WO2006021960A1 - Slim data storing device and process for producing the same - Google Patents

Abstract

Process for producing a slim data storage device in which digital data can be recorded optically. A substrate made from an optically recordable material is formed and a helical track is defined while applying a light sensitive layer. A laser sensitive layer and a reflective layer are applied to the substrate. A varnish coating is applied onto the reflective layer or a printable layer is laminated onto said reflective layer. The helical track is burned with desired optical digital data and the die is cut, while and carrying out any other desired finishing operation. The slim data storage device may be produced by injection molding or by high pressure injection molding.

Description

SLIM DATA STORING DEVICE AND PROCESS FOR PRODUCING

THE SAME

Field of the Invention

The present invention relates to the field of slim devices for storing digital information to be written and read using electro-optic methods, in particularly, but not exclusively, business cards, and to the technology for producing them. In a particular aspect, the invention relates to devices for storing data that are slimmer than those provided by the prior art. The invention further relates to a process for producing such devices and to accessories for the use thereof.

Background of the Invention

Currently, information is stored as digital data on a variety of media, such as CD-Rom, CD-R, DVD and the like. The information is read and/or written using readers and/or writers conventionally known and commonly used in P. Cs. All those media, however, give rise to devices having a thickness of 1200μ or the like, which thickness makes them unsuitable for many uses. A typical, though not the only, use in which the said thickness is a serious problem, is that of business cards.

Business cards are universally used for introducing, and leaving a reminder of, for example, a representative of a company or of an organization, a social contact or a potential employee seeking employment. Information for contacting the person distributing the card, such as the name, mailing address, telephone and fax numbers, and e-mail address, is listed on the card. Two types of business cards are part of the present art. One type is made of cardboard paper and all the information is printed on it. The other type is a small CD-like card made of polycarbonate, which holds on one side printed information and on the other side optic information. Said second type is 1200μ thick, and therefore only few can be carried in a business card holder. Further, it has a high cost, and therefore it usually contains only general company information, and not personal information of the cardholder. Other possible uses, such as for advertising, promotion and the like, are prevented by the aforesaid drawbacks of the CD -type cards. This invention is not concerned with such prior art business cards.

Prior art business cards with multimedia-stored information are disclosed in EP 1,002,662, WO 00/52685, WO 99/00765, CN 1,338,829, US 2002/0053595, JP 1127796, US 6,403,191, and GB 2353970. None of them is free of the drawbacks described hereinbefore or in general of drawbacks that severely limit their use.

Further, the art does not provide an appropriate technology for the production of thin data storing devices that could be utilized in present CD-Rom, CD-R, DVD and other like optical readers/writers, and which could be used in applications in which the existing information carrying devices are not usable.

It is therefore an object of the invention to provide method, apparatus, system and accessories for producing devices for optically storing digital data having thickness substantially smaller than 1200μ, e.g. from 50 to 600μ. This said thickness opens other fields of use e.g. marketing material, smart greeting cards, smart packaging containing digital information and such.

It is another object of the invention to provide slim optical devices, for storing data, usable, inter alia, as business cards. It is a further object of the invention to provide an auxiliary device intended, if needed, to enable reading/writing said aforementioned devices, by a standard CD-Rom, CD-R, DVD read/write device, and the like.

It is a still further object of the invention to provide a business card of a sufficiently small thickness that allows tens of cards with multimedia- stored information to be contained within a business card holder.

It is still further object of the present invention to provide a business card whose manufacturing costs are sufficiently low so as to be suitable and cost effective for applications which require only a limited distribution of cards.

It is a still further object of the present invention to provide a business card, which permits information to be optically stored therein may be input by the end user.

Other objects and advantages of the invention will appear as the description proceeds.

Summary of the Invention

The invention provides a process for producing a slim data storage device in which digital data can be recorded optically, which comprises the steps of: a) Forming a substrate; b) Defining a helical track and/or applying a light sensitive layer; c) Applying a laser sensitive layer; d) Applying a reflective layer to said substrate; e) Applying a varnish coating onto said reflective layer or laminating a printable layer onto said reflective layer; f) Burning with desired optical digital data; and g) Die cutting and carrying out any other desired finishing operation.

The term "burning", as used herein, means recording the digital data by optical means in said optically sensitive layer and/or reflective layer. In a preferred embodiment, the digital data is recorded by means of a laser and the optically sensitive layer is a layer sensitive to laser. Materials in which digital data can be recorded by laser, will be called herein "recordable materials" or "optically recordable materials".

In one embodiment of the invention, a slim data storage device is produced by injection molding or by high pressure injection molding. The steps of such a process comprise: a) Forming an injection mold having suitable projections complementary to desired recesses in the storage device which define bjbtic JhjMgt&ai αhadifeding an optically clear material in said mold whereby to form a slim substrate, said slim substrate preferably being a disk or having any other desired shape; c) Applying laser recordable material onto said substrate; c) Applying a reflective layer onto said laser recordable material; and d) Applying a varnish coating onto said reflective layer.

In one aspect, the reflective layer is applied onto the disk by chemical vapor deposition (CVD). The disk is placed in a high vacuum chamber at room temperature together with a crucible containing material to be deposited, e.g. Al. By means of a heating source, said material evaporates and then condenses on all exposed cool surfaces of the disk. Typical heating sources are E-Beam, resistive heating and RF-Inductive heating. In one aspect, the reflective layer is applied onto the disk by sputtering. The disk is placed in a vacuum chamber and a target of the material to be deposited, e.g. Al, is selected. Plasma is generated within a passive source gas such as Argon introduced to the chamber, and the ion bombardment is directed towards the target, causing material to be sputtered from the target and to be condensed on the disk. A strong magnetic field is generally used to concentrate the plasma near the target, so as to increase the deposition rate.

In another embodiment of the invention, a slim data storage device is produced by forming a film. The steps of such a process comprise: a) Providing an optically clear plastic laminate, preferably in the form of a roll; b) Defining a helical track on said laminate by stamping or by photolithography; c) Optionally, juxtaposing a mask to said laminate; d) Applying a laser sensitive layer to said laminate; e) Optionally, applying a separate light sensitive layer to said laminate which is in addition to said laser sensitive layer; f) Applying a reflective layer onto said laser sensitive layer; g) Applying a varnish coating onto said reflective layer or laminating said reflective layer onto a carrying layer such as cardboard, whereby to form a treated laminate; h) Collecting the treated laminate; i) Burning said treated laminate with desired optical digital data; j) Printing visual information on said treated laminate; and k) Die-cutting said treated laminate and carrying out any other desired finishing operation. In one aspect, a slim data storage device is produced by photolithography. Residues are preferably rinsed to thereby remove access material.

The helical track serves two purposes: (a) for directing a laser writer to form the data on the laminate (b) for directing a laser reader to read already formed data such that the laser head follows the track in order to read the information. The helical track- may be formed in different ways, e.g.: a) by stamping, either by roll or by a flat stamp; b) by photolithography, wherein the laminate, preferably made of cellulose, is pre-coated with a sensitive layer, exposed with a light source from infinity, such as by means of a mask, and is then rinsed. Forming said track by mechanical means is more cost effective and more reliable for mass production; however, photographic means are preferable for low volume production techniques and for the chemical industry.

Preferably, the treated laminate is collected in the form of a semi-finished roll of blank devices. Said laminate may also be called, and will sometimes be called, "web". In every case, the treated laminate is preferably dried before being rolled as a blank roll. Steps h-j, the final steps, are preferably carried out at a separate location, either at a print shop or at the home of an end user who uses a home printer for step i and a PC-installed CD-R writer for step h.

In one aspect wherein the laminate is made of an optically recordable material, particularly laser recordable, e.g. polycarbonate, and is not provided in the form of a roll, visual information is printed on the treated laminate and then the treated laminates are collected. In cases in which the material is not optically recordable, an optically sensitive layer is applied to the substrate before applying the reflective layer. The substrate or optically clear laminate, which is the raw material of the above described process, is preferably chosen from the group consisting of polycarbonate, polypropylene, PET, celluloid, and the like. Its thickness is preferably from 50 to 600μ. The breadth of the laminate roll and its length may be as desired.

The semi-finished roll of blank devices is also, as a product or article of manufacture, an aspect of the invention. It may be defined as a roll of optically clear plastic laminate, having a helical track defined thereon, and having an optically sensitive layer, a reflective layer, and a varnish coating, laid on one another in areas on which digital information may be recorded by optical recording means.

In another aspect, the present invention provides a business card data storage system, which comprises: I) a card comprising a generally circular storage medium for storing optical information and a surrounding rectangular portion in which contact information can be imprinted, said storage medium and said surrounding portion being substantially coplanar and being parts of a common, single article of manufacture; and, whenever necessary, II) an auxiliary, read/write adapter for enabling reading/writing said optical information by standard read/write devices, such as CD-Rom, CD-R, DVD, and the like, said adapter being typically circular and having a central opening for the insertion of said card. Preferably, said adapter has typically a thickness of 1200μ, to be compatible with commercially available readers and writers, e.g. CD and CDR drives, and the like.

Brief Description of the Drawings

In the drawings: Figs. IA, IB and 1C are a perspective, front, and rear views, respectively, of a business card in accordance with the present invention;

Fig. 2 is a front view of an adapter compatible with the business card of the present invention;

Fig. 3 is a schematic drawing of the process of manufacturing a business card according to one embodiment of the present invention; and

Fig. 4 is a schematic drawing of the process of manufacturing a business card according to a second embodiment of the present invention.

Detailed Description of Preferred Embodiments

The business card, which is an aspect of the present invention, provides both conventional written information as well as multimedia information which is optically stored within a storage medium formed within the card. The thickness of the card, ranging from 50-600 microns, is considerably less than has been known heretofore (approximately 1200 microns). In contrast with the prior art by which the storage medium is affixed to, and necessarily protrudes from, the bottom surface of the card, the storage medium of the present invention is substantially coplanar with the surrounding card material. The thickness of the business card of the present invention can be realized by a novel manufacturing process, described hereinafter, that allows for both the storage medium and the remaining portion of the business card, in which digital information is not stored, to be made from a singular article of manufacture, resulting in lowered manufacturing costs and in a more affordable end product.

Fig. IA illustrates a rectangular business card generally indicated at numeral 10, whose thinness is clearly seen. Business Card 10 is made of plastics, such as polycarbonate, polypropylene, PET, celluloid and the like, and comprises annular storage medium 5 for digital data delimited by outer diameter 7 and inner diameter 9, which is visible on bottom side 13 of the card, and a portion 18 surrounding the storage medium which is not optically storable. Storage medium 5 is centrally located within the card, and, as shown by Figs. IB and 1C, surrounds centering hole 15, whose center 17 coincides with the intersection of midlines 19 and 20 of the length and width, respectively, of the card. Storage medium 5 is substantially coplanar with portion 18. Top side 14 of the card, except for centering hole 15, is planar and is adapted for printing contact information thereon, such as the name, mailing address, telephone and fax numbers, and e-mail address of the holder of the card. The dimensions of business card 10 are similar to a conventional business card made of cardboard paper, e.g. with a length of up to 100 and a width of up to 60 mm.

The dimensions of storage medium 5, e.g. with an outer diameter less than 60 mm and an inner diameter greater than or equal to 15 mm, are generally selected such that the stored digital information can be read by conventional devices well known to those skilled in the art, such as a CD- ROM, CD-R and DVD. If the dimensions of business card 10 are not compatible with those of a selected device, adapter 30 may be used, as shown in Fig. 2. Adapter 30 is formed with a rectangular shaped recess 32 into which business card 10 may be placed.

Figs. 3 and 4 illustrate embodiments of the process of the invention, by which may be made slim storage devices for storing any kind of data, typically in digital form. A preferred, but not exclusive, kind of such devices is constituted by business cards.

In the embodiment of Fig. 3, an optically clear laminate of a plastic material, e.g. of PET, which is suitable for being plastically deformed via stamping/embossing is initially provided. The clear laminate is the substrate of the storage medium. It is preferably supplied, as shown in Fig. 3, in the form of a roll 41. A helical track is then defined on the clear laminate by stamping, by means of rollers 42, the letter A indicating a roll of support. A mask 43, in the form of a continuous belt guided by guide rolls A, is then juxtaposed to the stamped laminate, to define the areas to be irradiated by laser in the information registering operation mentioned hereinafter. When the mask is juxtaposed to the laminate, a laser- sensitive material is spread on the laminate through the mask by spreaders 44. Thereafter a metallic coating is applied to the laminate at 45 by CVD or by sputtering, with a layer of aluminum serving as a reflector. Said metallic coating is then topped with a layer of varnish at 46. "A" indicates throughout the drawing auxiliary rolls and support.

After the metallic coating has been formed and varnished, as set forth above, the varnished laminate is dried at B, and finally the resulting laminate, or web, which is now a semi-finished product, is rolled to form a roll 47. Said roll 47 of semi-finished product is then delivered to a print shop for the finishing operations of printing, die-cutting to the desired shapes, and registering the desired digital information, these last operations not being described because conventional. It will be understood that printing may be carried out on one side of the web and the registration of digital information on the other side thereof. Such printing and registration can be accomplished concurrently by passing the web between a printer and an electronic programmer, or they may be accomplished successively by processing one side of the web, optionally rolling it again, and then processing the other side.

Fig. 4 illustrates another embodiment of a process according to the present invention. A clear laminate, or any other suitable film, pre-coated to render it light-sensitive in the same way in which a camera film is rendered sensitive, is provided, preferably in the form of a roll 51. A helical track is then formed by photographic means. A light source 58 is provided, which is optically at infinity, viz. emits light in parallel beams or is at such a distance from the laminate that the beams of the light that reach the laminate may be considered as substantially parallel. However, it is preferable further to assure by suitable optical means the parallelism of the light beams that reach the laminate, as schematically indicated at 59. The radiation issuing from 59 passes through a mask 60, which photographically defines the desired helical track on the laminate roll 51. Thereafter this embodiment is the same as that of Fig. 3, numerals 63, 64, 65, 66, and 57 designating respectively the same elements designated to numerals 43, 44, 45, 46, and 47 of Fig. 3. Alternatively, elements 63 and 64 are not employed, provided that separate light sensitive and laser sensitive layers are applied to the laminate. Semi-finished roll 57 is then delivered to a print shop for the finished operations of printing, die-cutting to the desired shapes, and registering the desired digital information, these last operations not being described because conventional.

When optically recordable business cards are produced, it will be appreciated that since the card and the corresponding adapter are produced from the same material and may be cut out from the same semi¬ finished roll, fewer steps are needed to produce a plurality of them, resulting in lowered manufacturing costs.

Of the two sides of a web, one side will hold the data and the other will be a decorative side which will hold printed information. The decorative side may be formed with a removable laminate so that a plurality of business cards may be imprinted with the same insignia, for example, by the pressing of a common plate on the selected web portion. Similarly, a machine may register the desired in formation on a plurality of business cards in a short period of time, since the printing may occur and preferably occurs when said cards are still connected in a continuous web.

When a plurality of business cards are collectively burned, digital information commonly used by most end users is recorded in each storage medium. The information recorded during the burning process includes software for pre-editing, such as menu lists which enable an end user, whether an individual seeking employment or a worker at a print shop, for example, to individually format and load a business card. Exemplary menu lists include type of contact information to be entered, e.g. name, organization, title, telephone number, mailing address, etc. or format of text, picture, audio or video information to be stored. To further increase the storage capability of the business card, software patches may be recorded during the burning process to create links to other types of software, e.g. accessible via the Internet network.

While some embodiments of the invention have been described by way of illustration, it will be apparent that the invention can be carried into practice with many modifications, variations and adaptations, and with the use of numerous equivalents or alternative solutions that are within the scope of persons skilled in the art, without departing from the spirit of the invention or exceeding the scope of the claims.

Claims

1. Process for producing a slim data storage device in which digital data can be recorded optically, which comprises the steps of: a) Forming a substrate; b) Defining a helical track and/or applying a light sensitive layer; c) Applying a laser sensitive layer; d) Applying a reflective layer to said substrate; e) Applying a varnish coating onto said reflective layer or laminating a printable layer onto said reflective layer; f) Burning with desired optical digital data; and g) Die cutting and carrying out any other desired finishing operation.

2. Process according to claim 1, wherein the substrate is made of an optically recordable material.

3. Process according to claim 1, wherein a slim data storage device is produced by injection molding or by high pressure injection molding.

4. Process according to claim 3, comprising: a) Forming an injection mold having suitable projections complementary to desired recesses in the storage device which define optical digital data; b) Injection molding an optically clear material in said mold whereby to form a slim substrate; c) Applying laser recordable material onto said substrate; d) Applying a reflective layer onto said laser recordable material; and Applying a varnish coating onto said reflective layer.

5. Process according to claim 4, wherein the slim substrate is formed in the shape of a disk.

6. Process according to claim 1, wherein a slim data storage device is produced by forming a film.

7. Process according to claim 6, comprising: a) Providing an optically clear plastic laminate; b) Defining a helical track on said laminate by stamping or by photolithography; c) Optionally, juxtaposing a mask to said laminate; d) Applying a laser sensitive layer to said laminate; e) Optionally, applying a separate light sensitive layer to said laminate; f) Applying a reflective layer onto said laser sensitive layer; g) Applying a varnish coating onto said reflective layer or laminating said reflective layer onto a carrying layer such as cardboard, whereby to form a treated laminate; h) Collecting the treated laminate; i) Burning said treated laminate with desired optical digital data; j) Printing visual information on said treated laminate; and k) Die-cutting said treated laminate and carrying out any other desired finishing operation.

8. Process according to claim 6, wherein a slim data storage device is produced by photolithography.

9. Process according to claim 7, wherein the optically clear laminate is provided in the form of a roll.

10. Process according to claim 7, wherein the treated laminate is collected in the form of a semi-finished roll.

11. Process according to claim 7, wherein the helical track is defined by means of a stamping roll.

12. Process according to claim 6, wherein the reflective layer is applied onto the substrate by chemical vapor deposition

13. Process according to claim 6, wherein the reflective layer is applied onto the substrate by sputtering.

14. Process according to claim 1, wherein the helical track is defined by photolithography.

15. Process according to claim 14, wherein the helical track is defined by pre-coating the laminate with a sensitive film, exposing it with a light source through a mask, and rinsing it.

16. Process according to claim 10, wherein the treated laminate is dried before being collected in the form of a semi-finished roll.

17. Process according to claim 1, wherein the substrate is chosen from the group consisting of polycarbonate, polypropylene, PET, celluloid, and the like.

18. Business card for data storage, which comprises: I) a card comprising a generally circular storage medium for storing optical information and a surrounding rectangular portion in which contact information can be imprinted, said storage medium and said surrounding portion being substantially coplanar and being parts of a common, single article of manufacture; and, whenever necessary, II) an auxiliary, read/write adapter for enabling reading/writing said optical information by standard read/write devices.

19. Business card according to claim 18, wherein the adapter is circular and has a central opening for the insertion of the card.

20. Business card according to claim 18, wherein the adapter has the same thickness as the card.

21. Business card according to claim 18, wherein the adapter is significantly thicker than the card.

22. Business card according to claim 18, wherein the card has a thickness from 50 to 600μ .

23.As an article of manufacture, a semi-finished roll of blank devices comprising a roll of optically clear plastic laminate, having a helical track defined thereon and having an optically sensitive layer, a reflective layer, and a varnish coating, laid on one another in areas on which digital information may be recorded by optical recording means.