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WO2008053266A2 - Procédé de production et ligne de production pour fabriquer des disques optiques multicouches - Google Patents

Procédé de production et ligne de production pour fabriquer des disques optiques multicouches Download PDF

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Publication number
WO2008053266A2
WO2008053266A2 PCT/IB2006/003088 IB2006003088W WO2008053266A2 WO 2008053266 A2 WO2008053266 A2 WO 2008053266A2 IB 2006003088 W IB2006003088 W IB 2006003088W WO 2008053266 A2 WO2008053266 A2 WO 2008053266A2
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WO
WIPO (PCT)
Prior art keywords
layer
module
nonexpendable
washing
plastic
Prior art date
Application number
PCT/IB2006/003088
Other languages
English (en)
Other versions
WO2008053266A3 (fr
Inventor
Eugene Levich
Vladimir Binyukov
Dmitry Malakhov
Sergei Magnitskiy
Original Assignee
New Medium Enterprises, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by New Medium Enterprises, Inc. filed Critical New Medium Enterprises, Inc.
Priority to PCT/IB2006/003088 priority Critical patent/WO2008053266A2/fr
Priority to TW096141519A priority patent/TW200841338A/zh
Publication of WO2008053266A2 publication Critical patent/WO2008053266A2/fr
Publication of WO2008053266A3 publication Critical patent/WO2008053266A3/fr

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Classifications

    • G—PHYSICS
    • G11—INFORMATION STORAGE
    • G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
    • G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
    • G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
    • G11B7/26—Apparatus or processes specially adapted for the manufacture of record carriers
    • G11B7/263—Preparing and using a stamper, e.g. pressing or injection molding substrates
    • G—PHYSICS
    • G11—INFORMATION STORAGE
    • G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
    • G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
    • G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
    • G11B7/26—Apparatus or processes specially adapted for the manufacture of record carriers
    • G11B7/265—Apparatus for the mass production of optical record carriers, e.g. complete production stations, transport systems
    • G—PHYSICS
    • G11—INFORMATION STORAGE
    • G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
    • G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
    • G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
    • G11B7/26—Apparatus or processes specially adapted for the manufacture of record carriers
    • G11B7/266—Sputtering or spin-coating layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C2045/0079—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping applying a coating or covering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1406—Ultraviolet [UV] radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4845—Radiation curing adhesives, e.g. UV light curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/003—Reflective
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2017/00—Carriers for sound or information
    • B29L2017/001—Carriers of records containing fine grooves or impressions, e.g. disc records for needle playback, cylinder records
    • B29L2017/003—Records or discs
    • B29L2017/005—CD''s, DVD''s
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0831—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2429/00—Carriers for sound or information
    • B32B2429/02—Records or discs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic

Definitions

  • This invention is generally related to multilayer optical disc technologies and, more particularly, to manufacturing process and designs of corresponding production lines providing mass production of Versatile Multilayer Disc (VMD).
  • VMD Versatile Multilayer Disc
  • HDTV, HD-video and high-speed Internet require inexpensive data carriers with high recording capacity.
  • the data recording density on one layer can be increased by way of using a shorter laser wave length and, respectively, smaller pit sizes.
  • Another way is to increase the number of data layers, that is, to use a multilayer disc.
  • Conventional DVDs have at most 2 layers on one side of the disk.
  • Reading from optical information storage devices is usually carried out by a laser beam focused on one of the data layers with further registration of the reflected beam modulated with the pit-and-land pattern.
  • the U.S. Patents Nos. 4,090,031; 4,219,704 of Russell feature a multilayer optical disc with the layers containing recorded information on one side of the disk, and the laser beam scans the data recorded along the tracks either in the digital or analog form.
  • the reading device of such a disc was designed so that the reading beam could focus on each layer in turn.
  • the source of the reading light and detecting system were for the first time placed on one side of the disk. That was why, though they provided for the opportunity to make transparent layers (with different optical transmission capacities or made of different dyes or photo-luminescent materials), preference was given to reflective coatings.
  • the reading device readjusted from one layer to another either by changing the lens focus or changing the light filters (if the layers were made of the materials containing different dyes or photo- luminescent materials).
  • the patent also emphasizes an opportunity to make data layers like WORM and recordable type (phase-change, magneto-optics), as well as their combinations. It gives a detailed description of getting the tracking signal.
  • the drive uses a semi-conductor laser with 780-nm wavelength and an aberration compensator; the position of the focusing lens (with NA 0.55) was set by the servo-system.
  • the compensator had a stepped design, the first step was 0.4mm thick, the second - 0.8mm and the third - 1.2mm thick (they consider different types of such compensators).
  • the substrate with the relief of the 1st data layer is first covered with a semi-reflective coating, then with a UV-cured photopolymer; then the second stamper is stamped into it, UV-cured, making as a result the second data layer. Later the stamper is separated, the second data layer is covered with a reflective coating and a layer of adhesive.
  • DVD-9 the next step being sticking a blank substrate, and in case of DVD- 14, the second substrate with a single information layer, and with DVD- 18 - the second half of the "sandwich" including 3rd and 4th data layers manufactured in a similar way.
  • Manufacturing of DVD-9 in accordance with modified 2P process (WAMO) method includes steps:
  • DVD-9 can be manufactured by both the 1st and 2nd methods, whereas DVD- 14 and DVD- 18 (double-sided 3- or 4-layer discs respectively) require only the WAMO technology. Some companies to produce DVD-9 and DVD- 18 use it
  • the WAMO Surface Transfer Process for producing double-sided 3- or 4-layrer discs includes steps:
  • Figs.l and 2 a conventional WAMO method of a two-layer single-side DVD disc manufacturing is illustrated. Injection molding from the Ni-stamper is used to form a substrate of PMMA 101 with the data-carrying relief of the 2nd layer
  • the substrate is sputtered with a fully-reflective layer
  • the above-mentioned method of manufacturing multilayer discs has a number of disadvantages, namely: a low yield of valid discs connected with a high degree of faultiness while separating matrix 101 and transferring super thin reflective Al layer 103 to the polycarbonate substrate, as well as a chance of further breaking or deforming the reflective Al data layer 103 due to the shrinkage of photopolymeric glue 201. Moreover, this method is inapplicable to manufacturing discs with more than two layers on one side.
  • This invention offers a principle and methods of constructing of production line and production process for manufacturing single-sided multilayer reflective discs with high recording density in every layer, such as Versatile Multilayer Disc (VMD).
  • VMD Versatile Multilayer Disc
  • a production line for manufacturing multilayer optical discs having at least four information layers comprising: a first injection molding module for producing first polycarbonate substrate with relief of first layer, a second injection molding module for producing second polycarbonate substrate with relief of fourth layer, at least one sputtering module for partially reflecting layer spattering on said first and second substrate, at least one bonding module for bonding said first sputtered substrate to a first nonexpendable plastic stamper of a second information layer forming first sandwich-like structure and said second sputtered substrate to a second nonexpendable plastic stamper of a third information layer forming second sandwich-like structure, at least one separation module for separating said first sandwich-like structure and said first nonexpendable plastic stamper forming first blank and separating said second second sandwich-like structure and nonexpendable plastic stamper forming second blank, at least one washing module for washing said first blank and washing said second blank, at least one additional washing module for washing said first nonexpendable plastic stamp
  • a continuous production process for manufacturing multilayer optical discs including the steps: providing a first injection molding module and producing first polycarbonate substrate with relief of first layer, providing a second injection molding module and producing second polycarbonate substrate with relief of fourth layer, providing at least one sputtering module and sputtering on said first and second substrate partially reflecting layer, providing at least one bonding module and bonding said first sputtered substrate to a first nonexpendable plastic stamper of a second information layer and said second sputtered substrate to a second nonexpendable plastic stamper of a third information layer, providing at least one separation module and separating said first sandwich-like structure from said first plastic stamper and forming first blank and separating said second sandwich-like structure from said plastic stamper and forming second blank, providing at least one washing module and washing said first blank and washing said second blank, providing at least one additional washing module and washing said first plastic stamper and washing said second plastic stamper, providing at least one sputtering module and sp
  • Figs. 1 and 2 depict a prior art WAMO technology of producing two-layer single- side (DVD) disc;
  • Fig. 3 schematically illustrates VMD production line;
  • Fig. 4 shows a sectional view of a substrate with relief of first (or fourth) information layer sputtered with semi-reflective film bonded with cured photopolymer layer with relief of second (third) information layer (blanks 1, 2);
  • Fig 5 schematically illustrates production process of four-layer VMD with use of non-expandable plastic stampers
  • Figs. 6A and 6B schematically illustrate separation of plastic stamper from blank
  • Fig.7 shows a sectional view of a four-layer assembled VMD disc
  • Fig.8 illustrates off-line facilities for plastic stamper production.
  • Fig.9 A, B, C schematically illustrates integrated production line suitable for mass production of VMD-discs
  • Fig.lO schematically illustrates main cyclic part of production line suitable for manufacturing three and more layered VMD discs.
  • Proposed production process and production line for manufacturing multilayer optical disks enables to prduce multilayer discs with number of layers more than two readablefrom one side, and on the other hand it mostly enables to use the conventional DVD equipment (injecting molding, bonding, deposition, etc.) for manufacturing multi-layer optical discs, preferably single-sided VMD discs.
  • VMD production line with accordance with one aspect of the present invention, using standard equipment, is shown in Fig. 3.
  • FIG. 3 there are shown an injection molding module 301for substrate with the first layer, sputtering unit 302 for the first layer, DVD9 bonding/curing module 303 for bonding substrate with the first layer and plastic stamper of the second layer 307, separation module 304 for the first blank and plastic stamper of the second layer, washing module 305 for the first blank, washing module 306 for plastic stamper of second layer, plastic stamper of the second layer 307, sputtering module 308 for the second layer, injection molding 309 for substrate with the fourth layer, sputtering module 310 for fourth layer, bonding/curing module 311 for plastic stamper of the third layer and substrate with the fourth layer, separation module 312 for second blank and plastic stamper of third layer, washing module 313 for plastic stamper of third layer, washing module 314 for second blank, plastic stamper of third layer 315, sputtering module 316 of third layer.
  • Dye coater unit from CD-R or DVD-R line or lacquer unit from CD line can be used as a washing modules 305, 306, 313, 314.
  • Surfaces of just separated blanks which is illustrated in Fig. 4 and plastic stampers should be washed with isopropanol or ethyl alcohol for antistatic treatment and for removing of trace uncured photopolymer. More strong solvents should not be used for washing because they can dissolve and harm surface of polycarbonate.
  • Washing modules for washing plastic stampers preferably are connected by disc transporter and/or robotic handles to bonding/curing module 303 in order to cyclically use washed plastic stampers. Referring to Fig.
  • FIG. 5 there is illustrated a sectional view of a substrate with relief of first (or fourth) information layer sputtered with semi-reflective film bonded with cured photopolymer layer with relief of second (third) information layer (blank 1, 2).
  • Sputtering of the reflection layer is performed by, for example, UNAXIS CUBE
  • the thin reflective film is deposited onto polycarbonate substrate 401 under technical regimes for achieving required coefficients of reflection (1- 10%). It is worth to notice that to obtain the same jitter during read out we should have approximately the same signal from every layer (actually signal from the first layer should be slightly lower) The same reflection from the reflective layer is achieved if more energy is used during sputtering onto cured photopolymer surface compared to polycarbonate surface.
  • Reflection of fourth layer should be higher than third, reflection of third layer is higher than second and reflection of second layer is higher than first.
  • the proposed principal scheme of production line for manufacturing multilayer disks enables to use the conventional DVD machinery (injection molding, modules 301,309, sputtering, modules 302, 310, 308,316; bonding/curing, modules 303, 311, 317, separation modules 304,312, washing modules 305,306,313,314.) for manufacturing single-sided multi-layer optical discs such as VMD.
  • This production line may be built up from commercially available DVD modules with several specific modules which are described furtherbelow.
  • the machine is capable of producing all types of DVD discs as well.
  • the machine can be easily upgraded to produce multilayer HD DVD. It is worth to notice that the thickness of the photopolymer glue set to be about 20-40 ⁇ m.
  • a photopolymer glue may be for example, a mixture of bis-(methacryloxyethylene carbonate) diethylene glycol (OCM-2), Ebecryl 2002 (Cytek ) and photoinitiator is used.
  • OCM-2 bis-(methacryloxyethylene carbonate) diethylene glycol
  • Ebecryl 2002 Cytek
  • Photopolymer preferably, should have good resolution, i.e. replicate a stamper relief without distortion and it should have good adhesion to reflective layer. Photopolymer also should have good solubility in isopropanole or ethyl alcohol, which should be used for washing after separation of cured halves.
  • final bonding/curing module 317 two sandwiches are glued together.
  • normal photopolymer glue for DVD-9 can be used.
  • Modules of invented production line are preferably connected by disc transporter and/or robotic handles.
  • Fig. 5 schematically illustrates production process of four-layer VMD, using of non-expandable plastic stampers performed by the production line of Fig. 3.
  • Stamper of the first layer (normal direction of rotation) is placed into DVD Injection molding unit 301 and polycarbonate substrates with relief of the first layer 501 of required thickness is produced. Further, step 502, sputtering of reflection film onto substrate 501, with relieves of first information layer is performed, giving the substrate with relief of layer 1 covered with reflection coating 503.
  • Plastic substrate 504 with relief of 2nd information layer is manufactured in the off-line injection molding module. It is sputtered with anti-adhesive coating (procedure 505) and as a result the plastic stamper 307 is formed. Bonding/curing 506 of this plastic stamper and polycarbonate substrate with 1 layer covered with reflective film is performed to give the sandwich-like structure 507. After separation process 508 plastic stamper 307 returns to the cycle and released blank 1 is transferred to the sputtering module.
  • Nickel Stamper of the fourth layer (reverse direction of rotation) is placed into
  • DVD Injection molding unit and polycarbonate substrates with relief of the fourth layer 509 required thickness is produced. Further, step 510, sputtering of reflection film onto substrate 509, with relief of fourth information layer is performed, providing the substrate 511 with relief of layer 4 covered with reflection coating.
  • Plastic substrate 512 with relief of third information layer is manufactured in the off-line injection molding module. It is sputtered with antiadhesive coating (step 513) and as a result the plastic stamper 315 is formed. Step of bonding/curing 514 of this plastic stamper and polycarbonate substrate with fourth layer covered with reflective film is performed to provide a sandwich-like structure 515. After separation step 51,6 plastic stampers 307, 315 returns to the cycle and released second blank 520 is transferred to the sputtering module. Further, first blank 517) is sputtered (step 518) with reflective coating, preferably
  • Si providing first sandwich 519.
  • Second blank 520 is sputtered (step 521) with reflective coating preferably Si providing second sandwich 522.
  • step of gluing 523 of the first and second sandwiches is performed in final bonding/curing module giving final 4-layer VMD-disc 524.
  • FIGs. 6A and 6B there are illustrated an example of step of separation or pulling away plastic stamper 307 (315) from first (second) blank 517, 520
  • Separation of cured blanks 517, 520 may be performed using two vacuum chucks 601 attached preferably to the central portions of both sides of sandwich-like structure 507, 515
  • Fig.8 illustrates an off-line facilities for plastic stamper production.
  • an injection molding module 801 plasma enhanced chemical vapor deposition (PECVD) module 802 for antiadhesive layer deposition, lacquering unit for antiadhesive treatment 803, buffer 804 for plastic stampers with anti adhesive.
  • PECVD plasma enhanced chemical vapor deposition
  • Injection molding unit 801 is used for making plastic stampers 307, 315for second and third information layers (in case of four-layers VMD).
  • PECVD unit 802 is used for antiadhesion treatment of plastic stampers 307, 315.
  • Lacquering unit 803 is used for formation of antiadhesion coating and Buffer for plastic stampers 804 provides storing of ready plastic stampers.
  • Plastic stampers are made in off-line modules and can be used in in-line production line repeatedly.
  • Plastic stamper manufacturing a) Injection molding of plastic stampers for second and third layers (in case of four layers VMD).
  • Polycarbonate (or other polymeric) substrates of about 0.6 mm thickness and 120 mm diameter are made using DVD injection molding (module 801) from the stamper of the second layer 402.
  • Polycarbonate substrates of about 0.6 mm thickness and 120 mm diameter are made using DVD injection molding from the Stamper of the third layer 402. b) Antiadhesive coating.
  • the surface of plastic stampers preferably is treated to obtain antiadhesive properties. This is necessary for multiple using of plastic stampers and increasing of yield for 2P process. Low adhesion of plastic stampers eliminates delaminating of cured photopolymer from Si layer during separation process.
  • the surface of substrate becomes chemically modified in module 803 to decrease adhesion to photopolymer layer to be placed on the plastic stamper. So, the plastic stamper 406 is ready to multiple using without loosing of antiadhesive properties and quality of 2P replication, it is transferred to the buffer 804.
  • Integrated production line preferably comprises: injection molding module 901 for molding substrate for first layer and 912 for fourth layer, sputtering module 902 for sputtering first and module 913 for sputtering fourth information layers, bonding module 903 for bonding first layer with plastic stamper 307 and module
  • UV-curing stations 904 and 915 for bonding substrates with 1 and 4 layers with plastic stampers of 2nd and 3th layers consequently) for glue photopolymerization.
  • Inspection modules 923 and 927, bins 924 and 928 for sandwiches 1 and 2 consequently. Fitted sandwiches 1 and 2 are glued in bonding/curing 925 module buffer 926 for fitted sandwiches 1 substituting rejected during inspection of first sandwiches, buffer 929 for fitted sandwiches 2 substituting rejected during inspection sandwiches 2 output buffer 930 for fitted VMD discs,
  • 3-and more-layer VMD disc production lines Fig.10. schematically illustrates cyclic part of production line suitable for manufacturing more than 3 -layer VMD discs by adding every new layer in cycle
  • production line comprises: 1001 - Loading module of "i-th" blank 1002 - Sputtering of Layer i
  • At least one common manufacturing module can be used, due to desired throughput and/or capital investment, or all information layers can be formed consequently on one substrate, different types (CD ROM, DVD ROM, Blue Ray, HD-DVD, DVD-R, DVD-RW, etc.). and configurations (number of layers) of optical discs may be manufactured and that what is briefly claimed is just an example that in any way may limit the inventor rights.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Optical Record Carriers (AREA)
  • Optical Record Carriers And Manufacture Thereof (AREA)

Abstract

L'invention concerne un procédé de production et une ligne de production destinés à fabriquer des disques optiques multicouches. La technologie permet de produire des disques réfléchissants optiques multicouches de n'importe quel format CD ROM, DVD ROM, Blue Ray, HD-DVD, DVD-R, DVD- RW, etc., et, en particulier, un Disque Multicouche Versatile (VMD), utilisant principalement des lignes de production CD/DVD existantes avec une mise à niveau raisonnable.
PCT/IB2006/003088 2006-11-02 2006-11-02 Procédé de production et ligne de production pour fabriquer des disques optiques multicouches WO2008053266A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/IB2006/003088 WO2008053266A2 (fr) 2006-11-02 2006-11-02 Procédé de production et ligne de production pour fabriquer des disques optiques multicouches
TW096141519A TW200841338A (en) 2006-11-02 2007-11-02 Production process and production line for manufacturing multilayer optical discs

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2006/003088 WO2008053266A2 (fr) 2006-11-02 2006-11-02 Procédé de production et ligne de production pour fabriquer des disques optiques multicouches

Publications (2)

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WO2008053266A2 true WO2008053266A2 (fr) 2008-05-08
WO2008053266A3 WO2008053266A3 (fr) 2009-04-16

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TW (1) TW200841338A (fr)
WO (1) WO2008053266A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9275671B2 (en) 2011-06-09 2016-03-01 Case Western Reserve University Optical information storage medium

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5563798A (en) * 1994-04-05 1996-10-08 Applied Materials, Inc. Wafer positioning system
US6309496B1 (en) * 1999-03-04 2001-10-30 Wea Manfacturing Inc. Method and apparatus for making dual layer DVD discs
US20020130041A1 (en) * 2001-03-13 2002-09-19 Jyh-Chung Wen Method of regenerating a phase-change sputtering target for optical storage media

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5563798A (en) * 1994-04-05 1996-10-08 Applied Materials, Inc. Wafer positioning system
US6309496B1 (en) * 1999-03-04 2001-10-30 Wea Manfacturing Inc. Method and apparatus for making dual layer DVD discs
US20020130041A1 (en) * 2001-03-13 2002-09-19 Jyh-Chung Wen Method of regenerating a phase-change sputtering target for optical storage media

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9275671B2 (en) 2011-06-09 2016-03-01 Case Western Reserve University Optical information storage medium

Also Published As

Publication number Publication date
TW200841338A (en) 2008-10-16
WO2008053266A3 (fr) 2009-04-16

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