Method of making a microlens array and mold

摘要

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.