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Film enables cost-effective mass production of Blu-ray discs

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Film enables cost-effective mass production of Blu-ray discs
Posted by Dan Bell
Posted on 17/05/05 21:34
Number of views 818
Film enables cost-effective mass production of Blu-ray discs

According to this press release, Germany's Degussa, specifically the film and coating division, has come up with a new protective coating for Blu-ray discs. We already heard of Tough-coat from TDK, but apparently this patent pending procedure is more economical or superior or both.

One aspect of Blu-ray that was worrisome, is that the data is so close to the surface. Just as it states in the quote below, it's a mere tenth of a millimeter from the surface, whereas rival HD-DVD stores it's data .6mm from the surface. But Blu-ray chose to use the close proximity to the top of the disc to create a better numerical aperture (NA), which results in more data that can be written on each disc layer. This is why a BD will hold 25GB while HD-DVD can "only" hold 15GB per layer. However, this also creates an opportunity for damage, so much so that initially a cartridge was considered for BD. When TDK came along with tough-coat, this concept was chosen and the cartridge abandoned. Now, it seems Degussa has even improved upon TDK's solution as it seems like this process is getting a very warm reception!

The optical-disc format Blu-ray Disc (BD) is on the horizon. If BD is to be a success, the processes for manufacturing the discs have to be inexpensive. In a BD, the information layer is only 0.1 mm below the surface, allowing a smaller spot size of the laser beam and hence providing a much larger storage capacity than on a DVD. Because the 0.1 mm thick cover layer must satisfy stringent optical requirements, the manufacturing processes to date are expensive.

Now Degussa is announcing a breakthrough in this area. Based on a new technology (applied for patent) Degussa's Plexiglas Business Unit has developed a special film that meets all quality requirements for the 0.1 mm cover layer and can be manufactured by an economical process. That is the prerequisite for favorable mass production of the BD.



 

 

 

 

 

 

 

 

 

 

Cooperation partners Philips, Singulus and Sony have already manufactured functioning Blu-ray Disc samples based on EUROPLEX® PC 0F405 Film. Paul Put, General Manager of Philips Optical Media and Technology (OM&T): "We are very excited about this new breakthrough we jointly could achieve. This cost-effective, high quality 0.1 mm layer is the technology the media replication industry was looking for. The next step will be mass production of BD-ROM, BD-R and BD-RE based on the EUROPLEX® PC Film".

Degussa has decided on the relevant investments: "We will manufacture the quantities required for market launch from the end of 2005 in a pilot plant," says Dr. Herbert Groothues, Project Manager at Degussa, of the short-term objective. "From mid-2006, we will have a production unit capable of manufacturing EUROPLEX® PC Film for up to 500 million Blu-ray Discs per year."

We still have to wonder what impact this has on manufacturing costs and especially in comparison to tough coat or even with the rival HD-DVD. But, reading the above quotes, it seems that a decision has been made to go with Degussa, and it looks like soon we will see some media around too. With the Sony Playstation 3 supporting Blu-ray this could be welcome news for Sony, no doubt. You can read more about the Degussa company here.  

If you need to know more about either HD-DVD or Blu-ray and what makes them different from each other, please stop by and read this excellent HD-DVD vs. Blu-ray article by two staff members spath & H3rB3i. It contains a wealth of information and will help you to decide which format you prefer. This could be quite important, as we can almost rest assured that we will have both discs, at least for a while.

Source: Degussa





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Good and honest press-release. What I really was looking for is a phrase like "The manufacturing costs of the new layer is comparable of that of HD_DVD and in our lab tests it's strength has proven to be equal to 0.6 mills of the rival". Sorry for reading between the lines. Cheers.:X
Guess no more sleeves for me...
Maybe with all this scratch protection, consumers will see that some blanks are crap even without smudges and scratches.

Hopefully then, manufacturers will be forced to up the quality, or those like TY will promote their own and make them easy to identify.
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