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

Abstract

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 and bonding the replicas together to form a bonded replica structure having a surface with the nanostructure pattern imprinted therein and a surface area that is approximately the same as an outer embossing surface of the embosser drum to be formed. Advantageously, a single, one-piece metallic shim can subsequently be generated, appropriately shaped and welded at a single seam to form the embosser drum outer embossing surface.

1 . A method for use in fabricating an embosser drum, comprising:
 making a plurality of replicas of an embossing master, wherein each of the replicas includes a pattern of nanostructures;   bonding the plurality of replicas of the embossing master together in a particular orientation to create a bonded replica structure including a surface having a pattern of nanostructures thereon, wherein the pattern of nanostructures on the surface of the bonded replica structure comprises the combination of the patterns of nanostructures of the plurality of replicas of embossing master;   producing a replica of the bonded replica structure; and   generating an embossing plate from the replica of the bonded replica structure.   
     
     
         2 . The method of  claim 1 , wherein the embossing plate 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, and wherein the method further comprises:
 welding the opposing end surfaces of the embossing plate together at a single seam to form an embosser drum, wherein an outer embossing surface of the embosser drum comprises the first major opposing surface of the embossing plate.   
     
     
         3 . The method of  claim 1 , wherein each of the replicas of the embossing master includes a pair of opposing end surfaces and a pair of opposing side surfaces, wherein a length of the side surfaces is greater than a length of the end surfaces, and wherein the bonding comprises:
 bonding first and second of the replicas of the embossing master together along respective side surfaces at a first bonding seam.   
     
     
         4 . The method of  claim 3 , wherein each of the replicas of the embossing master comprises a pair of opposing major surfaces, wherein a first of the major surfaces includes the pattern of nanostructures, wherein the pattern of nanostructures comprises a set of generally parallel grooves, and wherein the first bonding seam extends generally parallel to the set of generally parallel grooves. 
     
     
         5 . The method of  claim 4 , wherein the bonded first replica structure comprises a pair of opposing major surfaces, wherein a first of the major surfaces includes the pattern of nanostructures, and wherein the first of the major surfaces comprises a surface area that is at least substantially the same as the outer embossing surface of the embosser drum. 
     
     
         6 . The method of  claim 3 , wherein the bonding further comprises:
 bonding third and fourth of the replicas of the embossing master together along respective side surfaces at a second bonding seam; and   bonding the first and second embossing master replicas to the third and fourth embossing master replicas along respective end surfaces at a third bonding seam, wherein the first and second bonding seams are at least substantially collinear, and wherein the first and second bonding seams are at least substantially perpendicular to the third bonding seam.   
     
     
         7 . The method of  claim 6 , wherein the bonding steps occur at least substantially simultaneously. 
     
     
         8 . The method of  claim 1 , wherein the outer embossing surface of the embosser drum has an axial width and a circumference, and wherein a width of the embossing master is approximately half the axial width of the embosser drum, and wherein a length of the embossing master is approximately half of the circumference of the embosser drum. 
     
     
         9 . (canceled) 
     
     
         10 . A method for producing at least one embosser drum that has a pattern of nanometer-scale grooves formed in an outer surface thereof, the method comprising:
 producing a plurality of replicas of an embossing master that has at least one surface with the pattern of nanometer-scale grooves therein, wherein each of the replicas of the embossing master comprises at least one surface with the pattern of nanometer-scale grooves therein;   bonding the plurality of replicas of the embossing master together to create a bonded replica structure having at least one surface with the pattern of nanometer-scale grooves formed therein, wherein the bonded replica structure comprises at least one bonding seam between adjacent one of the replicas of the embossing master that extends generally parallel to the nanometer-scale grooves, and wherein a surface area of the at least one surface of the bonded replica structure is at least substantially the same as a surface area of the outer surface of the embosser drum to be formed; and   producing a replica of the bonded replica structure.   
     
     
         11 . The method of  claim 21 , wherein the using further comprises:
 performing an electroforming process on the at least one surface of the replica of the bonded replica structure to create a metallic shim, wherein the metallic shim comprises the pattern of nanometer-scale grooves on at least one surface thereof; and   shaping the metallic shim to form the outer surface of the embosser drum.   
     
     
         12 . The method of  claim 11 , wherein the shaping comprises:
 welding opposing end surfaces of the metallic shim together to form the embosser drum, wherein the embosser drum comprises only a single seam.   
     
     
         13 . The method of  claim 12 , wherein the single seam of the embosser drum extends generally perpendicularly to the nanometer-scale grooves. 
     
     
         14 . The method of  claim 11 , further comprising:
 producing another replica of the bonded replica structure;   performing an electroforming process on at least one surface of the another replica to create another metallic shim, wherein the another metallic shim comprises the pattern of nanometer-scale grooves on at least one surface thereof; and   shaping the another metallic shim to form an outer surface of another embosser drum.   
     
     
         15 . The method of  claim 10 , wherein the embossing master comprises silicon and the replicas of the embossing master comprise a polymer. 
     
     
         16 . A method for pre-formatting optical tape media, the process comprising:
 obtaining a length of optical tape that has first and second opposing surfaces; and   embossing, using an embosser drum, a pattern of nanometer-scale structures 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 with only a single welded seam therein.   
     
     
         17 . The method of  claim 16 , wherein the embosser drum manufacturing process comprises the steps of:
 producing a plurality of replicas of an embossing master that has at least one surface including the pattern of nanometer-scale structures therein, wherein each of the replicas comprises at least one surface with at least a portion of the pattern of nanometer-scale structures therein;   bonding the plurality of replicas together to create a bonded replica structure having at least one surface with the pattern of nanometer-scale structures formed therein, wherein a surface area of the at least one surface of the bonded replica structure is at least substantially equal to a surface area of an outer embossing surface of the embosser drum to be formed;   generating a replica of the bonded replica structure; and   using the replica of the bonded replica structure to create the embosser drum.   
     
     
         18 . The method of  claim 17 , wherein the using comprises:
 forming an embossing plate from the replica of the bonded replica structure; and   welding opposing end surfaces of the embossing plate together at the single seam to form the embosser drum.   
     
     
         19 . The method of  claim 17 , wherein the bonded replica structure comprises at least one bonding seam between adjacent embossing master replicas that extends generally parallel to grooves of the nanostructure pattern. 
     
     
         20 . The method of  claim 17 , wherein the replica of the bonded replica structure is devoid of any seams. 
     
     
         21 . The method of  claim 10 , further comprising:
 using the replica of the bonded replica structure to create the embosser drum.