The present application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2003-300799 filed on Aug. 26, 2003. The content of the application is incorporated herein by reference in its entirety.
1. Field of the Invention
The present invention relates to a molding mold for molding an optical disc mold substrate for manufacturing an optical disc, the substrate for the optical disc, and the optical disc.
2. Description of the Prior Art
Conventional molding molds for molding an optical disc are constructed such that a stamper formed with hyperfine signal pits is held at its an inner peripheral portion within the molding molds, in which case an inner peripheral portion S1 of a stamper S is, as shown in
In a structure shown in
For instance, in the case of forming, e.g., a light transmissive layer by the spin coat method in manufacturing the optical disc such as a Blu-ray disc (using blue laser beams) expected as a next generation high-density recording medium at the present, if there exists much of the recessed portion A1 (particularly as a stepped portion close to the outer periphery becomes larger and as an inclination of the wall get steeper) or the burr B1 on the mold substrate, as explained above, a problem also arises, wherein this causes a decline of spin coating property and occurrences of the coating streaks and the unevenness of the thickness.
Moreover, the mold substrate can be formed flat by eliminating the recessed portion in the mold substrate in a way that adjusts a level relationship between the stamper surface and a mold configuring the cavity within a central hole of the stamper, e.g., the surface of the holder. It is, however, impossible to restrain the occurrence of the burr by all means. This occurrence of the burr is conspicuous especially when the central hole of the stamper is punched out by a punch from the stamper surface. A protruded configuration can be provided in terms of the level relationship, however, in the case of manufacturing, e.g., a 2- or more-tiered disc spacer layer by use of a 2P method, there is a problem that the level (stepped portion) is required to be adjusted equal to or smaller than the thickness of this spacer layer, and the requirement of accuracy of the thickness becomes more strict.
For example, Japanese Patent Application Laid-Open Publication No.2003-11169 discloses that the stamper is fitted and thus held in a flat state at its inner peripheral portion by a stamper holding member. Even when set in the thus-fitted state, a burr might occur on the flat face.
It is a primary object of the present invention to provide a molding mold, for molding a mold substrate for an optical disc, constructed to restrain an occurrence of a burr, etc. adversely affecting the optical disc and to enable an improvement of accuracy of thickness of the optical disc made by using the mold substrate.
It is another object of the present invention to provide a substrate for an optical disc that is constructed to enable the thickness accuracy to be improved.
It is a further object of the present invention to provide an optical disc with the improved thickness accuracy.
A molding mold according to an embodiment includes a mold member configuring a cavity for molding a mold substrate for an optical disc, and a stamper for transferring a hyperfine pattern onto the mold substrate, wherein the stamper is attached to the mold so that a vicinal part of an innermost periphery portion of the stamper protrudes on the side of the cavity, and a face formed by the mold member configuring an inner peripheral portion of the mold substrate is substantially flush with an information area face on which the hyperfine pattern has been transferred.
According to the present molding mold, the face formed by the mold member configuring the inner peripheral portion of the mold substrate is substantially flush with the information area face on which the hyperfine pattern of the stamper has been transferred, and the vicinal part of the innermost periphery portion of the stamper is disposed to protrude on the side of the cavity. Therefore, the burr produced between the stamper and the mold member becomes small enough not to be an obstacle against the spin coat on the mold substrate, and the resin is easy to flow toward the recessed portion corresponding to the vicinal part of the innermost periphery portion of the stamper. As a result, it is possible to restrain occurrences of coating streaks and unevenness of thickness, spin coating property is improved, and the thickness accuracy of the optical disc made by using the mold substrate can be improved.
Another molding mold according to the present embodiment includes a mold member configuring a cavity for molding a resin stamper applied to a photo polymer method (2P method) and used for transferring a hyperfine pattern onto a transferred face, and a stamper for transferring the hyperfine pattern onto the resin stamper, wherein the stamper is attached to the mold member so that a vicinal part of an innermost periphery portion of the stamper protrudes on the side of the cavity, and a face formed by the mold member configuring an inner peripheral portion of the resin stamper is substantially flush with an information area face on which the hyperfine pattern has been transferred.
According to the present molding mold, the face formed by the mold member configuring the inner peripheral portion of the resin stamper used in the 2P method is substantially flush with the information area face on which the hyperfine pattern of the stamper has been transferred, and the vicinal part of the innermost periphery portion of the stamper is disposed to protrude on the side of the cavity. Therefore, the burr produced between the stamper and the mold member becomes small enough not to be the obstacle against the spin coat on the mold substrate, and the resin is easy to flow toward the resin tamper recessed portion corresponding to the vicinal part of the innermost periphery portion of the stamper. As a result, it is possible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, and the thickness accuracy of the optical disc made by using the mold substrate can be improved.
In each the molding mold described above, it is preferable that the vicinal part of the inner periphery portion of the stamper, which protrudes on the side of the cavity, is positioned within a range of 0.3 mm through 5 mm on the side of an outer periphery in a radial direction from the innermost periphery of the stamper.
Note that preferably, the stamper has a central hole formed in its inner peripheral portion and is disposed so that the central hole gets fitted to the mold member.
A disc-shaped substrate for an optical disc according to the present embodiment includes an inner peripheral face so formed as to be configured by a mold member, and an information area face containing an information recording area in which a hyperfine pattern is transferred on the side of an outer periphery of the inner peripheral surface, wherein the inner peripheral face is substantially flush with the information area face, and a recessed portion formed by the vicinal part of the inner peripheral portion of the stamper is configured between the inner peripheral face and the information area face.
According to this substrate for the optical disc, the inner peripheral face is substantially flush with the information area face, and the recessed portion is formed between the inner peripheral face and the information area face. Therefore, the resin is easy to flow in the spin coating. As a result, it is possible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, and the thickness accuracy of the optical disc made by using the substrate for the optical disc can be improved.
In the disc-shaped substrate for the optical disc, it is preferable that the recessed portion configured between the information area face and the inner peripheral face is formed so that an inclined face extending towards the information area face has a more gentle slope than an inclined face extending towards the inner peripheral face from a deepest part of the recessed portion.
It is also preferable that the recessed portion is positioned within a range of 0.3 mm through 5 mm on the outer peripheral side in the radial direction from a position where the recess starts from the inner peripheral face.
An optical disc according to the present invention includes a substrate for an optical disc, including an inner peripheral face so formed as to be configured by a mold member, and an information area face having an information recording area in which a hyperfine pattern is formed on the side of an outer periphery of the inner peripheral surface, the inner peripheral face being substantially flush with the information area face, and a recessed portion formed by the vicinal part of the inner peripheral portion of the stamper being configured between the inner peripheral face and the information area face, and a resin layer formed on the substrate for the optical disc.
According to the present optical disc, in the substrate for the optical disc, the inner peripheral face is substantially flush with the information area face, and the recessed portion is formed between the inner peripheral face and the information area face. Therefore, the resin is easy to flow in the spin coating. As a result, it is possible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, and the thickness accuracy of the substrate for the optical disc and of the optical disc can be improved.
In the optical disc described above, the resin layer can be a light transmissive layer. With this contrivance, the optical disc having a 1-tiered information layer can be built up.
Further, it is preferable that the substrate for the optical disc is formed with the recessed portion configured between the information area face and the inner peripheral face so that an inclined face extending towards the information area face has a more gentle slope than an inclined face extending towards the inner peripheral face from a deepest part of the recessed portion.
It is also preferable that the recessed portion is positioned within a range of 0.3 mm through 5 mm on the outer peripheral side in the radial direction from a position where the recess starts from the inner peripheral face.
Another optical disc according to the present embodiment includes at least a substrate for an optical disc, including an inner peripheral face so formed as to be configured by a mold member, and an information area face having an information area in which a hyperfine pattern is formed on the side of an outer periphery of the inner peripheral surface, the inner peripheral face being substantially flush with the information area face, and a recessed portion formed by the vicinal part of the inner peripheral portion of the stamper being configured between the inner peripheral face and the information area face, and a resin layer formed on the substrate for the optical disc and formed with a hyperfine pattern on its surface.
According to the present optical disc, in the substrate for the optical disc, the inner peripheral face is substantially flush with the information area face, and the recessed portion is formed between the inner peripheral face and the information area face. Therefore, the resin is easy to flow in the spin coating based on the 2P method. As a result, it is possible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, and therefore the thickness accuracy of the substrate for the optical disc and of the optical disc can be improved. In this optical disc, the resin layer is formed as a spacer layer.
In the optical disc, it is preferable that the substrate for the optical disc is formed with the recessed portion configured between the information area face and the inner peripheral face so that an inclined face extending towards the information area face has a more gentle slope than an inclined face extending towards the inner peripheral face from a deepest part of the recessed portion.
Moreover, it is preferable that the recessed portion is positioned within a range of 0.3 mm through 5 mm on the outer peripheral side in the radial direction from a position where the recess starts from the inner peripheral face.
Further, the optical disc further includes a light transmissive layer formed on the surface of the resin layer, whereby the optical disc having the multi-tiered information layer can be built up.
Still another optical disc according to the present embodiment includes at least a substrate for the optical disc, and a resin layer formed on the substrate for the optical disc, wherein a face, opposite to the substrate, of the resin layer is formed corresponding to a resin stamper including an inner peripheral face so formed as to be configured by a mold member and an information area face having an information area in which a hyperfine pattern is formed on the side of an outer periphery of the inner peripheral surface, the inner peripheral face is substantially flush with the information area face, and a protruded portion is formed between the inner peripheral face and the information area face.
According to the present optical disc, in the formation of the resin layer, the inner peripheral face is substantially flush with the information area face, and the recessed portion is formed between the inner peripheral face and the information area face of the resin stamper. Therefore, the resin is easy to flow in the spin coating. As a result, it is possible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, and therefore the thickness accuracy of the resin layer and of the optical disc can be improved.
In the optical disc described above, it is preferable that the resin layer is formed with the protruded portion between the information area face and the inner peripheral face so that an inclined face extending towards the information area face has a more gentle slope than an inclined face extending towards the inner peripheral face from a highest part of the protruded portion.
It is further preferable that the protruded portion is positioned within a range of 0.3 mm through 5 mm on the outer peripheral side in the radial direction from a position where the protrusion starts from the inner peripheral face.
Moreover, at least a plurality of resin layers are provided, whereby the optical disc having the multi-tiered information layer can be built up.
Still moreover, the optical disc may further include a light transmissive layer formed at least on the surface of the resin layer.
Yet another optical disc according to the present embodiment includes at least a substrate for the optical disc including an inner peripheral face so formed as to be configured by a mold member, and an information area face having an information area in which a hyperfine pattern is formed on the side of an outer periphery of the inner peripheral surface, the inner peripheral face being substantially flush with the information area face, and a recessed portion formed by the vicinal part of the inner peripheral portion of the stamper being configured between the inner peripheral face and the information area face, and a resin layer formed on the substrate for the optical disc, wherein a face, opposite to the substrate, of the resin layer is formed corresponding to a resin stamper including an inner peripheral face so formed as to be configured by a mold member and an information area face having an information area in which a hyperfine pattern is formed on the side of an outer periphery of the inner peripheral surface, the inner peripheral face is substantially flush with the information area face, and a protruded portion is formed between the inner peripheral face and the information area face.
According to the present optical disc, in the substrate for the optical disc, the inner peripheral face is substantially flush with the information area face, and the recessed portion is formed between the inner peripheral face and the information area face. Therefore, the resin is easy to flow in the spin coating. As a result, it is possible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, the inner peripheral face and the information area face in the resin layer are substantially flush with each other, and the recessed portion is formed between the inner peripheral face and the information area face. Therefore, the resin is easy to flow in the spin coating. Consequently, it is feasible to restrain the occurrences of the coating streaks and the unevenness of thickness, the spin coating property is improved, and hence the thickness accuracy of the resin layer and of the optical disc can be improved.
In the optical disc described above, it is preferable that the substrate for the optical disc is formed with the recessed portion configured between the information area face and the inner peripheral face so that an inclined face extending towards the information area face has a more gentle slope than an inclined face extending towards the inner peripheral face from a deepest part of the recessed portion. In this case, it is preferable that the recessed portion is positioned within a range of 0.3 mm through 5 mm on the outer peripheral side in the radial direction from a position where the recess starts from the inner peripheral face.
Further, it is preferable that the resin layer is formed with the protruded portion between the information area face and the inner peripheral face so that an inclined face extending towards the information area face has a more gentle slope than an inclined face extending towards the inner peripheral face from a highest part of the protruded portion. In this case, it is preferable that the protruded portion is positioned within a range of 0.3 mm through 5 mm on the outer peripheral side in the radial direction from a position where the protrusion starts from the inner peripheral face.
Yet further, at least a plurality of resin layers can be provided, and the optical disc may further include a light transmissive layer formed at least on the surface of the resin layer. According to the present embodiment, it is possible to provide the molding mold, for molding the mold substrate for the optical disc, constructed to restrain the occurrence of the burr, etc. adversely affecting the optical disc and to enable the improvement of the accuracy of thickness of the optical disc made by using the mold substrate.
Moreover, it is feasible to provide the substrate for the optical disc that is constructed to enable the thickness accuracy to be improved. Still moreover, the optical disc with the improved thickness accuracy can be provided.
A best mode for carrying out the present invention will hereinafter be described with reference to the drawings.
The molding mold assembly shown in
A stamper 23 is composed of nickel, etc., in a plate-like shape. The stamper 23 has a stamper face 23a on the side of a cavity 20, which is formed with a hyperfine rugged pattern for recording, for instance, pieces of information. The stamper 23 is disposed in close proximity to the fixed mirror surface portion 21a of the fixed mold 21.
The cavity 20 having a configuration corresponding to a configuration of the mold substrate defined as a molded product, is formed between the stamper 23 of the fixed mold 21 and the movable mirror surface portion 22a of the movable mold 22. An end face 27a of the holder member 27 configures part of the cavity 20.
According to the molding mold assembly in
Next, a fitting position of the stamper in the fixed mold 21 of the molding mold assembly in
As shown in
Further, a bottom face of a recessed portion 27b in the end face 27a of the holder member 27 in
As shown in
A mold substrate 30 molded by the molding mold assembly in
Further, a burr produced on the inner periphery sided wall face 32b of the recessed portion 38 corresponding to a portion between the holder member 27 and the stamper 23 is comparatively small as seen in
A process of manufacturing a Blu-ray disc from the thus-acquired mold substrate molded as described above, will be explained with reference to
To start with, a mold substrate 10, which is, e.g., 120 mm in diameter and 1.1 mm in thickness, is molded of a polycarbonate (PC) resin by use of the molding mold assembly in
Next, layer formation (e.g., sputtering) of a variety of functional layers such as a recording layer, a reflection layer, etc. is effected on the information area face 13 of the mold substrate 10. As shown in
Next, a resin (e.g., an ultraviolet curing acrylic resin) layer is coated over the mold substrate 10 formed with the variety of functional layers. This resin layer is coated as a protective layer performing a role of physically or chemically protecting the variety of functional layers in the case of the optical disc such as a CD and a DVD classified as a type of being irradiated with laser beams used for recording and reproducing through the substrate.
Moreover, in the case of a high-NA type optical disc as represented by the Blu-ray disc, the disc is irradiated with the laser beams sued for recording and reproducing from the side opposite to the substrate and is therefore formed with a light transmissive layer over the variety of functional layers. A method of forming the light transmissive layer can involve, though not particularly limited, a case of forming by a spin coat method and a case of bonding and thus providing a separately prepared seat composed of a resin (which is a polycarbonate resin, an acrylic resin, etc.).
The spin coat method is that the resin is coated over the mold substrate 10 formed with the variety of functional layers in a way that rotates the mold substrate 10 at a comparatively low speed, and a resin layer having target layer thickness is to be formed by controlling the number of rotations and a period of rotation time.
In the case of the ultraviolet curing acrylic resin, irradiation of ultraviolet rays is next effected, whereby a resin layer (a light transmissive layer 15) that is 0.1 mm in thickness is, as shown in
It is possible to manufacture in the way described above a Blu-ray disc using blue laser beams of which a wavelength is, e.g., 405 nm as the recording/producing laser beams and capable of recording and reproducing through an optical system to which an optical pickup constructed of an objective lens group having a numerical aperture (NA) of 0.85 (NA=0.85) is applied.
In the aforementioned manufacturing process, on the surface of the mold substrate 10, there is no protrusion (a protruded portion in terms of a mold structure) hindering a flow of the resin towards the outer peripheral portion from the inner peripheral face 11 supplied with the resin, and besides the burr formed in the vicinity of the inner periphery sided wall face 18b of the recessed portion 18 is small and does not therefore become an obstacle against the spin coat. Thus, the surface of the mold substrate 10 exhibits a preferable spin coating property, and hence it is feasible to restrain occurrences of coating streaks and unevenness in thickness and to improve accuracy of the thickness of the light transmissive layer 15. This enables an improvement of accuracy of the thickness of the optical disc.
Furthermore, in the case of the optical disc such as the Blu-ray disc, etc., the inner peripheral surface 11 might become a fiducial face (clamp face) when the optical disc is installed into a recording/reproducing apparatus, and is employed as a reference for performing the record and reproduction on and form the information area face 33. Therefore, this positional relationship, if determined based on specifications, can not be changed voluntarily. The height positional relationship that the heights of these two faces are substantially equal to each other, is extremely vital and effective in recording/reproducing process.
The whole structure of the molding mold assembly is the same as in
As illustrated in
The innermost periphery vicinal portion 23e of the stamper 23 is pushed by the end face 29a of the sleeve member 29 and is thereby slightly inclined, and its edge (the edge of the central hole 23d) protrudes from the end face 27a of the holder member 27 towards the cavity 20, thus forming a tapered face inclined therefrom. The stamper face 23a apart from the innermost periphery vicinal portion 23e is a flat face that is substantially flush with (the same level as) the end face 27a of the holder member 27.
Note that an amount of the protrusion of the innermost periphery vicinal portion 23e can be adjusted by changing a height position of the sleeve member 29.
The mold substrate 30 molded by the molding mold assembly shown in
Further, the burr produced on the inner periphery sided wall face 32b of the recessed portion 38 corresponding to the portion between the holder member 27 and the stamper 23 is comparatively small as seen in
Next, a process of manufacturing a Blu-ray disc having a 2-tiered information layer from the thus-acquired mold substrate molded as described above, will be described with reference to
To begin with, as shown in
Next, the layer formation (e.g., sputtering) of the variety of functional layers such as the recording layer, the reflection layer, etc. is effected on the information area face 43 of the mold substrate 40. For instance, in the case of the playback-only optical disc, a reflection layer composed of aluminum, etc. is formed by sputtering on the hyperfine rugged portion 43a containing the groves, the pits, etc. It should be noted that in the case of the recordable type optical disc such as the write-once optical disc, the rewritable optical disc and so on, the functional layers such as the recording layer, etc., are formed on the hyperfine rugged portion 43a containing the grooves, the pits, etc. in accordance with a variety of purposes.
On the other hand, an olefin resin mold substrate 50, which is, e.g., 120 mm in diameter, is molded of an olefin resin by use of the same molding mold assembly as in
Next, a resin is coated over the olefin resin mold substrate 50 in a way that rotates this substrate 50 at a comparatively low speed, and a resin layer having target layer thickness is to be formed by controlling the number of rotations and a period of rotation time. Subsequently, each mold substrate is disposed so that the information area face 43 of the PC resin mold substrate 40 faces the information area face 54 of the olefin resin mold substrate, and is thus made tightly contiguous to the PC resin mold substrate 40. When the coated resin is of the ultraviolet curing type, the resin is cured by the irradiation of the ultraviolet rays, thereby forming a spacer layer 34 having thickness of 25 μm as shown in
Next, as shown in
Next, the layer formation (e.g., sputtering) of the variety of functional layers such as the recording layer, the reflection layer, etc., which can transmit a required amount of laser beams applied to the record and the reproduction, is again effected on the outer face 34a of the spacer layer 34 on the mold substrate 40. As shown in
Subsequently, a resin (e.g., an ultraviolet curing acrylic resin) layer (light transmissive layer) is formed on the mold substrate 40 provided with the variety of functional layers.
The method of forming the light transmissive layer can involve, though not particularly limited, the case of forming by the spin coat method and the case of bonding and thus providing the separately prepared seat composed of the resin (which is the polycarbonate resin, the acrylic resin, etc.).
The spin coat method is that the resin is coated over the mold substrate 40 formed with the variety of functional layers in a way that rotates the mold substrate 40 at a comparatively low speed, and the resin layer having target layer thickness is to be formed by controlling the number of rotations and a period of rotation time.
In the case of the ultraviolet curing acrylic resin, the resin is next cured by effecting the irradiation of ultraviolet rays, whereby the light transmissive layer 35 that is 75 μm in thickness is, as shown in
The Blu-ray disc having the 2-tiered information layer as shown in
Effects in the aforementioned process of manufacturing the optical disk in
When the spacer layer 34 is formed on the olefin resin mold substrate 50 by the spin coat method, there is no protrusion (the protruded portion in terms of the mold structure) hindering the flow of the resin towards the outer peripheral portion from the inside diameter portion 51 supplied with the resin, and consequently the coating is preferably conducted. Besides, as shown in
Moreover, as shown in
By contrast, as shown in
Further, as illustrated in
The present embodiment illustrated in
Next, a modified example in which the innermost periphery vicinal portion of the stamper in
The following is the modified example illustrated in
The mold substrate 30 molded by the molding mold assembly shown in
Further, the burr produced on the inner periphery sided wall face 32b of the recessed portion 37 corresponding to the portion between the holder member 27 and the stamper 23 is comparatively small as seen in
As shown in
The innermost periphery vicinal portion 23e of the stamper 23 is pushed by the end face 29a of the sleeve member 29 and is thereby slightly inclined, and its edge (the edge of the central hole 23d) protrudes from the end face 27a of the holder member 27 towards the cavity 20, thus forming a tapered face inclined therefrom. The stamper face 23a apart from the innermost periphery vicinal portion 23e is a flat face that is substantially flush with (the same level as) the end face 27a of the holder member 27 (with respect to their positions in the vertical direction in
Note that an amount of the protrusion of the innermost periphery vicinal portion 23e can be adjusted by changing a height position of the sleeve member 29.
The mold substrate 30 molded by the molding mold assembly shown in
The mold substrate molded by the molding mold assembly having the construction in
The present invention has been discussed so far by way of the embodiments but is not limited to these embodiments. The present invention can be modified in a variety of forms within the scope of the technical concept of the present invention. For example, in the manufacturing process in
Further, the Blu-ray disc has been exemplified with reference to
Moreover, the optical disc including the 2-tiered information layer has been exemplified with reference to
Number | Date | Country | Kind |
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2003-300799 | Aug 2003 | JP | national |