Patent Publication Number: US-6214412-B1

Title: System and method for distributing a resin disposed between a top substrate and a bottom substrate

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is related to the following applications, all of which are filed on the same date that this application is filed, all of which are assigned to the assignee of this application, and all of which are incorporated by reference in their entirety: 
     System and Method for Maintaining Concentricity of a Combination of a Top and Bottom Substrate During the Assembly of a Bonded Storage Disk (U.S. patent application Ser. No. 09/081,115, now U.S. Pat. No. 6,098,272); 
     System and Method for Curing a Resin Disposed Between a Top and Bottom Substrate with Thermal Management (U.S. patent application Ser. No. 09/081,154); 
     System and Method for Thermally Manipulating a Combination of a Top and Bottom Substrate Before a Curing Operation (U.S. patent application Ser. No. 09/081,153, now U.S. Pat. No. 6,103,039); 
     System and Method for Forming Bonded Storage Disks with Low Power Light Assembly U.S. patent application Ser. No. 09/081,536); 
     System and Method for Dispensing a Resin Between Substrates of a Bonded Storage Disk (U.S. patent application Ser. No. 09/081,116, now U.S. Pat. No. 6,106,657); and 
     Improved System and Method for Curing a Resin in a Bonded Storage Disk(U.S. patent application Ser. No. 09/081,117). 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to bonded storage disks and, more particularly, to improved methods of and systems for forming bonded storage disk, such as digital versatile disks (“DVDs”). 
     2. Discussion of Related Art 
     Two popular forms of storage media are compact disks (“CDs”) and digital versatile disks (“DVDs”). Each is a form of a bonded storage disk. A bonded storage disk has two or more substrates held together by a cured bonding agent. At least one of the substrates is formed to have “pits,” the distribution of which is representative of the information to be stored on the disk. These pits are metallized so that when they are “hit” by an optical signal they will reflect a signal indicative of the pit and thus the information. 
     Because of their ability to store vast amounts of information, DVDs have been well received in the market. To date, there are four specified DVD formats: DVD5, DVD9, DVD10, and DVD18. DVD5 is a single-sided, single-layered format (see FIG.  1 C); DVD9 is a single-sided, dual layered form (see FIG.  1 E); DVD10 is a dual-sided, single-layered format (see FIG.  1 D); and DVD18 is a dual-sided, dual-layered format (see FIG.  1 F). “Single-sided” means that the disk is intended to be read from one side only. “Dual-sided” means that the disk may be read from either side, with each side storing information. “Single-layered” means that for a given side there is one “layer” of information only. In this regard, a layer of information would mean a distribution of metallized pits  4 , which when hit with a light source  9  will reflect an information-carrying optical signal. “Dual-layered” means that for a given side there are two layers  4  of information. The specifications are provided in the DVD Book, v. 1.0, by the DVD Forum, which is hereby incorporated by reference in its entirety. The Figures are not to scale. For example, in actuality the substrate  6  is about 0.6 mm thick; for DVD9 the bonding layer  8  is about 50 microns thick ±15 microns, ±10 microns within a DVD, and ±4 microns within a revolution; and the metallization layer  4  is on the order of tens of nanometers.) 
     The formats specify several, but not all, characteristics of a disk. For example, referring to FIGS. 1A-F, which show a plan view of a DVD and a cross-section view of DVD5, DVD9, DVD10, and DVD18 formats, the formats specify the inner diameter of the center hole, the outer diameter of the DVD, the handling area, the inner mirror band, the data area, and the outer mirror band. They also specify the shape and location of a stacking ring, the pit size, the reflectivity of the metal layers and the type of the metal, and for some formats the thickness and optical characteristics of the bonding agent used to form bond layer  8  . In addition, the specifications list acceptable tolerances of certain “bulk parameters,” such as “radial tilt” and “tangential tilt.” The specifications also specify the thickness of the bonding layer and the acceptable amounts of bubbles and contaminants. 
     On the other hand, some aspects are undefined. For example, commercially-available substrate molding machines produce substrates having machine-specific moat locations and shapes. In the art, for example, there are known 22 mm moat geometries and 34 mm moat geometries. In addition, though the reflectivity of the metal layers is specified (sometimes by minimums, other times by minimums and maximums) the actual amount of metallization is not. 
     Typical DVD players include an optical reading mechanism for transmitting an optical signal to a surface of the DVD and for reading a reflected signal. Typically, this mechanism will read a bottom surface of the DVD, as perceived by an end-user and a DVD player. For two-sided formats, the DVD needs to be flipped to read the other side of the DVD. For dual-layer formats, the player adjusts the focus of the optical signal to read a given layer of the two layers of a given side. One orientation is used to illuminate a semi-reflective layer (which would be nearest to the read mechanism) and another orientation is used to illuminate a reflective layer (which would be farthest from the read mechanism). When reading the reflective layer, the optical signal passes through the semi-reflective layer and the bond layer on its way to and from the reflective layer, thus making the bond layer an optical component. 
     To date, manufacturing DVDs has been problematic, especially for dual-layer formats and especially for achieving desirable yields. In part this is the result of the extremely tight manufacturing tolerances specified by the formats and required by the market. In other part this is due to the complexities introduced with the dual-layer arrangements having the bonding layer be an optical component of a DVD. 
     Known systems are operating at undesirably low yields. Moreover, due to the difficulty in manufacturing these disks, many if not all DVD manufacturing systems operate as batch processes. These are undesirable because they require partially completed disks to be stored and staged before a subsequent manufacturing step is performed, thus increasing the cost and complexity of manufacturing. 
     Consequently, there is a need in the art for a system and method that can manufacture DVDs, including dual-layered disks, at high yields. There is also a need in the art for an in-line system that can manufacture DVDs, including dual-layer format DVDs, at acceptable yields. 
     SUMMARY 
     Under a preferred embodiment, a system and method distribute a resin disposed between a top substrate and a bottom substrate. Each substrate has a center hole, and the top and bottom substrates and the resin define an interior region. A top substrate assembly forms a seal over the center hole of the top substrate and creates a vacuum at the interior region. A bottom substrate assembly receives the top and bottom substrates with the resin disposed in-between. A spinning assembly causes the top and bottom substrates to spin according to a predetermined spin profile. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     In the drawings, 
     FIGS. 1A-F show the geometries of DVDs according to known DVD formats; 
     FIG. 2 is a plan view of an exemplary system; 
     FIGS. 3A-F show an exemplary conveyor; 
     FIGS. 4A-I show an exemplary metallization station; 
     FIGS. 5A-B show an exemplary dispense station; 
     FIG. 6 shows an exemplary substrate flipper; 
     FIGS. 7A-E show an exemplary dispense robot; 
     FIGS. 8A-B shows an exemplary plate of a top station; 
     FIGS. 9A-K show an exemplary bottom station; 
     FIGS. 10A-B show an exemplary rotary union; 
     FIGS. 11A-D show an exemplary top substrate bowing device; 
     FIGS. 12A-C show an exemplary dispense machine; 
     FIGS. 13A-B show an exemplary spin station robot; 
     FIGS. 14A-E show an exemplary spin assembly; 
     FIGS. 15A-H show an exemplary cure table assembly; 
     FIGS. 16A-D show an exemplary pre-cooling device; 
     FIGS. 17A-D show an exemplary lamp assembly; and 
     FIGS. 18 show an exemplary post-cooling device. 
    
    
     DETAILED DESCRIPTION 
     Preferred embodiments of the invention provide an in-line manufacturing system that attains high yields for bonded storage disks even for dual-layer formats. The system and method include novel resin dispensing, resin spinning, resin curing, and thermal management of the disks and the system. They also include novel aspects in the handling of substrates. 
     In this description, unless otherwise noted, reference to a top or a bottom substrate refers to a manufacturing perspective in which a top substrate is positioned above a bottom substrate during assembly of a DVD. This reference is the same as that of a DVD player&#39;s perspective except for DVD9 format in which case the top substrate from the manufacturing perspective will be the bottom substrate from the DVD player&#39;s perspective. 
     1. OVERALL SYSTEM 
     FIG. 2 is a plan view of an in-line manufacturing system  5  according to a preferred embodiment of the invention, shown working in conjunction with commercially-available molding machines  10 ,  15  and in-feed handling system  20  . The preferred system is capable of making, under programmatic control, DVDs according to the DVD5, DVD9, and DVD10 formats. 
     Each exemplary mold station provides 0.6 mm disk substrates  6  . One machine produces a top substrate for an eventual DVD and the other produces a bottom substrate. Each substrate has a distribution of “pits” representative of the information stored by the eventually-formed DVD. As explained above, the top substrate for DVD5, has no information layer. 
     The substrates  6  are received by in-feed station  20  , which may perform some initial handling and processing steps (e.g., ionization), and which transfers the substrates on to conveyor  25 . 
     The conveyor  25  carries the substrates  6  in a sequence of neighboring top and bottom substrates to metallizer station  30  , which forms a reflective or semi-reflective metallization layer on one side of a substrate  6  and which transfers metallized substrates back on to the conveyor  25 . All substrates  6  are metallized except for DVD5, format in which case every bottom substrate is metallized. 
     The conveyor  25  then carries the substrates  6  with the metallization face-up to dispense station  35 . The dispense station  35  includes mechanisms for arranging two consecutive substrates  6  (i.e., a top and bottom substrate) into alignment, with metallized surfaces facing each other in a bowed relationship to receive a UV-curable bonding agent (“resin”) in fluid state between the two aligned substrates. The mechanisms form a ring-like capillary bridge of resin between the top and bottom substrates. A resulting combination  7  of substrates and bonding agent (“combination”) is transferred back to conveyor  25 . 
     The conveyor  25  then carries the combination  7  to spin station  40 . This portion of conveyor  25  will be populated with combinations  7  at every other conveyor index. The spin station  40  and dispense station  35  are separated to allow capillary forces sufficient time to cause a desirable distribution of the resin extending to, but not beyond, the moats of the substrates. The spin station  40  spins the combination to distribute the resin more evenly and to better fill the space between the two substrates. 
     The spun combination  7  is then transferred to cure station  45 . Cure station  45  subjects the combination to a thermally-managed UV cure process to cure the bonding agent and bond together the two substrates of a combination  7  to form a DVD. 
     The DVD is then transferred to finishing station  50 , which performs quality assurance testing and transfers the cured DVD to an appropriate rack of acceptable DVDs or rejected DVDs. 
     The various stations are managed, monitored, and controlled by control station  55 . As will be explained below in context, control consists of the proper sequencing of a variety of pneumatical and electrical actuation in conjunction with the proper sequencing of vacuum and activation of valves and pumps. To keep the figures uncluttered, plumbing lines for resin, vacuum, and electrical signals are omitted, as are other conventional mechanisms such as pumps, tanks, and the like. 
     The discussion below is often described in relation to advancing a substrate  6  or combination  7  by “index” position. In this regard, unless otherwise noted, one index position corresponds to a unit of time. This unit of time in turn will depend on the type of DVD being manufactured, as will be explained below. Thus, distances measured in index positions correlate to time. Because the control of the system is effectively event driven, the index time may fluctuate and may involve some jitter. 
     The various stations and conveyor are enclosed and include air-cleaning mechanisms to attain a class  100  clean-room rating. Unless otherwise noted references to vacuum means about 22 inches of water. 
     2. MOLDING STATIONS 
     The system  5  is designed to work with automated injection molding stations  10 ,  15  to provide molded substrates  6 . Exemplary molding stations include the Discjet 600 from Netstal and the SD30 from Sumitomo. Though the DVD specification calls for a finished inner diameter of 15 mm, the system  5  preferably operates with substrates having inner diameters of between 15.04 mm and 15.08 mm to facilitate the handling of substrates. 
     3. IN-FEED STATION 
     An exemplary in-feed station  20  is the FLT U3000 available from First Light Technology, Inc., with software control to ensure that top-bottom pairs of substrates are presented to the conveyor  25 . Conveyor index  21  receives a top substrate and index  22  receives a bottom substrate for DVD5, and DVD10 formats (stacking ring, if any, projecting down); for DVD9 this top-bottom positioning is reversed. Both substrates are placed stacking ring down, moat side up. 
     4. CONVEYOR 
     Referring to FIG. 2, under a preferred embodiment, there are 14 index positions between in-feed station  20  (index position  22  ) and metallization station  30  thus corresponding to a time delay of approximately 32 seconds. During this time, the cooling fans are activated to cool the substrates  6  from approximately 250 ° F. to approximately 80° F. There are 10 index positions between the dispense station  35  (index position  37  ) and the spin station  40  thus corresponding to a time delay of approximately 23 seconds. Each index is separated from a neighboring index by about 3 inches. 
     The structure of the conveyor  25  is shown better in FIGS. 3A-E. Conveyor  25  includes a drivable, programmatically-controllable track  300  having “index” positions defined by spring-loaded, substrate-centering conveyor arbors  302  that project upward through a center of a conveyor nest  304  on which substrates or combinations may rest. The conveyor uses conventional driving and cooling technology and enclosures, such as that used in the U3000 family of systems from First Light, Inc, but has improved arbors  302  and nests  304 . The conveyor  25  includes a stand (not shown) to align conveyor nests  304  with the various stations to which and from which substrates  6  or combinations  7  are transferred, as described below. 
     Conveyor nest  304  is shown more particularly in FIGS. 3B-C, in perspective and cross-section views. The nest  304  is preferably made of ultra high molecular weight (“UHMW”) plastic but could be made of any other material that is suitably smooth and that has a similar wear character. FIG. 3C particularly shows the production dimensions of a preferred nest  304 . The sizes of the dimensions measured in inches are shown in Table 1, below. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 1.69 
                 K 
                 0.03 
                 U 
                 45° 
               
               
                 B 
                 1.25 
                 L 
                 0.149 
                 V 
                 0.04 × 45° 
               
               
                 C 
                 1.02 
                 M 
                 30° 
                 W 
                 1.062 
               
               
                 D 
                 0.868 
                 N 
                 0.640 
                 X 
                 1.023 
               
               
                 E 
                 0.808 
                 O 
                 0.734 
                 Y 
                 0.309 
               
               
                 F 
                 0.04 × 45° 
                 P 
                 0.886 
                 Z 
                 0.637 
               
               
                 G 
                 0.125 
                 Q 
                 1.002 
                 AA 
                 15° 
               
               
                 H 
                 0.063 
                 R 
                 1.25 
                 BB 
                 45° 
               
               
                 I 
                 0.062 
                 S 
                 1.75 
                 CC 
                  .010 RAD. 
               
               
                 J 
                 0.792 
                 T 
                 2.00 
                 DD 
                 15° 
               
               
                   
               
            
           
         
       
     
     Though some aspects of nest  304  are the result of legacy issues concerning the conventional driving mechanisms, other aspects of the shape are novel. An upper surface  306  has an outside diameter wide enough to support the handling area of a substrate  6  and has a hole  308  through which a conveyor arbor  302  (see FIGS. 3D-E) is positioned. More specifically, the internal bore of the hole  308  has a diameter, length, and beveled shape  309  chosen to mate with a preferred conveyor arbor  302 , so that the arbor  302  may be biased upwardly through the hole, but stopped by bevel  309  so that arbor  302  centers itself. The hole  308  also allows the arbor  302  to be depressed downward through the hole  308  below the surface  306 . This allowable movement in conjunction with the spring-loaded nature and shape of the arbor  302  forms part of a concentricity constraint for eventually formed combinations  7 . The other part of the concentricity constraint is formed by pick heads of handling robots, discussed below. 
     Conveyor arbor  302  is shown more particularly in FIGS. 3E-G, in perspective, cross-section, and plan views. The arbor  302  is preferably made of hardened and polished tool steel that is electro-less nickel plated. FIG. 3E particularly shows the production dimensions of a preferred arbor  302 . The sizes of the dimensions measured in inches are shown in Table 2, below. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 2 
               
               
                   
               
               
                 dimen- 
                   
                   
                   
                   
                   
               
               
                 sion 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 EE 
                 0.730 
                 JJ 
                 0.22 
                 OO 
                 0.806 
               
               
                 FF 
                 0.587 
                 KK 
                 0.302 
                 PP 
                 30° 
               
               
                 GG 
                 0.474 
                 LL 
                 0.419 
                 QQ 
                 0.004 RAD. 
               
               
                 HH 
                 0.150 RAD. 
                 MM 
                 0.03 × 45° 
               
               
                 II 
                 0.060 
                 NN 
                 0.40 
               
               
                   
               
            
           
         
       
     
     The arbor  302  is shaped to fit into upper portion  307  of nest  304 , yet be constrained from entirely passing through the hole  308 . Angled portion  316  mates with beveled portion  309  of nest  304 , so that the arbor may center itself when projecting upward. The arbor  302  is also shaped to allow its downward movement through the bore of hole  308 . Arbor  302  includes an inner recess  314  to receive a stainless steel biasing spring (not shown) to allow the arbor  302  to move vertically in response to the application and removal of force. The other end of the spring rests against a plate (not shown) carried by conveyor  25 . A preferred spring has a diameter of 0.375 inches, a length of 1.75 inches and a wire diameter of 0.035 inches. When upwardly biased by the spring, the arbor  302  projects above the upper surface  306  of the conveyor nest  304  by about 0.25 inches. In response to the application of downward force, the arbor can be pushed below surface  306  of nest  304 . This allowable movement forms part of a concentricity constraint for eventually formed combinations  7 . A rounded edge  310  of an upwardly projecting portion  312  of the arbor facilitates the handling of the substrates to transfer them on or off the arbor  302 . This is so because the handling robot only needs to center the i.d. hole of a substrate on the approximately 0.47 inch diameter of the upper portion of the arbor  302 , and gravity in conjunction with the low friction surface will cause the substrate to nest around the approximately 0.587 diameter of a lower portion of the upwardly projecting portion  312 . Hole  318  is used to receive mounting hardware (not shown). cl 5. METALLIZATION STATION 
     A preferred metallization station  30  (see FIG. 2) includes a dual cathode sputtering device  402  (see FIG. 4A) and a two-arm metallizer robot  400  (see FIGS.  4 B-I). The sputtering device  402  and robot  400  are mounted on stands (not shown) to place them in alignment with the conveyor  25  (see FIG.  2 ), as described below. 
     The metallization station  30  is responsible for receiving substrates  6  pit-side up and producing metallized substrates with metallization face up. The metallization covers the pits within a predetermined range of reflectivity to produce an information layer. 
     a. Operation 
     In operation, pick heads  406  and  408  are actuated downward to simultaneously vacuum-grab a metallized substrate from opening  404  and a substrate  6  from conveyor  25  at index position  31  (see FIG.  2 ). During the same index interval that the substrates are grabbed, i.e., without advancement of the conveyor  25 , the pick heads are actuated upward to lift the grabbed substrates, rotate 180° about axis  410 , and lower and release a substrate  6  to device opening  404  and a metallized substrate to the conveyor  25  at index  31 . 
     The substrate grabbed from index  6  is subsequently sputtered by the sputtering device  402 , under programmatic control, to metallize a top surface of a received substrate with one of either a reflective or semi-reflective metal. The substrate grabbed from device  402  and released on the conveyor  25  is carried to dispense station  35 . 
     For DVD5, format, every bottom substrate on the conveyor  25  is sputtered with aluminum and every top substrates is unsputtered. Under a preferred embodiment, the top substrates are not grabbed by the metallizer robot and instead immediately advance to the dispense station. This causes a certain off-set between the pairs of substrates that were initially presented to the conveyor  25 , but the sequence of top-bottom substrates is maintained. In another embodiment, the top substrate is presented to the sputtering device but is not metallized. For DVD9 format, every top substrate is sputtered with aluminum, for example, and every bottom substrate is sputtered with gold, for example. For DVD10 format, every substrate is sputtered with aluminum. 
     b. Sputtering Device 
     A preferred dual-cathode sputtering device  402  is described in U.S. Pat. No. 5,709,785, which is hereby incorporated by reference in its entirety. For the sake of brevity that description is not repeated here. The sputtering device  402  is capable of receiving a substrate  6  once every index interval and providing a metallized substrate once every index interval. There is a four index interval delay between the time when a substrate  6  is presented to the sputtering device  402  and when it emerges. The sputtering device  402  may be controlled to sputter a given substrate with one of the two cathode metals, e.g., aluminum or gold. In this fashion, the substrates may be sputtered with a reflective or semi-reflective material to form one of the information layers specified in a DVD format. 
     Under a preferred embodiment, the sputtering device is controlled to provide between 60-70% reflectivity for the reflective surface for DVD5; about 24% reflectivity for the semi-reflective surface and60-70% reflectivity for the reflective surface for DVD9; and for about60-70% reflectivity for DVD10. Like other process parameters the amount of reflectivity may be adjusted by the user. Moreover it has been discovered by the inventors that the distribution of metal layer  4  is not even; the sides of the pits have substantially less metal than the tops. 
     c. Metallizer Robot 
     Under a preferred embodiment, the metallizer robot  400  rotates 180° about axis  410  under programmatic control of rotary servo  412 . The pick heads  406  and  408  are mounted to pistons  405  which are programmatically controlled to move downward and upward. Each pick head  406  and  408  includes a load-lock assembly  414  to mate with an opening  404  of the sputtering device  402  to create a suitable vacuum seal. 
     More specifically, the servo  412  (part no. CP DR-5030B available from Compumotor) is mounted on a plate  416  which holds end stops  418  to prevent over-rotation and limit switches  420  to further facilitate in the prevention of over-rotation. Plate  416  is mounted to adapter  422  which is used to mount the robot  400  on a stand (not shown). Sheath  422  is used to hold plumbing (not shown). 
     An upper portion  413  of robot  400  is mounted to servo  412  with mounting hardware  411  and includes a cap  423  and equal length and radial arms  424  and  425  to which are mounted pneumatically-controllable pistons  405 . Aluminum load-lock assemblies  414  mount to pistons  405  (part no. CDQ2KWB32-UIA970655 available from SMC) and include a gasket  415  (part no. 2-356B70 available from National) mounted in recess  434  on the polished underside of lip  432  to help seal the assembly  414  with sputtering device opening  404  when so positioned. With particular reference to FIGS. 4E-G, an inner diameter ring  426  (“i.d. ring”) is compression fit into annular chamber  436  on the underside of load-lock assembly  414  and is in fluid communication with vacuum port  429  by a 0.113 inch diameter gland  438  in housing portion  428 . A preferred embodiment uses an i.d. ring  426  available from First Light, Inc. as part no. 10108. By application of vacuum to port  429  the ring  426  may be caused to vacuum grab a substrate  6  within a handling region of the substrate  6 . Vacuum port  430  is used to create a vacuum within opening  404  of the sputtering device, before a substrate is presented into an inner chamber (not shown) of device  400 . 
     FIGS. 4E-G particularly show the production dimensions of a preferred load lock assembly  414 . The sizes of the dimensions measured in inches are shown in Table 3, below. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 3 
               
               
                   
               
               
                 dimen- 
                   
                 dimen- 
                   
                   
                   
               
               
                 sion 
                 size 
                 sion 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 6.00 
                 Q 
                 0.28 
                 GG 
                 0.998 
               
               
                 B 
                 4.75 
                 R 
                 0.085 
                 HH 
                 5.35 
               
               
                 C 
                 3.38 
                 S 
                 0.2 
                 II 
                 0.13 
               
               
                 D 
                 1.25 
                 T 
                 0.25 
                 JJ 
                 0.72 
               
               
                 E 
                 0.906 
                 U 
                 0.721 
                 KK 
                 1.036 
               
               
                 F 
                 0.453 
                 V 
                  .005 RAD. 
                 LL 
                 0.269 
               
               
                 G 
                 0.6305 
                 W 
                 0.173 
                 MM 
                  .03125 RAD 
               
               
                 H 
                 0.199 
                 X 
                 0.055 
                 NN 
                 0.015 RAD. 
               
               
                 I 
                  .005/.010 
                 Y 
                 0.625 
                 OO 
                 24° 
               
               
                 J 
                  .06 × 45° 
                 Z 
                 0.665 
                 PP 
                 0.173 
               
               
                 K 
                 45° 
                 AA 
                 0.366 
                 QQ 
                 0.18 
               
               
                 L 
                 0.188 
                 BB 
                 0.625 
                 RR 
                 0.17 
               
               
                 M 
                 0.250 
                 CC 
                 0.689 
                 SS 
                 0.75 
               
               
                 N 
                 0.385 
                 DD 
                 0.753 
                 TT 
                 0.438 
               
               
                 O 
                 0.766 
                 EE 
                 0.82 
                 UU 
                 0.12 
               
               
                 P 
                 2.134 
                 FF 
                 0.94 
                 VV 
                 0.19 
               
               
                   
               
            
           
         
       
     
     The structure of i.d. ring  426  is shown in FIGS. 4H-I in perspective and cross-section views. Ring  426  preferably has a durometer rating of  55 . The ring  426  is defined by angled lip  446 , projecting up and radially outward, and angled lip  448 , projecting up and radially inward. An annular region  450  is defined in-between and at a base of the lips. Twelve equally-distributed holes  442  of about 0.06 inch diameter extend through region  450 . FIG. 4I particularly shows the production dimension of a preferred ring  426 , and table 4 shows the sizes of these dimensions measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 4 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 WW 
                 1.065 
                 AAA 
                 0.725 
                 EEE 
                 0.75 
               
               
                 XX 
                 1.025 
                 BBB 
                 0.685 
                 FFF 
                 1.0 
               
               
                 YY 
                 0.939 
                 CCC 
                 0.177 
                 GGG 
                 0.049 
               
               
                 ZZ 
                 0.811 
                 DDD 
                 0.115 
               
               
                   
               
            
           
         
       
     
     6. DISPENSE STATION 
     A portion of a preferred dispense station  35  is shown in plan view in FIG.  5 A. Dispense station  35  includes a dispense robot  502 , and two dispense machines  504  and  506 , each having a top station  510 , a bottom station  508 , a resin dispenser  514 , and a top substrate bow device  512  (see FIG.  11 A). FIG. 5B shows a dispense machine, e.g.,  504 , shown in side elevation view. Not shown in these Figures, but shown in plan view in FIG. 2, is a robot substrate flipper  600  (see FIG. 6) at index  33 . The dispense machines, flipper, and robot are mounted in alignment so that substrates may be removed from conveyor  25  at indexes  36  and  37  and so that substrates may be returned to index  36 , as explained below. 
     The dispense station  35  is responsible for receiving a top and a bottom substrate  6 , moat-side up (and consequently metallization, if any, face-up), from conveyor  25  and producing a combination  7  of substrates in which a top substrate&#39;s and a bottom substrate&#39;s moat side face each other and in which a bubble-free capillary bridge of resin is disposed as a ring-like pattern between the substrates. As will be explained below, this distribution of resin should distribute itself further throughout a region between the substrates as a consequence of capillary forces, and the consequent distribution should extend radially inward to the moat and should be substantially bubble-free. 
     a. Operation 
     In operation, a robot flipper  500  (see FIG. 6) of dispense station  35  lifts every top substrate off a conveyor nest at index  33 , rotates the substrate 180° so the top substrate is now moat-side down, and lowers the substrate back on to the same conveyor nest. 
     While one top substrate is being flipped, two neighboring substrates  6  are at index positions  36  (bottom substrate) and  37  (top substrate). 
     A dispense robot  502  vacuum grabs the two substrates at indexes  36  and  37  and moves them to an open dispense machine, i.e., one which is not currently in the process of forming a combination  7 . The top substrate is moved to a top station  510  (see particularly FIG. 5B) of a given, open dispense machine, e.g.,  504 , and the bottom substrate is moved to a bottom station  508  of the open machine. 
     A top substrate bow device  512  (see FIG. 11A) of that machine then grabs and lifts the top substrate from the top station  510  and moves it into vertical alignment with the bottom substrate at the bottom station. The top substrate bow device  512  and bottom station  508 , under programmatic control, cause the two substrates to form a bowed relationship according to a preferred bow profile and to rotate while maintaining this profile. The top substrate is bowed concave up, and the bottom substrate is bowed concave down. 
     A resin dispenser  514  of the dispense machine is programmatically controlled to move to a preferred position relative to the bow profile and to dispense a resin in the bowed opening to form a ring-like capillary bridge between the substrates. The substrates are then released at a controlled rate from the bow device  512  and bottom station  508  under programmatic control. 
     Prior to and while the above is occurring the other dispense machine, e.g.,  506 , has been in the process of doing the same to a different pair of top and bottom substrates and has finished forming a combination  7 . During the same index interval that the substrates are removed from indexes  36  and  37  and provided to one dispense machine, the robot  502  moves a combination  7  from the bottom station  508  of the other machine and moves into index  36 . This process is repeated to use the two dispense machines  504  and  506  in interleaved fashion. 
     b. Robot Flipper 
     The structure of robot flipper  600  at index  33  (see FIG. 2) is shown in FIG. 6 in perspective view. Flipper  600  includes two identical outer diameter, arcuate gripping arms  614  held by rotary grip  617  so that the arms form a partial circle. Each arm includes grooved fingers  616  having a lengthwise groove. The arms  614  and fingers  616  are shaped to grab an edge of a substrate when the arms are moved inward as shown by arrow  618 , and to release the edge when the arms are moved outward as shown by arrow  620 . The rotary grip  617  (part no. MRHQ16S-180S-F9VL-F9PL available from SMC) has linear actuation of the arms along arrows  618  and  620  and rotary actuation about axis  622  which is parallel to a longitudinal direction of each arm, as defined by arm members  624 . A pneumatically-controllable actuator  626  (part no. MGQL20-100-Z73 available from SMC) is mounted on stand  628  and holds rotary grip  617  so that when the actuator is in a lowered state the grooves of fingers  616  are in substantial horizontal alignment with and radially outward of a top substrate at index  33  and so that when the actuator is in a raised state there is substantial vertical clearance to rotate the arms  614  about axis  622  180°. In this fashion, the arms  614  may be actuated inward as shown by arrow  618  to grab a substrate at index  33 , to raise it, and to flip it, and they may be actuated outward as shown by arrow  620  to release a flipped substrate back on to a conveyor nest at index  33 . 
     c. Dispense Robot 
     The structure of dispense robot  502  is shown in FIGS. 7A-E in perspective exploded and cross section views. Dispense robot  502  includes a dual grabber assembly  730  that, under programmatic control, may be rotated about axis  731  by rotary servo  732  to place the grabber assembly in three states: a first state vertically aligns grabber assembly  730  above indexes  36  and  37  (as shown in FIG.  5 A); a second state vertically aligns grabber assembly  730  above a top station  510  and bottom station  508  of a first dispense machine  504 ; and a third state vertically aligns grabber assembly  730  above a top station  510  and bottom station of a second dispense machine  506 . In any of the three states, the grabber assembly  730 , under pneumatic control, may be lowered as shown by arrow  733  to grab substrates from the conveyor  25 , to release the substrates to a top and bottom station of one of the two dispense machines, or to grab a combination  7  from a bottom station  508  of one of the two dispense machines. Likewise, the assembly  730  may be raised to lift substrates from the conveyor  25 , to rotate the assembly  730  out of position after the release of the substrates to a top and bottom station of one of the two dispense machines, or to lift a grabbed combination  7  from one of the two dispense machines. 
     The servo  732  (part no. CP DR-5030B available from Compumotor) is mounted to plate  738  through a collar  734 . The plate holds end stops  736  and limit switches to help protect against over-rotation of the servo  732 . The plate  738  is mounted to stand assembly  750  which holds the servo  732  so that the grabber assembly  730  is above conveyor  25 . 
     Grabber assembly  730  includes a grabber mount  752 , which is mounted to strain relief  742 , and which holds pneumatically-controllable vertical actuator  754  (part no. MXS16-30-AT-A93L available from SMC). Actuator  754  is in fluid communication with vacuum ports  756  and is mounted to vertical plate  758 , which in turn is connected to assembly arm  760 . The arm includes two fixed grabber arbors  764  that project downward. On the hidden underside of arm  760  are two annular chambers in which i.d. rings  766  are compression fit. The i.d. rings are identical to i.d. rings  426 , described above, in relation to FIGS. 4H-I. The annular chambers are each in fluid communication via a vacuum gland (not shown) in arm  760  which is in communication with vacuum ports  762 . A plate  768  is attached to arm  760  in the position corresponding to a bottom substrate. Plate  768  is preferably made of UHMW plastic shaped to have a slightly raised, downward-projecting lip (not shown) of about 0.03 inches at an outer diameter region. The lip provides support to a top surface of a bottom substrate so that a bottom station  508  may later vacuum grab an outer diameter region of the substrate, as will be explained below. A sheath  744  protects plumbing (not shown) from friction. Electrical strain relief  746  is used to hold wiring and cap  748  covers the components. 
     The structure of a fixed arbor  764  of grabber assembly  730  is shown in FIGS. 7D-E in perspective and cross-section views. The arbor  764  is preferably made of hardened and polished tool steel that is electro-less nickel plated. FIG. 7E particularly shows the production specifications of a preferred arbor  764 , and Table 5 shows the sizes of those dimensions measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 5 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 A 
                 0.687 
                 E 
                 0.410 
                 I 
                 0.26 
               
               
                 B 
                 0.250 
                 F 
                 0.474 
                 J 
                  .03 × 45° 
               
               
                 C 
                 0.311 
                 G 
                 0.5925 
               
               
                 D 
                 0.576 
                 H 
                 0.08 
               
               
                   
               
            
           
         
       
     
     An angled edge  766  of a downward projecting portion  768  of the arbor facilitates the handling of the substrates to place them on or off the arbor  764 . The arbor  764  is shaped to fit into the i.d. hole of a substrate and to engage the conveyor arbor  302  (see FIG. 3E) to depress arbor  302  into nest  304 . Arbor hole  770  receives mounting hardware (not shown). The combination of arbors  302  and  764  forms a concentricity constraint that keeps the top and bottom substrates of a combination  7  aligned at the i.d. hole when the robot  502  transfers combinations  7  to conveyor  25 . More specifically, the 15.0 mm center hole is maintained to within +0.1 mm and −0.0 mm. 
     d. Top Station 
     The structure of a top station  510  of a dispense machine is shown in FIG.  5 B and FIGS. 8A-B. FIG. 5B is an elevation view of a dispense machine and illustrates that the top station  510  includes a stand  570  on which is mounted a plate  572  which is in horizontal alignment with bottom station  508 . FIG. 8A shows the plate  572  in perspective view, and FIG. 8B shows the plate  572  in cross-section view and particularly shows the production dimensions of a preferred plate  572 . The sizes of the dimensions measured in inches are shown in Table 6. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 6 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 4.725 
                 G 
                 45° 
                 M 
                 2.5 
               
               
                 B 
                 4.675 
                 H 
                 0.03 
                 N 
                 0.183 
               
               
                 C 
                 1.25 
                 I 
                 0.625 
                 O 
                 1.0 
               
               
                 D 
                 0.724 
                 J 
                 R.25 
                 P 
                  .03 × 45° 
               
               
                 E 
                 0.64 
                 K 
                 30° 
               
               
                 F 
                 45° 
                 L 
                 0.886 
               
               
                   
               
            
           
         
       
     
     The stand  570  holds the plate in horizontal alignment with a top surface of bottom station  508 . Preferably the plate  572  is made of UHMW plastic. Plate  572  includes a hole  876  sufficiently sized to receive the arbor  764  of the grabber assembly  730 . It also includes an upwardly-projecting lip  874  in alignment with upper surface portion  878 . Lip  874  provides support to a bottom surface (in this instance the moat-side, and metal-side, if any) of the top substrate so that a top substrate bow device  512  may vacuum grab an outer diameter region of the substrate, as will be explained below. Upper surface portion  878  provides support to a bottom surface (in this instance the moat-side, and metal-side, if any) of the top substrate so that a top substrate bow device  512  may vacuum grab a handling area region of the substrate, as will be explained below. Holes  880  receive hardware (not shown) for mounting plate  572  to stand  570 . 
     e. Bottom Station 
     The structure of a bottom station  508  of a dispense machine is shown in FIG. 9A-K in perspective and exploded views, along with FIGS. 10A-B which show a perspective and exploded view of a rotary union similar to one used by the bottom station. The bottom station  508  includes an i.d. region grabber assembly  902  and an o.d. region grabber assembly  904  in outward radial relation to assembly  902 . The i.d. region grabber assembly  902  and the o.d. region grabber assembly  904  may be caused to vacuum grab a bottom substrate presented to it by robot grabber assembly  730  of robot  502 . The i.d. region grabber assembly  902  vacuum grabs a substrate at a handling area region of a bottom surface of a bottom substrate, and the o.d. region grabber assembly  904  vacuum grabs a substrate at an outer diameter region of a bottom surface of a bottom substrate. The vacuum grabbing elements, described below, are activated when the vacuum grabber assembly  730  of robot  502  is in a state that places plate  768  over the bottom station  508 . In this fashion, the downward projecting lip of plate  768  provides support to the o.d. region and facilitates the vacuum grabbing of the o.d. region by a compressible o.d. vacuum ring  906  of 45 durometer. In a raised state, assembly  902  and  904  are in horizontal alignment, and in a lowered state, activated under programmatic control, the o.d. region grabber assembly  904  may be actuated vertically in the direction of axis arrow  910  to bow the bottom substrate concave down. 
     More specifically, the i.d. region grabber assembly  902  includes an i.d. ring  908  that is compression fit into an annular chamber of i.d. centering device  916  and around which i.d. chuck  914  is mounted. Ring  908  is identical to the i.d. ring  766  of robot  502  and ring  426  of robot  400 . The i.d. centering device  916  includes an opening  951  through which arbor  764  of grabber assembly  730  may fit and includes a vacuum gland  952  (see FIG. 9G) in fluid communication with the annular chamber  950  holding ring  908  and with a vacuum supply at the top of rod-mount  918 . Rod-mount  918  is attached to servo  920  passes through plate  922  and abuts plate  924 , which has holes in fluid communication with hub ports at a top surface of rotary union  926 . Rotary union  926  receives vacuum at its sleeve ports (see FIGS. 10A-B) and provides the vacuum at hub ports at the top surface. Thus, vacuum applied to rotary union  926  is in fluid communication with i.d. ring  908 . Rod-mount  918  is attached to rotary servo  920  (part no. DM1004C available from Compumotor) so that the i.d. region assembly may be caused to rotate under programmatic control. (The above arrangement is the one used for 34 mm geometries. For 22 mm geometries the i.d. ring  908  is removed and replaced with a stepped metal insert  970  (see FIG.  9 H)). 
     The o.d. region grabber assembly  904  includes o.d. ring  906  that is compression fit into annular chamber  932  of o.d. chuck  928 . The annular chamber is in fluid communication with a vacuum gland (not shown) and o.d. vacuum port (not shown) on chuck  928 . Thus vacuum applied to the o.d. vacuum port is in fluid communication with o.d. ring  906 . The o.d. chuck  928  include recess  929  into which i.d. centering device  916  fits when the bottom station is in the raised state. The o.d. chuck  928  is mounted to plate  934  which in turn is mounted to pneumatically-controllable bow actuator  936  (part no. Q97-4098 available from Compact Air) which is mounted to the plate portion  919  of rod-mount  918 . Actuator  936  includes a fixed inner portion  939  and a movable outer portion  939  that is attached to plate  934  and thus may be used to cause the o.d. chuck  928  to move along the longitudinal direction of rod-mount  918 . Because the o.d. assembly is also attached to servo  920  via rod-mount  918  it moves in unison with the inner assembly  902 . 
     The bottom station  508  further includes mounting hardware  942  to align the components as described above, a sheath  596  to cover the components, and a drain bowl  938  to catch resin residue, if any, from a dispensing operation. 
     The structure of i.d. chuck  914  is shown in FIGS. 9D-E in perspective and cross-section views. A preferred chuck is made of UHMW plastic and is sized to fit around a projected portion  948  on top of a horizontal portion  949  of centering device  950 . FIG. 9E shows the production dimensions of a preferred chuck and table 7 shows the sizes of these dimensions measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 7 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 2.0 
                 D 
                 1.118 
                 G 
                 .07 × 45° 
               
               
                 B 
                 1.522 
                 E 
                 0.03 
                 H 
                 .05 RAD. 
               
               
                 C 
                 1.207 
                 F 
                 0.25 
               
               
                   
               
            
           
         
       
     
     The structure of i.d. centering device  916  is shown in FIGS. 9F-G in perspective and cross-section views. FIG. 9G shows the production dimensions and table 8 shows the sizes of those dimensions measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 8 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 0.995 
                 G 
                  .01 × 45° 
                 M 
                  .01 RAD. 
               
               
                 B 
                 0.935 
                 H 
                 0.060 
                 N 
                 0.213 
               
               
                 C 
                 0.815 
                 I 
                 0.25 
                 O 
                 0.939 
               
               
                 D 
                 0.752 
                 J 
                 0.22 
                 P 
                 0.2 
               
               
                 E 
                 0.595 
                 K 
                 0.28 
               
               
                 F 
                 0.35 
                 L 
                 0.348 
               
               
                   
               
            
           
         
       
     
     The centering device includes annular chamber  950  in to which ring  908  is compression fit. Chamber  950  is in fluid communication with gland  952 . Opening  951  is sized to receive arbor  764  (see FIG.  7 D). 
     The structure of stepped metal insert  970  is shown in FIGS. 9H-I in plan and cross-section views. The metal insert is shaped to fit into the annular chamber used to hold the i.d. ring for the 34 mm geometry arrangement. It includes an initial elevation  762  of approximately 0.062 inches and a total height  764 . For the top bow device insert this height is 0.172 inches and for the bottom station this is 0.162 inches. The outer diameter  766  is approximately 0.998 inches and the inner diameter  768  is about 0.752 inches. 
     The structure of o.d. ring  906  is shown in FIGS. 9J-K in perspective and cross-section views. Ring  906  preferably has a durometer rating of  45 . The ring  906  is defined by angled lip  960 , projecting up and radially outward, and angled lip  962 , projecting up and radially inward. An annular region  964  is defined in-between and at a base of the lips. Thirty-six equally-distributed holes  966  of about 0.08 inch diameter extend through region  964 . FIG. 9K particularly shows the production dimensions of a preferred ring, and the sizes of the dimensions are shown in Table 9 measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 9 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 4.53 
                 E 
                 4.07 
                 I 
                 0.136 
               
               
                 B 
                 4.43 
                 F 
                 3.97 
                 J 
                 4.09 
               
               
                 C 
                 4.333 
                 G 
                 0.55 
                 K 
                 4.41 
               
               
                 D 
                 4.167 
                 H 
                 0.25 
               
               
                   
               
            
           
         
       
     
     The structure of an exemplary rotary union  1000  is shown in FIGS. 10A-B in perspective, exploded, and cross-section views. Rotary union  926  is identical to the union  1000  shown except that the hub of union  926  is sized differently to mate with plate  924  than the hub  1018  of union  1000 . Specifically the hub of union  926  is 3 inches in diameter and 0.5 inches thick. Union  1000  includes a sleeve  1001 , which receives body  1002  over which o-rings  1003  are placed at o-ring grooves  1024 . At each end of sleeve  1001  and around body  1002  a bearing  1030  is placed, and optionally a washer  1032 . Snap ring  1034  facilitates holding the assembly together. 
     In operation sleeve  1001  is stationary and body  1002  may rotate about the longitudinal axis of body  1002 . A given port of sleeve ports  1006  is in fluid communication with a hub port pair  1014  of hub  1018 . Thus, the rotary union  1000  allows the provision of fluid, such as air under pressure or vacuum, to rotating hub  1018 . Depending on the application, the fluid may emerge from a port on side  1016  of hub  1018  (as shown) or through a port  1019  on top surface  1020  (in this case shown plugged). 
     Sleeve  1001  has an outer diameter of about 1.75 inches and an inner bore of about 0.874 inches. Four sleeve ports  1006  extend through a surface of the sleeve  1001  and are positioned to be in alignment, when the union is constructed, with port grooves  1008  of body  1002 . Stepped opening  1005  includes an outer opening of about 1.125 inches diameter and about 0.126 inches deep to receive a top bearing  1030  and an inner opening of about 1.042 inches diameter and about 0.04 inches deep to form a gap to accommodate an inner race bearing  1030 . Identical openings exist at the opposite hidden end. 
     The body  1002  has an outer diameter at groove portion  1038  of about 0.870 inches and a series of port grooves  1008  and o-ring grooves  10024 . Each port groove  1008  has a corresponding o-ring groove on either side. Each groove has a depth of about 0.180 inches. The o-ring grooves  1024  are machined at the inner diameter to have a curved surface, concave radially outward. Each port groove  1008  has an opening  1010  (two openings being hidden from view) that extends radially inward and that is in fluid communication with a gland (not shown) about 0.166 inches in diameter that extends to hub  1018 . The hub  1018  includes four port pairs  1014 , each consisting of a hub port on a side edge  1016  of hub  1018  and a hub port on a top surface  1020  of hub  1018 . Two neighboring o-ring grooves are separated by a groove wall  1026  of about 0.108 inches wide, and groove walls  1028  are about 0.07 inches wide and separate an o-ring groove  1024  and a vacuum port groove  1008 . The o-ring grooves  1024  are about 0.111 inches wide, and the port grooves  1008  are about 0.12 inches wide. The hidden surface of hub  1018  extends to a neck  1036  that is about 0.146 inches deep and that has the same outer diameter of groove portion  1038 . Neck  1036  includes a stepped portion (not shown) about 0.970 inches in diameter and about 0.02 inches deep immediately adjacent to hub  1018 . Preferably the o-rings  1003  are well lubricated before fitting them into o-ring grooves  1024 . Snap ring groove  1036  is shaped to receive a snap ring  1034 . 
     f. Top Substrate Bow Device 
     FIGS. 11A-E show top substrate bow device  512  in perspective and exploded views. Top substrate bow device  512  includes frame  1102  having vertical supports  1104  and  1106  and horizontal member  1108 . A horizontal actuator  1110  is carried over horizontal member  1108 , and under pneumatic control it may be moved from a first position, which is in vertical alignment with top station  510 , to a second position, which is in vertical alignment with bottom station  508 . The horizontal actuator  1110  is connected to a vertical actuator  1112  which has substrate bowing assembly  1114  mounted to it. The vertical actuator  1112  is used to raise and lower the bowing assembly  1114  to grab a substrate from the top station  510  when in the first position and to lower the assembly  1312  to close proximity of the bottom substrate on the bottom station  508  when in the second position. The bowing assembly  1114  grabs and bows the top substrate as outlined above when describing the dispense operation. 
     More specifically, the bow assembly  1114  includes a rotary union  1116  identical to the union  1000  described in relation to FIG. 10, coupled to a mount  1118  on one end and attached to actuators  1110  and  1112 . The mount  1118  is coupled to spacer  1120 , which limits the throw of bow actuator  1122  (part no. CQ2KWB25-10D-XG10 available from SMC). Actuator  1122  is attached to housing  1124 , which on its hidden surface includes features for receiving compliance spring  1126 , housing  1128 , and o.d. ring  1134 . Actuator  1122 , under programmatic control, may be caused to lift the housing  1124  and thus the outer diameter region of the top substrate. Housing  1124  includes an annular chamber (not shown) on its hidden side into which o.d. ring  1134  is compression fit and which is in fluid communication with a vacuum gland (not shown). Vacuum is supplied to the chamber via port  1125 . Spring  1126  is preferably made of music wire and has a diameter of 0.975 inches, a length of 0.88 inches, and a wire diameter of 0.074 inches. Spring  1126  helps dampen the release of the housing  1124 . The dampened release has been found to minimize the existence of bubbles in eventually cured DVDs. The i.d. housing  1128  receives vacuum through opening  1129 , which is supplied by rotary union  1116 , via actuator shaft  1123 . The i.d. housing  1128  includes features on its underside to receive chuck  1130 , i.d. ring  1132  and arbor  1136 . The i.d. ring  1132  is compression fit into an annular chamber (not shown) that is in fluid communication with vacuum supplied by port  1129 . The i.d. ring is identical to those described above. The chuck  1130  is identical to chuck  914  described above (see FIGS.  9 D-E). (The above arrangement is the one used for 34 mm geometries. For 22 mm geometries the i.d. ring  1132  is removed and replaced with a stepped metal insert  970  (see FIG.  9 H)). 
     The structure of arbor  1136  is shown in FIGS. 11C-D in perspective and cross-section views. The arbor  1136  is preferably made of hardened and polished tool steel that is electro-less nickel plated. FIG. 11D particularly shows the production dimensions of a preferred arbor  1136 , and Table 10 shows those dimensions measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 10 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 0.687 
                 E 
                  .15 RAD. 
                 I 
                 0.131 
               
               
                 B 
                 0.250 
                 F 
                 0.410 
                 J 
                  .03 × 45° 
               
               
                 C 
                 0.311 
                 G 
                 0.474 
                 K 
                 0.26 
               
               
                 D 
                 0.576 
                 H 
                 0.5925 
               
               
                   
               
            
           
         
       
     
     Rounded edge  1138  facilitates mating with the i.d. centering device and helps form a concentricity constraint to keep the i.d. holes of the substrates aligned. Hole  1140  receives mounting hardware (not shown) 
     After the top substrate is moved into vertical alignment with the bottom substrate and lowered, the top substrate is bowed 1.5-4 mm up at the outer diameter and the bottom substrate is bowed 0-2 mm down at the outer diameter. 
     g. Resin Dispenser 
     The structure of the resin dispenser  514  is shown in FIGS. 12A-C in perspective and exploded views. Resin dispenser  514  includes a stand  1202  to hold mount  1220  which holds servo  1210  and waste cup  1214 . Servo  1210  (part no. DSRL-25-180-FW available from Festo) is connected to mounting plate  1222  to which is mounted horizontal actuator  1204  (part no. MXS12-50AS-A93L available from SMC). (Servo  1210  may be made to rotate the dispense assembly  1212  counter-clockwise such that needle  1215  is in vertical alignment with waste cup  1214 , for example, during maintenance operations.) Actuator  1204  may be pneumatically controlled, by application of vacuum to vacuum ports  1216  and  1218 , to move along the direction of arrow  1203  and is used to move needle  1215  into a desired position to dispense resin. Actuator  1204  holds micrometer plate  1224  and micrometer controls  1206  and  1208  (part nos. 101-X-M-PL and 101-X-M-PL-LEFT LOCK available from DEL-TRON). Micrometer controls  1206  and  1208  are used to fine tune the orientation of needle  1215 , respectively, horizontally or vertically to a desired position so that the dispensed resin may attain a desired trajectory as explained below. Holder  1226  is mounted to the combination of plate  1224  and controls  1206  and  1208  and holds a pilot-actuated metering dispense valve  1228  (part no. 752VW/SSHEAD available from EFD). Valve  1228  holds a needle collar  1230  (part no. P-340 available from Upchurch Scientific.) and needle  1215  and receives heated, pressurized resin through valve  1232 . 
     The structure of needle  1215  is shown in FIGS. 12C-D. For 34 mm moat geometries, needle  1215  is about 0.75 inches long and has a distal end  1230 , defined by a projection  1232  that is about 0.04 inches long, is 18 gauge stainless steel and that has an inner diameter of about 0.0315 to 0.0345 inches. Projection  1232  is adjacent to transition portion  1234  which is defined by about a 10° radially outward extension until it reaches proximal portion  1236 . Proximal portion  1236  has an inner diameter of about 0.053 inches and is 15 gauge stainless steel. Needle  1215  includes luer lock hub  1238 . 
     For 22 mm moat geometries, the same needle  1215  is used but with the following sizes. Needle  1215  is about 1.5 inches long and has a distal end  1230 , defined by a projection  1232  that is about 0.04 inches long, is 18 gauge stainless steel and that has an inner diameter of about 0.03 to 0.036 inches. Projection  1232  is adjacent to transition portion  1234  which is defined by about a 10° radially outward extension until it reaches proximal portion  1236 . Proximal portion  1236  has an inner diameter of about 0.053 inches and is 15 gauge stainless steel. Needle  1215  includes luer lock hub  1238 . 
     The resin dispenser  514  is controlled to move resin needle  1215  into a desired position. Preferred embodiments have the dispense process parameters adjusted based on the moat geometries. The following parameters are believed to be desirable starting points, but it is expected that end users may desire to adjust these parameters. 
     For 34 mm geometries this position is such that the tip of the needle is pointed radially toward the center point of the DVD and disposed about 19 mm from the outer diameter of the disk. The needle is approximately horizontal with a centerline of the bowed substrates. The needle  1215  projects resin about 5 mm while the bottom substrate is rotated at approximately 30-40 rpm for about  1  revolution (350-370°). The resin viscosity is about 600 cps. At an inner diameter region the substrates are clamped with about a 2 inch diameter with about 0.1 inches rounded interface edge due to the insert chuck. 
     For 22 mm geometries the resin is dispensed tangentially rather than radially. The needle is positioned along a tangent to a radius of the disk between 25-35 mm from the outer diameter. The needle may also be deflected relative to this tangent according to an angle ⊖ D  between 0-30°. The needle is approximately horizontal with a centerline of the bowed substrates. The needle  1215  projects resin while the bottom substrate is rotated at approximately 40-50 rpm for about 1 revolution (355-365°). The resin viscosity is about 400 cps. At an inner diameter region the substrates are clamped with about a 2 inch diameter with about 0.1 inches rounded interface edge due to the insert chuck. The metal insert (which replaces the i.d. rings for the top bow device and the bottom station) provides approximately a 0.03 inch gap at the 2 inch diameter interface. 
     The top substrate rotates in unison as a result of friction forces. The resin is heated to approximately 70-90° F. and about 1-3 ml of resin is dispensed at approximately 20-30 psi (though the psi is viscosity dependent). The above causes the resin to have a desirable arcuate trajectory that just touches the concave up bow of the top substrate. The rotation of the substrates causes the dispensed resin to form a capillary bridge ring in-between the substrates; for the 34 mm geometry this bridge is at approximately 20 mm-24 mm in from the outer diameter; for 22 mm geometries this bridge is at approximately 25 mm-35 mm. The needle  1215  is then retracted outwardly to clear the outer diameter of the substrates. 
     The bottom station and the top station then both begin to un-bow. The un-bow rate is a function of the exhaust settings on the actuators and the bottom station is set to un-bow at a slightly faster rate than the top station. Near the end of the un-bowing of the bottom station the vacuum to the o.d. ring of the bottom station is released. Slightly later the o.d. vacuum of the top bow device is released. The bottom station is then actuated again to release the o.d. vacuum grip. The use of the compliance spring in the top bow device makes the un-bowing of the top station more consistent, effectively acting as a low pass filter. 
     Though a dispense machine  514  may operate with many types of resins, system  5  (see FIG. 2) preferably operates with resin L539-064 (400 c.p.s) available from Quretech. The above arrangement has been found to form suitable capillary bridges on the substrates while achieving a suitably high fluid dispense velocity to minimize needle contamination, yet low enough to avoid fluid turbulence during dispense. 
     7. SPIN STATION 
     A preferred spin station  40  (see FIG. 2) includes spin station robot  1302  (see FIGS. 13A-B) and two identical spin assemblies  1304  (see FIG. 2 for plan view and FIG. 14A for perspective view). The spin assemblies  1304  and robot  1302  are mounted on stands (not shown for robot) to place them in alignment with the conveyor  25  (see FIG.  2 ), as described below. More specifically, robot  1302  is centered between index position  41  and a cure index position  46  in one direction, and between the two spin assemblies  1304  in an orthogonal direction (see FIG.  2 ). 
     The spin station  40  is responsible for receiving combinations  7  at index  41  and producing spun combinations in which a fluid-state cure agent is more evenly distributed in-between the substrates  6  of a combination  7 , extending from an inward location at or very near the moats to the outer diameter of the DVD. 
     a. Operation 
     The preferred spin station  40  is spaced from the dispense station  35  to allow a suitable time delay for capillary forces to attract the resin to the facing moats of combination  7  (see FIG.  1 B). Under a preferred embodiment, there is approximately a 24-28 second delay from the dispense station to the spin station for DVD5, and DVD10, and an approximate 33-39 second delay for DVD9. This is accomplished with a 4.8 second double-index cycle time for DVD5, a 5.2 for DVD9, and a 6.2 for DVD10. Because of the event-based control, the actual times experience some jitter. 
     Robot  1302  is positioned so that robot position  1360  corresponds to conveyor index  41 , robot position  1362  corresponds to a first spin assembly  1304 , robot position  1364  corresponds to cure index position  46 , and robot position  1366  corresponds to a second spin assembly  1304 . 
     In a first state, the robot  1302  simultaneously vacuum grabs a combination  7  from conveyor position  1360  with arm  1306  and a spun combination from a first spin assembly position  1362  with arm  1310 . In a second state, the robot  1302  rotates 90° clockwise about axis  1322  to simultaneously transfer the combination from the conveyor position  1360  to the first spin assembly position  1362  and the spun combination from first spin assembly position  1362  to the cure position  1364 . This transition to the second state correspondingly moves robot arm  1308  to conveyor position  1360  and arm  1312  to the second spin assembly position  1366 . While in the second state, the arm  1306  releases a combination to first spin assembly position  1362  and arm  1310  releases a spun combination to cure position  1364 . At the same time, arm  1308  grabs a combination from conveyor position  1360 , and arm  1312  grabs a spun combination from second assembly position  1366 . In a third state, the robot  1302  rotates 90° counter-clockwise about axis  1322  to simultaneously transfer the combination from the conveyor position  1360  to the second spin assembly position  1366  and the spun combination from the second spin assembly position  1366  to the cure index position  1364 . All of the above occurs under programmatic control and is repeated to interleave the operation of two spin assemblies. 
     Each spin assembly  1304  vacuum grabs the combinations from below by a spin device  1402 . For 34 mm moat geometries, a spin arm  1316  moves into position above the combination to form a vacuum seal above the top surface of the top substrate and to create a vacuum in an interior chamber  1320  of the combination (see FIG.  14 E). (The use of spin arm  1316  is optional for 22 mm geometries.) This vacuum created in the interior chamber is used to hold the resin that has migrated to or very near the moats. The spin device  1402  then spins the combination according to a predetermined spin profile to cause the resin to distribute radially outward and evenly. The vacuum at the interior chamber is chosen to balance the centrifugal forces created from the spin operation. Once spun, the combination is ready to be transferred by robot  1302  to the cure station  45  (index  46  in FIG. 2; robot position  1364  in FIG.  13 A). 
     b. Spin Robot 
     The structure of spin robot  1302  is shown in FIGS. 13A-B in perspective and exploded views. The robot  1302  has four equal-length and equally-spaced arms  1306 ,  1308 ,  1310 , and  1312 , projecting radially outward from axis  1322 . The arms and upper assembly  1328  may be caused to rotate by rotary servo  1314  (part no: DR5030 available from Compumotor) under programmatic control into one of the three states described above. Each arm has a downward projecting piston  1326  (part no: CDQ2WB15-50DCM-A731 available from SMC), which may be actuated vertically under programmatic control as described above. At a distal end of each piston a pick head  1324  is attached. 
     Each pick head  1324  includes a housing  1330 , having an annular chamber (hidden on underside) that is in fluid communication with a vacuum gland (not shown) that is in fluid communication with port  1342  connected to vacuum supply line  1328 . An i.d. ring  1332  identical to those described above is compression fit into the annular chamber. A compliance spring  1336  fits into a recess  1344  on the piston-side of housing  1330  and is held at the other end by retainer  1338  and nut  1340  which threads on to a piston bolt. Spring  1336  is preferably stainless steel, has a diameter of 0.845 inches, a length of 1.5 inches, and a wire diameter of 0.055 inches. A break-away post  1334  fits into an interior chamber  1346  of housing  1330  and screws onto a piston bolt (not shown) to hold the head  1324  on to the piston  1326 . Tapered features on  1334  and matching interior features of  1330  allow lateral/angular compliance when the assembly is caused to over-travel slightly. 
     c. Spin Assembly 
     The structure of spin assembly  1304  is shown in FIGS. 14A-D in perspective and exploded views. Spin assembly  1304  includes stand  1400  on a top surface of which is mounted spin arm  1316  and underneath the top surface of which is mounted spin device  1402 . Robot  1302  transfers combinations through opening  1404  onto a top surface of spin chuck  1406 . The top surface of spin chuck  1406  is in horizontal alignment with conveyor  25 . 
     The structure of the spin device  1402  is shown more particularly in FIG.  14 B. Chuck  1406  is made of aluminum and includes an annular chamber in fluid communication with a vacuum gland (not shown). The vacuum gland, in turn, is in fluid communication with a vacuum port at the center of the chuck  1406  and that is coupled to spindle port  1410  of rotary vacuum supply  1408  which supplies vacuum provided at input  1412 . Thus vacuum applied at input  1412  is in fluid communication with the annular chamber of chuck  1406 . An i.d. ring  1414 , identical to the ones described above except that its durometer rating is  55 , is compression fit into the annular chamber and is used to vacuum grab the bottom surface of a combination at the handling area. 
     The structure of the metal spin chuck  1406  is shown more particularly in FIG.  14 E. The i.d. arbor  1462  has an outer diameter of 0.591 inches +0.0 and −0.001 inches. The curved portion  1462  has a radius of curvature of about R.3745. Analogously to cure chuck arbor  1530  (see FIG.  15 D), arbor  1320  includes three symmetric recesses of about R.25 radius to lessen the surface contact with the i.d. hole of the combination. The chuck includes a raised lip  1464  which starts at about 4.625 inch diameter and ends at about 4.7 inch diameter and has a height of about 0.03 inches. 
     The rotary vacuum supply  1408  includes a housing and also have a bearing and is mounted to rotary servo  1416  (part no. MO-80 available from Mavilor) via adapter plate  1418 . The rotary may be programmatically controlled to implement a preferred spin profile. A preferred embodiment uses a dual acceleration profile that includes an initial acceleration of 50 rpss until a velocity of 1000 rpm ±200 rpm is attained. Then the combination is spun at that velocity for about 8 seconds ±2 seconds and the combination is again spun at an acceleration of about 200 rpss until a velocity of about 2800 rpm ±100 rpm is attained. The combination is spun at that velocity for about 0.5 to 1 second and then the combination is decelerated at a rate of about 200 rpss until the combination is caused to come to a rest. The dual acceleration profile causes a relatively even distribution of resin to result free of bubbles. It has been observed that the preferred spin profile when operating with the above preferred aspects and for 22 mm geometries causes a substantially even bond layer of approximately 45-58 microns ±7-8 microns within a disk, and ±≦3 microns within any radius. 
     The chuck  1406  is contained within spin bowl  1416  which is shaped to catch and drain to a reservoir (not shown) any resin projected as a result of the spinning operation. An o-ring  1417  is positioned between the chuck  1406  and the spin bowl  1416  to provide a seal. Another o-ring  1418  is provided on a top surface of the spin bowl  1416  to provide a seal with the exhaust manifold  1420  mounted on top of o-ring  1418 . Manifold  1420  catches and drains resin mist that may result from the spinning process, and a shield  1422  protects the combination from any projected resin or resin mist that moved upward and this protection may be supplemented with splash back screens, for example, of medium mesh. 
     The structure of spinner arm  1316  is shown more particularly with FIGS. 14C-E. Arm  1316  include a mount assembly  1430  which is connected to a rotary (not shown) to rotate an extension  1432  about axis  1434  under programmatic control to position spin head  1436  over opening  1404  of spin assembly  1304 . The spin head  1436  includes a 0.094 inch diameter vacuum gland (not shown) providing fluid communication to vacuum supply  1438  and a downward-facing center port (not shown) in head  1436 . 
     The head assembly&#39;s  1436  downward-facing port is aligned with an opening  1449  of ring housing  1448 , and is sealed by rotary seal  1456 . Ring housing  1448  is compression fit into a bearing  1454  which in turn is compression fit into a recess (not shown) of head assembly  1436 . Housing  1448  includes a vacuum gland (not shown) that extends from opening  1449  to a downward-facing port in the center of the housing. It also includes a downward-facing annular chamber (not shown) into which an i.d. ring  1452 , identical to those discussed above, is compression fit. The i.d. ring, in this instance, however, is not supplied with vacuum to vacuum grab a substrate or combination; instead, it is used just to form a seal when the head  1436  is actuated downward to engage a top surface of a combination. Vacuum supplied by port  1438  is used to create the vacuum in the interior chamber  1420  of the combination. For 34 mm geometries, about 18-24 inches of mercury of vacuum are provided. 
     The assembly  1430  includes a mount  1431  to attach to the rotary servo (not shown) that rotates extension  1432  into position. Vertical actuator  1440  (part no. MXU6-25-A93L available from SMC) is mounted to mount  1431  to raise and lower the spin arm  1316  in the direction of axis  1442  to engage and disengage a combination through opening  1404  in the spin assembly. 
     8. CURE STATION 
     A preferred cure station  45  (see FIG. 2) includes a cure table assembly  1500  (see FIG.  15 A-H), a thermal management system having a pre-cooling device  1600  (see FIG. 16A-C) and post-cooling devices  1800  (see FIGS.  18 A-B), and a lamp assembly  1700  (see FIGS.  17 A-C). The cure table assembly  1500  is mounted on a stand (not shown) to place a cure table surface  1508  in horizontal alignment with conveyor  25  and spin station  40  (see FIG.  2 ). The pre-cooling device  1600  is vertically aligned with a pre-cooling index  1512  and above surface  1508 . The lamp assembly  1700  is vertically aligned with a curing index  1514  and above surface  1508 , and post-cooling devices  1800  are vertically aligned with post-cool indexes  1516 ,  1518 , and  1520  and below surface  1508 . 
     The cure station  45  is responsible for receiving spun combinations (not shown) at a receiving index (index  46  in FIG. 2; robot position  1360  in FIG.  13 A and FIG. 15A) and producing a cured DVD ready to be tested by finishing station  50  (see FIG.  2 ). 
     a. Operation 
     After a combination is spun by the spin station, the spin robot  1302  transfers it to a free-floating cure chuck  1530  at receiving index  1360  of cure table assembly  1360 . Once there, the combination is double-stepped through the cure table  1502  to perform certain pre-cooling, curing, and post cooling operations. 
     More specifically, a spun combination makes the following path indicated by the arrows through a nine-index, double-step cure table  1502 . The combination is received at  1360  and double-stepped to cure index  1510 . Though two cure indexes are stepped, this occurs in one index interval. 
     Next, the combination is double-stepped to pre-cool index  1512  where a top surface of the spun combination is pre-cooled. In short, the pre-cooling operation is intended to pre-shrunk the top surface as an inverse operation to the thermal expansion that will occur in a subsequent cure operation. 
     The combination is then double-stepped to curing index  1514  where the spun combination is raised by a cure chuck lifting assembly  1560  (see FIGS. 15F-H) into a lamp assembly  1700  (see FIG. 17) and cured with UV light. This curing operation will introduce energy that is absorbed in part by the combination and by cure chuck  1530 . Raising the chuck  1530  to the lamp assembly helps isolate the energy absorption to the chuck  1530 , and helps insulate the table  1502 , which facilitates thermal management. During the curing operation, the cure chuck lifting assembly  1560  vacuum holds the entire combination flat and rotates the combination. This facilitates even curing and reduces warping. 
     The cured combination is then double-stepped in sequence through post-cooling indexes  1516 ,  1518 , and  1520 . At each post-cooling index a post cooling device  1800  (see FIG. 18) is raised into contact with the cure chuck  1530  to help cool the chuck. 
     The combination is then double-stepped to index  1522  where the cured, cooled combination (i.e., the DVD) is removed by the finishing station  50 . 
     Cure index  1524  is an empty station. 
     a. Cure Table Assembly 
     The structure of the cure table assembly  1500  is shown in FIGS. 15A-H in perspective and exploded views. The assembly  1500  includes a nine-index aluminum cure table  1502 , an aluminum cure chuck  1530 , and a cure-chuck lifting assembly  1560 , positioned below cure index  1514 . The table  502  is double-step rotated, i.e., 40° at a time, counter-clockwise by a servo (not shown). The table  502  includes nine beveled openings  1526  shaped to mate with a beveled surface  1532  of cure chuck  1530 . 
     The structure of cure chuck  1530  is shown in FIGS. 15B-C in perspective and cross-section views. The chuck  1530  includes thirteen outer grooves  1534  and two inner grooves  1536 . Each of the grooves is in fluid communication with a vacuum gland  1538  that is in fluid communication with a vacuum port  1540 . Each groove is about 0.040 inches wide. The outermost groove  1542  is about 0.3 inches from the chuck&#39;s edge. The innermost groove  1544  is about 0.383 inches from the centerline of the chuck  1530 . Each groove is separated from a neighboring groove by about 0.120 inches, except that the innermost outer groove  1546  is separated from the outermost inner groove  1548  by about 0.337 inches. (All separations are measured centerline to centerline.) The production dimensions of a preferred chuck  1530  are shown in FIG. 15C, and the sizes of those dimensions are shown in Table 11 measured in inches. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 11 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 0.34 
                 F 
                 0.35 
                 K 
                 0.196 
               
               
                 B 
                 0.3 
                 G 
                 0.165 
                 L 
                 4.276 
               
               
                 C 
                 90° 
                 H 
                 0.09 
                 M 
                 4.940 
               
               
                 D 
                 0.312 
                 I 
                 0.605 
                 N 
                 0.1 
               
               
                 E 
                 5.164 
                 J 
                 60° 
                 O 
                 60° 
               
               
                   
               
            
           
         
       
     
     Projection  1550  is sized to receive a cure chuck arbor  1554  (see FIGS. 15D-E) and recess  1552  is shaped to receive the cure chuck lifting assembly  1560  (see FIGS. 15F-H and the post-cooling devices  1800  (see FIG.  18 ). 
     The structure of cure chuck arbor  1554  is shown in FIGS. 15D-E in perspective and cross-section views. The arbor is preferably made of hardened and polished tool steel that is electro-less nickel plated. The shape of the arbor  1554  forms a concentricity constrain together with the spring-loaded pick head  1324  (FIG. 13B) of the spin robot  1302 . The arbor includes five equally spaced projections  1556  defined by cutaways  1157  having a radius of curvature of R.125. FIG. 15E shows the production dimensions of a preferred chuck arbor  1554 , and the sizes of those dimensions are shown in Table 12 measured in inches. The recessed shape of arbor  1554  lessens the surface area of the arbor that could potentially become contaminated with resin. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 12 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 P 
                 0.211 
                 S 
                 R.206 
                 V 
                 0.1 
               
               
                 Q 
                 .083 
                 T 
                 0.173 
                 W 
                 0.204 
               
               
                 R 
                 .052 
                 U 
                 0.35 × 45° 
                 X 
                 0.313 
               
               
                   
               
            
           
         
       
     
     A two-piece cure pad  1525  (see FIG. 15F) having outer piece  1527  and inner piece  1526  is placed over each chuck  1554  to distribute the vacuum supplied by port  1540  during the curing operation. A preferred pad  1525  is made of 0.0375 inch U.V. rubber (durometer value of 65) with pressure sensitive adhesive. FIG. 15F shows the production dimensions of a preferred pad, and Table 13 shows the size of those dimensions measured in inches (all measurements except Y and EE are radius measures). 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 13 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 Y 
                 5° 
                 FF 
                 2.88 
                 MM 
                 4.56 
               
               
                 Z 
                 1.68 
                 GG 
                 3.12 
                 NN 
                 1.01 
               
               
                 AA 
                 1.92 
                 HH 
                 3.36 
                 OO 
                 0.593 
               
               
                 BB 
                 2.16 
                 II 
                 3.6 
                 PP 
                 0.77 
               
               
                 CC 
                 2.4 
                 JJ 
                 3.84 
                 QQ 
                 4.66 
               
               
                 DD 
                 2.64 
                 KK 
                 4.08 
                 RR 
                 1.28 
               
               
                 EE 
                 2.5° 
                 LL 
                 4.34 
                 SS 
                 1.5 
               
               
                   
               
            
           
         
       
     
     Ring  1528 , unlike all other rings of both pieces  1526  and  1527 , has its holes spaced 5° apart. All other rings, e.g.,  1529 , have their holes spaced 10° apart. Each hole is 0.025 inch diameter. The distribution of vacuum holes has been observed to effectively hold the combination during the curing process while minimizing dimpling and waffling effects while combatting warping forces and providing thermal stability. 
     The structure of cure chuck lifting assembly  1560  is shown in FIGS. 15G-H in perspective and cross-section views. Lifting assembly  1560  is mounted below and in vertical alignment with index  1514  so that lifter head  1566 , under programmatic control, may be raised to engage recess  1552  and vacuum grab chuck  1530  to both hold chuck  1530  and to provide vacuum to port  1540  so that the chuck may hold the combination. Under a preferred embodiment, 850 mbar (max) of vacuum is applied to hold the chuck and the combination. 
     More specifically, head  1566  has a vacuum gland extending through its shaft  1565  that is connected to a vacuum supply (not shown). A top surface of head  1566  includes an annular chamber  1569  for holding an outer diameter o-ring  1570  and an annular chamber  1567  for holding an inner diameter o-ring  1568 . The o-rings are used to help seal vacuum within recess  1552  of chuck  1530  and to assist with any deflection of the chuck resulting from the application of vacuum. The head  1566  is bolted to plate  1572  which is bolted to servo  1562  (part no. M-JS0002FN001 available from NSK). Servo  1562  is attached to mount  1574  having vertical guides  1575  mounted within fixed mount  1576 . The mount  1574  may be raised or lowered within guides  1575 , under programmatic control, by cam  1565  and rotary actuator  1564  (part no. 11912/DSR-32-180-P available from Festo). 
     c. Pre-Cooling Device 
     The structure of the pre-cooling device  1600  is shown in FIGS. 16A-D in perspective and exploded views. Pre-cooling device is mounted above and in vertical alignment with cure index  1512 . The device  1600  is caused to blow turbulent cool air preferably at about 35-60° F. and at about 1-5 cfm onto a combination one double-step before the combination is subjected to the curing process. The pre-cooling will cause a top surface of the top substrate of a combination to have a lower temperature than a bottom substrate and thus cause the combination to shrink accordingly from the shrinkage induced in the top substrate. This shrinkage is designed to roughly match the inverse of the top substrate&#39;s expansion that results from the curing process. In short, the curing process will cause the top substrate to heat and thus expand. Without more, the curing and subsequent cooling would cause the combination to warp concave up. But, with the pre-cooling this effect is reduced by effectively pre-shrinking the combination, before the resin is cured. 
     Pre-cooling device  1600  includes a stand  1602  holding a vortex tube  1604  (part no. 3440 available from ExAir) to generate cool air and cone  1606  to distribute cool air. The cone  1606  and tube  1604  are connected by supply hose  1605 . The cone  1606  contains a baffle  1608  on its underside to move flow distribution away from the center of the disk. The production dimensions of a preferred cone  1606  and baffle  1608  are shown in FIGS. 16B-D, and the sizes of the dimensions are shown in table 14. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 14 
               
               
                   
               
               
                 dimension 
                 size 
                 dimension 
                 size 
                 dimension 
                 size 
               
               
                   
               
             
            
               
                 A 
                 1.403 
                 F 
                 4.724 
                 K 
                 0.25 
               
               
                 B 
                 1.0 
                 G 
                 0.128 
                 L 
                 5.274 
               
               
                 C 
                 0.578 
                 H 
                 0.047 
                 M 
                 0.578 
               
               
                 D 
                 1.5 
                 I 
                 0.094 
               
               
                 E 
                 30° 
                 J 
                 0.578 
               
               
                   
               
            
           
         
       
     
     d. Lamp Assembly 
     The structure of the lamp assembly  1700  is shown in FIGS. 17A-B in perspective and cross-section views. The lamp assembly  1700  is positioned above and in vertical alignment with cure index  1514  so that the lifting assembly  1560  may raise a vacuum-grabbed combination into the assembly  1700 . 
     The assembly  1700  includes a stand  1702  holding a nest  1703  having a first angled surface  1716  for mounting a first UV lamp  1704  and a second angled surface  1714  for mounting a second lamp  1706 . A liquid-cooled tunnel  1708  is positioned above index  1514  and receives the combination to be cured. To filter IR radiation caused by the lamps  1704  and  1706 , a first dichroic filter  1712  is positioned at an angle relative to lamp  1704  and a second dichroic filter  1710  is positioned at an angle relative to lamp  1706   
     The cure lamps  1704  and  1706  are preferably F300 lamps available from Fusion, Inc. with ‘D’ type bulbs. The bulbs from these lamps are normal to the Figure and emit a beam of light toward the combination, which is parallel to the top of tunnel  1708 , toward the outer diameter of the inner mirror band of the combination. The first and second angled surfaces  1716  and  1714  of nest  1703  hold the lamps  1704  and  1706  to have a target distance of 3.125 inches and an angle of incidence of 30°. The lamps hold the bulbs approximately 2.1 inches from the face of the lamp and have elliptical reflectors arranged around the bulbs. 
     Angle  1720  is preferably maximized provided that the above target distance and angle of incidence are substantially maintained. With currently-available lamps  1704  and  1706 , this angle is about 30°. The filters  1710  and  1712  are diachrilic cold reflectors and IR hot reflectors (part no. 526451 available from Fusion). 
     FIG. 17C shows the positioning of the lamps. FIG. 17D shows the light pattern resulting from the superimposed beams, in particular the percentage of light relative to the position on the substrate. As can be seen the light pattern is essentially flat across the entire area of interest. The angled light effectively directs the UV light at the sides of the metallized pits. These metallized pits have been found to have most of their reflective or semi-reflective material on the top of the pits and less material on the sides of the pits. Thus, by directing the light at the desired angle a much larger portion of the emitted UV light is transmitted through the metal into the space between the substrates where it can cure the resin and much less is reflected by the combination&#39;s metallized surface. Thus, UV energy is more efficiently transmitted to the bond resin resulting in less thermal stressing of the combination. Cooler combinations, in turn, reduce warping which otherwise occurs as a result of the thermal gradient between upper and lower substrates as described above. In contrast to conventional techniques which emit UV light normal to the surface of the combination, the preferred arrangement allows for lower intensity UV curing. 
     The tunnel  1708  is formed from cooper cylinder with coiled tubing silver soldered to it. The assembly is painted with black high temperature enamel and carries water at approximately 10-15° C. The tunnel is approximately 4 inches high and helps maintain a stable air temperature within cure station. 
     During the cure operation the combination is rotated by lifting assembly  1560  at an angular velocity of between 200-400 rpm. 
     The combination is subjected to the lamp energy for a predetermined time. Under a preferred embodiment that uses the Quretech resin identified above, the combination is subjected to light for 2.5 seconds for DVD5, disks, 3 seconds for DVD9 disks, and 3.5 seconds for DVD10. 
     The combination is raised and simultaneously rotated through tunnel  1708  so that the UV light emitted from lamps  1704  and  1706  has an effect as if the combination was suddenly flooded with light, rather than gradually exposed to increasing intensity of light. 
     e. Post Cooling Device 
     The structure of the post cooling device  1800  is shown in FIG. 18 in perspective view. A post cooling device is positioned under indexes  1516 ,  1518 , and  1520  to help cool the cure chuck  1530  after it has been heated as a result of the curing operation. 
     More specifically, post cooling device  1800  includes a liquid cooled chuck  1802  having a top plate  1804  mounted and sealed to a housing. Housing receives water at about 10-15° C. from supply lines  1810 . The housing is mounted to vertical actuator  1812  (part no. CXSL15-10 available from SMC) which is attached to mount  1822 . Actuator  1812  under programmatic control may be caused to raised the chuck  1802  into contact with recess  1552  of cure chuck  1530 . 
     Post-cooling facilitates testing in that any scanning operations or the like are performed on disks at approximately room temperature. 
     9. OTHER EMBODIMENTS 
     The above embodiment focused on a preferred low power curing system. Many of the combinations of processing parameters may yield desirable results. 
     The above embodiment focused on one exemplary in-line system. The actual arrangement was influenced by the economics of various stations. For example, the metallizer and molding machines are the most expensive stations and thus the remainder of the construction was largely influenced with a goal of keeping those stations busy. Thus higher or lower degrees of interleaving of other stations, e.g., dispense, are clearly within the ambit of the invention. 
     Moreover, there is a wide degree of flexibility and choice in the various handling mechanisms and robots, though certain aspects thereof are believed to be particularly novel, e.g., concentricity constraint. 
     In an exemplary embodiment, the top substrates of DVD5, format are not presented to the metallizer. Under alternative embodiments, the top substrate is presented to the metallizer but the metallizer is not energized to sputter that substrate. 
     One described embodiment pre-shrinks the top substrate in anticipation of its subsequent expansion during the curing operation. Alternatively, the bottom substrate could have been pre-expanded. 
     The described embodiments focused on a two lamp arrangement but the above teachings also apply to other arrangements including those with more or less lamps and different types of lamps. 
     Likewise, even for the two lamp arrangements various sub-arrangements may be desirable. As described above, the lamps may be arranged so that the superimposed pattern is desirable, though the pattern from a single one of the lamps may be less than desirable. Besides the above embodiment, for example, arrangements in which the lamps have a target distance of 4.1 inches are believed to be desirable, among others. Likewise, variations in the angles may be desirable. 
     The process parameters may be adjusted by the user. These parameters include, but are not limited to, the amount of metallization, the positioning of the metallization, the positioning of the resin needle, the angular velocity of the disks while resin is dispensed, the pressure and temperature of resin, the index interval, and the spin profile. Users may adjust these parameters to respond to observations made on the manufactured DVDs. For example, if the resin layer is thicker than desired one approach would be to increase the angular velocity of the combination during resin dispensing. Likewise the parameters may be adjusted based on process materials, such as the resin type used. 
     The preferred embodiment was described with reference to event-based control but other mechanisms could be substituted. 
     Certain conventions were carried throughout the description portion, e.g., top and bottom substrate, the meaning of “vacuum” etc. It should be understood that those conventions were intended to aid clarity of the detailed description and not to be definitions of those terms limiting the scope of the following claims. 
     Having described an exemplary embodiment, it should be apparent to persons of ordinary skill in the art that changes may be made to the embodiment described without departing from the spirit and scope of the invention.