Optical Disk Imaging Layer for Rapid Laser Labeling
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Solution Overview
Problem
Current methods for labeling optical data recording media such as CDs and DVDs are costly and time-consuming, especially for small quantities, and do not provide high-quality results, as they require elaborate stencil preparation and long labeling times.
Innovation Solution
An optical disk with an imaging layer comprising a matrix, a radiation-absorbing compound, an activator, a surface additive, and a color former, which can be quickly applied and processed using radiation energy to produce high-quality labels in shorter times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If screen-printing methods are used to label optical discs, then a wide variety of label content can be provided, but the process becomes cost ineffective and time-consuming for small quantities (less than 300-400 discs) due to fixed costs of unique materials and set-up
Solution Approach 1:
The patent extracts the labeling functionality from the traditional screen-printing process by providing a pre-formed imaging layer on the disc substrate. This eliminates the need for separate stencil preparation and ink application steps, allowing direct laser burning of labels. The imaging layer contains all necessary components (radiation-absorbing compound, color former, activator) integrated into the substrate, enabling rapid labeling without the overhead of screen-printing setup.
Solution Approach 2:
The imaging layer is prepared in advance during disc manufacturing, with radiation-absorbing compounds, color formers, and activators pre-positioned on the substrate. This preliminary preparation eliminates the need for time-consuming stencil creation and ink application during the labeling process, allowing users to directly burn labels with a laser pointer or similar device.
2Adaptability or versatility
If screen-printing methods are used, then customized label content can be achieved, but elaborate and time-consuming stencil preparation is required
Solution Approach 1:
The patent removes the stencil preparation step entirely by integrating the labeling functionality directly into the disc substrate through a pre-formed imaging layer. Users can directly burn any label design using a laser pointer without needing to create physical stencils, eliminating the time-consuming stencil-making process while maintaining full customization capability.
Solution Approach 2:
Instead of creating physical stencils for each label design, the patent enables direct digital-to-physical copying by allowing users to burn label images directly from digital files onto the disc using a laser pointer. The imaging layer responds to the laser energy by chemically changing to form the desired label pattern, eliminating the need for physical stencil copies.
3Productivity
If hand labeling or inkjet printing on adhesive labels is used, then small quantities can be labeled inexpensively, but high quality and precise alignment are not achieved
Solution Approach 1:
The patent merges the label and substrate into a single integrated structure by forming the imaging layer directly on the disc substrate. This eliminates the need for separate adhesive labels that require manual alignment, as the label becomes an intrinsic part of the disc surface. The imaging layer is applied uniformly across the entire substrate, ensuring precise positioning without manual alignment efforts.
Solution Approach 2:
The patent replaces the mechanical alignment process (manually positioning adhesive labels) with a chemical field-based approach. The imaging layer contains radiation-absorbing compounds that respond selectively to laser energy, allowing the label pattern to be defined by the laser beam path rather than physical label positioning. This substitution of mechanical alignment with optical-field control achieves superior precision.
4Reliability
If current imaging layer compositions are used, then labels can be formed, but labeling times are excessively long (20-24 minutes)
Solution Approach 1:
The patent optimizes the imaging layer composition by selecting specific radiation-absorbing compounds with high absorption coefficients at laser wavelengths, color formers with rapid color development kinetics, and activators that accelerate the color formation reaction. These parameter changes in the chemical composition enable the labeling process to complete in seconds rather than minutes, while maintaining reliable and permanent label formation.
Solution Approach 2:
The patent employs a composite imaging layer containing multiple functional components: radiation-absorbing compounds (for rapid energy absorption), color formers (for visible label creation), and activators (for accelerating the color formation reaction). This composite material structure enables simultaneous optimization of speed, reliability, and label quality, reducing labeling time from 20-24 minutes to under 14 minutes while maintaining label durability.
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
The described solution significantly reduces labeling time from 20-24 minutes to under 14 minutes by smoothing the substrate surface with the appropriate surface additive, allowing for faster laser focus and image formation with improved image quality.
Implementation Method 1
a radiation-absorbing compound; wherein the radiation-absorbing compound has a solubility of at least 2% by weight in the matrix
Implementation Method 2
significantly reduces labeling time from 20-24 minutes to under 14 minutes by smoothing the substrate surface with the appropriate surface additive, allowing for faster laser focus and image formation with improved image quality
Data Source
AI summary
Imaging layers, optical disks, and methods of preparation of each, are disclosed.