Classifications

• • 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

Definitions

• TECHNICAL FIELD This relates to a method for recycling Compact Discs (CDs) or Digital Video
• CDs Compact Discs often referred to as CDs
• DVDs Digital Vide Discs
• disc replicators make millions of CDs and DVDs annually.
• scrap CDs and DVDs results in some scrap.
• recycling of scrap CDs and DVDs has proven difficult because of the metallized layers within such discs.
• scrap discs are currently shredded, and remnants serve as filler for roads and highways. While some have experimented with using scrap paper for making new discs, none have attempted to recycle old discs to make new ones.
• a Blu-ray disc has a structure including a substrate having one of either a Compact Dies data layer and a DVD data layer along with a Blu-ray data layer.
• the Blu-ray discs of the present invention advantageously use Compact Discs (or DVDs) that are due to be scrapped or recycled as donor substrates for new Blu-ray discs, thereby saving polycarbonate material and eliminating the need to purchase injection molding equipment to manufacture Blu-ray discs.
• FIG. 1 is a cross-sectional view of one embodiment of the Blu-ray disc of the present invention formed using a Compact Disc substrate;
• FIG. 2 is a cross-sectional view of another embodiment of the Blu-ray disc of the present invention formed using a DVD substrate; and
• FIG. 3 is a flow diagram depicting a method for forming the Blu-ray disc of the present invention.
• the present invention makes use of the fact that Blu-ray discs have the same dimensions and form factor as CDs and DVDs with the important feature on Blu-ray discs being that the data surface is on the bottom surface of the disc as opposed to CD which has the data surface on the top directly under the printed label, and DVDs where the data layers are in the center of the two bonded half-discs.
• the clear, flat bottom surface of CDs and DVDs lend themselves to the addition of a newly embossed Blu-ray data layer that supersedes the previous CD (DVD) data and effectively turns the CD (DVD) into a Blu-ray disc.
• a CD disc structure is typically comprised of a CD (Compact Disc) data layer 103 formed on a plastic substrate 105 as shown in FIG. 1.
• the disc 100 of the present principles includes a Blu-ray data layer 104 formed on a surface of the plastic substrate 105 opposite the CD data layer 103.
• Blu-ray data layer 104 may be formed of one or more layers of resin material (not shown).
• a first resin layer may comprise a spacer layer formed directly on the CD substrate 105.
• a second resin layer may be formed on the first resin layer.
• the second resin layer typically contains the Blu-ray data surface.
• a discarded and/or unused CD substrate 105 having a CD data layer 103 formed thereon is cleaned as indicated in step 301.
• the cleaned CD substrate 105 may be coated on a surface opposite the CD layer 103 (read-through surface for laser) with a resin layer 104 as is used to make conventional Blu-ray disc via, for example, a wet- embossing process.
• Resin layer 104 is then cured, as indicated in step 303 of FIG. 3.
• the resin layer 104 may be cured using for example, ultra-violet radiation.
• the cured resin 104 is then coated with a 1-10 micron thick layer of "pit resin" as used in conventional Blu- ray wet-embossing process.
• the "pit resin” is used to form the Blu-ray data surface of the Blu-ray disc 100, as indicated in step 304 of FIG. 3.
• the pit-resin is embossed using a Blu-ray stamper and cured to form Blu-ray disc data surface.
• the embossing step replicates the Blu-ray data in the disc data surface.
• the curing step hardens the resin to prevent alteration of the replicated data.
• this surface is metallized to form a reflective surface thereover as indicated in step 306 of FIG. 3.
• a cover-layer and hardcoat are next applied to the Blu-ray disc structure as with conventional BD manufacturing process.
• the original CD (DVD) printed label 101 is coated with ink and overprint with a desired printed label for Blu-ray disc using conventional disc printing techniques.
• a DVD disc structure is typically comprised of a DVD data layer 203 formed between two plastic substrates 202 as shown in FIG. 2.
• the disc 200 of the present principles includes a Blu-ray data layer 204 formed on a surface of the plastic substrate 202 opposite the DVD data layer 203. Such a structure provides a Blu-ray disc structure in which the DVD data layer 203 may be ignored.
• Blu-ray data layer 204 may again be formed of one or more layers of resin material (not shown).
• a first resin layer may comprise a spacer layer formed directly on the CD substrate 105.
• a second resin layer may be formed on the first resin layer.
• the second resin layer typically contains the Blu-ray data surface. Referring to FIG. 3 the method of manufacture for the Blu-ray disc 200 of the present principles is described. A discarded and/or unused CD substrate 202 having a DVD data layer 203 formed thereon is cleaned as indicated in step 301.
• the cleaned DVD substrate 202 may be coated on a surface opposite the DVD layer 203 (read-through surface for laser) with a resin layer 204 as is used to make conventional Blu-ray disc via, for example, a wet- embossing process.
• Resin layer 204 is then cured, as indicated in step 303 of FIG. 3.
• the resin layer 104 may be cured using for example, ultra-violet radiation.
• the cured resin 204 is then coated with a 1-10 micron thick layer of "pit resin" as used in conventional BIu- ray wet-embossing process.
• the "pit resin” is used to form the Blu-ray data surface of the Blu-ray disc 200, as indicated in step 304 of FIG. 3.
• the pit-resin is embossed using a Blu-ray stamper and cured to form Blu-ray disc data surface.
• the embossing step replicates the Blu-ray data in the disc data surface.
• the curing step hardens the resin to prevent alteration of the replicated data.
• the Blu-ray data surface is formed in resin layer 204, this surface is metallized to form a reflective surface thereover as indicated in step 306 of FIG. 3.
• steps 302-306 For a Blu-ray dual layer disc (not shown) steps 302-306.
• a cover-layer and hardcoat are next applied to the Blu-ray disc structure as with conventional BD manufacturing process.
• the original DVD printed label 201 is coated with ink and overprint with a desired printed label for Blu-ray disc using conventional disc printing techniques.
• the present invention makes use of the fact that Blu-ray discs have the same dimensions and form factor as CDs and DVDs with the important feature on Blu-ray discs being that the data surface is on the bottom surface of the disc as opposed to CD which has the data surface on the top directly under the printed label, and DVDs where the data layers are in the center of the two bonded half-discs.
• the clear, flat bottom surface of CDs and DVDs lend themselves to the addition of a newly embossed Blu-ray data layer that supersedes the previous CD (DVD) data and effectively turns the CD (DVD) into a Blu-ray disc.
• the manufacturing of such a disc would require no material changes limited to the glass master or disc recording stage.

Landscapes

• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Manufacturing Optical Record Carriers (AREA)
• Optical Record Carriers And Manufacture Thereof (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

Publications (1)

Family

ID=39456407

Family Applications (1)

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Citations (7)

Family Cites Families (6)

• 2008
  • 2008-01-30 CN CN200880108201A patent/CN101802919A/zh active Pending
  • 2008-01-30 BR BRPI0815018-4A2A patent/BRPI0815018A2/pt not_active IP Right Cessation
  • 2008-01-30 WO PCT/US2008/001194 patent/WO2009038595A1/en not_active Ceased
  • 2008-01-30 EP EP08724940A patent/EP2191469A1/en not_active Withdrawn
  • 2008-01-30 KR KR1020107005696A patent/KR101505516B1/ko not_active Expired - Fee Related
  • 2008-01-30 JP JP2010525795A patent/JP2010541117A/ja active Pending
  • 2008-01-30 MX MX2010002198A patent/MX2010002198A/es active IP Right Grant
  • 2008-01-30 US US12/733,196 patent/US20100142360A1/en not_active Abandoned

Patent Citations (7)

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