Supercritical Fluid-Driven Polymer Phase Separation for Microlens with Tunable Dimension and Curvature

Microlenses are highly sought as reliable means for high-resolution optical imaging at low illumination intensities. Plano-convex configuration with tunable dimension and curvature is an essential feature in the microlens fabrication. In this study, we present a facile and green route for preparing well-defined microlenses based on polymer phase separation in the presence of supercritical carbon dioxide (scCO2). The behaviors of linear polymethylmethacrylate protruded from cross-linked silicone network in scCO2 environment are investigated from the perspectives of thermodynamics and kinetics. Microlenses with dimensions from 2 to 15 μm and contact angles from 55° to 112° are successfully obtained through the adjustment of the kinetic conditions and outgassing rate. With the tunable focal length, they exhibit intrinsic function of discerning submicroscale patterns that are unable to be observed directly under optical microscope. Moreover, size confinement on the substrate results in the generation of well-ordered microlens arrays, affording great promise for applications in bioimaging, photolithography, light harvesting, and optical nanosensing.