ORIENTED POLYESTER FILM

Abstract: An oriented polyester film has at least one surface rough­ ened by containing inactive particles and three-dimensional surface roughness exponents of the said roughened surface are within ranges simultaneously satisfying the following re­ lationships (I) to (III), while the number of coarse projections is in excess of the fourth grade: 0.014 ≦ SΔa ≦ 0.025 (I) 5.2 ≦ Sλa ≦ 13.0 (II) 0.012 ≦ SRa ≦ 0.050 (III) where SΔa represents three-dimensional average gradient, Sλa represents the spatial average wavelength (µm) of three-­ dimensional surface roughness and SRa represents three-­ dimensional central plane average roughness (µm).

Description: Field of the Invention The present invention relates to an oriented polyester film. More particularly, it relates to an oriented polyester film, that can be applied to a base film for use in a magnetic recording medium, and which has excellent slipperiness and endurable travelling performance. Background of the Invention In general, polyester films such as those of polyethylene terephthalate have excellent physical and chemical characteristics and are used as films for magnetic tapes, floppy disc, photographic films, films for condensers, packaging films, Roentgen films and microfilms, and also as films for fibre and moulded substances. The slip properties and abrasion resistance of such polyester films are critical to the film production and to the quality of the produced films. Particularly when a polyester film is roller-coated on its surface with a magnetic layer to be applied to a magnetic tape, there are considerable friction and abrasion between the film surface and the roller, resulting in wrinkles and scratches on the film surface. After the polyester film, coated with the magnetic layer, is slit, to be worked into an audio tape, video tape or a computer tape, there are considerable friction and abrasion between the tape and a guide portion, a reproduction head or the like when the tape is taken up from a reel or cassette or wound around the same, leading to scratches and distortion of the tape. Further, white pulverulent material is deposited as the result of scraping of the polyester film surface, causing lack of magnetic recording signals, i.e. drop-out. Coarse projections caused by agglomeration of added particles imperfectly dispersed in the polyester film, and the large size of the particles, also lead to disadvantages such as drop-out. In order to improve slipperiness and endurable travelling performance of such a film, the film surface is generally made irregular, in order to decrease the contact area between the film and a guide roll or the like. Such surface irregularity is generally formed by, for example, depositing insoluble particles from the catalyst residue in a polymer employed as the material for the film, as disclosed in US-A-4067855, or by adding inactive inorganic or organic particles, as disclosed in US-A-3980611. In general, as the particles in the polymeric material are increased in size, the slipperiness of the film is improved, but disadvantages occur, such as drop-out in precision use such as the application to a magnetic tape, and significant deterioration of electromagnetic transformation characteristics. Thus, the irregularity of the film surface must be precisely adjusted as to, inter alia, configuration, density and height. The size distribution of the particles has been generally comprehended only in terms of the average particle size, and not in terms of size distribution and configuration. It has therefore been difficult to obtain a desired film surface configuration DE-A-3034241 discloses an oriented polyester film carrying inactive inorganic particles that are lithium, calcium or phosphorus compounds. Summary of the Invention An oriented polyester film according to the present invention is defined in claim 1. A film of the invention is suitable for application as the base film for a magnetic tape. The oriented polyester film has improved dispersibility of added particles, low friction and good endurance, while the number of coarse projections is low. Detailed Description of the Invention The polyester employed in the present invention is preferably a crystalline polyester such as a polyalkylene naphthalate or, most preferably, polyethylene terephthalate, especially one comprising not less than 80 mol% of ethylene terephthalate as the repeating unit. Other copolymer components can be arbitrarily selected from dicarboxylic acid components such as isophthalic acid, p(β-oxyethoxy)benzoic acid, 2,6-naphthalenedicarboxylic acid, 4,4'-biphenyldicarboxylic acid, 4,4'-benzophenonedicarboxylic acid, bis(4-carboxylphenyl)ethane, adipic acid, sebacic acid, 5-sodium sulfoisophthalic acid and 1,4-cyclohexanedicarboxylic acid, glycol components such as propylene glycol, butanediol, neopentyl glycol, diethylene glycol, cyclohexanedimethanol, ethylene oxide adducts of bisphenol A, polyethylene glycol, polypropylene glycol and polytetramethylene glycol, and hydroxycarboxylic acid components such as p-hydroxybenzoic acid. A compound containing a small amount of an amide, urethane, ether or carbonate linkage may also be present as a copolymer component. The polyester can be prepared by any suitable method, such as the so-called direct polymerisation method in which an aromatic dicarboxylic acid is reacted with glycol, or the so-called ester interchange method in which an aromatic dicarboxylic acid dimethyl ether and glycol are subjected to transesterification. The film may be formed either as an uniaxial or, preferably, a biaxial film. One criterion of a film of the invention is the value of 2π.SRa/Sλa. This will be described herein as the three-dimensional average gradient (SΔa), which must be 0.014 to 0.025, preferably 0.015 to 0.025, and more preferably 0.016 to 0.025. The spatial average wavelength (Sλa), which forms another three-dimensional surface roughness exponent, must be 5.2 to 13.0, preferably 5.2 to 11.0, and more preferably 5.2 to 9.0. The three-dimensional central plane average roughness (SRa) must be 0.012 to 0.050, preferably 0.015 to 0.035. If SΔa is less than 0.14, Sλa is more than 13.0, or SRa is less than 0.012, slipperiness and endurable travelling performance cannot be sufficiently improved. Further, if SRa is in excess of 0.050, the number of coarse projections is increased. In our view, it is extremely difficult to form abrupt film surface projections when SΔa exceeds 0.024, or to form film surface projections whose spatial average wavelength (Sλa) is less than 5.2. Therefore, these respective upper and lower limits have no critical meaning. The polymer for a polyester film according to the present invention is preferably obtained by the following procedure: Particle size distribution of inactive particles employed in the present invention preferably simultaneously satisfies the following relationships: 0.2 ≦ D₅₀/D₅ ≦ 0.6 (VII) 150 ≦ D₅₀ x C ≦ 10000 (VIII) wherein D₅ and D₅₀ represent the inert particle size (µm) when the cumulative weight is respectively 5% and 50% of the total weight, and C represents the content (ppm) of the inert particles in the film. It is obvious that the particle size distribution width is decreased as the particle size distribution ratio (D₅₀/D₅) is increased. The particle size distribution ratio (D₅₀/D₅) is preferably 0.2 to 0.6, more preferably 0.23 to 0.6, and most preferably 0.26 to 0.6. In our view, it is impractical or extremely difficult to obtain particle size distribution at a particle size distribution ration (D₅₀/D₅) exceeding 0.6. Therefore, this upper limit has no critical meaning. Slipperiness and endurable travelling performance are insufficient when D₅₀ is small, in the case that D₅₀/D₅ is less than 0.2, while the number of coarse projections is increased in number, to cause disadvantages such as drop-out, when D₅ is large. When the particle size distribution is at 5% integration (by which is meant the cumulative weight as a percentage of the total weight), the particle size (D₅) is preferably 1 to 6 µm, more preferably 1.2 to 5.5 µm, and most preferably 1.4 to 5 µm. When D₅ is less than 1 µm, slipperiness and endurable travelling performance cannot be sufficiently improved. When D₅ is in excess of 6, the number of coarse projections is increased, to cause disadvantages such as drop-out. The content C (ppm) of the inactive particles is preferably determined in combination with the average particle size D₅₀ (µm), such that the product of C and D₅₀ is 150 to 10000, more preferably 250 to 8000, and most preferably 500 to 6000. When the said product is less than 150, slipperiness and endurable travelling performance cannot be sufficiently improved. When the said product is in excess of 10000 to the contrary, the coarse projections are increased in number. The inactive inorganic or organic particles employed in the present invention are not particularly restricted so far as the same satisfy the aforementioned equations (VII) and (VIII), but preferably prepared by calcium carbonate, silica, barium sulfate or titanium oxide, and most preferably by calcium carbonate. Components of such inactive particles are not restricted in preparation method etc. so far as the same satisfy the conditions defined above, with respect to both of natural and synthetic substances. For example, calcium carbonate may be prepared by heavy calcium carbonate, precipitated calcium carbonate or colloidal calcium carbonate. The inactive particles may be of a single kind or of two or more kinds, in order to improve the film winding characteristic. While the crystal form of the particles is not particularly restricted, the volume shape factor thereof is preferably within a range of 0.08 to π/6. The volume shape factor f is expressed as follows: f = V/D³ where V represents the particle volume (µm³) and D represents the maximum particle size (µm) in the plane of projection. The volume shape factor expresses the degree of massiveness of the particles, which are more massive or made spherical as the volume shape factor thereof approaches π/6. The term "average particle size" in this specification is intended to mean the particle size of equivalent spherical particle size distribution as calculated according to the Stokes' formula at 50 % integration. The inactive particles may be added to the polyester film according to the present invention in any arbitrary stage of the steps of producing the polyester film, while the same are preferably added before initial condensation is completed. Further, the inactive particles may be added to the polyester film in the form of slurry or powder, while the same are preferably dispersed in the form of slurry, particularly in the form of ethylene glycol (EG) slurry, in order to prevent scattering of the particles and to improve supply accuracy and homogeneity. In the case of the slurry form, dispersion must be uniformly performed in order to reproduce the original primary particles as much as possible. Further, processing such as grinding, classification or filtration of commercially available particulates may be employed to obtain particles of prescribed average size. The inactive particles are preferably added to the polyester film in the form of differentially scattered slurry coexisting with alkaline metallic salt of phosphoric acid and/or phosphorous acid. Examples of alkaline metallic salt of phosphoric acid and/or phosphorous acid are sodium salt, potassium salt and the like of orthophosphoric acid, pyrophosphoric acid, polymetaphosphoric acid, polyphosphoric acid, orthophosphorous acid, pyrophosphorous acid, polyphosphorous acid and polymetaphosphorous acid such as sodium primary phosphate, potassium primary phosphate, sodium secondary phosphate, potassium secondary phosphate, sodium tertiary phosphate, potassium tertiary phosphate, sodium pyrophosphate, potassium pyrophosphate, sodium dihydrogenpyrophosphate, sodium hexametaphosphate, potassium hexametaphosphate, sodium tripolyphosphate, potassium tripolyphosphate, sodium phosphite, sodium pyrophosphite, potassium pyrophosphite, sodium metaphosphite and potassium metaphosphite. The said alkaline metallic salt may be employed as a single substance or in combination of two or more substances. The content of the alkaline metallic salt is preferably 0.04 to 20 wt. % in terms of alkaline metal amount with respect to the inactive particles in the slurry as well as 3 to 50 ppm in terms of alkaline metal amount with respect to the produced polyester. When the content of the alkaline metallic salt is less than the said range, agglomeration of the inactive particles cannot be sufficiently prevented in the steps of producing the polyester film. When the said content is in excess of the aforementioned range, agglomeration of the inactive particles in the steps of producing the polyester film is no more prevented while side reaction by the alkaline metallic salt is increased to exert bad influence such as increase in polymer coloring. The said alkaline metallic salt must be added to the polyester in coexistence with the slurry dispersed with the inactive particles. The inactive particles can be dispersed in the slurry by any method such as a rotation type high-speed stirring method, a high-pressure homogeneous dispersion method, ultrasonic dispersion method or combination thereof. A solvent for the slurry of the inactive particles is preferably prepared by a single substance of ethylene glycol (EG), while other solvent such as water or alcohol may be mixed so far as the content of the same is less than 50 wt. %. The aforementioned alkaline metallic salt of phosphoric or phosphorous acid may be added in any stage during the period from preparation of the slurry. The said slurry may be added in any arbitrary stage previous to completion of initial condensation. The initial condensation is completed when intrinsic viscosity approximately reaches 0.2, and thereafter the added components are heterogeneously mixed since viscosity of the system of reaction is too high, whereby a homogeneous product cannot be obtained. Further, olygomer is unfavorably depolymerized to reduce productivity and increase the amount of byproduct of diethylene glycol (DEG). When aromatic dicarboxylic acid and glycol are directly reacted through the so-called direct polymerization method while employing calcium carbonate as inactive particles, addition of the slurry previous to completion of esterification causes reaction between calcium carbonate and aromatic dicarboxylic acid, whereby insoluble calcium salt is produced in the polyester film. Since such product salt tends to be agglomerated to cause coarse particles, the said slurry is particularly preferably added in a period from completion of esterification to completion of initial condensation. When calcium carbonate is employed as the inactive particles, it is more preferable to add the calcium carbonate to the polyester polymerization system in the form of slurry dispersed in coexistence with alkaline metallic salt of phosphoric and/or phosphorous acid and to add phosphoric compound containing no metallic salt to the polyester polymerization system. The phosphoric compound can be prepared by any substance so far as the same contains no metal and is soluble to the reaction system. Examples of such compound are phosphoric acid, phosphorous acid, phosphonic acid and derivatives thereof, such as phosphoric acid, trimethyl phosphate, triethyl phosphate, tributyl phosphate, triphenyl phosphate, monomethyl phosphate, dimethyl phosphate, monobutyl phosphate, dibutyl phosphate, phosphorous acid, trimethyl phosphite, triethyl phosphite, tributyl phosphite, triphenyl phosphite, methylphosphonic acid, methylphosphonic acid dimethylester, ethylphosphonic acid dimethylester, phenylphosphonic acid dimethylester, phenylphosphonic acid diethylester and phenylphosphonic acid diphenylester. Particularly phosphoric acid, phosphorous acid and ester derivatives thereof are preferable. Such phosphoric compound may be employed as a single substance or in combination of two or more substances. The content of the phosphoric compound must be in a range of 0.01 to 50, preferably of 0.05 to 20 in mole ratio to calcium carbonate. When the said content is less than 0.01, agglomeration of calcium carbonate cannot be sufficiently prevented in the steps of producing the polyester film. When the content is in excess of 50, agglomeration of calcium carbonate is no more prevented in the steps of producing the polyester film, while a problem such as increase in the amount of byproduct of DEG is caused. The phosphoric compound may be added to the polyester film in any stage previous to completion of initial condensation. The phosphoric compound and the calcium carbonate slurry can be added in any order, while the phosphoric compound is preferably added simultaneously with or previous to the calcium carbonate slurry, in order to more remarkably obtain the effect of the present invention. In case of simultaneous addition, the phosphoric compound may be mixed with the calcium carbonate slurry or added from a supply port separate from that for the calcium carbonate slurry when the phosphoric compound is employed as ester, while the phosphoric compound is preferably not mixed with the calcium carbonate slurry when the phosphoric compound is employed as acid. In polymerisation of the polyester film according to the present invention, alkaline metal compound or alkaline earth metal compound may be added in order to improve electrostatic adhesion. When Mg compound or Ca compound is employed to improve electrostatic adhesion of the polyester film, the said phosphoric compound is preferably divided to be added to the polyester film twice or more times. The method of producing the polyester film according to the present invention is applicable to both of the so-called ester interchange method of making transesterification of dimethylester of aromatic dicarboxylic acid and glycol and the so-called direct polymerization method of directly reacting aromatic dicarboxylic acid with glycol. Further, the present invention can be applied to both of batch type and continuous system production procedures. In case of the ester interchange method, the catalyst for transesterification is not particularly restricted but may be prepared by any catalyst well known in the art. In case of the direct polymerization method, an inhibitor for DEG generation can be arbitrarily prepared by amine or quaternary ammonium salt. A catalyst for polycondensation is not particularly restricted, but preferably appropriately selected from Sb compound, Ge compound and Ti compound. Alkaline metal compound, alkaline earth metal compound, Co compound or Zr compound may be arbitrarily employed in order to improve electrostatic adhesion of the polyester film. EXAMPLE Description is now made on Examples of the present invention and reference examples. In the following description, parts are by weight unless otherwise indicated. Measurement was carried out in the following manner: (1) Average Particle Size Employed was the value at 50 % integration in equivalent spherical particle size distribution obtained by a centrifugation type apparatus for measuring particle size distribution (CP-50 by Shimazu Seisakusho). (2) Surface Flatness of Film Indicated was centerline average roughness (RA (µm)) measured through a Surfcom 300A type surface roughness tester by Tokyo Seimitsu under the conditions of 1 µm in needle diameter, 0.07 g in loaded weight, 0.8 mm in standard length of measurement and 0.08 mm in cut-off. (3) Endurable Travelling Performance Endurable travelling performance was evaluated by employing a tester as shown in Fig. 1. Referring to Fig. 1, an end of a polyester film 10 is connected to an end of a crank 1. The polyester film 10 is extended along free rolls 2, 4, 6 and 8 to be in contact with a guide pin 5 of a household VTR. A load 9 is connected to the other end of the polyester film 10. Tension detectors 3 and 7 are provided between the free rolls 2 and 4 and between the free rolls 6 and 8 respectively. The roughened surface of the polyester film 10 was brought into contact with the guide pin 5 (0.15 µm in maximum projection height and 0.008 µm in centerline average roughness measured by a tracer type surface roughness tester) at an angle of 3/4 π (unit: radian) under an atmosphere at 23°C with relative humidity of 65 % to be supplied with tension of 50 g of constant load, and the crank 1 of 40 mm in length was rotated at angular velocity of 8.0 r.p.m. to reciprocate the polyester film 10 by 100 times, to evaluate increments (Δµkd and Δµks) in coefficients of dynamic friction and static friction from initial values respectively in five grades on the following criteria: grade 1 not less than 0.15 2 0.10 to 0.15 3 0.05 to 0.10 4 0.02 to 0.05 5 less than 0.02 (4) Sliding Property of Film A film slit in small width was run in contact with a metallic drum at a high speed for a long time to evaluate the tape tension after passage through the drum and the amount of white powder produced at the surface of the drum in five grades on the following criteria: grade 1 large tension (many scratches) 2 slightly large tension (considerably many scratches) 3 moderate tension (small scratches) 4 small tension (substantially no scratch) 5 extremely small tension (no scratch) (5) Three-Dimensional Surface Roughness Exponents of Film Surface roughness of the film was measured by a tracer type three-dimensional surface roughness tester (SE-3AK by Kosaka Kenkyusho) under conditions of 2 µm in needle radius and 70 mg in load at the cut-off value of 0.25 mm along the longitudinal direction of the film over 1 mm in length of measurement, to fetch data in the vertical direction in quantization width of 0.00312 µm per 2 µm in an external memory. Such measurement was made along the lateral direction of the film continuously by 150 times at intervals of 2 µm, i.e., over film lateral width of 0.3 mm. SRa : A portion of an area S M was sampled from a roughness curved surface on its central plane to set the X axis and Y axis of the rectangular coordinate system on the central plane of the sampled portion while expressing an axis orthogonal to the central plane as the Z axis, thereby to express the following value in the unit of µm: where L X L Y = S M Sλa: A surface configuration of a sine function of y = Asinw₀x having length ℓ of measurement, spatial angular frequency w₀ and amplitude A is assumed to perform the following calculation: thereby to obtain spatial wavelength λ₀. It is assumed that the centerline of the measured surface roughness is expressed as the X axis by its function y = f(x) , to define that the spatial wavelength λa of a sine function satisfying the relationship: with respect to f(x) is the spatial average wavelength of the function f(x). Thus, the spatial average wavelength (Sλa) of the three-dimensional surface roughness is defined as follows: where SRa: three-dimensional central plane average roughness SΔa: three-dimensional average gradient SΔa : It is assumed that Δr represets change in average circle radius r in the area and the number of particles obtained by cutting respective cutting planes of surface configuration (by average plane standard) to obtain ΔZ/Δr in cutting planes of respective levels and to average the respective values as three-dimensional average gradient. (6) Number of Coarse Projections on Film Surface A thin aluminum layer was deposited on the film surface to count the number (per measured area of 1 mm²) of coarse projections larger than the quadruplex ring through a two-beam interference microscope, thereby to express the coarse projection numbers on the following criteria: grade 1 not less than 16/mm² 2 12 to 15/mm² 3 8 to 11/mm² 4 4 to 7/mm² 5 0 to 3/mm² Example 1 Employed was a reaction apparatus for continuous esterification comprising a two-stage complete mixing tank provided with a stirrer, a dephlegmeter, a material inlet port and a product outlet port to continuously supply terephthalic acid TPA-ethylene glycol EG slurry adjusted to be 1.7 in mole ratio of (EG) to (TPA) while containing antimony trioxide of 289 ppm in terms of antimony atom in the unit of TPA to a system of a first esterification reactor provided with esterification product. Simultaneously an EG solution of magnesium acetate tetrahydrate was continuously supplied from a supply port separate from that for the TPA-EG slurry at the rate of 100 ppm in terms of Mg atom in the unit of polyester in the reaction product passing through the reactor, to cause reaction under the normal pressure with a mean residence time of 4.5 hours at a temperature of 255°C. The reaction product was continuously taken out from the system to be supplied to a second esterification reactor. With respect to the unit of polyester in the reaction product passing through the second esterification reactor, continuously supplied from separate supply ports were 0.5 parts by weight of EG, an EG solution of trimethyl phosphate of 64 ppm in terms of P atom and EG slurry of calcium carbonate of particle size distribution ratio (D₅₀/D₅) of 0.35 and D₅ of 3.4 µm to which 100 g/ℓ of an aqueous solution of sodium tripolyphosphate was added to be 0.80 wt. % in terms of Na atom with respect to calcium carbonate in the slurry, which slurry containing sodium tripolyphosphate was 2500 ppm in terms of calcium carbonate, to cause reaction under the normal pressure with mean residence time of 5.0 hours at a temperature of 260°C. The esterification product was continuously supplied to a two-stage continuous polycondensation reaction apparatus provided with a stirrer, a dephlegmeter, a material inlet port and a product outlet port to carry out polycondensation, thereby to obtain polyester of 0.620 in intrinsic viscosity. Table 1 shows film characteristics of a film of 15 µm obtained by fusion-extruding the said polymer, drawing the same by 3.5 times at 90°C in the vertical direction and 3.5 times at 130°C in the lateral direction and subjecting the same to heat treatment at 220°C. It is obvious that the film obtained by this Example has an extremely small number of coarse projections, is excellent in slipperiness and endurable travelling performance and is remarkably of high quality. Reference Examples 1 and 2 Films were obtained in the same manner as Example 1 while changing particle size distribution D₅ of calcium carbonate to 2.0 µm and 6.5 µm and D₅₀/D₅ to 0.17 and 0.35. Table 1 also shows the film characteristics thereof. The films of these reference examples are of low quality, being inferior in slipperiness and endurable travelling performance and having large numbers of coarse projections. Reference Example 3 A film was obtained in the same manner as Example 1 while adding no aqueous solution of sodium tripolyphosphate to the calcium carbonate slurry. Table 1 also shows the film characteristics thereof. It is obvious that the film of this reference example is excellent in slipperiness and endurable travelling performance, whereas the same has an extremely large number of coarse projections and is of low quality. Reference Example 4 A film was obtained in the same manner as Example 1 while adding no EG solution of trimethyl phosphate to the polymerization system. Table 1 also shows the film characteristics thereof. It is obvious that the film of this reference example is excellent in slipperiness and endurable travelling performance, whereas the same has an extremely large number of coarse projections and is of low quality. Reference Example 5 A film was obtained in the same manner as Example 1 while changing the content of calcium carbonate to 100 ppm. Table 1 also shows the film characteristics thereof. It is obvious that the film of this reference example has a small number of coarse projections, whereas the same is inferior in slipperiness and endurable travelling performance, and is of low quality. Reference Example 6 A film was obtained in the same manner as Example 1 while changing the content of calcium carbonate to 10000 ppm. Table 1 also shows the film characteristics thereof. It is obvious that the film of this reference example is excellent in slipperiness and endurable travelling performance, whereas the same has a large number of coarse projections and is of low quality. Further, the film of this reference example is inferior in surface flatness. Examples 2 to 4 Films were obtained in the same manner as Example 1 while replacing the aqueous solution of sodium tripolyphosphate to be added to calcium carbonate by various solutions of alkaline metallic salt of phosphoric acid. Table 1 also shows the film characteristics thereof. It is obvious that all of the films of these Examples have extremely small numbers of coarse projections, are excellent in slipperiness and endurable travelling performance and are remarkably of high quality. Example 5 A film was obtained in the same manner as Example 1 while changing the content of calcium carbonate to 1000 ppm and adding 2000 ppm of calcium carbonate having particle size distribution ratio (D₅₀/D₅) of 0.28 and D₅ of 1.9 µm. Table 1 also shows the film characteristics thereof. Reference Example 7 A film was obtained in the same manner as Example 1 while adding 1500 ppm of calcium carbonate having particle size distribution ratio (D₅₀/D₅) of 0.25, D₅ of 1.0 µm and volume shape factor of 0.07 and changing the content of Na tripolyphosphate with respect to polyester to 10 ppm. Table 1 also shows the film characteristics thereof. It is obvious that the film of this reference example has a small number of coarse projections, whereas the same is inferior in slipperiness and endurable travelling performance. Reference Example 8 A film was obtained in the same manner as Example 1 while employing 3500 ppm of kaoline having particle size distribution ratio (D₅₀/D₅) of 0.17, D₅ of 4.8 µm and volume shape factor of 0.05 in place of calcium carbonate and changing the content of Na tripolyphosphate with respect to polyester to 10 ppm and the content of trimethyl phosphate to 0.02 in mole ratio to kaoline. Table 1 also shows the film characteristics thereof. It is obvious that the film of this reference example is inferior in slipperiness and endurable travelling performance, has a large number of coarse projections, and is of low quality. Thus, it is obvious that the films obtained by the Examples of the present invention have extremely small numbers of coarse projections, are excellent in slipperiness and endurable travelling performance and are remarkably of high quality. Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.

Claims: An oriented polyester film having at least one surface roughened by the presence of less than 4 coarse projections per mm², measured upon deposition of a thin aluminium layer on the surface and counting the projections larger than the quadruplex ring through a two-beam interference microscope, resulting from inert particles in the film, in which the three-dimensional surface roughness is defined by: 0.014 ≦ 2π.SRa/Sλa ≦ 0.025 5.2 ≦ Sλa ≦ 13.0 and 0.012 ≦ SRa ≦ 0.050 wherein Sλa represents the spatial average wavelength (µm) of the three-dimensional surface roughness, when the surface roughness is considered as a sine curve and SRa represents the three-dimensional central plane average roughness (µm), calculated, with respect to a plane that is parallel to the film, the volume of the projections above the plane being equal to the volume of the troughs beneath the plane, as the volume (µm³) of the projections above the plane divided by the measuring area (µm²). A film according to claim 1, wherein 0.015 ≦ SRa ≦ 0.035. A film according to claim 1 or claim 2, wherein 0.016 ≦ 2π.SRa/Sλa ≦ 0.025 and 5.3 ≦ Sλa ≦ 10.0. A film according to any preceding claim, wherein 0.2 ≦ D₅₀/D₅ ≦ 0.6 and 150 ≦ D₅₀ x C ≦ 10000 wherein D₅ and D₅₀ represent the inert particle size (µm) when the cumulative weight is respectively 5% and 50% of the total weight, and C represents the content (ppm) of the inert particles in the film. A film according to any preceding claim, wherein 0.08 ≦ V/D³ ≦ π/6 wherein V represents the particle volume (µm³) and D represents the maximum particle size (µm) in the plane of projection. A film according to any preceding claim, wherein the inert particles are inorganic. A film according to claim 6, containing an alkali metal salt of phosphoric acid and/or phosphorous acid in addition to the inorganic particles. A film according to claim 7, which further comprises a phosphoric acid compound which is not a metal salt, and wherein the inorganic particles comprise calcium carbonate. A film according to claim 7 or claim 8, wherein the amount of the salt, calculated as the alkali metal, is 0,04 to 20 wt. % with respect to the inorganic particles, and 3 to 50 ppm with respect to the polyester. A film according to any preceding claim, which is biaxially-stretched. A magnetic recording tape comprising a film according to any preceding claim.

Inventors: KUZE, KATSUAKI, MAKIMURA, OSAMU, MATSUYAMA, YUJIRO, NISHINO, YASUHIRO
Applicants: NIPPON MAGPHANE KABUSHIKI KAISHA, TOYOBO CO., LTD.
Application year: 1987
Main classification: G11B5
IPC codes: B29D7, C08J5, B29C55, B29K67, G11B5, B29L7