Production with New In Closed Loop Control for DVD 9 - stangl.de

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To meet SINGULUS TECHNOLOGIES´ goal of introducing at least one new product
every year, we are now offering a new CD-R line to the market in 1999.
Since we supply equipment for the replication of pre-recorded CD and DVD optical
media, it is a logical step to supply production systems for recordable media as well.
Our engineering team followed the successful strategy we have employed for all
SINGULUS products: No ”Me too” products, but our own unique solution with
➟
proprietary know-how.
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continued from page 1:
When SINGULUS TECHNOLOGIES
entered into the CD-replication line
business in 1996, many observers said
”It might be too late”. However, many
customers have pushed us hard to offer
a SINGULUS solution for recordable
optical media as well.
After careful investigation, our engineering
team defined a modular concept for
both single and dual track systems. In
order to meet the faster cycle times of
new molding machines, the dye coating
modules are equipped with 3 cups per
track. Two cups are dedicated for dye
dispense and spinning whereas the third
cup performs edge wiping only.
After dye inspection and disc marking,
the good discs pass through a very
compact, high capacity curing oven
before they are fed into a SKYLINE
finishing line for metallization, lacquering
and final inspection.
Besides CD-R line hardware and all
peripheral equipment, SINGULUS
TECHNOLOGIES will also provide the
necessary process know-how. Process
engineers with production experience
are on staff to transfer this know-how
and to help customers to achieve a
smooth CD-R production start-up.
Today, all hardware and controls of the
new CD-R line are already capable of
DVD-R production. Major demand for
DVD-R is expected as soon as the
4.7 GByte version is finally specified by
the DVD forum.
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SINGULUS III - ���
Special designed Metallizer for DVD
The new SINGULUS III - ��� is specially
designed for DVD production and
allows easy integration in replication
lines to sputter layer 0 and layer 1 for
DVD 5, 10 and 9.
The design combines the patented
SMART CATHODE ® with an unique
process control system and therefor
uses identical cathode hardware for the
deposition of all target materials (such as
Al, Au and Si) without changing the
magnet arrays.
To run the SINGULUS III - ���
Metallizer in batch-process a new
12-spindle handling system has been
developed. This easy to use handling
system comes with a single turntable.
Discs from one spindle are loaded into
the SINGULUS III - ��� for sputtering
while coated discs are simultaneously
unloaded onto the next empty spindle.
This combination of handling system
and SINGULUS III - ��� operates fully
automatically both with and without
spacers, with full spindle integrity in
either case.

SPACELINE: Production with New In
Closed Loop Control for DVD 9
The strict layer uniformity specification
for DVD 9 (+/-3% ) and the specific
thickness profile of the fully reflective
and semi-reflective layers require high
demands on the metallization process.
The SMART CATHODE ® with its
variable magnetic field can achieve this
level of performance.
However, all sputter sources have two
characteristics in common:
� Over the target lifetime, the energy
required for the metallization process
must increase in a non-linear way.
This task is now carried out by the
process control system. However,
due to the specified layer uniformity
permanent inspection is still
necessary.
� Furthermore, the sputter process
itself could cause faults, which will
not be detected by the final scanner
inspection of the bonded DVD.
To solve these problems, SINGULUS
TECHNOLOGIES has now developed
a new in-line layer thickness measuring
system and a closed loop control
system to make DVD production
reliable and safe.
The in-line layer thickness measuring
system is specially designed to measure
the layer thickness and layer uniformity
of each sputter-coated disc half (layer 0
as well as layer 1), while the discs are
transported out of the metallizers.
A closed loop control system utilizes the
measured thickness distribution to
control the sputter behavior of both
SMART CATHODEs ® . This device makes
it possible to achieve an optimal layer
uniformity for target material over the
entire target lifetime. In addition, 100%
quality control inspection of each metallized
disc is automatically performed.
The layer thickness distribution of each
disc is displayed by the SPACELINE´s
central Process Control System;
thickness profiles as well as tolerances
can be pre-set.
Technical Data:
�Measuring gauge with integrated
light source and photo detector
�Dynamic range adapting to semireflective
and fully reflective layers
�20 measuring points per disc
�Measuring radius: 23 - 58 mm
�Suppression of noise and back
ground light
�100 % quality inspection of each
metallized disc
�Closed loop control of the sputter
process

-Line Measuring System and
Figure 1:
The measuring gauge measures the transmission
through the substrate while the two
disc halves (first layer 0, second layer 1)
are transported from the lock chambers of
the metallizers to the bonding station by
means of the central handling.
Figure 2:
The ascertained transmission values
are converted into a layer thickness profile.
This layer thickness profile is used to build
up a closed loop control system, which is
able to provide the required set point values
for the sputtering energy and the magnetic
field deflection.
Figure 3:
The operator pre-sets the layer thickness
profile (inner, middle and outer diameter).
The closed loop control system then adjusts
the actual values to these set values. Pre-set
chart and values are displayed on the
screen.
Fig.1
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SKYLINE
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SINGULUS TECHNOLOGIES
introduces the new SKYLINE ������
designed for both CD and DVD 5
replication.
This new replication system is a further
development of SINGULUS’
highly successful SKLYINE CD replication
system which now provides CD
replication as well as manufacturing of
DVD 5.
The conversion of SKYLINE ������
from CD to DVD manufacturing
requires no more than a mold change
and selection of the operation mode.
Since both DVD 5 halves are identical
and molded on the same injection
molding machine, the resulting DVD 5
is a well-balanced sandwich easily
meeting the narrow tilt specification.
for CD and DVD 5
Molding
SINGULUS TECHNOLOGIES’ new
system specifically targets customers
considering entry into DVD manufacturing
on a modest scale. Converting a
SKYLINE CD replication system from
manufacturing CDs to manufacturing
DVD 5s takes no more time than
changing dies on an injection molding
press.
Since both DVD halves are molded
on the same injection molding
machine, the cycle time for DVD 5 on
the SKYLINE ������� is twice the cycle
time of the injection molder.
All hardware and software modifications
have been designed so that any
SKYLINE in the field may be upgraded
to this new design.
Flip over of
every 2.CD
�
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Sputtering
� �
�� Disk 1 will be metallized
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Parking Position
�� Disk 2 will be parked before bonding
Bonding
UV-Drying
Inspection

New SKYLINE
Orders from Asia
Boomtown Hong Kong
Following the highly successful
REPLitech Asia show in Singapore in
late October 1998, order bookings
soared, particularly in Asia. In less than
10 weeks SINGULUS TECHNOLOGIES
received orders for more than 70
SKYLINES from Hong Kong and Taiwan
customers.
Customers’ purchasing decisions
were made in favor of SINGULUS
TECHNOLOGIES based on the
impressive performance of the
SKYLINE as well as the excellent
service support provided by our
Singapore office and by our representatives
VIKA International in Hong
Kong and Aceway in Taipeh.
Product Manager
SKYLINE
Reinhard Gerigk was appointed
SKYLINE Product Manager effective
October 1, 1998. Prior to joining
SINGULUS TECHNOLOGIES in
September 1995, Mr. Gerigk gained
valuable experience as a project
manager in the automotive engineering
industry. As a process engineer in
our R & D department, Mr. Gerigk
successfully developed the lacquering,
bonding and curing processes of
our CD and DVD replication systems
thus contributing to the excellent
reputation of our products.
In the future, Reinhard Gerigk will be
dedicated to the continuous improvement
of our existing SKYLINE
replication system and to meeting the
needs and concerns of key-account
and OEM customers.

4/02.99-MetaCom Printed in Germany, Technical alterations reserved
Project Management
for CD and DVD Replication Lines
Project Manager
Europe, Robert Link
Robert Link (left) joined SINGULUS
TECHNOLOGIES in July 1998 after
having worked as an electrical engineer
in the field of chemical analysis technology
at Leybold. He is responsible for all
our activities in Europe.
Germany:
SINGULUS TECHNOLOGIES AG
Junkersstrasse 1, D-63755 Alzenau
Phone: +49-(0) 60 23 - 945 -0
Fax: +49-(0) 60 23 - 945 -110
E-mail: sales@singulus.de
Internet: http://www.singulus.de
Great Britain:
SINGULUS TECHNOLOGIES UK LTD
Unit 2
Shrivenham Hundred Business Park
Watchfield, Swindon,Wiltshire SN6 8TZ
Phone: +44-17 93 - 78 42 00
Fax: +44-17 93 - 78 42 22
E-mail: singulus_uk@msn.com
Singapore:
SINGULUS TECHNOLOGIES Asia Pacific5
No.6+6A Jalan Klapa
SGP-199318 SINGAPORE
Phone: +65-294 - 28 35
Fax: +65-294 - 53 08
E-mail: Singulus@singnet.com.sg
Project Manager USA
and Asia,
Claus Kückens
Due to the rapid growth in the number
of CD and DVD lines, Claus Kückens
(right) was appointed Project Manager
for the US and Asia.
Before he joined SINGULUS TECH-
NOLOGIES, Claus Kückens gained
experience as mechanical engineer and
project manager in fields as varied as
production line engineering and industrial
engineering for coating automative
finishes.
w o r l d w i d e
United States and Canada:
SINGULUS TECHNOLOGIES Inc.
429 D Hayden Station Road
Windsor, CT 06095, USA
Phone: +1-860 - 683 - 8000
Fax: +1-860 - 683 - 8010
E-mail: mac@singulus.com
West-Coast Office:
5976 West Las Positas Blvd., Suite #118
Pleasanton, CA 94588, USA
Phone: +1-925 - 468 - 1790
Fax: +1-925 - 468 - 1793
E-mail: rnuffer@singulus.com
Latin America:
SINGULUS TECHNOLOGIES Ltda.
Latin America
Alameda dos Guaramomis
323 - Moema
São Paulo - SP/Brazil
Phone: +55-11 - 530 - 6050
Fax: +55-11 - 542 - 1366
E-mail: latinamerica@singulus.com.br
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SINGULUS Highlights
122 SKYLINE CD Replication lines
have been shipped and gone through
final acceptance at customers in 1998.
This is an increase of 50 % over
previous year.
The first SPACELINE with new
inline layer measuring and control
system is in production since
January 15, 1999 at Infodisc,
Taiwan.
A first order four CD-R lines has
been signed in December 1998.
Disc Americ has placed orders for
two more SPACELINEs increasing
their capacity for inline manufacturing
by a factor of 3.
SINGULUS and Netstal celebrated
the delivery of the 100th Discjet
CD molding machine on
November 19, 1998.
Dipl. Ing. Tadeusz Pupek has been
appointed representative for the
territory of Poland.
Dr. Ing. Petr Smid, Battenfeld Smid
a spol.., has been appointed
representative for the Czech Republic.
ACME Cassettes Hong Kong are
looking forward to installing SKYLINE
# 50 in the 1st quarter of 1999.
Laser Disc, Santiago de Chile, affiliate
of Laser Disc Argentina, switched to
SINGULUS TECHNOLOGIES and
received one SKYLINE in November
1998.
Representatives:
Australia: Opticraft Technologies
Phone: +61-3-97768388, Fax: +61-3-97769444
Benelux and France: Vacuum OnLine N.V.
Phone: +32-2-478 - 0184, Fax: +32-2-478 - 4040
China: SINGULUS VIKA China (Service/Parts)
Phone: +852-2406 - 7112, Fax: +852-2407 - 2021
Czech Republic: Battenfeld Smid a spol., s.r.o. Zastoupeni CR
Phone: +420-311-670253 Fax: +420-311-670795
Hong Kong: VIKA International Ltd. , E-mail: alfred@vika.com.hk
Phone: +852-2406 - 7753, Fax: +852-2896 - 0347
India: Optical Disc Technologies
Phone: +91-22-4307614, Fax: +91-22-4300373
Italia: Leroyka Records SRL, E-mail: leroyka@ntt.it
Phone: +39-2-86454011 Fax: +3902-86911377
Japan: MEDIKEN Inc.,E-mail: hyakusoko@mediken.co.ip
Phone: +81-3-5470 - 9801, Fax: +81-3-5470 - 9377
Korea: DAE JOO Industrial Company, E-mail: DAEJOO@UNITEL.CO.KR
Phone: +82-2-555 - 4017, Fax: +82-2-553 - 6076
Poland: Tadeusz Pupek, Dipl. Ing.
Phone: +49-8104 352 Fax: +49-8104 352
Spain and Portugal: Telstar S.A., E-Mail: telstar@telstar.es
Phone: +34 -93-785 - 2800, Fax: +34-93-785 - 9342
Taiwan: ACEWAY METROTEC CO., LTD., E-mail:a25960@ms18.hinet.net
Phone: +886-2-2716 - 9178, Fax: +886-2-2716 - 9014
Thailand: Datron Thai Co., Ltd., E-mail: solar@ksc15.th.com
Phone: +66-2-392-02246, Fax: +66-2-381-2971
Venezuela: H. Lüdemann CA, E-mail: 104721,3135@compuserve.com
Phone: +58-2619032 Fax: +58- 2614625