Our e-star 6500 is designed to be featured by two injection molding systems to guarantee high outputs on DVD-R media.
Of course you got as well the possibility to produce CD-R and change can be done within 5 hours. This is all to keep our partners the flexibility to react on the changing markets demands.
Cooling track In the cooling station shown on side an independent cooling device cools the substrate down to the exact needed temperature ｡V with a tolerance of 0.2｢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.
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.
Dye coating In our 6500 we have installed the same dye modul as in our e-star 5500. We have 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 so the system can run permanently without being affected on one single module or track and without complete downtimes during cleaning or maintenance.
Volumetric pumps dose precisely the dye on the disc. Because of the special valves we have realised 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.
Edge cleaning At our edge wiping process the discs are cleaned on both sides of the discs parallely. Also these process cups a driven by servomotors with a maximum spped of up to 10000 rpm to get perfect edges thus not have any influence on yield.
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 disc halves can be stored to avoid additional costs or can be used for production of quality B discs.
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 guarantee excellent quality.
Dye drying oven To guarantee a smooth and gentle disc drying at a low cycle we have integrated a compact drying oven with 4 rows and 107 positions each. We have integrated the same proofed principle from the cooling track:
the discs are stored vertically and rotate during transfer to guarantee a homogenous dye drying. Due to the fact thet the disc are heated on both sides parallely at a gentle temperature of 100｢XC there is no risk of deformation of the disc halves because of unequal heating.
After the dye-drying we have integrated a cooling device to renew the substrates to avoid any influence on yield because of the thermal load.
Buffer station 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.
Sputtering system Fast sputtering at high yields was our argument to enclose the Swivel 1.4. The metallizer is fully integrated into the system.
Relaxing period
After metallizing the substrates suffer from the thermal load. Our relaxing period helps to cool down the discs after sputtering; so the yield can rise up.
Bonding With our reliable point-to-point bonding we are able to bond the DVD-halves without any micro-bubbles.
Our bonding process is characterized by an adhesive apply on both disc halves at eight defined points and not in one ring. This helps to secure a good bonding result.
Adhesive apply The adhesive reservoirs are temperature and pressure regulated. This leds to permanently outgased adhesive and so guarantees an adhesivefree of micro-bubbles.
Process The disc halves are centered one at the bonding arm and second at the bonding plate with a 15 mm part centering pin to achieve a perfect sized bonding.
Through the dissoultion of the surface tension of the adhesive dots the disc halves suck themselves in without the need of high external pressureand without any micro-bubbles (adhesive-to-adhesive-process).
As we have profited from the physical properties of liquids we are able to save frail constructed handlings and so to have less maintenance and ensure parallely exqusite bonding results.
UV-laquer spin coating For spin coating a high precision is decisive. Our spin-cup is powered by a volumetric pump for exact dosing. The spin cup is driven by a servo motor at a speed of 6000 rpm. Two spinning cups offer the possibility to run on fast cycle while keeping a large process window for the operator.
UV curing Our UV-lamp is beded in a special mirrored corridor where all ray of light is focused on the disc. Our development leads to homogenous drying at a very low temperature. Because of the homogenous temperature 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.
Relaxing position The cooling table permits the user the possibility of a larger process window. A constant luminar airflow get the discs on the right temperature. Because of the smooth and gentle UV-drying the cooling period is short and a good quality is realized at a concurrent fast cycle time.
Final inspection State-of-the-art inline inspection scanners from Dr. Schwab take care that all important disc parameters, e.g. local defect size, disc deformation, and bonding layer thickness etc. are checked on each disc.
In case of production of CD-R the same scanner can do the inspection. Only change of parameters is requested, the scanner needs not be changed.
CD-R
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