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Learn Sheeting: Chapter 2—Technologies

In Chapter 1, Principles of Reflection, we discussed some of the basic ways light may behave when it interacts with different materials and objects. In this chapter, we examine how glass beads and prisms use the principles of reflection to create retroreflectivity.

Highlights:

  • Retroreflection is when light is sent back to its source.

  • Retroreflectors, such as traffic signs, use glass beads or prisms to send light back towards its source using the various principles of reflection.

  • Prisms tend to be more efficient at retroreflection, while glass beads tend to have less variation with viewing angle.


Retroreflection is when light is sent back to its source. Retroreflectors—devices that send light back to their sources—are used in traffic applications to send light back to the headlights of a vehicle.

In the illustration above, a cone of light is sent out from the headlights. Some of the light reaches the sign, where it is retroreflected by the retroreflector, in this case the sign sheeting. A cone of light is then sent back towards the car. The returning cone is referred to as the cone of retroreflection. There are two fundamental technologies for achieving retroreflection: glass beads and prisms.

Glass Beads

Glass beads use refraction to bend the incoming light towards a focal point where an aluminum coating reflects the light. As the light exits the glass bead, it bends again, going back to where it came from.


Because glass beads are spherical, they generally provide a uniform appearance with varying viewing angles; however, their spherical shape does not allow them to be packed together to provide 100% coverage. Additionally, depending on the glass bead’s properties and its environment, some of the incoming light glancing it may not be properly redirected to the aluminum coating and back, which appears as a dark ring surrounding the beads.

Finally, the reflective coating--applied through a process called metallization--tends to absorb some of the light as opposed to reflecting all of it.

Prisms

Prisms used in most standard retroreflectors look like the corner of a cube; they have three sides. This prism design is often referred to as “cube corner” or “corner cube”.


As discussed in Chapter 1, light bends when going from one optical density to a different density. When going from higher density to a lower density, such as a polymer to air, if the incident angle is right, light is bent so much that it cannot exit; this is known as total internal reflection.

In a cube corner prism, the angle between each pair of sides can be precisely controlled based on the desired performance and the material used. When light hits a side, it is reflected to another, and another, until it has been turned 180° and returned to its source. Unlike beads that leave a gap when packed together, prisms can be nested into an array, increasing overall efficiency.

Additionally, total internal reflection is a more efficient way of reflecting light as very little energy is lost through absorption or scattering.

The limitation with prisms is that they require light to hit each side within a particular angle range. Any light beyond this range will mostly transmit and is lost energy. Additionally, the outside corners of certain prisms may not be able to reflect light three times, so the light does not return to its source.

Finally, because of their asymmetrical shape, prisms do not provide as uniform of an appearance with varying viewing angles as glass beads. In general, however, prismatic products are much more efficient at retroreflecting light, meaning more of the incoming light can be returned to its source.

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