Glass based optical disk and manufacturing process

Abstract: A process for manufacture of a second surface optically recordable disk having ultraviolet (UV) inhibiting characteristics is disclosed. A reflective laminate sheet of aluminum, superimposed on a glass laminate substratum, is flow process produced by pyrolysis and precipitation of a layer of aluminum from gasified triisobutyl aluminum onto a laminate web of silicate (amorphous glass) which is concomitantly pyrolized from tetraethoxy silane, with or without alkoxide additives, and precipitated upon a flowing body of molten tin to form a dual laminate sheet. To complete the process, an optically active layer which is applied over the reflective layer is embossed with optically transparent ultraviolet (UV) inhibiting polycarbonate, protective covers, the mating surfaces of which, maybe, pregrooved and coded to form second surface optically active media. Covers with bonded laminates are then successively severed from the laminate sheet to yield independent second surface optically recordable media.

Description: GLASS BASED OPTICAL DISK AND MANUFACTURING PROCESS The invention relates to a method for the manufacture of a second surface optical recording storage disk, card or device with ultraviolet (UV) inhibiting characteristics 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 development of first surface optically recordable laminations which have been conveniently and efficiently manufactured in relatively wide webs of great length and width. By such means, optical recording laminations can be manufactured in an efficient and economical manner. However, although such first surface optical recording laminations 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 manner have significant disadvantages when compared to earlier second surface optical recording structures. In spite of a thin protective coating over the first surface optical 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 or reproduced and thereby causing subsequent loss of information. In addition, the relatively thin laminate sheet structure of an optical disk that may be 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 sheet derived optical recording disks be spun immediately above a flat stationary surface at a speed above a critical minimum which tends to flatten the disk to optical record or reproduce requirements by formation of an air bearing film. Furthermore, prior art optical recording media tend to decompose naturally in time due to effects of UV radiation. The present invention discloses a means for diminishing the normally incurred decomposition process. In view of the foregoing prior art limitations there exists a longstanding and continuing need for a new and improved process for mass production of optical recording disks or cards 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 focussed record or reproduce beam on the recordable layer, yet also having the economical manufacturing advantages of a first surface optical lamination of large sheets of an optical recording medium. The invention disclosed herein does just that by combining the technical advantages of a second surface optical medium together with the manufacturing simplicity and efficiency of a first surface optical recording medium The invention disclosed herein provides a method of fabrication of UV inhibited second surface optical recording disks or cards by combining attributes of two existing optical recording mediums, ie first surface optically recordable laminates and second surface optically recordable disks, and in addition provides a unique laminating process The invention conceives a continuous process for applying an optically transparent UV inhibiting cover, conventionally injection molded in disk shape or other desired shape, with or without preset data or tracking grooves as desired, to an assembly line produced first surface optical recording lamination conventionally having a pliant web support base, a reflective layer, and an optically reactive layer. The web support base is created by deposition of and extraction of a silicate glass, such as silicon dioxide glass (SiO₂), from a fluid flow and subsequent pyrolysis of tetraethoxy silane [(C₂H₅O)₄ Si], also knows as tetratheyl orthosilicate [(C₂H₅)₄ SiO₄], on a hot molten metal surface, such as tin (Sn) such that a web laminate of glass is formed thereon. Concomitant with said glass web formation, a web laminate of aluminium from a fluid/flow of an aluminium alkyl, such as triisobutyl aluminium [A] (C₄H₉)₃] on the hot surface of the congealed glass web. Following formation of the glass-aluminium laminate, an optically active layer is applied to the reflective aluminium layer. The cover component is compressed and embossed into the first surface optical recordable lamination component 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 lamination sheet to yield an independent second surface optical recording medium that is, in essence, manufactured in a simple and efficient flow process as opposed to the conventional multistep process of manufacturing second surface optical recording disk by starting with a disk substrate and the successively adding each desired layer, ie reflective layer, protective layer, etc., on a disk by disk basis. According to one aspect of the present invention, there is provided a laminating process for manufacture of second surface optically recordable media, characterised in that the process comprises the steps of: pyrolizing a first fluid to form a solid glass base laminate; pyrolizing a second fluid to form a solid reflective laminate bonded with said base laminate; covering said reflective laminate with an optically active laminate to form a first surface optically recordable laminate sheet; covering said optically active laminate with an optically transparent adhesive laminate; sequentially applying individual optically transparent, UV limiting covers to said adhesive laminate; compressing and embossing each cover into said adhesive laminate and said optically active laminate to form a series of individual second surface optically recordable media; and severing each individual second surface optically recordable medium from said series of media to form discrete second surface optically recordable media. According to a second aspect of the present invention, there is provided a laminating apparatus for manufacture of second surface optically recordable media characterised in that it comprises: means for forming a glass base laminate sheet; means coupled to said base laminate forming means for forming and bonding a reflective laminate to said base laminate sheet; means coupled to said reflective laminate forming means for forming and bonding an optically active laminate to said reflective laminate sheet to form a first surface optically recordable laminate sheet; means coupled to said optically active laminate forming means for sequentially embossing optically transparent ultraviolet (UV) limiting covers of defined geometric dimensions on said first surface optically recordable laminate sheet for forming a plurality of second surface optically recordable media; and means coupled to said cover embossing means for individually severing and sealing each second surface optically recordable medium and for forming discrete second surface optically recordable media. According to a third aspect of the present invention, there is provided a laminated second surface optical recording medium characterised in that it comprises: a glass base laminate; an aluminium reflective laminate bonded to said base laminate; a dye polymer optically active laminate bonded to said reflective laminate; and an optically transparent, UV limiting cover bonded to said active laminate. It is a primary object of the invention to provide an improved efficient and cost-saving method for mass production of second surface optical recording media by combining and utilizing portions of two distinct and independent existing methods of manufacturing: 1. First surface optical recording lamination sheets or tapes; and 2. Second surface optical recording disks or cards. Another object of the invention is to make a laminate substratum as part of a unified disk formation process by pyrolisis extraction of a silicate (glass) laminate from a fluid flow of tetraethoxy silane with or without alkoxide additives upon a flowing surface of molten tin. A further object of the invention is to superimpose as part of a unified disk formation process a reflective laminate upon the glass laminate substratum by pyrolisis extraction of an aluminium laminate from a fluid flow of triisobutyl aluminium upon the flowing glass laminate. Yet another object of the invention is to utilise at least two transformers whose conduction paths pass through and thereby resistively heat different volumes of molten tin to establish a temperature gradient between said volumes and thereby effecting pyrolize both tetraethoxy silane and triisobutyl aluminium on the surface of the molten tin. Yet a further object of the invention is to make novel second surface optically recordable media having inherent UV inhibiting characteristics. The foregoing 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 drawing and appended claims. Figure 1 illustrates an overall view of the manufacturing process to produce second surface optically recordable disks. Figure 2A illustrates a sideview of the second surface optically recordable disk on severance from laminate sheet. Figure 2B illustrates the completed optical disk with trimmed and sealed edge/periphery. The conceptual method for manufacture of second surface optically recordable media is, in large part, illustrated in Figure 1. The flow schematic of Figure 1 illustrates an overall view of the process and system claimed herein. It should be understood that various laminate layers described in the system of Figure 1 are not drawn to relative scale with respect to each other or the mechanisms through which they pass. All laminates are drawn with equal thickness for clarity of illustration. Referring to Figure 1, an internal view of a rectangular laminating enclosure 10 is illustrated having a first, second, third and fourth fluid inlets 12,14, 16 and 18 leading to a first, second, third and fourth vacated upper compartments, 20,22,24 and 26, respectively, separated by a first, second and third baffels 28, 30 and 32. A first and second combustible gas outputs 31 and 34, respectively, allow for exit of nonuseable gases which may be flared at a distal ends thereof 33 and 35. First fluid, inlet 12 is coupled through a first regulator 36, with flow feedback 37, to a tetraethoxy silane (TEOS) solution, [SiO(C₂H₅)₄], [Si(C₂H₅O)₄] liquid with or without other metal alkoxide additives dissolved in an appropriate organic solvent. these might be aluminium isopropoxide, [Al(C₃H₅O)₃], sodium methoxide [Na(CH₃O)] lithium ethoxide [Li(C₂H₅O)], or calcium methoxide [Ca(CH₃O)₂]; solvents for the foregoing solids might be methanol (CH₃OH), ethanol (C₂H₅OH), propanol (C₃H₇OH), butanol (C₄H₉OH), or some suitable combination of the foregoing. The purpose of the metal alkoxide additives is to adjust physical or chemical properties of the glass. An example would be to match the thermal expansion of the glass to that of aluminium. Second and fourth inlets 14 and 18 are coupled through a second regulator 40, with flow feedback 41, to an inert gas argon (Ar) source 42. Third inlet 16 is coupled through a third regulator 44, with flow feedback 45, to a triisobutyl aluminium (TIBA), [A](C₂H₅)₃],source 46. A dual-sprocket ladder chain-drive 48, travelling in the direction of indicated arrow 49 circulates throughout a body of molten metal such as tin (Sn) 50 in a lower compartment 51 of laminating enclosure 10. Chain drive 48 may be regulated by servo means 52 coupled to other components of the overall laminating process for proper timing as would be conventional in the art. Lower compartment 51 is provided with a forward indent 54 that is designed to be tangential to the surface of circulating molten metal 50 such that a forward meniscus 56 will not be allowed to interfere with lamination initiation thereon. An existing miniscus 58, at an exit window 60 of enclosure 10, allows separation of a lamination formed on molten metal 50 surface while passing through and supported by superior and inferior air bearings 62 and 64, respectively. Lower compartment 51, and molten metal 50, therein, are maintained at an elevated temperature by first and second transformers 66 and 68 which are independently regulated by a first and second variacs 70 and 72, respectively, such that the forward volume of molten metal 50 may be maintained at a higher temperature by transformer 66, relative to the exit volume heated by transformer 68. It should be noted that the currents generated by transformer 66 and 68 actually pass through metal 50, which in the preferred embodiment is tin, and due to resistance to relative current flow therein, generates the respective heat. Formation of a glass based dual laminate 11, which emanates from exit window 60, begins by deposition of a liquid layer of tetraethoxy silane solution (TEOS) 38 through inlet 12 on the surface of molten tin 50. The high heat of approximately 270°C at the forward surface of molten tin 50 pyrolizes the TEOS and thereby extracts from the TEOS an amorphous glass laminate 13 comprising silicate glass on the surface of molten tin 50. (C₂H₅O)₄Si = SiO₂ + 3C₂H₆ + 2 Co Thickness of the laminate is in direct proportion to the volume flow of TEOS and the speed of the moving surface of molten tin 50, which in turn is maintained in motion by chaindrive 48. An inert gas, which is argon (Ar) in the preferred embodiment, is applied to second compartment 22 at a pressure somewhat higher than any gas pressure in first compartment 20, such that the multitude of low atomic weight gases given off in the pyrolysis of TEOS to form glass laminate 13, is vented through first exit pipe 31 and flared at 33. The flow of molten tin 50, from first, second and third compartments 20, 22 and 24, toward exit window 60 caused by chain drive 48, carries glass laminate with a desired thickness determined by temperature of molten tin, by volume flow of TEOS, by speed of chain drive 48, by length of first compartment 20, and by rate of dual laminate 11 as it is pulled from enclosure 10. When the desired thickness of glass laminate 13 is achieved, laminate 13 passes through second compartment 22, containing inert gas, into third compartment 24 where a gas flow of triisobutyl aluminium (TIBA) is applied to the surface thereof. Again, the continuous flow of inert gas (Ar) into second and fourth compartments tends to keep TEOS and pyrolized hydrocarbon gases thereof, of low atomic weight in first compartment 20, and likewise maintains TIBA and pyrolized gases thereof, in third compartment 24. As pyrolysis of TIBA occurs in third compartment 24, an aluminium (Al) laminate 15 is precipitated upon glass laminate 11. 2Al(C₄H₉)₃ = 2Al + 6C₄H₈ + 3H₂ As with formation of glass laminate 11, a designed thickness of 25 micrometers (um) of aluminium laminate 15 is determined by temperature, by volume flow of TIBA, by speed of chain drive 48 and accompanying flow of tin, by length of third compartment 24, and by rate of flow of dual laminate 11, as it is pulled fro-enclosure 10. It should be noted that flow of argon (Ar) gas in fourth compartment 26 not only maintains TIBA and pyrolized gas derivatives thereof, in third compartment 24, but also keeps contaminates, exterior to enclosure 10, out of enclosure 10, and thereby maintains a clean laminating process. Aluminium reflective laminate 15, having reflectivity characteristics of at least 80%, is an aluminium laminate in the preferred embodiment of approximately 25 micrometers in thickness but may also be any reflective metal, metallic compound or alloy. As described above reflective laminate 15 is derived in the preferred embodiment from the precipitation of pure aluminium (Al) from a gas of triisobutyl aluminium [Al](C₄H₉)₃], flowing upon a body of molten tin, with butane (C₄H₈) and hydrogen (H₂) derivatives given off. The principles and one typical application of the aluminium deposition process is described in a publication of the Office of Technical Services of the U.S. Department of Commerce, June 1959, titled, "Development of a Method to Accomplish Aluminium Deposition by Gas Plating." Composite laminate 11, thusly created exits enclosure 10 by automatically separating from tin meniscus 58 at exit slot 60. On exiting therefrom, laminate 11 is first supported by superior and inferior air bearings 62 and 64 respectively, conventional to the art. A thickness sensor 74, may be any conventional x-ray, dielectric type or type sensor having the capacity to monitor and assure that a consistent and desired thickness of aluminium reflective laminate and glass laminate are maintained. To do so, servo 52, having a thickness adjusting mechanism 53, is coupled via dashed lines 76, 78, 80 and 82 to TIBA mixture regulator 44, to argon regulator 40, to TEOS regulator 36 and to tensioning and speed control mechanisims 84 and 86, conventional to the art. If more aluminium is needed to yield a thicker aluminium reflective layer 15, then regulator 44 is opened more to allow a greater flow of TIBA mixture into third compartment 24 of enclosure 10. Likewise, if more glass laminate thickness is needed TEOS regulator 36 is opened wider to allow a greater flow of TEOS. Composite laminate 11 is next pulled under a dye polymer dispenser 88 where a layer of optically reactive dye polymer 90 is sprayed timely and uniformly across the surface of reflective aluminium layer 15 to complete a process of forming a first layer optically reactive (recordable) laminate sheet. Optically reactive layer 90, which is generally in the realm of 100 nanometers (nm) in thickness, is a soluble dye polymer or dye-binder polymer blend, and is illustrated as being sprayed onto reflective layer 15, in a finely atomized spray; however, layer 90, may likewise be applied by rolling or dipping techniques, conventional to the art. Following application of optically active layer 90, an adhesive layer 101 is applied by a finely atomized spray of an adhjesive dispenser 103, operated upon by a pressurized nitrogen gas (N₂) source 106. However, it is understood that the functions of dye polymer and adhesive may be combined by use of a similar substance having both characteristics, eg, an adhesive dye polymer. The thusly formed first surface optically recordable laminate sheet 102, comprising optically active layer 90, reflective layer 15, and glass substratum, 134, is next passed through a partially evacuated cover placement and embossing compartment 104. On entering compartment 104, laminate sheet 102, first passes through a superior and an inferior stationary triple compartment entrance gland seals, 106 and 108 respectively. Entrance gland seals 106 and 108 and exit gland seals 107 and 109, operate to create a partial vacuum within compartment 104. Referring to gland seal 108, but applicable to all other gland seals, an outlet 110 is coupled to a vacuum pump creating a partial vacuum in first gland compartment 112. A first gland partition 114, having a small passage therethrough, allows for a creation of a greater vacuum in second gland compartment 116. Similarly, a second gland partition 118, having a small passageway therethrough, allows for creation of an even greater vacuum in third gland compartment 120, which leads to creation of a better vacuum in interior 121 of compressing compartment 104. A cover storage and dispensing device 122, positioned within compressing compartment 104, retains a stock of disk shaped covers 124 that are retained and dropped one at a time at regulated intervals by tripping means 126. Covers 124 may be in the preferred embodiment 80, 120, 130 or 200 millimeters (mm) in diameter and approximately one (1) mm in thickness. Covers 124, may be injection or compression molded, optical grade polycarbonate or polymethylmethacrylate (PMMA) of low birefringence. The optical material, however, comprising disk covers 124, is first treated for low transmittance of ultraviolet (UV) energy in order that protective cover 124, once mated with optically recordable laminate sheet 102, will not transmit damaging light energy that would decompose the dye polymer comprising the optically active layer of the recordable medium when subjected to an environment of harmful radiation. Ultraviolet (UV) absorbing material of the hydroxyphenyl benzotriazole class, an example of which might be a compound commercially offered under Cyanamid Corporation trademark "Cyasorb," UV 5411, may be spin coated upon covers 124 or may be an additive to the molding compound itself. As laminate sheet 102 flows along at a constant rate in the direction indicated by arrow 100, disk dispenser 122 systematically drops individual covers 124, on adhesive layer 101. Laminate sheet 102, with cover 124, is then compressed for permanent bonding and embossing between a superior and an inferior conveyor belt, 128 and 130, respectively. A superior and an inferior back plate, 140 and 142 respectively, are fixedly positioned behind conveyor belts 128 and 130, respectively, to guide and maintain position of belts 128 and 130, as they compress and emboss covers 124, into adhesive layer 101, and into optically active layer 90, of laminate sheet 102. Adding covers 124 to laminate sheet 102, converts the first surface optically recordable laminate sheet 102, into second surface optically recordable media 144. Second surface optically recordable media 144 exit embossing enclosure 104 through exit gland seals 107 and 109. Although all other gland seals, 106, 108 and 109 are stationary, superior exit gland seal 107, is provided with lifting means 146 to temporarily lift seal 107, as newly formed second surgace optically recordable media 144 exit enclosure 104. When gland seal 107 lifts to allow media 144 to exit enclosure 104, the partial vacuum in enclosure 104 is, of course, temporarily lost. Therefore, a slide valve 148 is provided in the intake side of an exhaust blower 150, such that as gland seal 107 is lifted slightly, slide valve 148 is closed. As gland seal 107 is returned to its seat, slide valve 148 is opened allowing exhaust blower 150 to evacuate enclosure 122 once more. Laminate sheet 102 with newly formed second surface optically recordable media 144 embossed therein now passes through a superior and inferior disk cutting means 152 and 154, respectively. Cutting means 152 and 154 are basically cylindrical punches in the preferred embodiment but may, of course, be any desired geometrical shape to make a variety of uniquely shaped recordable media for particular applications. Superior punch 152 is designed to be the same shape and diameter as covers 124 in the preferred embodiment. Punches 152 and 154 function in such manner that as covers 124 and respective embossed portion of laminate sheet 102 are severed from laminate sheet 102, the embossed laminate portion of the individual second surface optically recordable disk 156 thereby formed extends as a lip around the periphery of respective covers 124, attached thereto. Diameter of laminate 102 should be somewhat 23% greater than, diameter of respective covers 124 Once the second surface recordable medium 144 is cut from laminate sheet 102, it is converted into a second surface recordable disk 156, and is dropped to a finishing conveyor belt 158. Laminate sheet 102, with holes 162, punched therethrough is collected by a tension regulated collection roller 160 for disposal. As illustrated by an overall process enclosure 164, the foregoing process is not confined to a cleanroom environment, but within a dirty global environment by virtue of the higher gas pressure inside enclosure 164, than outside thereof. As described above, laminate sheet 102, comprising substratum glass laminate 13, reflective laminate 15, and reactive laminate 90, as well as covers 124, have been grossly distorted in relative thickness in Figure 1 for purpose of illustration of the overall invention flow process. Figure 2 provides, however, a clearer view of the relative dimension and a proper perspective of the semi-finished and finished product, Figure 2a and Figure 2b, respectively. In Figure 2a, a 130 mm cover 124, having a 15 mm extended laminate 102 lip, is subjected to a cutting, trimming and sealing process, conventional in the art. Faying surface of cover 124 is conventionally sealed with any of various thermoplastic or thermosetting resins, widely varying in flexibility, used in tough chemical-resistive coatings and adhesives, eg polyurethane, to yield the finished 130 mm, second surface optically recordable disk, illustrated in figure 2b.

Claims: A laminating process for manufacture of second surface optically recordable media, characterised in that the process comprises the steps of: pyrolizing a first fluid (38) to form a solid glass base laminate (13); pyrolizing a second fluid (46) to form a solid reflective laminate (15) bonded with said base laminate (13); covering said reflective laminate (15) with an optically active laminate (90) to form a first surface optically recordable laminate sheet (102); covering said optically active laminate (90) with an optically transparent adhesive laminate (101); sequentially applying individual optically transparent, UV limiting covers (124) to said adhesive laminate (101); compressing and embossing each cover (124) into said adhesive laminate (101) and said optically active laminate (90) to form a series of individual second surface optically recordable media (144); and severing each individual second surface optically recordable medium (144) from said series of media to form discrete second surface optically recordable media (156). A laminating process as claimed in claim 1, characterised in that said base laminate (13) is formed by extracting a laminate (13) of amorphous glass (SiO₂) on a flowing surface of molten metal (50) from a fluid flow of a silicate compound (38) upon said surface. A laminating process as claimed in claim 2, characterised in that said silicate compound (38) is tetraethoxy silane. A laminating process as claimed in any of claims 1 to 3, characterised in that said reflective laminate (15) is formed by extracting a laminate (15) of reflective metal from a compound (46) upon said glass laminate (13). A laminating process as claimed in claim 4, characterised in that said organometallic compound (46) is triisobutyl aluminium. A laminating process as claimed in any preceding claim, characterised in that said optically active laminate (90) is formed by spraying a layer of dye polymer (90) upon said reflective laminate (15). A laminating process as claimed in any preceding claim, characterised in that said adhesive laminate (101) is formed by spraying a layer of adhesive upon said reflective laminate (15). A laminating process as claimed in any preceding claim, characterised in that said covers (124) are injection moulded transparent polymers. A laminating process as claimed in claim 8, characterised in that said transparent polymer is polymethylmethacrylate. A laminating process as claimed in claim 8, characterised in that said transparent polymer is polycarbonate. A laminating apparatus for manufacture of second surface optically recordable media characterised in that it comprises: means (10,12,36) for forming a glass base laminate sheet (13); means (10,16,44) coupled to said base laminate forming means (10,12,36) for forming and bonding a reflective laminate (15) to said base laminate sheet (13); means (88) coupled to said reflective laminate forming means (10,16,44) for forming and bonding an optically active laminate (90) to said reflective laminate sheet (15) to form a first surface optically recordable laminate sheet (102); means (104) coupled to said optically active laminate forming means (88) for sequentially embossing optically transparent ultraviolet (UV) limiting covers (124) of defined geometric dimensions on said first surface optically recordable laminate sheet (102) for forming a plurality of second surface optically recordable media (144); and means (152,154) coupled to said cover embossing means (104) for individually severing and sealing each second surface optically recordable medium (144) and for forming discrete second surface optically recordable media (156). A laminating apparatus as claimed in claim 11, characterised in that said base laminate forming means (10, 12,36) comprises a container (51) holding a flowing body of molten metal (50) and having means (12,36) for dispensing a fluid flow of silicon and oxygen containing compound (38) on a surface of said molten metal (50), and for pyrolizing said compound to extract an amorphous glass laminate (13). A laminating apparatus as claimed in claim 12, characterised in that said container (51) further incorporates means (16,44) for dispensing a fluid flow of reflective metal containing compound (46) on said glass laminate (13) and for pyrolizing said compound (46) to extract a layer of metal to form said reflective laminate (15). A laminating apparatus as claimed in any of claims 11 to 13, characterised in that said optically active laminate forming means (88) comprises spraying means for dispensing a dye polymer (90). A laminating apparatus as claimed in any of claims 11 to 14, characterised in that said cover embossing means (104) comprises cover stacking, dispensing and compressing means (122,128,130). A laminating apparatus as claimed in any of claims 11 to 15, characterised in that said severing means (152,154) comprises a punch press. A laminated second surface optical recording medium characterised in that it comprises: a glass base laminate (13); an aluminium reflective laminate (15) bonded to said base laminate (13); a dye polymer optically active laminate (90) bonded to said reflective laminate (15); and an optically transparent, UV limiting cover (124) bonded to said active laminate (90). An optical recording medium as claimed in claim 17, characterised in that said cover (124) is an injection moulded, polymethyl methacrylate disk treated with certain UV limiting additives.

Inventors: GREGG DAVID PAUL, KEESTER KENNETH L, GREGG, DAVID PAUL, KEESTER, KENNETH L.
Applicants: DEL MAR AVIONICS
Application year: 1991
Main classification: G11B7
IPC codes: G11B7, C03B19, C03B18, C03C17