Mold and compression molding method for microlens arrays

A method for forming an array of optical elements comprising the steps of:

• (a) supporting a glass preform in a central nest area of a lower mold half and beneath an upper mold half, the lower mold half having a plurality of predetermined negative optical surface features therein;
• (b) heating the first and second mold halves and the glass preform to at least the glass transition temperature of the glass preform;
• (c) pressing the glass preform between the first and second mold halves to thereby form an integral array of optical elements, each of the optical elements being a positive of the predetermined negative optical surface features;
• (d) cooling the integral array of optical elements to below the glass transition temperature;
• and
• (e) removing the integral array of optical elements from the first and second mold halves.

An apparatus for forming an array of optical elements comprising:

• (a) a first mold half;
• (b) a second mold half with a plurality of predetermined negative optical surface features therein and a central nest area;
• (c) a glass preform supported in the central nest area;
• (d) a heater for heating the first and second mold halves and the glass preform to at least the glass transition temperature of the glass preform;
• and
• (e) means for compressing the glass preform between the first and second mold halves.

An apparatus for forming an array of optical elements compromising:

• (a) a first mold half including a first mold surface;
• (b) a second mold half including a second mold surface having a plurality of predetermined negative optical surface features therein;
• (c) a central nest area in said second mold surface for supporting a glass preform therein;
• and
• (d) a heat source surrounding said first and second mold halves and the glass perform residing in said central nest area.