Patent ID: 7931515

Claim:
A method of manufacturing a micro-lens array and light-emitting device, comprising a) forming a solution of an organic soluble copolymer or polymer blend comprising a hydrophilic, high surface energy component in combination with a hydrophobic, low surface energy component in a volatile water-immiscible organic solvent, b) casting the solution in a humid environment, and condensing water droplets on the cast solution, c) evaporating off the solvent and condensed water droplets from the cast composition to create a first structured polymer film with close packed surface cavities having a mean diameter of less than 20 micrometers, d) annealing the first structured polymer film at elevated temperature to achieve chemical re-construction to modify the surface of the first structured polymer film and obtain a relatively lower surface energy surface, e) coating a second fluid polymer composition over the first structured polymer film, f) curing the second fluid polymer composition while it is still in contact with the first structured polymer film to render it solid and create a transparent second structured film comprising a first flat side and a second side with an array of microlenses formed thereon corresponding to the cavities of the first structured film, wherein the second structured film comprises a relatively high surface energy material and has a refractive index greater than 1.45, and wherein the microlenses are randomly distributed over 300 μm×300 μm areas of the second structured film, g) separating the second structured film with the micro-lens array from the first structured polymer film, and h) attaching the flat side of the second structured film to a transparent substrate or cover of a light-emitting device through which light is emitted.