CN1784727A - 着色光盘及其制备方法 - Google Patents

着色光盘及其制备方法 Download PDF

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CN1784727A
CN1784727A CNA028274865A CN02827486A CN1784727A CN 1784727 A CN1784727 A CN 1784727A CN A028274865 A CNA028274865 A CN A028274865A CN 02827486 A CN02827486 A CN 02827486A CN 1784727 A CN1784727 A CN 1784727A
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equal
preparing
less
colorant
plastic
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范迪塔·佩-帕兰贾普
史蒂文·R·皮克
菲利普·肖特兰德
维格斯·托马斯
沙伦·S·韦斯
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SHPP Global Technologies BV
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General Electric Co
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Abstract

公开了光盘及其制备方法的实施方案。在一个实施方案中,光盘包括:至少两个包括分布在其间的粘合层和数据层的塑料基板(1),其中至少一个基板(1)是包括大于或等于约0.01重量%着色剂的读取侧基板,该着色剂量基于读取侧基板的总重量,和其中读取侧基板的UV粘合指数大于或等于约0.5。一种制备光盘的方法包括:形成包括大于或等于约0.01重量%着色剂的第一塑料基板,该着色剂量基于第一塑料基板的总重量,其中控制第一塑料基板的UV粘合指数到大于或等于约0.5;在第一塑料基板和第二基板之间布置数据层;采用粘合层粘合第一塑料基板到第二塑料基板;和固化粘合层。

Description

着色光盘及其制备方法
                  相关申请的交叉参考
本申请是2001年12月17日提交的美国专利申请No.09/683346的部分继续,该文献在此引入作为参考。
                        发明背景
本申请涉及数据存储介质(data storage media),和特别地涉及着色的(colored)数据存储介质。
数字化视频光盘(或DVD)缓慢但肯定地代替光盘(CD)。这些格式比CD提供明显更多的存储容量,因此允许至多8小时高数字质量的视频/音频内容的记录。全球2001年市场上销售的DVD数目可能超过十亿单位和期望到2004年达到约40亿。
为在总体尺寸与CD相同的盘中达到高存储密度,盘构造已经改变了。最基本和可见的差异在于DVD不再由单一1.2毫米厚塑料基板组成,而由两个0.6毫米粘合在一起的半部分(halves)组成(“DVD Demystified”,JimTaylor,ed.McGraw Hill,1998)。此外,读取激光波长(reading laser wavelength)从CD中的780纳米(纳米),它分布在光谱的近红外部分,变化到DVD的635或650纳米,它分布在可见光谱。依赖于DVD的类型(DVD-5、DVD-9、DVD-10、DVD-14、DVD-18、DVD-R、DVD-RW等),构造可基本从单侧/单层(DVD-5)变化到双侧/双层(DVD-18),更不必提及可记录格式如DVD-R和DVD-RW。与激光波长分布在可见光谱中的事实结合的,由光学介质构造施加的严格规范(用于1.20毫米DVD-只读盘的欧洲信息和通信系统标准化协会(European Association for Srandardizing Information and CommunicationSystems)(“ECMA”)规范(Specification)#267)使DVD制造成为难题。
基板的光学性能不是DVD的唯一要求。例如,在DVD中凹坑(pit)的尺寸更小,它意味着DVD比CD对树脂质量(杂质)更敏感。由于它们更薄的线规(gage)(代替1.2毫米的0.6毫米),在模塑方面DVD也比CD更具挑战性。事实上,树脂的流变(流动特性)是重要的,并被严格控制。另外,盘体厚度的不一致性也是光透缺陷的来源。由于它不仅仅更薄和在可见光谱中读取,而且也在比规则(regular)CD更高的旋转/扫描速度下读取,DVD对此缺陷的存在更敏感。由于与2个凹坑层相关的完全反射和半反射层两者的存在,多层的最先进格式(例如DVD-9,DVD-14和DVD-18)代表最高的困难程度(如形成地理定位器(geographic locator)的图案形成)。单层DVD,即DVD-5和DVD-10,不含有半反射层和仅包含一个凹坑层。由于盘构造中的差异,在单层盘和多层盘之间反射率要求非常不同。
迄今为止,采用无色树脂制造市场上销售的所有预记录或可记录多层DVD。DVD之间的唯一美学差异来自金属喷镀(即数据层)。例如当使用金时,获得金盘,和相似地,采用银、银合金或铝获得亮银盘。
                        发明概述
在此公开的是光盘及其制备方法。在一个实施方案中,光盘包括:至少两个包括分布在其间的粘合层(bonding layer)和数据层的塑料基板,其中至少一个基板是包括大于或等于约0.01重量%着色剂的读取侧(read side)基板,该着色剂量基于读取侧基板的总重量,和其中读取侧基板的UV粘合指数(UV Bonding Index)大于或等于约0.5。
一种制备光盘的方法包括:形成包括大于或等于约0.01重量%着色剂的第一塑料基板,该着色剂量基于第一塑料基板的总重量,其中控制第一塑料基板的UV粘合指数到大于或等于约0.5;在第一塑料基板和第二基板之间布置数据层;采用粘合层粘合第一塑料基板到第二塑料基板;和固化粘合层。
从如下附图简述、详细描述、和附图,这些和其它特征是明显的。
                        附图简述
现在参考如下图,其中:
图1是DVD9构造的概要表示;
图2是含有分布在基板第二侧上的单一反射层的CD构造的示意图;
图3是含有分布在基板中的单一反射层的DVD构造的示意图;
图4是含有两个分布在基板中的反射数据层,半反射数据层和完全反射数据层的DCD构造的示意图;
图5是含有单一反射数据层和单一激光的DVD构造的示意图;
图6是含有两个反射数据层的DVD构造的示意图,两个数据层都分布在基板中心的相对侧上,并且每个从基板的不同侧是可读取的;
图7是含有两个反射数据层的DVD构造的示意图,两个数据层分布在基板中心的相对侧上,和两者从基板的相同侧是可读取的;
图8是含有两个反射数据层的DVD构造的示意图,两个数据层分布在基板中心的相同侧上,和两者从基板的相同侧是可读取的;
图9是含有两个反射数据层的DVD构造的示意图,两个数据层分布在基板中心的每一侧上,和两者从基板的每一侧是可读取的;
图10是在0.014重量%加载下,几种着色剂在1.2毫米聚碳酸酯基板中光透射(light transmission)的图示说明;
图11是实验配制剂(formulations)透射曲线的图示说明;
图12是来自融合UV系统(fusion UV system)的类型“D”无电极灯泡光谱分布的图示说明;
图13是通过试验配制剂的基板传输的入射能量百分比的图示说明;和
图14是Daicure Clear SD-698漆的吸收光谱的图示说明。
                          详细描述
目前,使用透明(无色)树脂制备市场上发现的DVD。甚至在80℃下在85%相对湿度(RH)下老化4天之后,透明盘显示良好的光学/电性能(反射率,抖动,奇偶内(parity inner)(PI)误差,双折射等)以及良好的机械性能(径向/切向/垂直倾斜(vertical tilt))。在生产着色盘的尝试中,发现一些配制剂的粘合能力差,如在盘的机械性能,即径向/切向/垂直倾斜中反映的那样。事实上,一些着色盘完全不符合规范(如大于±800毫度(mdeg)的径向倾斜),并因此不能认为是由工业标准规范(用于1.20毫米(毫米)DVD-只读盘的欧洲信息和通信系统标准化协会规范#267)定义的功能盘(functional disk)。
粘合问题,它们可以在采用颜色和胶粘剂的任何类型盘,例如,任何类型DVD格式(如单层的(如DVD-5和DVD-10),多层的(如DVD-9、DVD-14、DVD-18))等中看到,相应于用于粘合DVD两个塑料基板的粘合层(另外称为漆或胶粘剂)的固化不足。粘合层的固化不足导致倾斜缺陷,或在最差的情况下,导致总体粘接障碍,其中两个基板不彼此粘附。
可以采用辐射胶粘剂(如可光固化粘合层)的UV光(如在约330-约410纳米(纳米)范围中),完成粘合DVD盘的塑料基板的过程。采用着色盘的问题在于着色的基板显示一些UV吸收,而吸收量依赖于着色剂的加载水平和化学本质。当通过塑料基板的UV光透射低时(例如,小于约1%的会通过透明基板透射的UV光),发生粘合问题。
为保证着色盘中基板层的适当粘合,通过着色基板传输阈能。阈能由在约330-约410纳米范围中传输的总光谱能量(瓦)定义。应当强调的是在此用与对于透明基板相同的固化时间定义阈能。应当理解可以与更长的固化时间一起采用更低的阈能,它们可增加由粘合层的光吸收效率并因此改进粘合。典型的固化时间小于约3秒,及优选是小于或等于约2秒。然而,循环时间大大增加,它会不利地影响盘生产率和因此不是可选择的方法。
可以按照称为“UV粘合指数”的参数量化阈能,该指数是着色基板吸收光谱以及辐射源光谱分布的函数。为获得UV粘合指数,首先将辐射源的光谱能输出和通过着色塑料基板的传输百分比的乘积,作为整个UV-可见光谱内波长的函数而计算。在330纳米到粘合层截止(即到其中粘合层不再吸收光的点)的波长范围内此曲线的积分,提供在该光谱范围内通过着色基板传输的总能量数值。通过着色基板的总能量与通过透明基板的总能量(由以上过程计算)的比例得到UV粘合指数的数值。尽管可以采用大于或等于约0.5的UV粘合指数,优选是大于或等于约1.0的UV粘合指数,更优选是大于或等于约2的UV粘合指数,和最优选是大于或等于约4.0的UV粘合指数。已经发现可以采用小于或等于约70,小于或等于约60,小于或等于约50,小于或等于约40,小于或等于约30,小于或等于约20,小于或等于约10,和甚至小于或等于约5的UV粘合指数。
可以从任何灯泡计算UV粘合指数。一些可能的灯泡包括来自融合UV系统的类型“D”灯泡、闪光脉冲(flash pulse)UV固化系统(Marubeni/OriginDVD Bonder)中的类型FQ20007灯泡、DVD边缘固化(edge cure)灯泡(M2Corp.)、来自Xenon Corp.的RC742灯泡等。相似地,可以计算任何粘合层的UV粘合指数,该粘合层在至少所需光谱的一部分中吸收光。一些可能的粘合层包括Daicure Series SD-693、SD-694、和SD698(DainipponInk&Chemicals,Inc.)、Quretech DVD065和DVD106、Kayarad MPZ-62等,以及包括至少一种上述粘合层的结合。
参考图1,数字化视频光盘(DVD)包括两个粘合的塑料基板(或树脂层)1,每个的厚度典型地小于或等于约1.0毫米(毫米),及优选小于或等于约0.7毫米。也优选厚度小于或等于约0.4毫米。至少一个基板包括一个或多个数据层(如3、5)。一般称为零层(layer zero)(或L0)的第一层3,最接近从其读取数据的盘侧面(表面7)。一般称为层1(L1)的第二层5距读出表面(readoutsurface)7更远。分布在L0(3)和L1(5)之间的典型地是胶粘剂9或任选地保护性涂层或分分隔层11。单侧DVD(即从分布在DVD一侧上的单一读出表面7读取的那些)可另外包括分布在DVD读出表面7的相对侧上的标签13。
在从读出表面7读取的单一层的情况下(如DVD5、DVD10),通过溅射或其它沉积工艺,采用薄反射数据层覆盖压印(stamped surface)表面。这产生典型地为约60-约100埃()厚的金属涂层。(参见图3、5和6)对于从相同读出表面7读取的两数据层DVD(如DVD9、DVD14、DVD18),当读取时激光必须能够从第一层3反射,但当读取第二层5时也通过第一层3聚焦(或传输)。(分别参见图4、7、8、和9;DVD9、DVD9、DVD14、DVD18)因此,第一层3是“半透明的”(即半反射的),而第二层5是“完全反射的”。在由光学介质协会设定的目前标准下,用于完全反射和半反射数据层的金属喷镀结合,如按照电参数R14H(如在ECMA规范#267中所述)测量的那样,在激光波长下应当为约18%(%)-约30%。在现有的DVD中,一般采用的激光波长小于或等于约700纳米,优选约400纳米-约675纳米,更优选约600纳米-约675纳米。尽管对于采用无色,光学质量树脂的DVD数据层设定这些金属喷镀标准,它们同样应用于采用着色树脂的DVD系统。
当向树脂中加入颜色时,影响通过基板和从基板反射的光透射。为了基板的光透射,改变在半反射和完全反射(LO(3)和L1(5))层上的金属喷镀本质和厚度。可以通过平衡金属喷镀厚度与半反射数据层3的反射率,和通过调节完全反射数据层5的厚度以保证它的反射率在所需规范内,获得所需的反射率。
可以使用各种反射材料获得单个数据层的金属喷镀。可以采用具有足够反射率以用作半反射和/或完全反射数据层的材料,如金属、合金等,和优选这些材料能溅射到基板上。一些可能的反射材料包括金、银、铂、硅、铝等,以及包括至少一种上述材料的合金和组合。例如,第一/第二反射数据层金属喷镀可以是金/铝、银合金/铝、银合金/银合金等。
除各个层3,5的总体反射率(overall reflectivity)以外,应当控制在随后的反射数据层(如层3,5)之间反射率的差异,以保证随后层(subsequent layer)的足够反射率。优选,在随后层(如第一和第二层3,5)之间反射率的差异小于或等于约5%,优选小于或等于约4%,和更优选小于或等于约3.0%。进一步优选在相邻反射数据层3,5之间的反射率差异大于或等于约0.5%,更优选大于或等于约1%。应当注意到尽管描述是关于两个层的,应当理解可以采用多于两个层,并且应当如上设定在随后层之间的反射率差异。
将反射数据层典型地溅射或其它方法布置在图案(如表面特征,如凹坑、凹槽、凸凹不平、开始/停止定向器(orientor)等)上,通过模塑、压花等将该图案成形入基板表面。例如,沉积可包括在第一图案化(patterned)表面上溅射半反射数据层。然后可以在半反射数据层上布置分隔层或保护性涂层。如果要形成多数据层(multiple data layer)DVD(如DVD14、DVD18等),可以在与半反射数据层相对的分隔层的侧面中形成第2图案化表面(如压印等)。然后可以将完全反射层溅射或其它方法沉积在分隔层上。可供选择地,对于DVD14构造,可以在第2基板(或树脂层)的图案化表面上沉积完全反射层。然后在半反射数据层和完全反射数据层一个或两者上布置分隔层或保护性涂层。然后可以在2个基板之间布置粘合剂或胶粘剂,并且它们可以粘合在一起以形成图3-9中说明的盘。任选地,可以沉积几个半反射数据层及在各个随后层之间的分隔层。
依赖于反射层的数目,反射数据层的反射率可以为约5%-约100%。如果采用单一反射数据层,反射率优选为约30%-约100%,更优选约35%-约90%,和甚至更优选约45%-约85%。如果采用双反射数据层,数据层的反射率为约5%-约45%,更优选约10%-约40%,和甚至更优选约15%-约35%,和特别优选约18%-约30%。最后,如果采用多反射数据层(如大于2个可从单一读取表面读取的反射数据层),反射率优选为约5%-约30%,更优选约5%-约25%。特别优选的范围目前是基于ECMA规范#267,其中对于双层DVD(如至少一个完全反射层和至少一个半反射层)反射率为约18%-约30%反射率,或单一层DVD(如一个完全反射层)反射率为约45%-约85%。
基板可包括任何光学质量塑料,如在激光波长范围内能够使约60%-小于94%光透过其的任何塑料。在该光透射范围内,优选,透射率大于或等于约70%,更优选大于或等于约74%,和特别优选大于或等于约78%。取决于采用的着色剂类型和数量,透射率可以小于或等于约92%,取决于着色剂的类型,可能小于或等于约88%和甚至小于或等于约85%。应当注意到随着色基板的透射率降低时,达到基板所需粘合力的能力变得更为困难。
塑料基板可包括树脂如无定形、结晶、半结晶热塑性塑料、热固性塑料、和包括至少一种上述塑料的结合。一些可能的塑料包括聚醚酰亚胺、聚醚醚酮、聚酰亚胺、聚氯乙烯、聚烯烃(包括但不限于,直链和环状聚烯烃并包括聚乙烯、氯化聚乙烯、聚丙烯等)、聚酯(包括,但不限于聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚对苯二甲酸环己烷二甲醇酯等)、聚酰胺、聚砜(包括,但不限于聚醚砜、聚醚醚砜、氢化聚砜等)、聚酰亚胺、聚醚酰亚胺、聚醚砜、聚苯硫醚、聚醚酮、聚醚醚酮、ABS树脂、聚苯乙烯(包括,但不限于氢化聚苯乙烯、间同立构和无规立构聚苯乙烯、聚环己基乙烯、苯乙烯-共-丙烯腈、苯乙烯-共-马来酐等)、聚丁二烯、聚丙烯酸酯(包括,但不限于聚甲基丙烯酸甲酯、甲基丙烯酸甲酯-聚酰亚胺共聚物等)、聚丙烯腈、聚缩醛、聚碳酸酯、聚苯醚(包括,但不限于衍生自2,6-二甲基苯酚的那些和与2,3,6-三甲基苯酚的共聚物等)、乙烯-醋酸乙烯酯共聚物、聚醋酸乙烯酯、液晶聚合物、乙烯-四氟乙烯共聚物、芳族聚酯、聚氟乙烯、聚偏1,1二氟乙烯、聚偏1,1二氯乙烯、四氟乙烯氟碳共聚物(如特氟隆)、环氧树脂(epoxy)、酚醛树脂(phenolic)、醇酸树脂、聚酯、聚酰亚胺、聚氨酯、聚硅氧烷、聚硅烷、双马来酰亚胺、氰酸酯、乙烯基树脂(vinyl)、苯并环丁烯、以及至少一种上述塑料的共混物、共聚物、混合物、反应产物、和复合材料。优选,基板包括聚碳酸酯,特别优选主要是聚碳酸酯(如大于或等于约80%聚碳酸酯)的基板。
在此使用的术语“聚碳酸酯”,“聚碳酸酯组合物”和“包括芳族碳酸酯链单元的组合物”包括含有通式(I)结构单元的组分:
Figure A0282748600121
其中R1基团总数的至少约60%是芳族有机基团和余量是脂族、脂环族、或芳族基团。优选,R1是芳族有机基团,更优选,通式(II)的基团:
                  -A1-Y1-A2-
                                  (II)
其中A1和A2各自为单环二价芳基和Y1是分隔A1和A2的含有一个或两个原子的桥接基团。在示意的实施方案中,一个原子分隔A1和A2。此类型基团的说明性、非限制性例子是-O-、-S-、-S(O)-、-S(O2)-、-C(O)-、亚甲基、环己基亚甲基、2-[2,2,1]-双环亚庚基、亚乙基、异亚丙基、新亚戊基、亚环己基、亚环十五烷基、亚环十二烷基、和亚金刚烷基。桥接基团Y1可以是烃基或饱和烃基如亚甲基、亚环己基或亚异丙基。
可以由其中仅一个原子分隔A1和A2的二羟基化合物的界面反应生产聚碳酸酯。在此使用的术语“二羟基化合物”包括,例如,具有如下通式(III)的双酚化合物:
Figure A0282748600131
其中Ra和Rb各自表示卤素原子或一价烃基,并且可以相同或不同,p和q各自独立地是0-4的整数,和Xa表示通式(IV)的一种:
Figure A0282748600133
其中Rc和Rd各自独立地表示氢原子或一价直链或环状烃基和Re是二价烃基。
合适二羟基化合物的一些说明性、非限制性例子包括由美国专利4217438中以名称或通式(属类或具体)公开的二元酚和二羟基取代的芳族烃。可以由通式(III)表示的双酚类型化合物的具体例子的非穷尽列举包括如下物质:1,1-双(4-羟苯基)甲烷、1,1-双(4-羟苯基)乙烷、2,2-双(4-羟苯基)丙烷(以下“双酚A”或“BPA”)、2,2-双(4-羟苯基)丁烷、2,2-双(4-羟苯基)辛烷、1,1-双(4-羟苯基)丙烷、1,1-双(4-羟苯基)正丁烷、双(4-羟苯基)苯基甲烷、2,2-双(4-羟基-1-甲基苯基)丙烷、1,1-双(4-羟基-叔丁基苯基)丙烷、双(羟基芳基)烷烃如2,2-双(4-羟基-3-溴苯基)丙烷、1,1-双(4-羟苯基)环戊烷、和双(羟基芳基)环烷烃如1,1-双(4-羟苯基)环己烷等,以及包括至少一种上述化合物的结合。
在需要使用碳酸酯共聚物而不是均聚物的情况下,也可以采用从两种或多种不同二元酚的聚合得到的聚碳酸酯或二元酚与二醇或与羧基或酸封端的聚酯或与二元酸或与羟基酸或与脂族二元酸的共聚物。一般情况下,有用的脂族二元酸含有2-约40个碳。优选的脂族二元酸是十二烷二酸。也可以采用多芳基化物和聚酯-碳酸酯树脂或它们的共混物。支化聚碳酸酯,以及直链聚碳酸酯和支化聚碳酸酯的共混物也是有用的。可以通过在聚合期间加入支化剂制备支化聚碳酸酯。
这些支化剂可包括含有至少三个官能团的多官能有机化合物,该官能团可以是羟基、羧基、羧酸酐、卤代甲酰基、和包括至少一种上述基团的混合物。具体的例子包括1,2,4-苯三酸、1,2,4-苯三酸酐、1,2,4-苯三酰氯、三-对羟基苯基乙烷、靛红-双酚、三-苯酚TC(1,3,5-三((对羟苯基)异丙基)苯)、三-苯酚PA(4(4(1,1-双(对羟苯基)乙基)α,α-二甲基苄基)苯酚)、4-氯甲酰基邻苯二甲酸酐、1,3,5-苯三酸和二苯酮四羧酸等。可以基于树脂的总重量,在约0.05重量%-约2.0重量%的水平下加入支化剂。支化剂和制备支化聚碳酸酯的过程描述于美国专利Nos.3635895和4001184。在此设想聚碳酸酯端基的所有类型。
优选的聚碳酸酯是基于双酚A,其中A1和A2每一个是对亚苯基和Y1是亚异丙基。优选,聚碳酸酯的重均分子量是约5,000-约100,000,更优选约10,000-约65,000,和最优选约15,000-约35,000。
在监测和评价聚碳酸酯的合成中,特别感兴趣的是确定聚碳酸酯中存在的Fries产物浓度。如说明的那样,Fries产物的显著产生可导致聚合物支化,导致不可控制的熔体行为。在此使用的术语“Fries”和“Fries产物”表示具有通式(V)的聚碳酸酯中的重复单元:
其中Xa是如关于上述通式(III)描述的二价基团。
聚碳酸酯组合物也可包括通常引入此类型树脂组合物的各种添加剂。这样的添加剂是,例如,填料或增强剂、热稳定剂、抗氧剂、光稳定剂、增塑剂、抗静电剂、脱模剂、另外的树脂、发泡剂等,以及包括至少一种上述添加剂的结合。填料或增强剂的例子包括玻璃纤维、石棉、碳纤维、二氧化硅、滑石和碳酸钙。热稳定剂的例子包括亚磷酸三苯酯、亚磷酸三-(2,6-二甲基苯基)酯、亚磷酸三-(混合单和二壬基苯基)酯、磷酸二甲基苯亚酯、和磷酸三甲酯。抗氧剂的例子包括十八烷基-3-(3,5-二-叔丁基-4-羟苯基)丙酸酯、和四[3-(3,5-二-叔丁基-4-羟苯基)丙酸]季戊四醇酯。光稳定剂的例子包括2-(2-羟基-5-甲基苯基)苯并三唑、2-(2-羟基-5-叔辛基苯基)苯并三唑和2-羟基-4-正辛氧基二苯酮。增塑剂的例子包括二辛基-4,5-环氧-六氢邻苯二甲酸酯、三-(辛氧基羰基乙基)异氰尿酸酯、三硬脂酸甘油酯和环氧大豆油。抗静电剂的例子包括单硬脂酸甘油酯、十八烷基磺酸钠、和十二烷基苯磺酸钠。脱模剂的例子包括硬脂酸十八烷基酯、蜂蜡、褐煤蜡和石蜡。其它树脂的例子包括但不限于聚丙烯、聚苯乙烯、聚甲基丙烯酸甲酯、和聚苯醚。可以使用任何上述添加剂的结合。可以在形成组合物的组分混合期间的合适时间混合这样的添加剂。
除聚合物和着色材料以外,组合物可任选地包括通常引入此类型树脂组合物的各种添加剂。这样的添加剂包括UV吸收剂;稳定剂,如光和热稳定剂(如酸性磷基化合物)、受阻酚、氧化锌、硫化锌粒子、或其结合;润滑剂(矿物油等)、增塑剂、抗氧剂、抗静电剂(苯磺酸四烷基铵盐、苯磺酸四烷基磷鎓盐等)、脱模剂(四硬脂酸季戊四醇酯、单硬脂酸甘油酯等)等、和包括至少一种上述添加剂的结合物。例如,基于聚合物的总重量,基板可包括约0.01重量%-约0.1重量%热稳定剂,约0.01重量%-约0.2重量%抗静电剂,和约0.1重量%-约1重量%脱模剂。
一些可能的抗氧剂包括,例如,有机亚磷酸酯,如三(壬基苯基)亚磷酸酯、三(2,4-二-叔丁基苯基)亚磷酸酯、双(2,4-二-叔丁基苯基)季戊四醇二亚磷酸酯、二硬脂基季戊四醇二亚磷酸酯等;烷基化一元酚,例如,多元酚与二烯烃的烷基化反应产物,例如,四[亚甲基(3,5-二-叔丁基-4-羟基氢化肉桂酸酯)]甲烷、3,5-二-叔丁基-4-羟基氢化肉桂酸十八烷基酯、2,4-二-叔丁基苯基亚磷酸酯等;对甲酚和二环戊二烯的丁基化反应产物、烷基化对苯二酚、羟基化硫代二苯基醚、亚烷基-双酚、苄基化合物、β-(3,5-二-叔丁基-4-羟苯基)-丙酸与一元或多元醇的酯、β-(5-叔丁基-4-羟基-3-甲基苯基)-丙酸与一元或多元醇的酯、硫代烷基或硫代芳基化合物的酯(例如,二硬脂基硫代丙酸酯、二月桂基硫代丙酸酯、双十三烷基硫代丙酸酯等),β-(3,5-二-叔丁基-4-羟苯基)-丙酸的酰胺等,以及包括至少一种上述抗氧剂的结合。
为协助聚合物,特别是聚碳酸酯的加工,也可以采用催化剂,即在挤出机或其它混合设备中。催化剂典型地协助控制获得材料的粘度。可能的催化剂包括氢氧化物,如氢氧化四烷基铵、氢氧化四烷基磷鎓等,及优选是氢氧化二乙基二甲基铵和氢氧化四丁基磷鎓。催化剂可以单独采用或与骤冷剂如酸(如磷酸)等结合采用。另外,可以在混合期间将水注入聚合物熔体中并通过排气口作为水蒸汽除去,以除去残余挥发性化合物。
通过使用能够充分混合各种前体的反应容器,如单或双螺杆挤出机、捏合机、掺合机等生产聚合物。然后通过模塑、挤出、辊压、压印、或相似技术将聚合物成形为基板。
采用胶粘剂或粘合剂(如分隔层或粘合层)将相邻的基板连接在一起。可以采用具有所需光学质量的任何粘合剂。一些可能的粘合剂包括胶水(如热胶水)、丙烯酸类树脂(如可紫外(UV)固化树脂,具有透明性(即优选大于或等于可UV固化丙烯酸类树脂)等,以及包括至少一种上述粘合剂的结合。
如采用粘合剂,分隔层可包括透明材料。一些可能的分隔层包括可UV固化的透明树脂。典型地,分隔(粘合)层是至多或超过几百微米(μm)厚,小于或等于约100μm的厚度有用,和约40μm-约700μm的厚度典型地用于目前的DVD格式。
可以通过向基板(如树脂层)、分隔层、面涂层、或包括至少一个上述层的任何结合中引入着色剂,而向DVD中加入颜色。可以采用几种方式获得盘的着色,如使用用于基板和/或分隔层的预着色树脂、在模塑机混合无色树脂和浓色母料(color concentrate)、和使用液体或粉末着色(或包括至少一种这些方法的结合)。不论着色剂的引入是通过在挤出工艺期间加入、通过无色粒料与浓色母料在模塑之前的物理混合、或在模塑机的液体或粉末着色,选择着色剂和它的浓度以满足DVD规范。甚至当采用着色剂时,保持基板的透明性(如在读取波长下大于或等于约60%透明性)以达到可引导(bootable)DVD。
基板的透明性直接涉及基板中存在的散射粒子数量和它们的尺寸。如果它们明显小于可见波长,将注意不到散射。由于着色剂可以是散射粒子的主要来源,优选过滤着色剂,及特别优选熔体过滤,如在挤出工艺中加入期间。优选,过滤的着色剂粒子(及其聚集体)的尺寸小于或等于约200纳米(纳米),优选小于或等于约50纳米的粒子(及其聚集体)的尺寸。
也优选选择着色剂使得它们在用于形成层的材料中增溶,在层中布置着色剂。在用于DVD层的材料中可溶解的着色剂包括染料(如“溶剂染料”)、有机着色剂、颜料等,它们表现如染料,即,在塑料中分散和不形成尺寸大于或等于约200纳米的聚集体的着色剂,及优选小于或等于约50纳米的聚集体尺寸。一些合适的着色剂包括,但不限于,如下物质化学族(chemical family)的那些:蒽醌(anthaquinone)、苝、周酮(perinone)、阴丹酮、喹吖啶酮、呫吨、噁嗪(oxazine)、噁唑啉、噻吨、靛青、硫靛、萘二酰亚胺(naphthalimide)、花青、呫吨、次甲基类、内酯、香豆素、双苯并噁唑基噻吩(bis-benzoxaxolylthiophene)(BBOT)、萘四羧酸衍生物、单偶氮和双偶氮颜料、三芳基甲烷、氨基酮、双(苯乙烯基)联苯衍生物、和包括至少一种上述着色剂的结合物。
确定塑料/着色剂结合和采用的着色剂数量的因素目前是基于以上提及的DVD规范(EMCA规范#267)。为获得半反射数据层和完全反射数据层,在用于着色多层DVD的规范中的反射率(约18%-约30%),平衡光透射和着色剂浓度。在DVD读回(readback)激光波长下通过基板(即DVD半部分)的光透射优选大于或等于约60%。着色剂加载,以及着色剂本质(如光谱透射曲线的形状)依赖于目标颜色和光透射率。
图10说明一些通常塑料着色剂(溶剂紫13、溶剂蓝97和溶剂绿28)的不同光透射。在所需波长下,如在650纳米下具有更低吸收率的着色剂,因此在此波长下显示最大透射并且是优选的。在所需波长下具有高吸收率的着色剂选择限制可能得到官能多层DVD的最大着色剂加载。由于可以在配制中在更高加载量下,使用在所需波长下具有更低吸收率的着色剂,更容易在功能盘中获得目标颜色。例如,由于它在650纳米下更低的吸收率,当尝试达到蓝色时,溶剂紫13优于溶剂蓝97。
典型地,基于包括着色剂的基板总重量,着色剂加载量大于或等于约0.01重量%(重量%),优选大于或等于约0.02重量%,更优选大于或等于约0.04重量%,甚至更优选大于或等于约0.4重量%,和最优选大于或等于约0.5重量%。进一步优选以如下数量采用着色剂:小于或等于约3.0重量%,更优选小于或等于约2.0重量%,甚至更优选小于或等于约1.0重量%,和特别优选小于或等于约0.75重量%。
除反射层和分隔层以外,可以采用层如保护层(如漆(lacquer)等)、紫外(UV)抑制剂层、防潮层(moisture barrier layer)、延性(ductility)层等,以及包括至少一个这些层的结合。
进一步由如下非限制性实施例说明公开内容。
                          实施例
如下实施例比较五种着色和透明DVD的粘合能力,该粘合能力与UV范围中通过基板传输的总能量相关。表1列出使用的配制剂的详细情况。在单螺杆挤出机中在290℃下共混和造粒所有六种配制剂。从造粒的材料使用标准过程模塑DVD和将盘进行完全电学(AudioDev DVDPro SA300Pulsetech Drive)和机械(Dr.Schenk PROmeteus MT136)测试。
  表1
  配制剂   样品(以重量份的数量)
  A   B   C   D   E1   F
  聚碳酸酯树脂   100   100   100   100   100   100
  单硬脂酸甘油酯   0.03   0.03   0.03   0.03   0.03   0.03
  双(2,4-二枯基苯基)季戊四醇二亚磷酸酯   0.02   0.02   0.02   0.02   0.02   0.02
  溶剂红52/macrolex红5B   0.15   0.2   0.3
  溶剂红207/rosaplast红601   0.4
  溶剂黄93/macrolex黄3G   0.05   0.15   0.1
  溶剂紫36/marcolex紫3R   0.01
1透明的
在模塑工艺期间,看出仅在配制剂B和C的情况下粘合层不能完全固化。两种塑料基板的此差粘合/粘结表现在规范以外的径向和切向倾斜。机械参数的测量指示所有配制剂的切向倾斜都在规范内,然而,如期望的那样,仅配制剂B和C径向倾斜测量在规范以外(参见表2)。
  表2
  盘的径向倾斜和传输数据
  样品   入射最小径向倾斜1mdeg   射出最大径向倾斜1mdeg2   平均径向倾斜1mdeg   %透射2
  A   -465   195   -3.5   86.67
  B   -1717   -1567   -1743   83.87
  C   -1808   -1845   -1467   83.42
  D   -382   -157   -364   81.96
  E   -290   -185   -235   87.17
  F   101   262   223   82.8
1±800mdeg
2在激光波长下
在图11中显示经过UV-可见区域在Hewlett Packard分光光度计型号8453(UV-VIS-MIR分光光度计)测量的配制剂A-E的透射曲线。如果已知辐射源的光谱分布,这些曲线可用于预测在任何波长下通过基板传输的能量。为说明的目的,来自融合UV系统的类型“D”灯泡辐射分布(图12)以获得入射能量的分布百分比,通过每个基板传输该入射能量(图13)。
在下表3中将表达为通过透明基板传输的能量分率,在约330-约410纳米(纳米)通过基板的总能量(由积分过程获得)制表。表3是表达为通过透明基板传输的能量分率,在约330-约410纳米波长范围内通过盘基板传输的总能量的比较。换言之,在下表3中将UV粘合指数制表。在表3中,清楚地看出配制剂B和C仅传输0.045%入射能量,该能量在阈能以下,导致差的粘合。另一方面,已经分别开发配制剂A,D和F以传输5.6%,13.1%和49%能量,该能量在1%的阈值以上,提供良好的粘合能力。
  表3
  样品   通过着色基板传输的能量与通过透明基板传输的能量的比例(%)(UV粘合指数)
  A   5.6
  B   0.044
  C   0.046
  D   13.1
  E   100
  F   49
此外,当粘合层中的光敏引发剂的吸收情况已知时,也可以通过积分通过基板传输的能量和引发剂吸光度的乘积,计算由引发剂吸收的总能量。图14显示在0.1重量%甲醇溶液中测量的(购自Shimadzu,日本的Shimadzu分光光度计)Daicure clear SD-698的吸收光谱,其是用于DVD粘合的丙烯酸类漆。以下将对于每种基板A-F由光敏引发剂吸收的总能量(表4)表达为透明基板的百分比。
  表4
  样品   表达为透明基板中吸光度百分比的由光敏引发剂吸收的总能量
  A   4
  B   0.042
  C   0.045
  D   11.3
  E   100
  F   49.9
通过控制在使用粘合剂的存储介质,如DVD中采用的着色基板吸光度的百分比,可以开发除良好电/机械性能以外具有良好粘合能力的着色DVD用坚固配制剂。光敏引发剂的吸光度数量超过约1%以获得可操作盘。因此,可以测定光敏引发剂的吸光度。然后可以调节着色剂的参数以达到大于或等于约0.05的UV粘合指数。可能的着色剂参数包括着色剂浓度,着色剂类型,以及包括至少一种上述参数的结合。应当注意甚至对于相似的颜色,即样品B,C,和F(即对眼睛相似的颜色),获得了极大不同的UV粘合指数,及B和C具有差粘合和F具有良好的粘合。应当进一步注意尽管在激光波长下F的传输%小B和C,也获得了良好的粘合。
尽管参考示例性实施方案描述了本发明,本领域技术人员理解的是可以进行各种变化和同等物可替换其元素而不背离本发明的范围。此外,可以进行许多改进以将特定的状况或材料适应于本发明的教导,而不背离其必须范围。因此,本发明并不意图限于公开的特定实施方案,该特定实施方案公开作为设想用于进行本发明的最好模式,但本发明包括属于所附权利要求范围的所有实施方案。

Claims (39)

1.一种制备光盘的方法,包括:
形成包括大于或等于约0.01重量%着色剂的第一塑料基板,该着色剂量基于所述第一塑料基板的总重量,其中将所述第一塑料基板的UV粘合指数控制到大于或等于约0.5;
在第一塑料基板和第二基板之间布置数据层;
采用粘合层将第一塑料基板粘合到第二塑料基板;和
固化所述粘合层。
2.根据权利要求1的制备光盘的方法,其中通过第一塑料基板的光透射在激光读取波长下是约60%-小于94%。
3.根据权利要求2的制备光盘的方法,其中所述光透射是约70%-约92%。
4.根据权利要求3的制备光盘的方法,其中所述光透射是约74%-约88%。
5.根据权利要求4的制备光盘的方法,其中所述光透射是约78%-约84%。
6.根据权利要求1的制备光盘的方法,其中所述UV粘合指数为小于或等于约70。
7.根据权利要求6的制备光盘的方法,其中所述UV粘合指数为小于或等于约60。
8.根据权利要求7的制备光盘的方法,其中所述UV粘合指数为小于或等于约50。
9.根据权利要求8的制备光盘的方法,其中所述UV粘合指数为小于或等于约40。
10.根据权利要求9的制备光盘的方法,其中所述UV粘合指数为小于或等于约30。
11.根据权利要求10的制备光盘的方法,其中所述UV粘合指数为小于或等于约20。
12.根据权利要求11的制备光盘的方法,其中所述UV粘合指数为小于或等于约10。
13.根据权利要求1的制备光盘的方法,其中所述第一塑料基板包括大于或等于约0.02重量%着色剂,该着色剂量基于所述第一塑料基板的总重量。
14.根据权利要求13的制备光盘的方法,其中所述第一塑料基板包括大于或等于约0.04重量%着色剂,该着色剂量基于第一塑料基板的总重量。
15.根据权利要求1的制备光盘的方法,进一步包括从塑料树脂和着色剂形成塑料材料,其中所述塑料材料包括大于或等于约0.01重量%着色剂,该着色剂量基于塑料材料的总重量,并且其中所述塑料材料具有与第一塑料基板相同的着色剂浓度;和从所述塑料材料形成第一塑料基板。
16.根据权利要求1的制备光盘的方法,进一步包括从塑料树脂形成第一塑料基板,其中所述塑料树脂包括与第一塑料基板不同的着色剂浓度。
17.根据权利要求1的制备光盘的方法,进一步包括测定所述粘合层中光敏引发剂的吸光度,和调节着色剂的参数以达到大于或等于约0.05的UV粘合指数,其中所述参数选自着色剂浓度、着色剂类型、以及包括至少一种上述参数的结合。
18.一种制备光盘的方法,包括:
从塑料树脂和着色剂形成塑料材料,其中所述塑料材料包括大于或等于约0.01重量%着色剂,该着色剂量基于所述塑料材料的总重量;
从所述塑料材料形成第一塑料基板,其中第一塑料基板的UV粘合指数大于或等于约0.5,和其中所述塑料材料具有与第一塑料基板相同的着色剂浓度;
在第一塑料基板和第二基板之间布置数据层;
采用粘合层将第一塑料基板粘合到所述第二塑料基板;和
固化所述粘合层。
19.根据权利要求18的制备光盘的方法,其中所述UV粘合指数为小于或等于约40。
20.根据权利要求19的制备光盘的方法,其中所述UV粘合指数为小于或等于约30。
21.根据权利要求20的制备光盘的方法,其中所述UV粘合指数为小于或等于约20。
22.根据权利要求21的制备光盘的方法,其中所述UV粘合指数为小于或等于约10。
23.一种光盘,包括:
至少两个塑料基板(1),其包括分布在其间的粘合层和数据层,其中至少一个所述基板(1)是包括大于或等于约0.01重量%着色剂的读取侧基板,该着色剂量基于所述读取侧基板的总重量,并且其中所述读取侧基板的UV粘合指数大于或等于约0.5。
24.根据权利要求23的光盘,其中所述光盘选自DVD5、DVD9、DVD10、DVD14和DVD18。
25.根据权利要求23的光盘,其中通过所述读取侧基板的光透射在激光读取波长下是约60%-小于94%。
26.根据权利要求25的光盘,其中所述光透射是约70%-约92%。
27.根据权利要求26的光盘,其中所述光透射是约74%-约88%。
28.根据权利要求27的光盘,其中所述光透射是约78%-约84%。
29.根据权利要求23的光盘,其中所述读取侧基板的厚度为约0.4毫米-约1毫米。
30.根据权利要求23的光盘,其中所述UV粘合指数为小于或等于约70。
31.根据权利要求30的光盘,其中所述UV粘合指数为小于或等于约60。
32.根据权利要求31的光盘,其中所述UV粘合指数为小于或等于约50。
33.根据权利要求32的光盘,其中所述UV粘合指数为小于或等于约40。
34.根据权利要求33的光盘,其中所述UV粘合指数为小于或等于约30。
35.根据权利要求34的光盘,其中所述UV粘合指数为小于或等于约20。
36.根据权利要求35的光盘,其中所述UV粘合指数为小于或等于约10。
37.根据权利要求23的光盘,其中所述塑料选自无定形热塑性塑料、结晶热塑性塑料、半结晶热塑性塑料、热固性塑料、和包括至少一种上述塑料的共混物、共聚物、反应产物、和复合材料。
38.根据权利要求37的光盘,其中所述塑料选自聚醚酰亚胺、聚醚醚酮、聚酰亚胺、聚氯乙烯、聚烯烃、聚酯、聚酰胺、聚砜、聚酰亚胺、聚醚酰亚胺、聚醚砜、聚苯硫醚、聚醚酮、聚醚醚酮、ABS树脂、聚苯乙烯、聚丁二烯、聚丙烯酸酯、聚丙烯腈、聚缩醛、聚苯醚、乙烯-醋酸乙烯酯共聚物、聚醋酸乙烯酯、液晶聚合物、乙烯-四氟乙烯共聚物、芳族聚酯、聚氟乙烯、聚偏1,1二氟乙烯、聚偏1,1二氯乙烯、四氟乙烯碳氟化合物共聚物、环氧树脂、酚醛树脂、醇酸树脂、聚酯、聚酰亚胺、聚氨酯、聚硅氧烷、聚硅烷、双马来酰亚胺、氰酸酯、乙烯基树脂、苯并环丁烯树脂、和包括至少一种上述塑料的共混物、共聚物、反应产物、和复合材料。
39.根据权利要求23的光盘,其中所述着色剂选自蒽醌、苝、周酮、阴丹酮、喹吖啶酮、呫吨、噁嗪、噻吨、靛青、硫靛、萘二酰亚胺、花青、呫吨、次甲基类、内酯、香豆素、双苯并噁唑基噻吩(BBOT)、萘四羧酸衍生物、单偶氮和双偶氮颜料、三芳基甲烷、氨基酮、双(苯乙烯基)联苯衍生物、和包括至少一种上述着色剂的反应产物和共混物。
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US20030150553A1 (en) 2003-08-14
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US6916519B2 (en) 2005-07-12
US6673410B2 (en) 2004-01-06

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