Forming information transfer lens array

• US 20040050104A1
• Filed: 09/18/2002
• Published: 03/18/2004
• Est. Priority Date: 09/18/2002
• Status: Abandoned Application

• Current Assignee: Eastman Kodak Company
• Original Assignee: Eastman Kodak Company
• Inventors: Miller, Darryl E., Ghosh, Syamal K., Carlton, Donn B.
• Application Number:
  US10/246,556
• Publication Number:
  US 20040050104A1
• Time in Patent Office: Days
• US Class Current: 65/36
• CPC Class Codes: G02B 3/0031 Replication or moulding, e.g. hot embossing, UV-casting, injection moulding

Abstract

A method of forming an array of optical elements for use in transmitting information includes using glass compression molding to form a plurality of discrete microlens element using a glass compression molding technique; placing each discrete microlens element in a mold cavity and aligning each microlens element in a predetermined location arranged in the form of a linear or two dimensional array; and molding by injection thermo-setting material into the cavity around each microlens element and cooling such thermo-setting material to form an integral array of optical elements that are retained in their respective locations.

Claims

1. A method of forming an array of optical elements for use in transmitting information comprising the steps of:

(a) using glass compression molding to form a plurality of discrete microlens element using a glass compression molding technique;

(b) placing each discrete microlens element in a mold cavity and aligning each microlens element in a predetermined location arranged in the form of a linear or two dimensional array; and

(c) molding by injecting thermo-setting material into the cavity around each microlens element and cooling such thermo-setting material to form an integral array of optical elements that are retained in their respective locations.

7. A product made in accordance with claim 1.

2. A method of forming an array of optical elements for use in transmitting information comprising the steps of:

(a) forming a plurality of discrete microlens element using a glass compression molding technique;

(b) placing each discrete microlens element in a mold cavity and aligning each microlens element in a predetermined location arranged in the form of a linear or two dimensional array; and

(c) heating thermo-setting material, injecting the heated thermo-setting material into the cavity, while applying pressure to such heated thermo-setting material to form such microlens array.

3. The method of claim 2 wherein the thermo-setting material includes a polymer selected from the group consisting of polyethylene, cellulose acetate, polystyrene or polycarbonate and a mixture thereof.

4. The method of claim 2 wherein the thermo-setting material includes a ceramic having low coefficient of thermal expansion consisting of silicon nitride or silicon carbide or a mixture thereof.

5. The method of claim 2 wherein thermo-setting material includes a glass frit having low coefficient of thermal expansion consisting of glass.

6. The method of claim 4 wherein the coefficient of thermal expansion of the ceramic ranges from 3.2×

10<sup>−

6</sup>/⁰C to 4.4×

10<sup>−

6</sup>/⁰C.