CD_DVDPP

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Manufacturing of CDs and DVDs

Christie Nickson

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Introduction

z Compact Discs

y Digital technology

y Excellent sound quality

y 650 MB storage

z DVD

y Excellent sound and video qualityy More storage, 4.7-17 GB

z

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Manufacturing Process

z Premastering

z Mastering

z Plating/Electroforming

z Injection Molding

z Metallization/Spin

Coating

z Lacquering

z Screen

Printing/Packaging

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Premastering

z Information inspected and prepared for CD or

DVD.

z Audio premastering

y PQ Encoding

y Digital Audio Editing

z DVD premasteringy Authoring

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Mastering

z Transfer data onto glass

master by laser beam.

z Laser creates pits on a film

on the glass.

z 2 techniques

y Photo Resisty Dye-Polymer

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Photo Resist

z Thin layer (0.12

micrometer) of photo

resist spin coated onhighly polished glass

surface.

zLaser beam recorder exposes areas on the

photo resist layer.

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Photo Resist

z Photo resist chemically developed to create

pits in exposed areas.

z Developed photo resist vacuum coated with

thin layer of nickel or nickel alloy.

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Dye-Polymer Process

z Dry process - no chemical developing.

z Dye material used on glass that vaporizes

when heat of recording laser is absorbed

creating the pits.

z Advantage is another laser can check pit size

and depth during recording and errors foundimmediately.

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Plating/Electroforming

z Negative copy of master is

made out of metal.

z Glass master placed in tank

of nickel plating solution.

z 0.3-0.4 mm thick layer of

metal forms on master.z

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Plating/Electroforming

z Metal and master are separated creating

negative copy (father).

z Father is then used to create metal copy of

master (mother) by same method.

z Mother is then used to create many metal

stampers.z Each stamper can be used to produce several

thousand discs.

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Injection Molding

z Stamper is installed in plastic

injection molding machine.

z Polycarbonate resin is injected

into mold under pressure.

z Resin cools, solidifies and is

removed from mold.

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Metallization/Spin Coating

z Discs are transparent after molding.

z A thin layer of aluminum is applied by

vacuum deposition.

z Metallization is necessary to get a mirror

surface which will reflect laser light and read

pits.

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Lacquering

z A layer of lacquer is applied by

spin coating.

z Lacquer protects aluminum

from oxidizing, which would

make the disk unreadable.

z Lacquer is cured by ultra-violetlight.

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Screen Printing &

Packaging

z Upper surface can be printed

with up to 5 colors.

z Flat silk screen process used

and ink is cured with UV

light.

z Disks are packaged for protection and marketing and

shipped to customer.

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Quality

z Mastering

y Disc master/stamper player

y Pit geometry checked with high power microscope

y PQ testing

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Quality - Replication

z Samples from each run tested.

z Physical dimensions:

y thickness

y center hole diameter

z Analysis of electrical signals.

z Mechanical tests.

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QA Tests & Signals

z Samples from each press for each run tested

y Reflectivity

y Asymmetry

y Push Pull

y Cross Talk

yBirefringence

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Mechanical Tests

z Mechanical tests that are run with the signal

tests include:

y Radial noise

y Eccentricity

y Track pitch

yScan velocity

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DVD Manufacturing

z DVDs are more difficult to manufacture

y Shallower pits and smaller pit size

y Smaller track pitch

y Tighter tolerances

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Pit Sizes on a CD

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DVD Bonding

z DVDs consist of 2 substrates bonded together.

z 3 processes can be used for bonding:

y Hot melt bonding

y Radical UV cured bonding

y Cationic UV bonding

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CD & DVD Formats

z CD 650 MB

z DVDs

y Single layer, single sided 4.7 GB

y Single layer, double sided 9.4 GB

y Dual layer, single sided 8.5 GB

y Dual layer, double sided 17.0 GB

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DVD Formats

z Single layer, single sided DVDs - active

substrate is metallized and bonded to blank

substrate.

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DVD Formats

z Single layer, double sided DVDs - both

substrates are metallized and bonded together.

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DVD Formats

z Dual layer, single sided DVDs - one substrate

has 2 metallization layers.

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DVD Formats

z Dual layer, double sided DVDs - both

substrates have 2 metallization layers.

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Future

z New technologies like blue lasers will increase

capacities.

z By 2005, it is predicted DVDs will havecapacities of 50 GB per side.

Documents

CD_DVDPP