Investigation of the deposition of microsphere monolayers for fabrication of microlens arrays.

Convective deposition of a monolayer of microspheres by drawing a meniscus of a suspension across a substrate is used to fabricate microlens arrays to enhance the photon extraction efficiency of light emitting diodes (LEDs). The self-assembly of a colloidal crystal within the blade-drawn thin film is dominated by capillary forces and the thickness of this crystal depends on many parameters, including the deposition rate and particle size. This study investigates these and other parameters such as angle and hydrophobicity of the deposition blade that have not previously been considered. Using a confocal laser scanning microscope, the local and long-range order of the deposited particles are evaluated by the radial distribution function, and the fraction of the number of nearest neighbors and local bond order, demonstrating the dependence of the microstructure on the deposition parameters. Our results suggest previous descriptions of the critical deposition parameters are inadequate for understanding how various processing conditions influence deposition. For instance, increasing the deposition blade angle from 20 degrees up to 90 degrees requires an increase in deposition rate to achieve a monolayer deposition. The microlens arrays were fabricated on LEDs where polystyrene and silica are coated in consecutive depositions. Heat is used to sacrifice the polystyrene layers to result in an ordered array of partially buried silica microspheres that act as lenses to scatter light from the device. Enhancement in light extraction efficiency of 2.66 times was demonstrated for InGaN-based light emitting diodes employing micron scale microlens arrays with 1 um diameter silica microspheres.