METHOD OF MAKING A RETROREFLECTIVE ARTICLE AND A RETROREFLECTIVE ARTICLE HAVING AN ALUMINUM REFLECTOR

A process for making a retroreflective article that includes the steps of providing a device (tool or a mold) having a first structured surface; applying a reflective layer on the first structured surface resulting in a first adhesion value between the reflective layer and the first structured surface, the reflective layer having an exposed surface; applying a molding polymer to the exposed surface of the reflective layer resulting in a second adhesion value between the reflective layer and the molding polymer. The second adhesion value is higher than the first adhesion value. The device is separated from the molding poylmer to yield a retroreflective article that h as a second structured surface that is the reverse image of the first structure d surface. The separation causes a transfer of the reflective layer from the first structured surface to the retroreflective article. The method allows t he reflective layer to be formed during the separation step, rather than being formed independent of creating the second structured surface. The method can yield an article that has a second structured surface coated with an aluminu m reflective material having aluminum microstructures that are predominantly amorphous on a first side (the side near the second structured surface) and predominantly crystalline on a second side, which is opposite the first side .