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 use in fabricating an embosser drum, comprising:
using an embossing master that includes a surface with a pattern of nanostructures to create an embossing plate that includes a pair of opposing end surfaces and a pair of opposing major surfaces, wherein the embossing plate includes the pattern of nanostructures on a first of the opposing major surfaces; welding the opposing end surfaces of the embossing plate together at a single seam to form a cylinder, wherein an interior surface of the cylinder comprises the first major opposing surface of the embossing plate; producing, using the interior surface of the cylinder, an embosser drum, wherein an outer embossing surface of the embosser drum comprises the pattern of nanostructures, wherein the producing includes applying a metallic layer on the interior surface of the cylinder to produce the embosser drum, and; separating the cylinder from the embosser drum, wherein the separating includes:
cutting the cylinder along the single seam; andremoving the cylinder from the embosser drum.