Pedestal-type microlens fabrication process
First Claim
1. A method for fabricating microlenses comprising the steps ofdepositing an optically opaque coating on a substrate;
- forming an aperture through said coating, said aperture having predetermined lateral dimensions;
forming a pedestal on said coating, with said pedestal being substantially laterally centered on said aperture;
said pedestal having an upper surface of predetermined area and shape, with said surface having an outer circumference bounded by a sharp edge drop off;
freely flowing a predetermined equilibrium volume of molten lens forming material laterally on said surface, said lens forming material being selected to wet said surface as it flows thereacross, and said volume being selected so that said flow is laterally confined circumferentially of said surface by said edge, thereby causing said molten lens forming material to substantially conform to the shape of said surface and to assume a semi-arcuate profile of substantially constant radius as determined by its volume; and
solidifying said lens forming material to form a microlens having said shape and profile, together with an aperture defined by the aperture formed through said coating.
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Accused Products
Abstract
Monolithic microlenses and microlens arrays are manufactured on opto-electronic devices and other substrates by using sharp edge pedestals to confine the lateral flow of a molten lens material. The lens material wets the upper surfaces of the pedestals, but the pedestal edges confine the flow, so the lens material conforms to the shape of the pedestal surface and assumes a semi-arcuate profile due to its surface tension. Spin coating and photolithographic patterning may be employed to form the pedestals and to deposit the lens material thereon. The lens material is melted after being deposited, so the pedestals advantageously are stabilized to prevent them from deforming at the temperature of the molten lens material.
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Citations
10 Claims
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1. A method for fabricating microlenses comprising the steps of
depositing an optically opaque coating on a substrate; -
forming an aperture through said coating, said aperture having predetermined lateral dimensions; forming a pedestal on said coating, with said pedestal being substantially laterally centered on said aperture;
said pedestal having an upper surface of predetermined area and shape, with said surface having an outer circumference bounded by a sharp edge drop off;freely flowing a predetermined equilibrium volume of molten lens forming material laterally on said surface, said lens forming material being selected to wet said surface as it flows thereacross, and said volume being selected so that said flow is laterally confined circumferentially of said surface by said edge, thereby causing said molten lens forming material to substantially conform to the shape of said surface and to assume a semi-arcuate profile of substantially constant radius as determined by its volume; and solidifying said lens forming material to form a microlens having said shape and profile, together with an aperture defined by the aperture formed through said coating. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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Specification