METHOD OF PRINTING ON A DISC

Abstract

The invention provides for a method of manufacturing a stamper for embossing data on an optical disc comprising the steps of printing the data to be embossed directly on a glass master to form a printing layer; sputtering of metal or alloy on said printing layer; forming a layer of metal or alloy on the sputtered layer, separating the metal or alloy layers from the glass to form a stamper.

Description

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The accompanying drawings illustrate the preferred embodiments of the invention and together with the following detailed description serve to explain the principles of the invention.

FIG. 1 illustrates a method of manufacturing a disc in the prior art.

FIG. 2 illustrates a disc manufactured in accordance with the method of the prior art.

FIG. 3 illustrates the method of manufacture of a stamper in the prior art.

FIG. 4 illustrates the method of manufacturing a stamper in accordance with an embodiment of the invention.

FIG. 5 illustrates the method of manufacturing a disc in accordance with an embodiment of the invention.

FIG. 6 illustrates a disc formed in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

The invention in accordance with one embodiment provides for a method of printing on discs without using a photoresist layer, laser, thermal branding or applying a reflective layer to each dummy layer.

The method in accordance with the invention provides for molding the image directly on the dummy layer during manufacture of the dummy layer. The dummy layer so produced is bonded directly to the active layer without requiring a reflective or protective layer. The side of the dummy layer with the embossed printing is not the side used for bonding and thus the other flat surface of the dummy layer is used for bonding not requiring any protective coating. The embossed image on the top surface can be felt and is easily visible on account of the distance between the edges of the embossed image that reflect light more prominently.

FIG. 4 illustrates the method of manufacturing a stamper for a disc in accordance with an embodiment of the invention. To mold the image directly on the disc during manufacture the corresponding stamper is to be manufactured. The glass master is prepared by first directly printing on the glass as shown in step A. The glass master with the image printed on it directly is then directly sent to the sputtering stage and a layer of nickel is grown on it. The remaining stages of stamper formation are conventional. Conventional printing such as screen or offset printing may be carried out on the glass master.

To print directly on the glass master, special jigs are formed to hold the glass. The surface of the glass master is preferably treated to make it hydrophilic before printing, as indicated by step A of FIG. 4. In order to make the glass hydrophilic it is treated with alcohol, acetone or any other known substance for this purpose. The surface of glass is made hydrophilic to retain the printing carried out on it. Printing of the graphical information or artwork is now carried out directly on the surface of the treated glass master, as indicated by step B. After printing the printed surface is cured by a UV lamp for a short period to firm up the print on the glass so that subsequent stages of conventional stamper development may be carried out as indicated by steps C and D.

Optionally, after curing the printing on the glass, the glass master is spun with water washing on the printed surface to smoothen the edges and improve the graphical image quality.

The stamper formed in accordance with the invention forms pits on the dummy layer that are at least 3 microns deep and may be within the range of 3-20 microns. The greater depth of the pits does not require a reflective or protective layer to be added. Moreover, the side of the dummy disc with the embossed image is not used for bonding to the active layer. The side with the image embossed forms the top surface of the disc.

FIG. 5 illustrates the process of manufacturing the disc in accordance with an embodiment of the invention. Steps A, C, D, and E for manufacturing the active layer remains the same as in FIG. 1. Step B of manufacturing the dummy layer now produces the dummy layer with the image molded on one surface. The other side of the dummy layer is then bonded to the active layer. The final disc is directly sent for packing without the added step of printing.

The disc manufactured in accordance with the invention reduces final time for dispatch from the manufacturing facility. The method also eliminates the use of a laser for forming the stamper for the dummy layer and consequently also eliminates the requirement of sputtering on each dummy layer. The inventive method endeavors at reducing costs by the elimination of an entire stage of the manufacturing process thereby also eliminating the associated inventory, machine, space, manpower and raw material requirements.

The method of forming images on discs in accordance with the invention allows for complicated images to be printed and eliminates the risk of disc damage during the printing stage. Furthermore counterfeiters cannot easily copy the disc so manufactured, as removal of embossed data from the dummy layer would tend to damage the disc.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the scope of the invention are desired to be protected.

Claims

1. A method of manufacturing a stamper for embossing data on an optical disc comprising the steps of: printing data to be embossed directly on a glass master to form a printing layer;sputtering of metal or alloy on said printing layer;forming a layer of metal or alloy on the sputtered layer,separating the metal or alloy layers from the glass to form a stamper.

2. A method of manufacturing a stamper as claimed in claim 1 wherein the glass is treated to make it hydrophilic before printing is carried out.

3. A method of manufacturing a stamper as claimed in claim 1 wherein screen printing is done on the glass master.

4. A method of manufacturing a stamper as claimed in claim 1 wherein the printing layer is cured under a ultra-violet lamp to firm up the print.

5. A method of manufacturing a stamper as claimed in claim 4 wherein the printing layer is washed to remove the burrs & to smoothen the edges of the print.

6. A method of manufacturing a stamper as claimed in claim 1 wherein the printed layer has pits formed corresponding to the data to be transferred.

7. A method of manufacturing a stamper as claimed in claim 6 wherein the depth of the pits formed on the printing layer is at least 2 microns.

8. A method of manufacturing a dual layer optical disc comprising of an active layer and a dummy layer comprising the steps of: producing an active layer with data recorded on it by a stamper;producing a dummy layer with data embossed on one surface by a stamper;bonding the active layer with the embossed dummy layer on the surface other than the embossed surface of the dummy layer.

9. A dual layer optical disc comprising an active layer and a dummy layer bonded together, said dummy layer having one surface with embossed data wherein the embossed surface forms the top surface of the disc.

10. A dual layer optical disc as claimed in claim 9 wherein the embossed surface has pits that are at least 2 microns deep.

11. A method of manufacturing a stamper substantially as herein described with reference to and as illustrated by the accompanying drawings.