Polymer Microlens Array Research Articles

Polymeric microlens array formed on a discontinuous wetting surface using a self-assembly technique

In this paper, we demonstrate a facile way to prepare polymeric microlens arrays (MLAs) based on a discontinuous wetting surface using a self-assembly technique. A patterned hydrophobic-octadecyltrichlorosilane (OTS) surface was prepared by UV/O3 irradiation through a shadow mask. The area exposed to UV/O3 irradiation turned highly hydrophilic, whereas the area protected by the mask remained highly hydrophobic, generating the patterned OTS surface. The surface energy of the OTS/glass surface changed from 23 to 72.8 mN/m after 17 min of UV/O3 treatment. The scribing of the optical glue-NOA 81 onto the microhole array enabled one to obtain the MLAs due to the generation of the NOA 81 droplet array via the surface tension. After UV light curing, the cured NOA 81 droplet array with uniform dimensions within a large area exhibited excellent MLA characteristics. Moreover, the method developed in this study is simple in operation, low-cost, and requires neither a clean room nor expensive equipment.

A Super-Boosted Hybrid Plasmonic Upconversion Process for Photodetection at 1550nm Wavelength.

A super-boosted hybrid plasmonic upconversion (UC) architecture comprising a hierarchical plasmonic upconversion (HPU) film and a polymeric microlens array (MLA) film is proposed for efficient photodetection at a wavelength of 1550nm. Plasmonic metasurfaces and Au core-satellite nanoassembly (CSNA) films can strongly induce a more effective plasmonic effect by providing numerous hot spots in an intense local electromagnetic field up to wavelengths exceeding 1550nm. Hence, significant UC emission enhancement is realized via the amplified plasmonic coupling of an HPU film comprising an Au CSNA and UC nanoparticles. Furthermore, an MLA polymer film is synergistically coupled with the HPU film, thereby focusing the incident near-infrared light in the micrometer region, including the plasmonic nanostructure area. Consequently, the plasmonic effect super-boosted by microfocusing the incident light, significantly lowers the detectable power limit of a device, resulting in superior sensitivity and responsivity at weak excitation powers. Finally, a triple-cation perovskite-based photodetector coupled with the hybrid plasmonic UC film exhibits the excellent values of responsivity and detectivity of 9.80AW-1 and 8.22×1012 Jones at a weak power density of ≈0.03mWcm-2 , respectively, demonstrating that the device performance is enhanced by more than 104 magnitudes over a reference sample.

High-resolution imaging and fast number estimation of suspended particles using dewetted polymer microlenses in a microfluidic channel

We have fabricated polymer micro-lens array by self-organized dewetting inside the microchannel, which shows remarkable enhancement in the resolution, contrast and more than 10 times add-on magnification to a microscope. These lenses are demonstrated to resolve sub-micrometer features and detect moving micro-particles when suspension is flown in a microchannel. Polystyrene (PS) micro-lenses are fabricated on a polydimethylsiloxane (PDMS) substrate using the controlled dewetting of PS thin film then this PDMS substrate is used to close the microchannel with inverted micro-lenses on it. An aqueous suspension of polystyrene particles is flown through the microchannel and we have observed the particles through an optical microscope. Focusing and magnification through PS micro-lenses is analyzed to get a quantitative estimate of the particle number density in the solution. This method offers a promising low-cost high throughput solution for determining the approximate number density of flowing particles or suitably stained biological cells. Particularly in a pathology lab it can tremendously increase detection limit by enabling visibility of sub-micrometer pathogens using a standard laboratory microscope.

Mechanisms and optimization for the rapid fabrication method of polymeric microlens arrays.

This paper presents a simple and cost-effective rapid method to make defect-free polymeric microlens arrays at room temperature without applying external pressure. This method uses an optically clear and high-transparency Norland Optical Adhesive (NOA) monomer solution. This is realized by using a combination of a mold and an ultraviolet (UV) polymerization technique. NOA can cross-link in a tenth of a second upon UV exposure. The uniformity and surface quality of the manufactured microlens arrays are investigated through atomic force microscopy and optical microscopy techniques. Experimental results show that the microlens arrays manufactured by the polymerization process are of very high quality without any defects. Further, the surface quality of the lenses can be significantly enhanced by increasing the viscosity of the photosensitive monomer solution.

Picosecond Laser Interference Patterning of Periodical Micro-Architectures on Metallic Molds for Hot Embossing.

In this work, it is demonstrated that direct laser interference patterning (DLIP) is a method capable of producing microtextured metallic molds for hot embossing processes. Three different metals (Cr, Ni, and Cu), relevant for the mold production used in nanoimprinting systems, are patterned by DLIP using a picosecond laser source emitting at a 532 nm wavelength. The results show that the quality and surface topography of the produced hole-like micropatterns are determined by the laser processing parameters, such as irradiated energy density and the number of pulses. Laser-induced periodic surface structures (LIPSS) are also observed on the treated surfaces, whose shapes, periodicities, and orientations are strongly dependent on the accumulated fluence. Finally, the three structured metals are used as embossing molds to imprint microlenses on polymethyl methacrylate (PMMA) foils using an electrohydraulic press. Topographical profiles demonstrate that the obtained structures are comparable to the masters showing a satisfactory reproduction of the texture. The polymeric microlens arrays that showed the best surface homogeneity and overall quality were those embossed with the Cr molds.

Control of Femtoliter Liquid on a Microlens: A Way to Flexible Dual-Microlens Arrays.

Microlens arrays are key elements for light management in optoelectronic devices. The recent advancement in the wearable intelligent electronics has driven the development of flexible microlenses. In this work, we show a controllable and scalable surface-droplet-based strategy to create unconventional flexible polymer microlens arrays. The technique is underpinned by the morphological transition of femtoliter liquid on the surface of a microlens surrounded by a planar area. We found that the droplet liquid wetted the rim of the microlens first and gradually moved upward to the microlens surface with an increase in the liquid volume. The morphology evolution of the droplet is in good agreement with the predication from our simulations based on the interfacial energy minimization under the condition of the pinned boundary. The shape of the droplet on the microlens is well controlled by the droplet volume, aspect ratio of the microlens, and the interfacial energy of the droplets on the microlens. As a result, the obtained structures of one microlens partially covered by a droplet can be produced in arrays over a large scale, serving as templates for fabricating transparent polymer double microlens arrays for improved light emission from the optoelectronic device.

Fast and cost effective fabrication of microlens arrays for enhancing light out-coupling of organic light-emitting diodes

The efficiency of organic light-emitting diodes (OLEDs) deposited on flat substrates is strongly limited by the total internal reflection at the air-substrate interface. An effective strategy to reduce the amount of substrate modes and enhance the light out-coupling into the air is attaching a microlens array (MLA) on the external surface of OLEDs. In this study, polymeric MLA with periods between 1.2 µm and 2.0 µm are patterned by plate-to-plate nano-imprint lithography using metallic stamps structured by direct laser interference patterning. When MLA with a spatial period of 2.0 µm and a structure depth of 200 nm are employed on red, green and blue OLEDs, the external quantum efficiency is increased to 11.4%, 6.6% and 12.7%, respectively, due to a reduction of internally reflected radiation at the air-MLA-glass interfaces.

Injection Compression Molded Microlens Arrays for Hyperspectral Imaging.

In this work, a polymer microlens array (MLA) for a hyperspectral imaging (HSI) system is produced by means of ultraprecision milling (UP-milling) and injection compression molding. Due to the large number of over 12,000 microlenses on less than 2 cm², the fabrication process is challenging and requires full process control. The study evaluates the process chain and optimizes the single process steps to achieve high quality polymer MLAs. Furthermore, design elements like mounting features are included to facilitate the integration into the final HSI system. The mold insert was produced using ultraprecision milling with a diamond cutting tool. The machining time was optimized to avoid temperature drifts and enable high accuracy. Therefore, single immersions of the diamond tool at a defined angle was used to fabricate each microlens. The MLAs were replicated using injection compression molding. For this process, an injection compression molding tool with moveable frame plate was designed and fabricated. The structured mold insert was used to generate the compression movement, resulting in a homogeneous pressure distribution. The characterization of the MLAs showed high form accuracy of the microlenses and the mounting features. The functionality of the molded optical part could be demonstrated in an HIS system by focusing light spectrums onto a CCD image sensor.

3D fabrication of spherical microlens arrays on concave and convex silica surfaces

Three-dimensional (3D) microlens arrays are a group of micro-optics structures on curved surfaces that offer unique optical functions such as wide field of view in a compact arrangement. This paper reports an improved rapid lapping and molding system for 3D fabrication of spherical microlens arrays on non-planar surfaces including concave and convex surfaces for optical applications. Unlike traditional approaches for 3D micro patterns on curved silicon/silica substrates, this research demonstrates a low-cost and efficient chemical mechanical polishing process by lapping precision microlenses with steel balls and diamond slurries. Different from lapping on plane surfaces, lapping parameters for each micro cavity need to be accurately calculated and controlled to obtain microlenses with same apertures. Therefore, a micro wear model for micro cavity lapping process was established to calculate cavity sag height with the knowledge of down force, relative velocity and lapping time. Several groups of microlenses lapping were then conducted under the same conditions to validate the micro wear model. Guided by the micro wear model, two groups of microlens arrays were fabricated on concave and convex surfaces respectively. The shape accuracy and surface texture of the microlens arrays were evaluated by using a white light interferometer. Afterwards, the silica molds were coated with graphene film and then utilized to copy the 3D microstructures onto polymers by rapid surface molding. The wide angle imaging characterization of the 3D polymeric microlens arrays was illustrated by a simple optical setup and the measured MTF curves using the slanted-edge method. The improved manufacturing platform demonstrates a new approach for 3D microlens arrays fabrication on hard substrates in a cost effective way.

Controllable long focal length microlens based on thermal expansion.

A novel method to fabricate a microlens array with a long focal length has been developed in this paper. It is based on the fabricating and heating of a microlens consisting of two materials with a great difference in coefficient of thermal expansion. A thermal expansion process leads to considerable deformation of the microlens surface and significant increase in focal length, which could be controlled by altering the processing temperature. Cylindrical polymeric microlens arrays with different focal lengths were successfully fabricated. By measuring the focal length and temperature dependence of the cylindrical microlens geometry, the formation mechanism was analyzed and validated. While the temperature is ranged from 20°C to 50°C, the focal length of the cylindrical microlens has been extended by 38.2% and the longest focal length was obtained up to 6.6mm for the microlens with a linewidth of 240μm.

Fabrication of polymer microlens array with controllable focal length by modifying surface wettability.

A straightforward technique for fabricating low-cost microlens arrays with controllable focal length is developed. By harnessing and manipulating the interfacial energy between the liquid-state acrylate resin and the solidified polydimethylsiloxane (PDMS), the surface of the acrylate resin in the PDMS microhole presents a spherical shape and the curvature can be flexibly controlled. With the change of the processing time for the surface modification of the PDMS microholes, the focal length of the concave microlenses varies from -296.3 μm to -67.4 μm. The numerical aperture of 0.45 is realized. The focal length and the aperture of the microlenses are also affected by the diameter of the microholes. The fabricated concave microlens array can be employed as a master to further duplicate convex microlens array. A good image quality can be achieved by using the convex microlens arrays.

Fabrication of microlens array with controllable high NA and tailored optical characteristics using confined ink-jetting

This work presents an economic and controllable fabricating method of high numerical aperture (NA) polymer microlens array (MLA) based on ink-jetting technology. The MLAs are ink-jetted to align on micro platforms patterned flexible PDMS substrate. The shape of a sole lens is constructed by the ink-jetted pre-cured polymer volume confined on a micro platform. In this way, MLAs with targeted geometries—as well as tailored optical characteristics—can be printed, leading to freely designed optical properties. High NA from 0.446 to 0.885 and focal lengths between 99.26 μm and 39.45 μm are demonstrated, confirming theoretical predictions. Particularly, both the simulations and experimental measurements in optical properties are carried out, demonstrating that microlenses with shapes beyond a hemisphere (CA > 90°) exhibits higher light utilization efficiency and wider viewing angle. Meanwhile, the MLAs are fabricated on flexible PDMS substrates and can be attached to other curved surfaces for wider field of view imaging and higher sensitivity.

A Microlens Array with Different Focal Lengths Fabricated by Roll-To-Roll UV Lithography

A simple, highly efficient and low cost roll-to-roll (R2R) UV imprinting lithography facility was achieved for fabricating micro-structures. Firstly, a novel microlens array with focuses distributed on a curved surface was designed and analyzed by an optical software ZEMAX. Then an ultra-precision diamond machine was applied to generate the freeform microlens array features on the master mold, and a belt-type polydimethylsiloxane (PDMS) mold with a microlens array pattern was prepared from the machined master mold. The R2R process was employed to replicate the microlens arrays, followed by an evaluation of their profiles and optical properties. Our experiments demonstrate that the applied method is reliable and efficient for producing the polymeric microlens arrays.

Light management in perovskite solar cells and organic LEDs with microlens arrays.

We demonstrate enhanced absorption in solar cells and enhanced light emission in OLEDs by light interaction with a periodically structured microlens array. We simulate n-i-p perovskite solar cells with a microlens at the air-glass interface, with rigorous scattering matrix simulations. The microlens focuses light in nanoscale regions within the absorber layer enhancing the solar cell. Optimal period of ~700 nm and microlens height of ~800-1000 nm, provides absorption (photocurrent) enhancement of 6% (6.3%). An external polymer microlens array on the air-glass side of the OLED generates experimental and theoretical enhancements >100%, by outcoupling trapped modes in the glass substrate.

Design and application of flexible insert for microinjection compression molding polymer microlens arrays with tunable height

A flexible insert is assembled using easily available porous plate and flexible polymer film. Then, applying microinjection compression molding technology, a fast and efficient method is proposed for successive, mass and one‐step replication of polymer microlens arrays (MLAs). Orderly MLAs with convex microlenses are successfully prepared without a given micro‐feature on the insert corresponding to that on the MLAs. Interestingly, the flexible films are deformed to arc‐like profiles that match with the shape of the microlenses with different curvatures under the action of different mold compression forces. Hence, by only changing the compression force, a series of high quality MLAs with tunable height and so geometrical‐morphology are molded by one flexible insert. The molded MLAs exhibit average heights of 61.61–86.28 µm by varying the compression force from 90 to 120 kN. The molded MLAs exhibit favorable geometrical‐morphology uniformity and optical properties. The proposed method is an accessible approach to avoid expensive equipment and complicated procedure for manufacturing the mold microfeature. POLYM. ENG. SCI., 58:213–219, 2018. © 2017 Society of Plastics Engineers

High Numerical Aperture Hexagonal Stacked Ring-Based Bidirectional Flexible Polymer Microlens Array.

Flexible imprinted photonic nanostructures that are able to diffract/focus narrow-band light have potential applications in optical lenses, filters, tunable lasers, displays, and biosensing. Nanophotonic structures through holography and roll-to-roll printing may reduce fabrication complexities and expenses and enable mass production. Here, 3D photonic nanostructures of a stacked ring array were imprinted on acrylate polymer (AP) over poly(ethylene terephthalate) (PET) substrate through holography and lift-off processes to create a microlens array (MLA). The surface structure of the array consisted of circular nonostepped pyramids, and repeated patterns were in hexagonal arrangements. Stacked-ring-based MLA (SMLA) on a flexible AP-PET substrate showed efficient bidirectional light focusing and maximum numerical aperture (NA = 0.60) with a reasonable filling factor. The nanostructures produced a well-ordered hexagonally focused diffraction pattern in the far field, and power intensities were measured through angle-resolved experiments. The variation of nanostep dimensions (width and height) and the number of steps resulted in different photonic bandgaps, and the arrays produced distance-dependent narrow-band light focusing. The validation of the SMLA was demonstrated through the text, image, and hologram projection experiments. It is anticipated that imprinted bidirectional SMLA over flexible substrates may find applications in optical systems, displays, and portable sensors.

Polymeric microlens array formed directly on glass plate

We prepared a polymeric microlens array (MLA) using ultraviolet (UV) light to cure photosensitive monomers through a photomask. After a short-time UV exposure, the uncured monomers experience a process of partial wetting and self-development on the surface of cured monomers. As a result, a geometric relief with a lens character is generated. Depending on the pattern of the photomask, either a convex or concave MLA can be fabricated. The mechanism of forming the MLA is explained and the concept is proved experimentally. Owing to the merits of simple fabrication, good flexibility, and high optical performance, the MLA has potential applications in light diffusers, fiber/organic light-emitting diode couplers, biomedical imaging, and displays.

Design, fabrication, and testing of a Shack-Hartmann sensor with an automatic registration feature.

In this research, design, construction, and testing of an innovative Shack-Hartmann sensor are described. As the most critical component, a polymer microlens array is injection molded and mounted on a board-level CMOS camera such that the focal plane of the microlens array is on the camera's image plane. To allow for automatic registration of the spots of the measured area, a diffusing surface was created at the center of the lens array in the same diamond machining process in an uninterrupted operation. This unique diffusing surface does not generate an image spot. The no-spot feature functions as the reference in the measurement on the camera's image plane. Using this unique feature, large global tip-tilt error can be detected and eliminated. In this research, both experiments and simulation have shown that the Shack-Hartmann sensor built using low cost components is capable of precision wavefront detection. This research also demonstrated that automatic registration based on the diffusing surface is simple and reliable.

Fabrication of Large-Scale Microlens Arrays Based on Screen Printing for Integral Imaging 3D Display.

The low-cost large-scale fabrication of microlens arrays (MLAs) with precise alignment, great uniformity of focusing, and good converging performance are of great importance for integral imaging 3D display. In this work, a simple and effective method for large-scale polymer microlens arrays using screen printing has been successfully presented. The results show that the MLAs possess high-quality surface morphology and excellent optical performances. Furthermore, the microlens' shape and size, i.e., the diameter, the height, and the distance between two adjacent microlenses of the MLAs can be easily controlled by modifying the reflowing time and the size of open apertures of the screen. MLAs with the neighboring microlenses almost tangent can be achieved under suitable size of open apertures of the screen and reflowing time, which can remarkably reduce the color moiré patterns caused by the stray light between the blank areas of the MLAs in the integral imaging 3D display system, exhibiting much better reconstruction performance.

Fabrication of polymer lenses and microlens array for lab-on-a-chip devices

Microlenses and microlens arrays are assuming an increasingly important role in optical devices and communication systems. In response to their extended use in different fields of technology, a great emphasis is being placed on research into simple manufacturing approaches for these micro-optical components as well as on the characterization of their performance. This paper provides an overview of the recent emerging technologies for the fabrication of polymer microlenses by electrical, mechanical, chemical, and pyro-electrical methods. Attention is mainly focused on polymer molding and self-assembling for microlens arrays, while ink-jet printing is proposed for on-demand printing of lenses with high resolution. Among all the emerging techniques proposed, the pyro-electrodynamic approach has recently achieved great interest as an easy multiscale approach for the fabrication of polymer microlens arrays through a flexible process driven by electrohydrodynamic pressure. As each processing method has distinct advantages and limitations, the most significant characteristic parameters and the measurements of these parameters are discussed for each method.