ODSA Optical Disc Seminar Asia September 1, 2005

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ODSA Optical Disc Seminar AsiaSeptember 1, 2005
Solutions for manufacture of new formats

• Dr Torsten Dippell
• Manager Field Process Engineering Optical Disc

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Table of content

• Standard manufacturing of HD-DVD-ROM HD-DVD-ROM
  format / Process steps in general / Machine for
  HD-DVD-ROM
• Standard manufacturing of Blu-ray Disc ROMBD ROM
  format / Process steps in general / Cover layer
  applicationmachine layouts for BD ROM
• Recordable formatsSpecification status / Single
  layer or dual layer / Recording materials
• Nano imprint process

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The HD-DVD-ROM format
The layout of a HD-DVD-ROM disc
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Layout of a High Density DVD (HD DVD-ROM)
120 mm
0.6 mm
15 GB
20 µm
L1
55 nm
1.2 mm
0.6 mm
L0
Substrate (Polycarbonate) Full reflective layer
(Al) Adhesive (Acrylic lacquer) Substrate
(Polycarbonate)
Laser beam (?405 nm)
(formerly known as Advanced Optical Disc or AOD)
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Layout of a High Density DVD Dual Layer (HD
DVD-ROM)
Layout of dual layer ( 30 GB)
0.6 mm
50 nm
20 µm
15 nm
L1
0.6 mm
L0
Substrate (Polycarbonate) Semi Reflective Layer
(Si, Ag) Adhesive (Acrylic Lacquer) Full
Reflective Layer (Al) Substrate (Polycarbonate)
Laser beam (?405 nm)
Also possible double-sided dual layer ( 60 GB)
analogous to DVD-18
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Process steps for HD-DVD-ROM manufacturing
The material flow in a HD-DVD-ROM machine
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Process steps for HD DVD-ROM manufacturing
BONDING
Hard Coat ?
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Bonding - Space layer thickness uniformity
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Space layer thickness repeatability
Global Bonding Layer Thickness HD DVD
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Hard Coating
A scratch and finger print protection
M A C H I N E
Hard Coat
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The advantage of hard coat
Protection for finger prints
Protection for scratches
without hard coat
Jitter
with hard coat
Steel wool abrasion cycles
Size of laser beam
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A machine layout
Is there a difference between DVD and HD-DVD?
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Schematic Drawing for HD DVD-ROM line
Hard coating
Bonding
IMM
Receiver unit
Cooling belt
IMM
Metallizer
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A layout of the PEGASUS line
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The Blu-ray Disc ROM format
The layout of a Blu-ray disc
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Blu-ray Disc (BD) ROM format
Layout of a Blu-ray Disc (BD)
120 mm
1.1 mm
23/25/27 GB single sided
50-60 nm
1.2 mm
100 µm
Full reflective layer (Al) Substrate
(Polycarbonate) Cover layer
Laser beam (?405 nm)

• Data is molded in PC substrate
• Reflecting layer is applied on substrate side
• The adhesive and tape cover layer has to be
  passed by the read out laser.

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Blu-ray Disc 50 GB
120 mm
1.1 mm
50 GB double sided
60 nm
1.2 mm
20 µm
15 nm
80 µm
Full reflective layer (Al) Substrate
(Polycarbonate) Semi reflective layer (Ag)
Laser beam (?405 nm)

• Data for L1 is molded in PC substrate
• Reflecting layer is applied on substrate side
• The adhesive is structured with L0 by 2P process
• Semi reflective layer is applied an cured
  adhesive and is covered by a cover layer.

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Process Steps for BD ROM

• The necessary process steps
• Injection molding
• Metallizing
• Adding cover layer
• Cap coat
• Spin-on
• Cover bond
• Hard coat

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Process Steps for BD ROM (single layer)
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Process Step 1 Injection Molding
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Process Step 2- Metallization
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Process Step 3 - Cover Layer
C R I T I C A L (uniformity 2 µm)
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Cap coating technology
Variable parameters v, m, h, b
b capillary plate width d wet film
thickness l capillary plate height h
distance liquid level to capillary plate tips m
capillary plate tips to substrate surface v
coating velocity
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Cap coating technology (SHT patent)
CapCoat nozzle
Chuck
Fluid bath
Substrate
3. Contact nozzle-substrate
2. Capillary plates move up
1. Load substrate to chuck (face down)
5. End of capillary apply process
4. Capillary apply process in progress
6. Stand-by position
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Process Step 3 - Cover layer by Spin-on process
Typical uniformity of a spin coated layer
2µm
thickness
Spin Coating in one step
radius
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Process Step 3 - Cover Layer by Cover Bond Process
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Cover Tape Specifications
Current status BD Rom specification of film
manufacturer
perpendicular 50 nm in-plane 5 nm
thickness 80 µm tolerance 1.5 µm
no value specified, but laser deflection 28
Process Step 4 Hard Coating
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The machine for manufacturing BD ROM

• The machine layouts
• Cap coat
• Cover bond

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Schematic Drawing for BD ROM line with Cap Coating
Hard coating
Cap coating
IMM 4-5sec. cycle time
Receiver unit
Cooling belt
IMM 4-5sec. cycle time
Metallizer
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Machine layout for BD ROM line with Cap coat
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Schematic drawing for BD ROM line with cover bond
process
IMM 4-5sec. cycle time
Cover layer feed in
Bonding curing
Hard coating
Receiver unit
Cooling belt
IMM 4-5sec. cycle time
Metallizer
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Machine layout for BD ROM line with cover bond
process
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The costs for materialsin comparison of processes

• Cap coat
• Cover bond

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Comparison of material costs of cap coating and
cover bond
Calculated with high prices (status from Q1 /
2005)
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The recordable formatsDisc layoutSingle layer
or dual layer?Recording material
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HD-DVD-Recordable
Layout of a HD-DVD Recordable (HD-DVD-R) or
Rewritable (HD DVD-RW)
Recording layer Full reflective layer
(Ag) Substrate (Polycarbonate) Adhesive
(Acrylic lacquer) Substrate (Polycarbonate)
Read-out and recording Laser beam (?405 nm)

• Reflecting layer is applied on substrate side
  with groove structure
• Recording layer upon reflective layer
• The cover layer has to be passed by the read out
  laser
• Data is applied in recording layer

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BD Recordable
RRecord EErase
Layout of a Blu-ray Disc Recordable (BD-R) or
Rewritable (BD-RE)
Recording layer Full reflective layer
(Ag) Substrate (Polycarbonate) Cover layer
Read-out and recording Laser beam (?405 nm)

• Reflecting layer is applied on substrate side
  with groove structure
• Recording layer is added on reflective layer
• The cover layer has to be passed by the read out
  laser
• Data is applied in recording layer

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Two different recording methods
Inorganic recording layer (Phase change material)
Organic recording layer (Blue laser dye material)
Not limited to Rewritable
We are in contact with large brand name
co-operation partners for both recording methods
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Nano imprint process
Benefits Comparison Process Concept
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Additional Feature Tape with structure -
Nanoimprint
Fast production possible (Long term IMM
production only for DUMMY
substrates) ? Fast production with lower
risk of piracy
Easy process change for dual layer BD One layer
in PC substrate, the second layer

in cover tape
Additional coating on tape possible The change
for recordable or rewritable is an
additional process step before sputtering the
tape
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Disc format comparison - Nano imprint and
conventional BluRay disc
Conventional BD
Nano imprint BD

• Data is molded in PC substrate
• Reflecting layer is applied on substrate side
• The adhesive and tape cover layer has to be
  passed by the read out laser.

• Data structure is in tape
• Reflective layer is applied on tape
• The adhesive is dispensed between cover tape and
  (dummy) substrate
• The laser dont has to pass the adhesive layer

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STEAG HamaTech module for structuring a tape
Recording layer deposition
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Thank you for your attention !