Multilayer Optical Disk Bonding with Masked UV Curing
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Solution Overview
Problem
The challenge in producing multilayer optical recording media is to minimize warpage and protrusions (burr) after bonding, as existing methods often result in radial tilt issues and adhesive protrusions that can contaminate disk drives.
Innovation Solution
A method involving the use of a UV curable adhesive between disks, where the disks are rotated and masked at their edges with a mask member, with ultraviolet rays emitted from the light emission surface to preliminarily cure the adhesive, ensuring minimal warpage and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If UV curable adhesive is used to bond multiple optical recording disks, then the recording capacity is increased, but warpage and burr formation occur on the bonded disks
Solution Approach 1:
The patent applies preliminary UV irradiation to partially cure the adhesive before final bonding. By performing this preliminary curing action in advance, the adhesive achieves initial fixation that prevents excessive flow and burr formation, while still allowing for subsequent complete curing to ensure strong bonding strength.
Solution Approach 2:
The patent introduces a mask member that selectively masks specific regions (such as the center hole area) during UV irradiation. This creates local quality differences in the adhesive curing - the masked regions remain uncured or partially cured while other regions achieve full curing, preventing warpage and burr formation in critical areas.
2Strength
If UV irradiation is applied to cure the adhesive, then bonding strength is improved, but warpage occurs due to uneven curing
Solution Approach 1:
The mask member creates selective UV irradiation patterns, allowing different regions of the adhesive to cure at different rates. This controlled non-uniform curing prevents the uniform stress distribution that causes warpage, while still achieving sufficient bonding strength in the critical bonding areas.
Solution Approach 2:
The preliminary UV irradiation step partially cures the adhesive before final positioning and complete curing. This preliminary action reduces the adhesive's流动性 (flowability) to prevent excessive spreading and warpage, while the subsequent complete curing ensures full bonding strength.
3Strength
If the adhesive is fully cured immediately, then bonding strength is maximized, but burr formation increases due to adhesive protrusion
Solution Approach 1:
The patent performs preliminary UV irradiation to partially cure the adhesive before the bonding process is complete. This preliminary curing reduces the adhesive's flowability, preventing it from protruding and forming burrs, while the subsequent complete curing ensures maximum bonding strength is achieved.
Solution Approach 2:
The patent changes the curing parameter of the adhesive from fully cured to partially cured during the bonding process. By controlling the degree of curing at different stages, the adhesive's physical properties (such as viscosity and flowability) are modified to prevent burr formation while maintaining bonding capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces warpage and burr occurrence, maintaining radial tilt within standard ranges and preventing adhesive protrusions, thus enhancing the quality and reliability of the multilayer optical recording medium.
Implementation Method 1
emitting ultraviolet rays for preliminarily curing the UV curable adhesive from the side of a light emission surface of the first disk during rotation
Data Source
AI summary
There is provided a method of producing a multilayer optical recording medium through which the occurrence of burrs is reduced. The method of producing a multilayer optical recording medium includes, when a UV curable adhesive is interposed between a first disk and a second disk, the first disk and the second disk are rotated, and when at least one of the vicinities of inner circumferential edges and the vicinities of outer circumferential edges of the first disk and the second disk is masked with a mask member, emitting ultraviolet rays for preliminarily curing the UV curable adhesive from the side of a light emission surface of the first disk during rotation.