| |
| United States Patent
|
6,726,527 |
| Lalli , et al. |
April 27, 2004 |
Automatic disc repair system
Abstract
An automatic system for repairing scratches on optically-read
discs, (e.g., compact discs often called "CD's" or DVD's). More
specifically, an automatic system for refurbishing a plurality of
disc surfaces at substantially the same time, such that when
refurbished, an optical reader, which uses a laser to read digital
information stored on such a disc, can read the digital information
on the disc without the optical distortion caused by a scratch.
| Inventors: |
Lalli; Edward A.
(Glendale, AZ), Doherty; William M. (Phoenix, AZ),
Doherty, Jr.; John L. (Glendale, AZ) |
| Appl. No.:
|
10/164,071 |
| Filed: |
June 6, 2002 |
| Current U.S.
Class: |
451/5 ;
451/287; 451/288; 451/41 |
| Current
International Class: |
B24B
7/20 (20060101); B24B 7/22 (20060101); B24B 049/00 () |
| Field of
Search: |
451/5,41,288,287,285,28 |
References Cited
[Referenced By]
U.S. Patent
Documents
Primary Examiner: Wilson; Lee D.
Attorney, Agent or Firm:
Stoneman; Martin L.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
The present application is related to applicant's prior U.S.
Provisional Application No. 60/296,991, filed Jun. 8, 2001, entitled
"AUTOMATIC DISC REPAIR SYSTEM", the contents of which are herein
incorporated by reference and are not admitted to be prior art with
respect to the present invention by their mention in this
cross-reference section.
Claims
What is claimed is:
1. A system, for reconditioning at least one scratched operating
surface of at least one optically-read disc, comprising, in
combination: a) at least one rotatable supporter, comprising a
support surface positioned in substantially a first plane, to
support the at least one optically-read disc; b) at least one
powered rotater to rotate said at least one rotatable supporter; and
c) at least one abrader, rotatably powered by said at least one
powered rotater, structured and arranged to repair the operating
surface of at least one optically-read disc by abrading the
scratched operating surface by rotation in a second plane
substantially parallel to said first plane.
2. The system according to claim 1, b) wherein said at least on
abrader further comprises a series of diamond grit abrasives ranging
from a larger diamond grit to a smaller diamond grit.
3. The system according to claim 1 wherein said at least one abrader
is structured and arranged to only abrade the data storage band
portion of the at least one optically-read disc.
4. The system according to claim 1 wherein said at least one
rotatable supporter comprises at least one spindle adapted to fit a
central aperture of the at least one optically-read disc.
5. The system according to claim 1 wherein said at least one abrader
is adapted to abrade the protective layer of the at least one
optically-read disc.
6. The system according to claim 1 wherein said at least one abrader
is adapted to abrade the plastic layer of the at least one
optically-read disc.
7. A system, for reconditioning at least one scratched operating
surface, of each of a plurality of optically-read discs comprising
central apertures, comprising, in combination: a) a plurality of
rotatable supporting means, comprising a plurality of support
surfaces, each respective said support surface being positioned in
substantially a first plane, for supporting each respective
optically-read discs; b) power means for powered rotation about a
first axis; c) abrader means, rotatably powered by said power means,
for abrading each respective scratched operating surface of each
respective optically-read disc by rotation in a second plane
substantially parallel to said first plane; d) wherein each
respective said support surface comprises at least one spindle
adapted to fit the central aperture of each respective
optically-read disc.
8. The system according to claim 7 further comprising disc transport
means for placing a plurality of respective optically-read discs on
respective said support surfaces.
9. The system according to claim 8, further comprising: a) abrasive
means for abrading at least one scratched operating surface of at
least one optically-read disc; and b) wherein said abrasive means
comprises a series of diamond grit abrasives ranging from a larger
diamond grit to a smaller diamond grit.
10. The system according to claim 7 further comprising disc
transport means for removing a plurality of respective
optically-read discs from respective said support surfaces.
11. The system according to claim 10, further comprising: a)
abrasive means for abrading at least one scratched operating surface
of at least one optically-read disc; and b) wherein said abrasive
means comprises a series of diamond grit abrasives ranging from a
larger diamond grit to a smaller diamond grit.
12. The system according to claim 7, further comprising: a) abrasive
means for abrading at least one scratched operating surface of at
least one optically-read disc; and b) wherein said abrasive means
comprises a series of diamond grit abrasives ranging from a larger
diamond grit to a smaller diamond grit.
13. A system, for reconditioning at least one scratched operating
surface of each of a plurality of optically-read discs comprising
central apertures, comprising, in combination: a) a plurality of
system stations, each said system station comprising; i) a plurality
of rotatable supporting moans, comprising a plurality of support
surfaces, each respective said support surface being positioned in
substantially a first plane, for supporting each respective
optically-read discs; ii) power means for powered rotation about a
first axis; iii) abrader means, rotatably powered by said power
means, for abrading each respective scratched operating surface of
each respective optically-read disc by rotation in a second plane
substantially parallel to said first plane iv) wherein each
respective said support surface comprises at least one spindle
adapted to fit the central aperture of each respective
optically-read disc; and b) disc transport means for moving each
respective optically-read disc from a first said system station to a
second said system station.
14. The system according to claim 13 further comprising; a) abrasive
means for abrading at least one scratched operating surface of at
least one optically-read disc; b) wherein said abrasive means
comprises a plurality of abrasive compounds, each said abrasive
compounds comprising a different range of grit sizes; and c) wherein
each said system station is structured and arranged to utilize at
least one said range of grit sizes of said abrasive compounds.
15. The system according to claim 14 wherein a first said system
station utilizes a larger said range of grit sizes of said abrasive
compounds than an adjoining second said system station.
16. The system according to claim 15 wherein said disc transport
means is structured and arranged to transport said at least one disc
from said first station to said second station.
17. The system according to claim 16, further comprising: a)
abrasive means for abrading at least one scratched operating surface
of at least one optically-read disc; and b) wherein said abrasive
means comprises a series of diamond grit abrasives ranging from a
larger diamond grit to a smaller diamond grit.
18. The system according to claim 15, further comprising: a)
abrasive means for abrading at least one scratched operating surface
of at least one optically-read disc; and b) wherein said abrasive
means comprises a series of diamond grit abrasives ranging from a
larger diamond grit to a smaller diamond grit.
19. The system according to claim 14, further comprising: a)
abrasive means for abrading at least one scratched operating surface
of at Least one optically-read disc; and b) wherein said abrasive
means comprises a series of diamond grit abrasives ranging from a
larger diamond grit to a smaller diamond grit.
20. The system according to claim 13, further comprising: a)
abrasive means for abrading at least one scratched operating surface
of at least one optically-read disc; and b) wherein said abrasive
means comprises a series of diamond grit abrasives ranging from a
larger diamond grit to a smaller diamond grit.
Description
BACKGROUND
This invention relates to an automatic system for repairing
scratches on optically-read discs, e.g., compact discs (often called
"CD's" or DVD's). More specifically, this invention provides an
automatic system for refurbishing a plurality of disc surfaces at
substantially the same time, such that when refurbished, an optical
reader, which uses a laser to read digital information stored on
such a disc, can read the digital information on the disc 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 size varies slightly as to CD's
or DVD's. The disc typically has a center aperture approximately 5/8
inches in diameter for receiving a centering spindle in a playback
apparatus. Digitally recorded material typically extends on one or
both sides of the disc, from a data band extending 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 may extend on one or both
sides, 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.
Such scratched discs are commercially repaired in quantity. The
refurbishing of these discs in quantity is labor intensive and a
more inexpensive means for such commercial repair services is
desirable. Thus, there exists a need for a more efficient solution
to the problems of quantity repair of 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 an automatic disc
repair system embodied by an automatic system and apparatus which is
provided for the purpose of repairing multiple discs at a time, such
that the digital information on such discs 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 system for reconditioning at least one
scratched operating surface of at least one optically-read disc,
comprising, in combination: at least one rotatable supporting means,
comprising a support surface positioned in substantially a first
plane, for supporting the at least one optically-read disc; power
means for powered rotation about a first axis; and abrader means,
rotatably powered by such power means, for abrading the scratched
operating surface by rotation in a second plane substantially
parallel to such first plane.
According to another preferred embodiment of the present invention,
this invention provides a system for reconditioning at least one
scratched operating surface of each of a plurality of optically-read
discs, comprising, in combination: a plurality of rotatable
supporting means, comprising a plurality of support surfaces, each
respective such support surface being positioned in substantially a
first plane, for supporting each respective optically-read discs;
power means for powered rotation about a first axis; and abrader
means, rotatably powered by such power means, for abrading each
respective scratched operating surface of each respective
optically-read disc by rotation in a second plane substantially
parallel to such first plane.
It also provides such a system further comprising disc transport
means for placing a plurality of respective optically-read discs on
respective such support surfaces. And, it provides such a system
further comprising disc transport means for removing a plurality of
respective optically-read discs from respective such support
surfaces.
According to yet another preferred embodiment of the present
invention, this invention provides a system for reconditioning at
least one scratched operating surface of each of a plurality of
optically-read discs, comprising, in combination: a plurality of
system stations, each such system station comprising; a plurality of
rotatable supporting means, comprising a plurality of support
surfaces, each respective such support surface being positioned in
substantially a first plane, for supporting each respective
optically-read discs; power means for powered rotation about a first
axis; abrader means, rotatably powered by such power means, for
abrading each respective scratched operating surface of each
respective optically-read disc by rotation in a second plane
substantially parallel to such first plane; and disc transport means
for moving each respective optically-read disc from a first such
system station to a second such system station.
Further, it provides such a system further comprising; abrasive
means for abrading at least one scratched operating surface of at
least one optically-read disc; wherein such abrasive means comprises
a plurality of abrasive compounds, each such abrasive compounds
comprising a different range of grit sizes; and wherein each such
system station is structured and arranged to utilize at least one
such range of grit sizes of such abrasive compounds. It also
provides such a system wherein a first such system station utilizes
a larger such range of grit sizes of such abrasive compounds than an
adjoining second such system station.
Even further, it provides such a system wherein such disc transport
means is structured and arranged to transport such at least one disc
from such first station to such second station.
According to still other preferred embodiments of the present
invention, this invention provides the system according to each of
the above statements, further comprising: abrasive means for
abrading at least one scratched operating surface of at least one
optically-read disc; and wherein such abrasive means comprises a
series of diamond grit abrasives ranging from a larger diamond grit
to a smaller diamond grit.
This invention further provides each and every novel detail, system,
method or device mentioned in this provisional application,
including drawing, claims, and abstract.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the automatic disc repair system
according to a preferred embodiment of the present invention.
FIG. 2 is a top view of an optically-read disc illustrating a
typical disc data band and data storage area.
FIG. 3 is a side view partially in section of the disc of FIG. 2.
FIG. 4 is a diagrammatic top view illustrating the rotation of the
rotatable disc supports, power driven rotatable polisher, pulley,
belt and power drive motor of the automatic disc repair system
according to a preferred embodiment of the present invention.
FIG. 5 is a partial perspective view, partially in section
illustrating the power driven rotatable polisher in a raised
position along with application of an abrasive of the automatic disc
repair system according to a preferred embodiment of the present
invention.
FIG. 6 is a partial perspective view, partially in section
illustrating the power driven rotatable polisher in a lowered
position along with application of an abrasive of the automatic disc
repair system according to a preferred embodiment of the present
invention.
FIG. 7 is a partial perspective view, partially in section
illustrating the adjustability of the rotatable disc supports
individually and the adjustable base along a first and second
respective axis, of the automatic disc repair system according to a
preferred embodiment of the present invention.
FIG. 8 is a perspective view, partially in section of the automatic
disc repair system illustrating the adjustability of the adjustable
base along a third axis and the adjustability of the vertically
adjustable assembly along a fourth axis according to a preferred
embodiment of the present invention.
FIG. 9 is a perspective view, partially in section of the automatic
disc repair system further illustrating the adjustability of the
adjustable base along a third axis and the adjustability of the
vertically adjustable assembly along a fourth axis according to a
preferred embodiment of the present invention.
FIG. 10 is a front view of the automatic disc repair system
according to a preferred embodiment of the present invention.
FIG. 11 is a plan view of the automatic disc repair system utilizing
multiple stations according to another preferred embodiment of the
present invention.
FIG. 12 is a further illustration in plan view of the automatic disc
repair system of FIG. 11.
FIG. 13 is a plan view of multiple stations of the automatic disc
repair system according to a further preferred embodiment of the
present invention.
FIG. 14 is a plan view of multiple stations of the automatic disc
repair system according to an even further preferred embodiment of
the present invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
Illustrated in FIG. 1 is a perspective view of the automatic disc
repair system 20 (illustrating a single station 18) according to a
preferred embodiment of the present invention. In the illustrated
embodiment, there are preferably four rotatable disc supports 22,
24, 26, and 28. Preferably, each rotatable disc support 22, 24, 26,
and 28 comprises a respective support surface 30a, 30b, 30c, and
30d, and a central spindle 32. Preferably, each respective support
surface 30a, 30b, 30c, and 30d is approximately 43/4 inches in
diameter, however under appropriate circumstances, other sizes may
suffice (preferably sized to match the disc being refurbished).
Preferably, the spindle 32 is approximately 5/8 inches in diameter
(to fit the central aperture on a disc).
Preferably, rotatable disc supports 22, 24, 26, and 28 are attached
to an adjustable base 34. Preferably, adjustable base 34 may be
adjusted along two axis, Axis X and Axis Y. In addition, rotatable
disc supports 22 and 28 are preferably further adjustably attached
on a sliding mechanism 36, attached to adjustable base 34 such that
rotatable disc supports 22 and 28 may be further adjusted.
Preferably, rotatable disc supports 22 and 28 may be further
adjusted along Axis X', which is preferably parallel to Axis X.
Preferably, sliding mechanism 36 is adjusted by an actuator 38 which
is preferably digitally controlled. Preferably, the actuator has an
adjustment of at least about 10 millimeters to adjust to the size
difference between standard CD discs and DVD10 and DVD18 discs.
The automatic disc repair system 20 also comprises a power-driven
rotatable polisher 40. Preferably, polisher 40 further comprises a
center drive spindle 42 and a removably-attached polishing disc 44.
Preferably, the polishing disc 44 comprises a medium density,
closed-cell foam, 51/2-inch-diameter, 3/4-inch thick polishing disc
(such as that available from Foamex, 4011 West Clarendon, Phoenix,
Ariz. 85019). Preferably, the center drive spindle 42 is power
driven through the use of a pulley 46, attached to the center drive
spindle 42, and a belt 48 arrangement driven by a power drive motor
50, as shown. Preferably, the rotatable polisher 40, center drive
spindle 42, removably attached polishing disc 44, pulley 46, belt 48
and power drive motor 50 are all attached to a vertically adjustable
assembly 52, as shown. Preferably, vertically adjustable assembly 52
is adjustable along Axis Z, as shown. In all the preferred
embodiment described herein, vertical pressure on the discs during
abrading is preferably controlled by bringing the foam disc 44 to
touching-the-CD position and then moving the spindle holding the
disc 44 downward another 10 millimeters into abrading position.
Preferably, the adjustments of Axis X, Axis Y, Axis X', and Axis Z
are digitally controlled. Illustrated in FIG. 1 are cable 54 and
cable 58 which extend from a control unit 56 (preferably US Digital
Controller E2-200-200-E). Preferably, the control unit 56 has, or is
connected to, a computer (see computer 110 shown in FIG. 8 and FIG.
9) further comprising appropriate software (known by those
knowledgeable in the art, such as that utilizing G-code, a common
computer numeric control programming language) for programming and
directing the positioning of the adjustable base 34, sliding
mechanism 36 and vertically adjustable assembly 52. In addition, the
control unit 56 also preferably controls the power drive motor 50
speed, on/off mode and several other functions that will be
described in further detail below. Under appropriate circumstances
other arrangements may suffice.
Also illustrated in FIG. 1 is enclosure 60. Preferably, enclosure 60
is a clear plastic material (e.g., Plexiglas.RTM. or Lucite.RTM.)
and provides an area which is substantially enclosed on all but the
top, as shown. Preferably, enclosure 60 is about sixteen inches wide
by about twelve inches deep by about seven and one-half inches high
and comprises, preferably, about one-quarter-inch-thick material.
Preferably, the enclosure 60 assists in maintaining the cleanliness
of the workplace external to the enclosure 60 and assists in waste
removal and recycling of the refurbishing materials (described with
respect to FIG. 10 below). Preferably, attached to enclosure 60 is
solenoid valve 62 which comprises an adjustable spray arm 64
(preferably, an about nine-inch flexible hose with about a
three-thousand PSI rating) and spray tip 66. It is preferable to
have a solenoid valve 62, adjustable spray arm 64 and spray tip 66
on both ends of the enclosure (see FIG. 10, and solenoid valve 62',
adjustable spray arm 64' and spray tip 66'). Preferably, the
solenoid valve 62 assists in controlling abrasive material which is
preferably sprayed onto the disc supports, 22, 24, 26, and 28
(further explained in reference to FIG. 10). Under appropriate
circumstances, only a water mist for cooling may be so sprayed and
the abrasive material applied directly to each disc. In addition,
there is a drain 68, preferably attached on the rear portion 70 of
the enclosure 60 which is used to drain the abrasive material 90
and/or cooling fluid from the enclosure (further detailed in FIGS.
8-10). Preferably, enclosure 60 is sloped no less than 5 degrees
such that the abrasive material 90 will move toward the drain 68.
Preferably, drain 68 is about a 5/8-inch opening.
FIG. 2 is a top view of an optically-read disc 72 illustrating a
typical disc data band 74, stacking ring 76, and data storage band
78. FIG. 3 is a side view partially in section of the disc of FIG.
2. Typical Compact Discs (herein referred to as CD's) utilize data
on a single side. Recently, use of DVD discs (digital video discs)
have utilized two sides for data storage. The process for
refurbishing either side of such discs is substantially similar to
that herein described. In the embodiment of a CD illustrated in FIG.
2 and FIG. 3, the digital information is contained on a relatively
thin layer of metallic material 80 covered by a protective layer of
synthetic material, preferably plastic layer 82 (although under
appropriate circumstances other materials may suffice). Typically,
with current technology, a laser within a playback apparatus reads
the digital information through the plastic layer 82. If the plastic
layer 82 becomes scratched or stained, the laser cannot accurately
read the digital information. Preferably, the refurbishing of the
optically-read disc 72 occurs only in the data storage band 78.
Preferably, the abrading does not extend past the stacking ring 76.
The disc data band 74 is primarily used for initialization of the
disc 72, depending on the disc format.
FIG. 4 is a diagrammatic top view illustrating the rotation of the
rotatable disc supports, 22, 24, 26, and 28, power driven rotatable
polisher 40, pulley 46, belt 48 and power drive motor 50 of the
automatic disc repair system 20 according to a preferred embodiment
of the present invention. Preferably, power drive motor 50 turns a
pulley 84. In the illustrated embodiment, the pulley 84 rotates
counterclockwise; however, under appropriate circumstances other
arrangements may be suitable. Preferably, the rotation from pulley
84 is transferred to pulley 46 by belt 48 which is connected to both
pulley 46 and pulley 84.
Preferably, pulley 46 is connected by spindle 86 to rotatable
polisher 40. In the above described manner, rotation is transferred
from the power drive motor 50 to the rotatable polisher 40
(preferably a nominal rpm of about 1200, a preferable range of about
600 to 2000 rpm). Preferably, the power drive motor 50 is a 110 volt
Dayton Motor serial #2M145. Preferably, pulley 84 is about a 1-inch
gear and pulley 46 is about a 23/4 inch gear. Preferably, spindle 86
is between about a 1/4-inch and about a 5/8-inch spindle diameter.
Preferably, belt 48 is a 3/8-inch synchronous, segmented belt (made
by BAN). As will be further described below in FIG. 6, during
operation of the automatic disc repair system 20, the rotatable
polisher 40 preferably contacts four discs 72, which are placed on
support surfaces 30a, 30b, 30c, and 30d. Preferably, support
surfaces 30a, 30b, 30c, and 30d comprise a surface having a non-slip
surface, which is preferably a rubber material (e.g., a custom cut
piece of open-cell rubber approximately 1/8-inch thick, Model No.
O-C SBR SNG #3120, available from RubberiteO Corp., 301 East Goetz
Ave, Santa Ana, Calif. 92707). Preferably, support surfaces 30a,
30b, 30c, and 30d are connected to respective rotatable disc
supports 22, 24, 26, and 28 (as shown in FIG. 1). Preferably,
rotatable disc supports 22, 24, 26, and 28 comprise bearings 88 (see
FIG. 5) which allow the support surfaces 30a, 30b, 30c, and 30d to
rotate (all in the same plane), preferably horizontally, as shown,
and preferably in a parallel plane to that of abrading surface of
the rotatable polisher 40. Preferably, bearings 88 comprise an
integral shaft bearing as made by Hoover NSK such as serial #885586.
Preferably, when rotatable polisher 40 with attached polishing disc
44 contacts the discs 72, the rotating motion of the rotatable
polisher 40 with attached polishing disc 44 causes the support
surfaces 30a, 30b, 30c, and 30d to rotate in the opposite direction,
as shown. Preferably, bearings 88 create a slight resistance to the
rotatable disc supports 22, 24, 26, and 28 such that there is a
slight slowdown in the otherwise rotating speed the abrader 44 would
friction-drive the support surfaces. For the herein described
preferred embodiments, with the described support bearings and the
described vertical "pressure" movement (of about 10 millimeters), at
a spindle drive rotation of 1200 rpm (with a 51/2-inch foam abrader
44), the driven rotation speed of the rotatable disc supports 22,
24, 26, and 28 is about the same rpm (i.e., about 1200 rpm) for
standard-size CD supports.
FIG. 5 is a partial perspective view, partially in section,
illustrating the power driven rotatable polisher 40 in a raised
position (along Axis Z) and the application of an abrasive 90 of the
automatic disc repair system 20 according to a preferred embodiment
of the present invention. FIG. 6 is a partial perspective view,
partially in section, illustrating the power driven rotatable
polisher 40 in an operating position 94 (see FIG. 8) along with
application of an abrasive 90 of the automatic disc repair system 20
according to a preferred embodiment of the present invention.
During operation, a disc 72 is preferably placed onto each of the
respective support surfaces 30a, 30b, 30c, and 30d. Preferably, an
abrasive 90 is then applied onto the disc 72. Preferably, the
abrasive 90 is sprayed-on, as shown. Preferably, a series of
abrasives 90 is serially applied to each disc with each successive
abrasive varying downward in grit size such that each successive
grit size assists in the removal of ever lesser amounts of material
from the disc 72. Preferably, a diamond abrasive is used.
Preferably, diamond abrasive (e.g., those available from Engis
Corp., 105 W. Hintz Rd., Wheeling, Ill. 60090) is utilized as the
abrasive 90 material at the preferred following grits: 60 microns,
30 microns, 15 microns and 6 microns. Under appropriate
circumstances, other arrangements may be suitable. As will be
further explained with respect to FIG. 7 through FIG. 9, the support
surfaces 30a, 30b, 30c, and 30d and accompanying discs 72 are
located along Axis X, Axis Y and Axis X' by positioning of the
adjustable base 34, sliding mechanism 36 and assembly 52. The
support surfaces 30a, 30b, 30c, and 30d and accompanying discs 72
are preferably located such that Axis Z is centered in the removably
attached polishing disc 44 and is located equi-distant from the
center of each respective spindle 32. In this manner the polishing
disc 44, when in the operating position 94, (as shown in FIG. 6)
will equally abrade each respective disc 72 as the polishing disc 44
rotates (preferably as shown in FIG. 4). Preferably, the disc 72 is
only abraded in the data storage band 78 area of each disc 72
(described in FIG. 2).
Preferably, the abrasive 90 is applied just prior and used during
the polishing process for a period of about one minute for each
grit. Preferably, between applications of different grit, a
cleansing fluid is sprayed onto the disc. Preferably, the cleansing
fluid is water and is distributed through the solenoid valve 62,
adjustable spray arm 64 and spray tip 66 or a separate such system.
Under appropriate circumstances other arrangements may be suitable.
FIG. 7 is a partial perspective view, partially in section,
illustrating the adjustability of the rotatable disc supports
(illustrating rotatable disc supports 22 and 24) individually and
the adjustable base 34 along a first and second respective axis, of
the automatic disc repair system 20 according to a preferred
embodiment of the present invention. Preferably, adjustable base 34
is supported by platform 96, which is slidably adjustable using a
screw 98 and actuator 100 assembly, as shown, to adjust the platform
96 along a first axis 97, which is preferably in the direction of
Axis X (See FIG. 1) and preferably horizontal. Preferably,
adjustable base 34 is supported by platform 96 using a slidable
reverse bevel key-way and groove assembly 99, as shown. Preferably,
the actuator 100 is digitally controlled, however, under appropriate
circumstances other arrangements may suffice. Preferably, rotatable
disc supports 24 and 26 (See FIG. 1) are slidably attached to
sliding mechanism 36. Preferably, sliding mechanism 36 is slidably
adjustable using an actuator 38 which preferably either pulls or
pushes the sliding mechanism 36 along a second axis 101, which is
preferably in the direction of Axis X' (See FIG. 1) and preferably
horizontal.
FIG. 8 is a perspective view, partially in section, of the automatic
disc repair system 20 illustrating the adjustability of the
adjustable base 34 outward, as shown, along a third axis 103, which
is preferably in the direction of Axis Y (See FIG. 1) and preferably
horizontal, and the adjustability of the vertically adjustable
assembly 52 upward, as shown, along a fourth axis 92, which is
preferably in the direction of Axis Z (See FIG. 1) and preferably in
the vertical direction, according to a preferred embodiment of the
present invention. FIG. 9 is a perspective view, partially in
section, of the automatic disc repair system further illustrating
the adjustability of the adjustable base 34 inward, as shown, along
a third axis 103', which is preferably in the direction of Axis Y
(See FIG. 1) and preferably horizontal, and the adjustability of the
vertically adjustable assembly 52 downward, as shown, along a fourth
axis 92', which is preferably in the direction of Axis Z (See FIG.
1) and preferably in the vertical direction, according to a
preferred embodiment of the present invention.
Preferably, platform 96 is supported by base 102 which is slidably
adjustable using a screw 104 and actuator 106 assembly, as shown, to
adjust the base 102 along third axis 103 and 103' (Axis Y).
Preferably, platform 96 is supported by base 102 using a slidable
reverse bevel key-way and groove assembly 108, as shown. Preferably,
the actuator 106 is digitally controlled, however, under appropriate
circumstances other arrangements may suffice.
Preferably, the digital control comprises a computer 110, however,
under appropriate circumstances other arrangements may suffice.
Preferably, computer 110 is connected to a control unit 56 which in
turn is preferably hard-wire-connected to control the adjustable
base 34, sliding mechanism 36 and vertically adjustable assembly 52.
In addition, the control unit 56 also preferably controls the
actuator 38, power drive motor 50 speed, vertically adjustable
assembly 52, on/off power to the motors, solenoid valve 62, actuator
100, actuator 106 assembly and may also be used to control (per the
later description herein) the placement or removal of the discs 72
from the respective support surfaces 30a, 30b, 30c, and 30d. FIG. 10
is a front view of the automatic disc repair system 20 according to
a preferred embodiment of the present invention. The preferable
hard-wiring is further illustrated in FIG. 8, FIG. 9 and FIG. 10 as:
cable 112, connecting the control unit 56 to the power drive motor
50; cable 54, connecting the control unit 56 to vertically
adjustable assembly 52; cable 58, connecting the control unit 56 to
actuator 106 assembly; cable 114, connecting the control unit 56 to
computer 110; cable 116, connecting the control unit 56 to solenoid
valve 62; cable 118, connecting the control unit 56 to solenoid
valve 62'; and cable 120, connecting the control unit 56 to actuator
100.
FIG. 10 illustrates reservoir 122 which preferably holds abrasive 90
material. In the illustrated preferred embodiment, one reservoir 122
is used for each multiple station in an assembly line set-up which
will be discussed further below. In another preferred embodiment,
multiple reservoirs 122 may be used or a single reservoir divided
into compartments, one for each diamond abrasive grit. Under
appropriate circumstances, other arrangements may suffice. As
discussed previously, the preferred diamond grits are 60 microns, 30
microns, 15 microns and 6 microns. The abrasive 90 is preferably
dispersed through the use of solenoid valve 62 which comprises an
adjustable spray arm 64 and spray tip 66 and solenoid valve 62',
adjustable spray arm 64' and spray tip 66'. Preferably, the solenoid
valve 62 is connected to the computer 110 which preferably sends a
digital signal to the control unit 56 assisting in controlling
abrasive material which is to be sprayed onto the discs 72 on
support surfaces 30a, 30b, 30c, and 30d. Preferably, the preferred
embodiment utilizes a filter and pump 124 arrangement to recycle the
diamond abrasive and filter out the impurities from the abrasive
process, thereby allowing re-use of the diamond abrasive.
Preferably, the abrasive 90 material is a slurry 128 composed of a
mix of diamond abrasive and fluid. Preferably a fluid make-up source
126 is connected to the filter and pump 124 to add additional fluid
required to replace that lost through the refurbishing process. The
fluid is preferably water.
The operation of the automatic disc repair system 20 will now be
further detailed according to a preferred embodiment of the present
invention. Preferably, when utilizing a single automatic disc repair
system 20, comprising a single station 18, the following sequencing
occurs, preferably in an automated fashion (using a computer 110
programmed for sending control information to the control unit 56):
Sequence Action
A) The power driven rotatable polisher 40 is located in a raised
position by raising vertically adjustable assembly 52 along Axis Z,
as shown in FIG. 8.
B) Adjustable base 34 is arranged along two axis, Axis X and Axis Y.
Preferably adjusting base 34 fully outward along Axis Y and
centering base 34 along Axis X, such that Axis Z is centered
perpendicular to Axis X, as partially shown in FIG. 8.
C) Rotatable disc supports 22 and 28 are arranged such that all the
support surfaces 30a, 30b, 30c, and 30d will be aligned in such a
manner that they are adjusted along Axis X', which is preferably
parallel to Axis X, such that during operation of the automatic disc
repair system 20, the rotatable polisher 40 preferably will contact
all four discs 72 simultaneously (referencing FIG. 4 and FIG. 9),
which are placed on support surfaces 30a, 30b, 30c, and 30d to
polish all the discs 72 up to the stacking ring 76 (shown in FIG.
2). This distance varies depending on whether a CD or DVD disc is
being refurbished.
D) Preferably, subsequent to the above described positioning of the
automatic disc repair system 20, either by automation or by manual
means a disc 72 is placed onto each respective support surfaces 30a,
30b, 30c, and 30d.
E) Adjustable base 34 is arranged along two axis, Axis X and Axis Y.
Preferably, base 34 is then adjusted along Axis Y and along Axis X,
such that Axis Z is centered perpendicular to Axis X; and the
rotatable polisher 40 along Axis Z will contact all four discs 72
simultaneously, when lowered as shown in FIG. 4 onto support
surfaces 30a, 30b, 30c, and 30d such that the rotatable polisher 40
will polish all the discs 72 up to the stacking ring 76
simultaneously.
F) Preferably, the power driven rotatable polisher 40 is then
located in a lowered position by lowering vertically adjustable
assembly 52 along Axis Z, as shown in FIG. 9 such that the rotatable
polisher 40 along Axis Z will contact all four discs 72
simultaneously (when lowered as shown in FIG. 4, onto the support
surfaces 30a, 30b, 30c, and 30d).
G) Preferably, as the rotatable polisher 40 contacts the four discs
72, the computer preferably sends a digital signal to the control
unit 56 preferably starting the power drive motor 50 and setting the
speed of the power drive motor 50 such that the spindle will rotate
at about 1200 Revolutions per minute (RPM). In the described
embodiment, an RPM of about 1200 preferably applied for
approximately 1 minute of polishing per respective application of
diamond abrasive grit will yield the preferred amount of removal of
the plastic layer 82 (such that the plastic layer 82 is refurbished
and the scratches removed after complete application of the
described series of abrasives 90). Under appropriate circumstances,
those knowledgeable in the art may choose to use other appropriate
arrangements of revolutions per minute, polishing time, and abrasive
that will also suffice.
H) Preferably, as the rotatable polisher 40 contacts the four discs
72, abrasive 90 is applied onto the four discs 72. Preferably, the
abrasive 90 is applied using multiple reservoirs 122 or a single
reservoir 122 divided into compartments, one for each diamond
abrasive grit (Under appropriate circumstances other arrangements
may suffice). As discussed previously, the preferred diamond grits
are 60 microns, 30 microns, 15 microns and 6 microns. The abrasive
90 is preferably dispersed through the use of solenoid valve 62
which comprises an adjustable spray arm 64 and spray tip 66 and
solenoid valve 62', adjustable spray arm 64' and spray tip 66'.
Preferably, the solenoid valve 62 is connected to the computer 110
which preferably sends a digital signal to the control unit 56
assisting in controlling abrasive material which is to be sprayed
onto the discs 72 on support surfaces 30a, 30b, 30c, and 30d.
I) Preferably, upon completion of the series of abrasive 90
applications and cleanings described above, the power driven
rotatable polisher 40 is re-located in a raised position by raising
vertically adjustable assembly 52 along Axis Z, as shown in FIG. 8.
Adjustable base 34 is arranged along two axis, Axis X and Axis Y.
Preferably adjusting base 34 fully outward along Axis Y and
centering base 34 along Axis X, such that Axis Z is centered
perpendicular to Axis X, as partially shown in FIG. 8. Then, discs
72 are removed from the support surfaces 30a, 30b, 30c, and 30d.
Preferably, the discs 72 are checked to verify all scratches have
been removed and the disc 72 is ready for playback. Preferably, a
laser photo-check device 128 (see FIG. 11) is used to check the disc
72 for proper scratch removal.
FIG. 11 is a plan view of the automatic disc repair system 130
utilizing multiple stations 132, 134, 136, and 138 according to
another preferred embodiment of the present invention. FIG. 12 is a
further illustration in plan view of the automatic disc repair
system 130 of FIG. 11. In this embodiment, the automatic disc repair
system 130 comprises multiple stations 132, 134, 136, and 138,
respectively. Preferably each station 132, 134, 136, and 138
comprises a single station 18 as described above with minor
modifications to work within a system of four stations. Preferably,
the disc repair system 130 is automated. Preferably, a robotic-arm
assembly 140 utilizing a vacuum-head assembly 142 is used to remove
and replace discs 72 along the four stations 132, 134, 136, and 138,
respectively. The general use of such equipment as robotic-arm
assembly 140 and vacuum-head assembly 142 is well known by those
skilled in such art. Under appropriate circumstances other methods
and machinery may be used to accomplish such tasks.
In operation, as illustrated in FIG. 11 and FIG. 12, the robotic-arm
assembly 140 preferably picks up four scratched discs 72 from a
stack 144 of such discs. Preferably the disc stack 144 is located as
shown, such that the robotic-arm assembly can move in a straight
line, as shown and illustrated by line 146. Preferably, the
robotic-arm assembly 140 comprises a vacuum-head assembly 142 which
is able to pick-up a single disc 72 or multiple discs 72. In the
illustrated preferred embodiment, the vacuum-head assembly 142
further comprises four pick-up heads 142a, 142b, 142c and 142d
enabling the vacuum-head assembly 142 to pick up four discs 72 at a
time.
Preferably, the first station 132 operates as described above for
single station 18, positioning as described above in sequencing "A"
through "C". Preferably, the robotic-arm assembly 140 is positioned,
preferably by use of a computer-program-controlled system working in
conjunction with the control units 56 of the individual stations.
Preferably, the entire operation of the automatic disc repair system
130 is controlled by a single master program. Those knowledgeable in
the art are familiar with such control systems and under appropriate
circumstances other combinations of control systems may also
suffice. Preferably, the robotic-arm assembly 140 moves to a
position wherein the four pick-up heads 142a, 142b, 142c and 142d
places the discs 72 onto each respective support surfaces 30a, 30b,
30c, and 30d (described above in sequence "D" as being by manual or
automatic means). Once the discs 72 are placed onto each respective
support surface 30a, 30b, 30c, and 30d, sequencing "E" through "G"
preferably takes place. Preferably, during sequence "H", first
station 132 utilizes a heavier abrasive 90, preferably 60 micron
grit diamond abrasive. Preferably, sequence "I" occurs relocating
the polisher 40 in a raised position by raising vertically
adjustable assembly 52 along Axis Z, as shown in FIG. 8 and locating
adjustable base 34 fully outward along Axis Y and centering base 34
along Axis X, such that Axis Z is centered perpendicular to Axis X,
as partially shown in FIG. 8. Preferably, robotic-arm assembly 140
then operates vacuum-head assembly 142 utilizing pick-up heads 142a,
142b, 142c and 142d to remove the discs 72 from each respective
support surface 30a, 30b, 30c, and 30d picking up the respective
discs 72 from the first station 132 respective support surfaces 30a,
30b, 30c, and 30d and transferring them respectively to second
station 134 respective support surfaces 30a, 30b, 30c, and 30d.
Preferably, the sequencing described above for station 132 is
repeated in station 134 except that abrasive 90 is preferably
reduced to 30 micron grit. Preferably, upon completion of the
sequencing at station 134, robotic-arm assembly 140 then operates
vacuum-head assembly 142 picking up the discs 72 from the second
station 134 support surfaces 30a, 30b, 30c, and 30d and transferring
them to third station 136 support surfaces 30a, 30b, 30c, and 30d.
Preferably, the sequencing described above for station 134 is
repeated in station 136 except that abrasive 90 is preferably
reduced to 15 micron grit. Preferably, upon completion of the
sequencing at station 136, robotic-arm assembly 140 then operates
vacuum-head assembly 142 picking up the discs 72 from the third
station 136 support surfaces 30a, 30b, 30c, and 30d and transferring
them to fourth station 138 support surfaces 30a, 30b, 30c, and 30d.
Preferably, the sequencing described above for station 136 is
repeated in station 138 except that abrasive 90 is preferably
reduced to 6 micron grit. Preferably, upon completion of the
sequencing at station 138, robotic-arm assembly 140 then operates
vacuum-head assembly 142 picking up the discs 72 from the fourth
station 138 support surfaces 30a, 30b, 30c, and 30d and transferring
them to a temporary stack 148 which comprises four similar support
surfaces 148a, 148b, 148c, and 148d.
Preferably, the discs 72 are then checked for scratches by a laser
photo-check device 128 (see FIG. 11). Preferably, rejected discs 72
are placed in a rejected stack 150 comprising similar support
surfaces 150a, 150b, 150c, and 150d.
Preferably, after the station "line" is in full operation, the discs
72 have been removed from the fourth station 138 support surfaces
30a, 30b, 30c, and 30d, the robotic-arm assembly 140 may be seen as
sequentially operating vacuum-head assembly 142 picking up the discs
72 from a third station 136 and placing them on an empty fourth
station 138; then picking up the discs 72 from a second station 134
and placing them on a third station 136; then picking up the discs
72 from a first station 132 and placing them on a second station
134; and finally picking up the discs 72 from the stack 144 and
placing them on a first station 132. Under appropriate
circumstances, multiple "lines" may be implemented by a single
robotic-arm assembly or one or more "lines" may be implemented by a
desired number of robotic arm assemblies. It is preferred in the
described embodiment to use one robotic arm assembly for each pair
of "lines" (see FIG. 13).
Preferably, each station 132, 134, 136, and 138 has a reservoir 122
as shown in FIG. 10 and described above, which preferably holds
abrasive 90 material. Preferably, one reservoir 122 is used for each
multiple station 132, 134, 136, and 138 in an assembly line set-up
and contains a single grit for each station. For example, reservoir
122 at station 132 preferably holds 60 micron grit; reservoir 122 at
station 134 preferably holds 30 micron grit; reservoir 122 at
station 136 preferably holds 15 micron grit; and reservoir 122 at
station 138 preferably holds 6 micron grit. Further, each station
132, 134, 136, and 138 preferably has a filter and pump 124
arrangement to recycle the diamond abrasive and filter out the
impurities from the abrasive process, thereby allowing re-use of the
diamond abrasive.
FIG. 13 is a plan view of multiple stations of the automatic disc
repair system 160 according to a further preferred embodiment of the
present invention. In this embodiment, two four-station automatic
disc repair sub-systems 162 and 164 (or "lines") are working
together with a single robotic-arm 166. Under appropriate
circumstances multiple robotic arms 166 might also suffice.
Preferably, four-station automatic disc repair sub-system 162
comprises station 168, 170, 172, and 174. Preferably, four-station
automatic disc repair sub-system 164 comprises station 176, 178,
180, and 182. Preferably, in the described embodiment, the
robotic-arm 166 loads discs 72 onto each respective support surfaces
30a, 30b, 30c, and 30d of each respective station in the direction
of Arrow 184 and Arrow 185 (from station 1 through station 4). Under
appropriate circumstances, changing the direction of the loading and
unloading may be desired.
Preferably, each four-station automatic disc repair subsystem 162
and 164 operates as described above in FIG. 11 and FIG. 12, in
describing automatic disc repair system 130. Preferably, automatic
disc repair system 160 utilizes a single robotic-arm 166 for both
four-station automatic disc repair subsystems 162 and 164. Further,
the robotic-arm assembly 140 is positioned and operated, preferably,
by use of a computer program controlled system working in
conjunction with the control units 56 of the individual stations.
Preferably, the entire operation of the automatic disc repair system
160 is controlled by a single master program and computer that
coordinates the single robotic-arm 166 and the operation of the
individual stations 168, 170, 172, 174, 176, 178, 180, and 182.
FIG. 14 is a plan view of multiple stations of the automatic disc
repair system 190 according to an even further preferred embodiment
of the present invention. Preferably, in this embodiment, a
four-station system comprising stations 192, 194, 196, and 198 is
arranged in a circular manner as illustrated. Preferably, a single
robotic-arm assembly 200 then operates vacuum-head assembly 202
utilizing pick-up heads 202a, 202b, 202c and 202d to remove the
discs 72 from the disc stack 210 and placing the discs 72 onto each
respective support surfaces 30a, 30b, 30c, and 30d of the station
192. Preferably, as described above, sequencing "E" through "G"
preferably takes place. Preferably, during sequence "H", first
station 192 utilizes a heavier abrasive 90, preferably 60 micron
grit diamond abrasive. Preferably, the robotic-arm assembly 200 then
moves to a position to have vacuum-head assembly 202 utilize pick-up
heads 202a, 202b, 202c and 202d to remove the discs 72 from first
station 192 support surfaces 30a, 30b, 30c, and 30d and transferring
them to second station 194 support surfaces 30a, 30b, 30c, and 30d.
Preferably, the sequencing described above for station 192 is
repeated in station 194 except that abrasive 90 is preferably
reduced to 30 micron grit. Preferably, upon completion of the
sequencing at station 194, robotic-arm assembly 200 then operates
vacuum-head assembly 202 picking up the discs 72 from the second
station 194 support surfaces 30a, 30b, 30c, and 30d and transferring
them to third station 196 support surfaces 30a 30b, 30c, and 30d.
Preferably, the sequencing described above for station 194 is
repeated in station 196 except that abrasive 90 is preferably
reduced to 15 micron grit. Preferably, upon completion of the
sequencing at station 196, robotic-arm assembly 200 then operates
vacuum-head assembly 202 picking up the discs 72 from the third
station 196 support surfaces 30a, 30b, 30c, and 30d and transferring
them to fourth station 198 support surfaces 30a, 30b, 30c, and 30d.
Preferably, the sequencing described above for station 196 is
repeated in station 198 except that abrasive 90 is preferably
reduced to 6 micron grit. Preferably, upon completion of the
sequencing at station 198, robotic-arm assembly 200 then operates
vacuum-head assembly 202 picking up the discs 72 from the fourth
station 198 support surfaces 30a, 30b, 30c, and 30d and transferring
them to a temporary stack 204 which comprises four similar support
surfaces 204a, 204b, 204c, and 204d. Preferably, the discs 72 are
checked for scratches by a laser photo-check device 208 (see FIG.
11). Preferably, rejected discs 72 are placed in a rejected stack
206.
Preferably, after the discs 72 have been removed from the fourth
station 198 support surfaces 30a, 30b, 30c, and 30d, and the "line"
is operating, the robotic-arm assembly 200 then generally preferably
operates vacuum-head assembly 202 picking up the discs 72 from the
third station 196 and placing them on the fourth station 198; then
picking up the discs 72 from the second station 194 and placing them
on the third station 196; then picking up the discs 72 from the
first station 192 and placing them on the second station 194; and
finally picking up the discs 72 from the stack 210 and placing them
on the first station 192. This sequencing of operation may be
preferably altered depending on how long an operation at each
station takes, how many arms are used, etc.
Preferably, the entire operation of the automatic disc repair system
190 is controlled by a single master program. Those knowledgeable in
the art are familiar with such control systems and under appropriate
circumstances other combinations of control systems may also
suffice.
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 and
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.
* * * * *
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