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US5300263A
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Method of making a microlens array and mold
Assignee: 3M Co
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Filing: 1992-10-28
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Granted: 1994-04-05
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Expires: 2012-10-28
Abstract
Abstract A method of making a microlens array and mold, and the articles made therefrom. The method involves forming a plurality of adjacent receptacles on a surface and partially filling the receptacles with a hardenable liquid, thereby forming a meniscus in each receptacle. A lens material can then be applied to the menisci, thereby forming an array of generally spherical microlenses. In one embodiment, the perimeters of the microlenses are modified rectangles in that each edge of the lens is a symmetrical elliptical arc, the ends of which terminate at the corners of the rectangle, and the middle of which curves toward the center of the rectangle.
Inventors
- 👤 Timothy L. Hoopman
- 👤 David J. W. Aastuen
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 14:20
CPC Classifications
G; G02; G02B; G02B3/00; G02B3/0006; G02B3/0012; G02B3/0031; B; B29; B29C; B29C33/00; B29C33/0022; B29C33/38; B29C33/3842; B29C33/3857; B29C33/3878; B29C33/3892; B29D; B29D11/00; B29D11/00009; B29D11/00278; G02B3/0025; B29L; B29L2011/00; B29L2011/0016; G02B3/0037; G02B3/0056; Y; Y10; Y10S; Y10S425/00; Y10S425/808
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
81 words
A method of making a microlens array mold, comprising: (a) forming an array of pyramid-shaped receptacles having parallelogram-shaped apertures; (b) applying a hardenable liquid to the array of pyramid-shaped receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (c) hardening the liquid to form a plurality of concave lens mold surfaces in the pyramid-shaped receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 2
Independent Claim
81 words
A method of making a microlens array mold, comprising: (a) forming an array of pyramid-shaped receptacles having parallelogram-shaped apertures; (b) applying a hardenable liquid to the array of pyramid-shaped receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (c) hardening the liquid to form a plurality of concave lens mold surfaces in the pyramid-shaped receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 3
Dependent Claim
87 words
The method of claim 1, wherein step (a) comprises: providing a first plurality of parallel grooves in a substrate surface; providing a second plurality of parallel grooves in the substrate surface, wherein the second plurality of grooves intersects the first plurality of grooves; and forming a negative replica of the substrate surface, thereby forming a first and second plurality of parallel raised walls corresponding to the first and second plurality of parallel grooves, whereby the pluralities of intersecting walls define an array of receptacles having parallelogram-shaped apertures.
Claim 4
Dependent Claim
21 words
The method of claim 2, wherein the first plurality of parallel grooves is perpendicular to the second plurality of parallel grooves.
Claim 5
Dependent Claim
51 words
The method of claim 1, further comprising, after step (c), the following steps; (d) applying a conductive layer to the concave lens mold surfaces; and (e) electroforming the conductive layer to form a nickel negative of the conductive layer, thereby forming a plurality of convex lens mold surfaces in the receptacles.
Claim 6
Dependent Claim
39 words
The method of claim 4, further comprising, after step (e), the step of electroforming the nickel negative to form a nickel positive of the conductive layer, thereby forming a plurality of concave lens mold surfaces corresponding to the receptacles.
Claim 7
Dependent Claim
145 words
The method of claim 1, wherein the receptacle apertures are rectangular and are defined by a first plurality of parallel walls which are perpendicular to and intersect a second plurality of parallel walls, further comprising, before step (b), the steps of: providing a first plurality of arcuate grooves in the first plurality of parallel walls, wherein the arcuate grooves are parallel to the second plurality of parallel walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the second plurality of parallel walls; and providing a second plurality of arcuate grooves in the second plurality of parallel walls, wherein the arcuate grooves are parallel to the first plurality of walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the first plurality of parallel walls.
Claim 8
Dependent Claim
46 words
The method of claim 6, wherein the shape of each arcuate groove is defined by the projection of the intersection of a desired spherical lens surface with the wall into a plane which has its surface normal oriented parallel to the length of the arcuate groove.
Claim 9
Dependent Claim
12 words
The method of claim 1, wherein the pyramid-shaped receptacles have flat bottoms.
Claim 10
Independent Claim
100 words
A method of making a microlens array, comprising: (a) forming an array of receptacles having generally polygonal apertures; (b) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; (c) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses; (d) applying a hardenable lens material to the array; and (e) hardening the lens material, thereby forming an array of generally spherical microlenses.
Claim 11
Independent Claim
100 words
A method of making a microlens array, comprising: (a) forming an array of receptacles having generally polygonal apertures; (b) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; (c) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses; (d) applying a hardenable lens material to the array; and (e) hardening the lens material, thereby forming an array of generally spherical microlenses.
Claim 12
Dependent Claim
88 words
The method of claim 9, wherein step (a) comprises: providing a first plurality of parallel grooves in a substrate surface; providing a second plurality of parallel grooves in the substrate surface, wherein the second plurality of grooves intersects the first plurality of grooves; and forming a negative replica of the substrate surface, thereby forming a first and second plurality of parallel raised walls corresponding to the first and second plurality of parallel grooves, whereby the pluralities of intersecting walls define an array of receptacles having generally polygonal apertures.
Claim 13
Dependent Claim
21 words
The method of claim 10, wherein the first plurality of parallel grooves is perpendicular to the second plurality of parallel grooves.
Claim 14
Dependent Claim
10 words
The method of claim 10, wherein the grooves are V-shaped.
Claim 15
Dependent Claim
14 words
The method of claim 10, wherein the grooves are provided by a machining process.
Claim 16
Dependent Claim
49 words
The method of claim 9, further comprising, after step (c), the following steps: applying a conductive layer to the concave lens mold surfaces; and electroforming the conductive layer to form a nickel negative of the conductive layer, thereby forming a plurality of convex lens mold surfaces in the receptacles.
Claim 17
Dependent Claim
41 words
The method of claim 14, further comprising, after electroforming the conductive layer, the step of electroforming the nickel negative to form a nickel positive of the conductive layer, thereby forming a plurality of concave lens mold surfaces corresponding to the receptacles.
Claim 18
Dependent Claim
145 words
The method of claim 9, wherein the receptacle apertures are rectangular and are defined by a first plurality of parallel walls which are perpendicular to and intersect a second plurality of parallel walls, further comprising, before step (b), the steps of: providing a first plurality of arcuate grooves in the first plurality of parallel walls, wherein the arcuate grooves are parallel to the second plurality of parallel walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the second plurality of parallel walls; and providing a second plurality of arcuate grooves in the second plurality of parallel walls, wherein the arcuate grooves are parallel to the first plurality of walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the first plurality of parallel walls.
Claim 19
Dependent Claim
46 words
The method of claim 16, wherein the shape of each arcuate groove is defined by the projection of the intersection of a desired spherical lens surface with the wall into a plane which has its surface normal oriented parallel to the length of the arcuate groove.
Claim 20
Dependent Claim
11 words
The method of claim 9, wherein the receptacle apertures are triangular.
Claim 21
Independent Claim
150 words
A method of making a microlens array mold, comprising: (a) providing a first plurality of parallel grooves in a substrate surface; (b) providing a second plurality of parallel grooves in the substrate surface, wherein the second plurality of grooves intersects the first plurality of grooves; (c) forming a negative replica of the substrate surface, thereby forming a first and second plurality of parallel raised walls corresponding to the first and second plurality of parallel grooves, whereby the pluralities of intersecting walls define an array of receptacles having generally polygonal apertures; (d) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (e) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 22
Independent Claim
150 words
A method of making a microlens array mold, comprising: (a) providing a first plurality of parallel grooves in a substrate surface; (b) providing a second plurality of parallel grooves in the substrate surface, wherein the second plurality of grooves intersects the first plurality of grooves; (c) forming a negative replica of the substrate surface, thereby forming a first and second plurality of parallel raised walls corresponding to the first and second plurality of parallel grooves, whereby the pluralities of intersecting walls define an array of receptacles having generally polygonal apertures; (d) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (e) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 23
Dependent Claim
51 words
The method of claim 19, further comprising, after step (e), the following steps; (f) applying a conductive layer to the concave lens mold surfaces; and (g) electroforming the conductive layer to form a nickel negative of the conductive layer, thereby forming a plurality of convex lens mold surfaces in the receptacles.
Claim 24
Dependent Claim
39 words
The method of claim 20, further comprising, after step (g), the step of electroforming the nickel negative to form a nickel positive of the conductive layer, thereby forming a plurality of concave lens mold surfaces corresponding to the receptacles.
Claim 25
Dependent Claim
21 words
The method of claim 19, wherein the first plurality of parallel grooves is perpendicular to the second plurality of parallel grooves.
Claim 26
Independent Claim
203 words
A method of making a microlens array mold, comprising: (a) forming an array of receptacles having rectangular apertures defined by a first plurality of parallel walls which are perpendicular to and intersect a second plurality of parallel walls; (b) providing a first plurality of arcuate grooves in the first plurality of parallel walls, wherein the arcuate grooves are parallel to the second plurality of parallel walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the second plurality of parallel walls; (c) providing a second plurality of arcuate grooves in the second plurality of parallel walls, wherein the arcuate grooves are parallel to the first plurality of walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the first plurality of parallel walls; (d) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (e) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 27
Independent Claim
203 words
A method of making a microlens array mold, comprising: (a) forming an array of receptacles having rectangular apertures defined by a first plurality of parallel walls which are perpendicular to and intersect a second plurality of parallel walls; (b) providing a first plurality of arcuate grooves in the first plurality of parallel walls, wherein the arcuate grooves are parallel to the second plurality of parallel walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the second plurality of parallel walls; (c) providing a second plurality of arcuate grooves in the second plurality of parallel walls, wherein the arcuate grooves are parallel to the first plurality of walls, and wherein each arcuate groove is centered between and spans the distance between each pair of adjacent walls in the first plurality of parallel walls; (d) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (e) hardening the liquid to form a plurality of concave lens mold surfaces in the receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 28
Dependent Claim
46 words
The method of claim 23, wherein the shape of each arcuate groove is defined by the projection of the intersection of a desired spherical lens surface with the wall into a plane which has its surface normal oriented parallel to the length of the arcuate groove.
Claim 29
Independent Claim
80 words
A method of making a microlens array mold, comprising: (a) forming an array of tetrahedral receptacles having triangular apertures; (b) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (c) hardening the liquid to form a plurality of concave lens mold surfaces in the triangular receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 30
Independent Claim
80 words
A method of making a microlens array mold, comprising: (a) forming an array of tetrahedral receptacles having triangular apertures; (b) applying a hardenable liquid to the array of receptacles so that the receptacles are partially filled with the liquid, whereby a plurality of menisci are formed in the receptacles; and (c) hardening the liquid to form a plurality of concave lens mold surfaces in the triangular receptacles, thereby forming a mold capable of forming an array of generally spherical microlenses.
Claim 31
Dependent Claim
61 words
The method of claim 25, wherein each tetrahedral receptacle is defined by three walls and the receptacle apertures are equilateral triangles, and further comprising, after step (a) and before step (b), the step of providing one arcuate groove through the top of each wall of each receptacle, wherein each groove is centered between and spans the distance between each adjacent wall.
Claim 32
Dependent Claim
46 words
The method of claim 26, wherein the shape of each arcuate groove is defined by the projection of the intersection of a desired spherical lens surface with the wall into a plane which has its surface normal oriented parallel to the length of the arcuate groove.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-04-04 | 1997-10-04 | 1998-04-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-04-04 | 2001-10-04 | 2002-04-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-04-04 | 2005-10-04 | 2006-04-05 | $7700.00 | Window Closed / Lapsed |