CN1467718A - 光盘及其制造方法 - Google Patents

光盘及其制造方法 Download PDF

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CN1467718A
CN1467718A CNA031385249A CN03138524A CN1467718A CN 1467718 A CN1467718 A CN 1467718A CN A031385249 A CNA031385249 A CN A031385249A CN 03138524 A CN03138524 A CN 03138524A CN 1467718 A CN1467718 A CN 1467718A
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substrate
external coating
curable resin
ultraviolet curable
tack coat
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CN1201313C (zh
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�˱�Т
高泽孝次
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Toshiba Corp
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Toshiba Corp
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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Abstract

一种光盘，具有基片(1)上的记录层(2)、粘结在该记录层上的由紫外线固化树脂制成的粘结层(3)、粘结在粘结层上的透明层(4)、以及在透明薄膜上形成的由紫外线固化树脂制成的外涂层(5)，它还具有混合层(6)，该层是通过粘结层和外涂层的紫外线固化树脂混合而形成的。因此，粘结层、外涂层和混合层是一体固化的，所以该基片完全由透明的紫外线固化树脂所覆盖，从而可以以足够的强度保护透光层A。

Description

光盘及其制造方法
技术领域
本发明涉及一种光盘，其中从设在基片上的透光层侧照射激光束以记录和复制信息，本发明尤其涉及一种其中设有用于透光层的保护层的光盘以及一种制造该光盘的制造方法。
背景技术
近年来，光记录介质例如光盘日益普及，例如在用于DVD设备的DVD(数字化多用盘)或者DVD-R中，从基片的背面照射激光束以记录和复制信息。但是在新一代DVD设备等中，按照如下方式记录和复制信息，即在基片的表面上形成一记录层，在该记录层上设有一透光层，并且从该光盘的正面照射激光束。
也就是说，在该光盘中，记录层(一种沉积的层，它直接涉及到例如反射膜、介质材料膜和相变膜的相变类型光盘的记录、擦除和复制特征)形成在其中通过注塑方法形成有导槽的透明塑料基片或通过所谓的2P方法制成的基片上，并且透光层(由紫外线固化树脂制成的粘结膜和透明薄膜)形成在记录层上。通常记录层是通过溅射方法形成的，而透光层是以这样一种方式形成的，即利用旋涂方法在基片和记录层上涂覆树脂液体然后固化，并且使该透明薄膜固定。
但是当将透光层形成至基片的最外侧端时，操作的外力会产生问题例如易于分开。其原因如下。即，透光层必须比记录层大以便保护记录层。透光层具有大约为100μm的厚度，并且需要用具有优异平整性的透明薄膜覆盖，因为必须减小双折射，并且必须使厚度在基片整个外表面上均匀。但是，在采用了上述结构的情况中，由于构成透光层的透明薄膜的最外侧端部分厚达100μm，所以很容易在基片最外侧端部分产生台阶。在一些情况中，该透明薄膜在操作期间由于被卡住(hitch)而分离，从而记录层可能会破裂。
参考在日本专利申请KOKAI公开5-81701中公开的光盘制造方法，该申请公开了形成用于保护给定层的外涂层的技术，该文献中披露了在金属反射层上形成保护层和树脂层以便保护金属反射层不会从基片上分开。在光盘中，从基片的背面向记录层照射激光束，以记录和复制信息。
但是由于该参考文献所示的光盘不是新一代光盘，所以该激光束是从基片的背面向记录层照射的。因此，与本发明一个实施方案的光盘不同的是，没有披露包括透明薄膜和粘结层在内的透光层被粘结在基片上并且以足够的强度受到保护，同时保持了透明性。因此存在着以下问题：其中通过从光盘的正面照射激光束来进行记录和复制的光盘的透光层不能被粘结并且以足够的强度受到保护。
也就是说，根据现有的制造方法，在其中通过从光盘的正面照射激光束来进行记录和复制、同时保持透明性的光盘中，包括透明薄膜和粘结层的透光层不能被粘结在基片上并以足够的强度受到保护。
发明内容
本发明的一个实施方案提供一种光盘，其中位于基片上的包括有透明薄膜和粘结层的透光层以足够的强度受到保护，本发明还提供一种用于新一代光盘的制造方法，在该光盘中记录和复制是通过从光盘的正面照射激光束来进行的。
为了解决上述问题，本发明涉及这样一种光盘，它包括其中记录有提供在基片上的信息的记录层、由紫外线固化树脂制成的用来将至少记录层粘结在基片上的粘结层、设置成粘结在粘结层上的透明薄膜层、由紫外线固化树脂制成的并且形成在透明薄膜层上的外涂层、以及通过粘结层和外涂层的紫外线固化树脂的混合物而紧邻外涂层形成的混合层。
在本发明一个实施方案的光盘中，记录层设置在基片上并且用粘结层固定以便通过从光盘的正面照射激光束来进行记录和复制，然后粘结透明薄膜以便保护该记录层。另外，透明薄膜由与粘结层同样的紫外线固化树脂形成的外涂层保护，从而具有足够的强度。此时，在粘结层中使用的紫外线固化树脂和在外涂层中使用的紫外线固化树脂在粘结层的截面部分和在基片的接触部分处混合，并且形成了覆盖粘结层的截面部分以及基片的接触部分的混合层。因此，具有透明性的紫外线固化树脂完全覆盖了基片，从而可以以足够的强度保护包括透明薄膜和粘结层的透光层以及位于透光层下面的记录层。
这样，通过混合并且一体地形成粘结层和外涂层，从而在制造过程中只要用一次紫外照射就可以使紫外线固化树脂固化，因此简化了制造过程。
附图的简要说明
图1为根据本发明一个实施方案的光盘的第一实施方案的纵向剖视图；
图2为根据本发明一个实施方案的光盘的第二实施方案的纵向剖视图；
图3为根据本发明一个实施方案的光盘的第三实施方案的纵向剖视图；
图4为根据本发明一个实施方案的光盘的第四实施方案的纵向剖视图；
图5为根据本发明一个实施方案的光盘的第五实施方案的顶视图；
图6为根据本发明一个实施方案的光盘的第六实施方案的顶视图；
图7为根据本发明一个实施方案的光盘的第五实施方案的剖视图；
图8为根据本发明一个实施方案的光盘的第六实施方案的剖视图；
图9为第一光盘的纵向剖视图，该光盘是根据本发明一个实施方案的光盘的对比实施例；
图10为第二光盘的纵向剖视图，该光盘是根据本发明一个实施方案的光盘的对比实施例；
图11为第三光盘的纵向剖视图，该光盘是根据本发明一个实施方案的光盘的对比实施例；
图12为一流程图，说明了用来制造根据本发明一个实施方案的光盘的过程。
优选实施方案的详细说明
下面将参照这些附图对一种光盘和一种制造光盘的方法进行详细说明。
[第一实施方案]
第一实施方案提供了这样一种光盘，其中包括有粘结层和小于设在该光盘上的基片的透明薄膜的透光层是通过是由紫外线固化树脂制成的粘结层、外涂层和这些材料的混合层粘结并且保护的。图1为根据本发明一个实施方案的光盘的纵向剖视图，而图9为作为根据本发明一个实施方案的光盘的对比实施例的第一光盘的纵向剖视图。
图9显示出这样一种光盘，其中没有设置根据本发明一个实施方案的外涂层和混合层。在图9中所示的光盘中，基片1的外周边粘结表面7和透明薄膜4容易由于基片1和透明薄膜4的变形、线性膨胀或平面收缩而分离。尤其是这种现象容易在高温和高湿度的环境中出现。这是因为基片1和保护层的材料在热变形性能、线性膨胀系数、热缩性能和吸湿性能(吸水率)方面不同。另外，由于从基片1的最外面的周边到记录区域的距离非常短，大约为1mm，一旦在基片1和记录层3之间存在有粘性稍微不好的部分，则该分离会从该部分传播到记录区域，从而破坏记录层2。
当厚度大约为100μm的透明薄膜4只是通过紫外线固化树脂粘结时，在透明薄膜4的最外面的周边部分中很容易产生台阶。另一方面，当在冲切中在透明薄膜4的外直径边缘表面处产生该薄膜等的折痕等时，粘结就容易不完整。这容易导致空气侵入和透明薄膜4的不良粘结。在这种情况中，由于离记录区域的距离较短，因此不能充分对记录层2进行保护，所以该记录层2更容易分离。当由分离引起的回复显著时，该记录层2不会完全被透光层的透明薄膜4所覆盖，并且有时记录层的一部分暴露在空气中，从而该记录层2的耐久性就不行了。
如在图1中所示一样，在根据本发明第一实施方案的光盘中，在透明薄膜4上形成有一层由紫外线固化树脂制成的外涂层5，并且包括粘结层3和外涂层5的混合层6至少设置在粘结层3的截面表面和基片的侧面中。在这里，采用直径比基片1小的透明薄膜4。
如上所述，由于粘结层3和外涂层5都是紫外线固化树脂，所以该混合层6很容易形成在粘结层3和外涂层5的混合部分中。粘结层3、外涂层5和混合层6通过连续紫外线固化树脂而形成为一体，从而基片1和记录层3的粘结表面“G”被混合层6覆盖，并且记录层2和包括粘结层3和透明薄膜4在内的透光层“A”相互粘结，并且以极高的强度受到保护。这已经得到了在下面所述的耐久性测试充分证实。
(制造根据本发明一个实施方案的光盘的方法)
下面将采用流程图对制造根据本发明一个实施方案的光盘的方法进行详细说明。图12的流程图说明了用来制造根据本发明一个实施方案的光盘的过程。
在根据本发明一个实施方案的光盘中，在图12中所示的流程图中首先制备出透明基片1(由聚碳酸酯树脂制成，直径为120mm并且厚度为1.1mm)，它具有1mm宽0.5mm深且直径为22mm的凹陷和导槽(S1)。然后，用磁控管溅射设备将记录层2形成在基片1上。顺序形成由AlMo合金制成的金属反射膜、由ZnS和SiO2制成的介电保护膜、由GeSbTe合金制成的相变材料膜以及上述介电保护膜，作为记录层2。相变材料膜的组分如此构成，从而该组分在405nm的波长下具有良好的记录、擦除和反复记录/复制特性，并且扩大了结晶相和非晶相之间的反射率差异。对于金属反射膜而言，该组分形成为具有改善相变光盘的反射率的功能。
这里，采用直径为36mm的掩模作为内半径掩模，并且采用直径为119mm的掩模作为外半径掩模。这是因为记录区域形成至内外半径附近以便尽可能不会减小记录容量。
然后，将紫外线固化型粘结剂1涂布到基片1上，在该基片上已经采用旋涂方法形成有记录层2(S2)。这里，举例来说将粘结剂11的粘度设定为Na。将前面制备好的用于透光的环形透明薄膜4(外径为119mm，内径为16mm且厚度为0.1mm，而且比基片1梢小)安放在所涂布的紫外线固化型粘结剂11上(S3)。紧接着，通过使旋涂机的主轴转动以排干多余的粘结剂，从而在记录层2和透明薄膜4之间形成粘结层3(S4)。这里，粘结层3的粘结剂11具有溢出部分12。
随后，采用旋涂方法将紫外线固化型外涂层试剂13涂布在由粘结层3固定住的透明薄膜4上(S5)。这里，举例来说，将外涂层试剂13的粘度设定为粘度Nb，它比前面粘结剂11的粘度更低，但是该外涂层试剂13也可以具有相同的粘度Na。通过使旋涂机的主轴转动以排干多余的粘结剂，从而在由粘结层3固定住的透明薄膜4上形成外涂层5。因为用于透光的透明薄膜4的粘结剂还没有固化，所以这些粘结剂在外周边部分处在相同的非固化状态中与外涂层试剂混合，这就导致形成混合层6(S6)。然后通过从外涂层5的侧面照射紫外线，从而使粘结层和外涂层侧5固化以形成相变光盘(S7)。通过控制转盘的旋转圈数，从而在固化之后使粘结层和外涂层5形成2-5μm的厚度。
因此，在该光盘的外周边部分中，其中粘结剂和外涂层试剂混合在一起的层形成为环绕基片1的侧面。因此，利用一次紫外线照射使粘结层3、外涂层5和混合层6结合在一起并且固化，从而基片1就牢牢地被已经固化的紫外线固化树脂保护着。因此，包括透明层4和粘结层3在内的透光层“A”以极高的强度受到保护，这可以通过在下面所述的耐久性测试进行充分验证。
举例来说，优选的是，光盘的厚度为1.0mm-1.2mm，并且透明膜片的厚度为50μm-110μm。
[第二实施方案]
第二实施方案提供了这样一种光盘，其中包括粘结层和其直径与形成在该光盘上的基片相同的透明薄膜在内的透光层是通过是由紫外线固化树脂制成的粘结层、外涂层和这些材料的混合层粘结和保护的。图2为根据本发明一个实施方案的光盘的第二实施方案的纵向剖视图。
在图2中，按照与第一实施方案相同的方法制备出该相变光盘，除了采用其外径与基片1同样为120mm的用于透光的透明薄膜4。因此，在大多数光盘中，其中粘结剂和外涂层试剂在外周边部分中混合在一起的混合层形成为环绕至基片1的侧面。
因此，与第一实施方案类似，粘结层3、外涂层5和混合层6形成为一体，从而包括透明层4和粘结层3在内的透光层“A”以及记录层2可以以极高的强度被粘结和保护。
[第三实施方案]
第三实施方案提供了这样一种光盘，其中透光层是通过是由紫外线固化树脂制成的粘结层、外涂层以及这些材料的混合层粘合并保护，所述透光层包括粘结层以及直径比光盘上的基片直径大的透明薄膜。图3是表示根据本发明的一个实施方案的光盘第三实施方案纵向视图。
在图3中，按照与第一实施方案同样的方式制造相变光盘，但是用于透光的透明薄膜4具有比基片1直径大的为121mm的较大外直径。结果，在大多数光盘中，形成了在外周部分混合有粘合剂以及外涂层剂的混合层，从而环绕着(go round)基片1的侧面。在基片1的侧面部分，用于透光的透明薄膜4的突出部分嵌入在混合有粘合剂以及外涂层剂的混合层中。
相应的，与第一实施方案类似，粘结层3、外涂层5以及混合层6形成为一体，从而可以以极高的强度粘合和保护包括透明薄膜4和粘结层3的透光层“A”以及记录层2。
[第四实施方案]
第四实施方案提供了这样一种光盘，其中与第一实施方案中的光盘相同，包括粘结层以及直径小于光盘上的基片直径的透明薄膜的透光层是通过是由紫外线固化树脂制成的粘结层、外涂层和这些材料的混合层粘合和保护的，但是不同的是用无尘擦拭器擦除基片的侧面，以去除混合层。图4为根据本发明一个实施方案的光盘的第四实施方案的纵向剖视图。
在图4中，按照与第一实施方案同样的方式制造相变光盘，但是在形成外涂层剂层之后，用无尘擦拭器擦除基片1的侧面。在光盘外周部分的侧面中，将粘合剂和外涂层剂擦除干净，因此其形状没有例如台阶的变化。
因此，与第一实施方案相类似，粘结层3、外涂层5以及混合层6形成为一体，从而可以以极高的强度粘合和保护包括透明薄膜4和粘结层3的透光层“A”以及记录层2。
[第五实施方案]
第五实施方案提供这样一种光盘，其中按照如下方式避免了因为光盘驱动器的轴接触导致的分离，即光盘上的透明薄膜4的中心部分被部分切去，并且除了这一点以外与第一实施方案等相同，由都是紫外线固化树脂制成的粘结层、外涂层和这些材料的混合层粘合和保护粘合和保护光盘。图5为根据本发明一个实施方案的光盘的第五实施方案的顶视图，图7为根据本发明一个实施方案的光盘的第五实施方案的剖视图。
在这些图中，在按照与第一实施方案同样的方式制造相变光盘之后，切掉透明薄膜4的直径为16-21mm的部分“T”，在端面上施加紫外固化型保护剂，利用紫外照射固化该保护剂，以形成保护层7。结果，透明薄膜4的内周部分比起基片1来更处于外侧，因此即使内周部分接触到手指也不会有不舒服的感觉。按照这种方式，通过提供覆盖透明薄膜4的内周端部的保护层7，在内周部分中缓解了盘驱动器轴等的接触导致的卡住(hitch)，可以防止由卡住导致的透明薄膜4的分离。
[第六实施方案]
第六实施方案提供了这样一种光盘，其中按照如下方式防止光盘之间的粘结以抑制分离，即在光盘上设置环状片作为垫片，并且除了这一点之外与第一实施方案等相同，由都是紫外线固化树脂制成的粘结层、外涂层和这些材料的混合层粘合和保护粘合和保护光盘。图6是表示根据本发明光盘的第六实施方案的俯视图，图8是表示根据本发明一个实施方案的光盘的第六实施方案的截面图。
在这些图中，在按照与第一实施方案同样的方式制造相变光盘之后，利用粘合剂将外直径为38mm、内直径为35mm、厚度为0.1mm的片层8按照同心的方式粘合在外涂层5上。这样即使将每个基片叠放在堆叠架(jig)中时也可以防止每个基片的粘合。
在第六实施方案中，利用粘合剂将环状片6同心地粘合在光盘上，因此可以防止光盘之间的粘合，在操作过程中可以防止透光层A的分离。
(耐用性测试)
为了验证本发明一个实施方案的光盘的优点，在本发明第一至第四实施方案的光盘中以及如图9-11所示的没有外涂层的对比实施例1至对比实施例3中的相应光盘中进行(1)下落测试和(2)环境测试的耐用性测试。以下显示对比实施例1-3以及每个测试的详细内容。
(对比实施例1)
图9是作为本发明一个实施方案光盘的对比实施例的第一光盘的纵向视图。在第一光盘中，按照与第一实施方案同样的方式形成透光层“A”，但是不施加紫外固化型外涂层剂。结果，在透光层“A”中，在基片1的最外周端部产生了台阶。因此发现，透光层A因为在操作过程中台阶部分处被卡住而易于导致分离。
(对比实施例2)
图10是作为本发明一个实施方案光盘的对比实施例的第二光盘的纵向视图。按照与第二实施方案同样的方式形成相变光盘，但是不施加紫外固化型外涂层剂。结果，透光层“A”中最外周的端面与基片1的最外周端面齐平。因此发现，在操作过程中透光层“A”因为在透明薄膜4的最外周端面部分被卡住而易于发生分离，因为构成透光层“A”的透明薄膜4中的最外周端面部分是锐角。另外，如第二实施方案所示，因为透光层“A”的最外周端面没有被外涂层锁保护，构成透光层的透明薄膜4中的具有锐角的最外周端面部分是暴露的，因此可以称之为操作过程中安全性低。
(对比实施例3)
图11是作为本发明一个实施方案光盘的对比实施例的第三光盘的纵向剖视图。按照与第三实施方案同样的方式形成相变光盘，但是没有涂覆紫外固化型外涂层剂。此时，在基片1的侧面部分中产生透明薄膜4的突出部分。图11所示形状是指比图9所示形状更容易发生透明薄膜4分离的状态，因为在透明薄膜4的突出部分容易导致被卡住。
(1)下落测试
按照以下方式检查盘的高耐冲击性，即第一至第四实施方案的光盘以及第一至第三对比实施例的光盘从地面以上一米处向水泥地面下落，从而竖直碰撞外周的端面。
在第一至第四实施方案的光盘中没有发现任何一种光盘发生了透光层“A”分离。但是，在对比实施例1的光盘中，在基片1的外周部分中发现透光层A分离，尤其是在第二和第三对比实施例中，证实了透光层“A”分离直至记录层2的记录区域，记录层2破裂。
如上所述，在根据本发明一个实施方案的第一至第四实施方案的光盘中，可以从实验中验证，高耐冲击性获得极大改善。
(2)环境测试
按照如下方式检查光盘的形状变化，即对第一至第四实施方案的光盘以及第一至第三对比实施例的光盘在80℃和90％RH下进行约1000小时的环境测试。
通过肉眼检查，在第一至第四实施方案的光盘中没有发现形状变化。但是在对比实施例1的光盘中，在基片1的外周部分发生透光层“A”的分离，尤其是在第二和第三对比实施例的光盘中，证实了透光层“A”的分离一直发展到记录层2的记录区域，记录层2发生侵蚀(corrosion)。
如上所述，在根据本发明一个实施方案的第一至第四实施方案的光盘中，可以确认的是，与第一至第三对比实施例的光盘相比，耐腐蚀性得到极大改善。
虽然本领域普通技术人员可以从上述各个实施方案中了解本发明，但是本领域普通技术人员可以很容易想到这些实施方案的其它各种变型，并且可以不用创造性的劳动就能够将本发明应用于各个实施方案。因此，本发明覆盖了不与所披露的原理和新颖特征相抵触的宽大范围，而且并不限于上述实施方案。
例如，虽然在上述实施方案中对用于记录/复制的光盘进行了说明，但是本发明还可以应用于只读光盘-只读存储器。在该情况中，记录层2是通过一层由Al、AlMo合金等制成的光反射膜形成的。
如前面详细描述的一样，本发明提供这样一种光盘，其中形成有其中透明薄膜的粘结层和外涂层的紫外线固化树脂混合在一起的混合层，从而粘结层、外涂层和混合层一体地固化。因此，该基片完全由透明的紫外线固化树脂覆盖，并且包括透明薄膜和粘结层在内的透光层以充分的强度受到保护。
本发明的高耐冲击性和耐腐蚀性的优点可以通过针对(1)下落测试和(2)环境测试的对比试验而得到充分地验证。

Claims (12)

1.一种光盘，其特征在于，包括：
一记录层，它设置在基片上并在其中记录信息；
一粘结层，它由紫外线固化树脂制成，用来至少将记录层粘结在基片上；
一透明薄膜层，设置成粘结在粘结层上；
一外涂层，它形成在透明薄膜层上并且由紫外线固化树脂制成；以及
一混合层，它按照粘结层和外涂层的紫外线固化树脂混合的方式紧接着外涂层形成。
2.如权利要求1所述的光盘，其特征在于，所述粘结层由具有第一粘度的紫外线固化树脂形成，所述外涂层由具有比第一粘度低的第二粘度的紫外线固化树脂形成。
3.如权利要求1所述的光盘，其特征在于，所述基片的厚度为1.0mm-1.2mm，所述透明薄膜的厚度为50μm至110μm。
4.如权利要求1所述的光盘，其特征在于，所述透明薄膜的直径小于所述基片的直径。
5.如权利要求1所述的光盘，其特征在于，所述透明薄膜的直径等于所述基片的直径。
6.如权利要求所述1的光盘，其特征在于，所述透明薄膜的直径大于所述基片的直径。
7.如权利要求1所述的光盘，其特征在于，所述混合层形成在所述粘结层和透明层的侧面上，而不形成在所述基片的侧面上。
8.如权利要求1所述的光盘，其特征在于，还包括一保护层，它由紫外线固化树脂制成，并覆盖着设在光盘中央的通孔的侧面以及所述透明薄膜的至少一个切面(cut face)。
9.如权利要求1所述的光盘，其特征在于，在设在光盘中央的通孔的同心圆中在所述外涂层上还设有一环状薄膜层。
10.一种光盘的制造方法，其特征在于包括如下步骤：
形成一记录层，该层设置在一基片上并且在其中记录信息；
将一透明薄膜层粘结在一基片上，在基片上通过形成由紫外线固化树脂制成的粘结层而形成有所述记录层；
将由紫外线固化树脂制成的一外涂层形成在所述透明薄膜层上；
形成一混合层，该层以这样一种方式紧接外涂层形成，即粘结层的突出部分和外涂层的紫外线固化树脂的每一个在所述外涂层的成形过程中混合；并且
通过向所述基片照射紫外光，从而使粘结层、外涂层和混合层的紫外线固化树脂固化。
11.如权利要求10所述的光盘制造方法，其特征在于，所述粘结层由具有第一粘度的紫外线固化树脂形成，所述外涂层由具有比第一粘度低的第二粘度的紫外线固化树脂形成。
12.如权利要求10所述的光盘制造方法，其特征在于，所述基片的厚度为1.0mm至1.2mm，所述透明薄膜的厚度为50μm至110μm。
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