Imation Corporation

Legger Col. A.b. LLC

Minnesota Mining and Manufacturing Company

Other

Donald J Kerfeld

Jathan D Edwards

Chad R Sandstrom

Dean E Sitz

Douglas R Plourde

Ted L Bahns

Roger J Anderson

Barry E Brovold

John R Johnson

Anthony O Banal

Larry A Lien

Terry W Lewis

Douglas J Chaput

Kristi L Chavez

Data storage replica disks having a surface relief pattern with replica lands and replica grooves are provided.

Replica disk for data storage

A data storage master disk and method of making a data storage master disk. The data storage disk master is for use in a data storage disk replication process. The data storage disk molding processes produces replica disks having a surface relief pattern with replica lands and replica grooves. The method includes providing a master substrate. The master substrate is at least partially covered with a layer of photosensitive material. A surface relief pattern having master lands and master grooves is recorded in the data storage disk master, including the steps of exposing and developing the photosensitive material is controlled to form master grooves extending down to a substrate interface between the master substrate and the layer of photosensitive material, such that the width of the master grooves at the substrate interface corresponds to a desired width of the replica lands.

Reverse optical mastering for data storage disk replicas

A date storage master disk and method of making a data storage master disk. The data storage disk master is for use in a data storage disk replication process. The data storage disk molding processes produces replica disks having a surface relief pattern with replica lands and replica grooves. The method includes providing a master substrate. The master substrate is at least partially covered with a layer of photosensitive material. A surface relief pattern having master lands and master grooves is recorded in the data storage disk master, including the steps of exposing and developing the photosensitive material is controlled to form master grooves extending down to a substrate interface between the master substrate and the layer of photosensitive material, such that the width of the master grooves at the substrate interface corresponds to a desired width of the replica lands.

Reverse optical mastering for data storage disk stamper

A data storage master disk and method of making a data storage master disk. The data storage disk master is for use in a data storage disk replication process. The data storage disk molding processes produces replica disks having a surface relief pattern with replica lands and replica grooves. The method includes providing a master substrate. The master substrate is at least partially covered with a layer of photosensitive material. A surface relief pattern having master lands and master grooves is recorded in the data storage disk master, including the steps of exposing and developing the photosensitive material. The exposing and developing of a specified thickness of photosensitive material is controlled to form master grooves extending down to a substrate interface between the master substrate and the layer of photosensitive material, such that the width of the master grooves at the substrate interface corresponds to a desired width of the replica lands.

An optical disk exhibiting no detrimental thickness increase (edge wedge effect) that arises at the outer diameter of an optical disk substrate during an injection molding manufacturing process, and an apparatus and method for making such a disk. The optical disk of the present invention is designed for use with an optical disk player, especially where the data on the optical disk is stored air incident. This optical disk includes a disk substrate made from a molded polymeric material. The disk substrate has a first major surface, a second major surface, and an outer edge. The first major surface of the optical disk includes a data region having an intermediate portion and an outer portion. The outer portion extends to the outer edge of the optical disk. The disk substrate has a thickness defined by the distance between the first major surface and the second major surface. The optical disk also includes an information layer covering the data region. In the present invention, the thickness of the intermediate portion of the data region is substantially equal to the thickness of the outer portion of the data region such that the outer portion of the data region is capable of being used by the optical disk player.

Optical disk mold tooling for reduced edge wedge

In one embodiment, the invention is directed to a manufacturing process for optical data storage disks that makes use of a check disk very early in the production cycle. The check disk can be replicated directly from the master without destroying the master. The check disk may then be tested in order to validate the pattern created on the master. In some cases, the check disk may be delivered to customers, allowing the customers to verify the check disk. Once the check disk has been verified, the master can be used to create one or more stampers, which can be used in a mass production process for creating optical data storage disks. However, if the check disk is defective or otherwise not acceptable, the production cycle can be halted prior to creating any stampers. In this manner, the invention can be used to avoid creation of defective stampers or other defective mass production tools.

Check disk for optical data storage disk manufacturing

The invention is directed toward techniques for creating molded substrates for use in various different data storage media. The molded substrates have improved thickness profiles that can improve media quality, and in some cases facilitate higher data storage densities. In many cases, the improved thickness profile is a thickness profile that has improved flatness. Mechanical flatness or optical flatness can be achieved. In particular, optical flatness is desirable for substrates used in holographic data storage media having a sandwiched construction.

Variable thickness stamper for creation of flat molded substrates

The invention is directed towards techniques for creating optical data storage disks. In one embodiment, the invention provides a simultaneous two-sided rolling bead process. For example, a method may include positioning a first bead of photopolymer for distribution between a bottom stamper and a substrate, and positioning a second bead of photopolymer for distribution between a top stamper and the substrate. The method may also include passing a roller over the top stamper to distribute the beads of photopolymer, curing the photopolymer, and removing the substrate from the stampers. The simultaneous two-sided rolling bead process can be repeated on the same medium to create a two-sided dual-layer data storage medium or a two-sided multi-layer data storage medium.

Two-sided replication of data storage media

The invention is directed toward techniques for stamping optical data storage disks. A master is first created to include several distinct information regions etched upon a master surface. The master is then used to create one or more stampers. The stampers include a number of distinct stamper regions in locations corresponding to locations of the distinct information regions on the master. The stamper is then used to create a number of first replica disks that include distinct replicated regions. The distinct replicated regions are removed from the first replica disks to define second disks.

Replicated regions on optical disks

In exemplary embodiments, the invention provides one or more processes for making stampers for stamping replica data storage disks. For instance, the invention may provide a process for making a family of stampers from one master. Moreover, the invention may provide a way to systematically adjust the depth of the grooves on a stamper in a particular family of stampers while maintaining groove widths that are substantially the same as those of the master.

Growing community of inventors

Saint Paul, MN, United States of America

Donald J Kerfeld