Disc pairing in optical disc replication

Abstract

An optical disc consistent with certain embodiments has a first half-disc and a second half-disc. A layer of bonding material is distributed between the first half-disc and the second half-disc by depositing the bonding material on the first half-disc, placing the first half-disc and second half-disc in a chamber, reducing the pressure within the chamber to a first pressure below an ambient pressure; and bringing the first half-disc and the second half-disc into close proximity within the chamber. This abstract is not to be considered limiting, since other embodiments may deviate from the features described in this abstract.

1 . An optical disc manufactured using a method for pairing an upper half-disc and a lower half-disc of an optical disc, the optical disc comprising: 
 an upper half-disc and a lower half-disc, and wherein the upper half-disc and the lower half-disc are mated together using a method comprising:    loading the upper half-disc into an upper housing;    loading the lower half-disc into a lower housing;    dispensing a bonding material onto a surface of at least one of the lower half-disc and the upper half-disc;    bringing the upper housing and the lower housing together to form a chamber between the upper housing and the lower housing.    reducing the pressure within the chamber to a first pressure below an ambient pressure; and    bringing the upper half-disc and the lower half-disc into close proximity within the chamber to distribute the bonding material between the upper surface of the lower half-disc and the lower surface of the upper half-disc and form the optical disc,    wherein the lower half-disc is supported on a pair plate in the lower housing and wherein bringing the upper half-disc and the lower half-disc into close proximity within the chamber comprises increasing a pressure below a flexible diaphragm in the lower housing from a second pressure to a pressure greater than the pressure in the chamber, causing the flexible diaphragm to flex upwards and displace the pair plate upwards.    
     
     
         2 . An optical disc accordance with  claim 1 , wherein the method for mating the upper half-disc to the lower half-disc further comprises: 
 increasing the pressure within the chamber from the first pressure to the ambient pressure; and    removing the paired disc from the chamber.    
     
     
         3 . An optical disc accordance with  claim 1 , wherein the lower half-disc is supported on a pair plate in the lower housing and wherein bringing the upper half-disc and the lower half-disc into close proximity within the chamber comprises increasing a pressure below a flexible diaphragm in the lower housing from a second pressure to a pressure greater than the pressure in the chamber, causing the flexible diaphragm to flex upwards and displace the pair plate upwards.  
     
     
         4 . An optical disc accordance with  claim 1 , wherein the second pressure below the flexible diaphragm is less than the first pressure in the chamber.  
     
     
         5 . An optical disc accordance with  claim 1 , wherein reducing the pressure within the chamber to the first pressure below the ambient pressure comprises applying suction to a vacuum port in the chamber.  
     
     
         6 . An optical disc manufactured using a method for pairing an upper half-disc and a lower half-disc of an optical disc, the optical disc comprising: 
 an upper half-disc and a lower half-disc, and wherein the upper half-disc and the lower half-disc are mated together using a method comprising:    loading the first half-disc into a first housing;    loading the second half-disc into a second housing;    dispensing a bonding material onto a surface of at least one of the first half-disc and the second half-disc;    bringing the first housing and the second housing together to form a chamber between the first housing and the second housing.    reducing the pressure within the chamber to a first pressure below an ambient pressure; and    bringing the first half-disc and the second half-disc into close proximity within the chamber to distribute the bonding material between a surface of the first half-disc and a surface of the second half-disc and form a paired disc,    wherein the second half-disc is supported on a pair plate in the second housing and wherein bringing the first half-disc and the second half-disc into close proximity within the chamber comprises increasing a pressure below a flexible diaphragm in the second housing from a second pressure to a pressure greater than the pressure in the chamber, causing the flexible diaphragm to flex upwards and displace the pair plate upwards.    
     
     
         7 . An optical disc according to  claim 6 , wherein the method, further comprises: 
 increasing the pressure within the chamber from the first pressure to the ambient pressure; and    removing the paired disc from the chamber.    
     
     
         8 . An optical disc according to  claim 6 , wherein the second half-disc is supported on a pair plate in the second housing and wherein bringing the first half-disc and the second half-disc into close proximity within the chamber comprises increasing a pressure below a flexible diaphragm in the second housing from a second pressure to a pressure greater than the pressure in the chamber, causing the flexible diaphragm to flex upwards and displace the pair plate upwards.  
     
     
         9 . An optical disc according to  claim 6 , wherein the second pressure below the flexible diaphragm is less than the first pressure in the chamber.  
     
     
         10 . An optical disc according to  claim 6 , wherein reducing the pressure within the chamber to the first pressure below the ambient pressure comprises applying suction to a vacuum port in the chamber.  
     
     
         11 . An optical disc manufactured using a method for pairing an upper half-disc and a lower half-disc of an optical disc, the optical disc comprising: 
 an upper half-disc and a lower half-disc, and wherein the upper half-disc and the lower half-disc are mated together using a method comprising:    dispensing an ultraviolet curable resin onto a surface of at least one of the upper half-disc and the lower half-disc;    placing the upper half-disc and lower half-disc in a chamber;    reducing the pressure within the chamber to a first pressure below an ambient pressure;    bringing the upper half-disc and the lower half-disc into close proximity within the chamber to distribute the bonding material between the upper surface of the lower half-disc and the lower surface of the upper half-disc and form a paired disc;    spinning the paired disc to remove excess ultraviolet curable resin; and    exposing the paired disc to ultraviolet light to cure the ultraviolet curable resin and form the optical disc,    wherein the lower half-disc is supported on a pair plate in the chamber and wherein bringing the upper half-disc and the lower half-disc into close proximity within the chamber comprises increasing a pressure below a flexible diaphragm in the chamber from a second pressure to a pressure greater than the pressure in the chamber, causing the flexible diaphragm to flex upwards and displace the pair plate upwards.    
     
     
         12 . An optical disc in accordance with  claim 11 , wherein the method further comprises: 
 checking the optical disc for defects; and    discarding the optical disc if a defect is found.    
     
     
         13 . An optical disc in accordance with  claim 11 , wherein placing the upper half-disc and lower half-disc in the chamber comprises: 
 loading the upper half-disc into an upper housing;    loading the lower half-disc into a lower housing; and    bringing the upper housing and the lower housing together to form the chamber between the upper housing and the lower housing.    
     
     
         14 . An optical disc comprising: 
 a first half-disc;    a second half-disc; and    a layer of bonding material distributed between the first half-disc and the second half-disc by depositing the bonding material on the first half-disc, placing the first half-disc and second half-disc in a chamber, reducing the pressure within the chamber to a first pressure below an ambient pressure; and    bringing the first half-disc and the second half-disc into close proximity within the chamber.    
     
     
         15 . An optical disc in accordance with  claim 14 , wherein the bonding material comprises an ultraviolet curable resin that is cured by exposure to ultraviolet light.  
     
     
         16 . An optical disc in accordance with  claim 14 , wherein the optical disc comprises a digital versatile disc (DVD).