Anamorphic microlens array

1. A process for making a transparent polymeric film bearing on the light exit surface of the film an array of close-packed convex elliptical microlenses having a distribution of sizes and oriented in one direction comprising the steps of

(a) providing a first structured polymeric film with hemispherical micro-cavities

(b) heating the first structured polymeric film to a temperature above the glass transition temperature (Tg) of the polymer composing the film;

(c) stretching the first structured polymeric film to form micro-cavities of the desired asymmetric shape;

(d) cooling the first structured polymeric film below Tg while the film is maintained in the stretched configuration to lock in the asymmetric shape of the micro-cavities;

(e) coating a curable second fluid polymer composition over the first structured polymeric film to form a second polymeric film; and

(f) curing the second polymer film while it is still in contact with the first structured polymeric film to render it solid and create a transparent second polymeric structured film comprising a first typically flat side and a second side with an array of microlenses formed thereon corresponding to the asymmetric shaped micro-cavities of the first structured film and separating the second structured polymeric film with the microlens array from the first structured polymeric film.

2. The process of claim 1 wherein the Tg of the first structured polymeric film is at least 50° C.

3. The process of claim 1 wherein the Tg of the first structured polymeric film is at least 70° C.

4. The process of claim 1 wherein the Tg of the first structured polymeric film is at least 90° C.

5. The process of claim 1 wherein curing is accomplished is thermally- or photo-cured.

6. The process of claim 1 wherein the first structured polymeric film with hemispherical micro-cavities is obtained by the steps of:

(a) casting a solution of an organic soluble polymer in a volatile water immiscible organic solvent having specific gravity greater than 1 on a suitable surface;

(b) exposing the cast solution to a humid environment and condensing water droplets on the cast solution; and

(c) evaporating off the solvent and condensed water droplets from the cast composition to create the first structured polymeric film with hemispherical micro-cavities.

7. The process of claim 6 wherein the surface energy of the organic soluble polymer composing the first structured polymeric film is greater than 30 dynes/cm.

8. The process of claim 6 wherein the surface energy of the organic soluble polymer is greater than 35 dynes/cm.

9. The process of claim 6 wherein the weight average molecular weight of the organic soluble polymer is in the range of 20,000 to 500,000.

10. The process of claim 6 wherein the contact angle between a drop of water and the surface of the organic soluble polymer is between 50 and 90 degrees.

11. The process of claim 6 wherein the contact angle between a drop of water and the surface of the organic soluble polymer is between 60 and 80 degrees.

12. The process of claim 1 wherein Young's Modulus of the first structured polymeric film decreases to below 10 7 Pa when the polymer is heated above Tg.

13. The process of claim 1 wherein Young's Modulus of the first structured polymeric film is between 10 9 and 10 10 Pa when the polymer is below Tg.

14. The process of claim 6 wherein the solution of organic soluble polymer further contains a fluorocarbon surfactant.

15. The process of claim 6 wherein the boiling point of the water immiscible organic solvent is less than 120° C. at normal atmospheric pressure.

16. The process of claim 6 wherein the organic solvent used with the organic soluble polymer comprises one selected from the group consisting of halogen based organic solvents, aromatic solvents, water insoluble ketone solvents, and carbon disulfide.