The present invention relates to a high-density optical disc medium.
In recent years, optical discs are widely applied to audio and visual (AV) fields. For example, in a digital versatile disc (DVD) mainly for movie contents, formats of write once read many (WORM) type and rewritable type such as a DVD-R, a DVD-RAM and a DVD-RW have been developed and the DVDs come into popular use as a next-generation recording device of a video tape recorder (VTR). In response to future diffusion of BS digital broadcasting and broadband communication, it is expected that an optical disc format which enables recording of compressed images of higher quality or an optical disc format which makes a portable optical disc more compact at an identical capacity and has high network affinity will appear.
These next-generation optical discs should have high density absolutely. In DVDs proposed currently, a disc of 120 mm in diameter has a capacity of 4.7 GB. However, a capacity of 20 GB or more is required for a ROM having a picture quality identical with that of digital broadcasting or for performing recording and reproduction. At this time, a density of five times or more is necessary.
Usually, density of an optical disc depends on a spot diameter of a light beam for recording and reproduction and the spot diameter of the light beam is determined by (λ/NA) in which “λ” denotes a wavelength and “NA” denotes a numerical aperture of an objective lens. Therefore, in order to raise the density, it is necessary to reduce the wavelength and increase the numerical aperture. If the numerical aperture is increased while the wavelength is kept constant, comatic aberration caused by tilt of the disc poses a problem and thus, a method in which thickness of a layer allowing transmission of the light beam is reduced is employed. An optical disc medium employing such method is proposed in Japanese Patent Laid-Open Publication No. 10-326435 (1998).
However, development of a high-definition and high-precision optical disc substrate is indispensable for reducing the track pitch. Among others, in a molding process, it is important how accurately tracks of the narrow pitch or minute pre-pits can be transferred. It is extremely difficult to uniformly mold a signal recording face from its inner periphery to its outer periphery by transferring such shapes. Usually, transfer at the inner periphery and the outer periphery of the signal recording face can be made substantially identically by raising temperature of dies of a molding machine. However, if the temperature of the dies of the molding machine is raised, warpage of the substrate itself becomes large and thus, the system is not operable.
With a view to eliminating the above mentioned drawbacks of prior art, the present invention has for its object to provide a high-density optical disc medium in which substrate molding and signal quality are stable and which is suitable for reducing thickness of a device.
In order to accomplish this object of the present invention, an optical disc medium of the present invention includes a recording layer which has an inner peripheral region extending radially outwardly from a central bore to a signal start boundary and a signal region extending radially outwardly from the signal start boundary. A light transmitting layer is disposed on the recording layer and the signal region of one face of the recording layer adjacent to the light transmitting layer occupies a laser beam incident face such that either reproduction or recording and reproduction of information is performed from the recording layer via the light transmitting layer. The inner peripheral region of the face of the recording layer is formed flat and a recess is formed, on one face of the optical disc medium opposite to the light transmitting layer, in an area corresponding to the inner peripheral region of the recording layer.
Hereinafter, embodiments of the present invention are described with reference to the drawings.
Then, molding operation is described. Initially, before the movable die 203 comes into contact with the stationary die 202, the resin molten at high temperature is introduced into the cavity 209 from the inlet 208. When the movable die 203 applies pressure to the stationary die 202 upon its contact with the stationary die 202, the disc is formed in the cavity 209. At this time, the introduced resin is set at a temperature of about 380° C., while the stationary die 202 and the movable die 203 are set at a temperature of about 120° C. The temperature of the dies 202 and 203 is set lower than that of the resin such that the resin is cooled and solidified in the dies 202 and 203. The substrate of the optical disc of the present invention is manufactured by using this disc molding die 200 and shape of a recess of the substrate is produced to various sizes by an annular projection 207.
In
This results from the recess 34 formed on the substrate 33 of the optical disc 30. At the time of molding of the substrate 33, the resin held at high temperature is introduced into the dies. However, since the die temperature is equal to a solidification point of the resin, cooling of the resin is started simultaneously with introduction of the resin into the dies. Here, if a convex and concave portions are not formed on a light incident face and its opposite face of a substrate in the same manner as the substrate 303 of the conventional optical disc 300, the resin proceeds to the outer periphery of the substrate while being cooled. As a result, the resin does not penetrate into high-density grooves, i.e., thin grooves formed on the stamper, thereby resulting in deterioration of transfer property.
On the other hand, in the substrate 33 of the optical disc 30 of the present invention, the resin introduced into the dies is once restricted at the recess 34. At this time, pressure of the resin rises upon its restriction at the recess 34 and thus, the resin is set in a reheated state. Therefore, since the resin which has passed through the recess 34 proceeds to the outer peripheral portion of the substrate 33 while being held at high temperature, the resin is completely transferred to even the high-density grooves. Meanwhile, since the substrate 33 can be molded while the dies are held at low temperature, there is no increase of tilt of the substrate 33 due to rise of the die temperature.
Supposing that the substrate 33 has a thickness of 1.1 mm and an outside diameter of 80 mm and the recess 34 has a size of 2 mm from an inside diameter of the substrate 33 and a depth of 0.3 mm, Table 1 below shows transfer ratio at a diameter of the central bore 35, i.e., an inside diameter w of the disc in mm and a radial position r of the disc in mm. By molding the substrate 33 by the use of a stamper having a track pitch of 0.3 microns, a groove width of 0.2 microns and a groove depth of 30 nm, the transfer ratio is calculated by dividing a groove depth of the molded substrate 33 by the groove depth of the stamper. At the time of molding, the resin has a temperature of 380° C. and the dies have a temperature of 125° C. The formed grooves have a diameter of 22 to 79 mm.
It is seen from Table 1 that even in a quite small disc having the inside diameter w of 6 mm, a remarkably excellent transfer ratio of 97% is obtained. In case the inside diameter w of the disc is small, it becomes difficult to perform transfer at the outer peripheral signal region due to cooling of the resin. However, in the present invention, when the inside diameter w of the disc is smaller than 20 mm, sufficient transfer ratios can be gained. In addition, even if the inside diameter w of the disc is not more than 6 mm, a usable disc can be manufactured.
By setting a thickness and an outside diameter of the substrate 33 at 1.1 mm and 80 mm, respectively,
b=(w1−w)/2
In
Meanwhile, in
By setting a thickness and an outside diameter of the substrate 33 at 1.2 mm and 80 mm, respectively, Table 2 above shows relation between various depths of the recess 34 and transfer ratio. The ratio W of the inside diameter w of the disc to the diameter w1 of the recess 34 is set at 0.7. By molding the substrate 33 by the use of the stamper having the track pitch of 0.3 microns, the groove width of 0.2 microns and the groove depth of 30 nm in the same manner as described above, the transfer ratio is calculated by dividing a groove depth of the molded substrate 33 by the groove depth of the stamper. As shown in
It was found that the transfer ratio is improved drastically by merely changing the depth of (d1−d) of the recess 34 from 1.2 mm to 1.1 mm. On the contrary, when the depth of (d1−d) of the recess 34 is 0.1 mm, the remaining disc body has a thickness of mere 0.1 mm, filling of the resin becomes insufficient, thus resulting in drop of the transfer ratio. Moreover, in this case, since the inside diameter of the disc is deformed during handling of the substrate 33 at the time the substrate 33 is transferred from a molding process to a deposition process, the disc cannot be used actually.
However, if the depth (d1−d) of the recess 34 reaches 0.2 mm, both the transfer ratio and handling property are upgraded. Since rigidity of the disc body is approximately proportional to a cube of its thickness, it is considered that the disc is not deformed during its handling. Therefore, it was confirmed that the present invention applies to a range in which the depth of (d1−d) of the recess 34 is smaller than 0.12 mm but is larger than 0.1 mm. Furthermore, in view of rigidity of the recess 34, it is most desirable that the depth of (d1−d) of the recess 34 ranges from 0.3 to 0.8 mm.
Meanwhile, in this embodiment, the present inventors conducted experiments by setting the outside diameter of the substrate 33 at 80 mm. However, in the optical disc 30, the outside diameter of the substrate 33 is not restricted to 80 mm but similar effects are obtained also when the substrate 33 has an outside diameter of, for example, about 50 mm or 120 mm.
Usually, when the optical disc 50 is secured to a turntable, available are a first method in which the disc is clamped mechanically by using a hub provided on an upper face of the disc, a second method in which a disc clamp claw is provided on the turntable and the disc is pressed against the disc clamp claw from below so as to be clamped and a third method in which a hub made of magnetic material is mounted on the disc and a magnet is provided on a motor so as to clamp the disc.
If the hub is provided on the upper face of the disc, height of the hub is added to that of the disc. Therefore, this design is disadvantageous for making a disc drive thinner. Hence, in the present invention, the hub 55 made of magnetic material is mounted in the recess 54 of the optical disc 50 as shown in
In order to positively mount the magnetic hub 55 on the substrate 51 in the optical disc 50 of
Meanwhile, by forming on the substrate 91 the protrusion 96 having a width of not less than 0.1 mm, the weld 97 can be formed. The results of the experiments of the present inventors have revealed that the width of the protrusion 96 is not less than 0.2 mm preferably but ranges from 0.2 to 10 mm more preferably.
However, in case the protrusion 96 having, for example, a width of 0.1 mm and a height of 5 mm is injection molded, transfer of the resin to the protrusion 96 becomes unstable. Meanwhile, flow of the resin which has passed through the recess 94 is disturbed by the protrusion 96 and thus, an underside portion of the disc opposite to the protrusion 96, namely, -a disc clamp region may also become unstable.
Thus, in order to form the protrusion 96 stably,
Meanwhile, since in a radial direction of the optical disc 100, the outer peripheral face f2 of the protrusion 106 is disposed inwardly of a location corresponding to the signal start boundary of the recording layer 102, injection molding pressure rises again at the signal region 107. As a result, such two advantages are obtained that transfer is performed favorably and strength of the disc clamp region 108 is raised. According to the experiments of the present inventors, a width of the protrusion 106 including the inclined outer peripheral face f2 may be 1 mm or more but desirably ranges from 2 to 8 mm.
A method of manufacturing the intermediate layer 123 and the first recording layer 122 in the optical disc 120 of the present invention is described. Initially, after the substrate 125 has been molded, the second recording layer 124 for recording and reproducing signals is produced by sputtering. Then, the intermediate layer 123 is formed by spin coating the ultraviolet resin. A stamper for the first recording layer 122 is brought into close contact with the intermediate layer 123 so as to form grooves on the intermediate layer 123. After the stamper for the first recording layer 122 has been detached from the intermediate layer 123, the first recording layer 122 is produced by sputtering through adjustment of its thickness to such a value that the beam is transmitted through the first recording layer 122 up to the second recording layer 124. Furthermore, in the same manner as the first embodiment, the light transmitting layer 121 is formed by bonding the polycarbonate sheet to the first recording layer 122. Here, the intermediate layer 123 is set at a thickness of 25 microns, the polycarbonate sheet is set at a thickness of 50 microns and the ultraviolet resin is set at a thickness of 25 microns such that a thickness from the second recording layer 124 to the surface of the light transmitting layer 121 assumes 100 microns.
The optical disc 120 is recorded and reproduced by performing both focusing and tracking on each of the first and second recording layers 122 and 124. Hence, recording and reproduction on the second recording layer 124 are performed by a beam transmitted through the first recording layer 122 and a beam reflected by the first recording layer 122. A beam which is reflected by the second recording layer 124 after having been transmitted through the first recording layer 122 drops in quantity as compared with a case of a single recording layer and therefore, is required to have quite high precision. In this embodiment, since the recess 126 is provided on one face of the optical disc 120 opposite to the light transmitting layer 121, transfer ratio of the grooves can be raised and thus, the grooves can be produced more accurately than a conventional optical disc.
In the embodiments of the present invention, the polycarbonate sheet is used for the light transmitting layer. However, the present invention is not limited to the polycarbonate sheet. For example, the polycarbonate sheet may also be replaced by an olefin resin sheet, an acrylic resin sheet, a sheet of ultraviolet resin only or a sheet of ultraviolet resin and polycarbonate.
Meanwhile, the light transmitting layer is set at a thickness of 0.1 mm but its thickness is not limited to 0.1 mm. For example, even if the light transmitting layer is set at a thickness of 0.3 mm by setting the polycarbonate sheet at a thickness of 0.25 mm and the ultraviolet resin at a thickness of 50 μm, similar effects are gained.
As is clear from the foregoing description, if the optical disc medium of the present invention is used, transfer property at the time of molding of the substrate can be upgraded greatly by maintaining disc tilt at a small value and the disc can be made thin, so that it is possible to provide an optical disc in which disc tilt is restrained to the small value and which is suitable for large capacity, high density and thin design.
Number | Date | Country | Kind |
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2002-104827 | Apr 2002 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP02/13162 | 12/17/2002 | WO |