Electrohydrodynamic assisted droplet alignment for lens fabrication by droplet evaporation

Abstract

Lens fabrication by droplet evaporation has attracted a lot of attention since the fabrication approach is simple and moldless. Droplet position accuracy is a critical parameter in this approach, and thus it is of great importance to use accurate methods to realize the droplet position alignment. In this paper, we propose an electrohydrodynamic (EHD) assisted droplet alignment method. An electrostatic force was induced at the interface between materials to overcome the surface tension and gravity. The deviation of droplet position from the center region was eliminated and alignment was successfully realized. We demonstrated the capability of the proposed method theoretically and experimentally. First, we built a simulation model coupled with the three-phase flow formulations and the EHD equations to study the three-phase flowing process in an electric field. Results show that it is the uneven electric field distribution that leads to the relative movement of the droplet. Then, we conducted experiments to verify the method. Experimental results are consistent with the numerical simulation results. Moreover, we successfully fabricated a crater lens after applying the proposed method. A light emitting diode module packaging with the fabricated crater lens shows a significant light intensity distribution adjustment compared with a spherical cap lens.