Fabrication of Nanostructures on Surface of Micro-Lens Arrays Using Reactive Ion Etching

In this study, we fabricated a nanostructure on the surface of the micro-lens array (MLA), which is one of the light extraction technologies of organic light-emitting diodes (OLEDs), by performing the Reactive Ion -Etching (RIE) process. The MLA consists of a lensed area and a lens-less bottom (flat film area). We performed a systematic analysis to find ways to improve the light extraction efficiency of the MLA surface and flat film area. By controlling the RIE process time and type of gas plasma, nanostructures were formed on the surface of the MLA. O₂ and CF₄ gas plasmas resulted in nanostructures with tall heights and high aspect ratios, whereas CHF₃ and Ar gas plasmas resulted in nanostructures with small heights and low aspect ratios. Furthermore, it was found that the nanostructures were not covered over the entire area, and the extent to which the nanostructures were distributed varied depending on the process time. As the RIE process time increases, the nanostructure expands from the top surface of the MLA to the flat film area. This limited the light extraction efficiency improvement. At a short process time of 50 s, nanostructures were formed only on the upper surface of the MLA hemisphere, which increased the light extraction efficiency. However, at long process times over 50 s, the surface of the hemisphere of MLA was covered with vertically aligned nanostructures, which decreased the efficiency. While the flat film area was covered with nanostructures at the longest process time of ~3200 s, it was effective, but the total efficiency was further decreased by the trade-off between them. As a result, the high-aspect-ratio nanostructured MLA patterned only on the top surface of the hemispherical MLA with a 50 s O₂ plasma treatment showed the highest efficiency, which was slightly higher than that of the bare MLA. We expect that if the nanostructures can be formed in a direction perpendicular to the MLA surface and the flat film area simultaneously, the light extraction efficiency would be further improved.