Optimal design of the splicing structure for metal working molds of cube corner retroreflective sheeting

The principle of retroreflection and the formation characteristics of the effective area in metal cube corner retroreflectors (CCRs) based on geometric optics are analyzed. The design formulas for the optimal splicing structure of metal CCR molds in the direction of 90° are derived. Optical simulation software is utilized to simulate the impact of different cutting positions on the effective area of CCRs, and nickel working molds are fabricated for experimental validation of the splicing process. Splicing at the optimal position can achieve the maximum retroreflective efficiency at the joint and weaken the traces of splices.