Abstract

This paper reports a novel and effective method to fabricate microlens arrays on polycarbonate films by hybrid extrusion rolling embossing. The metallic cylinder mold bearing an array of micro-holes is fabricated using photolithography with dry film resist. During the extrusion rolling embossing process, the extruded PC film is immediately pressed against the surface of the roller mold. Under the influence of the rolling pressure and surface tension, an array of convex microlenses is formed. The uniformity and optical properties have been verified. An efficient continuous mass production technique has been demonstrated.

© 2007 Optical Society of America

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References

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  1. D. Daly, R. F. Stevens, M. C. Hutley, and N. Davies, "The manufacture of microlenses by melting photoresist," Meas. Sci. Technol. 1, 759-766 (1990). http://www.iop.org/EJ/toc/0957-0233/1/8
    [CrossRef]
  2. X.-C. Yuan, W. X. Yu, N. Q. Ngo, and W. C. Cheong, "Cost-effective fabrication of microlenses on hybrid sol-gel glass with a high-energy beam-sensitive gray-scale mask," Opt. Express 10, 303-308 (2002).
    [PubMed]
  3. W. X. Yu, and X. -C. Yuan, "UV induced controllable volume growth in hybrid sol-gel glass for fabrication of a refractive microlens by use of a grayscale mask," Opt. Express 11, 2253-2258 (2003).
    [CrossRef] [PubMed]
  4. C. Y. Chang, S. Y. Yang, L. S. Huang, and K. H. Hsieh, "Fabrication of polymer microlens arrays using capillary forming with a soft mold of micro-holes array and UV-curable polymer," Opt. Express 14, 6253-6258 (2006).
    [CrossRef] [PubMed]
  5. V. Bardinal, E. Daran, T. Leïchlé, C. Vergnenègre, C. Levallois, T. Camps, V. Conedera, J. B. Doucet, and F. Carcenac, "Fabrication and characterization of microlens arrays using a cantilever-based spotter," Opt. Express 15, 6900-6907 (2007).
    [CrossRef] [PubMed]
  6. W. L. Chang, and P. K. Wei, "Fabrication of a close-packed hemispherical submicron lens array and its application in photolithography," Opt. Express 15, 6774-6783 (2007).
    [CrossRef] [PubMed]
  7. S.-I. Chang, and J.-B. Yoon, "Shape-controlled, high fill-factor microlens arrays fabricated by a 3D diffuser lithography and plastic replication method," Opt. Express 12, 6366-6371 (2004).
    [CrossRef] [PubMed]
  8. R. Guo, S. Xiao, X. Zhai, J. Li, A. Xia, and W. Huang, "Micro lens fabrication by means of femtosecond two photon photopolymerization," Opt. Express 14, 810-816 (2006).
    [CrossRef] [PubMed]
  9. B.K. Lee, D.S. Kim and T.H. Kwon, "Replication of microlens arrays by injection molding, Microsystem Technologies,"  10, 531-535 (2004).
  10. N. S. Ong, Y. H. Koh and Y. Q. Fu, "Microlens array produced using hot embossing process," Microelectron. Eng. 60, 365-379 (2002).
    [CrossRef]
  11. S.-M. Kim and S. Kang, "Replication qualities and optical properties of UV-moulded microlens arrays," J. Phys. D: Appl. Phys. 36, 2451-2456 (2003).
    [CrossRef]
  12. C. Y. Chang, S.Y. Yang, and J. L. Sheh, "A roller embossing process for rapid fabrication of microlens arrays on glass substrates," Microsyst. Technol. 12, 754-759 (2006).
    [CrossRef]

2007 (2)

2006 (3)

2004 (2)

B.K. Lee, D.S. Kim and T.H. Kwon, "Replication of microlens arrays by injection molding, Microsystem Technologies,"  10, 531-535 (2004).

S.-I. Chang, and J.-B. Yoon, "Shape-controlled, high fill-factor microlens arrays fabricated by a 3D diffuser lithography and plastic replication method," Opt. Express 12, 6366-6371 (2004).
[CrossRef] [PubMed]

2003 (2)

2002 (2)

1990 (1)

D. Daly, R. F. Stevens, M. C. Hutley, and N. Davies, "The manufacture of microlenses by melting photoresist," Meas. Sci. Technol. 1, 759-766 (1990). http://www.iop.org/EJ/toc/0957-0233/1/8
[CrossRef]

J. Phys. D: Appl. Phys. (1)

S.-M. Kim and S. Kang, "Replication qualities and optical properties of UV-moulded microlens arrays," J. Phys. D: Appl. Phys. 36, 2451-2456 (2003).
[CrossRef]

Meas. Sci. Technol. (1)

D. Daly, R. F. Stevens, M. C. Hutley, and N. Davies, "The manufacture of microlenses by melting photoresist," Meas. Sci. Technol. 1, 759-766 (1990). http://www.iop.org/EJ/toc/0957-0233/1/8
[CrossRef]

Microelectron. Eng. (1)

N. S. Ong, Y. H. Koh and Y. Q. Fu, "Microlens array produced using hot embossing process," Microelectron. Eng. 60, 365-379 (2002).
[CrossRef]

Microsyst. Technol. (1)

C. Y. Chang, S.Y. Yang, and J. L. Sheh, "A roller embossing process for rapid fabrication of microlens arrays on glass substrates," Microsyst. Technol. 12, 754-759 (2006).
[CrossRef]

Microsystem Technologies (1)

B.K. Lee, D.S. Kim and T.H. Kwon, "Replication of microlens arrays by injection molding, Microsystem Technologies,"  10, 531-535 (2004).

Opt. Express (7)

X.-C. Yuan, W. X. Yu, N. Q. Ngo, and W. C. Cheong, "Cost-effective fabrication of microlenses on hybrid sol-gel glass with a high-energy beam-sensitive gray-scale mask," Opt. Express 10, 303-308 (2002).
[PubMed]

W. X. Yu, and X. -C. Yuan, "UV induced controllable volume growth in hybrid sol-gel glass for fabrication of a refractive microlens by use of a grayscale mask," Opt. Express 11, 2253-2258 (2003).
[CrossRef] [PubMed]

C. Y. Chang, S. Y. Yang, L. S. Huang, and K. H. Hsieh, "Fabrication of polymer microlens arrays using capillary forming with a soft mold of micro-holes array and UV-curable polymer," Opt. Express 14, 6253-6258 (2006).
[CrossRef] [PubMed]

V. Bardinal, E. Daran, T. Leïchlé, C. Vergnenègre, C. Levallois, T. Camps, V. Conedera, J. B. Doucet, and F. Carcenac, "Fabrication and characterization of microlens arrays using a cantilever-based spotter," Opt. Express 15, 6900-6907 (2007).
[CrossRef] [PubMed]

W. L. Chang, and P. K. Wei, "Fabrication of a close-packed hemispherical submicron lens array and its application in photolithography," Opt. Express 15, 6774-6783 (2007).
[CrossRef] [PubMed]

S.-I. Chang, and J.-B. Yoon, "Shape-controlled, high fill-factor microlens arrays fabricated by a 3D diffuser lithography and plastic replication method," Opt. Express 12, 6366-6371 (2004).
[CrossRef] [PubMed]

R. Guo, S. Xiao, X. Zhai, J. Li, A. Xia, and W. Huang, "Micro lens fabrication by means of femtosecond two photon photopolymerization," Opt. Express 14, 810-816 (2006).
[CrossRef] [PubMed]

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Figures (7)

Fig. 1.
Fig. 1.

Dry film resist (a) schematics showing the conformation (not to the scale) (b) photograph of the roll of DFR

Fig. 2.
Fig. 2.

Schematic diagrams of microstructure fabrication process on roller using dry film resist

Fig. 3.
Fig. 3.

Images of the fabricated roller mold with micro-hole arrays using (a) a digital camera (b) SEM (c) 3-D surface profiler

Fig. 4.
Fig. 4.

Schematic diagram and photograph showing the hybrid extrusion rolling embossing facility

Fig. 5.
Fig. 5.

Under proper rolling pressure, PC film is partially protruded in the holes and form the convex lens due to surface tension during rolling embossing

Fig. 6.
Fig. 6.

Fabricated microlens array on PC film (a) SEM (b) 3-D Surface profiler

Fig. 7.
Fig. 7.

microlens array focal length measurement system

Tables (1)

Tables Icon

Table 1. The diameter of the micro-holes after each step during roller fabrication process

Metrics