Microlens arrays are key elements for light management in optoelectronic devices. The recent advancement in the wearable intelligent electronics has driven the development of flexible microlenses. In this work, we show a controllable and scalable surface-droplet-based strategy to create unconventional flexible polymer microlens arrays. The technique is underpinned by the morphological transition of femtoliter liquid on the surface of a microlens surrounded by a planar area. We found that the droplet liquid wetted the rim of the microlens first and gradually moved upward to the microlens surface with an increase in the liquid volume. The morphology evolution of the droplet is in good agreement with the predication from our simulations based on the interfacial energy minimization under the condition of the pinned boundary. The shape of the droplet on the microlens is well controlled by the droplet volume, aspect ratio of the microlens, and the interfacial energy of the droplets on the microlens. As a result, the obtained structures of one microlens partially covered by a droplet can be produced in arrays over a large scale, serving as templates for fabricating transparent polymer double microlens arrays for improved light emission from the optoelectronic device.
Keywords: droplets; light ehancement; microlens arrays; solvent exchange; suface evolver; surface patterning.