Disc pairing in optical disc replication

Abstract

An apparatus for bonding an upper half-disc and a lower half-disc to form an optical disc, the apparatus has an upper housing, operable to hold the upper half-disc and a lower housing, operable to support the lower half-disc and operable to contact with the upper housing to form an air-tight chamber between the upper housing and the lower housing. A actuator operates to pair the upper half-disc and the lower half disc by bringing the upper half-disc and the lower half disc into close proximity within the air-tight chamber while pressure in the air-tight chamber is held below ambient air pressure, where bringing the upper half-disc and the lower half disc into close proximity distributes a bonding material between the upper half-disc and the lower half-disc to fill the space between the upper half-disc and the lower half-disc. This abstract is not to be considered limiting, since other embodiments may deviate from the features described in this abstract.

1 . An apparatus for bonding an upper half-disc and a lower half-disc to form an optical disc, the apparatus comprising:
 an upper housing, operable to hold the upper half-disc;   a lower housing, operable to support the lower half-disc and operable to contact with the upper housing to form an air-tight chamber between the upper housing and the lower housing; and   an actuator operable to pair the upper half-disc and the lower half disc by bringing the upper half-disc and the lower half disc into close proximity within the air-tight chamber while pressure in the air-tight chamber is held below ambient air pressure;   
       wherein bringing the upper half-disc and the lower half disc into close proximity distributes a bonding material between the upper half-disc and the lower half-disc to fill the space between the upper half-disc and the lower half-disc. 
     
     
         2 . An apparatus in accordance with  claim 1 , further comprising:
 a pair plate located in the lower housing and operable to support the lower half-disc;   
       wherein the actuator comprises a pressure actuated flexible diaphragm mounted in the lower housing below the pair plate. 
     
     
         3 . An apparatus in accordance with  claim 2 , wherein the flexible diaphragm is flexed upwards when pressure below the flexible diaphragm exceeds the pressure in the air-tight chamber. 
     
     
         4 . An apparatus in accordance with  claim 2 , wherein the flexible diaphragm is prevented from flexing upwards when pressure below the flexible diaphragm is less than the pressure in the air-tight chamber. 
     
     
         5 . An apparatus in accordance with  claim 2 , further comprising:
 a center pin coupled to the upper housing for aligning the upper half-disc in the upper housing; and   a stop pin coupled to the pair plate;   
       wherein, in operation, upward motion of the pair plate is halted when the stop pin contacts the center pin to control the thickness of the bonding material between the upper half-disc and the lower half-disc. 
     
     
         6 . An apparatus in accordance with  claim 2 , further comprising at least tape strip adhered to that surface of the pair plate that is operable to support the lower half-disc. 
     
     
         7 . An apparatus in accordance with  claim 1 , further comprising an o-ring seal seated in the periphery of the lower housing, wherein the o-ring seal provides an air-tight seal between the upper housing and the lower housing when the upper housing and the lower housing are brought together. 
     
     
         8 . An apparatus in accordance with  claim 1 , further comprising a spinner unit, operable to spin the paired upper half-disc and the lower half disc to remove excess bonding material. 
     
     
         9 . An apparatus in accordance with  claim 1 , wherein the bonding material is an ultraviolet curable resin, further comprising an ultraviolet unit, operable to expose the paired upper half-disc and the lower half disc to ultraviolet light. 
     
     
         10 . An apparatus for bonding an upper half-disc and a lower half-disc to form an optical disc, the apparatus comprising:
 means for dispensing a bonding material onto a surface of at least one of the lower half-disc and the upper half disc;   means for forming an air-tight chamber around the upper and lower half-discs;   means for reducing the pressure in the air-tight chamber to a first pressure below an ambient pressure; and   actuator means for bringing the upper half-disc and the lower half disc into close proximity of each other within the air-tight chamber;   
       wherein bringing the upper half-disc and the lower half disc into close proximity of each other distributes the bonding material between the upper half-disc and the lower half-disc. 
     
     
         11 . An apparatus in accordance with  claim 10 , further comprising:
 a pair plate for supporting the lower half-disc; and   a pressure actuated flexible diaphragm below the pair plate, operable to flex upwards and displace the pair plate when the pressure below the flexible diaphragm exceeds the pressure above the flexible diaphragm;   
       wherein the actuator means comprises a means for controlling the pressure below the flexible diaphragm. 
     
     
         12 . An apparatus for bonding a first half-disc and a second half-disc to form an optical disc, the apparatus comprising:
 means for dispensing a bonding material onto a surface of at least one of the first half-disc and the second half-disc;   means for forming an air-tight chamber around the first and second half-discs;   means for reducing the pressure in the air-tight chamber to a first pressure below an ambient pressure; and   actuator means for bringing the first half-disc and the second half disc into close proximity of each other within the air-tight chamber;   
       wherein bringing the first half-disc and the second half disc into close proximity of each other distributes the bonding material between the first half-disc and the second half-disc. 
     
     
         13 . An apparatus in accordance with  claim 12 , further comprising:
 a pair plate for supporting the first half-disc; and   a pressure actuated flexible diaphragm below the pair plate, operable to flex upwards and displace the pair plate when the pressure below the flexible diaphragm exceeds the pressure above the flexible diaphragm;   
       wherein the actuator means comprises a means for controlling the pressure below the flexible diaphragm. 
     
     
         14 . An apparatus in accordance with  claim 12 , further comprising:
 means for creating raised regions on that surface of the pair plate that supports the first half-disc.   
     
     
         15 . An apparatus for bonding an upper half-disc and a lower half-disc to form an optical disc, the apparatus comprising:
 an upper housing, operable to hold the upper half-disc;   a lower housing, operable to support the lower half-disc and operable to contact with the upper housing to form an air-tight chamber between the upper housing and the lower housing;   a pair plate located in the lower housing and operable to support the lower half-disc; and   an actuator operable to pair the upper half-disc and the lower half disc by bringing the upper half-disc and the lower half disc into close proximity within the air-tight chamber while pressure in the air-tight chamber is held below Ambient air pressure, wherein the actuator comprises a pressure actuated flexible diaphragm mounted in the lower housing below the pair plate;   a center pin coupled to the upper housing for aligning the upper half-disc in the upper housing; and   a stop pin coupled to the pair plate;   tape strip adhered to that surface of the pair plate that is operable to support the lower half-disc;   an o-ring seal seated in the periphery of the lower housing, wherein the o-ring seal provides an air-tight seal between the upper housing and the lower housing when the upper housing and the lower housing are brought together;   
       wherein bringing the upper half-disc and the lower half disc into close proximity distributes a bonding material between the upper half-disc and the lower half-disc to fill the space between the upper half-disc and the lower half-disc; 
       wherein the flexible diaphragm is flexed upwards when pressure below the flexible diaphragm exceeds the pressure in the air-tight chamber, and wherein the flexible diaphragm is prevented from flexing upwards when pressure below the flexible diaphragm is less than the pressure in the air-tight chamber; and 
       wherein, in operation, upward motion of the pair plate is halted when the stop pin contacts the center pin to control the thickness of the bonding material between the upper half-disc and the lower half-disc. 
     
     
         16 . An apparatus in accordance with  claim 15 , further comprising a spinner unit, operable to spin the paired upper half-disc and the lower half disc to remove excess bonding material. 
     
     
         17 . An apparatus in accordance with  claim 15 , wherein the bonding material is an ultraviolet curable resin, further comprising an ultraviolet unit, operable to expose the paired upper half-disc and the lower half disc to ultraviolet light.