Replication tools and related fabrication methos and apparatus

Abstract

Durable replication tools are disclosed for replication of relief patterns in desired media, for example in optical recording or data storage media. Methods of making such durable replication tools are disclosed, including recording and developing a relief pattern on a selected surface of a support cylinder, creating a durable layer with a complementary relief replica of the pattern, separating the durable layer from the support cylinder. Apparatus are disclosed for fabricating such replication tools, including systems and apparatus for recording a desired relief pattern on a surface of a support cylinder. Also disclosed are electro deposition cells for forming a durable tool sleeve having a desired relief pattern. The replication tool relief features may have critical dimensions down to the micron and nanometer regime.

What is claimed is: 
     
         1 . A replication tool comprising:
 a sleeve having an outer durable surface defined by a first diameter and an inner surface defined by a second diameter, the inner surface forming a bore, wherein the sleeve has a height along a longitudinal axis perpendicular to the inner and outer diameters;   a relief pattern disposed on the outer surface of the sleeve, wherein the relief pattern includes a seamless three-dimensional pattern; and   a mounting fixture for supporting the sleeve in rotation as the outer surface of the sleeve is pressed against a substrate.   
     
     
         2 . The tool of  claim 1 , wherein the mounting fixture comprises:
 a support shaft extending though the bore of the sleeve;   an elastomeric insert configured for insertion into the bore of the support cylinder and about the support shaft; and   a compression assembly arranged so as to compress the elastomeric insert in a direction along the longitudinal axis of the support cylinder to expand the insert along the inner diameter of the support cylinder.   
     
     
         3 . The tool of  claim 2 , wherein the compression assembly includes:
 threads on the support shaft;   a pair of thrust washers configured to receive the support shaft, one washer at each end of the sleeve; and   a pair of compression nuts configured for threaded connection to the threads of the support shaft, one compression nut at each end of the sleeve, wherein rotation of each compression nut in one direction tightens the nut against the adjacent thrust washer and rotation in the opposite direction loosens the nut against the thrush washer.   
     
     
         4 . The tool of  claim 1 , wherein the relief pattern includes desired features of micron-scale size. 
     
     
         5 . The tool of  claim 1 , wherein the relief pattern includes features of nanometer-scale size. 
     
     
         6 . The tool of  claim 1 , wherein the mounting fixture comprises an expandable arbor. 
     
     
         7 . The tool of  claim 1 , wherein the mounting fixture comprises a rigid sleeve having an outer surface adapted to the bore of the sleeve to hold the sleeve against rotational movement relative to the mounting fixture.