DVD BONDING
USING HIGH ENERGY
PULSED UV/VIS LIGHT
TAKE THE
0.6-SECOND
CURE!
XENON’s PULSED UV IS
SLASHING CURE TIMES AND
CYCLE TIMES WHILE BOOSTING
DVD YIELDS
0.6-second cure times —that’s
an eye-popping figure. XENON Corporation,
the speed leader, has documented cure
times as low as 0.6 seconds for DVD-5, and
1.2 seconds for DVD-9.
And lightning fast cure times are just one
of the many benefits of pulsed UV curing
technology. Others include: higher yields,
reduced complexity, safe, mercury-free
operation, and fast ON/OFF.
The leading DVD manufacturers are
designing in XENON’s CoolCureXL-DVD®,
XENON’s pulsed UV technology because it
reduces “shrinkage” through
tilt management and through
lower temperature rise of the
DVD substrate during the
curing cycle.
Shorter cure times reduce overall cycle
times of DVD bonders which means higher
DVD output.
XENON Corporation’s CoolCureXL-DVD
pulsed UV systems are installed in more
than 1000 DVD bonders the world over.
Vastly improved yields and dramatically
reduced cure times that result in low cycle
times… these are reasons that the leaders
in DVD manufacture are switching to pulsed
UV curing technology and to aligning with
XENON’s proven history.
Pulsed UV curing is less
complex than mercury systems, and it is safer for the
user too. And finally, instant
ON and OFF is a benefit
manufacturers appreciate.
For more information,
request the booklet: DVD
Bonding… Using High
Energy Pulsed UV/VIS
Light. Call or access our
website at
www.xenoncorp.com/dvd/
XENON’s PULSED UV ...
CURES WHILE IT YIELDS
www.xenoncorp.com
+1 800-936-6695
+1 781-938-3594
Table of Contents
TABLE OF CONTENTS
Chapter 1: Introduction to Ultraviolet light (UV) ------------------------------------------------------ 4
Comparison: Pulsed Light versus Continuous Wave UV
Pulsed Light Properties
Chapter 2: Pulsed Light Systems ------------------------------------------------------------------------- 5
Chapter 3: Benefits of Pulsed Light in DVD Bonding ----------------------------------------------- 6
Low heat transfer to substrate
Deep penetration of polycarbonate layers
Instant on/off control processing
Broad Spectrum of Light
Flexibility of Lamp Shape
Spectrum Tuning
Edge curing
Tilt management using energy control and dual pulsed lamps
Comparing Lacquer CD Curing Requirements with Those of DVD Bonding
Ease of System Integration
Safety and Environmental Benefits
UV-Curing Adhesives and Lacquers
Achieving Fast Cure times
Chapter 4: Non Contact Surface Treatment Using Pulsed UV/Visible Light ------------------ 11
Chapter 5: Emerging Technologies Using High Energy Pulsed UV/Visible Systems ------ 13
Data Storage Devices Based on Holographic Technology
Graphics for the Play Side of Optical Media
Chapter 6: Next Generation DVD Systems ------------------------------------------------------------- 14
M2
Pfeiffer Vacuum
Chapter 7: Conclusion --------------------------------------------------------------------------------------- 16
References
Acknowledgments
Chapter 8: Model RC-1002 System Specifications -------------------------------------------------- 17
3
Chapter 1: Introduction
1: Introduction to Ultraviolet Light
(UV)
UV is unable to penetrate opaque materials and
meet low temperature, safety, and flexibility requirements. Advantages of pulsed light include faster
processing, little or no substrate temperature buildup,
process flexibility, freedom from toxic lamp materials,
penetration of opaque solutions, and ease of meeting
special lamp configuration requirements. Pulsed light
is usually the technology of choice when continuous
UV fails to maintain low substrate temperature or to
penetrate thick and opaque materials.
Electromagnetic radiation is the theory of propagation of all energy, and extends from the extremes of
sound to gamma rays, and includes radio waves,
microwaves, infrared, visible light, X-rays and ultraviolet light. Ultraviolet light occupies that region of the
spectrum between visible light and x-rays.
By definition, the wavelengths of ultraviolet radiation
extend from 400 nm (nanometers) down to about 100
nm (or 4000Å to 1000Å). Below 180 nm, ultraviolet
radiation can only propagate in a vacuum, and is
commonly referred to as vacuum UV. The UV
spectral region is often divided into bands referred to
as:
Band
Ozone generating
Bacterial (germicidal)
Erythemal
“Black light”
Pulsed Light Properties
The difference between pulsed UV light and continuous UV light is illustrated in Figure 1 in terms of pulse
amplitude and controlled spaced pulses. Peak power
levels with pulsed light can be as high as 1 x 106
watts, with pulse widths in the microsecond region.
The pulsed-lamp spectrum is also directly dependent
on the characteristics of the electrical operating
conditions. Shifting the current will yield the optimum
wavelength for a particular application. The broad
Wavelength
180 to 200 nm
220 to 300 nm
280 to 320 nm
320 to 400 nm
A more common grouping in radiometric terms is:
Band
UV-A (phototherapy)
UV-B (sunburn)
UV-C carcinogenic
Wavelength
315 to 400 nm
280 to 315 nm
100 to 280 nm
There are several sources of plasma-created UV
radiation, the most common being the electric arc,
the mercury lamp, and the most efficient of all, the
pulsed xenon lamp. Whatever the application, the
quest for increased energy in the UV is incessant, as
always, and the demand for the efficient UV generator increases constantly with new applications. A
primary characteristic of the pulsed xenon lamp is its
capability of generating wideband radiation (50 nm to
5 microns) with unequalled high efficiency … especially in the ultraviolet spectral region from 180 nm
(air-cutoff) to 400 nm.
Figure 1: A comparison of pulsed vs. continuous UV light
(pulsed light illustrated in a single pulse and burst mode)
spectrum can be tuned to peak in different spectral
ranges.
Pulsed light is a fast, safe, environmentally benign
and flexible technology capable of meeting all the
needs of DVD bonding. About 50% to 60% of the
input electrical energy is converted to optical energy,
with an efficacy in the range of about 150 to 280
lumens/watt when operated at optimum conditions.
Generally, a xenon pulsed source can be designed to
outperform any other source
Comparison: Pulsed Light vs. Continuous Wave
UV
The two fundamental methods of delivering UV are
continuous (CW) and pulsed. Pulsed light is inherently different from continuous UV light such as,
fluorescence, halogen, mercury vapor, or microwavegenerated continuous light sources. Pulsed light is
particularly useful in applications where continuous
4
Chapter 2 Pulsed Light Systems
2: Pulsed Light Systems
Figure 2 illustrates the five functional elements of a
high energy pulsed UV/Visible light system. These
basic elements are:
➀ HIGH VOLTAGE POWER SUPPLY
➁ STORAGE CAPACITOR
➂ INDUCTOR
➃ FLASHLAMP
➄ TRIGGER CIRCUIT
The high-voltage dc power supply, protected by
current-limiting, is used to charge the storage
capacitor to a voltage below the gas breakdown
voltage, or ionization, of the flashlamp. When the
capacitor is fully charged to this level, the power
supply is momentarily prevented from further charging. A high voltage trigger pulse is then supplied to
the flashlamp, typically through a trigger wire wound
around the flashlamp. This trigger pulse ionizes the
gas in the flashlamp allowing the energy stored in the
capacitor to discharge through it. The capacitor and
inductor values control the flashlamp peak current,
rise time and pulse width, insuring the optimum
energy transfer within the flashlamp. The flashlamp
discharge converts the capacitor/inductor electrical
energy to radiant energy in the form of UV/Visible
radiation which in turn is delivered to the intended
target. This process is then repeated, typically 10
pulses/second, resulting in a series of controlled,
shaped, high energy UV/Visible pulses.
Figure 2: Basic Pulsed UV/Visible Light System
5
Chapter 3: Benefits of Pulsed Light
3: Benefits of Pulsed Light in DVD
Bonding
operate at the same high temperatures
required to vaporize the mercury in mercury
vapor lamps;
The most important reasons for considering pulsed
UV/Visible systems for DVD bonding over continuous
UV systems are:
• The high peak power of the pulses, which
eliminates the need for high average power;
• The elimination of continuous infrared radiation; flashlamps are turned completely off/on in
microseconds.
• Safety
• Temperature control
• Process effectiveness
• Process speed
• Process flexibility
These features result in one or more of the following
benefits of pulsed light technology:
1. Low heat transfer
2. High peak power for deep penetration of
opaque substances
3. Instant on/off (no warm-up required), for ease
of control
4. Broad spectrum
Figure 3: Instead of continuously warming the substrate,
as does continuous UV, pulsed UV/Visible light provides
cooling periods between pulses.
5. Special lamp configurations
6. Spectrum Tuning
For manufacturers seeking higher yields and faster
production, the important benefit of maintaining the
substrate at a lower temperature during the process
is the ability to eliminate disc warping.
7. Edge Curing
8. Tilt Management
Benefit # 2 – Deep penetration of polycarbonate
layers
Each of these benefits will be discussed in detail to
more clearly reveal how pulsed UV/Visible light aligns
itself to the needs of today’s DVD bonding process.
A significant characteristic of a pulsed UV/Visible
lamp is the ability to provide deep penetration due to
high peak power. The high peak power of the pulsed
lamp allows the UV to penetrate the polycarbonate
substrate layer with sufficient energy to complete the
cure of the adhesive sandwiched in between the twopolycarbonate layers. In comparison, a continuous
UV mercury lamp delivers about one third of its
energy as heat at or near the surface of the disc, thus
requiring significantly more average power and often
requiring water cooling. One Xenon customer used
pulsed light to reduce the average power from
between 5,000 and 6,000 watts with mercury vapor
lamps to an average of 400 watts.
Benefit # 1 - Low heat transfer to substrate
Although some heat enhances polymerization, the
process of photo polymerization is designed to occur
mainly with light. Lower temperatures achieved with
pulsed light can help improve yields. Five key reasons, illustrated in Figure 3, that minimize temperature buildup when using pulsed UV/Visible in a DVD
bonding process are:
• The short-duration pulses, which are too fast
for heat buildup;
• The presence of a cooling period between the
pulses;
Deep penetration of a substrate also depends on
another pulse characteristic: pulse width. This same
customer tested thermal loading of DVD-10 discs
• The fact that pulsed UV lamps do not have to
6
Chapter 3: Benefits of Pulsed Light
(dual sided, single layered) using two pulsed UV
lamps with different pulse widths, The more energetic
pulse lasted 1 ms, with smooth ramp up and drop off.
The second pulse contained only 60% as much
energy, but presented it in a 0.32 ms pulse with a
very sharp onset and a higher peak power. To cure
the DVD adhesive, 6 pulses of the more energetic
system or 10 pulses of the less energetic system
were required. When researchers measured the
temperature of the glass pattern underneath the
DVDs over a number of cycles, they found that the
longer pulses raise the glass temperature considerably more than the shorter pulses.
Visible bonding can start, stop and start almost
instantly with the simple pressing of a button or
sending of a control signal from a programmable
logic controller (PLC). The ability to start and stop in
microseconds provides longer lamp life. During the
time a DVD is being indexed, the lamp can be shut
off and instantly flashed when required. Pulsed UV
light leads to better quality, higher yields, and lower
operating costs.
Benefit # 4 - Spectrum Flexibility
Pulsed UV/Visible lamps emit a broad spectrum of
light with wavelength ranging from 200 nm (2000
angstroms) to 1,000 nm (10,000 angstroms) – from
UV region to the visible region and to the IR
region. Pulsed light is the only technology which
allows the light spectrum to be changed without
changing the lamp, as illustrated in Figure 5.
Variations in current will result in predetermined
changes in the flashlamp spectrum. This is
extremely significant because it allows matching
the flashlamp wavelengths to the chemistry of
the bonding adhesive. Additionally, changes in
the heat delivered to smaller and thinner
Figure 4: An automated DVD Bonder with Xenon’s Pulsed
Light Equipment designed in.
Benefit # 3 - Instant on/off control processing
In meeting the demands for today’s high volume
manufacturing lines, DVD manufacturers are constantly seeking improvements that will lead to
savings with shorter process times along with lower
system maintenance costs. DVD adhesive curing
with conventional mercury vapor lamps requires both
a long warm-up period and keeping lamps on
continuously during the manufacturing process. The
warm-up time and mechanical shielding requirements imposed by mercury lamps during the noncuring phase of the cycle are undesirable. Responding to these problems, pulsed UV lamps provide full
curing energy in microseconds instead of minutes of
warm-up time necessary for mercury vapor lamps.
Figure 5: Pulsed UV lamps provides a wide spectrum,
from UV to the visible range
substrates can be controlled using this method.
Benefit # 5 – Flexibility of Lamp Shape
Pulsed UV lamps can be supplied in a variety of shapes
to fit demanding requirements. A pulsed UV lamp can
be formed to any shape a glassblower can bend quartz
as illustrated in figure 6. Such shapes include circular,
helical, serpentine and spiral.
Using a pulsed UV system affords the user an
advantage in controlling the process. Pulsed UV/
7
Chapter 3: Benefits of Pulsed Light
Newly developed formulations for DVD that require
both UV and visible light to cure, benefit from pulsed
UV/Visible lamps that radiate in both the UV and
visible regions of the spectrum. These new adhesives
won’t cure when exposed to fluorescent room lighting
(like visible curing adhesives), and require less UV
light when compared to adhesives that cure with only
UV light. Broad spectrum pulsed lamps provide a
wide range of wavelength selection. As a result,
pulsed lamp systems can be used with adhesives
from different vendors. Buyers of fully automated
multimillion-dollar machines benefit by having more
than one formulation choice for their process.
Figure 6: Multi-shaped lamps illustrating flexibility of
lamp design
Benefit # 7 - Edge curing
Another advantage for DVD manufacturers when they
select a pulsed lamp system is the shape of the
pulsed lamp. Traditionally, mercury lamps have been
limited to short arc or linear lamp designs, although
other lamp shapes may fit the application better. For
example, a spiral lamp design can provide better
uniformity and enhanced matching of the illumination
area for a DVD as shown in figure 8. By including an
outer ring, this spiral lamp is designed to meet the
DVD edge cure bonding requirements. The outer ring
of the spiral lamp proved itself to one Xenon customer when it was first installed more than four years
ago. In particular, the spiral lamp shape eliminated
the previous problem of “tacky” edge cures that the
customer was experiencing prior to using a pulsed
lamp system.
Benefit # 6 - Spectrum Tuning
The spectrum of a single pulse of light is a universe of
flexibility unto itself. The spectrum of a single pulse can
be controlled to meet unique DVD bonding requirements. When the lamp is triggered and the xenon gas
ionizes, the light spectrum initially starts with the
shorter wavelengths and moves toward longer wavelengths as the pulse forms, as illustrated in Figure 7.
The amount of UV, visible, and IR can be set for each
specific application. An example of this is a semiconductor application requiring 100 microseconds of UV,
50 microseconds of visible light and 25 microseconds
of IR from a single pulse. This spectrum distribution
creates a “super” hard photo-resist capable of withstanding very high ion implant dosages without
damage. Prior to using a “tuned” UV pulsed system, the
limit of the industry was 700 watts. The goal was to
achieve a 10% improvement. The single pulse tuning
brought the power handling capability to 2,000 watts,
500 watts higher than the highest power ion implant
system could deliver at maximum output. These results
provided a significant technical breakthrough for the
semiconductor industry.
Figure 8: Spiral lamp, designed to match DVD shape,
provides superior edge cure
Figure 7: A Single pulse of light, illustrating
spectral components
8
Chapter 3: Benefits of Pulsed Light
Benefit # 8 - Tilt management using energy
control and dual pulsed lamps
All DVDs’ are layers made from heat sensitive
polymers. Further, the trend to thinner DVD
materials is making them even more heat
sensitive. Processing steps that overheat the
plastic can cause changes in the DVD tilt.
Excessive tilt can impair the quality and yield.
For the DVD manufacturer this is clearly unacceptable. The lower substrate temperature that
can be achieved with pulsed UV curing can help
prevent excessive tilt. The wavelength of the
pulsed light can be tailored to deliver a precise
energy with each pulse, thereby providing tilt
management. Further tilt management is
achieved by the use of top and bottom pulsed
light lamps. Each lamp is sequenced under
Figure 10: Dual Lamps operated from a single power
Programmable Logic Control (PLC) for tilt
supply and controller
management of batch processing. The full
benefits of tilt management using pulsed light
operate two lamps from one power source.
have been realized in full production.This was achieved
with two independently controlled pulsed light systems,
Comparing Lacquer CD Curing Requirements
as shown in figure 9.
with Those of DVD Bonding
When curing lacquer coatings on CDs,
continuous mercury lamps have traditionally been the selected method. These
surface coatings are easily penetrated
with continuous UV light unless extremely
high production speeds are required.
However, the curing requirements for
DVD bonding are significantly different.
The light must penetrate a 0.6 mm
polycarbonate substrate containing one
or more information layers on one or both
sides to reach the bonding adhesive.
Moreover, light needs to penetrate the
DVD polycarbonate layer with sufficient
energy to affect the adhesive cure at a
low temperature and high speed. Further,
new developments in DVD (such as DVD18 which are double sided, dual layered)
pose even tougher penetration requirements. Because DVDs have shallower
Figure 9: Pulsed UV lamp housings (top and bottom) sandwich the
DVD for tilt management.
and smaller pits, smaller track pitch and
tighter tolerances on tilt and jitter than
CDs,
the
effect
of temperature on the substrate is
In order to reduce the cost of two complete pulsed
much
more
pronounced.
DVD further challenges the
lamp systems, Xenon Corporation introduced their
UV technology with tough edge curing and tilt
RC-1002 system, shown in Figure 10, designed to
management requirements.
9
Chapter 3: Benefits of Pulsed Light
Ease of System Integration
UV-Curing Adhesives and Lacquers
The integration of a pulsed UV system into a DVD
line eliminates the need for demanding water cooling
or equipment placement constraints. Because of the
low heat feature of a pulsed UV system, with the
resulting low average power (400 watts for a pulsed
light system versus 5,000 watts for a mercury lamp
system) lamp and reflector cooling is reduced to
Achieving optimum cure times requires the use of
specially formulated, fast curing, bonding adhesives
that take advantage of pulsed UV’s emissions in both
the UV and visible regions. Typically the adhesive is
applied to the disk surface by a spinning or skimming
process, requiring the use of low viscosity material.
There are many UV-curing adhesives available that
are designed to offer fast cure speed, excellent bond
integrity and dimensional stability for all disc formats;
DVD-5; DVD-9; DVD-18; etc. The table below lists
manufacturers who provide pulse UV curable adhesives and lacquers.
Web Site
Manufacturer
www.bordenchem.com
Borden Chemical, Inc
Dainippon Ink and Chemicals, Inc. www.dic.co.jp
Eques Coatings
www.eques.nl
Sony Chemicals Corporation
www.sonychemicals.com
Achieving Fast Cure times
The overall achievement of applying high energy,
pulsed UV curing systems in DVD bonders, is
reduced cure time when compared to conventional
mercury lamp UV systems. With shorter cure time,
overall cycle times of DVD bonders are reduced
resulting in the cost of manufacturing dropping due to
a higher output of DVDs.
Figure 11: Pulsed UV/Visible lamps can be placed at a
distance from the controller and power supply. These
compact electronic units help minimize the footprint of
an automated bonder
simple air cooling blowers. Because a pulsed UV light
system is modular and compact in design, equipment
such as power supply and controller can be located
as far as 20 feet away from the lamp. These additional features provide DVD bonder manufacturers
with flexibility in placing components within their
bonders. Figure 11 illustrates one such DVD bonder
where the pulsed light system controller and power
supplies were placed at the rear, affording quick and
convenient access for maintenance procedures.
Examples of pulsed UV curing systems that are
currently being employed in over 1000 DVD Bonders
Installed worldwide are Xenon Corporation’s models
RC-742 and RC-1002. These modular curing systems are designed to provide a broad spectrum of
high intensity UV/Visible radiation utilizing a unique
spiral flashlamp and lamp housing reflector design.
The average power per pulse is 100 w/cm² (measured at 10 pulses/sec, broadband, 1.25 in (31.75
mm) from the face of the lamp housing). Peak power
is 1000 w/cm². The table below lists the actual cure
times achieved using these systems under actual
production conditions.
Safety and Environmental Benefits of Pulsed UV/
Visible Systems
The pulsed UV process is environmentally benign
since it does not create or use volatile organic
compounds (VOCs) or create suspended airborne
particulates. Pulsed UV lamps do not use microwaves or contain toxic materials, such as mercury,
and therefore do not expose personnel to the potential hazards due to lamp breakage.
Format
DVD-5
DVD-9
DVD-10
DVD-14
DVD-18
Cure Time
0.6 seconds
1.2 seconds
1.4 seconds
1.2 seconds
1.2 seconds
Future pulsed UV systems are evolving from work
focused on delivering the UV/Visible energy at even
higher rates (>10 pulses/sec), resulting in bonding
cure times on the order of 40% less than today’s
results.
10
Chapter 4: Non-contact Surface Treatment Studies
• Thermoplastic polyolefin
(TPO)
Reactor Grade (RTPO)
Mechanical grade
(MTPO)
• Sheet molding compound
(SMC)
(EAR)
Regular (SMC1)
Toughened (SMC2)
• Polyphenylene Sulphide
(PPS)
White (PPS1)
Black (PPS2)
4: Non-contact Surface Treatment
Studies Using Pulsed UV/Visible
Light
Pulsed UV can be used as a non-contact polymer
surface treatment, as reported by Prof. Lawrence T.
Drzal, Composite Materials & Structures Center,
Dept. of Chemical Engineering and Materials Science, Michigan State University (USA).
Paint and adhesive performance depends on the
quality (cleanliness and surface energy) of the
substrate (adherent) surface. Disadvantages of
existing surface pretreatment methods like plasma,
flame, corona, and solvent washing are that they are
labor intensive, time consuming, cause damage to
the adherent surface, and emit volatile organic
compounds. Many polymers used as matrices for
polymer composites are being investigated. Figures
12a and 12b, obtained at MSU with a wide range of
thermoset and thermoplastic polymers, illustrates the
significant improvements in surface energy that can
be obtained. This has resulted in better wetting of
plastic surfaces by adhesives and coatings, and
substantial increase in adhesion of UV treated
surfaces as measured by a tensile butt test to an
epoxy matrix. Polymers investigated have included
thermoplastic as well as thermoset matrices. Although this group of polymeric matrices represents
some of the materials commonly used in industry
(TPO, polypropylene, polyester, polycarbonate, poly
phenylene sulfide, poly methylmethacrylate and vinyl
ester), the breadth of applicability of this pulsed UV
surface treatment method indicates that it has a high
potential of being very useful with other materials as
well.
• Polypropylene (PP)
• Polybutylene terephthalate
(PBT)
• Bulk Molding Compound
(BMC)
• Diene rubber (DR)
• Ethylene Acrylic Rubber
• Polymethyl methacrylate
(PMMA)
• Vinyl Ester (VE)
• Polycarbonate (PC)
• Bexloy (lonomer) Composite
Figure 12b: Samples treated with pulsed UV (Figure
provided by Prof. Lawrence T. Drzal)
A model including the important parameters of this
UV surface treatment and comparison of methods
are shown in Figures 13 and 14 respectively. The
flexibility of pulse light delivery to the substrate (i.e.,
pulse recurrence frequency, pulse duration, and
spectrum) brings “tuning” possibilities to various
substrates. Pulsed UV meets the need for a continuous, environmentally benign, fast, cost effective and
non-contact surface preparation process.
Lamp intensity
Ozone concentration
Humidity
Substrate temperature
Nature of gas flow
Exposure time
Pulse frequency (UV flashlamps)
Nature of the substrate
UV
UV photons
Polymer
Figure 12a: Improvements in surface energy when
treated with pulsed UV (Figure provided by Prof.
Lawrence T. Drzal)
Oxygen
Carbon
Ozone
Oxygen radical
Figure 13: Parameters for surface treatment process
model. (Figure provided by Prof Lawrence T. Drzal)
11
Chapter 4: Non-contact Surface Treatment Studies
Conventional Surface Treatments
(Flame, Corona, Plasma, Chemical)
UV Surface Treatment
Current Status
Flame, Corona and Chemical Wash are
mainstream surface treatment technologies.
Plasma - limited acceptance.
Developing technology Equipment manufacturing base exists.
Environmental
Impact
Chemical – VOC emission, waste disposal.
Corona – High levels of ozone produced.
Flame – Greenhouse gases, organic fuels.
Very low levels of ozone produced in
contained environment.
Ability to Treat
Flame, Corona and Plasma Treatments have
Complex Geometries severe limitations in treating complex
geometries.
Line-of-sight treatment. Potential to treat
complex geometries is excellent.
Treatment Time
Corona, Flame – Very fast treatment times
Chemical, Plasma – Moderate treatment times
Fast treatment times
(Time scales inversely with lamp power)
Hazards
Chemical – human exposure, waste disposal
Corona – very efficient Ozone production
UV protection for humans
Cost
Corona, Flame, Chemical – Inexpensive
Plasma – Expensive
Inexpensive
Suitability in
Manufacturing
Environment
Corona, Flame – Web treatment applications.
Removal of process gases required.
Chemical – Adverse environmental impact,
hazardous.
Plasma – Unsuitable for large scales.
Excellent suitability for all applications –
flat, complex geometries, large scale.
Minimal hazards – UV protection,
Removal of low levels of ozone required.
Figure 14: Comparison of conventional surface treatment and pulsed UV. (Figure provided by Prof. Lawrence T. Drzal)
12
Chapter 5: Emerging Technologies
5: Emerging Technologies using
High Energy Pulsed UV/Visible
Systems
materials,” said Dr. Parag Mehta, VP Aprilis Corp.
“Xenon is regarded as the supplier of choice for their
lighting systems in DVD manufacturing.”
The Optical Disc market is achieving ever increasing
growth by demonstrating its ability to provide new and
innovative products. High energy pulsed UV/Visible
systems are providing a key tool in the development
of new systems. Companies such as Aprilis Corp and
Spectra Systems Corporation are utilizing pulsed UV
technology to offer products that are truly exciting.
Data Storage Devices Based on Holographic
Technology
Graphics for the Play Side of Optical Media
Aprilis
Aprilis is developing the first data storage devices
based on holographic data storage technology.
Holographic data storage records data as twodimensional optical “pages”, instead of as a serial
stream of bits as occurs in conventional magnetic or
optical storage. Many holographic pages can be
independently written and retrieved from any given
location in the media, so data density are significantly
higher than conventional magnetic storage and an
order of magnitude higher than optical storage such
as CD and DVD. Since writing and reading of the
data consists of transferring large digital arrays from
each storage location, the data transfer rates can be
hundreds of megabytes/second compared to ~5 MB/
sec. for DVDs. Furthermore, the data arrays can be
searched by optical correlation methods, greatly
reducing the dependence of the search on processor
speed, and leading to a significant improvement in
the performance of database applications.
Spectra Systems has introduced a breakthrough
technology in DVD/CD coating and in optical disc
manufacturing. Called MediaCoatTM, the technology
allows graphics, alpha-numerics and barcodes to be
applied on the play sides of optical discs; this means
targeted advertising messages can receive greater
notice on motion picture, music and software discs.
The technology is compatible with all pre-recorded
optical media formats.
Two Xenon flashlamps are used to cure MediaCoat
on a disc, Spectra Systems R&D explains. “For the
color coating (first coating applied), we use a xenon
lamp because it is a true blackbody radiator in the UV
and provides UV power that is independent of the
discrete, narrow radiation lines of a conventional
lamp. We select the wavelength cutoff with filters or
reflectors. For the protective over-coating (second
coating applied), it is important to use as little power
as possible to overcome oxygen inhibition. Using the
Xenon’s high peak power pulsed lamps accomplishes
this while allowing us to use less total power.”
When Aprilis designed their new manufacturing
equipment for DHDTM media, it required a unique light
source that provided precise spectral output, very
uniform fluence and a high degree of reproducibility.
Aprilis, indeed, could not have wished for a better
partner than Xenon in development of this light
source. Aprilis engineers worked with the Xenon
team which designed and delivered the light source
in record time.
Spectra Systems has made an agreement with
Singulus Technologies AG, to develop and commercialize customized equipment for applying Media
Coat. Singulus will manufacture and sell MediaCoat
equipment and Spectra will sell its proprietary
lacquer formulation and provide licensing opportunities to replicators.
“From our perspective, Xenon was an obvious choice
because of the depth of industry experience Xenon
has in providing the light source for photo curable
13
Chapter 6: Next Generation DVD Systems
6: Next Generation DVD
Systems
M2 is one of the world's
leading manufacturers of
optical disc production
systems and equipment for
CD, CD-ROM, CD-R, DVD and DVD-R/DVD+R. M2's
equipment includes the heralded SQ1 for CD and
equipment like the SQ2 for CD and all DVD formats,
and the SQ3 for recordable formats. The SQ3 can
handle both CD-R and DVD-R production. The SQ1
and SQ2 are the world's first fully integrated modular
optical disc replicating machines. Engineered in
single units (with the world's smallest footprint), SQ1
and SQ2 features integration of all components for
buffering, sputtering, spin coating, curing, inspection
and restacking of CD and DVD discs in one machine.
Both the SQ2 and the SQ3 also features M2's unique
CenterBond™ technology, which allows for bonding
all the way to the center of the disc. The SpinCure™
technology creates uniform bonding layers.
The acceptance of Xenon Corporation’s high energy
pulsed UV/Visible systems in high volume DVD and
CD manufacturing started over four years ago. At
that time, one Xenon Corporation customer completed an extensive evaluation of Xenon’s pulsed
light technology, confirming their ability to achieve
higher production speeds with improved yields due
to tilt management and lower substrate temperature.
Since that time, the customer has converted over
150 installations to incorporate the Xenon Corporation Model RC-742 CoolCureXL-DVD® pulsed light
system.
Acceptance of pulsed UV/Visible light as the industry
standard for DVD bonding has spread since this
conversion was started. Examples of new bonders
that are now coming to the market, incorporating
Xenon’s pulsed high energy UV/Visible equipment
are systems from M2 Engineering AB (Model SQ2)
and Pfeiffer Vacuum Technology AG. Brief descriptions of their new systems are shown below.
The SQ2 system, incorporating Xenon Corporation's
Twin-XL Pulsed UV/Visible System, offers one of the
fastest and most productive DVD-9 production lines
on the market with a cycle time below 3.5 seconds.
The bonding of the DVD discs is the most crucial
process in DVD-9 production. The SQ2 system offers
the revolutionary CenterBond™ and
SpinCure™ technology taking DVD
bonding
into a new dimension. The
SpinCure™
technology
enables up to
25% lower
adhesive costs
than other
bonding
techniques,
resulting in
savings of at
least $20,000
per year and line.
The size of the
machine means fewer parts, less maintenance and
less electrical power consumption. The SQ2 consumes only 40% electrical power compared to other
systems, resulting in a savings of more than $13,000
per year per system.
14
Chapter 6: Next Generation DVD Systems
A specially designed, simple conveyor delivers DVD
half discs in vertical orientation from molding to
metallization. Two separate integrated Pfeiffer
Vacuum Single Layer Metalizer apply the L0 and L1
metal layers respectively. All metals including silicon
and silver alloys are optional. Attention to uniform
cooling of all discs throughout the process is a key
feature of the system.
DVD Line
The new replication system for production of DVD
discs.
This fully integrated system is designed to produce
DVD bonded discs at 3-second cycle times and
accommodates all models of injection molding
machines currently employed in the industry.
Servo controlled stepper motors and Siemens PLC
support a smooth handling of discs with a minimum
number of transport stations during the critical steps
of bonding and curing. Close attention to temperature
control and management are key elements of the
systems overall design. Achieving stable, ambient
disc temperature of all discs during production
addresses and compensates for the inherent
stresses of DVD inline production. Dual spin stations
provide consistently high cycle times with precise
bond layer uniformity. Xenon flashlamp curing from
two sides enables thorough curing with tilt control.
Subsequent cooling prior to in-line inspection
ensures that newly bonded discs are optimally
evaluated for all physical parameters prior to placement on an 8-spindles turntable. The ability to sort
fff
rejects into specific
categories on three separate
spindles provides additional control in production.
15
Chapter 7: Conclusions
7: Conclusion
References:
Pulsed UV can solve a variety of challenging problems for DVD manufacturers. Key attributes of this
technology when applied in DVD adhesive bonding
are:
1. Panico, L.R., Pulsed UV Curing for DVD Production,
REPLItech, May, 2000
(1) Elimination of heat-induced damage to the disc,
3. Panico, L.R., Pulsed UV Curing for Heat Sensitive Medical
Devices, October 1997
2. Panico, L.R., Pulsed UV Curing Provides User-Friendly
Solutions to Tough Problems , Adhesive Age, January 1997
(2) Deep penetration through opaque materials for
complete bonding at high speeds,
4. O’Hora, D.E., Beuschel, Pulsed Light Exposure Eliminates
Oxygen Effect in Negative Photoresists, Technical Communications, IBM RadCure, 1978
(3) Proven technology offering higher yields and
lower costs.
5. Capobianco, Robert A., Chief Scientist, Xenon Corporation, UV Curing Equipment for Assembly Applications, Xenon
Application Note AN-103, May 2002
Pulsed UV curing systems lend themselves to DVD
production because the lamp geometry, spectrum,
and pulse shapes can be designed to match the DVD
substrate and adhesive requirements. Pulsed lamp
systems offer ease of integration into complete
bonding systems by virtue of their ability to be
switched on and off without warm-up and cool-down
periods. These systems do not require water cooling,
do not need rotation of the disc, provide tilt management and have longer lamp lifetimes. Pulsed UV lamp
systems are mercury free and environmentally
benign since they do not create or use volatile
organic compounds (VOCs) or create suspended
airborne particulates.
6. Panico, L.R., Flash Polymerization, 1976 Radiation Conf.
Proceedings, SME, Dearborn, MI.
7. Panico, L.R., Xenon Rapid Curing Process, 1975 Radiation Curing, SME, Dearborn, MI.
8. Miller, B., Executive Editor, Pulsed Light Systems Cures
Thick Thermosets in a Flash, Plastic World, Cahners Publishing Co., Inc., February 17, 1975
9. Panico, L.R., Simulating the Sun with Pulsed Light, 6th
Space Simulation Conference, May 1972.
10. L. P. Haack, A. M. Straccia, J. W. Holubka, A. Bhurke, M.
Xie, L. T. Drzal, Chemistry Of Surface Modification With UV/
Ozone For Improved Intercoat Adhesion In Multilayered
Coating Systems, Surf. Intrf. Anal., 29, No. 12, pages 829-836,
(2000)
11. Lawrence T. Drzal, R. Schalek, P. Askeland, M. Rich, A.
Bhurke And P. Tummala, Ultraviolet Light Surface Treatment Of
Polymers, Composite And Metals As An Environmentally
Benign Surface Preparation, International Technical Conference, Seattle, WA, November 4-8, 2001
Acknowledgment
Professor Lawrence T. Drzal
Composite Materials and Structures Center
Department of Chemical Engineering and Materials
Science
Michigan State University
East Lansing, MI USA
16
Chapter 8: RC-1002 System Specifications
management. The individual
flashlamps respond automatically to
the programmed trigger pulse and
deliver the full energy with each
pulse. 4.2" (106 mm) spiral
flashlamps and lamp housings are
designed to specifically match the
requirements of DVD/CD bonding.
MODULAR COMPONENTS
The RC-1002 system offers modular
construction for ease of integration
into automated machines. The low
heat of a pulsed UV system, with the
resulting low average power (400
watts), results in flashlamp and
reflector cooling reduced to simple
air cooling blowers. Additionally,
because the RC-1002 is modular
and compact in design, equipment
such as power supply and control modules can be
located as far as 20 feet away from the Lamp Housings. These additional features provide DVD bonder
manufacturers with flexibility in placing components
within their bonders. A family of flashlamps and Lamp
Housings and related spectra are also available with
this system.
FEATURES
• Modular components
• Optically isolated user interface
• Adjustable power range up to 2000 watts
• Dual Flashlamp control
SAFETY and ENVIRONMENTAL FEATURES
• No toxic materials, such as mercury or
microwaves are involved
The pulsed high energy UV/Visible process is
environmentally benign since it does not create or
use volatile organic compounds (VOCs) or create
suspended airborne particulates. RC-1002 pulsed
flashlamps do not use microwaves or contain toxic
materials, such as mercury, and therefore do not
expose personnel to the potential hazards due to
flashlamp breakage.
APPLICATIONS
• DVD Bonding
• CD Lacquer Curing
GENERAL DESCRIPTION
LAMP HOUSING COOLING
Model RC-1002 CoolCureXL-DVD® Ultraviolet/Visible
Curing System is a modular light source designed to
provide a broad spectrum of high intensity pulsed
light ranging from 200 to 1000 nanometers. The
average power per pulse is 100 w/cm² (measured at
10 pulses/sec, broadband, 1.25" (31.75 mm) from
the face of the Lamp Housing). Peak power is 1000
w/cm². The RC-1002 system is designed to function
as part of an integrated on-line processing system
with low voltage DC control circuitry using a Programmable Logic Controller (PLC).
The 4.2" Spiral Lamp Housing has been designed for
continuous forced air cooling to insure the flashlamp
temperature is maintained during
operation. Air volume of 300 cubic
feet per minute is required. Light
blocking air exhaust filter is provided
on the Lamp Housing. To provide
adequate cooling for the Lamp
Housing and flashlamp, a blower kit
is available. This kit includes a
blower, mains power cord, air filter,
flexible aluminum ducting and hose clamps.
DUAL FLASHLAMPS
Model RC-1002 adds dual Lamp Housing capability
to the benefits of pulsed UV/Visible light curing
technology. The RC-1002 high speed Switch Logic
module controls two flashlamps resulting in higher
throughput, low substrate temperature and tilt
CoolCureXL-DVD® is a registered trademark of Xenon
Corporation
17
Chapter 8: RC-1002 System Specifications
All specifications are typical unless otherwise noted (TAMBIENT @ +25 °C, VINPUT = 208 Vrms)
System Units
Construction
PFN/Control Module
Switch Logic Module
High Voltage Power Supply
Lamp Housing
User Interface:
PFN/Control Module
Switch Logic Module
High Voltage Power Supply Module
4.2" Lamp Housing (2/system)
Blower Kit¹ (2/system)
Steel, chromate over zinc plate
Steel, chromate over zinc plate
Gold anodized aluminum
Steel, chromate over zinc plate
37-pin I/O connector located on the Switch Logic
Module. System can accept from 3 VDC to 32 VDC (24
VDC preferred).
Power Input
PFN Control Module
Switch Logic Module
High Voltage Power Supply Module
4.2" Lamp Housing Module
Lamp Housing Blower
1-phase 200-240 Vrms, 50/60 Hz, 1.0 amp
1-phase 200-240 Vrms, 50/60 Hz, 1.0 amp
1-phase 200-240 Vrms, 50/60 Hz, 15 amps
Supplied from Switch Logic Module
1-phase 200-240 Vrms, 50/60 Hz, 4 amps
Power Output to Flashlamp
2000 watts maximum
4.2" Spiral Lamp Housing
Average Power²
Peak Power²
High Voltage Cable
Trigger Cable
Flashlamp Options
Window Opening
Light Footprint
Optimum distance to target
100 w/cm² /pulse
1000 w/cm²
10-feet (3048 mm)
10-feet (3048 mm)
4.2" (106 mm) Spiral, Clear Fused Quartz, Type C
4.2" (106 mm) Spiral, Germisil, Type B
6" x 6" (152.4 x 152.4 mm)
5.50" (139.7 mm) diameter
1.25" (31.8 mm) from window face
Control
Optically isolated interface to computer PLC
Flashlamp pulse rate (10 pulses/sec): factory set
PFN level: factory set
Interlocks
Lamp Housing access cover, interconnect cables, and
user interface connector
Cooling
PFN/Control Module - internal fan
Switch Logic Module – static convection cooling
HVPS Module - internal fan
Lamp Housing Module- external blower providing
300 Cubic Feet per Minute @ 2.0 in. H2O (8.5 m3/min.
@ 500 Pa)
18
Chapter 8: RC-1002 System Specifications
Outline Dimensions
PFN/Control Module
Switch Logic Module
High Voltage Power Supply
Lamp Housing
Height x Width x Depth
5.75" x 12.0" x 9.0" (146 x 305 x 229 mm)
5.75" x 12.0" x 9.0" (146 x 305 x 229 mm
5.80" x 6.60" x 12.5" (147 x 168 x 306 mm)
6.00" x 7.80" x 9.5" (152 x 198 x 241 mm)
Weight
PFN/Control Unit
Switch Logic Module
High Voltage Power Supply
Lamp Housing
Operating Environment
Temperature
Relative Humidity
40 pounds (18.2 kg)
23 pounds (10.5 kg)
11 pounds (5.0 kg)
12 pounds (5.4 kg)
0 - 40°C (32-104°F)
10 - 80% (non-condensing)
Notes:
1 – Lamp Housing Blower Kit includes blower, blower filter, metallic ducting, duct clamps and mains power cord
2 – Power measured at 10 pulses/sec, broadband, 1.25” (31.8 mm) from face of window
Specifications subject to change without notice.
ORDERING GUIDE
Model RC-1002 CoolCureXL-DVD® Curing Systems
are modular. Listed below are the various components and accessories that are available. Consult
with Xenon Corporation Sales for assistance in
selecting the components that best match a specific
application
Item
Part Number
Pulse Forming Network (PFN)/Control Module
490-0189
Switch Control Module
490-0226
High Voltage Power Supply
289-0017
Lamp Housing Module, 4.2" Spiral
860-0100
Flashlamp, 4.2" Spiral, Clear Fused Quartz, Type C
890-1890
Flashlamp, 4.2" Spiral, Germisil, Type B
890-1886
Safety Glasses, UV Blocking
910-0001
Control Cable, 15 pin, 2 meter
580-0046
Control Cable, 37-pin
580-0076
Control Cable
580-0077
BNC Control Cable
580-0079
Blower Kit
390-0067
User Manual, Setup and Maintenance
810-0072
User Manual, 4.2" Spiral Lamp Housing
810-0069
19
Chapter 8: RC-1002 System Specifications
PFN/Control Module
Switch Control Module
20
Chapter 8: RC-1002 System Specifications
DIMENSIONSARE IN INCHES
MILLIMETERS
DRAWNIN THIRDANGLEPROJECTION
11
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High Voltage Power Supply Module
4.2" Spiral Lamp Housing
21
Chapter 8: RC-1002 System Specifications
GREEN/YELLOW
BROWN
BLUE
C-14 SHROUDED PLUG
MATES WITH C-13
CONNECTOR
200-240 VAC TO BLOWER MOTOR
POWER CORD LENGTH: 84.0 / 2134
MOTOR
Ø 4.00/10.2X 72/1828.8 LONG
FLEXIBLE ALUMINUM AIR
DUCT TOLAMP HOUSING
13.75 (MOTOR & BLOWER)
349.25
AIR BLOWER
HOSE CLAMPS
SUPPLIEDWITH
DUCT
AIR FILTER
TO LAMP
HOUSING
10.50
Ø 266.70
NOTES:
1. DIMENSIONS ARE IN INCHES/MILLIMETERS
20.25
514.35
7.00 (AIR FILTER)
177.80
FILTER IS WING-NUT REMOVABLE.
FILTER ATTACHMENT KIT AND
ASSEMBLY INSTRUCTIONSARE
SUPPLIEDWITH BLOWER
12.89
327.32
Blower with Attached Components; Air Filter, Metallic Ducting, Hose Clamps, Mains Power Cord
2. DRAWNIN THIRD ANGLE PROJECTION
22
23
XENON Corporation
37 Upton Drive, Wilmington, Massachusetts 01887-1018
Tel: +1 978 661-9033, 800-936-6695 (U.S.A. only); Fax: +1 978 661-9055
E-mail: info@xenoncorp.com
www.xenoncorp.com
© 2004 Xenon Corporation All rights reserved. No part of the contents of this brochure may be reproduced without the
written permission of Xenon Corporation.
CoolCureXL-DVD is a registered trademark of Xenon Corporation.
Printed in the United States of America
SB103-05/04-500