Method for manufacturing an optical storage device

Abstract: A method for manufacturing of a second surface optical recording disk is disclosed. An optically transparent disk cover (10) with tracking grooves (30) and data etched on amating side thereof is mated and embossed into an optically reactive layer of a first surface optical recording laminate web or sheet having an optically active layer (22), a reflective layer (20) and a web support layer (18). The second surface optical recording device thereby created is then cut from the laminate web to yield a second surface optical recording disk.

Description: This invention relates to an optical storage disk, card or device and in particular a method for the manufacture thereof. Existing optical disk or card art relating to write once-read many (WORM), magneto-optical (erasable) type or similar optical recording devices generally consists of a laminated or multilayered structure having a rigid support substrate, a reflective layer, a photosensitive optically reactive second surface layer which is, depending upon disk or card application, covered by a first surface optically transparent protective coating layer. Historically each said layer has been subsequently superimposed intermittently upon the preceding layer on a disk by disk basis, by various succeeding methods such as injection or compression molding, spin coating, sputtering, vacuum deposition, and, in general, by means of individual layer by layer lamination techniques. Each substrate is processed to receive succeeding such lamination coatings individually, serially or in batches of small numbers. More recent trends in optical recording technology have led to the development of first surface optically recordable laminates which have been conveniently and efficiently manufactured in a continuous, rather than intermittent, manner in wide webs of great length and width in a manner analogous to conventional manufacture of magnetic tape. By such means, optically recordable laminates may likewise be manufactured in an efficient and economical manner. However, although such first surface optically recordable laminates may be cut into circular or rectangular sheets as well as traditional lengthy tapes, the relatively thin, first surface optically recordable disks or cards produced in such a manner have significant disadvantages when compared to earlier second surface optically recordable structures. In spite of a thin protective coating over the first surface optically recordable layer of such laminated sheets, randomly attracted dust particles of but a micron or so in diameter, not visible to the unaided eye, may lodge very close to the first surface optically reactive layer, thereby blocking out significant areas of the optically reactive layer causing commensurate dropouts of data to be recorded and reproduced subsequent loss of information. In addition, the relatively thin laminate sheet structure of optical disks cut from an optical laminate sheet has no rigid structural component and therefore has a tendency to bend and curl. Therefore, it is necessary that such laminate optically recordable disks be spun immediately above a flat stationary surface at a speed above a critical minimum which flattens the disk to optical record/reproduce requirements by formation of an air bearing film. There exists therefore a longstanding and continuing need for a new and improved optically recordable disk having the rigid, second surface optical attributes of a thick and transparent substrate and therefore a surface which will hold dust and mechanical defects at a safe distance from the plane of a focused record/reproduce beam on the recordable layer, yet also having the economical manufacturing advantages of a first surface optical lamination of large sheets of an optically recordable medium. A method for forming such a disk is described in an article entitled "Web-based Rigid Optical Disk" at page 280 of Research Disclosure publication number 242 of June 1984. This discloses a method comprising the steps of positioning in a planar orientation a sheet of optically recordable laminate having at least one reflective layer and at least one first surface optically recordable layer; placing a formattable surface of an optically transparent cover on a surface of said first surface optically recordable layer; compressing the sheet of said laminate with said cover to create a permanent and sealed bond thereof thereby creating a formattable second surface optically recordable structure; and cutting said second surface optically recordable structure from said sheet of optically recordable laminate. In this method, the circumference only of the cover is bonded to the recording layer such that an air layer is located between the cover and said recordable layer. The invention disclosed herein provides a new and novel method of fabricating an optically recordable disk by combining attributes of two existing optical disk types and by such means as further yields a new and novel optically recordable medium as well. The present invention as defined in appended claim 1 is characterised over that disclosed in the Research Disclosure article in that the cover is directly bonded with its entire formattable surface to said surface of said first surface optically recordable layer and the compressing of said sheet of laminate with said cover is conducted under a degree of vacuum to prevent gas entrapment between the surfaces of the laminate and the cover. The invention involves applying an optically transparent cover, conventionally molded in disk shape or other desired shape, with or without preset data or tracking grooves as desired, to a conventionally manufactured first surface optically recordable laminate conventionally having a pliant web support base, a reflective layer, and an optically reactive layer; however, not having a conventionally thin and pliant protective layer such that said cover directly bonds with its entire surface to the optically reactive layer. Said cover is then compressed into a first surface optically recordable laminate to bond and seal permanently the two components and thereby yield a second surface optical recording medium. The newly formed second surface optical recording structure is then cut from the laminate sheet to yield a second surface optically recordable laminate that is, in essence, manufactured in a two-step process as opposed to the conventional multistep process of manufacturing a second surface optical recording disk by starting with a disk substrate and then successively adding each desired layer, i.e. reflective layer and protective layer. It is therefore a primary object of the invention to provide an improved efficient and cost-saving method of manufacturing a second surface optical recording medium by combining and utilising portions of two distinct and independent existing methods of manufacturing first surface optically recordable laminate tapes with second surface optical recording disks. It is a further object of the invention to provide a new and novel optically recordable medium produced by such novel manufacturing process. These and other objectives, features, benefits, and advantages of the disclosed invention will become more readily apparent upon reading the following detailed description of the preferred embodiment in view of the accompanying drawings, of which:- Figure 1 illustrates a disk-shaped optically transparent cover being impressed upon a first surface optically recordable laminate sheet; Figure 2 illustrates a second surface optically recordable disk obtained by the figure 1 process; Figure 3 illustrates a cutaway view of figure 2; Figure 4 illustrates the compression-embossing process of cover and laminate sheet; Figure 5 illustrates the unique preferred embodiment tracking groove requirements; and Figure 6 illustrates the recording and reading characteristics of a disk made by the invention process. The invention method for manufacturing a second surface recordable medium is in large part illustrated in Fig. 1., wherein a relatively thick disk-shaped optically transparent cover 10 is illustrated by arrow 13 as being impressed upon a first surface optically recordable laminate sheet 12 of indefinite length and width and relatively invariant depth. Although laminate sheet 12, less the protective layer , is a commercially available item, it may be independently manufactured. A web substrate 18 of laminate sheet 12 consists of a commercially available film-forming material such as polyethylene terephthalate (PET) in the preferred embodiment but may likewise be other material of high elastic modulus. In the embodiment disclosed herein, web substrate 18 of great optical smoothness conventionally serves as a pliant support structure for superimposition thereon of succeeding laminate layers, and also serves as a nonrecordable side of an optically recordable laminate web, tape, or sheet, and, dependent upon thickness thereof, provides a degree of protection as well. Web substrate 18 may normally be 25 um in thickness, and of indefinite length and width, as is necessary to accomodate production of a large number of second surface optically recordable disks, cards or other desired format. A reflective layer 20 of approximately 100 nm in thickness is aluminum in the preferred embodiment but may also be gold, silver, or copper alloy, and is conventionally vacuum deposited upon base layer 18. A photoreactive layer 22 is then applied to reflective layer 22 to complete the processing of optically recordable laminate sheet 12. Optically reactive layer 22 is generally in the realm of 100 nm in thickness, is a soluble dye polymer or dye-binder polymer blend, and is conventionally applied by spin coating, spraying, rolling or dipping. The dye in reactive layer 22 is a cyanine stable polymethine having photospectrometric absorbence peaks at or near the wavelength of a record/reproduce laser or beam of radiation. Specific thickness of optically reactive later 22 must be determined as a function of the laser (radiation) wavelength, 780 nm in the preferred embodiment, the refractive indices of the dye polymer in reactive layer 22, and reflective characteristics of reflective layer 20, as is well understood by practitioners in the art. Once first surface optically recordable laminate sheet 12 is so manufactured or provided, it is then converted into second surface optically recordable disk or card by forced application thereto of optically transparent cover 10. Cover 10 is generally a disk-shaped polycarbonate structure and in the realm of 120 to 300 mm in diameter for industrial, commerical, government and entertainment data recording applications; however, it should be understood that size of the disk is determined solely on need and application. Cover 10 is circular in the preferred embodiment, but may, of course, be of any geometrical design as needed for particular applications. Cover 10 is provided with a spindle hole 24 in the center thereof and has a planar exposed side 26 and a grooved mating side 28. Grooved side 28 is provided with a spiral laser tracking groove 30 or in the preferred embodiment as illustrated in cutaway view of Fig. 3. Grooved side 28, may, however, be formatted or provided with encoding information and data corresponding to sectors, addresses, and beginning/ending codes. Dashed lines 32 indicate hidden spiral or concentric tracking grooves on mating side 28 of cover 10. Alternatively, second side 28 may be provided with no tracking or coding impressions. Grooved mating side 28 of cover 10 is forcefully applied and embossed into first surface optically recordable layer 22 of laminate sheet 12 as illustrated in Fig. 4, with sufficient pressure to insure a sealed and permanently embossed and bonded composite. A pressure of approximately two atmospheres (2X10 5 pascal or nt/m 2 ) is sufficient. Upon proper setting and curing of the seal between cover 10 and laminate structure 12 (approximately 1 minute) the cover/laminate structure is now a second surface optically recordable structure and is circularly sheared from laminate sheet 12 as a separate structure illustrated in Fig. 2. Fig. 2 illustrates the finished product: a second surface optically recordable disk comprising a first surface optically transparent cover 10, a second surface optically recordable/reactive layer 22, a reflective layer 20 and a web substrate layer 18. A cross section of the cover-laminate embossing process is illustrated in Fig. 4. As illustrated in Fig. 4 the grooved mating side 28 of cover 10 is mated with and embossed into the optically active layer 22 of laminate sheet 12. Uniform pressure distribution is necessary and provided to eliminate all pockets or anomalies between the two surfaces. Elastomeric pads 34 and 36 mounted on pressure plates 38 and 40, respectively, provide the necessary flexible distribution of pressure indicated by arrows 42 and 44. Throughout the embossing process, a degree of vacuum in the realm of a torr (1.3X10 -3 atmospheres) is necessary such that no atmosphere or gas may be entrapped between the faying surfaces of cover 10 and laminate sheet 12. Plasticity of the dye polymer in reactive layer 22 permits conformance with the grooved surface 28 of cover 10, thereby completely eliminating all voids in the faying surfaces. It is conceived that many such covers 10 may be embossed at the same time on a single-laminate sheet 12 and likewise many such embossed disks may be simultaneously sheared from laminate sheet 12 in a mass production process. Referring now to Fig. 5, a blown-up section of a portion of the embossing surfaces of Fig. 4 is provided. In the preferred embodiment grooves (G) of cover 10 when meshed with optically active laminate layer 22 must have a width of 0.4 to 0.6 um and a depth (D) of 0.1 um. The land (L) between grooves (G) must be 1.0 um yielding a pitch (P) of 1.4-1.6 um. Referring now to Fig. 6, a view is illustrated of the recording/reading (writing/reproducing) process of the second surface optically recordable medium thusly constructed. Typically a laser beam 45 of wavelength is focused by an objective lens 46 onto a grooved track 30 of the second surface optically recordable disk described in Fig. 3. Beam 45 passes through optically transparent layer 10 and through optically reactive layer 22 where the energy of the beam 45 initiates a chemical reaction with the dye polymer therein. Beam 45 passes through optically reactive layer 22 to reflective layer 20 where it is reflected passing back through optically reactive layer 22 thereby enhancing the activity of optically reactive elements therein, to yield an occluded area 48 that can later be read and interpreted as data. Of even greater import is the ability of the second surface recordable disk to "see through" a typical dust particle 50. If a similar dust particle 52 were to be on the optically active surface 22, it could sufficiently block transmission of the laser beam to prevent either write or read modes.

Claims: A process for making a second surface optically recordable structure, comprising the steps of: positioning in a planar orientation a sheet of optically recordable laminate (12) having at least one reflective layer (20) and at least one first surface optically recordable layer (22); placing a formattable surface (28) of an optically transparent cover (10) on a surface of said first surface optically recordable layer (22); compressing said sheet of laminate (12) with said cover (10) to create a permanent and sealed bond thereof thereby creating a formattable second surface optically recordable structure; and cutting said second surface optically recordable structure from said sheet of optically recordable laminate (12); characterised in that the cover (10) is directly bonded with its entire surface (28) to said surface of said first surface optically recordable layer (22) and the compressing of said sheet of laminate (12) with said cover (10) is conducted under a degree of vacuum to prevent gas entrapment between the surfaces of the laminate (12) and the cover (10). A process according to claim 1, characterised in that said sheet of optically recordable laminate (12) comprises: at least one support layer (18); the optically reflective layer (20) superimposed upon said support layer (18); and the optically reactive recordable layer 22 superimposed upon said reflective layer (20). A process according to claim 2, characterised in that said support layer (18) consists of a polymer, such as polyethylene terephthalate. A process according to claim 2 or claim 3, characterised in that said optically reflective layer (20) consists of a metallic material. A process according to any one of claims 2 to 4, characterised in that said optically reactive layer (22) consists of a dye polymer. A process according to any of the preceding claims, characterised in that said formattable, optically transparent cover (10) consists of a thermoplastic molded polymer. A process according to claim 6, characterised in that said optically transparent cover (10) is formatted with a spiral tracking groove (30). A process according to claim 6, characterised in that said optically transparent cover (10) is formatted with concentric tracking grooves. A process according to any one of claims 6 to 8, characterised in that said optically transparent cover (10) is formatted with data corresponding to sectors, addresses and beginning/ending encoding. An optically recordable strcture comprising an optically recordable laminate (12) having at least one first surface optically recordable layer (22) with a capability of forming regions of variably reflected radiation to a focused radiation beam impinging through an optically transparent cover (10) having a formattable surface (28), wherein said cover (10) is bonded to a surface of said optically recordable layer (22) thereby converting said first surface optically recordable laminate into a second surface optically recordable structure, characterised in that the cover layer (10) is directly bonded with its entire surface (28) to the surface of the recordable layer (22) by compression. An optically recordable structure as defined in claim 10 wherein the optically recordable laminate further comprises: a support layer (18); and an optically reflective layer (20) superimposed upon said support layer (18) ; said optically reactive recordable layer (22) being superimposed upon said reflective layer (18); and said formattable optically transparent cover (10) being superimposed upon said reactive layer (22). A recordable structure according to claim 11, characterised in that said support layer (18) consists of a polymer, such as polyethylene terephthalate. A recordable structure according to claim 11 or claim 12, characterised in that said reflective layer (20) consists of a metallic material. A recordable structure according to any one of claims 11 to 13, characterised in that said reactive layer (22) consists of a dye polymer. A recordable structure according to any one of claims 11 to 14, characterised in that said formattable, optically transparent cover (10) consists of a thermoplastic moulded polymer such as polycarbonate. A recordable structure according to claim 15, characterised in that said optically transparent cover (10) is formatted with a spiral tracking groove (30). A recordable structure according to claim 15, characterised in that said optically transparent cover (10) is formatted with concentric tracking grooves. A recordable structure according to any one of claims 15 to 17, characterised in that said optically transparent cover (10) is formatted with sectors, addresses, and beginning/ending encoding.

Inventors: GREGG DAVID PAUL, GREGG, DAVID PAUL
Applicants: DEL MAR AVIONICS
Application year: 1990
Main classification: G11B7
IPC codes: G11B7