Our e-star 5500 is designed for two injection molding systems to achieve high outputs on CD-R.
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Layout
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Cooling track
In the cooling station shown on side a constant luminar air flow cools the substrate down to the exact needed temperature ｡V the tolerance lies within 1｢XC. The discs are positioned vertically to cool both sides of the discs. Parallely the discs rotate during transfer so this guarantees a homogenous smooth cooling without any deformation.
The approach of this vertical storage design minimizes the space requirement of the cooling device.
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Buffer
With the optional available buffer station between cooling track and dye unit the customer gets the possibility to service the dye unit while maintaining the injection molding systems. The buffer can be unloaded during stamper change for example. This feature increases the uptime of the system while not the complete system has to be shut down during maintenance of a single unit.
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Dye coating
In recordable media production exact dye coating is decisive. Krauss Maffei fitted the e-star with two independet tracks with 2 dye coating and one edge wiping module served by one central handling each.
All modules are stand alone process cups to give the user the possibility to maintain or optimize each cup individually while running full production on the other cups.
Each process cup is connected to an luminar air flow system. The constant and controllable air flow results in constant evaporation conditions on all 6 process cups.
Also, the dye dispense program as well as the dye spinning program can be regulated inde-pendently at each process cup.
Dye cups
Volumetric pumps precisely dose the dye on the disc. Because of special valves we have realized a low dead volume and no drops on the discs.
The process cups are driven by servo motors with a speed of up to 12000 rpm independent from dye coating This result perfect dye coated discs.
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Edge cleaning
At our edge wiping process the discs are cleaned on both sides of the discs parallely.
The edge wiping cups a driven by servomotors with a maximum speed of up to 6000 rpm to get perfect edges thus not have any influence on yield. As the edge wiping process does not require extrem high power we have integrated motors to achieve best results but to realize low energy consumption for low production costs for our partners.
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Dye inspection
A seperate scanner checks the quality of the coated disc halves. The scanner is fully adjustable. Quality B disc can be sorted out and are handled on a extra spindle. So these discs halves can be stored to avoid additional costs or can be used for production of special quality B discs.
Due to the scanner's precise measurement of optical dye-density by special spectrometer features, the system comes with all tools needed to create a full inspection report.
As well we have integrated a sample spindle. So our partners can define how often the production should be checked. Together with an optional inkjet printer our partners can create reports to be send with the products to verify excellent quality.
Also serial printing of the products can be applied on the printing station including all special disc information required.
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Dye drying oven
To guarantee a smooth and gentle disc drying at a low cycles we have integrated a compact drying oven with 2 independent heating elements featuring 2 rows with 107 positions each. We have integrated our proofed principle:
the discs are stored vertically and rotate during transfer to guarantee a homogenous dye drying. Due to the fact the the disc are heated on both sides parallely there is no risk of deformation of the disc halves because of unequal cooling.
Because the oven also functions as a buffer (2 heating elements with 2 rows with 107 positions each = 428 discs in oven) the maximum needed tempereaturte goes up to 100｢XC. Thus we can ensure the discs keep within the specifications while keeping required energy to a minimum.
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Buffer
The optional available buffer station between oven and finishing unit allows the customer to change target while the dye unit can proceed.
With this buffer station enclosed there is no need to shut down the complete system when servicing one single unit. So uptime can be increased and offers the customer the possibility to run the line real 24 hours a day.
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Sputtering system
We have transfered our knowledge of our sucessfull e-star 4000 to our CD-R finfishing unit. The Metallizer is fully integrated into the system to guarnatee a stabil process. The Metallizer is part of our one-serves-all central handling unit. This unit give the line its speed by coordinating all process steps.
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UV-laquer spin coating
For spin coating a high precision is decisive. Our spin-cup is powered by a volumetric pump for exact doing. The spin cup is driven by a servo motor with aspeed of 6000 rpm.
The laque-system is designed to meet all the requirements of the numerous laquers actual available.
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UV-curing
The UV-curing station is water-cooled to avoid heat radiation on the disc. The UV-lamp is beded in a special mirrored corridor where all ray of light is focused on the disc. This development besides leads to homogenous drying at a very low temperature. Because of the homogenous thermal load at any part of the disc the tilt is going against zero. And with a current consumption of 2 kW only, less energy is required to achieve excellent UV-curing.
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Final inspection
A final scanner is checking the disc on mechanical and optical defcts. The scanner is totally taylorable in specifications. The scanner can be replaced against any type of suiable scanner for our customers optionally.
The high resolution optics provideinformative feedback about the production conditions.To ensure optimal process control multiple source statistical and defect analyzing features come along with autocalibration of the system.
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CD-R
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