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Economical production of high quality prerecorded and recordable optical discs

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TAURUS ... Automated comparison with desired dye profile. Optimization of 4 dye coating parameters to reduce dye profile deviations ... – PowerPoint PPT presentation

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Title: Economical production of high quality prerecorded and recordable optical discs


1
Economical production of high quality pre-recorde
d and recordable optical discs
Ullrich Speer
2
CONTENT
  • STEAG HamaTech in Middle East
  • Cost of Ownership in Production
  • STEAG HamaTech Solutions PRE-RECORDED
  • STEAG HamaTech Solutions RECORDABLE

3
STEAG HamaTech in Middle East
Kamel MEdisk Javaneeh Lohe Zarrine Media
Plant POD
Part Center Iran (PCI)
Technical Centre Dubai
4
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

5
Total cost per disc
6
Cost of consumables per disc
7
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

8
The STEAG HamaTech solutions for your production
9
The STEAG HamaTech solutions for your production
Pre-recorded
10
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

11
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

12
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

13
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

14
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

15
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

16
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

17
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

18
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

19
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.

20
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

21
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

22
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

23
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

24
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

25
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

26
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

27
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

28
Key statements
29
The STEAG HamaTech solutions for your production
Recordable
30
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
31
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
32
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

33
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
34
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

35
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

36
Closed-loop dye process control
Process optimization during production
37
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

38
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

39
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

40
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
41
Summary
  • TAURUS with 2 IMM Cycle 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

42
Your solutions for economical replication of
optical discs
43
YOUR RELIABLE PARTNER IN A CHANGING
WORLD www.steag-hamatech.com
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