Method of making a microlens array and mold
First Claim
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1. A method of making a microlens array mold, comprising:
- (a) forming an array of pyramid-shaped receptacles having parallelogram-shaped apertures;
(b) applying a hardenable liquid to the array of pyramid-shaped receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and
(c) hardening the liquid to form a plurality of concave lens mold surfaces in the pyramid-shaped receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
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Abstract
A method of making a microlens array and mold, and the articles made therefrom. The method involves forming a plurality of adjacent receptacles on a surface and partially filling the receptacles with a hardenable liquid, thereby forming a meniscus in each receptacle. A lens material can then be applied to the menisci, thereby forming an array of generally spherical microlenses. In one embodiment, the perimeters of the microlenses are modified rectangles in that each edge of the lens is a symmetrical elliptical arc, the ends of which terminate at the corners of the rectangle, and the middle of which curves toward the center of the rectangle.
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Citations
27 Claims
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1. A method of making a microlens array mold, comprising:
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(a) forming an array of pyramid-shaped receptacles having parallelogram-shaped apertures; (b) applying a hardenable liquid to the array of pyramid-shaped receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (c) hardening the liquid to form a plurality of concave lens mold surfaces in the pyramid-shaped receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of making a microlens array, comprising:
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(a) forming an array of receptacles having generally polygonal apertures; (b) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; (c) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses; (d) applying a hardenable lens material to the array; and (e) hardening the lens material, thereby forming an array of generally spherical microlenses. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method of making a microlens array mold, comprising:
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(a) providing a first plurality of parallel grooves in a substrate surface; (b) providing a second plurality of parallel grooves in the substrate surface, wherein the second plurality of grooves intersects the first plurality of grooves; (c) forming a negative replica of the substrate surface, thereby forming a first and second plurality of parallel raised walls corresponding to the first and second plurality of parallel grooves, whereby the pluralities of intersecting walls define an array of receptacles having generally polygonal apertures; (d) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (e) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses. - View Dependent Claims (20, 21, 22)
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23. A method of making a microlens array mold, comprising:
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(a) forming an array of receptacles having rectangular apertures defined by a first plurality of parallel walls which are perpendicular to and intersect a second plurality of parallel walls; (b) providing a first plurality of arcuate grooves in the first plurality of parallel walls, wherein the arcuate grooves are parallel to the second plurality of parallel walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the second plurality of parallel walls; (c) providing a second plurality of arcuate grooves in the second plurality of parallel walls, wherein the arcuate grooves are parallel to the first plurality of walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the first plurality of parallel walls; (d) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (e) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses. - View Dependent Claims (24)
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25. A method of making a microlens array mold, comprising:
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(a) forming an array of tetrahedral receptacles having triangular apertures; (b) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (c) hardening the liquid to form a plurality of concave lens mold surfaces in the triangular receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses. - View Dependent Claims (26, 27)
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Specification