Metal alloys for the reflective or the semi-reflective layer of an optical storage medium

Abstract

Metal alloy thin films are provided for use in the highly reflective and semi-reflective layers of optical discs. Alloys include silver alloyed with gold, palladium, copper, rhodium, ruthenium, osmium, iridium, and platinum. Other alloys include copper alloys with silver, magnesium, cadmium, aluminum, nickel, beryllium, zirconium and zinc. These alloys have moderate to high reflectivity and reasonable corrosion resistance in the ambient environment.

Description

PRIORITY CLAIM[0001]This application is a continuation of my prior application Ser. No. 10 / 939,074 filed on Sep. 10, 2004, which is a continuation-in-part of my prior application Ser. No. 10 / 342,649 filed Jan. 15, 2003, which is now U.S. Pat. No. 6,790,503, which issued on Sep. 14, 2004, which is a continuation-in-part of my prior application Ser. No. 10 / 090,855 filed Mar. 4, 2002, which is now U.S. Pat. No. 6,764,735, which issued on Jul. 20, 2004, which is a continuation-in-part of my prior application Ser. No. 09 / 661,062 filed Sep. 13, 2000, which is now U.S. Pat. No. 6,451,402, which issued on Sep. 17, 2002, which is a continuation-in-part of my prior application Ser. No. 09 / 557,135, filed Apr. 25, 2000, ABN, which is a continuation-in-part of my prior application Ser. No. 09 / 438,864, filed Nov. 12, 1999, which is now U.S. Pat. No. 6,280,811, which issued on Aug. 28, 2001, which is a continuation-in-part of my prior application Ser. No. 09 / 102,163, filed Jun. 22, 1998, which is ...

AI Technical Summary

Benefits of technology

[0051]Another embodiment is a class of copper containing alloys with moderate to high reflectivity and good corrosion resistance for use as thin film reflective layers in optical storage devices.

[0052]Yet another embodiment provides silver and or copper alloys that are lower cost alternatives to the use of gold in the reflective or semi-reflective layers of recordable compact disc and that still satisfy other functional requirements of the discs such as high reflectivity and corrosion resistance.

[0053]Still another embodiment provides silver and / or copper alloys for use as the reflective or semi-reflective layers in various versions of the prerecorded mini-disc (MD) and other current or future generations of optical discs in which reflectivity, corrosion resistance, and ease of application are all important requirements for a low cost and high performance product.

Problems solved by technology

Although gold naturally offers a rich color and satisfies all the functional requirements of a highly reflective layer, it is comparatively much more expensive than aluminum.

But unfortunately, the exchange is not truly satisfactory because the copper alloy's corrosion resistance, in general, is considered worse than aluminum, which results in a disc that has a shorter life span than one with an aluminum reflective layer.

But because the dye may contain halogen ions or other chemicals that can corrode the reflective layer, many commonly used reflective layer materials such as aluminum may not be suitable to give the CD-R disc a reasonable life span.

But while gold satisfies all the functional requirements of CD-R discs, it is a very expensive solution.

But once again, it is also comparatively more expensive than other metals.

Moreover, silicon also has a tendency to react with oxygen and nitrogen during sputtering, which introduces a whole additional set of problems.

For example, usually the application of silicon requires a more complicated sputtering apparatus than one that is normally required to apply other reflective metals.

And as a result, neither gold nor silicon offers an ideal semi-reflective layer for use in this type of disc.

For example, a 2 or 3 micron thick variation in the cover layer will introduce very high spherical aberration in the playback signal, potentially degrading the signal to an unacceptable low level.

Another major problem with the Blu-ray format is that the current generation of production equipment used for DVDs can not be used to produce discs with the Blu-ray format, because the proposed format is too different from currently used DVD format.

The need to invest in new equipment to manufacture Blu-ray discs substantially increases the cost of making the Blu-ray disc, and presents another obstacle to adopting the Blu-ray disc system as the standard for the next generation of DVD.

Although manufacturing an AOD disc is less complicated and less challenging than manufacturing a Blu-ray disc, AOD suffers one drawback.

The need for this mechanism will increase the cost of players designed to read AOD discs.

Some difficulties in the production of a DVD-RW have arisen due to the higher information density requirements of the DVD format.

But once again, gold is also comparatively more expensive than other metals, making the DVD-RW format prohibitively expensive.

Pure silver has higher reflectivity and thermal conductivity than gold, but its corrosion resistance is relatively poor as compared to gold.

Aluminum alloy's reflectivity and thermal conductivity is considerably lower than either gold or silver, and therefore is not necessarily a good choice for the reflective layer in DVD-RW or DVD+RW.

Images