TY - GEN
T1 - The novel fabrication method and optimum tooling design used for microlens arrays
AU - Shen, Yung Kang
AU - Shen, Yu Sheng
PY - 2006
Y1 - 2006
N2 - This paper reports a simple and novel procedure for mass production of microlens arrays. In this paper, a microlens array master is formed by room temperature imprint lithography and thermal reflow process. Next, electroforming is carried out to fabricate the metal mold insert from the microlens array master. Finally, micro-hot embossing is used to replicate microlens arrays. In this paper, a L9 experimental matrix design based on the Taguchi method is constructed to optimize the replication quality of molded microlens arrays. The results of the statistical analysis indicated that the processing temperature is the principal parameter affecting the sag height of the molded microlens array. The optimal processing parameters are processing temperature of 150°C, embossing pressure of 5.21MPa, processing time of 90s and de-molding temperature of 70°C. The 200×200 arrays of molded microlens, with a diameter of 150μm, a pitch of 200μm and a sag height of 31.51μm have been successfully fabricated. The average surface roughness of the molded microlens array is 4.31nm.
AB - This paper reports a simple and novel procedure for mass production of microlens arrays. In this paper, a microlens array master is formed by room temperature imprint lithography and thermal reflow process. Next, electroforming is carried out to fabricate the metal mold insert from the microlens array master. Finally, micro-hot embossing is used to replicate microlens arrays. In this paper, a L9 experimental matrix design based on the Taguchi method is constructed to optimize the replication quality of molded microlens arrays. The results of the statistical analysis indicated that the processing temperature is the principal parameter affecting the sag height of the molded microlens array. The optimal processing parameters are processing temperature of 150°C, embossing pressure of 5.21MPa, processing time of 90s and de-molding temperature of 70°C. The 200×200 arrays of molded microlens, with a diameter of 150μm, a pitch of 200μm and a sag height of 31.51μm have been successfully fabricated. The average surface roughness of the molded microlens array is 4.31nm.
KW - Micrlens array
KW - Micro hot embossing molding
UR - http://www.scopus.com/inward/record.url?scp=46149123702&partnerID=8YFLogxK
UR - http://www.scopus.com/inward/citedby.url?scp=46149123702&partnerID=8YFLogxK
U2 - 10.1109/NEMS.2006.334683
DO - 10.1109/NEMS.2006.334683
M3 - Conference contribution
AN - SCOPUS:46149123702
SN - 1424401402
SN - 9781424401406
T3 - Proceedings of 1st IEEE International Conference on Nano Micro Engineered and Molecular Systems, 1st IEEE-NEMS
SP - 187
EP - 191
BT - Proceedings of 1st IEEE International Conference on Nano Micro Engineered and Molecular Systems, 1st IEEE-NEMS
T2 - 1st IEEE International Conference on Nano Micro Engineered and Molecular Systems, 1st IEEE-NEMS
Y2 - 18 January 2006 through 21 January 2006
ER -