Stacked film optical data storage device and method of manufacture

A method of manufacture comprising:

• providing a plurality of thin functional film extrusions;
• providing a plurality of thin spacer film extrusions;
• transporting the plurality of thin functional film extrusions and the plurality of thin spacer film extrusions, via a roll-to-roll system;
• aligning the plurality of thin functional film extrusions with the plurality of thin spacer film extrusions, wherein a first thin spacer film extrusion has a first thickness and a second thin spacer film extrusion has a second thickness, wherein the first thickness is different than the second thickness;
• and
• adhering the plurality of thin spacer film extrusions and the plurality of thin functional film extrusions together, thereby forming a stacked film structure, the stacked film structure defined by a thin space film extrusion located between two thin functional film extrusions.

A method of manufacture comprising:

• providing a thin spacer film, via a roll-to-roll system;
• applying a functional film coating to the thin spacer film;
• curing the thin space film and the functional film thereby creating a functional film and thin spacer film pair, wherein a first thin spacer film has a first thickness and a second thin spacer film has a second thickness, wherein the first thickness is different than the second thickness;
• transporting a plurality of functional film and thin spacer film pairs, via a roll-to-roll system;
• aligning the plurality of functional film and thin spacer film pairs;
• and
• thermally adhering the plurality of functional film and thin spacer film pairs together, thereby forming a stacked film structure.

A data storage device comprising:

• a substrate layer comprising a moldable non-photopolymer plastic substrate and a servo layer therein;
• and
• a stacked film structure adjoining the substrate layer, the stacked film structure further comprising:
• a plurality of functional films, wherein each functional film includes a data layer;
• and
• at least one spacer film disposed between the plurality of functional films, the at least one spacer film comprises a plurality of spacer films each disposed between two of the plurality of functional films.

A data storage device data storage device comprising:

• a substrate layer comprising a moldable non-photopolymer plastic substrate and a servo layer therein;
• and
• a stacked film structure adjoining the substrate layer, the stacked film structure further comprising:
• a plurality of functional films, wherein each functional film includes a data layer, further wherein a first functional film is comprised of a first material and a second functional film is comprised of a second material, wherein the first material is sensitive to a different wavelength than the second material, further comprising a third functional film comprised of a third material, wherein the third material is sensitive to a different wavelength than the first material and the second material;
• and
• at least one spacer film disposed between the plurality of functional films.

A method of manufacture comprising:

• providing a thin spacer film, via a roll-to-roll system;
• applying a functional film coating to the thin spacer film;
• curing the thin space film and the functional film thereby creating a functional film and thin spacer film pair;
• transporting a plurality of functional film and thin spacer film pairs, via a roll-to-roll system;
• aligning the plurality of functional film and thin spacer film pairs;
• thermally adhering the plurality of functional film and thin spacer film pairs together, thereby forming a stacked film structure;
• bonding the stacked film structure to at least one substrate layer, thereby defining a data storage device;
• cutting the data storage device to a predefined size and shape, thereby defining a data storage disc;
• and
• applying a coating on one of a front surface and a back surface of the data storage disc, the coating comprising one of a barrier coating, an anti-reflection coating, and an anti-scratch coating.