| |
| United States Patent
|
6,942,552 |
| Lalli , et al. |
September 13, 2005
|
Disc repair system
Abstract
A disc repair system 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, etc., 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 system utilizes diamond grit as an abrading compound to
recondition the disc surface.
| Inventors: |
Lalli; Edward A.
(Glendale, AZ), Doherty; William M. (Phoenix, AZ),
Doherty, Jr.; John L. (Glendale, AZ) |
| Appl. No.:
|
10/666,890 |
| Filed: |
September 18, 2003 |
Related U.S. Patent Documents
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Application Number |
Filing Date |
Patent Number |
Issue Date |
|
766802 |
Jan., 2001 |
6638149 |
|
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| 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: |
451/57,59,63,28,37,41 |
References Cited
[Referenced By]
U.S. Patent
Documents
Primary Examiner: Nguyen; Dung Van
Attorney, Agent or Firm:
Stoneman Law Offices, Ltd. Stoneman; Martin L. Erlick;
Benjamin K.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of application
Ser. No. 09/766,802, filed Jan. 22, 2001, now U.S. Pat. No.
6,638,149, entitled "Disc Repair System" which is not admitted to be
prior art with respect to the present invention by mention in this
cross-reference section.
Claims
What is claimed is:
1. A consumer kit for reconditioning a scratched operating surface
of at least one optically-read disc, comprising, in combination: a)
at least one optically-read-disc holder adapted to hold the at least
one optically-read disc in a substantially stationary position with
the optically-read surface exposed and facing upwardly; b) at least
one abrasive product adapted to abrade the operating surface when
rotatably rubbed on the operating surface; and c) at least one
hand-held rotary power tool comprising i) a powered rotary spindle
structured and arranged to removably hold the at least one abrasive
product; and d) wherein said at least one abrasive product comprises
diamond grit abrasive.
2. The consumer kit according to claim 1 wherein said at least one
abrasive product comprises diamond grit abrasive ranging from about
60 micron diamond grit to about 6 micron diamond grit.
3. A system for reconditioning at least one scratched operating
surface of at least one optically-read disc, comprising, in
combination: a) at least one holding means for holding the at least
one optically-read disc; b) at least one abrasive means for abrading
the at least one scratched operating surface of the at least one
optically-read disc; c) wherein said at least one abrasive means
comprises at least one diamond abrasive of at least one grit size.
4. A system for reconditioning at least one scratched operating
surface of at least one optically-read disc, comprising, in
combination: a) at least one holder structured and arranged to hold
the at least one optically-read disc; b) at least one abrader
structured and arranged to abrade the at least one scratched
operating surface of the at least one optically-read disc; c)
wherein said at least one abrader comprises at least one diamond
abrasive of at least one grit size.
5. A system for reconditioning at least one scratched operating
surface of at least one optically-read disc, comprising in
combination: a) an optically-read-disc holder structured and
arranged to hold the at least one optically-read disc in a desired
position; b) a set of diamond abrasive products structured and
arranged to abrade the at least one scratched operating surface when
rubbed on the at least one scratched operating surface.
6. The system according to claim 5, wherein said set of diamond
abrasive products comprises abrasive particles at least 6 microns in
size.
7. The system according to claim 5, wherein said set of diamond
abrasive products comprises a progressively finer abrasive particle
series in a range between about 60 microns to about 6 microns.
8. The system according to claim 5, wherein said set of diamond
abrasive products further comprises: a) 60 micron diamond grit; b)
30 micron diamond grit; c) 15 micron diamond grit; and d) 6 micron
diamond grit.
9. A method for reconditioning at least one scratched operating
surface of at least one optically-read disc, comprising, in
combination, the steps of: a) placing the at least one
optically-read disc on the at least one holding means, with the
scratched operating surface exposed; b) providing a set of diamond
abrasive products structured and arranged to remove material from
said scratched operating surface when rubbed on said scratched
operating surface.
10. The method according to claim 9, wherein said set of diamond
abrasive products comprises abrasive particles at least 6 microns in
size.
11. The method according to claim 9, wherein said set of diamond
abrasive products comprises a progressively finer abrasive particle
series in a range between about 60 microns to about 6 microns.
12. The method according to claim 9, wherein said set of diamond
abrasive products further comprises: a) 60 micron diamond grit; b)
30 micron diamond grit; c) 15 micron diamond grit; and d) 6 micron
diamond grit.
Description
BACKGROUND
This invention relates to a system for repairing scratches on
optically-read discs, such as, for example, compact discs, digital
video discs, etc. (often called "CD's" and "DVDs" respectively).
More specifically, this invention provides a more efficient system
for refurbishing the compact disc surface such that an optical
reader, which, for example, may use 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.
In the past, repair systems using diatomaceous earth and/or alumina
oxides and/or silica oxides as abrasives have been contemplated for
removing scratches from compact discs. However, these abrasives
quickly degrade and lose effectiveness. Further abrasives such as
diatomaceous earth, alumina oxides, and silica oxides do not provide
a highly uniform particle size, which is desirable in abrading
optical discs to remove scratches.
OBJECTS AND FEATURES 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
which repairs scratches in optically read discs so that the digital
information may be read by an optical reader. In addition, it is a
primary object and feature of this invention to provide such a
system which utilizes diamond grit as an abrasive, to provide
consistent abrasive particle size for more effective scratch
removal.
A further primary object and feature of the present invention is to
provide such a system that is efficient, inexpensive, and handy.
Other objects and features of this invention will become apparent
with reference to the following 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. In accordance with a
preferred embodiment hereof, this invention provides a consumer kit
for reconditioning a scratched operating surface of at least one
optically-read disc, comprising, in combination: at least one
optically-read-disc holder adapted to hold the at least one
optically-read disc in a substantially stationary position with the
optically-read surface exposed and facing upwardly; at least one
abrasive product adapted to abrade the operating surface when
rotatably rubbed on the operating surface; and at least one
hand-held rotary power tool comprising a powered rotary spindle
structured and arranged to removably hold the at least one abrasive
product; and wherein such at least one abrasive product comprises
diamond grit abrasive. Moreover, it provides such a consumer kit
wherein such at least one abrasive product comprises diamond grit
abrasive ranging from about 60 micron diamond grit to about 6 micron
diamond grit.
In accordance with another preferred embodiment hereof, 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 holding means for holding
the at least one optically-read disc; at least one abrasive means
for abrading the at least one scratched operating surface of the at
least one optically-read disc; wherein such at least one abrasive
means comprises at least one diamond abrasive of at least one grit
size.
In accordance with another preferred embodiment hereof, 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 holder structured and
arranged to hold the at least one optically-read disc; at least one
abrader structured and arranged to abrade the at least one scratched
operating surface of the at least one optically-read disc; wherein
such at least one abrader comprises at least one diamond abrasive of
at least one grit size.
In accordance with another preferred embodiment hereof, this
invention provides a system for reconditioning at least one
scratched operating surface of at least one optically-read disc,
comprising in combination: an optically-read-disc holder structured
and arranged to hold the at least one optically-read disc in a
desired position; a set of diamond abrasive products structured and
arranged to abrade the at least one scratched operating surface when
rubbed on the at least one scratched operating surface.
Additionally, it provides such a system, wherein such set of diamond
abrasive products comprises abrasive particles at least 6 microns in
size. Also, it provides such a system, wherein such set of diamond
abrasive products comprises a progressively finer abrasive particle
series in a range between about 60 microns to about 6 microns. In
addition, it provides such a system, wherein such set of diamond
abrasive products further comprises: 60 micron diamond grit; 30
micron diamond grit; 15 micron diamond grit; and 6 micron diamond
grit.
In accordance with another preferred embodiment hereof, this
invention provides a method for reconditioning at least one
scratched operating surface of at least one optically-read disc,
comprising, in combination, the steps of: placing the at least one
optically-read disc on the at least one holding means, with the
scratched operating surface exposed; providing a set of diamond
abrasive products structured and arranged to remove material from
such scratched operating surface when rubbed on such scratched
operating surface. And, it provides such a method, wherein such set
of diamond abrasive products comprises abrasive particles at least 6
microns in size. Further, it provides such a system, wherein such
set of diamond abrasive products comprises a progressively finer
abrasive particle series in a range between about 60 microns to
about 6 microns. Even further, it provides such a system, wherein
such set of diamond abrasive products further comprises: 60 micron
diamond grit; 30 micron diamond grit; 15 micron diamond grit; and 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 THE BEST MODE AND PREFERRED EMBODIMENTS 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 X
101/2 inches long X 21/2 inches high. The body 22 and cover 24 are
preferably metal. Upon reading the teachings of this specification,
those with ordinary skill in the art will now understand that, under
appropriate circumstances, considering issues such as manufacturing
cost, market demand, etc., other materials, shapes and size
arrangements may suffice, such as, for example, using plastic and/or
another material instead or in addition to metal, smaller or larger
dimensions, different shapes such as a round box, oval box, etc.
Preferably, 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).
Preferably, 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). Upon reading the teachings of this specification, those with
ordinary skill in the art will now understand that, under
appropriate circumstances, considering issues such as manufacturing
cost, market demand, etc., other arrangements may suffice, such as,
for example, holding insert may be made from a variety of other
materials (e.g. non-foamed plastic), or formed in other ways, etc.
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. Upon reading the teachings of
this specification, those with ordinary skill in the art will now
understand that, under appropriate circumstances, considering issues
such as manufacturing cost, intended use, optical disc material,
etc., other polishing compound arrangements may suffice, such as,
for example, alternate polishing compounds, etc. A container 40 of
buffing compound (e.g., buffing compound #1 from Springer Ind., 930
W. Birchwood, Mesa, Ariz.) preferably fits into space 41. Upon
reading the teachings of this specification, those with ordinary
skill in the art will now understand that, under appropriate
circumstances, considering issues such as manufacturing cost,
intended use, optical disc material, etc., other buffing compound
arrangements may suffice, such as, for example, alternate buffing
compounds, etc. 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 unshaped 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. For abrasives such as diatomaceous earth, alumina oxides
and silica oxides variance and inconsistencies in grit particle size
typically result from the manufacturing processes and from
properties inherent to the material composition. Further, such grit
particles wear down and break into smaller pieces over time.
Preferably, diamond grit particles are synthetically manufactured,
which allow for highly consistent grit particle sizes that more
effectively abrade discs for optical reading. 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.sup.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.
* * * * *
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