MAGNETIC RECORDING DISC AND PROCESS FOR THE PRODUCTION THEREOF

Abstract: A magnetic recording disc is formed by forming a undercoating layer on a non magnetic flexible substrate with a thickness of 1.0 through 10 micronmeters and a surface roughness smaller than 0.035 micronmeters, said undercoat­ ing layer including electrical conductive powder, polyurethane resin and cross-linking agent, and at least one magnetic layer is formed on the undercoating layer, so as to enable to form recording tracks with a high density.

Description: TITLE OF THE INVENTION MAGNETIC RECORDING DISC AND PROCESS FOR THE PRODUCTION THEREOF FIELD OF THE INVENTION The present invention relates to a magnetic recording disc, and more particularly to a magnetic recording disc suitable for a high density recording disc and process for the production thereof. BACKGROUND OF THE INVENTION In order to accomplish recording with a high track density on a magnetic recording disc, in other words, to make the recording tracks narrow, it is necessary to use such a magnetic recording disc having an isotropic magnetic characteristic in circumferential direction of the magnetic recording disc with a good S/N ratio. However, it has been almost impossible for magnetic recording discs produced by any known processes to record with a high track density up to 200 recording tracks per inch of 3 inch diameter magnetic recording disc for example. In order to obtain a recording disc having a high S/N ratio and an isotropic magnetic characteristic in a circumferential direction, improvement is usually directed to the substrate layer or magnetic layer, since the magnetic recording disc is basically formed by these layers. As to the characteristic of the substrate, from the view point of providing a magnetic recording disc with an isotropic characteristic relative to the circumferental direction, it is preferred to use such a material that an isotropic characteristic is excluded so that the difference between the maximum and minimum values of the co-efficient of thermal expansion relative to the surface direction is lower than 8 x 10 6 C 1, In a case where the difference between the maximum and minimum values of the co-efficient of thermal expansion is greater than 8 x lO-boC-I the lsotropy of the magnetic recording disc is lowered, whereby a high track density can not be expected As to the characteristic of the magnetic layer, from the view point of improving S/N ratio, it is preferred to use such magnetic material having a high flux saturation Br and coercive force lic. However, in order to increase the output with an equal linear recording density, residual magnetic flux density Br must be great. In addition, it is also preferred to provide the magnetic layer above an undercoating layer. The present inventors experimentally prepared a magnetic recording disc by coating the magnetic layer above an undercoating layer. The magnetic recording disc formed as above showed a high output level but there occurred a great output fiuctuation and modulation noise. As the result of the study by the inventors about the problems described above, it has been found that the degree of the output fluctuation and the modulation noise depend on the characteristic of the undercoating layer rather than the characteristic of the substrate or magnetic layer. The undercoating layer is provided for the purposes of 1. increasing the bonding force between the substrate and the magnetic layer; 2. preventing undesired effects to the magnetic layer from small projections and recesses on the surface of the substrate, fish eye, oriyomer or filler; 3. decreasing surface electric resistance and optical permeability. To accomplish the items 1 and 2 it is sufficient to provide the undercoating layer made of resin material or mixture of a resin material and a cross-linking agent with a desired thickness. However, in order to accomplish the purpose of the item 3, it is necessary to mix electrical conductive powder into the undercoating layer and in this case there occurs the problem of the output fluctuation and modulation noise. According to the known process, the undercoating layer is formed by coating the coating material in which electric conductive powder is dispersed within resin solution then being dried under a high temperature for volatizing the solution. According to the conventional process of making the coating layer, it has been believes that the undercoating layer should be as thin as possible by the reason described below, In a mechanical coating process, stress caused by coating force occurs not only on the coating layer but on the undercoating layer. Therefore, the undercoating layer must resist against the stress. In a case where the undercoating layer is thicker than a predetermined value, the undercoating layer is deformed by the stress of the coating force due to flexibility of the undercoating layer. On the contrary, i order to form a thin undercoating layer, the coating material must have a low viscosity. Therefore, in the prior art, the coating material was prepared by solving the solid material having a relatively low density in a great amount of the solvent for lowering the viscosity of the coating material. In fact, in the Japanese Patent Publication (unexamined) of 150129/1973, it is described that the density of the resin solution including electric conductive powder for the undercoating layer is 1 through 10% so as to provide a thin undercoating layer. However, in a case where the undercoating layer is formed by such a coating material or iow viscosity shows various disadvantages described below; 1. It is very difficult to uniforr.ly disperse the primary grain of the electric conductive powder in the resin material, therefore, the powder is undesirably dispersed in the form of a relatively large secondary grain with unevenness, whereby there liLay occur voids in the coated layer formed by the coating material as ascribed above with conductive powder dispersed. 2. In a case where the density of the coating material is relatively low with a great amount of the solution, there tends to occur a large amount of voids due to vaporization of the solvent by dry in addition to the voids occurred by the reason or the above item 1, whereby the flatness of the surface of the magnetic recording disc is undesirably harmed. When the magnetic layer is coated on the undercoating layer having the voids, the magnetic material enters into the voids, thereby forming unevenness in either the thickness of the magnetic layer and the distribution density of the magnetic material caused by the voids which are distributed ununiformly in the undercoating layer, thereby resulting in an output fluctuation, 2. furthermore, the solvent contained ln the magnetic coating material is solved and entered in the undercoating layer partly because the voids enlarge the surface area of the undercoating layer, whereby the undercoating layer is partly solved and the resin material of the undercoating layer is entered in the magnetic layer, resulting in change of the component of the magnetic coating composition, and in turn causing the density of the magnetic material of the magnetic coating layer to be ununiform, and in turn resulting in increase of the moaulation noise. Through the analysis of the known magnetic recording disc as described above, the inventors have discovered the following fact that the main reason of the output fluctuation of the prior art magnetic recording disc is not caused by the thickness ol the undercoating layer but is caused by either the voids in the undercoating layer and the ununifcrm surface of the undercoating layer. Thus it has been discovered that a magnetic recording disc having a uniform flatness of the surface without the voids in the undercoating layer can effectively prevent the output fluctuation and modulation noise. It has been further discovered by the present inventors that the greater the thickness of the undercoating layer, the greater the rate of the increment or the residual magnetic flux density Br, thereby resulting in increment of the output. In addition, the greater the thickness of the undercoating layer, the smaller the effect of the unevenness, fish eye and the origomer filler of the surface of the substrate and the surface resistivity and optical permeability of the magnetic recording disc can be effectively decreased. SUMMARY OF THE INVENTION An essential object of the present invention is to provide a magnetic recording disc which is possible to form recording tracks with a high density. Another object of the present invention is to provide a magnetic recording disc having a high S/N ratio with a small fluctuation or the output and a low modulation noise. A further object of the present invention is to provide a magnetic recording disc having a isotropic magnetic characteristic in the circumferential direction. In one aspect of the magnetic recording disc according to the present invention, a flexible substrate of non magnetic material is coated by a undercoating layer of 1.0 through 10 micron meters with a surface roughness of lower than 0.035 micronmeters composed or electrically conductive powder and polyurethane resin including a cross-linking agent and the undercoating layer is coated with a magnetic layer having magnetic powder dispersed in bonding material The density o the solid composition of the coating material of the undercoating layer may be higher than 10 %, preferably than 20% and the thickness of the undercoating layer is 1.0 micronmeter through 10 micronmeters, preferably 1.0 through 3.0 microrsteters. The recording medium formed in the manner described above may be subjected to a calendering process so as to eliminate the voids in the undercoating layer for obtaining the surface roughness lower than 0.030 micronmeters. By employing the mixture of a polyurethane resin and a cross-linking agent as the resin material of the undercoating layer, it can be prevented that the undercoating material is solved and entered in the magnetic layer at the coating process of the magnetic layer. In the magnetic recording disc tormed by the methods as described above with the high output magnetic layers of the residual magnetic flux density Br higher than 900 gauss, a small output fluctuation and a low modulation noise with high S/N ratio can be accomplished. DESCRIPTION OF THE PREFERRED EMBODIMENT In one specific aspect of the magnetic recording disc according to the present invention, the material for the flexible substrate is not limited, various composition, for examples, such as polyethylene terephtharate; polyester group such as polyethylene-2 or 6-naphtharate; polyolefine group such as polyethylene or polypropylene; cellulose acetate such as cellulose triacetate, cellulose diacetate, polyimide and/or polyamide can be used as the substrate. Preferably, the thickness of the substrate may be in a range of 10 through 100 micronmeters. As the electrical conductive material of the undercoating layer, carbon powder such as carbon black, graphite, carbonblack with graphite layer; metal or metallic alloy such as silver, cupper, tin, alminium, Zinc, chromium and/or titanium can be used by selecting at ieast one of them with a possible diameter of the grain. Preferably, carbon black, more particularly MOGUL L (having a grain diameter 24 mili micron, oil absorption 60 CC/100g, (DBP) surfadce area 138 m2 /g) sold by Cabot Corporation in U.S.A. is used. As polyurethane resin, polyether polyurethane bearing at its terminal, at least one of an isocyanate group and a hydroxyl group may be used. As the specific example of the polyurethane resin, TAKENATE M-407 sold Dy Takeda Chemical Industries Co., SPANDEX T-5250 or T-5201 sold by DAINIPPON INK AND CHEMICALS, INC. or DESMOFEN 1200 sold by Bayer Ltd.. may be used. As the specific examples oi the isocianate compounds for the cross-linking agent, DESNODUR L sold by Bayer Ltd. or CORONATE L sold by NIPPON POLYURETHANE CO. may be used. Preferably, the polyurethane resin and the magnetic powder are mixed by the ratio of 10:90 (by weight), more preferably 10:80 through 70:30 and turther more preferably 40:60 through 60:40. The resin material as described above and magnetic powder are mixed to provide coating material by a dispersing machine such as ball mill, sand mill or pebble mill with at least any one of the solvent such as toluene, xylene, MEK, MINK, cycrohexanon, aceton, THF, ethyl acetate, DMF. The coating material may be coated by a knife coater, gravure roll coater or reverse roll coater. A specific attention should be paid for the density of the coating material so that the solid component of the coating material should be in the range higher than 10%. After the coating material is coated on the substrate for making the undercoating layer, the calendering process may be performed on the undercoating layer if necessary. As to the magnetic layer to be formed on the undercoating layer thus formed, the shape of the magnetic powder may be acicular or grain metallic iron powder, metallic cobalt powder; other alloy powder; Y r-E'e,03 powder, Foe304 powder or intermediate oxide or cobalt doped magnetic particle thereof may be used. In particular the cobalt doped magnetic oxided iron particle is preferred. In addition, the magnetic powder having a saturation magnetization 6 of greater than 60 emu/g with a coercive force Sc of greater than 200 Oe is preferably used. Specific examples of the binder to bind the magnetic powder to the substrate are a polyvinyl chloride resin, a polyvinyl acetate resin, a copolymer of vinyl chloride and vinyl acetate, a copolymer of vinyl chloride, vinyl acetate and vinyl alcohol, a polyurethane resin, a cellulose type resin, a polyester resin ana its sulfonate, a copolymer of vinylidene chloride and acrylonitrile, a copolymer of acrylonitrile and butadiene, an isoprene rubber, a butadiene rubber and their mixtures. The binder optionally contains a cross-linking agent (e.g. a isocyanate compound having a low molecular weight) and further a fatty acid, a fatty acid ester, a hydrocarbon type lubricant, fluorine-containing lubricant, a silicone type lubricant. In order to form the magnetic layer, the magnetic coating material is prepared using the magnetic powder as described above with the binder resin and suitable adding agent and the solvent as described with rererence to the material of the undercoating layer, then coated on the undercoating layer in a similar process. It is noted for producing the magnetic recording disc having a magnetic isotropic characteristic in the circumferential direction to make the magnetic orientation of the magnetic powder isotropic at the time of coating the magnetic layer on the undercoating layer. In a case where the magnetic recording discs are shaped by punching after the undercoating layer and magnetic layer are formed on the substrate, preferably, the process of magnetic orientation against the magnetic powder is omitted or the random orientation is performed at the time of punching. In a case where shaping into the disc form is performed by the punching process before the magnetic layer is coated on the undercoating layer, preferably the orientation process may be performed by so called spin coating method. A calendering process may be performed without causing any problem after coating and/or drying the magnetic layer. In a case where the magnetic layers are formed on both sides of the disc, preferably the undercoating layers are formed on both sides of the substrate first and in turn the both of the magnetic layers may be formed on the both undercoating layers simultaneously rather than finishing one side first then finishing another side for avoiding curling of the disc. In this case, it is most desired to perform the calendering process for each of the undercoating layers when the undercoating is finished. (EXAMPLE 1) Component of the coating material of the electrically conductive non magnetic material. MOGUL L ( carbon black manufactured by CABOT in the United State) 100 by weight VAGH (a copolymer of vinyl chloride, vinyl acetate and vinyl alcohor manufactured by U.C.C, in the United State) 27 by weight T 5250 (polyester polyurethane resin manufactured by DAINIPPON INK AND CHEMICALS, INC.) 27 by weight COLONATE L (tri-functional low molecular weight lsocianate compound manufactured by NIPPON POLYUXETHAGE ROGYO CO.) 3 by weight crohexanon 200 by weight toluene 200 by weight The above composition was mixed and dispersed in the ball mill and prepared the undercoating material, which was coated on both sides of a polyester film of thickness of 75 microraneters having the difference 6 x 10 6 4C between the maximum value and the minimum value of the co-efficient of thermal expansion in the surface direction of the magnetic recording disc, then dried and in turn the calendering process was performed so as to form both of the undercoating layers with the thickness of 2.0 micronmeters with a surface roughness of 0,020 micronmeters. The surface roughness was measured by the contact needle surface roughness meter made by TOKYO SEIMITSU CO. and the result was represented by C.L.A value (center line average) with the cut-off 0.08mm. The magnetic coating material described below was coated on the undercoating layer formed as describea above with the thickness of 1.0 micronmeter and dried, further the calendering process was performed, whereby the magnetic layers were formed and soaked for one minute in the solution co'issting of oleylorate 45 by weight, stearic acid 5 by weight and hexan 1000 by weight and subsequently the lubricant was impregnated and in turn the magnetic recording medium was punched to shape into the round magnetic recording disc. Component of the magnetic coating material Magnetic powder; &gamma;-Fe2O3 including Cobalt with the coercive force Hc of 650 Oe and 6s of 72emu/g 300 by weight VAGH (a copolymer of vinyl chloride, vinyl acetate and vinyl alcohor manufactured by U.C.C. in the United State) 57 by weight N1432J ( a copolymer cf acrylonitrile and butadiene manufactured by Nippon Zeon Co. Ltd.) 11 by weight COLONATE L (tri-functional low molecular weight isocianate compound manufactured by NIPPON POLYURETHANE KOGYO CO.) 7 by weight HS-500 (carbon black manufactured by ASAHI CARBON CO.) 34 by weight &alpha;-Fe2O3 powder 11 by weight methylisobutylketone 420 by weight toluene 420 by weight (EXAMPLE 2) Magnetic recording discs similar to the example 1 were prepared without calendering process at the time of making undercoatiny layer with the thickness of 4.0 micronmeters. The surface roughness was 0.030 micronmeters, (EXAI4PLE 3) Magnetic recording discs were prepared in the same manner as in the example 1 except for changing the difference of the maximum value and minimum value of the co-efficient of thermal expansion of the substrate in the surface direction of the disc to 16 x 10-6 0C -1 (EXAMPLE 4) Magnetic recording discs were prepared in the same manner as in the example 1 except tor changing the amount or the magnetic powder of > -Fe203 including cobalt to 270 by weight from 300 by weight, the amount of VAGH to 80 by weight from 57 by weight, the amount of N1432J to 15 by weight from 11 by weight and the amount of COLONATE L to 10 by weight from 7 by weight. (COMPARISON 1) In the magnetic recording disc of the example 2, the component of the electrically conductive non magnetic material of the coating material were changed as below. Carbon black (SC carbon manufactured by Colombia Chemical CO.) 10 by weight polyester resin (Pylon TS-9504 manufactured by TOYO BOSS'SKI CO.) 25 by weight Methylethylketon 200 by weight Cycrohexanon 100 by weight The thickness of the undercoating layer was 0.8 micronmeters and the surface roughness was 0.040 micron meters. (COMPARISON 2) Magnetic recording discs were prepared in the same manner as in the example 2 except for changing the thickness of the undercoating layer to 20.0 micron meters from 4.0 micronmeters. The surface roughness of the undercoating layer was 0.050 micronmeters. (COMPARISON 3) Magnetic recording discs were prepared in the same manner as in the example 1 except for changing the thickness or the undercoating layer to 20.Omicron meters from 2.0 micronmeters. The surface roughness ot the undercoating layer was 0.030 micronmeters. (COMPARISON 4) Magnetic recording discs were prepared in the same manner as in the comparison 1 except or changing the amount of the magnetic powder of -Fe2O3 including cobalt to 270 by weight from 300 by weight, the amount of VAGH to 80 by weight from 57 by weight, the amount of N1432 to 15 by weight from 11 by weight and the amount or COLONATE L to 10 by weight from 7 by weight. The magnetic characteristics of the examples and comparisons were measured under the magnetic field of 100e by magnetometer VSM-3 of sample vibration type made by TOEI KOGYO CO. Also the magnetic characteristic of the magnetic powder added in the magnetic coating material was measured in the similar way. The result of the measurement is shown in the TABLE 1. The magnetic recording discs of the examples 1 through 4 and comparisons 1 through 4 were tested in terms of the output value, modulation noise and output fluctuation under the the circumstance of temperature of 100C and 408 RH with the writing in frequency 125 KHz, rotation speed 300 r.p.m., the recording density 9KBPI and the track width 75 micronmeters using floppy disc characteristic measuring machine made by HITCH1 MAXELL CO. The output is represented by the following equation; A = (a + b)/2, wherein a is the average output value with reverence to the output wave toria including the maximum output for one round track length with the magnetic field reverseÅa by 2000 gauss and b is the average output value with reference to the output wave form including the minimum output for one round track length with the magnetic field reversed by 2000 gauss. The output fluctuation is calculated by the following equation; B = (a-b)/(a+b)xlOO %. The modulation noise is represented by the noise level at 120KHz. The magnetic recording discs to which the data were recorded were allowed to stand in the circumstance at 400C and 40% RH without additional recording, after the output, output fluctuation (referred to as OUTPUT FLUC. in TABLE 1) and modulation noise (MOD. NOISE) were stabilized, measurement was made. The result of the measurement is represented in the TABLE 1. As understood from the result of tile measurement, the magnetic recording disc according to the present invention shows a high output, with the output fluctuation and modulation noise can be effectively reduced. Also the high output value with low fiuctuation and modulation noise can be malntainea even if the circumstances in which the magnetic recording disc is placed is changed. It is noted that a magnetic recording disc which enables to form a high density recording track can be accomplished by only combination of a non maynetic substrate and a magnetic layer having a high S/N ratio. T A B L E 1 EMI20.1 <SEP> Br <SEP> Ha <SEP> 10 C <SEP> 40% <SEP> RH <SEP> 40 C <SEP> 40% <SEP> RH <tb> <SEP> (Gauss) <SEP> (Os) <SEP> OUTPUT <SEP> MOD. <SEP> OUTPUT <SEP> OUTPUT <SEP> MOD. <SEP> OUTPUT <tb> <SEP> NOISE <SEP> FLUC. <SEP> NOISE <SEP> FLUC. <tb> EX. <SEP> 1 <SEP> 1000 <SEP> 630 <SEP> (dB) <SEP> (dB) <SEP> (%) <SEP> (dB) <SEP> (dB) <SEP> (%) <tb> <SEP> +2.5 <SEP> -3.0 <SEP> 2.0 <SEP> +1.4 <SEP> -4.0 <SEP> 3.0 <tb> EX. <SEP> 2 <SEP> 1050 <SEP> 625 <SEP> +2.5 <SEP> -2.0 <SEP> 4.0 <SEP> +1.4 <SEP> -3.0 <SEP> 5.0 <tb> EX. <SEP> 3 <SEP> 1000 <SEP> 630 <SEP> +2.0 <SEP> -2.5 <SEP> 2.0 <SEP> -0.2 <SEP> -2.5 <SEP> 13.0 <tb> EX. <SEP> 4 <SEP> 850 <SEP> 645 <SEP> +0.2 <SEP> -2.5 <SEP> 2.0 <SEP> -0.9 <SEP> -2.5 <SEP> 3.0 <tb> COMP. <SEP> 1 <SEP> 950 <SEP> 635 <SEP> +1.8 <SEP> +2.0 <SEP> 9.0 <SEP> +0.7 <SEP> +1.1 <SEP> 10.0 <tb> COMP. <SEP> 2 <SEP> 1100 <SEP> 620 <SEP> +1.5 <SEP> +1.0 <SEP> 10.0 <SEP> +0.5 <SEP> +0.2 <SEP> 11.0 <tb> COMP. <SEP> 3 <SEP> 1100 <SEP> 620 <SEP> +1.8 <SEP> -0.2 <SEP> 9.0 <SEP> +0.7 <SEP> -1.1 <SEP> 10.0 <tb> COMP. <SEP> 4 <SEP> 800 <SEP> 650 <SEP> 0 <SEP> 0 <SEP> 9.0 <SEP> -1.1 <SEP> -0.3 <SEP> 1.00 <tb>

Claims: What is claimed is 1. A magnetic recording disc comprising a non magnetic flexible substrate, at least one undercoating layer formed on the one surface of the substrate with a thickness of 1.0 through 10 micronmeters and a surface roughness smaller than 0.035 micronmters, said undercoating layer including electrical conductive powder, polyurethane resin and cross-linking agent, and at least one magnetic layer formed on the undercoating layer, said magnetic layer including magnetic powder dispersed in binding agents. 2. The magnetic recording disc according to claim 1, wherein said electrical conductive powder is carbon black. 3. The magnetic recording disc according to claim 1, wherein said polyurethane resin is at least one selected from the group consisting of polyetherpolyurethane and polyesterpolyurethane and bears, at its terminal, at least one of an isocyanate group and a hydroxyl group. 4. The magnetic recording disc according to claim 1, said undercoating layer is composed of the polyurethane resin and electrical conductive powder mixed in a ratio of 10:90 through 90:10 (by weight). 5. The magnetic recording disc according to claim ', wherein said undercoating layer is composed or the polyurethane resin and electrical conductive powder mixed in a ratio of 10:80 through 70:30 (by weight). 6. The magnetic recording disc according to claim 1, wherein said undercoating layer is composed of the polyurethane resin and electrical conductive powder mixed in a ratio of 40:60 through 60:40 (by weight). 7. The magnetic recording disc according to claim 1, wherein said cross-linking agent includes a isocyanate compound having a low molecular weight. 8. The magnetic recording disc according to claim 1, wherein the thickness of the undercoating layer is 1.0 through 3.0 micronmeters. 9. The magnetic recording disc according to claim I, wherein the surface roughness of the undercoating layer is smaller than O.Q30 micronmeters. 10. The magnetic recording disc according to claim l, wherein said magnetic powder has a saturation magnetization 6s higher than 65 emu and coercive force Hc higher than 200 Oe. 11. The magnetic recording disc according to claim 1, wherein said magnetic powder is cobalt doped oxide iron powder. 12. The magnetic recording disc according to claim 1, wherein said non magnetic flexible substrate has a difference of the maximum value and minimum value of the co-efficient of thermal expansion lower than 8 x 10 1 13. The magnetic recording disc according to claim 1, wherein said undercoating layer and magnetic layer are formed on the both sides of the substrate. 14. A process of making a magnetic recording disc comprising a step for dispersisig a magnetic powder, a polyurethane resin and a cross-linking agent in an organic solvent tor preparing undercoating layer material, a step of coating the undercoating material on a non magnetic flexible substrate for forming a undercoating layer, a step of forming a magnetic layer, thereby preparing magnetic recording medium, and step for forming a magnetic recording disc by punching the magnetic recording medium, characterized in that the total amount of the electrical powder, polyurethane resin and cross-linking agent by weight is higher than 10% of another total amount of sum or the said total amount and the organic solvent. 15, The process of making a magnetic recording disc according to claim 14 characterized by further comprising a calendering process effected on the undercoating layer. 16. The process of making a magnetic recording disc according to claim 14, said undercoating layer is formed in a range 1.0 through 10 micronmeters under an aiLbient temperature when dried.

Inventors: FUNAHASHI, MASAYA, INOUE, KENICHI, MIYAKE, AKIRA C/O HITACHI MAXELL LTD., MIYATA, TERUHISA C/O HITACHI MAXELL LTD.
Applicants: HITACHI MAXELL LTD.
Application year: 1985
Main classification: G11B5
IPC codes: C09D175, G11B5, C09D5