Abstract

Fresnel lens arrays are widely employed in concentrator photovoltaics, photonic devices, and integral imaging systems. In this study, a rapid non-isothermal imprinting process for Fresnel lens arrays was proposed. In this process, a heated mold with microstructures was momentarily pressed onto a thermoplastic polymer surface that was initially kept at room temperature. The microstructures of the mold can be copied completely to the polymer substrate by imprinting consecutively until a continuous surface Fresnel lens array is obtained. Different from more traditional molding processes, the substrate does not need to be heated and cooled repeatedly in the replicating process. In addition, the imprinting process is carried out at room temperature, which can greatly reduce the thermal cycle time and energy consumption. Generally speaking, the material flow and stress distribution of the substrate need to be monitored so that the microlenses with a high precision surface finish can be produced in the non-isothermal imprinting process. To verify this, the finite element method (FEM) model for the non-isothermal process was established, and the feasibility of this process was analyzed. A hexagonal continuous surface Fresnel lens array was then fabricated, and its geometrical contour and imaging performance were tested. The experimental results showed this new process could be an effective and low-cost optical fabrication technology for high-quality production of Fresnel lens arrays.

© 2021 Optical Society of America

Full Article  |  PDF Article
More Like This
Microforging technique for rapid, low-cost fabrication of lens array molds

Craig R. Forest, Miguel A. Saez, and Ian W. Hunter
Appl. Opt. 46(36) 8668-8673 (2007)

Soft mold-based hot embossing process for precision imprinting of optical components on non-planar surfaces

Jianwei Chen, Chenglin Gu, Hui Lin, and Shih-Chi Chen
Opt. Express 23(16) 20977-20985 (2015)

References

You do not have subscription access to this journal. Citation lists with outbound citation links are available to subscribers only. You may subscribe either as an Optica member, or as an authorized user of your institution.

Contact your librarian or system administrator
or
Login to access Optica Member Subscription

Cited By

You do not have subscription access to this journal. Cited by links are available to subscribers only. You may subscribe either as an Optica member, or as an authorized user of your institution.

Contact your librarian or system administrator
or
Login to access Optica Member Subscription

Figures (10)

You do not have subscription access to this journal. Figure files are available to subscribers only. You may subscribe either as an Optica member, or as an authorized user of your institution.

Contact your librarian or system administrator
or
Login to access Optica Member Subscription

Tables (2)

You do not have subscription access to this journal. Article tables are available to subscribers only. You may subscribe either as an Optica member, or as an authorized user of your institution.

Contact your librarian or system administrator
or
Login to access Optica Member Subscription

Equations (1)

You do not have subscription access to this journal. Equations are available to subscribers only. You may subscribe either as an Optica member, or as an authorized user of your institution.

Contact your librarian or system administrator
or
Login to access Optica Member Subscription

Metrics