Proprietary & Confidential Practical manufacturing of BDR/RE discs Overview of the technologies Manufacturing challenges & Path forward Dr. Giriraj Nyati CTO-Blank Optical Media & Sr.VP - Corp.Technology Moser Baer India Ltd Media Tech, Macau, China March 15, 2011
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Proprietary & Confidential
Practical manufacturing of BDR/RE discs
Overview of the technologies
Manufacturing challenges
&
Path forward
Dr. Giriraj Nyati
CTO-Blank Optical Media & Sr.VP - Corp.Technology
Moser Baer India Ltd
Media Tech, Macau, China
March 15, 2011
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Moserbaer Group: Manufacturing:
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Moserbaer Group:Histroy of Manufacturing
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Moserbaer Group: With Japanese Partners
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3/15/2011
World Class Quality Standards
Quality Policy
“We are committed to Excellence and total Customer satisfaction through team work, ceaseless innovation and timely delivery of Quality Products of International Standard.”
Enablers
Real-time process controls: Online reaction to out-of-control limit conditions
Process improvement teams: Follow advanced SPC tools to drive continual improvement on critical processes and operate within tighter process windows
Certification under ISO 9001 : 2000
Certification ISO 14001:2004 & OHSAS 18001:1999
Integrated Management System implemented in the entire Plant
SONY’s Green Partner
SA 8000 Certified
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Opportunities for BD Technology
Gamut of Application Avenues
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What is BDR/RE used for?
1. For recording of TV program
2. For BD ROM copying
Facts that would fuel the BDR/RE
Demand:
1. Transition to digital and HD broadcasting.
2. Relaxation in copy protection law to allow BD ROM
copying.
BDR/RE Applications
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Why the demand would go up: Digital Broadcasting
Digital broadcasting is not identical to HD digital broadcasting. However,
all HD broadcasting could be classified as Digital Broadcasting.
Area Eng of Analog
Broadcasting
Level Key Point
Japan 14 July’ 2011 All broadcasting is
HD
HD broadcasting is
main
USA 17 Feb’2009 Some broadcasting
is HD
CATV is main. CATV is
exchanging to HD
broadcasting now
Europe 2012? Some broadcasting
is HD
England has started,
Next is Germany and
France
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Area Type Capacity of 2 hours Copy Control System
Japan MPEG-2/AAC
1440X1080
1920X 1080
15.3GB
21.6GB
Copy Once EPN *
USA MPEG-2/DD
1280X720p
About 10GB Broadcasting Flag
Europe MPEG-2 or 4/DD
1280X720p
About 13-17GB Not yet
Types of HD Broadcasting and Copy Control System
* Encryption and non assertion
Why the demand would go up: Digital Broadcasting
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Relaxation in Copying BD ROM
I expect that copying of BD ROM may be
allowed legally under some protection
regulation. Currently this is prohibited
through AACS.
Why the demand would go up: BD ROM copying
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Image of BDR Demand
BD
R D
em
and
(Japan
centr
ic T
V r
ecord
er)
2012
Rom
Copy S
tart
Long life span : 20-25 years
Time Horizon
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Blu-ray formats: Demand forecast
0
200
400
600
800
1000
1200
Million/Year
MBI Forecast of Global Blank BD Market
BDRE SL
BDRE DL
BDR SL
BDR DL
BDRE SL 2 20 49 71 133 204 206
BDRE DL 4 7 6 4
BDR SL 21 64 185 441 798
BDR DL 11 25 49 42
2007 2008 2009 2010 2011 2012 2013
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BD manufacturing :
It is all to do with the available tolerances
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BDR/RE discs: Technology
There are two type of recording conditions: H2L & L2H
H2L: Refers to reflectivity transition from high to low after laser recording ,
BDRE & BDR (inorganic) are based on this concept.
L2H: Refers to reflectivity transition from low to high after laser recording ,BDR
organic is based on this concept.
For H2L concept , On-groove recording is used.
For BDR organic ,In-groove recording is required because of certain design
issues like reversed push-pull polarity and low-to-high recording.
Inorganic recording
“On-groove recording”100 um cover
Organic recording
“In-groove recording”
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1.1mm PC Substrate
Reflective layer
Dielectric layer
Recording Layer-1
Recording Layer-2
Dielectric layer
Cover Layer
Hard Coat
1.1mm PC Substrate
Reflective Layer
Dye layer
Barrier layer
Cover Layer
Hard Coat
Inorganic Type(BDR*/RE) Organic Type(BDR)
Recording
layer *
BDR/RE discs: Disc Design
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Double Layer(DL)
BD-R/RE Multi Layer Disc Technology
Quadruple Layer(QL)
Triple Layer(TL)
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Successful
Manufacturing
of Blu-ray Discs
Manufacturing
Equipments
Technology,
Process and
Product Design
Test and
Measurement
Set-up
Media
Compatibility
Skill Set
Manufacturing of BDR/RE discs: Important factors
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Manufacturing challenges: Mastering
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Manufacturing challenges: Mastering
vendor -1
vendor-2
vendor- 3
S-No Parameter Instrument Remarks
1
Groove
Depth/Width
Depth/WA
AFMit is about the specific stamper
design and easy to match
2
Groove
Depth/Width
Depth/WA
DOMSxe Its about the specific stamper design
3 Thickness ADE have to validate its impact
4 Elec-Testing CATS No comparison
5Back Surface
Roughness
Roughness
Measurem
ent
Vendor-1
RA=0.03
RY=0.40
RZ=0.25
Vendor-3
RA=0.04
RY=0.41
RZ=0.28
Results comparable
6 Hardness (HV)Hardness
Tester
Vendor-1
Data area =208
Backsurface =180
Vendor-3
Data area =299
backsurface =216
Vendor-3 having high hardness as
compare with competitor stamper
7 Mechanical Eta Spikes error
Reverse Taper Thickness found on competitor stamper
CATS showing error in competitor stamper made
spikes error with competitor stamper made
Comparative Stamper Analysis
Observations / Results
GD/WA comparable with Vendor-3 Spec and GW 35
nm higher in Vendor-1
As per DOMSxe study, GD on competitor stamper is
observed low as compare with Vendor-3 also GW is
higher
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Manufacturing challenges: issues in Mastering
GD variation needs to be controlled :+/- 2nm ,Need good
process control & higher tonnage moulding machine with
extremely good replication capability.
Groove finishing/Groove Roughness improvement is major
challenge because of higher density of grooves ( lower track
pitch) .
Stamper back side roughness : more critical to control TE/FE
specially for high speed media (6X BDR & beyond)
Cost of manufacturing is significantly higher because mother
stamper is used as production stamper and only a limited
number of mothers can be produced from one father family.
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Manufacturing challenges- Issues in sputtering
Sputtering / Stack layer deposition:
• High vacuum levels in process chambers >10E-5 mbar