Microlens Array Fabrication via Hydrophilic Zone Self-Assembly
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Solution Overview
Problem
Current methods for fabricating microlens arrays (MLAs) are costly, time-consuming, and require high-temperature processes or complex etch-transfer methods, limiting their efficiency and accuracy.
Innovation Solution
A fabrication method utilizing a hydrophilic modified polymer layer on a substrate, where light, gas, or liquid is used to create a hydrophilic zone, followed by coating with a liquid material and curing under UV light to form microlenses, eliminating the need for high-temperature processes and etch-transfer methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fabrication methods (ink jet printing, photoresist thermal reflow, hot press molding, photomask lithography, laser etching) are used, then microlens arrays can be fabricated, but the process cost, time consumption, and facility cost increase significantly
Solution Approach 1:
The polymer layer automatically forms microlenses through its own hydrophobic/hydrophilic properties when exposed to UV/ozone treatment, eliminating the need for external molding tools or complex alignment systems. The material self-organizes into lens structures based on surface energy differences created by the treatment pattern.
Solution Approach 2:
The patent replaces mechanical fabrication methods (molding, pressing, lithography) with a chemical/physical field-based approach using UV/ozone treatment to modify surface properties. Instead of mechanically forming lenses, the process uses photo-oxidation to create hydrophilic patterns that guide liquid polymer self-assembly.
2Temperature
If hydrophobic effect method is used to fabricate MLAs, then heating process is eliminated, but etch-transfer process or printing method is still required to define hydrophobic boundaries
Solution Approach 1:
The patent extracts and eliminates the most complex step from the hydrophobic method—the etch-transfer or printing process used to define boundaries. Instead of requiring separate boundary definition steps, the UV/ozone treatment directly creates the hydrophilic patterns that serve as both boundaries and formation templates for the microlenses.
Solution Approach 2:
The patent merges the boundary definition function and the microlens formation function into a single UV/ozone treatment step. The same treatment that creates hydrophilic zones also defines where microlenses will form, combining multiple process functions into one operation.
3Manufacturing precision
If high-temperature processes are used for microlens fabrication, then microlenses can be formed, but thermal residual stress is introduced and fabrication cost increases
Solution Approach 1:
The patent substitutes thermal fields with photo-oxidation chemical fields to achieve microlens formation. UV/ozone treatment modifies surface chemistry at room temperature to create hydrophilic patterns, eliminating thermal stress entirely while maintaining precise microlens formation through controlled surface energy distribution.
4Manufacturing precision
If conventional fabrication methods are used, then microlenses can be fabricated, but facility cost and equipment investment are high
Solution Approach 1:
The patent uses a simple polymer layer that can be easily deposited and processed without expensive equipment. The method employs common materials (polymer coatings, UV/ozone treatment) rather than requiring specialized optical benches, clean rooms, or precision manufacturing equipment, dramatically reducing facility and equipment costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables rapid, low-cost, and accurate fabrication of MLAs at room temperature, allowing for controlled microlens curvature and size through UV/ozone treatment and external electric field adjustments, resulting in high mechanical strength and efficient microlens formation without thermal residual stress.
Implementation Method 1
modifying the interface hydrophilic modified polymer layer by using UV/ozone and thereby to create a hydrophilic zone on the interface hydrophilic modified polymer layer
Implementation Method 2
immersing the substrate in a liquid material and removing it therefrom so as to condense a plurality of liquid microlenses in the hydrophilic zone
Implementation Method 3
curing the plurality of liquid microlenses with UV light to form a plurality of microlenses
Implementation Method 4
exploiting the hydrophilicity and electric field effect
Data Source
AI summary
The present invention discloses a fabrication method of a microlens array (MLA) and an MLA fabricated using the same. The fabrication method of an MLA comprises: providing a substrate with an interface hydrophilic modified polymer layer; using light, gas or liquid with the property of converting the polymer' hydrophilicity to create a hydrophilic zone on the interface hydrophilic modified polymer layer; coating the substrate with a liquid material to condense a plurality of liquid microlenses in the hydrophilic zone; and curing the plurality of liquid microlenses to form a plurality of microlenses. Therefore, the fabrication method of an MLA has advantages of fast speed, low cost, no etch transfer and low temperature.