Economical production of high quality prerecorded and recordable optical discs

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Economical productionof high qualitypre-recorde
dandrecordableoptical discs
Ullrich Speer
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CONTENT

• STEAG HamaTech in Middle East
• Cost of Ownership in Production
• STEAG HamaTech Solutions PRE-RECORDED
• STEAG HamaTech Solutions RECORDABLE

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STEAG HamaTech in Middle East
Kamel MEdisk Javaneeh Lohe Zarrine Media
Plant POD
Part Center Iran (PCI)
Technical Centre Dubai
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What are the real costs for the replicator ???
To understand the cost per disc issue it has to
be clear where the costs are generated

• Depreciation / initial investment
• Consumables (adhesive, targets, PC, process gas,
  stamper)
• Power consumption / facility costs
• Human resources

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Total cost per disc
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Cost of consumables per disc
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The important goal for the integrator
Use our knowledge for your success!!!

• Reduce the cost of ownership regarding process /
  usage of consumables
• Reduce the cost of ownership regarding downtimes
  (service and maintenance)
• Reduce the cost of ownership regarding human
  resources

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The STEAG HamaTech solutions for your production
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The STEAG HamaTech solutions for your production
Pre-recorded
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Solution for CD Production DELOS

• For production of pre-recorded CDs (120mm and
  80mm)

• Molding All standard IMMs

• Metallization STEAG HamaTech R-cathode

• Inspection STEAG ETA-Optik
• Inline quality inspection

• CD cycle time less than 3.0 sec (depending on
  IMM)
• Yield better than 95 for CD
• Uptime 95 for all formats
• More than 26,000 good CD in 24 hours

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Solution for DVD HD production PEGASUS

• For production of pre-recorded formats
• DVD-5, DVD-9, DVD-10, HD-DVD SL DL

• Molding Netstal, Sumitomo, Toyo

• Metallization STEAG HamaTech R-cathode

• Bonding Gap bonding

• Inspection STEAG ETA-Optik
• Inline quality inspection

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Performance

• DVD-5 cycle time approx. 2.0 sec
• DVD-9 cycle time approx. 2.0 sec
• DVD-10 cycle time approx. 2.0 sec
• HD-DVD SL cycle time
• HD-DVD DL cycle time
• Yield better than 92 for DVD
• Uptime 95 for all formats
• More than 37,000 good DVD-9 in 24 hours

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Housing and Footprint

• The Challenge
• Small footprint combined with good access to all
  components

• STEAG HamaTech Solution
• Advanced housing concept with outperforming
  access
• Only 17 m² footprint of complete line
• Max. height of 1.8m allows good overview above
  and below working level
• Fast installation of system (1 day)

• Advantage
• Higher uptime by easy access for maintenance
• High productivity by more efficient use of clean
  room space
• Short start up time

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Disc Handling

• The Challenge
• Accurate and fast handling of discs to all
  process steps

• STEAG HamaTech Solution
• Highest reliability by precise servo motor driven
  handlers

• Advantage
• Avoiding disc loss
• Maximizing uptime ( 95)
• Reliable system for day in / day out production
• ? High output

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Inline Substrate Thickness Control

• The Challenge
• Measurement of the layer 0 substrate thickness
• Feedback system for parameter control

• STEAG HamaTech Solution
• Optical substrate thickness measurement system
  designed by STEAG ETA-Optik
• Can be integrated as option

• Advantage
• System can be interfaced to all PEGASUS lines
• Wide range of measured thicknesses
• Cost savings for polycarbonate

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Controlled Disc Cooling

• The Challenge
• Cooling discs uniformly to minimize tilt
  variability prior to metallization

• STEAG HamaTech Solution
• Discs are floating
• No disc contact to pins
• Cool down to environment temperature

• Advantage
• Substrates have consistent tilt, leading to a
  stable metallization and bonding process

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Metallizing

• The Challenge
• Very uniform layer L0 to meet DVD-9
  specifications
• Long target life

• STEAG HamaTech Solution
• STEAG HamaTech Dual Cathode Metallizer for L0 and
  L1

• Advantage
• Uniformity of the semi-reflective layer
• Most advanced silver alloy technology
• Leading technology from one supplier

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Housing and Footprint

• The Challenge
• Small footprint combined with good access to all
  components

• STEAG HamaTech Solution
• Accessible arranged components completely
  integrated

• Advantage
• Higher uptime by easy access for maintenance
• No additional cabinet space needed

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Inline Thickness Control (ITC)

• The Challenge
• Measurement of the layer thickness and layer
  thickness uniformity on optical disc
• Closed loop connection to adjust metallizing
  process.

• STEAG HamaTech Solution
• Optical layer thickness measurement system
  designed by STEAG ETA-Optik
• High intensity diode at 880nm and sensitive photo
  detector

• Advantage
• System can be interfaced to all STEAG HamaTech
  metallizers in production lines.
• Wide range of measured thicknesses 10nm ...
  100nm for metals, 5nm ... 35nm for silicon.

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Sample Station

• The Challenge
• Online control of half sides during production

• STEAG HamaTech Solution
• Easy access and order possibilities for half sides

• Advantage
• Quality control without stopping the machine
• Control of clear discs and sputtered half sides
• Numbers of samples can be selected by software

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Bonding Station

• The Challenge
• Consistent bonding conditions even with unstable
  clean room environment
• Adhesive application and disc bonding without
  bubbles

• STEAG HamaTech Solution
• Adhesive temperature control system
• Dual dispense bonding
• Fast loading logistic

• Advantage
• Consistent adhesive viscosity
• Consistent quality even with outside
• temperature changes
• Fast cycle times
• Higher yield ? high output

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Spacer Layer Uniformity (1)

• The Challenge
• Adhesive layer uniformity near the center of the
  disc and on total disc

• STEAG HamaTech Solution
• Intermediate turn table (3 disc positions), after
  dispense before spinout to distribute adhesive
  evenly driven by natural capillary forces

• Advantage
• Reduced variation of layer thickness
• Small defects near the center hole are eliminated
  
• Enlarged bonding process window
• HD-DVD layer thickness will be supported

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Spacer Layer Uniformity (2)

• The Challenge
• Adhesive layer uniformity near the center of the
  disc

• STEAG HamaTech Solution
• ID cap function to secure perfect ID area
• Use for all formats by having a top pressure

• Advantage
• Reduced variation of layer thickness
• Small defects near the center hole are eliminated
  
• Enlarged bonding process window
• HD-DVD layer thickness will be supported

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Tilt Control

• The Challenge
• Active influence for disc shape

• STEAG HamaTech Solution
• Patented Vortex-Cooling system
• Turbulent air flow
• Control of time and pressure

• Advantage
• Easy control of disc shape
• Reduced tilt

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Adhesive Curing

• The Challenge
• Complete and uniform adhesive curing with less
  heat generation for all formats

• STEAG HamaTech Solution
• Special UV lamp provides selective spectral
  filtering to minimizes heat input to discs
• Good surface edge curing

• Advantage
• Adhesive is cured with less total energy
• Reduced tilt values at QC
• Short cycle times

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Receiver Unit

• The Challenge
• Small footprint with high loading capacity
• Long time between exchange of spindles

• STEAG HamaTech Solution
• 12 spindles for good discs
• 3 spindles for reject

• Advantage
• Approx. 25 min between exchange
• No cycle time loss due to 360 handling
• Less human resources to operate lines

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User Software Interface

• Windows based user interface / Touch Screen

• Disc map shows the position of all discs in the
  line

• Different operating languages available like
• - English, French, Spanish, German,
  Italian, Chinese, others are possible

• Navigation system and integrated report system
  available
• Key Card function as option for better
  production security
• OCTOPUS software for production control and
  networking of the facility

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Key statements
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The STEAG HamaTech solutions for your production
Recordable
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Road map moulding DVD/R process(es)
Cycle time depends on the process (groove
geometry, stamper replication)
DVD-R line 3503, AWM 5.1, 8x, 4.0 sec
TAURUS, AWM 6.1, 16x, 2.5 sec
DVD-R line 3503, AWM 6.1, 16x, 3.5 sec
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TAURUS DVD/R LINE
Advanced Cooling
Buffer Spindle
Buffer Spindles
Bonding Unit
Heating Units
Final Inspection
4 m x 10 m
Dye Layer Inspection
Dye Coating
Metallizer
Edge Cleaning
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Controlled substrate cooling

• Challenges
• Uniform disc cooling
• Avoiding tilt variability
• STEAG HamaTech Solution
• Pre-stabilizer holds the discs without any
  external forces
• Smooth free-convection cooling
• Advantages
• Fast disc stabilization
• No influence of cooling on tilt
• Very fast molding speeds possible

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Substrate cooling overview
Pre-Stabilizer
Advanced Cooler

• Advantages
• Extremely homogeneous and effective substrate
  cooling
• Forceless cooling
• Thoroughly conditioned substrates before dye
  coating (even at 2 sec cycle time)

2sec
12sec
30sec
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Dye coating

• Challenge
• Highly efficient coating module, allowing
  application of various different dye technologies
• STEAG HamaTech Solution
• 6 independent stainless steel dye coating cups
  driven by AC servo motors (top speed 10,000 rpm)
• Process Advantages
• Flexibility for different dye process times
• Flexibility for different dye process guiding
• Reduced maintenance due to high-quality
  components
• No chemical interactions

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Closed-loop dye process control

• Challenges
• Compensation of unavoidable environmental changes
  to dye layer properties
• Precise control of radial dye layer profile
• Operator-free optimization
• STEAG HamaTech Solution
• Closed-loop process control based on
• In-line measurement of each disc
• Dye cup specific measurement analysis
• Automated comparison with desired dye profile
• Optimization of 4 dye coating parameters to
  reduce dye profile deviations

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Closed-loop dye process control
Process optimization during production
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Drying / Heating

• Challenges
• Complete evaporation of the dye solvent
• Capable for different dye technologies
• STEAG HamaTech Solution
• Two compact stack dryers with horizontally stored
  discs (142 each stack)
• Constant hot airflow (up to 100C set-point),
  while discs are rotating

• Process Advantages
• Very homogeneous temperature distribution on the
  disc
• First in-first out principle for constant
  drying/heating times
• Same treatment conditions for active and dummy
  disc
• Separate drying/heating units for active and
  dummy disc
• Capable for different dye technologies

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Edge cleaning

• Challenge
• Highly precise positioning of solvent dispense
  needle
• STEAG HamaTech Solution
• Edge cleaning after sputtering process
• Process Advantages
• Easy needle adjustment ? increased uptime
• No danger of solvent drops on dye ? higher yield
• Edge pre-shaped by sputter mask ? perfect edges

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Buffer functionality

• Challenges
• Different process speeds to be compensated to
  optimize output
• Intermediate stops of processes should be
  compensated (e.g. molding, coating, bonding)

• STEAG HamaTech Solution
• Two buffer positions
• Load and unload functionality of buffers
• Separate buffering for active and dummy side

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Results Mechanical Parameters
cpk-values Radial und tangential deviation DVDR
16x
cpk 2.5
cpk 1.3
Economical production of high-quality
pre-recorded and recordable optical discs / IMTS
Dubai 28thSeptember 2005
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Summary

• TAURUS with 2 IMMCycle time of below 3.0
  seconds
• ? Avoiding dual cavity
• ? Avoiding 3 or 4 IMM
• ? 16x proven
• ? Better investment-cost/output ratio than
  competitors
• ? Lower complexity than competitors

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Your solutions for economical replication of
optical discs
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YOUR RELIABLE PARTNER IN A CHANGING
WORLD www.steag-hamatech.com