Imprinting mold and method for making lens array

Abstract

An exemplary method for making a lens array is as follows. An imprinting mold and a substrate are provided. A blob of molding material is applied on each molding section of the substrate. The first alignment marks, and the second alignment mark of the imprinting mold are aligned with the fourth alignment marks, and the third alignment mark of one of the imprinting regions, respectively. The imprinting mold is pressed on the molding material on the imprinting region. The pressed portions of the imprinting region are solidified to obtain lenses in the imprinting region. The imprinting mold is pressed on another one of the imprinting region, and the imprinting mold is removed. This process is repeated for each other imprinting region. Thus, a lens array is obtained.

1 . An imprinting mold comprising a molding surface, the molding surface comprising:
 a plurality of microstructures defined thereat;   a plurality of first alignment marks adjacent each of the microstructures; and   a second alignment mark.   
     
     
         2 . The imprinting mold of  claim 1 , wherein the second alignment mark is formed at a periphery of the molding surface. 
     
     
         3 . The imprinting mold of  claim 1 , wherein the first alignment marks are protrusions protruding from the molding surface. 
     
     
         4 . The imprinting mold of  claim 1 , wherein the first alignment marks are recesses defined in the molding surface. 
     
     
         5 . The imprinting mold of  claim 1 , wherein the second alignment mark is a protrusion protruding from the molding surface. 
     
     
         6 . The imprinting mold of  claim 1 , wherein the second alignment mark is a recess defined in the molding surface. 
     
     
         7 . The imprinting mold of  claim 1 , wherein the second alignment mark has a larger size than that of each of the first alignment marks. 
     
     
         8 . The imprinting mold of  claim 1 , wherein two of the plurality of first alignment marks are arranged symmetrically opposite each other across the center of a corresponding one of the microstructures, and are spaced apart from the microstructure. 
     
     
         9 . A method for making a lens array, the method comprising:
 (1) providing an imprinting mold, the imprinting mold comprising a molding surface, the molding surface comprising a plurality of microstructures defined thereat, a plurality of first alignment marks adjacent each of the microstructures, and a second alignment mark;   (2) providing a substrate, the substrate comprising a surface, the surface being divided into a plurality of imprinting regions, a third alignment mark corresponding to the second alignment mark being formed in each of the imprinting regions, each of the imprinting regions being divided into a plurality of molding sections, a plurality of fourth alignment marks being formed in each of the molding sections, the fourth alignment marks corresponding to the first alignment marks;   (3) applying a blob of molding material on each of the molding sections of at least one of the imprinting regions;   (4) aligning the first alignment marks and the second alignment mark of the imprinting mold with the fourth alignment marks and the third alignment mark of one imprinting region which has the molding material applied thereon, respectively;   (5) pressing the imprinting mold on the molding material on the imprinting region;   (6) solidifying the pressed portions of molding material on the imprinting region to obtain a plurality of lenses on the imprinting region; and   (7) repeating (3) if and as needed and repeating (4) through (6) as needed to obtain a lens array comprising a plurality of the lenses.   
     
     
         10 . The method of  claim 9 , wherein the molding material is selected from the group consisting of epoxy resin, acrylate-based resin, polyurethane, and polymerized siloxane. 
     
     
         11 . The method of  claim 9 , wherein the pressed portions are solidified by ultraviolet (UV) light irradiation. 
     
     
         12 . The method of  claim 9 , wherein the third alignment mark is a protrusion protruding from the surface of the substrate. 
     
     
         13 . The method of  claim 9 , wherein the third alignment mark is a recess defined in the surface of the substrate. 
     
     
         14 . The method of  claim 9 , wherein the fourth alignment marks are protrusions protruding from the surface of the substrate. 
     
     
         15 . The method of  claim 9 , wherein the fourth alignment marks are recesses defined in the surface of the substrate. 
     
     
         16 . A method for making a lens array, the method comprising:
 (1) providing an imprinting mold, the imprinting mold comprising a molding surface, the molding surface comprising a plurality of microstructures defined thereat, a plurality of first alignment marks adjacent each of the microstructures, and a second alignment mark, the second alignment mark being formed at a periphery of the molding surface;   (2) providing a substrate, the substrate comprising a surface, the surface being divided into a plurality of imprinting regions, a third alignment mark corresponding to the second alignment mark being formed in each of the imprinting regions, each of the imprinting regions being divided into a plurality of molding sections, a plurality of fourth alignment marks being formed in each of the molding sections, the fourth alignment marks corresponding to the first alignment marks;   (3) applying a blob of molding material on each of the molding sections of at least one of the imprinting regions;   (4) aligning the first alignment marks and the second alignment mark of the imprinting mold with the fourth alignment marks and the third alignment mark of one imprinting region which has the molding material applied thereon, respectively;   (5) pressing the imprinting mold on the molding material on the imprinting region;   (6) solidifying the pressed portions of molding material on the imprinting region to obtain a plurality of lenses on the imprinting region; and   (7) selectively repeating any one or more of (3) through (6) if and as required to obtain a lens array comprising a plurality of the lenses.