Methods for manufacturing an embosser drum for use in pre-formatting optical tape media

摘要

Various embodiments herein include utilities for generating embosser drums that are used to pre-format optical media such as optical tape with a pattern of nanostructures such as wobbled grooves. One utility includes generating a plurality of replicas from an embossing master, bonding the replicas together to form a bonded replica structure having a surface with the nanostructure pattern imprinted therein, creating a replica of the bonded replica structure and electroforming a metallic layer onto the bonded replica structure replica to create a single, one piece, metallic shim which can be used to create a weld-less embosser drum.

主权项

1. A method for pre-formatting optical tape media, the method comprising:
obtaining a length of optical tape that has first and second opposing surfaces; and embossing, using an embosser drum, a nanostructure pattern into at least one of the first and second opposing surfaces, wherein the embosser drum is manufactured by a process that results in the embosser drum including an outer embossing surface that is free of welded seams therein; wherein the embosser drum manufacturing process comprises the steps of:
interconnecting opposing end surfaces of a metallic shim together at a single seam to form a first cylinder having an interior surface with the nanostructure pattern;wherein the metallic shim is manufactured by a process that comprises:producing a plurality of replicas of an embossing master that has a surface including the nanostructure pattern, wherein each of the replicas comprises a surface with at least a portion of the nanostructure pattern therein; bonding the plurality of replicas together to create a bonded replica structure having a surface with the nanostructure pattern formed therein; generating a replica of the bonded replica structure; and performing a metallizing process on the bonded replica structure replica to create the metallic shim;applying a metallic layer to the interior surface of the cylinder to form a second cylinder on the interior surface of the first cylinder; andremoving the first cylinder from the second cylinder, wherein the second cylinder comprises the embosser drum.