Method and apparatus for recording on optical discs

Abstract: Method and apparatus for a portable clean environment used for recording optical disc masters by enclosing a light sensitive optical disc in a container that prevents ambient contamination from destroying the pristine environment necessary to create optical disc masters. A transparent optical disc, having an optically active lamina on at least one surface of the transparent optical disc, is enclosed in a dish shaped container that is generally free of particulate larger than 0.2 microns, the enclosure assembly effectively preserving a class 10 cleanroom environment. The dish shaped enclosure isolates the surface of the optical disc used to record data from contamination due to ambient conditions while exposing the nonwriting surface of the optical disc to enable laser writing. A foil seal protects the exposed nonwriting surface of the optical disc from ambient contamination during storage and until recording is desired. Once recording is desired, the foil seal is removed, the entire assembly is placed on the spindle of a turntable, and the transparent optical disc allows laser light to pass through the optical disc and focus on the optically active lamina to form pits within the optically active lamina by either ablating the lamina or by consuming the lamina. The optical disc is then removed from the cover in a cleanroom where electroforming is done on the optical disc to create a disc master.

Description: This application is related to companion patent application entitled "Process for Manufacturing an Optical Disc Master", United States Serial Number 07/482,033 filed 16 October 1990. Information contained in said related application that is essential to the understanding of the present invention has been included in the detailed description to the present invention. This invention relates generally to the art of recording optical disc masters, and more particularly to a method and apparatus for enclosing a pregrooved, transparent optical disc in a portable container that effectively maintains a cleanroom environment, which is adaptable to serve as the site mounting for optical discs and optical disc masters during precision recording thereon. When the packaged disc assembly is mounted on a spindle for recording, the process of recording by laser causes effective ablating or consumption of thin optically active layers on the optical disc surfaces to form pits. The optically modified surface can then be electroformed to form a disc master. Optical disc masters are articles from which all pre-recorded mass produced consumer optical discs are subsequently molded. Current methods of producing optical disc masters employ highly stable precision turntable apparatus operating in a cleanroom environment. One currently used method is the photoresist technique commonly used in the semiconductor industry. This method would spin coat a lamina of photoresist material upon a very thick, smooth, polished circular plate of glass. A data modulated laser is set immediately above the plate by means of a complex translational mechanism that enables the laser to move outward from the center of the glass plate while rotating the glass plate on a turntable and concomitantly radiating the surface of the material on the plate. This results in a spiral track being created in the photoresist material by the laser. Pits are created by exposure to the data modulated laser along the spiral path. This process requires that the entire equipment and operation be performed in what is typically called a cleanroom environment in which the laser path is unobstructed and the photoresist material remains flawless and uncontaminated. Currently, there are variations in photoresist mastering techniques which employ the turntable and spiral track system described above. By using ablative surfaces rather than photoresist material on the circular glass plates, lasers can ablate the optical disc surface to cause the desired pits. However, a cleanroom environment is required for all steps in this process. The construction and maintaining of a cleanroom environment is in itself cumbersome and expensive. Also, the present art of manufacturing optical disc masters in cleanrooms is costly. There remains a need for advance beyond the prior art to a manner of mastering optical discs that is simpler and more economical. EP-A-0010017 describes an optical disc assembly which includes an optical disc upon which a user can record their own data. The assembly includes an optical disc assembly comprising: a transparent optical disc having a writing surface with an optically active lamina formed thereon, and a nonwriting surface, said transparent optical disc permitting laser light of a predetermined wavelength, to pass through it to focus on said optically active lamina to record data thereon; and a cover secured to said transparent optical disc, said cover being constructed to be of a size and shape to enclose said optically active lamina and create a cavity immediately above said optically active lamina within said cover. The cover is adhered to the optical disc by an outer circumferential edge and a central flange surrounding a central aperture. JP-A-63-292474 describes a container for storing optical disc stampers. The container has a removable cover secured to the container by a screw which extends through a central aperture of the cover and central apertures of stampers stored within the container. The container totally encloses the stampers stored therein and the stampers are separated from each other and the cover by spacers. It has, however, been discovered that the recording of optical disc masters is possible in a portable cleanroom environment, wherein a pregrooved transparent plastic flat disc having an optically active lamina deposited on its pregrooved surface, can be enclosed by a dish shaped, optically opaque, plastic cover, such that the area enclosed by the cover immediately adjacent to the optically active lamina, is isolated from the ambient surroundings of the dish shaped cover. The environment of this isolated area can then be controlled to yield cleanroom conditions, resulting in a portable assembly that can be removed from a cleanroom and easily stored. By direct mounting of the portable assembly on a turntable spindle, a data modulated laser beam can track the pregrooved surface to form pits in the optically active lamina by either ablating or consuming the optically active lamina, thus recording data from the data modulated laser. Thus, the present invention provides an assembly which is characterised over the prior art in that the cover maintains a portable cleanroom environment used in the recording phase of optical disc master manufacturing such that the writing surface containing the optically active lamina is isolated from ambient atmospheric contamination and the assembly includes means for removably securing the optical disc to the cover. Disclosed herein is a process and associated apparatus used to create and maintain an environment that is sufficiently clean for use in recording optical disc masters which in turn will then be used in the mass production of duplicate optical discs. The optical disc masters, as produced by the process described herein will be used to create plastic molding press tooling which will in turn be used in the mass production of duplicate optical discs. A cleanroom environment is only necessary in producing the unrecorded laser sensitive discs, which are thereafter portable and protected from light and dirt contamination until recording by the sealed recording disc mounting assembly disclosed in the present invention. It is an object of this invention to create a process for recording of optical disc masters which frees the recording process from having to take place in a cleanroom but instead allows the making of optical disc masters by enclosing an optical disc and having a laser make pits in an optically active lamina on the surface of the optical disc by either ablating or by consuming the optically active lamina surface, while keeping the lamina surface free of particulate matter prior to electroforming. Yet another object of this invention is to create an optical environment in which optical discs having an optically active lamina applied to at least one surface, may have pits formed in the optically active lamina by a focused laser either ablating or consuming the lamina. Another object of the invention is to provide a protective cover for optical recording discs which is a compact, lightweight and sealed assembly thus simplifying and reducing the cost for storing, shipping and handling of optical recording discs. Yet another object of the invention is to prevent ambient light from contaminating the optically active lamina on an optical recording disc which would otherwise experience gradual degradation of the optically active lamina surface. Thus an optical recording disc is given a long shelf life before losing its active response to laser light. It is further the object of the invention to create a process in which optical disc mastering can be accomplished with a vastly reduced cost for capital equipment and can be accomplished in a manner that is significantly less time consuming than the methods that are presently employed. It is further the object of the invention to create a method of recording optical disc masters in an inexpensive, disposable micro-clean environment, and thus avoid the use of expensive cleanroom technology at the time the recordings for optical disc masters are made. The foregoing and further features of the present invention will be more readily understood from the following description of a preferred embodiment, by way of example thereof, and with reference to the accompanying drawings of which: Figure 1 is a cut-away side view of the invention in the condition used for recording; Figure 2a is a top perspective view of the invention in the pre-recording position with a cut-away portion; Figure 2b is a bottom perspective view of the invention in the pre-recording position with a cut-away section; and Figure 3 is an exploded perspective view of the invention showing its major components. Although the invention pertains to a portable, inexpensive and convenient method and apparatus for maintaining a cleanroom environment, certain specific information pertaining to the structure of the enclosed optical disc is necessary to fully understand and appreciate the nature of the invention. Therefore, a brief description of the specific type of optical disc used with the present invention is included herein below. In the preferred embodiment of the invention, as seen in Figure 1, a method of writing on a transparent pregrooved optical disc 2 is disclosed. The transparent pregrooved optical disc 2 has an optically active lamina 19 deposited on the writing surface 18 of the optical disc 2. By employing a laser 16 that follows grooves 3 in the writing surface 18 of the optical disc 2, pits are formed in the writing surface 18 of the optical disc 2 by either ablating or by consuming the optically active lamina 19 to form the pits. As can be seen, the optically transparent optical disc 2 is enclosed by the cover 4. The optical disc 2 is made of polycarbonate material such that the optical disc 2 is transparent having an index of refraction of approximately 1.5. In the preferred embodiment of the invention, optical disc 2 has a spiral tracking groove 3 that is made with exacting groove shape and depth dimensions. The optical disc 2 has an optically active lamina 19 spin coated onto the spiral grooved surface 43, in writing (recording) on the disc, a data modulated laser beam is finely focused on the optically active lamina 19 to form pits by either: a) near total ablation of the optically active lamina 19, or b) by consuming the optically active lamina 19 that is deposited on the writing surface 18 of the transparent optical disc 2. During recording, light from the laser actually passes through the nonwriting surface 38 of the optical disc 2 and focuses on the optically active lamina 19 to create the desired pits. After the pits are formed, the optical disc 2 is removed from the cover 4 in a cleanroom to prevent particulate matter or other forms of contamination from being embedded within the pitted surface of the optical disc 2. It is necessary that the ambient atmosphere should not be allowed to contaminate the pitted surface so that an optical disc stamper can be made therefrom by electroforming. Still referring to Figure 1, the pregrooved transparent optical disc 2 is contained within the cover 4 such that a spacial cavity 14 exists above the writing surface 18 of the optical disc 2 which is isolated from ambient conditions. The writing surface 18 of the transparent optical disc 2, that contains the optically active lamina, is thus isolated from the ambient air by the cover 4, resulting in protection from damage caused by physical contact or particulate matter . The cover 4 consists of a dish shaped top 8 having a circumferential wall 6 around the circumferential edge of the top 8. The entire assembly 10 consists of the cover 4 with the optical disc 2 attached to the inside of the cover 4 by an adhesive lining 30, and the assembly 10 is also held together by removable rim 12 attached to the circumferential wall 6 of cover 4 and to the optical disc 2. The adhesive lining 30 secures the optical disc 2 to the cover 4. The rim 12 ensures that the optical disc 2 will not become dislodged from the cover 4 before removal of the optical disc 2 is desired after the laser 16 creates the pits in the writing surface 18 of the optical disc 2. Once pits are created and the recording is complete, the optical disc 2, containing the desired pits, can be removed in a cleanroom to be electroformed. The entire assembly 10 forms a cavity 14 that effectively reproduces a cleanroom environment. Here, a cleanroom environment is one that is virtually free of all particulate matter on the order of 0.2 micron or larger. In the preferred embodiment, vent 20 permits the free flow of air molecules between the internal cavity 14 and the ambient air in order to equalise changes in the pressure. Although, vent 20 prevents the entire assembly 10 from being airtight, from the ambient air, on the order of 0.2 microns or larger, does not enter the spacial cavity 14 where the pits are to be formed on the pregrooved optical disc 2. Thus, a cleanroom environment is preserved to the extent that particulate matter, on the order of 0.2 microns or larger, is kept out of spacial cavity 14. As seen in Figures 2a and 2b, also part of the assembly 10 is foil layer 36 which attaches to the underside of the assembly. The foil layer 36 is used to prevent ambient contamination such as light, dust, smoke or fingerprints from contaminating the optically transparent bottom nonwriting surface 38 of optical disc 2 and to prevent ambient light transfer to the upper writing surface with its optically active lamina 19 during shelf storage of assembly 10. The foil layer 36 is peeled away from the assembly 10 prior to insertion of the assembly 10 into a recording machine. Referring to Figure 2a, the cover 4 has a circular top 8 in which recessed area 26 defines a central aperture 24 within the dish shaped cover 4. The central aperture 24 is circular and concentric with the overall dish shape of the cover 4 and with the circular top 8. The enclosed pregrooved transparent optical disc 2 will also have a central aperture 28 whose center will also be concentric with that of the cover 4, central aperture 24, while the pregrooved optical disc 2 remains fixedly attached to cover 4 during the writing process in which the entire assembly 10 is placed such that the apertures (24,28) engage the spindle in a recording machine. The inside surface of the cover 4 has an adhesive layer 30 useful in securing the pregrooved optical disc 2 to the cover 4, and also, to trap particulate matter that may be inside the cover. The recessed area 26 of the cover 4 will meet the area of the optical disc 2 that defines the central aperture 28 of the optical disc 2 to isolate the internal cavity 14 from the ambient air. The adhesive layer 30, along the inside cover, will make contact with that area of the pregrooved optical disc 2 that defines central aperture 28. The nonwriting surface 38 of the optical disc 2 is exposed to the ambient air once the foil layer 36 is removed. However, there are no paths for ambient air to enter inside the spacial cavity 14 of the cover 4. The inside surface of the cover 4, along the circumferential wall 6, will also have an adhesive layer 30 that will meet the surface of the pregrooved transparent optical disc 2 thus ensuring that no air will pass through the junction between the optical disc 2 and the circumferential wall 6, of the cover 4. The area on the writing surface 18, of the optical disc 2 that defines circular aperture 28, rests securely against the edge of the central aperture in the cover 24, thus, isolating the writing surface 18 of the optical disc 2 from the ambient air. Referring now to Figures 2b, a bottom view of the entire assembly 10 shows the transparent optical disc that is attached to the cover 4 and to rim 12. In the preferred embodiment, the optical disc 2 is made from a transparent polycarbonate material that permits the passage of laser light to create pits on the writing surface 18 of the pregrooved optical disc 2. The optically transparent nature of the optical disc 2 must be such that it will not defuse light from the laser 16. It is necessary that the laser light is properly focused on the writing surface of the transparent pregrooved optical disc 2 to create pits by either ablating the optically active lamina 19 on the writing surface 18 of the optical disc 2, or by consuming the optical active lamina 19, thus, recording data. The optical disc 2 is separated from the entire assembly 10 in a cleanroom once the pits are made. The pitted optical disc is then electroformed to have a stamper created and an optical disc master is thus created. As shown in Figures 3, the entire assembly 10 consists of cover 4 with optical disc 2 that fits inside the cover 4. Rim 12 holds optical disc 2 fixedly in place until the desired time. Foil layer 36 insulates the underside of the assembly from the ambient contamination, and is removed from the assembly prior to recording. The recessed area 26, of the cover 4, fits against the area of the writing surface 18 of the transparent optical disc 2 that defines the optical disc central aperture 28. The cover adhesive 30 prevents the flow of air, in the areas of the cover 4 and the optical disc 2, that define their respective central apertures (24,28). The circumferential edge of the optical disc 2 rests against circumferential wall 6 of the cover 4, the cover adhesive prevents air flow at this junction. The assembly 10 has a foil layer 36 that protects the nonwriting surface 38 of optical disc 2 from contamination during transport and storage. Foil layer 36 is removed for the recording of information onto optical disc 2. While a particular embodiment of the invention as disclosed is claimed herein, modifications and variations of the invention are possible within the scope of the appended claims. Thus, it is not the intention that the specific limitations of the particular disclosure of the present invention made herein limit the present invention, but that all possible variations encompassed by the appended claims shall determine the scope of the present invention.

Claims: An optical disc assembly comprising: a transparent optical disc (2) having a writing surface (18) with an optically active lamina (19) formed thereon, and a nonwriting surface (38), said transparent optical disc (2) permitting laser light of a predetermined wavelength to pass through it to focus on said optically active lamina (19) to record data thereon; and a cover (4) secured to said transparent optical disc (2), said cover (4) being constructed to be of a size and shape to enclose said optically active lamina (19) and create a cavity (14) immediately above said optically active lamina (19) within said cover (4), characterised in that said cover (4) maintains a portable cleanroom environment used in the recording phase of optical disc master manufacturing such that said writing surface (18) containing said optically active lamina (19) is isolated from ambient atmospheric contamination and said assembly includes means (12, 30) for removably securing said optical disc (2) to said cover (4). An optical disc assembly as claimed in claim 1, characterised in that it includes sealing means (36) removably attached to said optical disc assembly, said sealing means (36) being constructed from an optically opaque material and attached to said optical disc assembly from the underside facing said nonwriting surface (38) of said optical disc (2), said sealing means (36) being operative to prevent ambient contamination from entering said optical disc assembly, such that removing said sealing means (36) exposes said optically active lamina (19) to laser beam writing. An optical disc assembly as claimed in claim 1 or claim 2, characterised in that the means (12,30) for removably securing the optical disc (2) to the cover (4) comprises clamping means (12) used for fixedly attaching said transparent optical disc (2) to said cover (4). An optical disc assembly as claimed in any preceding claim, characterised in that it includes a centering flange on said cover (4), said centering flange being of the size and shape to seal against said optical disc (2) while providing for mounting of said optical disc assembly in a writing position in which laser light may enter said optical disc assembly to form pits on said optically active lamina (19). An optical disc assembly as claimed in any preceding claim characterised in that said cover (4) has a top area (8) that is essentially dish shaped, said top area (8) having a recessed area (26) defining a circular aperture (24) that is concentric with said dish shaped top area (8), and attaching to the circumferential edge of said optical disc (2) such that said optical disc assembly can be placed onto a disc drive spindle where laser beam recording can be accomplished. An optical disc assembly as claimed in any one of claims 3 to 5, characterised in that said clamping means (12) consists of a removable rim (12) that can fixedly attach to said circumferential wall (6) and hold said transparent optical disc (2) within the space contained between said dish shaped top area (8) and said circumferential wall (6). An optical disc assembly as claimed in any preceding claim, characterised in that said transparent optical disc (2) has either a spiral groove (3) or a set of concentric grooves to enable a laser to follow said grooves (3) when forming pits on said transparent optical disc (2). An optical disc assembly as claimed in claim 7, characterised in that pits formed on said optical disc (2) have a geometry that is determined by the geometry of said grooves (3). An optical disc assembly as claimed in any one of claims 4 to 8, characterised in that said cover (4) has an adhesive layer (30) on portions of said cover (4) that make physical contact with said optical disc (2), said adhesive layer (30) forming a seal where contact is made between said cover (4) and said optical disc (2) thereby preventing air flow between said cavity (14) enclosing said optically active lamina (19) from the ambient atmosphere. An optical disc assembly as claimed in any preceding claim, characterised in that said cover includes a vent (20) to allow for pressure equalization of air enclosed by said cover (4) and the ambient air, said vent (20) having a filter (22) to prevent particulate matter from entering said cover (4) while still allowing the flow of air through said vent (20). A method of manufacturing optical disc masters, comprising the steps of: providing a transparent optical disc (2) having a writing surface (18) with an optically active lamina (19) formed thereon, and a non-writing surface (38); securing a cover (4) to said optical disc (2), said cover (4) being constructed to be of a size and shape to enclose said optically active lamina (19) and create a cavity (14) immediately above said optically active lamina (19) within said cover (4); writing to said optically active lamina (19) by focusing a laser light through said transparent optical disc (2) onto said optically active lamina (19), thereby recording data thereon by forming pits within said optically active lamina (19); characterised in that said optical disc (2) is removably secured to the cover (4) and said cover (4) maintains a portable cleanroom environment used in the recording phase of optical disc master manufacturing such that said writing surface (18) containing said optically active lamina (19) is isolated from ambient atmospheric contamination; and said method includes the step of removing the optical disc (2) from said cover (4), in a cleanroom, after pits have been formed on said optical disc so that an optical disc master can be formed thereon. A method as claimed in claim 11, characterised in that the step of securing said optical disc (2) to said cover (4) employs a vent (20) to equalize pressure between said cavity (14) and the ambient atmosphere, said vent (20) further including a filter (22) to control particulate matter size allowable within the cleanroom environment enclosed between said cover (4) and said optical disc (2). A method as claimed in claim 11 or claim 12, characterised in that the step of writing to said optical disc (2) having said optically active lamina (19) deposited further includes employing a data modulated laser tracking along a pregrooved surface on said optical disc (2), said laser being programmed to form pits on said disc (2), said pits being of the size and shape to be readable in a compact disc player. A method of making optical disc masters comprising the steps of: employing a transparent optical disc (2) having an optically active lamina (19) deposited on at least one surface; securing said optical disc (2) to a cover (4) while in a cleanroom environment to control the size of particular matter within a cavity (14) between said optical disc (2) and cover (4); allowing a laser to be focused on said optically active lamina (19) on said transparent optical disc (2); forming pits in said optically active lamina (19) by means of the laser either ablating or consuming said optically active lamina; characterised in that it includes the step of removing said optical disc (2) once the pits are made in a cleanroom; and electroforming the pitted surface of said optical disc (2) to form a disc master. A method as claimed in claim 14, characterised in that said method further includes the step of venting said cavity (14) to equalise air pressure inside said cavity (14) with that of the ambient atmosphere and filtering the air that is vented through said cavity (14). A method as claimed in claim 14 or claim 15, characterised in that said transparent optical disc (2) has a pregrooved surface to enable laser tracking when pits are being formed in said optically active lamina (19). A method as claimed in claim 16, characterised in that pits are formed within the grooves (3) of said pregrooved surface of a size and shape determined by the dimensions of the grooves (3) and a thickness sufficient to create light and dark reflectivity patterns for playback of the recorded disc on a common disc player.

Inventors: BEAUCHAMP ROBERT CRAIG, DOBBIN ROBERT BRUCE, LOEPPKY DAVID GEORGE, NORTON JIM RODNEY, BEAUCHAMP, ROBERT CRAIG, DOBBIN, ROBERT BRUCE, LOEPPKY,DAVID GEORGE, NORTON, JIM RODNEY
Applicants: DEL MAR AVIONICS
Application year: 1991
Main classification: G11B7
IPC codes: G11B7