US 20040209034A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2004/0209034 A1 Tompson et al. (43) Pub. Date: Oct. 21, 2004 (54) LIMITED PLAY OPTICAL DEVICES WITH Publication Classification INTERSTITIAL REACTIVE LAYER AND METHODS OF MAKING SAME (51) Int. Cl." ....................................................... B32B 3/02 (52) U.S. Cl. ............................................................ 428/64.4 (75) Inventors: Robert F. Tompson, Kennebunk, ME (US); Neil Exter, Lexington, MA (US); (57) ABSTRACT Yannis Bakos, New York, NY (US); Richard A. Minns, Arlington, MA Methods and apparatus are provided for making an optically (US); Larry Takiff, Arlington, MA readable Storage media in which the reading beam passes (US) through a bonding layer configured with a reactive material Correspondence Address: that transforms from an optically transparent State to an WILMER CUTLER PICKERING HALE AND optically opaque State after exposure to a predefined Stimu DORR LLP lus, thereby inhibiting access to the data encoded on the 60 STATE STREET optically readable Storage media. The method includes Steps BOSTON, MA 02109 (US) of Synthesizing a blocked dye combining the blocked dye with a carrier material curing the resultant combination (73) Assignee: Flexplay Technologies, Inc., New York, deblocking the dye to produce a reduced dye in the resultant NY bonding layer exposing the optically readable Storage media (21) Appl. No.: 10/837,826 with the reactive material in its bonding layer to a prede termined Stimulus. In a further aspect of the present inven (22) Filed: May 3, 2004 tion methods and apparatus are provided for making an optically readable Storage media wherein the reading light Related U.S. Application Data passes through the bonding layer and the data encoded information is encoded on the L1 Substrate. In yet another (63) Continuation of application No. 10/163,474, filed on aspect of the present invention methods and apparatus are Jun. 5, 2002, now Pat. No. 6,756,103. provided for making an optically readable Storage media (60) Provisional application No. 60/295,903, filed on Jun. with at least two mechanisms for limiting access to the 5, 2001. encoded data of the optically readable Storage media. Patent Application Publication Oct. 21, 2004 Sheet 1 of 18 US 2004/0209034 A1 2-1 hoto Resist 4NYYYYYYYYYYYYYYY 5Glass1 O Pri re Plate Land 25 20 Pit ZZZZX A A A A 10 Primer 4N5222-24swVVya Ny VNLN NNNNN v. Glass Plate I- 30 Father Stamper ZZZZZZZZZZZZZZZ s 35 Glass Master XSXSX.30 Father Stamper N-45 Son Stamper 40 Mother Since FIG. 1 DVD -51 Substrate Adhesive layer not in (Top disc/Dummy Side) the optical path 115 DVD-5 110 % 100 DVD-50 Substrate 105 Reflective Layer (Bottom disc/Read Side) Read Out Laser Spot FIG. 2 Patent Application Publication Oct. 21, 2004 Sheet 2 of 18 US 2004/0209034 A1 Father Stamper 0.4mm Polycarbonate Disc 30 injection Molded L0 Adhesive Layer not in the optical path 110 L1 Layer / 115 Dummy Top Disc 105 Reflective Metal Layer 100 L0 Layer / --Read Side Bottom information aSef Pickup Disc Beam FIG. 3 200 UULTULT - R f l r u 205 i -i il ---- t ---- --- Single-Sided, Single-Layer Single-Sided, Dual-Layer max capacity: 4.7 GByte max capacity: 6.5 GByte Double-Sided, Single-Layer Double-Sided, Dual-Layer max capacity: 9.4 GByte max capacity: 17 GByte FIG.4 Patent Application Publication Oct. 21, 2004 Sheet 3 of 18 US 2004/0209034 A1 Thickness (mm) (1.45;0.643) (1.56:0.630) 0.64 (1.65;0.630) 0.62 0.60 0.58 (1.45;0.583) (1.56;0.570 (1.65;0.570) 1.40 150 1.60 1.70 Index of refraction FIG. 5A Thickness (mm) (1.45;0.653) (1.56;0.640) 0.64 0.62 Maximum thickness 0.60 of the Substrate, 0.58 including the spacer 0.56 (1450.563) (1.56:0.550) (1.65;0.550) 140 150 160 1.70 . Minimum thickness index of refraction of the substrate FIG. 5B Patent Application Publication Oct. 21, 2004 Sheet 4 of 18 US 2004/0209034 A1 Single-Layer 32O \ information Area -- T --> Data Area 300 305 Lead-in Area Lead-out Area Dual-Layer Parallel Track Path (PTP) 299 \ Lead-in Area Lead-out Area 32O 305 Data Area 2EC PCC 2. Layer 1 2ED 2 Layer 0 Data Area 300 305 Lead-in Area Lead-out Area Dual-Layer Opposite Track Path (OTP) 325 V Lead-Out Area Middle Area 320 330 Data Area 2-E - I Layer 1 2-D C T Layer 0 Data Area 300 330 Lead-in Area Middle Area FIG.6 Patent Application Publication Oct. 21, 2004 Sheet 5 of 18 US 2004/0209034 A1 DVD -51 Substrate (Top disc/Read Side) In the optical path 420 400 % N 410 415 Reflective Layer DVD -5 LO Substrate (Bottom disc/Dummy Side) Read Out Laser Spot FIG. 7 0.6 mm Polycarbonate Disc Injection Molded L1 Adhesive Layer in the optical path 401 420-Layed 40 information Disc Mother 41 Reflective Metal Stamper O Layer 415 L0 Layer / Bottom Dummy 405 Disc Laser Pickup Beam FIG. 8 Patent Application Publication Oct. 21, 2004 Sheet 6 of 18 US 2004/0209034 A1 L1 Substrate 115 bonding layer 110 450 stamper LO reference plane Substrate 100 reading laser FIG. 9 Substrate 420 450 stamper bonding layer 401 reference plane L0 substrate 415 405 reading laser FIG. 10 Patent Application Publication Oct. 21, 2004 Sheet 7 of 18 US 2004/0209034 A1 DVD-5 Father / Son Stamper Track Pitch On Land reference FIG. 11 DVD-5 Mother Stamper Track Pitch Stamper Land PlaneReference Pit Patent Application Publication Oct. 21, 2004 Sheet 8 of 18 US 2004/0209034 A1 Replicated DVD-5 From Mother Stamper Father/Stamper Reverse Spiral and reduced Scanning Velocity 30 0.6 mm Polycarbonate Disc Injection Molded LO 420 Special DVD-5 Design #2 401 Adhesive in the optical path 410 Reflective Metal Layer 415 LO / Bottom Dummy Disc C- Read Side 405 Laser Pikup Beam F.G. 14 Patent Application Publication Oct. 21, 2004 Sheet 9 of 18 US 2004/0209034 A1 L1 Substrate 555 420 stamper reference 550 bonding layer plane LO substrate 415 405 reading laser FIG. 15 L1 Substrate 565 560 565 stamper Treference bonding layer plane Substrate reading laser FIG. 16 Patent Application Publication Oct. 21, 2004 Sheet 10 of 18 US 2004/0209034 A1 7775-14-6) S CorN 2 C E.H2O, NaOH "Orior'sN Methylene Blue, (MB) CH2Cl2 (613-11-6) (61-73-4) 75-09-2) Leucomethylene Blue,(LMB) Japan: ENCS No. 5-909 > -ooog N S N ---Ot. VN 52sCH2Cl2 "CIOr's2. is: 1122-58-3 Yield ~ 76% O o-- (184842-33-9 BOC-LMB O Xo-CF,(80522-42-51.5eq.O N COOS NN ( ) C26H39N3O2SSi O1 Oc (108-48-5) Tipsoc-LMB _r Yield ~ 70-85% FIG. 17 Patent Application Publication Oct. 21, 2004 Sheet 11 of 18 US 2004/0209034 A1 No Bar 2.0 O Open N. --Open dry air 15 AOpen room air o PCN O PC dry air 1.0 A PC room air O 100 200 300 400 Time(Hours) F.G. 18A DABCO 1 EQ O Open N2 o PC N2 --Open dry air O-PC dry air AOpen room air APC room air O 100 200 300 400 Time(Hours) FI G. 1 8B DABCO 10 EO O Open N. - Open dry air A Open room air o PC N. O PC dry air A PC room air O 100 200 300 400 Time(Hours) FI G. 1 8C Patent Application Publication Oct. 21, 2004 Sheet 12 of 18 US 2004/0209034 A1 400 500 600 700 800 FIG. 19 DVD 9 Partially Metalizes L0 1 Layer / Information L1 Reflective Disc Layer Adhesive Layer in the LO Semi-Reflective optical path Layer COvering Lead-in Area L0 / Bottom Dummy Disc L1 Data Area LO Lead-in FIG. 20 Patent Application Publication Oct. 21, 2004 Sheet 14 of 18 US 2004/0209034 A1 Z LTd8TÕTEETÕ?T?TIEWTWISOOTGOOTE?OT8LOTE Patent Application Publication Oct. 21, 2004 Sheet 15 of 18 US 2004/0209034 A1 c? CC E ver E o 9. CD O ?h e O OO.co CNOOO r CN Na H US 2004/0209034 A1 Oct. 21, 2004 LIMITED PLAY OPTICAL DEVICES WITH bling, Shattering, corroding, bending, changing refractive INTERSTITIAL REACTIVE LAYER AND properties or combinations of these, among other possibili METHODS OF MAKING SAME ties. 0001. This application is a continuation of U.S. applica 0006 Optical discs with Such a layer changing from a tion Ser. No. 10/163,474, filed Jun. 5, 2002, which is transparent to an opaque State in response to a Stimulus Such incorporated herein by reference. as exposure to oxygen in the atmosphere, or the light of the reading laser, can be used to manufacture limited-play FIELD OF THE INVENTION optical discs (such as DVDs) that become unusable in a predetermined way (Such as within a certain period of 0002 This invention relates to optically readable data exposure to environmental oxygen). Such discs can find a Storage media and, more particularly, to methods, compo variety of commercial applications, Such as the viewing of Sitions, and articles of manufacture of optically readable data a Video by consumers at a moment chosen by the consumer Storage media wherein the data is accessible for a finite and without the need to return the expired optical disc. period of time. 0007. The interfering layer that renders the disc unplay able by inhibiting the reading of the data can be applied via BACKGROUND OF THE INVENTION a variety of techniques to the Surface of an optical disc.