EP1459311A2 - Disques optiques colores et leurs procedes de fabrication - Google Patents
Disques optiques colores et leurs procedes de fabricationInfo
- Publication number
- EP1459311A2 EP1459311A2 EP02776245A EP02776245A EP1459311A2 EP 1459311 A2 EP1459311 A2 EP 1459311A2 EP 02776245 A EP02776245 A EP 02776245A EP 02776245 A EP02776245 A EP 02776245A EP 1459311 A2 EP1459311 A2 EP 1459311A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- optical disc
- equal
- making
- bonding
- less
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
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- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
- G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
- G11B7/26—Apparatus or processes specially adapted for the manufacture of record carriers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D17/00—Producing carriers of records containing fine grooves or impressions, e.g. disc records for needle playback, cylinder records; Producing record discs from master stencils
- B29D17/005—Producing optically read record carriers, e.g. optical discs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/0041—Optical brightening agents, organic pigments
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- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
- G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
- G11B7/241—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material
- G11B7/252—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers
- G11B7/253—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of substrates
- G11B7/2533—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of substrates comprising resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
- B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
- B29C65/4845—Radiation curing adhesives, e.g. UV light curing adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/002—Coloured
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2017/00—Carriers for sound or information
- B29L2017/001—Carriers of records containing fine grooves or impressions, e.g. disc records for needle playback, cylinder records
- B29L2017/003—Records or discs
- B29L2017/005—CD''s, DVD''s
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B2038/0052—Other operations not otherwise provided for
- B32B2038/0076—Curing, vulcanising, cross-linking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2429/00—Carriers for sound or information
- B32B2429/02—Records or discs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
- G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
- G11B7/241—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material
- G11B7/252—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers
- G11B7/253—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of substrates
- G11B7/2533—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of substrates comprising resins
- G11B7/2534—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of substrates comprising resins polycarbonates [PC]
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- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
- G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
- G11B7/241—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material
- G11B7/252—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers
- G11B7/256—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of layers improving adhesion between layers
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- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
- G11B7/24—Record carriers characterised by shape, structure or physical properties, or by the selection of the material
- G11B7/241—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material
- G11B7/252—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers
- G11B7/258—Record carriers characterised by shape, structure or physical properties, or by the selection of the material characterised by the selection of the material of layers other than recording layers of reflective layers
Definitions
- This disclosure relates to a data storage media, and especially relates to a colored data storage media.
- DVDs Digital Versatile Disks
- CDs Compact disks
- the disk construction has been changed.
- the most fundamental and visible difference is that a DVD is no longer made of a single 1.2 mm thick plastic substrate but of two 0.6 mm halves that are bonded together ("DVD Demystified:" by Jim Taylor, ed. McGraw Hill, 1998).
- the reading laser wavelength has changed from 780 nanometers (nm) in CDs, which is located in the near infrared part of the spectrum, to 635 or 650 nm for DVDs that is located in the visible spectrum.
- DVD-R DVD-R
- the construction can vary substantially, going from a single side/single layer (DVD-5) to double side/double layer (DVD- 18), not to mention the recordable formats such as DVD-R and DVD-RW.
- the tight specifications European Association for Standardizing Information and Communication Systems ("ECMA") Specifications #267 for 1.20 mm DVD-Read only disk) imposed by the Optical Media consortium, combined with the fact that the laser wavelength is located in the visible spectrum makes DVD manufacturing a challenge.
- ECMA European Association for Standardizing Information and Communication Systems
- the optical properties of the substrate are not the only requirements for DVDs.
- the size of the pits is much smaller in a DVD, which implies that a DVD is more sensitive to resin quality (impurities) than a CD.
- the rheology (flow characteristics) of the resin is important and tightly controlled.
- inconsistencies in the thickness of the disk body are also a source of defects in optical disks.
- a DVD is much more sensitive to the presence of such defects because it is not only thinner and read in the visible spectrum, but it is also read at a higher rotational/scanning speed than a regular CD.
- the most advanced DVD formats that are multi-layered represent the highest degree of difficulty because of the presence of both a fully reflective and a semi-reflective layer associated with 2 layers of pits (e.g., patterning which forms geographic locators).
- Single layered DVDs i.e. DVD-5 and DVD- 10
- reflectivity requirements are very different between single layered and multi-layered disks.
- the optical discs comprise: at least two plastic substrates comprising a bonding layer and a data layer disposed therebetween, wherein at least one of the substrates is a read side substrate comprising greater than or equal to about 0.01 wt% colorant, based upon the total weight of the read side substrate, and wherein the read side substrate has a UV Bonding Index of greater than or equal to about 0.5.
- One method for making the optical disc comprises: forming a first plastic substrate comprising greater than or equal to about 0.01 wt% colorant, based upon the total weight of the first plastic substrate, wherein a UV Bonding Index of the first plastic substrate is controlled to be greater than or equal to about 0.5, disposing a data layer between the first plastic substrate and a second substrate, bonding the first plastic substrate to the second plastic substrate with a bonding layer, and curing the bonding layer.
- Figure 1 is a schematic representation of a DVD 9 construction
- Figure 2 is a schematic of a CD construction having a single reflective layer disposed at a second side of the substrate;
- Figure 3 is a schematic of a DVD construction having a single reflective data layer disposed within the substrate
- Figure 4 is a schematic of a DVD construction having two reflective data layers, a semi-reflective data layer and a fully reflective data layer, disposed within the substrate;
- Figure 5 is a schematic of a DVD construction having a single reflective data layer and a single laser
- Figure 6 is a schematic of a DVD construction having two reflective data layers, both disposed on opposite sides of the center of the substrate, and each readable from different sides of the substrate;
- Figure 7 is a schematic of a DVD construction having two reflective data layers, both disposed on opposite sides of the center of the substrate, and both readable from the same side of the substrate;
- Figure 8 is a schematic of a DVD construction having two reflective data layers, both disposed on the same side of the center of the substrate, and both readable from the same side of the substrate;
- Figure 9 is a schematic of a DVD construction having four reflective data layers, two disposed on each side of the center of the substrate, and two readable from each side of the substrate;
- Figure 10 is a graphical illustration of light transmission of several colorants in 1.2 mm polycarbonate substrate at a loading of 0.014 weight percent.
- Figure 1 1 is a graphical illustration of transmission curves of experimental formulations
- Figure 12 are graphical illustrations of a spectral distribution of type "D" electrodeless bulb from fusion UV systems
- Figure 13 is a graphical representation of a percentage of incident energy transmitted through substrates of experimental formulations.
- Figure 14 is a graphical representation of the abso ⁇ tion spectrum of Daicure Clear SD-698 lacquer.
- DVDs found on the market are made using clear (colorless) resin.
- the clear disks show good optical/electrical properties (reflectivity, jitter, parity inner (PI) errors, birefringence, etc.) as well as good mechanical properties (radial/tangential/vertical tilt), even after aging at 80°C at 85% relative humidity (RH) for 4 days.
- RH relative humidity
- any type of DVD format e.g., single layered (such as DVD-5 and DVD- 10), multi-layered (such as DVD-9, DVD- 14, DVD- 18), and the like
- an insufficient curing of the bonding layer otherwise known as the lacquer or adhesive
- the insufficient curing of the bonding layer leads to tilt defects or, in the worst case, to a total adhesion failure where the two substrates do not stick to each other.
- the process of bonding the plastic substrates of the DVD discs can be accomplished with UV light (e.g., in the about 330 to about 410 nanometer (nm) range) that irradiates the adhesive (e.g., photocurable bonding layer).
- UV light e.g., in the about 330 to about 410 nanometer (nm) range
- the adhesive e.g., photocurable bonding layer.
- the issue with the colored discs is that the colored substrates exhibit some UV abso ⁇ tion with the amount of abso ⁇ tion dependent on the level of loading and chemical nature of the colorant.
- the bonding problems occur when the amount of UV light transmission through the plastic substrate is low (for example, less than about 1 % of the UV light that would transmit through a clear substrate).
- a threshold energy is transmitted through the colored substrate.
- the threshold energy is defined by the total spectral energy (watts) transmitted in the about 330 to about 410 nm range. It should be emphasized that the threshold energy is herein defined with the same cure time as for a clear substrate. It is understood that a lower threshold energy could be employed with a longer cure time which could increase the efficiency of light abso ⁇ tion by the bonding layer and consequently improve bonding.
- Typical curing time is less than about 3 seconds, with less than or equal to about 2 seconds preferred. However, the cycle time would be increased considerably which would negatively impact disc production rate and hence is not the method of choice.
- the threshold energy can be quantified in terms of a parameter known as the "UV Bonding Index" which is a function of the abso ⁇ tion spectrum of the colored substrate as well as the spectral distribution of the irradiating source.
- UV Bonding Index a parameter known as the "UV Bonding Index” which is a function of the abso ⁇ tion spectrum of the colored substrate as well as the spectral distribution of the irradiating source.
- the product of the spectral energy output of the irradiating source and percentage transmission through the colored plastic substrate is first calculated as a function of wavelength over the entire UV-Visible spectrum. Integration of this curve over the wavelength range 330 nm to the bonding layer cutoff (i.e., to the point where the bonding layer no longer absorbs the light) provides a value for total energy transmitted through the colored substrate in that spectral range.
- UV Bonding Index The ratio of the total energy passing through a colored substrate to that of the energy passing through a clear substrate (calculated by the above procedure) gives a value for the UV Bonding Index.
- a UV Bonding Index of greater than or equal to about 0.5 can be employed, a UV Bonding Index of greater than or equal to about 1.0 is preferred, greater than or equal to about 2 is more preferred, greater than or equal to about 4.0 is even more preferred. It has been discovered that UV Bonding Indices of less than or equal to about 70, less than or equal to about 60, less than or equal to about 50, less than or equal to about 40, less than or equal to about 30, less than or equal to about 20, less than or equal to about 10, and even less than or equal to about 5 can be employed.
- the UV Bonding Index can be calculated for any lamp. Some possible lamps include the Type 'D' bulb from Fusion UV Systems, Type FQ20007 bulb in the Flash Pulse UV curing system (Marubeni/Origin DVD Bonder), DVD Edge Cure lamp (M2 Co ⁇ .), RC742 lamps from Xenon Co ⁇ ., and the like. Similarly, the UV Bonding Index can be calculated for any bonding layer that absorbs light in at least a portion of the desired spectrum.
- a digital versatile disk comprises two bonded plastic substrates (or resin layers) 1 , each typically having a thickness less than or equal to about 1.0 millimeter (mm), with a thickness of less than or equal to about 0.7 mm preferred. A thickness of greater than or equal to about 0.4 mm is also preferred. At least one substrate comprises one or more layers (e.g., 3, 5), of data.
- Single sided DVD's i.e., those that will be read from a single readout surface 7 disposed on one side of the DVD), can additionally comprise a label 13 disposed on the side of the DVD opposite the readout surface 7.
- a stamped surface is covered with a thin reflective data layer by a sputtering or other deposition process. This creates a metallic coating typically about 60 to about 100 angstroms (A) thick. (See Figures 3, 5, and 6)
- the laser must be able to reflect from the first layer 3 when reading it, but also focus (or transmit) through the first layer 3 when reading the second layer 5.
- the first layer 3 is "semi- transparent" (i.e., semi-reflective), while the second layer 5 is "fully-reflective".
- metallization combination for the fully-reflective and semi-reflective data layers should be about 18 percent (%) to about 30% at the wavelength of the laser.
- the laser wavelength generally employed is less than or equal to about 700 nm, with about 400 nm to about 675 nm preferred, and about 600 nm to about 675 nm more preferred.
- Metallization for the individual data layer(s) can be obtained using various reflective materials.
- Materials e.g., metals, alloys, and the like, having sufficient reflectivity to be employed as the semi-reflective and/or fully reflective data layers, and which can preferably be sputtered onto the substrate, can be employed.
- Some possible reflective materials comprise gold, silver, platinum, silicon, aluminum, and the like, as well as alloys and combinations comprising at least one of the foregoing materials.
- the first/second reflective data layer metallization can be gold/aluminum, silver alloy/aluminum, silver alloy/silver alloy, or the like.
- the difference in reflectivity between subsequent reflective data layers should be controlled, in order to ensure sufficient reflectivity of the subsequent layer.
- the difference in reflectivity between subsequent layers is less than or equal to about 5%, with less than or equal to about 4% preferred, and less than or equal to about 3.0% more preferred.
- the reflective data layers are typically sputtered or otherwise disposed on a pattern (e.g., surface features such as pits, grooves, asperities, start/stop orientor, and/or the like) formed into a surface of the substrate via molding, embossing, or the like.
- Depositions for example, can comprise sputtering a semi-reflective data layer over a first patterned surface.
- a separator layer or protective coating can then be disposed over the semi-reflective data layer.
- a 2 nd patterned surface can be formed (e.g., stamped or the like) in the side of the separator layer opposite the semi-reflective data layer.
- a fully reflective data layer can then be sputtered or otherwise deposited on the separator layer.
- the fully reflective data layer can be deposited on a patterned surface of a 2 nd substrate (or resin layer).
- a separate layer or protective coating is then disposed on one or both of the semi-reflective data layer and the fully reflective data layer.
- a bonding agent or adhesive can then be disposed between the 2 substrates and they can be bonded together to form a disk as illustrated in Figures 3-9.
- several semi-reflective data layers can be deposited with a separator layer between each subsequent layer.
- the reflectivity of the reflective data layer(s) can be about 5% to about 100%, depending upon the number of reflective layers. If a single reflective data layer is employed, the reflectivity is preferably about 30% to about 100%, with about 35% to about 90% more preferred, and about 45% to about 85% even more preferred. If a dual reflective data layer is employed, the reflectivity of the data layers is preferably about 5% to about 45%, with about 10% to about 40% more preferred, about 15% to about 35% even more preferred, and about 18% to about 30% especially preferred. Finally, if multiple reflective data layers (e.g., greater than 2 reflective data layers readable from a single reading surface) are employed, the reflectivity is preferably about 5% to about 30%, with about 5% to about 25% more preferred.
- the especially preferred ranges are currently based upon the ECMA specification #267, wherein the reflectivity is either about 18% to about 30% reflectivity for a dual layered DVD (e.g., at least one fully reflective layer and at least one semi-reflective layer) or about 45% to about 85% reflectivity for a single layer DVD (e.g., one fully reflective layer).
- the substrate can comprise any optical quality plastic, e.g., any plastic that enables the transmission of about 60% to less than 94% of light therethrough, in the wavelength region of the laser.
- the transmissivity is greater than or equal to about 70%, with greater than or equal to about 74% more preferred, and greater than or equal to about 78% especially preferred.
- the transmissivity can be less than or equal to about 92%, with less than or equal to about 88% and even less than or equal to about 85%o possible, depending upon the type of colorant. It should be noted that as the transmissivity of the colored substrate decreases, the ability to attain the desired adhesion of the substrates becomes more difficult.
- the plastic substrate can comprise a resin such as an amo ⁇ hous, crystalline, or semi- crystalline thermoplastic, a thermoset, or a combination comprising at least one of the foregoing plastics.
- plastics include polyetherimides, polyetheretherketones, polyimides, polyvinyl chloride, polyolefins (including, but not limited to, linear and cyclic polyolefins and including polyethylene, chlorinated polyethylene, polypropylene, and the like), polyesters (including, but not limited to, polyethylene terephthalate, polybutylene terephthalate, polycyclohexylmethylene terephthalate, and the like), polyamides, polysulfones (including, but not limited to, polyethersulfones, polyetherethersulfones, hydrogenated polysulfones, and the like), polyimides, polyether imides, polyether sulfones, polyphenylene sulfides, polyether ketones, polyether
- the substrate comprises polycarbonate, with a primarily polycarbonate (e.g., greater than or equal to about 80% polycarbonate) substrate especially preferred.
- a primarily polycarbonate e.g., greater than or equal to about 80% polycarbonate
- composition comprising aromatic carbonate chain units includes compositions having structural units of the formula (I):
- R 1 is an aromatic organic radical and, more preferably, a radical of the formula (II):
- each of A 1 and A 2 is a monocyclic divalent aryl radical and Y 1 is a bridging
- radicals of this type are -O-, -S-, -S(O)-, -S(O 2 )-, -C(O)-, methylene, cyclohexyl- methylene, 2-[2,2,l ]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene, and adamantylidene.
- the bridging radical Y 1 can be a hydrocarbon group or a saturated hydrocarbon group such as methylene, cyclohexylidene or isopropylidene.
- dihydroxy compound includes, for example, bisphenol compounds having general formula (III) as follows:
- R a and R b each represent a halogen atom or a monovalent hydrocarbon group and may be the same or different; p and q are each independently integers from 0 to 4; and X a represents one of the groups of formula (IV):
- R c and R d each independently represent a hydrogen atom or a monovalent linear or cyclic hydrocarbon group and R c is a divalent hydrocarbon group.
- dihydroxy compounds include dihydric phenols and the dihydroxy-substituted aromatic hydrocarbons disclosed by name or formula (generic or specific) in U.S. Patent No. 4,217,438.
- a nonexclusive list of specific examples of the types of bisphenol compounds that may be represented by formula (III) includes the following: l ,l -bis(4-hydroxyphenyl) methane; l ,l -bis(4- hydroxyphenyl) ethane; 2,2-bis(4-hydroxyphenyl) propane (hereinafter "bisphenol A” or "BPA”); 2,2-bis(4-hydroxyphenyl) butane; 2,2-bis(4-hydroxyphenyl) octane; 1 ,1 - bis(4-hydroxyphenyl) propane; l ,l -bis(4-hydroxyphenyl) n-butane; bis(4- hydroxyphenyl) phenylmethane; 2,2-bis(4-hydroxy-l-methylphenyl) propane; 1 ,1 - bis(4-hydroxy-t-butylphenyl) propane; bis(hydroxyaryl) alkanes such as 2,2-bis(4- hydroxy-3-bromopheny
- polycarbonates resulting from the polymerization of two or more different dihydric phenols or a copolymer of a dihydric phenol with a glycol or with a hydroxy- or acid-terminated polyester or with a dibasic acid or with a hydroxy acid or with an aliphatic diacid in the event a carbonate copolymer rather than a homopolymer is desired for use.
- useful aliphatic diacids have from 2 to about 40 carbons.
- a preferred aliphatic diacid is dodecandioic acid.
- Polyarylates and polyester-carbonate resins or their blends can also be employed.
- Branched polycarbonates are also useful, as well as blends of linear polycarbonate and a branched polycarbonate The branched polycarbonates may be prepared by adding a branching agent during polymerization.
- branching agents may comprise polyfunctional organic compounds containing at least three functional groups that may be hydroxyl, carboxyl, carboxyhc anhydride, haloformy], and mixtures comprising at least one of the foregoing groups.
- Specific examples include t ⁇ mellitic acid, t ⁇ mellitic anhydride, t ⁇ mellitic trichloride, tns-p- hydroxy phenyl ethane, isatin-bis-phenol, t ⁇ s-phenol TC (l ,3,5-t ⁇ s((p- hydroxyphenyl) ⁇ sopropyl)benzene), t ⁇ s-phenol PA (4(4(1 , l -b ⁇ s(p-hydroxyphenyl)- ethyl) alpha,alpha-d ⁇ methyl benzyl)phenol), 4-chloroformyl phthalic anhydride, t ⁇ mesic acid and benzophenone tetracarboxylic acid, and the like
- the branching agents may be
- Preferred polycarbonates are based on bisphenol A, in which each of A 1 and A 2 is p- phenylene and Y 1 is isopropylidene.
- the weight average molecular weight of the polycarbonate is about 5,000 to about 100,000, more preferably about 10,000 to about 65,000, and most preferably about 15,000 to about 35,000.
- Fries and “Fries product” denote a repeating unit in polycarbonate having the formula (V)
- X a is a bivalent radical as described in connection with formula (III) described above.
- the polycarbonate composition may also include various additives ordinarily inco ⁇ orated in resin compositions of this type.
- additives are, for example, fillers or reinforcing agents; heat stabilizers; antioxidants; light stabilizers; plasticizers; antistatic agents; mold releasing agents; additional resins; blowing agents; and the like, as well as combinations comprising at least one of the foregoing additives.
- fillers or reinforcing agents include glass fibers, asbestos, carbon fibers, silica, talc and calcium carbonate.
- heat stabilizers examples include triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono-and di- nonylphenyl)phosphite, dimethylbenzene phosphonate, and trimethyl phosphate.
- antioxidants include octadecyl-3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate, and pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate].
- Examples of light stabilizers include 2-(2-hydroxy-5- methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole and 2- hydroxy-4-n-octoxy benzophenone.
- plasticizers include dioctyl-4,5- epoxy-hexahydrophthalate, tris-(octoxycarbonylethyl)isocyanurate, tristearin and epoxidized soybean oil.
- Examples of the antistatic agent include glycerol monostearate, sodium stearyl sulfonate, and sodium dodecylbenzenesulfonate.
- mold releasing agents include stearyl stearate, beeswax, montan wax and paraffin wax.
- other resins include but are not limited to polypropylene, polystyrene, polymethyl methacrylate, and polyphenylene oxide. Combinations of any of the foregoing additives may be used. Such additives may be mixed at a suitable time during the mixing of the components for forming the composition.
- the composition may optionally include various additives ordinarily inco ⁇ orated in resin compositions of this type.
- additives may include UV absorbers; stabilizers, such as light and thermal stabilizers (e.g., acidic phosphorous-based compounds); hindered phenols; zinc oxide, zinc sulfide particles, or combination thereof; lubricants (mineral oil, and the like); plasticizers; antioxidants; anti-static agents (tetra alkylammonium benzene sulfonate salts, tetra alkylphosphonium benzene sulfonate salts, and the like); mold releasing agents (pentaerythritol tetrastearate; glycerol monstearate, and the like); and the like, and combinations comprising at least one of the foregoing additives.
- stabilizers such as light and thermal stabilizers (e.g., acidic phosphorous-based compounds); hindered phenols; zinc oxide, zinc s
- the substrate can comprise about 0.01 weight percent wt%> to about 0.1 wt% heat stabilizer; about 0.01 wt% to about 0.2 wt% antistatic agent; and about 0.1 wt% to about 1 wt% mold releasing agent; based upon the total weight of the polymer.
- antioxidants include, for example, organophosphites, e.g., tris(nonyl- phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t- butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite and the like; alkylated monophenols, polyphenols and alkylated reaction products of polyphenols with dienes, such as, for example, tetrakis[methylene(3,5-di-tert-butyl-4- hydroxyhydrocinnamate)] methane, 3,5-di-tert-butyl-4-hydroxyhydrocinnamate octadecyl, 2,4-di-tert-butylphenyl phosphite, and the like; butylated reaction products of para-cre
- catalyst(s) may also be employed, namely in the extruder or other mixing device.
- the catalyst typically assists in controlling the viscosity of the resulting material.
- Possible catalysts include hydroxides, such as tetraalkylammonium hydroxide, tetraalkylphosphonium hydroxide, and the like, with diethyldimethylammonium hydroxide and tetrabutylphosphonium hydroxide preferred.
- the catalyst(s) can be employed alone or in combination with quenchers such as acids, such as phosphoric acid, and the like. Additionally, water may be injected into the polymer melt during compounding and removed as water vapor through a vent to remove residual volatile compounds.
- the polymer is produced by using a reaction vessel capable of adequately mixing various precursors, such as a single or twin screw extruder, kneader, blender, or the like.
- a reaction vessel capable of adequately mixing various precursors, such as a single or twin screw extruder, kneader, blender, or the like.
- the polymer is then formed, via a molding, extrusion, rolling, stamping, or similar techniques, into a substrate.
- Adjacent substrates are attached together with an adhesive or bonding agent (e.g., separator or bonding layer).
- an adhesive or bonding agent e.g., separator or bonding layer.
- Any bonding agent having the desired optical qualities can be employed.
- Some possible bonding agents include glue (e.g., hot glue), acrylic resin (e.g., ultra-violet (UV) curable acrylic resin, with transparent (i.e., greater than or equal to UV curable acrylic resin preferred), and the like, as well as combinations comprising at least one of the foregoing bonding agents.
- the separating layer can comprise a transparent material.
- Some possible separating layers include UV curable transparent resins.
- the separating (bonding) layer is up to or exceeding several hundreds of micrometers ( ⁇ m) thick, with a thickness of less than or equal to about 100 ⁇ m useful, and a thickness of about 40 ⁇ m to about 70 ⁇ m typically employed with current DVD formats.
- the color can be added to the DVD by inco ⁇ orating colorant into the substrate (e.g., the resin layer), the separator layer(s), a top coat, or any combination comprising at least one of the foregoing layers.
- the coloring of the disk can be obtained in several ways, e.g., using a pre-colored resin for the substrate(s) and/or separating layer(s), mixing a colorless resin and a color concentrate at the molding machine, and using liquid or powder coloring (or a combination comprising at least one of these methods). Whether the colorants are introduced by feeding during the extrusion process, by physical mixing of colorless pellets with a color concentrate before molding, or by liquid or powder coloring at the molding machine, the colorant and its concentration are chosen to meet the DVD specifications.
- the colorant is preferably filtered, with melt filtering especially preferred, e.g., during adding in the extrusion process.
- the size of the filtered colorant particles (and aggregates thereof) is less than or equal to about 200 nanometers (nm), with a particle (and aggregate) size of less than or equal to about 50 nm preferred.
- Colorants are also preferably selected so that they solubilize in the material used to form the layer in which the colorant is disposed.
- Colorants that are soluble in the materials used for DVD layers include dyes (e.g., "solvent dyes"), organic colorants, pigments, and the like, which behave like dyes; i.e., colorants that disperse in the plastic and do not form aggregates having a size greater than or equal to about 200 nm, with an aggregate size less than or equal to about 50 nm preferred.
- colorants include, but are not limited to, those of the chemical family of anthraquinones, perylenes, perinones, indanthrones, quinacridones, xanthenes, oxazines, oxazolines, thioxanthenes, indigoids, thioindigoids, naphtalimides, cyanines, xanthenes, methines, lactones, coumarins, bis-benzoxaxolylthiophenes (BBOT), napthalenetetracarboxylic derivatives, monoazo and disazo pigments, triarylmethanes, aminoketones, bis(styryl)biphenyl derivatives, and the like, as well as combinations comprising at least one of the foregoing colorants.
- BBOT bis-benzoxaxolylthiophenes
- the colorant that has the lower abso ⁇ tivity at the desired wavelength e.g., at 650 nm, therefore exhibits the maximum transmission at this wavelength and is preferred.
- Selection of colorants with high abso ⁇ tivity at the desired wavelength limits the maximum colorant loading possible to yield a functional multi-layered DVD. Since colorants with a lower abso ⁇ tivity at the desired wavelength can be used at higher loadings in the formulation it becomes easier to obtain the target color in a functional disk. For instance, Solvent Violet 13 is preferred over Solvent Blue 97 when trying to achieve a blue color because of its lower abso ⁇ tivity at 650 nm.
- the colorant loading is greater than or equal to about 0.01 weight percent (wt%), with greater than or equal to about 0.02 wt% preferred, greater than or equal to about 0.04 wt% more preferred, greater than or equal to about 0.4 wt% even more preferred, and greater than or equal to about 0.5 wt% most preferred, based upon the total weight of the substrate comprising the colorant. It is further preferred to employ colorant in an amount of less than or equal to about 3.0 wt%, with less than or equal to about 2.0 wt% more preferred, less than or equal to about 1.0 wt% even more preferred, and less than or equal to about 0.75 wt% especially preferred.
- layers such as protective layer(s) (e.g., lacquers, and the like), ultra-violet (UV) inhibitor layer(s), moisture barrier layer(s), ductility layer(s), and the like, as well as combinations comprising at least one of these layers, can be employed.
- protective layer(s) e.g., lacquers, and the like
- UV inhibitor layer(s) e.g., ultra-violet (UV) inhibitor layer(s)
- moisture barrier layer(s) e.g., ductility layer(s), and the like
- ductility layer(s) e.g., ductility layer(s), and the like
- Table 1 lists the details of the formulations used. All six formulations were blended and pelletized in a single screw extruder at 290°C. DVDs were molded from the pelletized material using standard procedure and the discs were subjected to complete electrical (AudioDev DVDPro SA300 Pulsetech Drive) and mechanical (Dr. Schenk PROmeteus MT136) testing.
- the total energy passing through the substrate about 330 to about 410 nanometers (nm) (obtained by an integration procedure) expressed as a fraction of energy transmitted through the clear substrate is tabulated below in Table 3.
- Table 3 is a comparison of total energy transmitted through disc substrates in the wavelength range of about 330 to about 410 nm, expressed as a function of percent energy transmitted through clear substrate.
- the UV Bonding Index is tabulated below in Table 3.
- formulations B and C transmit only 0.045% of the incident energy which, being below the threshhold level, leads to poor bonding.
- formulations A, D and F have been developed to transmit 5.6%, 13.1% and 49% of the energy, respectively, which, being above the threshhold of 1%, provides good bonding capability.
- the total energy absorbed by the initiator can also be calculated by integrating the product of the energy transmitted through the substrate and the absorbance of the initiator.
- Figure 14 shows the abso ⁇ tion spectrum of Daicure clear SD-698, measured in 0.1 wt% methanol solution (Shimadzu Spectrophotometer commercially available from Shimadzu, Japan), an acrylic lacquer used in DVD bonding.
- the total energy absorbed by the photoinitiator for each of the substrates A-F expressed as a percentage of the clear is tabulated below (Table 4).
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Abstract
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/683,346 US6475589B1 (en) | 2001-12-17 | 2001-12-17 | Colored optical discs and methods for making the same |
US683346 | 2001-12-17 | ||
US10/063,906 US6673410B2 (en) | 2001-12-17 | 2002-05-22 | Colored optical discs and methods for making the same |
US63906 | 2002-05-22 | ||
PCT/US2002/033503 WO2003052751A2 (fr) | 2001-12-17 | 2002-10-16 | Disques optiques colores et leurs procedes de fabrication |
Publications (1)
Publication Number | Publication Date |
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EP1459311A2 true EP1459311A2 (fr) | 2004-09-22 |
Family
ID=29253870
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP02776245A Withdrawn EP1459311A2 (fr) | 2001-12-17 | 2002-10-16 | Disques optiques colores et leurs procedes de fabrication |
Country Status (5)
Country | Link |
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EP (1) | EP1459311A2 (fr) |
JP (1) | JP2005513694A (fr) |
AU (1) | AU2002342079A1 (fr) |
TW (1) | TWI273593B (fr) |
WO (1) | WO2003052751A2 (fr) |
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JP4140726B2 (ja) | 2004-09-14 | 2008-08-27 | 太陽誘電株式会社 | 光情報記録媒体 |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US6507550B1 (en) * | 1998-08-10 | 2003-01-14 | Fuji Photo Film Co., Ltd. | Optical data storage medium |
US6686041B2 (en) * | 2000-04-28 | 2004-02-03 | Teijin Chemicals Ltd | Coloring master pellet for optical molded article and colored optical disk substrate |
US6475588B1 (en) * | 2001-08-07 | 2002-11-05 | General Electric Company | Colored digital versatile disks |
-
2002
- 2002-10-16 WO PCT/US2002/033503 patent/WO2003052751A2/fr active Application Filing
- 2002-10-16 AU AU2002342079A patent/AU2002342079A1/en not_active Abandoned
- 2002-10-16 JP JP2003553560A patent/JP2005513694A/ja active Pending
- 2002-10-16 EP EP02776245A patent/EP1459311A2/fr not_active Withdrawn
- 2002-12-04 TW TW091135186A patent/TWI273593B/zh not_active IP Right Cessation
Non-Patent Citations (1)
Title |
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See references of WO03052751A2 * |
Also Published As
Publication number | Publication date |
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TWI273593B (en) | 2007-02-11 |
WO2003052751A2 (fr) | 2003-06-26 |
WO2003052751A3 (fr) | 2003-10-30 |
AU2002342079A8 (en) | 2003-06-30 |
TW200303014A (en) | 2003-08-16 |
JP2005513694A (ja) | 2005-05-12 |
AU2002342079A1 (en) | 2003-06-30 |
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