Microlens array diffuser for a light-emitting diode backlight system

Hyperspectral screen-image-synthesis meter with scattering-noise suppression

The screen image synthesis (SIS) meter was originally proposed as a high-speed measurement tool, which fused the measured data from multiple sample-rotational angles to produce a whole-field measurement result. However, it suffered from stray light noise and lacked the capability of spectrum measurement. In this study, we propose an SIS system embedded with a snapshot hyperspectral technology, which was based on a dispersion image of the sparse sampling screen (SSS). When a photo was captured, it was transformed and calibrated to hyperspectral data at a specific sample-rotational angle. After the hyperspectral data in all sample-rotational angles were captured, an SIS image-fusion process was then applied to get the whole field hyperspectral data. By applying SSS to the SIS meter, we not only create a screen image synthesis hyperspectral meter but also effectively address the issue of stray-light noise. In the experiment, we analyze its correctness by comparing the hyperspectral value with a one-dimensional spectrum goniometer (ODSG). We also show the 2D color temperature coefficient distribution and compare it with the ODSG. Experimental results also demonstrate the feasibility in terms of both spectrum distribution meter and color coefficient temperature distribution meter.

Fabrication of tungsten-based optical diffuser using fiberform nanostructure via efficient plasma route

Optical diffusion is an essential process used to manage photons in a wide range of photoelectric systems. This work proposes an approach to fabricate novel optical diffusers by a plasma-processing technique, using fiberform nanostructures formed by helium plasma irradiation and subsequent annealing. After an annealing procedure in the air for oxidation, the optical properties and the light-diffusing abilities of these nanostructured thin films were studied. In addition to the morphology analysis and total transmittance measurement, the diffusion efficiency of the optical diffusers was analyzed using a transmitted scatter distribution function (TDF). It was revealed that the diffusion efficiency of a device with an irradiation time of 30 minutes could reach 97%. The results demonstrate the potential of these nanostructured optical diffusers for various photoelectric applications.

Ultra-precision manufacturing of microlens arrays using an optimum machining process chain

There are still significant challenges in the accurate and uniform manufacturing of microlens arrays (MLAs) with advanced ultra-precision diamond cutting technologies due to increasingly stringent requirements and shape complexity. In this paper, an optimum machining process chain is proposed based on the integration of a micro-abrasive fluid jet polishing (MAFJP) process to improve the machining quality by single point diamond turning (SPDT). The MLAs were first machined and compensated by SPDT until the maximum possible surface quality was obtained. The MAFJP was used to correct the surface form error and reduce the nonuniformity for each lens. The polishing characterization was analyzed based on the computational fluid dynamics (CFD) method to enhance the polishing efficiency. To better polish the freeform surface, two-step tool path generation using a regional adaptive path and a raster and cross path was employed. Moreover, the compensation error map was also investigated by revealing the relationship between the material removal mechanism and the surface curvature and polishing parameters. A series of experiments were conducted to prove the reliability and capability of the proposed method. The results indicate that the two integrated machining processes are capable of improving the surface form accuracy with a decrease in PV value from 1.67 µm to 0.56 µm and also elimination of the nonuniform surface error for the lenses.

Toward Perfect Optical Diffusers: Dielectric Huygens' Metasurfaces with Critical Positional Disorder

Conventional optical diffusers, such as thick volume scatterers (Rayleigh scattering) or microstructured surface scatterers (geometric scattering), lack the potential for on-chip integration and are thus incompatible with next-generation photonic devices. Dielectric Huygens' metasurfaces, on the other hand, consist of 2D arrangements of resonant dielectric nanoparticles and therefore constitute a promising material platform for ultrathin and highly efficient photonic devices. When the nanoparticles are arranged in a random but statistically specific fashion, diffusers with exceptional properties are expected to come within reach. This work explores how dielectric Huygens' metasurfaces can implement wavelength-selective diffusers with negligible absorption losses and nearly Lambertian scattering profiles that are largely independent of the angle and polarization of incident waves. The combination of tailored positional disorder with a carefully balanced electric and magnetic response of the nanoparticles is shown to be an integral requirement for the operation as a diffuser. The proposed metasurfaces' directional scattering performance is characterized both experimentally and numerically, and their usability in wavefront-shaping applications is highlighted. Since the metasurfaces operate on the principles of Mie scattering and are embedded in a glassy environment, they may easily be incorporated in integrated photonic devices, fiber optics, or mechanically robust augmented reality displays.

Low-cost, thermoplastic micro-lens array with a carbon black light screen for bio-mimetic vision

Micro-lens array is a great example of bio-mimetic technology which was inspired by compound eyes found in insects and is used in lasers, optical communication, and 3D imaging. In this study, a micro-lens array was fabricated from cyclic olefin copolymer using a cost-effective method: compression molding and thermal reflow. Also, a light screen was installed between lenses to reduce the optical interference for clearer individual images. Cyclic olefin copolymer-based micro-lens array showed good optical results under a standard optical microscope. By placing the fabricated micro-lens array directly on an image sensor, it was observed that the light screen shows significant improvement in image quality. Also, the point spread function was analyzed to confirm the optical performance and the effectiveness of the micro-lens array with the light screen installed.

Design of a free-form surface microlens array optical system with high efficiency and uniformity

The microlens array has been widely applied in LED lighting source due to its special optical properties, but most of the research lacks the analysis and optimization of the complete mathematical models. Hence, the new design method of a free-form surface microlens array optical system is proposed in this paper. Based on the characteristics of TIR and the law of refraction, a complete mathematical model of the free-form microlens is established. By numerically solving a set of differential equations, the profile of the free-form surface microlens is obtained. Then we rotate the profile to get the free-form surface microlens. Finally, the proposed microlens array is simulated and analyzed in near-field and far-field situations, respectively. We also discuss the influence of microlens array characteristics on illumination performance. The result shows the uniformity and efficiency have been improved, both of which can reach more than 90%.

Using Micromachined Molds, Partial-curing PDMS Bonding Technique, and Multiple Casting to Create Hybrid Microfluidic Chip for Microlens Array

In a previous study, we presented a novel manufacturing process for the creation of 6 × 6 and 8 × 8 microlens arrays (MLAs) comprising lenses with diameters of 1000 μm, 500 μm, and 200 μm within an area that covers 10 mm × 10 mm. In the current study, we revised the manufacturing process to allow for the fabrication of MLAs of far higher density (15 × 15 and 29 × 29 within the same area). In this paper, we detail the revised manufacturing scheme, including the micromachining of molds, the partial-curing polydimethylsiloxane (PDMS) bonding used to fuse the glass substrate and PDMS, and the multi-step casting process. The primary challenges that are involved in creating MLAs of this density were ensuring uniform membrane thickness and preventing leakage between the PDMS and glass substrate. The experiment results demonstrated that the revised fabrication process is capable of producing high density arrays: Design I produced 15 × 15 MLAs with lens diameter of 0.5 mm and fill factor of 47.94%, while Design II produced 29 × 29 MLAs with lens diameter of 0.25 mm and fill factor of 40.87%. The partial-curing PDMS bonding system also proved to be effective in fusing PDMS with glass (maximum bonding strength of approximately six bars). Finally, the redesigned mold was used to create PDMS membranes of high thickness uniformity (coefficient of variance <0.07) and microlenses of high lens height uniformity (coefficient of variance <0.15).

Manufacture of Highly Transparent and Hazy Cellulose Nanofibril Films via Coating TEMPO-Oxidized Wood Fibers

Traditionally, inorganic nanoparticles (SiO₂, TiO₂) have been utilized to tune the optical haze of optoelectronic devices. However, restricted to complex and costly processes for incorporating these nanoparticles, a simple and low-cost approach becomes particularly important. In this work, a simple, effective, and low-cost method was proposed to improve optical haze of transparent cellulose nanofibril films by directly depositing micro-sized 2,2,6,6-tetramethylpiperidine-1-oxyl (TEMPO)-oxidized wood fibers ("coating" method). The obtained films had a high total transmittance of 85% and a high haze of 62%. The film samples also showed a high tensile strength of 80 MPa and excellent thermal stability. Dual sides of the obtained films had different microstructures: one side was extremely smooth (root-mean-square roughness of 6.25 nm), and the other was extremely rough (root-mean-square roughness of 918 nm). As a reference, micro-sized TEMPO-oxidized wood fibers and cellulose nanofibrils were mixed to form a transparent and hazy film ("blending" method). These results show that hazy transparent films prepared using the "coating" method exhibit superior application performances than films prepared using the "blending" method.

Ultraprecision machining of microlens arrays with integrated on-machine surface metrology

Microlens arrays (MLAs) are increasingly applied in high-end photonics and imaging systems. Advanced diamond turning machining with tool servo technique is a superior method of fabricating micro-structured arrays with sub-micrometer form accuracy and nanometer surface finish. This paper proposes an innovative framework for ultraprecision machining of MLA. The established metrology-integrated machining platform consists of a 3-axis ultraprecision turning machine and a nanometric interferometric probe. On-machine surface measurement enables the in situ inspection and characterization of MLA features while preserving the consistency between the machining and measurement coordinate. The dedicated surface error characterization method and 3D corrective machining strategy are also presented. An experimental study is carried out in order to prove the proposed MLA characterization's and 3D corrective machining's effectiveness in improving the MLA surface accuracy.

Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces

Freeform surfaces are featured with superior optical and physical properties and are widely adopted in advanced optical systems. Slow tool servo (STS) ultra-precision machining is an enabling manufacturing technology for fabrication of non-rotationally symmetric surfaces. This work presents a theoretical and experimental study of surface topography generation in STS machining of freeform surfaces. To achieve the nanometric surface topography, a systematic approach for tool path generation was investigated, including tool path planning, tool geometry selection, and tool radius compensation. The tool radius compensation is performed only in one direction to ensure no high frequency motion is imposed on the non-dynamic axis. The development of the surface generation simulation allows the prediction of the surface topography under various tool and machining variables. Furthermore, it provides an important means for better understanding the surface generation mechanism without the need for costly trial and error tests. Machining and measurement experiments of a sinusoidal grid and microlens array sample validated the proposed tool path generation and demonstrated the effectiveness of the STS machining process to fabricate freeform surfaces with nanometric topography. The measurement results also show a uniform topography distribution over the entire surface and agree well with the simulated results.

Light extraction enhancement and directional control of scintillator by using microlens arrays

The total internal reflection restricts light extraction efficiency of scintillator, leading to reduced detection efficiency and signal-to-noise ratio in the field of scintillator-based radiation detection system. This research presents the method of applying microlens arrays to improve the light extraction efficiency as well as achieve directional control of emission for scintillators. For BGO (Bi₄Ge₃O₁₂) scintillator covered with PMMA (polymethyl-methacrylate) hemispherical microlens array, the 2.59-fold in particular angle (θ_em = 45°) and overall 1.94-fold angle-integrated enhancement ratios have been obtained. Furthermore, we analyze and optimize some parameters of microlens arrays such as the packing arrangement, duty ratio, size, refractive index, and shape. As a result, when the refractive index of microlens is slightly larger than that of scintillator, a maximum 6.23-fold angle-integrated enhancements can be achieved. It can be concluded that the microlens array covered on scintillator has considerable value for practical applications on radiation detection.

Laser inscription of pseudorandom structures for microphotonic diffuser applications

Optical diffusers provide a solution for a variety of applications requiring a Gaussian intensity distribution including imaging systems, biomedical optics, and aerospace. Advances in laser ablation processes have allowed the rapid production of efficient optical diffusers. Here, we demonstrate a novel technique to fabricate high-quality glass optical diffusers with cost-efficiency using a continuous CO2 laser. Surface relief pseudorandom microstructures were patterned on both sides of the glass substrates. A numerical simulation of the temperature distribution showed that the CO2 laser drills a 137 μm hole in the glass for every 2 ms of processing time. FFT simulation was utilized to design predictable optical diffusers. The pseudorandom microstructures were characterized by optical microscopy, Raman spectroscopy, and angle-resolved spectroscopy to assess their chemical properties, optical scattering, transmittance, and polarization response. Increasing laser exposure and the number of diffusing surfaces enhanced the diffusion and homogenized the incident light. The recorded speckle pattern showed high contrast with sharp bright spot free diffusion in the far field view range (250 mm). A model of glass surface peeling was also developed to prevent its occurrence during the fabrication process. The demonstrated method provides an economical approach in fabricating optical glass diffusers in a controlled and predictable manner. The produced optical diffusers have application in fibre optics, LED systems, and spotlights.

Diffraction of partially-coherent light beams by microlens arrays

The synthesis method including wave-optics and ray-tracing for the acceleration of the simulation of micro-optical systems has been developed. The effects of the spatial coherence and randomization of microlens array (MLA) parameters have been considered. The method based on coherent states representation for the calculation of the optical efficiency of microlens arrays taking into account the light source polarization has been developed. Numerical simulations of the intensity distributions and spreading angle of a diffracted beam have been carried out.

Specular and Diffuse Reflectance of Phase-Separated Polymer Blend Films

Diffuse reflectors have various applications in devices ranging from liquid crystal displays to light emitting diodes, to coatings. Herein, specular and diffuse reflectance from controlled phase separation of polymer blend films, a well-known self-organization process, are studied. Temperature-induced spinodal phase separation of polymer blend films in which one of the components is selectively extracted is shown to exhibit enhanced surface roughness as compared to unextracted films, leading to a notable increase of diffuse reflectance. Diffuse reflectance of UV-visible light from such selectively leached phase-separated blend films is determined by a synergy of varying lateral scale of phase separation (≈200 nm to 1 μm) and blend film surface roughness (0-40 nm). These critical parameters are controlled by tuning annealing time (0.5-3 h) and temperature (140, 150, 160 °C) of phase separation. Angle-resolved diffuse reflection studies show that the surface-roughened polymer films exhibit diffuse reflectance up to 40° from normal incident light in contrast to optically uniform as-cast films that exhibit largely specular reflectance. Furthermore, the intensity of the diffusively reflected light can be enhanced (300-700 nm) or reduced (220-300 nm) significantly by coating the leached phase-separated films with a thin silver over layer.

Femtosecond laser directed fabrication of optical diffusers

Optical diffusers are widely used in filament lamps, imaging systems, display technologies, lasers, and Light Emitting Diodes (LEDs). Here, a method for the fabrication of optical diffusers through femtosecond laser machining is demonstrated. Float glass surfaces were ablated with femtosecond laser light to form nanoscale ripples with dimensions comparable to the wavelength of visible light. These structures produce highly efficient and wide field of view diffusers. The machined patterns altered the average surface roughness, with the majority of particles in the range of a few hundred nanometers. The optical diffusion characteristic and a maximum diffusion angle of near 172° was achieved with optimum machining parameters. The transmission performance of the diffusers was measured to be ∼30% across the visible spectrum. The demonstrated technique has potential for producing low-cost large area optical devices. The process benefits from the flexibility of the laser writing method and enables the production of custom optical diffusers.

Polymerization-Induced Growth of Microprotuberance on the Photocuring Coating

Surface pattern on the nano- and microscale is of great interest due to its special optical effect, which might find potential application in optical devices such as LCD display, packaging of LED chip, and thin-film solar cell. We here developed a facile bottom-up approach to fabricate microprotuberance (MP) on surface by using curable resin via sequential photocuring at room temperature and thermal polymerization at high temperature. The curable resin is composed of random fluorinated polystyrene (PSF) as blinder and trimethylolpropane trimethacrylate (TMPTA) as cross-linker. The polymerization of TMPTA during the annealing process at high temperature induces phase separation between the PSF and TMPTA cross-linked network, resulting in the extrusion of PSF and the formation of protuberance on the surface. The formation mechanism of MP was studied in detail by investigating the effect of annealing time, temperature, thickness of film, and PSF on the size and morphology. MPs with size from one to tens of micrometers were fabricated through this one-pot strategy. Moreover, encapsulation of integrated GaN/InGaN-based LED chip by the cross-linked coating with MP can enhance the light extraction efficiency and light diffusion obviously.

Large-Area Sub-Wavelength Optical Patterning via Long-Range Ordered Polymer Lens Array

Fabrication of large-area, highly orderly, and high-resolution nanostructures in a cost-effective fashion prompts advances in nanotechnology. Herein, for the first time, we demonstrate a unique strategy to prepare a long-range highly regular polymer lens from photoresist nanotrenches based templates, which are obtained from underexposure. The relationship between exposure dose and the cross-sectional morphology of produced photoresist nanostructures is revealed for the first time. The polymer lens arrays are repeatedly used for rapid generation of sub-100 nm nanopatterns across centimeter-scale areas. The light focusing properties of the nanoscale polymer lens are investigated by both simulation and experiment. It is found that the geometry, size of the lens, and the exposure dose can be deployed to adjust the produced feature size, spacing, and shapes. Because the polymer lenses are derived from top-down photolithography, the nearly perfect long-range periodicity of produced nanopatterns is ensured, and the feature shapes can be flexibly designed. Because this nanolithographic strategy enables subwavelength periodical nanopatterns with controllable feature size, geometry, and composition in a cost-effective manner, it can be optimized as a viable and potent nanofabrication tool for various technological applications.

Recent progress in see-through three-dimensional displays using holographic optical elements [Invited]

The principles and characteristics of see-through 3D displays are presented. We especially focus on the integral-imaging display system using a holographic optical element (IDHOE), which is able to display 3D images and satisfy the see-through property at the same time. The technique has the advantage of the high transparency and capability of displaying autostereoscopic 3D images. We have analyzed optical properties of IDHOE for both recording and displaying stages. Furthermore, various studies of new applications and system improvements for IDHOE are introduced. Thanks to the characteristics of holographic volume grating, it is possible to implement a full-color lens-array holographic optical element and conjugated reconstruction as well as 2D/3D convertible IDHOE. Studies on the improvements of viewing characteristics including a viewing angle, fill factor, and resolution are also presented. Lastly, essential issues and their possible solutions are discussed as future work.

Multiscale Micro-Nano Nested Structures: Engineered Surface Morphology for Efficient Light Escaping in Organic Light-Emitting Diodes

Various micro-to-nanometer scale structures are extremely attractive for light escaping in organic light-emitting diodes. To develop and optimize such structures, an innovative approach was demonstrated for the first time to fabricate multiscale micro-nano nested structures by photolithography with a well-designed mask pattern followed by a controllable thermal reflow process. The experimental and theoretical characterizations verify that these unique nested structures hold the capability of light concentration, noticeable low haze, and efficient antireflection. As a proof-of-concept, the incorporation of this pattern onto the glass substrate efficiently facilitates light escaping from the device, resulting in current efficiency 1.60 times and external quantum efficiency 1.63 times that of a control flat device, respectively. Moreover, compared to a hexagonally arranged microlens array and quasi-random biomimetic moth eye nanostructures, the nested structures proposed here can magically tune the spatial emission profile to comply with the Lambertian radiation pattern. Hence, this novel structure is expected to be of great potential in related ubiquitous optoelectronic applications and provide scientific inspiration to other novel multiscale micro-nanostructure research.

Optical properties of polycarbonate/styrene-co-acrylonitrile blends: effects of molecular weight of the matrix

In this paper, the effects of the molecular weight of a polycarbonate (PC) matrix on the phase morphology and optical properties of a PC/styrene-co-acrylonitrile (SAN) blend were investigated. A scanning electron microscope is used to analyze the phase morphology of the blends, and Mie scattering theory is used to analyze the changing laws of the optical properties of PC/SAN blends with the increasing of PC molecular weight. Results show that the average particle diameter is not strongly changed with different PC molecular weight because the values of the viscosity ratios are very close to each other. But it is obvious that the number of large particles gradually reduced while small particles (especially d<2  μm) significantly increased with the increasing of PC molecular weight. And the increase in small particles will result in an increase in backward scattering so the transmittance of PC/SAN blends decreases with the increase of PC molecular weight. However, the balance of the scattering coefficients and the number concentration of particles eventually lead to the haze of the blends being very close, despite having different PC molecular weights. Meanwhile, the photographs of scattering patterns indicate that the PC/SAN blends whose component weight ratios are fixed at 70:30 have excellent antiglare properties, despite the changes in molecular weight of the PC matrix.

Full-color holographic diffuser using time-scheduled iterative exposure

A compact wavelength multiplexing technique is proposed and experimentally investigated to improve the efficiency of a full-color holographic diffuser using photopolymer. The exposure responses of a monochromatic hologram and a three wavelength multiplexed hologram recorded in photopolymer film are presented. The time-scheduled exposure energies at wavelengths of 633, 532, and 473 nm were chosen to optimize the uniform diffraction efficiency of the wavelength multiplexed hologram. These three wavelength iterative sequences of exposures are applied to achieve a specific color balance for a multicolor holographic diffuser. The experimental results confirm that the fabrication method is well suited to the manufacture of holographic diffusers for full-color display applications.

Hydrothermal synthesis of ZnO@polysiloxane microspheres and their application in preparing optical diffusers

ZnO@polysiloxane hybrid microspheres were successfully prepared by a simple one-pot synthesis. The novel diffuser based on ZnO@polysiloxane fillers possessed suitable light transmittance, good diffusion capacity, and low incident angle dependence.

Large-scale high quality glass microlens arrays fabricated by laser enhanced wet etching

Large-scale high quality microlens arrays (MLAs) play an important role in enhancing the imaging quality of CCD and CMOS as well as the light extraction efficiency of LEDs and OLEDs. To meet the requirement in MLAs' wide application areas, a rapid fabrication method to fabricate large-scale MLAs with high quality, high fill factor and high uniformity is needed, especially on the glass substrate. In this paper, we present a simple and cost-efficient approach to the development of both concave and convex large-scale microlens arrays (MLAs) by using femtosecond laser wet etching method and replication technique. A large-scale high quality square-shaped microlens array with 512 × 512 units was fabricated.The unit size is 20 × 20 μm² on the whole scale of 1 × 1 cm². Its perfect uniformity and optical performance are demonstrated.

Lateral flow through a parallel gap driven by surface hydrophilicity and liquid edge pinning for creating microlens array

This letter proposes a surface-energy driven process for economically creating polymer microlens array (MLA) with well controllable curvatures. When a UV-curable prepolymer flows into a cell constructed by multiple holes on a top template and a flat substrate, since the edge pinning of the contact line, an array of curved air/prepolymer interface forms around each microhole of the template. Then a UV-radiation of the bulk prepolymer leads to a solid microlens array. The curvature of the air/prepolymer interface can be controlled by choosing materials with different interface free energy or varying the gap height mechanically.

Two-dimensional and three-dimensional transparent screens based on lens-array holographic optical elements

Two-dimensional (2D) and three-dimensional (3D) transparent screens can be created using lens-array holographic optical elements (HOEs). Lens-array HOEs can be used to perform 2D and 3D imaging for Bragg matched images while maintaining the transparent properties of the images in the background scenes. 2D or 3D imaging on the proposed screen is determined by the relative size of an elemental-lens on the lens-array to a pixel on the projected image. The 2D and 3D displays on the lens-array HOEs are implemented by the diffusion of light on each elemental-lens and by taking advantage of reflection-type integral imaging, respectively. We constructed an HOE recording setup and recorded two lens-array HOEs having different optical specifications, permitting them to function as 2D and 3D transparent screens. Experiments regarding 2D and 3D imaging on the proposed transparent screens are carried out and the viewing characteristics in both cases are discussed. The experimental results show that the proposed screens are capable of providing 2D and 3D images properly while satisfying the see-through properties.

Fabrication of large curvature microlens array using confined laser swelling method

This Letter proposes a confined laser swelling method to fabricate large curvature microlens arrays. Unlike the polymers in conventional free laser swelling, the swelling polymer, which is methyl red-doped polymethyl methacrylate here, is confined between walls formed by a substrate and a flexible cover layer. Because swelling occurs in an enclosed space, decomposed segments remain in the matrix, resulting in a large hump at the side of the flexible cover layer. The results show that these humps are tens of times higher than those acquired by conventional methods and this method has potential for high efficiency large curvature microlens fabrication.

Generation of a uniform-square focal spot by a compound lens for solar concentration applications

This paper describes a compound lens for solar photovoltaic system applications, which is composed of a front aspheric or Fresnel surface and a back array of concave surfaces. In contrast to earlier designs, the proposed method can simultaneously focus and shape sun light into a uniform-square pattern on the solar cell. For a square solar cell, this approach can maximize the solar cell's opto-electric conversion efficiency by enhancing the concentrated pattern's uniformity. In this article, the theoretical models of the beam shaping focused lens is derived and then compared with experimental data. The tolerance in assembling the component of the concentrator is also analyzed and the corresponding simulation and experimental results are discussed in detail.

Bidirectional scattering distribution function by screen imaging synthesis

Light-emitting diodes are common light sources in modern lighting. The optical distribution of an LED package and the bidirectional scattering distribution function (BSDF) of diffusing optical components are important factors in lighting design. This paper proposes an innovative method of measuring both the optical distribution of LEDs and BSDF quickly. The proposed method uses a 2-D screen and a camera to capture the illumination on a screen, and acquires the whole-field optical distribution by synthesizing the images on the screen in different angles. This paper presents theoretical calculations and experimental results demonstrating the construction of the BSDF.

Fabrication of ellipticity-controlled microlens arrays by controlling the parameters of the multiple-exposure two-beam interference technique

We demonstrate a promising method for fabrication of plastic microlens arrays (MLAs) with a controllable ellipticity and structure, by using the combination of multiple-exposure two-beam interference and plastic replication techniques. Multiple exposures of a two-beam interference pattern with a wavelength of 442 nm into a thick positive photoresist (AZ-4620) were used to form different two-dimensional periodic structures. Thanks to the developing effect of the positive photoresist, fabricated structures consisting of hemielliptical- or hemispherical-shaped concave holes were obtained. By controlling the rotation angle between different exposures, both the shape and structure of the holes varied. By adjusting the dosage ratio between different exposures, the shape of the holes was modified while the structure of the holes was unchanged. The photoresist concave microstructures were then transferred to plastic MLAs by employing replication and embossing techniques. The fabricated MLAs were characterized by a scanning electron microscope and atomic force microscope measurements. We show that the ellipticity of the microlenses can be well controlled from 0 (hemispherical) to 0.96 (hemielliptical) by changing the rotation angle or dosage ratio between the two exposures.

Maskless fabrication of concave microlens arrays on silica glasses by a femtosecond-laser-enhanced local wet etching method

A simple and efficient technique for large-area manufacturing of concave microlens arrays (MLAs) on silica glasses with femtosecond (fs)-laser-enhanced chemical wet etching is demonstrated. By means of fs laser in situ irradiations followed by the hydrofluoric acid etching process, large area close-packed rectangular and hexagonal concave MLAs with diameters less than a hundred of micrometers are fabricated within a few hours. The fabricated MLAs exhibit excellent surface quality and uniformity. In contrast to the classic thermal reflow process, the presented technique is a maskless process and allows the flexible control of the size, shape and the packing pattern of the MLAs by adjusting the parameters such as the pulse energy, the number of shots and etching time.

Electrowetting on a polymer microlens array

This paper reports on the electrowetting behavior of a flexible poly(dimethylsiloxane) (PDMS) microlens array. A Cr and Au double-layered electrode was formed on an array of microlenses with diameters of 10 microm and heights of 13 microm. A deposition of parylene and a coating of Teflon were followed for electrical insulation as well as for enhancement of the hydrophobicity. On the nearly superhydrophobic microlens array surface, the electrowetting of a deionized water droplet was observed over the contact angle range of approximately 140 degrees to approximately 58 degrees by applying 0-200 V, respectively. The electrowetting phenomenon was reversible even in air environment with applied voltages of less than 100 V. The electrowetting on the microlens array surface lost its reversibility after the microlens array surface was completely wetted when the water meniscus touched the bottom of the microlens array. Analysis of meniscus shapes and net force direction follows to elucidate the reversibility. The convex curvature of the microlens caused gradual rather than abrupt impalement of water into the gap among the microlenses.

Micropatterned single lens for wide-angle light-emitting diodes

This work presents a simple and effective method for a wide-angle light-emitting diode module by using a single lens corrugated with micropattern arrays. Impinged onto the micropattern arrays of a curved surface, light undergoes an enhancement of the illumination angle due to omnidirectional diffraction. A hemispherical dome lens with micropattern arrays is microfabricated by a reconfigurable microtemplating and a replica molding method. Depending on the micropattern size, the experimental and simulation results show the micropatterned single lens has the wide illumination angle as well as the high extraction efficiency of an incoming LED light source, compared with a conventional dome lens.

Manufacture of dual-side surface-relief diffusers with various cross angles using ultrasonic embossing technique

This paper reports a simple and effective ultrasonic embossing method which enables the rapid fabrication of dual-side surface-relief plastic diffusers with various cross angles. Metallic master molds bearing microstructures are fabricated using a tungsten carbide turning machine. A 1500-Watt ultrasonic vibrator with an output frequency of 20 kHz was used to replicate the microstructure onto 1 mm thick PMMA and PET films in the experiments. During ultrasonic embossing, the ultrasonic energy is converted into heat through intermolecular friction at the master mold/plastic plate interface due to asperities to melt the thermoplastic at the interface and thereby to replicate the microstructure. Under the proper processing conditions, high-performance dual-sided plastic diffusers of various cross-angles can be successfully fabricated. The proposed method shows great potential for fast fabrication of micro-optical components due to its simplicity and versatility.

Optic diffusers based on photopolymerizable hologram material with an ionic liquid as additive

Symmetric and asymmetric diffusers with a directional diffusion property were both fabricated based on a photopolymerizable hologram material using an ionic liquid as an additive. The diffusion property can be regulated by changing the concentration of the ionic liquid. The fiber structure, the surface-relief structure, and the formation of nanoparticles led to the directional diffusion property of the diffuser.

Fabrication of microlens array diffuser films with controllable haze distribution by combination of breath figures and replica molding methods

This work demonstrates the fabrication of a simple, low-cost microlens array (MLA) diffuser film with controllable haze distribution (diffusion effect) by a combination of "breath figures" (BFs) and micro-replica molding methods. Polystyrene (PS) molds obtained by BFs method contain concave, hexagonal packed air holes formed by the condensation of water vapor on cooling surfaces in a chamber in which relevant influence factors can be controlled. The sizes of the air holes in the BFs PS molds can be controlled by varying such factors as chamber temperature, chamber relative humidity, substrate temperature and others. The temperature distribution on the substrate affects the distribution of diameters of the air holes formed in a BFs PS mold. Convex PDMS (poly-dimethylsiloxane) MLAs were obtained by molding from the BFs PS molds. The focal lengths of MLAs were measured and compared with theoretical values. The diffusion effect of the diffuser films with MLAs of diameters 6 microm and 3 microm were compared. The results indicate that an MLA with a smaller diameter has a larger diffusion effect.

Random phase plate for wavefront sensing via phase retrieval and a volume speckle field

A random phase plate is prepared by illuminating a photoresist plate with a fully developed speckle field and using the developed phase plate (DPP) as a diffuser. Wavefront sensing is implemented using phase retrieval based on the recording of speckle intensity patterns at various distances from the DPP and the wave propagation equation. The effects of the roughness height of the DPP on the phase retrieval are investigated. From simulations a roughness height of lambda/10 results in a speckle field that yields good phase reconstruction for the spherical test wavefront incident on the DPP. From the experiments different portions of the DPP that received varying exposures are examined. A section of the phase plate with a characteristic roughness height facilitated the generation of a speckle field that is optimum for the phase retrieval algorithm. Thus a random phase plate with varying roughness height allows optimized measurements of wavefronts with different curvatures. Analytical expressions describing the second-order intensity statistics (fourth-order field statistics) for a field traversing a specific diffuser are presented. This DPP will not give rise to a fully developed speckle field, but knowing the statistics of the depth of the DPP will facilitate a rigorous treatment of the problem.