| |
| United States Patent
|
6,638,149 |
| Lalli , et al. |
October 28, 2003 |
Disc repair system
Abstract
A disc repair system embodied by a consumer kit, which is
provided for the purpose of consumer-repairing of scratches on
optically-read discs (e.g., digitally recorded discs, known
commonly, as "CD" discs or "DVD" discs, containing audio or video or
other formats of data information), such that an optical reader,
which uses a laser to read digital information stored on a compact
disc, can read the digital information without the optical
distortion caused by a scratch. The consumer kit (in a special box
package) contains a hand-held rotator which is preferably used in
combination with abrading compounds, abrasive discs, and wiping
cloths to recondition the disc surface.
| Inventors: |
Lalli; Edward A.
(Glendale, AZ), Doherty; William M. (Phoenix, AZ),
Doherty, Jr.; John L. (Glendale, AZ) |
| Appl. No.:
|
09/766,802 |
| Filed: |
January 22, 2001 |
| Current U.S.
Class: |
451/63 ;
451/37 |
| Current
International Class: |
B24B
29/00 (20060101); B24B 29/02 (20060101); G11B
23/50 (20060101); B24B 001/00 () |
| Field of
Search: |
451/57,59,63,41,37,28 |
References Cited
[Referenced By]
U.S. Patent
Documents
Primary Examiner: Nguyen; Dung Van
Attorney, Agent or Firm:
Stoneman; Martin L.
Claims
What is claimed is:
1. A consumer kit for reconditioning a scratched operating surface
of an optically-read disc, comprising, in combination: a) a holding
means for holding the disc in a substantially stationary position
with the operating surface exposed and facing upwardly; b) an
abrader means for abrading the operating surface; c) a hand-held
power tool means for powered rubbing of said abrader means on the
operating surface; and d) a cleaning means for cleaning the
operating surface; e) wherein at least one said holding means, at
least one abrader means, at least hand-held power tool means, and at
least one cleaning means are packaged in a consumer kit.
2. The consumer kit according to claim 1, further comprising a
container means for containing said consumer kit within a box having
a lid.
3. The consumer kit according to claim 2, wherein said lid comprises
said holding means.
4. A consumer kit according to claim 2, wherein said box comprises
spacer means for orderly arranging of elements of said consumer kit.
5. A consumer kit according to claim 1, wherein said abrader means
comprises a series of abrasives for abrading the operating surface
in a user-controlled manner.
6. A consumer kit according to claim 5, wherein said hand-held power
tool means comprises a powered rotary spindle.
7. A consumer kit according to claim 6, further comprising a set of
polishing means removably attachable to said rotary spindle for
polishing the operating surface.
8. A consumer kit according to claim 7, wherein abrader means
further comprises said set of polishing means.
9. A consumer kit for reconditioning a scratched operating surface
of an optically-read disc, comprising, in combination: a) an
optically-read-disc holder structured and arranged to hold the
optically-read disc in a substantially stationary position with the
operating surface exposed and facing upwardly; b) a set of abrasive
products structured and arranged to abrade the operating surface in
an ordered manner when rotatably rubbed on the operating surface; c)
a hand-held rotary power tool having a powered rotary spindle
structured and arranged to removably hold one said spindle-rotatable
abrasive product; and d) a set of wipes each structured and arranged
to clean the operating surface.
10. The consumer kit according to claim 9, further comprising a box,
having a lid, structured and arranged to contain said consumer kit.
11. The consumer kit according to claim 10, wherein said lid
comprises said optically-read-disc holder.
12. The consumer kit according to claim 10, wherein said box
comprises a spacer structured and arranged to assist orderly
arranging of elements of said consumer kit.
13. The consumer kit according to claim 12, wherein said set of
abrasive products comprises: a) a set of polishing pads each
structured and arranged to be removably attached to said rotary
spindle; and b) a polishing compound.
14. The consumer kit according to claim 13, wherein said set of
abrasive products further comprises: a) a buffing pad structured and
arranged to be removably attached to said rotary spindle; and b) a
buffing compound.
15. The consumer kit according to claim 13, wherein said set of
abrasive products further comprises: a) a 15 grit micron abrading
disc; b) a 9 grit micron abrading disc; c) a 3 grit micron abrading
disc; d) a polishing compound less than 9 grit; and e) a cleaning
disc having a lesser grit than the polishing compound.
16. The consumer kit according to claim 13, wherein said set of
abrasive products further comprises a series of diamond grit
abrasives ranging from about 60 micron diamond grit to about 6
micron diamond grit.
17. A method for using consumer kit elements to recondition a
scratched operating surface of an optically-read disc, comprising,
in combination, the steps of: a) placing the optically-read disc in
a stationary position on a portable holder provided by the consumer
kit, with the scratched operating surface facing upwardly; b)
providing, by said consumer kit, a set of abrasion products
structured and arranged to remove material from said scratched
operating surface when rubbed on said scratched operating surface;
c) using a hand-held rotating power tool having a rotary spindle,
provided by said consumer kit, rubbing in a polishing order a
selection of said abrasion products on said scratched operating
surface; and d) cleaning said scratched operating surface.
18. The method according to claim 17, wherein said set of abrasive
products comprises: a) a set of polishing pads each structured and
arranged to be removably attached to said rotary spindle; and b) a
polishing compound.
19. The method according to claim 18, wherein said set of abrasive
products further comprises: a) a buffing pad structured and arranged
to be removably attached to said rotary spindle; and b) a buffing
compound.
20. The method according to claim 18, wherein said set of abrasive
products further comprises: a) a 15 grit micron abrading disc; b) a
9 grit micron abrading disc; c) a 3 grit micron abrading disc; d) a
polishing compound less than 9 grit; and e) a cleaning disc having a
lesser grit than the polishing compound.
21. The method according to claim 18, wherein said set of abrasive
products further comprises a series of diamond grit abrasives
ranging from about 60 micron diamond grit to about 6 micron diamond
grit.
Description
BACKGROUND
This invention relates to a system for repairing scratches on
optically-read discs, e.g., compact discs (often called "CD's").
More specifically, this invention provides a more efficient system
for refurbishing the compact disc surface such that an optical
reader, which uses a laser to read digital information stored on a
compact disc, can read the digital information without the optical
distortion caused by a scratch.
Typically, digitally recorded discs, known commonly as "CD" discs or
"DVD" discs, contain audio or video information. The digital
information is currently interpolated or read by an optical reader
that uses one or more laser beams or other light amplified beams to
read the digital information. The current state of the art of
manufacture of these CD discs is such that they are comprised of a
round disc composed of a synthetic material (e.g., plastic), with a
typical diameter of approximately 43/4 inches and an approximate
thickness of 1/16 inches. The disc has a center aperture typically
approximately 5/8 inches in diameter for receiving a centering
spindle in a playback apparatus. Digitally recorded material
typically extends on one side of the disc, from about 3/4 inches
from the center aperture outward to within about 1/4 inch of the
peripheral end of the disc. A bearing area typically extends on the
other side, in approximately the same dimensions, for bearing on a
playback apparatus which spins the disc at high speed. The digital
information is contained on a relatively thin layer of metallic
material covered by a protective layer of the synthetic material,
usually a plastic. A laser within the playback apparatus reads the
digital information through the plastic layer. Recently (for
example), optically-read discs include multi-layer laminated discs;
and it is pointed out that describing discs generally herein is not
intended to limit the technology of optically-read discs which is
addressed herein. If the plastic layer becomes scratched or stained,
the laser light will distort and not accurately read the digital
information.
Although such scratched discs may be commercially repaired in
quantity, as from a rental facility, the individual consumer-user of
such a disc has no inexpensive availability to such commercial
repair services and will often consider the disc practically
unrepairable and purchase a new one. Also, when attempting to trade
an old disc for a new one, such individual consumer will often find
that a scratched disc may not be traded in, and the used value is
compromised. Thus, there exists a need for a more efficient solution
to the problems of a consumer who owns scratched discs.
OBJECTS OF THE INVENTION
A primary object and feature of the present invention is to fulfill
the above-mentioned need by the provision of a disc repair system
embodied by a consumer kit, which is provided for the purpose of
user-repairing of the scratches, such that the digital information
may be read by an optical reader playback apparatus. In addition, it
is a primary object of this invention to provide such other
advantages as will become apparent with reference to the following
invention descriptions.
SUMMARY OF THE INVENTION
According to a preferred embodiment of the present invention, this
invention provides a consumer kit for reconditioning a scratched
operating surface of an optically-read disc, comprising, in
combination: a holding means for holding the disc in a substantially
stationary position with the operating surface exposed and facing
upwardly; an abrader means for abrading the operating surface; a
hand-held power tool means for powered rubbing of such abrader means
on the operating surface; and a cleaning means for cleaning the
operating surface. It also provides such a system further comprising
a container means for containing such consumer kit within a box
having a lid. Further, it provides such a system wherein such lid
comprises such holding means. Also, it provides such a system
wherein such box comprises spacer means for orderly arranging of
elements of such consumer kit, and it provides such a system wherein
such abrader means comprises a series of abrasives for abrading the
operating surface in a user-controlled manner.
Moreover, it provides such a system wherein such hand-held power
tool means comprises a powered rotary spindle; and such a system
further comprises a set of polishing means removably attachable to
such rotary spindle for polishing the operating surface. Still
further, it provides such a system wherein abrader means further
comprises such set of polishing means.
According to another preferred embodiment of the present invention,
this invention provides a consumer kit for reconditioning a
scratched operating surface of an optically-read disc, comprising,
in combination: an optically-read-disc holder structured and
arranged to hold the optically-read disc in a substantially
stationary position with the operating surface exposed and facing
upwardly; a set of abrasive products structured and arranged to
abrade the operating surface in an ordered manner when rotatably
rubbed on the operating surface; a hand-held rotary power tool
having a powered rotary spindle structured and arranged to removably
hold one such spindle-rotatable abrasive product; and a set of wipes
each structured and arranged to clean the operating surface.
Additionally, it provides such a system further comprising a box
having a lid, structured and arranged to contain such consumer kit;
and such a system wherein such lid comprises such
optically-read-disc holder; and further, wherein such box comprises
a spacer structured and arranged to assist orderly arranging of
elements of such consumer kit. It also provides such a system
wherein such set of abrasive products comprises: a set of polishing
pads each structured and arranged to be removably attached to such
rotary spindle; and a polishing compound. And, it provides such a
system wherein such set of abrasive products further comprises: a
buffing pad structured and arranged to be removably attached to such
rotary spindle; and a buffing compound.
Even further, it provides such a system wherein such set of abrasive
products further comprises: a 15 grit micron abrading disc; a 9 grit
micron abrading disc; a 3 grit micron abrading disc; a polishing
compound less than 9 grit; and a cleaning disc having a lesser grit
than the polishing compound. Still further, it provides such a
system wherein such set of abrasive products further comprises a
series of diamond grit abrasives ranging from about 60 micron
diamond grit to about 6 micron diamond grit.
According to yet another preferred embodiment of the present
invention, this invention provides a method for using consumer-kit
elements to recondition a scratched operating surface of an
optically-read disc, comprising, in combination, the steps of:
placing the optically-read disc in a stationary position on a
portable holder provided by the consumer kit, with the scratched
operating surface facing upwardly; providing, by such consumer kit,
a set of abrasion products structured and arranged to remove
material from such scratched operating surface when rubbed on such
scratched operating surface; using a hand-held rotating power tool,
having a rotary spindle, provided by such consumer kit, rubbing in a
polishing order a selection of such abrasion products on such
scratched operating surface; and using cleaning elements provided by
such consumer kit, cleaning such scratched operating surface. It
also provides such a system wherein such set of abrasive products
comprises a set of polishing pads each structured and arranged to be
removably attached to such rotary spindle; and a polishing compound.
Even further, it provides such a system wherein such set of abrasive
products further comprises: a buffing pad structured and arranged to
be removably attached to such rotary spindle; and a buffing
compound. Also, it provides such a system wherein such set of
abrasive products further comprises: a 15 grit micron abrading disc;
a 9 grit micron abrading disc; a 3 grit micron abrading disc; a
polishing compound less than 9 grit; and a cleaning disc having a
lesser grit than the polishing compound. And, it provides such a
system wherein such set of abrasive products further comprises a
series of diamond grit abrasives ranging from about 60 micron
diamond grit to about 6 micron diamond grit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the container of a preferred
embodiment of the disc repair system kit.
FIG. 2 is a perspective view of the internal parts of the disc
repair system kit.
FIG. 3 is a cross-section view through the compact disc and holder
of section 3--3 of FIG. 2 of the disc repair system kit.
FIG. 4 is a perspective view of the hand-held disc rotator.
FIG. 5 is a perspective view illustrating the application of another
embodiment of the polishing pad to a polishing disc.
FIG. 6 is a perspective view of a polishing pad removably attached
to a polishing disc.
FIG. 7 is a perspective view of a buffing pad.
FIG. 8 is a perspective view of a polishing pad and polishing disc
shown attached to a disc rotator.
FIG. 9 is a perspective view illustrating application of a polishing
compound to the polishing disc.
FIG. 10 is a perspective view illustrating the application of the
polishing disc upon the compact disc.
FIG. 11 is a perspective view further illustrating the application
of the polishing disc upon the compact disc.
FIG. 12 is a perspective view illustrating application of a buffing
compound to the buffing pad.
FIG. 13 is a perspective view illustrating the application of the
buffing pad upon the compact disc.
FIG. 14 is a perspective view further illustrating the application
of the buffing pad upon the compact disc.
FIG. 15 is a perspective view illustrating the application of the
final wiping cloth upon the compact disc.
FIG. 16 is a perspective view illustrating another preferred
embodiment of a compact disc holder.
FIG. 17 is a cross-section view through the compact disc holder of
section 16--16 of FIG. 16.
FIG. 18 is a perspective view of an alternate embodiment of an
applicator for a diamond abrasive polishing compound.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
Illustrated in FIG. 1 is an overall view of the container 20 of a
preferred embodiment of the disc repair system kit 10. The container
20 is preferably comprised of a body 22 and a cover 24. Preferably,
body 22 (embodying herein a container means for containing such
consumer kit within a box having a lid; and a box, having a lid,
structured and arranged to contain such consumer kit) is best
embodied by a rectangular box approximately sized at 6 inches
wide.times.101/2 inches long.times.21/2 inches high. The body 22 and
cover 24 are preferably metal, but may be manufactured in any
suitable material (e.g. plastic). Any suitably sized or shaped body
that would contain all of the necessary parts, as will be described
further herein, would also (non-preferably) suffice. The body 22 has
a cover 24 which is made such that it fits snugly over the body 22.
Preferably, cover 24 has a rubber anti-slip disc 26 on or near each
of the corners of the top 28. The purpose of these discs is to
assist in keeping cover 24 from slipping when it is turned on its
top 28, and the inside portion 29 (shown further in FIG. 2) is used
to hold a disc 30 (i.e., a compact disc or CD, a digital video disc
or DVD, or yet some other optically-read disc which is manufactured
in a similar manner).
FIG. 2 is a perspective view of a preferred embodiment of the parts
of the disc repair system kit 10. Referring first to cover 24, cover
24 is illustrated with the inside portion 29 in the up position and
the top 28 preferably resting on a flat surface (not shown). Located
in the center of the top 24 is a rubber disc holder 34 (e.g., a
custom cut piece of open-cell rubber approximately 1/8 inch thick,
Model No. O-C SBR SNG #3120, available from Rubberite Corp., 301
East Goetz Ave, Santa Ana, Calif. 92707, placed on a custom cut
piece of 1/8 inch steel plate). Preferably, rubber disc holder 34 is
about 43/4 inches in diameter. Preferably, rubber disc holder 34 is
sized such that it is the same size as a standard compact disc. The
compact disc is preferably set on the rubber disc holder 34 with the
operating surface exposed and facing upwardly (this arrangement
embodying herein a holding means for holding the disc in a
substantially stationary position with the operating surface exposed
and facing upwardly; and an optically-read-disc holder structured
and arranged to hold the optically-read disc in a substantially
stationary position with the operating surface exposed and facing
upwardly). Preferably, in the center of rubber disc holder 34 is a
round spindle 32 approximately 9/16 of an inch in diameter. The
spindle 32 has a smaller portion 33 (see FIG. 1) which is inserted
into the cover 24. The smaller portion 33 is preferably about 1/4
inch in diameter and is adhesively inserted in a same sized 1/4 inch
hole in the center of cover 24 (see FIG. 1). Both the spindle 32 and
rubber disc holder 34 are preferably permanently adhered to the
cover 24 (this arrangement embodying herein wherein such lid
comprises such optically-read-disc holder; and wherein such lid
comprises such holding means). The preferred adhesive is
double-sided adhesive tape; however, there may be other suitable
adhesives that would suffice (e.g., clear acrylic adhesive). Box
body 22 contains a foam insert 36 (e.g., a closed cell rigid foam,
such as that available from Foamex, 4011 West Clarendon, Phoenix,
Ariz. 85019) which is structured and arranged to removably hold the
components (later described herein) of the disc repair system kit 10
(this arrangement embodying herein wherein such box comprises spacer
means for orderly arranging of elements of such consumer kit; and
wherein such box comprises a spacer structured and arranged to
assist orderly arranging of elements of such consumer kit). Those
skilled in the art will readily recognize that such a holding insert
may be easily made from a variety of other materials (e.g.
non-foamed plastic), or formed in many other ways.
The additional components of the disc repair system kit 10 are now
described herein. A container 38 of polishing compound (e.g., blend
#19-polish A from Unichem Corp., 110 E Main Ave., Casa Grande, Ariz.
85230) preferably fits into space 39. Those skilled in the art will
readily recognize that such polishing compounds may be easily
obtained or custom blended. A container 40 of buffing compound
(e.g., buffing compound #1 from Springer Ind., 930 W. Birchwood,
Mesa, Ariz.) preferably fits into space 41. Those skilled in the art
will readily recognize that such buffing compounds may be easily
obtained or custom blended. A polishing pad 42 (e.g., medium density
closed cell foam, such as that available from Foamex, 4011 West
Clarendon, Phoenix, Ariz. 85019) and polishing discs 44 (e.g., 15
grit micron wet/dry aluminum oxide abrasive paper from 3M
corporation, and, preferably also including 9 grit micron and 3 grit
micron such paper discs, as mentioned herein, with appropriate
spaces) preferably fit into space 46. A foam pad with a linen backer
(included as an example used for diamond abrasives; otherwise, an
extra polishing pad 42 is inserted here) preferably fits into space
50. A polishing pad 52 and polishing discs 54 (e.g., 9 micron
wet/dry aluminum oxide abrasive paper from 3M corporation)
preferably fit into space 56. (The above polishing pads, discs and
polishing compounds embody herein wherein abrader means further
comprises such set of polishing means; and an abrader means for
abrading the operating surface; and also a set of abrasion products
structured and arranged to remove material from such scratched
operating surface when rubbed on such scratched operating surface;
and further embody herein wherein such abrader means comprises a
series of abrasives for abrading the operating surface in a
user-controlled manner; and even further embody herein a set of
abrasive products structured and arranged to abrade the operating
surface in an ordered manner when rotatably rubbed on the operating
surface). A hand-held disc rotator 58, preferably with an adjustable
RPM of 600-1200, preferably fits into space 60. Those with ordinary
skill in the art of small electrically-operated disc rotators will,
without undue experimentation, be able to design and build such a
rotator having proper torque and other characteristics for disc
polishing. A buffing pad 62 (e.g., medium density closed cell foam,
such as that available from Foamex, 4011 West Clarendon, Phoenix,
Ariz. 85019, with attached 40 pound fabric linen available from a
fabric store, such as H&R sales, 1118 N 35.sup.th Avenue, Phoenix,
Ariz. 85009) preferably fits into space 64. A buffing pad 66 (same
material as buffing pad 62) preferably fits into space 68. A package
70 of disc wiping cloths 72 (e.g., hydro-entangled 1.6 oz
polyester/rayon blend fabric) is included. This arrangement embodies
herein a set of wipes each structured and arranged to clean the
operating surface. A set of instructions 74 is also included. These
above-described items will be further herein explained below.
Illustrated in FIG. 3 is a diagrammatic cross-sectional view
(relative dimensions may be inaccurate) through the CD disc 30 and
rubber disc holder 34 of section 3--3 of FIG. 2 of the disc repair
system kit 10. Rubber disc holder 34 is shown adhesively mounted to
the inside portion 29 of cover 24. Spindle 32 is shown preferably
mounted in the center of the rubber disc holder 34 and is
approximately 9/16 inch in diameter. The spindle 32 has a smaller
portion 33, which is preferably about 1/4 inches in diameter, and is
permanently adhesively inserted in a same-nominal-sized 1/4 inch
hole in the center of cover 24.
FIG. 4 illustrates a perspective view of the hand-held disc rotator
58. The disc rotator 58 is preferably a battery-operated (and, in
appropriate circumstances, other AC and DC power sources, as
engineered by those with ordinary skill in this art) hand-held
device (embodying herein wherein such hand-held power tool means
comprises a powered rotary spindle). Illustrated is one (preferred)
example. The illustrated unit has 4 AA batteries 80 for power, and
an on/off switch 82. The device uses an electric motor to turn a
spindle 76, upon which a flat round disc 75 is connected (embodying
herein wherein such hand-held power tool means comprises a powered
rotary spindle: and a hand-held power tool means for powered rubbing
of such abrader means on the operating surface; and a hand-held
rotary power tool having a powered rotary spindle structured and
arranged to removably hold one such spindle-rotatable abrasive
product). These general types of devices are well-known in the art
and will not be further described. The preferred revolutions per
minute (RPM's) are between 600 RPM and 1200 RPM. Preferably, the
disc rotator is a variable speed device. Alternate RPM's may be
used; preferences will vary, depending on the abrasive grit of the
sanding pad and the amount of time the abrasive is applied to the
disc. Attached to the end of the flat round disc 75 is a hook fabric
78 for the purpose of attaching loop fabric-type material 86 (e.g.,
synthetic hook and loop materials used for removable attachment
purposes; e.g., Velcro.RTM.) used for removably attaching the
polishing pads 42 and 52 and buffing pads 62 and 66 to disc 75. A
foam pad with a linen backer 48 is illustrated as an example for the
purpose of using a diamond abrasive, and is explained in detail
below.
FIG. 5 is a perspective view illustrating the application of another
embodiment of the polishing pad 42 with an attached polishing disc
44. Preferably, with reference to FIG. 6, polishing pad 42 is
comprised of a dense foam 87 cut in a round cylindrical shape
approximately 15/16 inches in diameter and 1/4 inch in height.
Preferably, one flat 15/16 inch diameter portion has a thin fabric
cover 84 (e.g., hydro-entangled 1.6 oz. polyester/rayon blend
fabric, see FIG. 6) permanently glued (with any permanent adhesive)
to it, and the other flat 15/16 inch diameter portion has a loop
fabric-type material 86 (e.g., synthetic hook and loop materials
used for removable attachment purposes; e.g., Velcro.RTM.)
permanently attached to the foam. The loop fabric 86 is used to
removably attach the polishing pad 42 to the hook fabric 78 on the
flat round disc 75 of the disc rotator 58 (embodying herein a set of
polishing means removably attachable to such rotary spindle for
polishing the operating surface; and a set of polishing pads each
structured and arranged to be removably attached to such rotary
spindle). In a preferred embodiment, polishing disc 44 is comprised
of a 15/16 inch diameter disc, which is paper thin in thickness, and
has a removable adhesive 96 on one side and an abrasive 93
approximately 15 microns thick on the other side. Covering the
adhesive side 96 is a release sheet cover paper 92 (e.g., common to
those knowledgeable in the art, such as 70 pound calendar stock).
The release sheet cover paper 92 is removed, as illustrated in FIG.
5, and the adhesive side of the polishing disc 44 is applied with
hand pressure to the underside 90 of the polishing pad 42 (i.e., the
side without the loop fabric material 86).
FIG. 6 is a perspective view of a polishing pad 42 described above,
without the polishing disc 44 attached. The description of FIG. 5
and FIG. 6 also applies to polishing pads 52 and 48.
FIG. 7 is a perspective view of a buffing pad 62. Buffing pad 62 is
similar to buffing pad 66 and operates equally to buffing pad 66.
Preferably, buffing pad 62 consists of a dense foam 94 cut in a
round cylindrical shape approximately 15/16 inches in diameter and
3/4 inch in height. Preferably, one flat 15/16 inch diameter portion
has a loop fabric material 86 permanently attached to the foam. The
other 15/16 inch diameter portion remains uncovered foam. The foam
is used as a buffing surface for an abrasive that is applied to the
surface of the foam and will be further described in detail below.
The loop fabric 86 is used to removably attach the buffing pad 62 to
the hook fabric 78 on the flat round disc 75 of the disc rotator 58
(embodying herein a buffing pad structured and arranged to be
removably attached to such rotary spindle).
FIG. 8 is a perspective view of a polishing pad 42 and attached
polishing disc 44 shown attached to a disc rotator 58. Preferably,
the polishing pad 42 is attached to the disc rotator 58 utilizing
the above described hook fabric 78 and loop fabric 86 attachment. As
illustrated, the polishing pad 42 is attached with the loop fabric
86 connected to the hook fabric 78 on the flat round disc 75 of the
disc rotator 58 in a relatively upward position, and the abrasive
side, in a relatively downward position. (The buffing pad 62
attaches in a similar manner).
FIGS. 9 through 15 illustrate a preferred embodiment of the method
of use/operation of the preferred disc repair kit system. Digitally
recorded discs, known commonly as CD discs or DVD discs, may contain
audio or video information. The digital information is currently
interpolated or read by an optical reader that uses one or more
laser beams or other light amplified beams to read the digital
information; and such optical reading ability is the only intended
limitation in using herein a specific term or embodiment like "CD
disc". The current state of the art of manufacture of these CD discs
is such that they are comprised of a round disc composed of a
synthetic material (e.g., plastic), with a diameter of approximately
43/4 inches and an approximate thickness of 1/16 inches. The disc
has a center aperture approximately 5/8 inches in diameter for
receiving a centering spindle in a playback apparatus. Digitally
recorded material extends on one side of the disc from about 3/4
inches from the center aperture outward to within about 1/4 inch of
the peripheral end of the disc. A bearing area extends on the other
side, in approximately the same dimensions, for bearing on the
playback apparatus which spins the disc. The operation of the disc
reader and playback apparatus is well-known by those skilled in the
art and will not be further explained.
The side of the disc with digital data information is now further
discussed. The digital information is contained on a relatively thin
layer of metallic material covered by a protective layer of
synthetic material, usually a plastic. A laser within the playback
apparatus reads the digital information through the plastic layer
27. If the plastic layer 27 becomes scratched or stained, the laser
cannot accurately read the digital information. The present
embodiment of the disc repair system, a consumer kit, is provided
for the purpose of solving the above-described problem.
Referring again to FIGS. 9 through 15, use of the disc repair system
kit 10 reconditions the plastic covering such that the laser can
optically read the digital information on the disc 30 and play it
back with a playback apparatus. In operation, as shown in FIG. 10,
the disc repair system kit 10 user places the scratched disc 30 onto
the rubber disc holder 34 with the digital data side (that is
scratched) facing upwardly (embodying herein placing the
optically-read disc in a stationary position on a portable holder
provided by the consumer kit, with the scratched operating surface
facing upwardly). The disc 30 is placed such that the center spindle
32 fits into the center aperture of the disc 30. A polishing pad 42
with an attached polishing disc 44 assembly is placed onto the flat
round disc 75 of the disc rotator 58 as shown in FIG. 9. Preferably,
polishing disk 44 is a 15 micron grit abrasive surface. The disc
rotator 58 is turned such that the surface of the polishing disc 44
is facing upwardly. Preferably, one or more drops of polishing
compound 100 are applied to the polishing disc 44. The disc rotator
58 is then turned such that the surface of the polishing disc 44 is
over the area of the disc 30 which is scratched and to be repaired,
as shown in FIG. 10. For purposes of identifying the scratched area
to be repaired, the rubber disc holder 34 has four quadrant marks
31, which are placed perpendicular to each other through the center
of the disc. These marks, as shown, divide the rubber disc holder 34
into four quadrants. These quadrants are illustrated in FIG. 10 as
quadrant 101, quadrant 102, quadrant 103 and quadrant 104.
Preferably, as disc rotator 58 is turned over such that the surface
of the polishing disc 44 comes into contact with the disc 30, the
disc rotator 58 is turned on.
Preferably, the disc rotator 58 rotates the polishing disc 44 at
approximately 600-1200 revolutions per minute (RPM's). The disc
rotator 58 is moved back and forth over the scratched area,
preferably covering the entire quadrant area that encompasses the
scratch. For example, FIG. 11 illustrates a scratch that is being
repaired in the area of quadrant 102 and quadrant 103. It is
important that there be enough polishing compound 100 used to
adequately cover the area being repaired. It may be necessary to
repeat the step illustrated in FIG. 9 and FIG. 10 and add more
polishing compound 100. The polishing disc 44 should be kept wet
during the polishing process. Typically and preferably, the initial
polishing process lasts about one minute. The initial polishing
process illustrated in FIGS. 9-11 is used to remove a portion of the
thin plastic layer 27 covering the digital data, thereby also
removing the scratch(es).
The second polishing process is as described with respect to FIGS.
9-10, but occurs with polishing pad 52 and polishing discs 54.
Preferably, polishing disc 54 is a 9 micron grit abrasive surface.
As described in the first polishing process, the polishing pad 52
with an attached polishing disc 54 assembly is placed onto the flat
round disc 75 of the disc rotator 58. The disc rotator 58 is turned
such that the surface of the polishing disc 54 is facing upwardly.
Preferably, one or more drops of polishing compound 100 are applied
to the polishing disc 54. The disc rotator 58 is then turned such
that the surface of the polishing disc 54 is over the area of the
disc 30 which is scratched and to be repaired. Once again, as the
disc rotator 58 is turned over such that the surface of the
polishing disc 54 comes into contact with the disc 30, the disc
rotator 58 is turned on. Preferably, the disc rotator 58 rotates the
polishing disc 54 at approximately 600-1200 revolutions per minute
(RPM's). The disc rotator 58 is moved back and forth over the
scratched area, preferably covering the entire quadrant area that
encompasses the scratch (this arrangement embodying herein using a
hand-held rotating power tool having a rotary spindle, provided by
such consumer kit, rubbing in a polishing order a selection of such
abrasion products on such scratched operating surface). Preferably,
the second polishing process lasts about one minute. Similar to the
initial polishing, it may be necessary to add more polishing
compound 100 as the polishing disc 44 should be kept wet during the
polishing process. Since the abrasive grit of the polishing disc 54
is less abrasive than polishing disc 44, the plastic layer 27 will
continue to be smoothed. Preferably, this smoothing process allows
the laser to read the digital data as described previously.
The next step in the scratched disc repairing process is buffing. As
illustrated in FIGS. 12-14, the buffing process is quite similar to
the polishing process. Preferably, a buffing pad 62 (or buffing pad
66, being equal) is placed onto the flat round disc 75 of the disc
rotator 58 using the hook 78 and loop fabric 86 attachment. As
illustrated in FIG. 12, several drops of buffing compound 109 are
placed onto the buffing pad 62. The disc rotator 58 is then turned
over such that the surface of the buffing pad 62 is in the quadrant
over the area of the disc 30 which is scratched and has been
polished. As stated, preferably, as shown in FIG. 13, the disc
rotator 58 is then turned over such that the surface of the buffing
pad 62 comes into contact with the disc 30, and the disc rotator 58
is turned on. Preferably, the disc rotator 58 rotates the buffing
pad 62 at approximately 6-800 revolutions per minute (RPM's). The
disc rotator 58 is moved back and forth over the scratched area, as
shown in FIG. 13, preferably covering the entire quadrant area(s)
that encompasses the scratch (e.g., quadrants 102 and 103, as
illustrated in FIG. 14). The buffing process is preferably
accomplished similarly to the initial polishing process wherein it
may be necessary to add more buffing compound 109 as the buffing pad
62 should be kept moist during the buffing process. Since the
abrasive grit of the buffing compound 109 in combination with the
buffing pad 62 is less abrasive than polishing disc 54, the plastic
layer 27 will continue to be smoothed. The buffing compound 109 is
preferably applied until the disc appears shiny. The buffing
compound 109 is a light abrasive and may also be applied to the
entire disc to remove small scratches that would not necessitate the
use of the heavier abrasive in the polishing compound 100.
Upon completing the buffing step, the user removes a disc wiping
cloth 72 from the disc-wipe package 70. The disc wiping cloth 72 is
used to remove the buffing compound 109 and swirl marks as shown in
FIG. 15 (this arrangement embodying herein cleaning means for
cleaning the operating surface; and a set of wipes each structured
and arranged to clean the operating surface; and also a cleaning
disc having a lesser grit than the polishing compound). In addition,
disc wiping cloth 72 is used in conjunction with water or a
disc-wiping solution comprised of a lightweight clear plastic polish
(familiar to those skilled in the art) to lightly fill in any
remaining buffing or swirl marks and add an additional coating of
clear plastic polish to the plastic layer 27 of the disc 30
(embodying herein using cleaning elements provided by such consumer
kit, cleaning such scratched operating surface), further enhancing
the readability of the digital material through the plastic layer
27.
FIGS. 16 and 17 illustrate yet another embodiment of a rubber disc
holder 110. Preferably, rubber disc holder 110 may be used on a work
table top, or if the rubber disc holder 34 (see FIG. 2) is not used.
Rubber disc holder 110 is preferably comprised of metal (but may be
comprised of other suitable materials, such as plastic), and it
performs a similar function to rubber disc holder 34. Instead of
four quadrant marks 31, which are placed perpendicular to each other
through the center of the disc, rubber disc holder 110 preferably
has four u-shaped notches 112 placed perpendicular to each other.
The u-shaped notches 112 divide the rubber disc holder 110 into four
equal quadrants and assist the user in identifying the scratched
area to be repaired. Preferably, rubber disc holder 110 is about
43/4 inches square with a rubber disk 114 about 43/4 inches in
diameter centered in the square. Preferably, rubber disc holder 110
is sized such that it is the same size as a standard compact disc.
Preferably, in the center of rubber disc holder 110 is a round
spindle 116 approximately 9/16 of an inch in diameter which
penetrates both the rubber disk 114 and the rubber disc holder 110.
The spindle 116 has a smaller portion 118 which is inserted through
a 1/4 inch hole in the bottom of rubber disc holder 110. The smaller
portion 118 is preferably about 1/4 inch in diameter and is
adhesively inserted in a same sized 1/4 inch hole in the center of
rubber disc holder 110. Both the spindle 118 and rubber disc 114 are
preferably permanently adhered to the rubber disc holder 110. One
preferred adhesive method is use of a double-sided adhesive tape;
however, other suitable permanent adhesives would suffice.
FIG. 18 is a perspective view of an alternate embodiment of an
applicator 120 for diamond abrasives. In this embodiment, a series
of varying grit diamond abrasive compounds are used to remove
scratches. In operation, this embodiment is for an upgraded disc
repair system kit 10 preferably structured by adding all described
elements needed for abrading with diamond grit. Preferably, the
diamond abrasives are a series of varying grit diamond abrasive
compounds which are used to remove the scratches on the discs in
lieu of and/or in addition to the above-described polishing and
buffing compounds and discs. The diamond abrasive kit will be
similar to the above-described embodiment of the disc repair system
kit 10 with the differences as described below.
Preferably, for deep scratches, diamond abrasive (e.g., those
available from Engis Corp., 105 W. Hintz Rd., Wheeling, Ill. 60090)
is provided in the kit at the following grits: 60 microns, 30
microns, 15 microns and 6 microns (embodying herein wherein such set
of abrasive products further comprises a series of diamond grit
abrasives ranging from about 60 micron diamond grit to about 6
micron diamond grit). The diamond abrasive is used on the designated
pad, which is a foam pad with a linen backer 48 (e.g., medium
density closed cell foam, such as that available from Foamex, 4011
West Clarendon, Phoenix, Ariz. 85019, with attached 40 pound fabric
linen available from a fabric store, such as H&R Sales, 1118 N
35.sub.th Avenue, Phoenix, Ariz. 85009). Preferably, at least four
of the foam pads with a linen backer 48 would be put in the deluxe
disc repair system kit 10 in addition to the polishing pads 52 and
polishing discs 44. Preferably, each of the diamond abrasives is
applied on a separate and clean foam pad with a linen backer 48 for
a period of about two minutes on each application. Preferably, each
of the diamond abrasives is colored in a different color, so as to
be distinguished from one another. Preferably, the disc repair
system kit 10 user places the scratched disc 30 onto the rubber disc
holder 34 with the digital data side that is scratched facing
upwardly. Then the preferred steps may be followed with help of
FIGS. 9-15. The disc 30 is placed such that the center spindle 32
fits into the center aperture of the disc 30. A foam pad with a
linen backer 48 is placed onto the flat round disc 75 of the disc
rotator 58. The disc rotator 58 is turned over such that the surface
of the foam pad with a linen backer 48 is facing upwardly.
Preferably, one or more drops of 60 micron abrasive is applied to
the surface of the foam pad with a linen backer 48. The disc rotator
58 is then turned such that the surface of the foam pad with a linen
backer 48 is over the area of the disc 30 which is scratched and to
be repaired. As stated previously, for purposes of identifying the
scratched area to be repaired, the rubber disc holder 34 has four
quadrant marks 31 which are placed perpendicular to each other
through the center of the disc. These marks divide the rubber disc
holder 34 into four quadrants. These quadrants are illustrated in
FIG. 10 as quadrant 101, quadrant 102, quadrant 103 and quadrant
104. Preferably, as disc rotator 58 is turned over such that the
surface of the foam pad with a linen backer 48 and 60 micron diamond
adhesive comes into contact with the disc 30, the disc rotator 58 is
turned on.
Preferably, the disc rotator 58 rotates the foam pad with a linen
backer 48 at approximately 600-1200 revolutions per minute (RPM's).
The disc rotator 58 is moved back and forth over the scratched area;
preferably, covering the entire quadrant area that encompasses the
scratch. For example, FIG. 11 illustrates a scratch that is being
repaired in the area of quadrant 102 and quadrant 103. It is
important that there be enough 60 micron diamond abrasive to
adequately cover the area being repaired. It may be necessary to
repeat the step illustrated in FIG. 9 and add more 60 micron diamond
abrasive. Pad 48 should be kept wet with diamond abrasive during the
entire polishing process. Preferably, the initial polishing process
lasts about two minutes. The initial diamond abrasive polishing
process is similar to that illustrated in FIGS. 9-11 with the
exception of the use of the diamond abrasive in lieu of the
polishing compound and polishing discs. Preferably, the initial
polishing process is used to remove a portion of the thin plastic
layer 27 covering the digital data, thereby also removing the
scratch(es).
The second polishing process occurs with a 30 micron diamond
abrasive and a second foam pad with a linen backer 48. As described
in the first polishing process, a foam pad with a linen backer 48 is
placed onto the flat round disc 75 of the disc rotator 58. The disc
rotator 58 is turned over such that the surface of the foam pad with
a linen backer 48 is facing upwardly. Preferably, one or more drops
of 30 micron abrasive is applied to the surface of the foam pad with
a linen backer 48. The disc rotator 58 is then turned such that the
surface of the foam pad with a linen backer 48 is over the area of
the disc 30 which is scratched and to be repaired. Preferably, the
disc rotator 58 rotates the polishing disc 54 at approximately
600-1200 revolutions per minute (RPM's). The disc rotator 58 is
moved back and forth over the scratched area; preferably, covering
the entire quadrant area that encompasses the scratch. Preferably,
the second polishing process lasts about two minutes. Similar to the
initial polishing, it may be necessary to add more 30 micron
abrasive polishing compound as the backer 48 should be kept wet
during the polishing process. Since the abrasive grit of the 30
micron abrasive is less abrasive than the 60 micron abrasive, the
plastic layer 27 will continue to be smoothed. Preferably, this
smoothing process eventually allows the laser to read the digital
data, as described previously.
Preferably, the above steps are repeated two more times using 15
micron diamond abrasive and 9 micron diamond abrasive. Since the
abrasive grit of the abrasives continues to be less and less
abrasive, the plastic layer 27 will continue to be smoothed.
Upon completing the abrasive polishing step, the next step in the
scratched disc repairing process is buffing. As discussed previously
and illustrated in FIGS. 12-14, the buffing process is as follows:
Preferably, a buffing pad 62 (or buffing pad 66, being equal) is
placed onto the flat round disc 75 of the disc rotator 58 using the
hook 78 and loop fabric 86 attachment. As illustrated in FIG. 12,
several drops of buffing compound 109 are placed onto the buffing
pad 62. The disc rotator 58 is then turned such that the surface of
the buffing pad 62 is in the quadrant over the area of the disc 30
which is scratched and has been polished. Preferably, the disc
rotator 58 is then turned over such that the surface of the buffing
pad 62 comes into contact with the disc 30, and the disc rotator 58
is turned on. Preferably, the disc rotator 58 rotates the buffing
pad 62 at approximately 6-800 revolutions per minute (RPM's). The
disc rotator 58 is moved back and forth over the scratched area;
preferably, covering the entire quadrant area that encompasses the
scratch (e.g., quadrant 102 and 103 as illustrated in FIG. 14). The
buffing process is preferably accomplished similarly to the initial
polishing process wherein it may be necessary to add more buffing
compound 109 as the buffing pad 62 should be kept moist during the
buffing process. Since the abrasive grit of the buffing compound 109
in combination with the buffing pad 62 is less abrasive than the
polishing grits, the plastic layer 27 will continue to be smoothed.
The buffing compound 109 is preferably applied until the disc
appears shiny. The buffing compound 109 is a light abrasive and may
also be applied to the entire disc to remove small scratches that
would not necessitate the use of the heavier abrasive in the
polishing compound 100.
Upon completing the buffing process, the user removes a disc wiping
cloth 72 from the disc-wipe package 70. The disc wiping cloth 72 is
used to remove the remaining 9 micron abrasive and any left-over
swirl marks (as shown in FIG. 15). In addition, disc wiping cloth 72
is used in conjunction with a disc-wiping solution comprised of a
lightweight clear plastic polish, which is a mixture of distilled
water, silicone additive, and alcohol (familiar to those skilled in
the art) to lightly fill in any remaining buffing or swirl marks and
add an additional coating of clear plastic polish (silicone) to the
plastic layer 27 of the disc 30, further enhancing the readability
of the digital material through the plastic layer 27.
Although applicant has described applicant's preferred embodiments
of this invention, it will be understood that the broadest scope of
this invention includes such modifications as diverse shapes, sizes
and materials. Such scope is limited only by the below claims as
read in connection with the above specification. Further, many other
advantages of applicant's invention will be apparent to those
skilled in the art from the above descriptions and the below claims.
* * * * *
|
|