 204 divides
the lower (as viewed in FIG. 22) side 210 in a shorter side portion
and a longer side portion. The edge 205 intersects the right side
to divide it into longer and shorter side portions. Finally, the
edge 206 intersects the upper side 212 to divide it into a longer
side portion and a shorter side portion.
The pin 198 has a cube axis 208a which is an imaginary line passing
through the apex 207 and with respect to which each of the faces
201, 202, and 203 are symmetrically arranged. In other words, the
same angle 34.degree.16' is formed between the cube axis 108a and
each of the faces 201, 202, and 203. Similarly the cube axis 208a
is symmetrically arranged with respect to the edges 204, 205, and
206, the angle between each of the edges and the cube axes 208a
being the same.
The pin 198 also has a pin axis 208b which, in FIG. 22, is
perpendicular to the plane of the paper. Thus, the pin 198 and the
cube-corner formation 200 have a square outline when projected in a
plane perpendicular to the pin axis 208b. It should be noted that
the cube axis 208a is not aligned with the pin axis 208b. In the
particular form illustrated, the angle between the cube axes 208a
and the pin axis 208b in a diagonal plane of the square outline is
about 6.degree.. The arrangement of the standard pin is depicted by
the dotted lines in FIG. 22. The three mutually perpendicular edges
are respectively designated 204a, 205a, and 206a, intersecting in
an apex 207a. The apex 207a is located at the geometric center of
the square outline depicted. With such an arrangement, the cube
axis and the pin axis would be in alignment. In the modified form
illustrated by the solid lines, the entire cube-corner formation
200 has been tilted along the diagonal of the square outline. Thus,
the cube-corner formation has the same characteristics as the
reflector element 150. A second pin 218 has the same construction
as the pin 198, except that one is the mirror image of the other.
The relationship of the pins 198 and 218 to their respective cube
and pin axes is the same as the relationship of the reflector
elements 160 and 180 to their respective cube and element axes.
A number of the pins 98 and 208 are arranged into a pin bundle, as
illustrated in FIGS. 25 and 26. In plan view, the pin bundle has
the same appearance as the rear of the reflector 150 illustrated in
FIG. 13. The longitudinally extending pin axes of the pins 198 and
218 are parallel to each other, so that the flat sides of each pin
respectively abut against the flat sides of adjacent pins.
Accordingly, the pin bundle will have the same compact arrangement
achieved with nonangled pins, despite the fact that the cube-corner
formations 200 and 220 are skewed. In the interest of brevity, the
details of the manner in which the pins 198 and 218 are assembled
into the pin bundle will not be described further, except to point
out that the parts of the pin bundle correspond to the reflector
150 and similar reference numerals having been applied; for
example, an element axis is marked 168b and the corresponding pin
axis is marked 208b. The pin bundle is used to make a reflector in
the same manner used in respect to the first embodiment.
Turning now to FIGS. 27 to 38 of the drawings, a third embodiment
of the present invention will be described. The instant embodiment
has a zone of reflectorization in each of two perpendicular planes,
and the reflector elements have cube axes inclined at two different
angles in each plane. The reflector incorporating the features of
the second embodiment is designated generally 250. The reflector
250 operates in the same manner as the reflector 50 to reflect
light rays back to the source within predetermined zones of
reflectorization which are defined by the various cube axes.
The reflector 250 comprises a plurality of reflector elements 260,
each including three faces 261, 262, and 263 which intersect along
edges 264, 265, and 266. The faces 261, 262, and 263 are inclined
away from a common peak or apex 267. Each of the faces is
substantially perpendicular to the other faces, that is, the face
261 is perpendicular to the faces 262 and 263; the face 263 is
perpendicular to the faces 261 and 262; etc. The cube axis 268a is
an imaginary line which passes through the apex 267 and with
respect to which axis each of the faces 261, 262, and 263 are
symmetrically arranged. In other words, the same angle is formed
between the cube axis 268a and each of the faces 261, 262, and 263.
Similarly, the cube axis 268a is symmetrically arranged with
respect to the edges 264, 265, and 266, the angle between each of
the edges and the cube axis 268a being the same.
The reflector element 260 also has an element axis 268b, which in
FIG. 27, is perpendicular to the plane of the paper. The reflector
element 260 has a rectangular outline when projected in a plane
perpendicular to the element axis 268b; the outline is square in
the embodiment illustrated. It should be noted that the cube axis
268a is not aligned with the element axis 268b. The arrangement of
a reflector element in which these axes are aligned is depicted by
the dotted lines in FIG. 27. The three mutually perpendicular edges
are designated 264a, 265a, and 266a, intersecting in an apex 267a.
The apex 267a is located in the geometric center of the square
outline depicted. With such an arrangement, the cube axis and the
element axis are in alignment.
In the modified form illustrated by the solid lines, the entire
cube-corner formation has been tilted to the right and upwardly, as
viewed in FIG. 27. In this third embodiment, such tilt is performed
in a diagonal plane, which contains the edge 265, the cube axis
268a, and the element axis 268b. It is in this predetermined plane
that a wide angle response is attained. The angle between the cube
axis 268a and the element axis 268b, measured in such predetermined
plane is in the range of about 6.degree. to 13.degree.. In the
particular form illustrated, such angle is 6.degree..
The reflector element 260 has two rectilinear sides 270 and 271,
which sides and the edge 265 intersect in a common point. A third
side 272 of the element 260 is divided by the end of the edge 264
into longer and shorter side portions. The remaining side 269 of
the reflector element 260 is divided into shorter and longer side
portions by virtue of the intersection of the edge 266 with such
side.
The faces 262 and 263 are symmetrical and symmetrically disposed on
opposite sides of the edge 265, while the face 261 is symmetrical
about a plane passing through the edge 265 and the opposite corner
of the element 260. The faces 262 and 263 are mirror images, and
each has a different shape and area than the face 261.
Referring to FIG. 31, there is shown a unit consisting of four
elements 260 each being rotated 90.degree. with respect to the
adjacent reflector element and disposed in the four quadrants of a
square outline. Thus, a plane passing through the edges 265 of one
pair of diagonally opposite reflector elements 260 is perpendicular
to a plane passing through the edges 265 of another pair of
diagonally opposite reflector elements 260. The four faces 261 meet
at a common point which is the center of the unit.
All of the element axes 268b of the reflector elements 260 are
parallel throughout the reflector 250. The sides 269 of the
reflector elements 260 are respectively in common with the sides
272 of adjacent reflector elements 260. Each mating pair of sides
within the unit is substantially identical, so that each juncture
is substantially perfect (no axial displacement).
Each unit, as illustrated in FIG. 31, is bounded by one set of two
parallel planes defined by the sides 270 and 271, and by another
set of two parallel planes, also defined by the sides 270 and 271,
which intersect the first two planes. Each mating pair of sides of
adjoining units is identical, so that each juncture is
substantially perfect (no axial displacement).
Each reflector element 260 is capable of reflecting light back
toward the source thereof within a zone of reflectorization defined
by the associated cube axis 268a and in a diagonal plane containing
the cube axis 268a and the element axis 268b. Assuming the same
exemplary values used in respect to the first and second
embodiments, each reflector element 260 has a zone of
reflectorization of -26.degree. to +8.degree. in each diagonal
plane. The combined zone of reflectorization resulting from the
individual zones of reflectorization of one pair of diagonally
opposite reflector elements is measured in a first plane passing
diagonally through the unit and is equal to .+-.26.degree.. The
combined zone of reflectorization resulting from the individual
zones of reflectorization in the other pair of diagonally opposite
reflector elements is measured in a second plane passing diagonally
through the unit perpendicular to the first plane and is equal to
.+-.26.degree.. Thus, it can be seen that the reflector 250
furnishes zones of reflectorization in two perpendicular
planes.
The units illustrated in FIG. 31 are interspersed throughout the
reflector 250, so that it will appear fully illuminated throughout
its area to a viewer in the combined zones of reflectorization.
A particular advantage achieved by the reflector 250 is the absence
of "slippage" and resultant "shadowing" between adjacent reflector
elements 260, whether in a unit or between units. No slippage loss
is present since there is no discontinuity or axial displacement
between adjacent reflector elements. All of the element axes 268b
are parallel, and, therefore, each element 260 has a square outline
in the same plane. Accordingly, there is no "slippage" between the
reflector elements.
Turning now to FIGS. 34 to 38, the method of making the reflector
shown in FIGS. 27 to 33 will be described. There is shown in FIG.
34 a pin 298 (the pin 298 is shown very much enlarged and may have
side-to-side dimension of .04 inches or less) having a square
outline, which pin has an elongated shank 299 and a cube-corner
formation 300 at one end thereof. The cube-corner formation 300 has
three mutually perpendicular faces 301, 302, and 303, adjacent
pairs of faces respectively meeting at edges 304, 305, and 306. The
faces 301, 302, and 303 are inclined away from a common peak or
apex 307. Each of the faces is substantially perpendicular to the
other faces, that is: the face 301 is perpendicular to the faces
302 and 303; the face 303 is perpendicular to the faces 301 and
302; etc. The pin 298 has two rectilinear sides 310 and 311, which
sides and the edge 305 intersect in a common point. A third side
312 of the cube-corner formation 300 is divided by the end of the
edge 304 into longer and shorter side portions. The remaining side
309 of the cube-corner formation 300 is divided into shorter and
longer side portions by virtue of the intersection of the edge 306
with such side.
The faces 302 and 303 are symmetrical and symmetrically disposed on
opposite sides of the edge 305, while the face 301 is symmetrical
about a plane passing through the edge 305 and the opposite corner
of the formation 300. The faces 302 and 303 are mirror images, and
each has a different shape and area than the face 301.
The pin 298 has a cube axis 308a which is an imaginary line passing
through the apex 307 and with respect to which each of the faces
301, 302, and 303 are symmetrically arranged. In other words, the
same angle 34.degree.16' is formed between the cube axis 208a and
each of the faces 301, 302, and 303. Similarly, the cube axis 308a
is symmetrically arranged with respect to the edges 304, 305, and
306, the angle between each of the edges and the cube axes 308a
being the same.
The pin 298 also has a pin axis 308b which, in FIG. 34, is
perpendicular to the plane of the paper. Thus, the pin 298 and the
cube-corner formation 300 have a square outline when projected in a
plane perpendicular to the pin axis 308b. It should be noted that
the cube axis 308a is not aligned with the pin axis 308b. In the
particular form illustrated, there is an angle of 6.degree. between
these two axes in a diagonal plane containing the edge 305, the
cube axis 308a, and the pin axis 308b. The arrangement of the
standard pin is depicted by the dotted lines in FIG. 34. The three
mutually perpendicular edges are respectively designated 304a,
305a, and 306a, intersecting in an apex 307a. The apex 307a is
located at the geometric center of the square outline depicted.
With such an arrangement, the cube axis and the pin axis would be
in alignment. In the modified form illustrated by the solid lines,
the entire cube-corner formation 300 has been tilted along the
diagonal of the outline. Thus, the cube-corner formation has the
same characteristics as the reflector element 260. The relationship
of the pin 298 to its cube axis 308a and pin axis 308b is the same
as the relationship of the reflector element 160 to its cube axis
168a and element axis 168b.
A number of the pins 298 are arranged into a pin bundle as
illustrated in FIGS. 37 and 38. In plan view, the pin bundle has
the same appearance as the rear of the reflector 250 illustrated in
FIG. 30. The longitudinally extending pin axes of the pins 298 are
parallel to each other, so that the flat sides of each pin
respectively abut against the flat sides of adjacent pins.
Accordingly, the pin bundle will have the same compact arrangement
achieved with nonangled pins, despite the fact that the cube-corner
formations 300 are skewed. In the interest of brevity, the details
of the manner in which the pins 298 are assembled into the pin
bundle will not be described further, except to point out that the
parts of the pin bundle correspond to the reflector 250 and similar
reference numerals having been applied; for example, an element
axis is marked 268b and the corresponding pin axis is marked 308b.
The pin bundle is used to make a reflector in the same manner used
in respect to the first and second embodiments.
What has been described, therefore, are three embodiments of a side
angle reflector which accepts light within a relatively broad zone.
In the first embodiment, that zone is measured in one plane; in the
second and third embodiments, two such zones are provided in two
perpendicular planes, so as to accept light over a broad range of
entrance angles. The latter two embodiments are also less
susceptible to variation by virtue of change in orientation (that
is, rotated by an axis parallel to the element axes). An approved
apparatus of making each of the three reflectors has also been
described, which consists in providing a pin with its cube-corner
formation tilted with respect to the pin axis.
It is believed that the invention, its mode of construction and
assembly, and many of its advantages should be readily understood
from the foregoing without further description, and it should also
be manifest that, while preferred embodiments of the invention have
been shown and described for illustrative purposes, the structural
details are, nevertheless, capable of wide variation within the
purview of the invention as defined in the appended claims.
* * * * *