Acicular magnetic iron based alloy particles for magnetic recording and method of producing the same

Abstract: Acicular magnetic iron based alloy particles for use in magnetic recording media contain in the vicinity of the surfaces of said particles from 1.5 to 10 mol% of B (calculated as B) based on the amount of Fe and from 1.5 to 10 mol% of Co (calculated as Co) based on the amount of Fe and have a saturation magnetization of not less than 125 Am²/kg (125 emu/g) and a Switching Field Distribution (S.F.D.) value of not more than 0.50.

Description: The present invention relates to acicular magnetic iron based alloy particles suitable for use in magnetic recording and having high coercive force, high saturation magnetization, excellent stability against oxidation and excellent S.F.D. (Switching Field Distribution), and further having good dispersibility ascribed to an excellent wetting property and deagglomeration property with respect to a binder, in particular a binder containing a resin having an acid functional group, or a large specific surface area, and to a process for producing such particles. With the recent development of smaller-sized and lighter-weight magnetic recording apparatus, there has been an increasing necessity for a recording medium, such as a magnetic tape and a magnetic disk, having a higher performance. In other words, a magnetic recording medium is required which has a higher recording density, and higher output characteristic, in particular an improved frequency characteristic and a lowered noise level. The properties which magnetic particles are required to have in order to satisfy the above-described demands on a magnetic recording medium, particularly magnetic characteristics, are a high coercive force and a large saturation magnetization. Magnetic particles suitable for high-output and high-density recording, namely magnetic particles having a high coercive force and a large saturation magnetization, have recently rapidly been developed. As magnetic particles having such characteristics, acicular magnetic iron based alloy particles obtained by heat-treating acicular goethite particles or acicular hematite particles in a reducing gas are known and are put to practical use. The coercive force of acicular magnetic iron based alloy particles is dependent on the shapes of the particles, in particular the aspect ratio (major axis : minor axis), and has a tendency or aggrandizing with an increase in aspect ratio. The saturation magnetization has a tendency to increase with the acceleration of reduction by raising the reducing temperature. The coercive force and the saturation magnetization have reverse correlation. That is, with the progress of reduction, the saturation magnetization is enhanced but the shapes of the particles are destroyed thereby reducing the coercive force. Thus, acicular magnetic iron based alloy particles having both a high coercive force and a large saturation magnetization are strongly demanded. Acicular magnetic iron based alloy particles having a high coercive force and a large saturation magnetization are very unstable. More specifically, since the acicular magnetic iron based alloy particles used for a magnetic recording medium are very fine particles having a particle size of not more than 1 µm, the surface activity of the particles is so large that when they are taken out into air after reduction, they rapidly react with the oxygen in air and consequently ignite and release heat. In addition, the oxidation reaction converts these particles into oxides, thereby greatly reducing the magnetic characteristics, in particular the saturation magnetization, so that it is impossible to obtain acicular magnetic iron based alloy particles having a large saturation magnetization, which is an object of the present invention. For these reasons, acicular magnetic iron based alloy particles having excellent stability against oxidation are strongly demanded. There is no end to the recent demand for improvement of the properties of acicular magnetic iron based alloy particles. In addition to a high coercive force, a larger saturation magnetization, an excellent stability against oxidation and an excellent S.F.D. (Switching Field Distribution) are strongly demanded. This is clear from the description in JP-A-63-26821 (1988): "Fig. 1 shows the relationship between the S.F.D. value, and the recording and reproducing output of the above-described magnetic disc.... The relationship between the S.F.D. value, and the recording and reproducing output is linear, as is obvious from Fig. 1, which proves that the use of ferromagnetic particles having a small S.F.D. value enhances the recording and reproducing output. That is, in order to increase the recording and reproducing output, the S.F.D. value is preferably as small as possible. In order to obtain a higher output than an ordinary one, it is necessary that the S.F.D. value is not more than 0.6." A resin having an OH group, which has conventionally been widely used as a resin for magnetic recording media, is disadvantageous in that the resin needs to contain a large amount of dispersant in order to disperse magnetic particles in a binder. As a result the dispersant remaining in the coated film influences the surface properties of the coated film such as viscosity, which creates problems in operation, for example due to a change in the ambient temperature. To solve this problem, the recent tendency is to reduce the amount of dispersant mixed with a binder as much as possible or not to use a dispersant at all. Various investigations have been made, for example into the nature of the resin and the surface properties of the magnetic particles. A resin having a COOH group or an SO₄Na group has been used in place of the resin having an OH group. Magnetic particles having an improvement of the wetting property and the deagglomeration property with respect to the resin having an acid functional group such as a COOH group or an SO₄Na group are strongly demanded in order to enhance the dispersibility of the binder. It is known that the noise level of a magnetic recording medium reduces in proportion to the specific surface area of acicular magnetic iron based alloy particles. This phenomenon is shown in, for example, "Fig. 1" of JP-A-58-159231 (1983). "Fig. 1" shows the relationship between the noise level of a magnetic tape produced from magnetic metal particles and the specific surface area of the particles used. The noise level linearly decreases with the increase in the specific surface area of the particles. Acicular magnetic iron based alloy particles are, therefore, strongly required to have as large a specific surface area as possible. Various attempts have heretofore been made to improve the properties of acicular magnetic iron based alloy particles. For example, the following methods are known: a method of coating starting material particles such as acicular goethite particles and acicular hematite particles with a cobalt compound and thereafter heat-treating the particles in a reducing atmosphere [JP-A-54-122664 (1979) and JP-B-58-55203 (1983)]; a method of coating starting material particles with a boron compound and thereafter heat-treating the particles in a reducing atmosphere [JP-A-54-57459 (1979), JP-B-54-42832 (1979), JP-A-58-48611 (1983), JP-A-58-46607 (1983), JP-B-59-32881 (1984), JP-A-59-5603 (1984), JP-A-61-174304 (1986), JP-A-61-186410 (1986) and JP-B-59-32881 (1984)]; and a method of coating starting material particles with a water-soluble boron compound and water-soluble salts of, for example, Aℓ, Cr, Ge or Nd and thereafter heat-treating the particles in a reducing atmosphere JP-A-61-186410 (1986)]. Acicular magnetic iron based alloy particles having a high coercive force, a large saturation magnetization, an excellent stability against oxidation and an excellent S.F.D. value are now in the strongest demand, but no acicular magnetic iron based alloy particles having all these properties together have been produced by any known method. More specifically, although acicular magnetic iron based alloy particles having a high coercive force and a large saturation magnetization are generally obtained by the above-described methods, for example, the stability of saturation magnetization of the acicular magnetic iron based alloy particles produced by the process described in JP-A-58-46607 (1983) is about 10 to 30%, and the stability of saturation magnetization of the acicular magnetic iron based alloy particles produced by the process described in JP-A-59-5603 (1984) is about 15%, both being insufficient. The S.F.D. values of the conventional acicular magnetic iron based alloy particles are also unsatisfactory as will be described later. Accordingly, acicular magnetic iron based alloy particles which have a high coercive force, a high saturation magnetization, an excellent stability against oxidation and an excellent S.F.D. value, and further have a good dispersibility ascribed to an excellent wetting property and deagglomeration property with respect to a binder, in particular a binder containing a resin having an acid functional group, or a large specific surface area in addition to the above properties are strongly demanded. The present invention provides acicular magnetic iron-based alloy particles suitable for use in magnetic recording media, which (a) comprise a coating containing B and Co in respective amounts of, based on the amount of Fe in the said particles, from 1.5 to 10 mol% of B (calculated as B) and from 1.5 to 10 mol% of Co (calculated as Co); (b) have a saturation magnetization of not less than 125 Am²/kg (125 emu/g); (c) have a Switching Field Distribution (S.F.D.) value of not more than 0.50; (d) have a coercive force of not less than 1,400 Oe; and (e) have a change in saturation magnetization of not more than 15 %. The coating of the above acicular particles may, for example, further contain from 1.0 to 10 mol% of Al (calculated as Al) and/or from 0.3 to 10 mol% of Ni (calculated as Ni) based on the amount of Fe. The coating of the above acicular particles may also, for example, contain Si in an amount from 1.0 to 10 mol% (calculated as SiO₂) based on the amount of Fe, optionally together with from 1.0 to 10 mol% of Al (calculated as Al) based on the amount of Fe. The present invention further provides a process for producing acicular magnetic iron based alloy particles, suitable for use in magnetic recording media containing boron and cobalt in the vicinity of the surfaces of the particles and having a saturation magnetization of not less than 125 Am²/kg (125 emu/g) and a S.F.D. value of not more than 0.50, comprising: (i) coating the surfaces of acicular goethite particles with a boron compound and a cobalt compound; (ii) heat-treating the coated particles in air at a temperature of from 300 to 600°C to obtain thereby acicular hematite particles coated with a boron oxide and a cobalt oxide; and (iii) heat-treating the said acicular hematite particles at a temperature of from 300 to 500°C in a reducing atmosphere. The present invention further provides a magnetic recording medium in which the magnetic particles are acicular particles as defined above or which have been produced by a process as defined above. The particles of the present invention preferably have a change in aaturation magnetization of not more than 10%. The particles of the present invention which contain the B, Co and Al and/or Ni preferably have a change in saturation magnetization of not more than 10%. They have a good dispersibility ascribed to an excellent wetting property and deagglomeration property with respect to a binder, in particular a binder containing a resin having an acid functional group. The particles of the present invention which contain the B, Co and Si, or the B, Co, Si and Al, preferably have a change in saturation magnetization of not more than 10%. They also preferably have a large specific surface area of not less than 45.0 m²/g. Acicular magnetic iron based alloy particles according to the present invention are produced by coating the surfaces of acicular goethite particles with: (1) a boron compound and a cobalt compound; (2) a boron compound, a cobalt compound, and an aluminium compound and/or a nickel compound; or (3) a boron compound, a cobalt compound and a silicon compound, or a silicon compound and an aluminium compound, heat-treating the thus obtained particles in air at a temperature of 300 to 600°C to obtain coated acicular hematite particles, and heat-treating the thus obtained acicular hematite particles at a temperature of 300 to 500°C in a reducing atmosphere. (1) Acicular magnetic iron based alloy particles having a high coercive force, a large saturation magnetization, an excellent stability against oxidation and an excellent S.F.D. value cannot be obtained by coating the starting material particles only with a boron compound or a cobalt compound, or by introducing boron and/or cobalt elements into the starting material particles, as will be shown in the later Comparative Examples. It is only by coating the starting material particles with a boron compound and a cobalt compound that acicular magnetic iron based alloy particles according to the present invention can be obtained. (2) Acicular magnetic iron based alloy particles according to the present invention containing aluminium in addition to boron and cobalt have a large resin adsorption, as will be shown in the later Examples, so that it is clear that these particles have an excellent wetting property with a binder containing a resin, in particular a resin having an acid functional group, in addition to the properties described in (1). Acicular magnetic iron based alloy particles according to the present invention containing nickel in addition to boron and cobalt have excellent initial dispersibility, as will be shown in the later Examples, so that it is clear that these particles have an excellent deagglomeration property with a binder containing a resin, in particular a resin having an acid functional group, in addition to the properties described in (1). Acicular magnetic iron based alloy particles according to the present invention containing aluminium and nickel in addition to boron and cobalt have an excellent gloss, as will be shown in the later Examples, so that it is clear that these particles have an excellent dispersibility ascribed to an excellent wetting property and deagglomeration property with a binder containing a resin, in particular a resin having an acid functional group, in addition to the properties described in (1). (3) Acicular magnetic iron based alloy particles according to the present invention containing boron, cobalt and silicon, or silicon and aluminium, have a large specific surface area in addition to the properties of the particles described in (1). The acicular goethite particles used in the present invention can be produced by any ordinary method such as by oxidizing a suspension containing ferrous hydroxide and having a pH of not less than 11 obtained by mixing an aqueous ferrous salt solution and not less than an equivalent of an alkali solution, by passing an oxygen-containing gas thereinto at a temperature of not higher than 80°C [JP-B-39-5610 (1964)] and by oxidizing a suspension containing FeCO₃ obtained by reacting an aqueous ferrous salt solution with an alkali carbonate, by passing an oxygen-containing gas thereinto [JP-A-50-80999 (1975)]. By changing the reaction conditions or additives, for example, in these methods, it is possible to use particles having a particle length of 0.1 to 0.4 µm and an aspect ratio of 5 : 1 to 20 : 1. In the reaction for producing the goethite particles, metal ions of, for example, Co, Ni, Zn, Mn or Cu, which are generally added in order to improve the properties of the acicular magnetic iron based alloy particles, may be added. In order to obtain acicular magnetic iron based alloy particles the required S.F.D. value, especially of not more than 0.47, the acicular goethite particles having a uniform particle size and being free of dendrites which are obtained by the latter method are preferably used as the starting material particles. In particular, when acicular goethite particles having a uniform particle size, being free of dendrites, having a particle length of 0.18 to 0.3 µm and a large aspect ratio, especially of not less than 10 : 1, are used, it is possible to obtain acicular magnetic iron based alloy particles having a more preferable S.F.D. value, especially of not more than 0.45. Examples of acicular goethite particles used as the starting material are disclosed in US-A-4,133,677, US-A-4,130,158, US-A-4,437,881, US-A-3,652,334, US-A-4,773,931, JP-B-55-29577 (1980), JP-B-60-11446 (1985), JP-B-59-48768 (1984), JP-A-63-325436 (1988) and European Patent Application No. 0377933. Examples of the boron compound are KBO₂, H₃BO₃, HBO₂ and B₂O₃. The coating of acicular goethite particles with a boron compound is preferably carried out by mixing an aqueous solution containing boron with the acicular goethite particles, stirring the mixture, filtering out the particles and drying the thus obtained particles. The amount of boron coating the particle surfaces is 1.5 to 10 mol% based on Fe (calculated as B). If it is less than 1.5 mol%, sintering of the particles and sintering between the particles occurs, thereby making it difficult to obtain acicular magnetic iron based alloy particles having a high coercive force. If it is more than 10 mol%, the progress of reduction is obstructed, thereby making it difficult to obtain the desired acicular magnetic iron based alloy particles. Examples of the cobalt compound are cobalt sulfate, cobalt nitrate, cobalt acetate, cobalt chloride and cobalt hydroxide. The coating of acicular goethite particles with a cobalt compound is preferably carried out by mixing an aqueous solution containing cobalt with the acicular goethite particles, stirring the mixture, neutralizing the mixture with an aqueous alkaline solution or an aqueous acid solution, if necessary, filtering out the particles and drying the thus obtained particles. The amount of cobalt coating the particle surfaces is 1.5 to 10.0 mol% based on Fe (calculated as Co). If it is less than 1.5 mol%, the saturation magnetization is not more than 125 emu/g and the S.F.D. value exceeds 0.50. Even if it is more than 10.0 mol%, it is possible to obtain the acicular magnetic iron based alloy particles which are objective particles of the present invention, but it is pointless that the acicular magnetic iron based alloy particles contain more Co than necessary. Examples of the aluminium compound are aluminium sulfate, aluminium nitrate, aluminium chloride, aluminium hydroxide, sodium aluminate and alumina sol. The coating of acicular goethite particles with an aluminium compound is preferably carried out by mixing an aqueous solution containing aluminium with the acicular goethite particles, stirring the mixture, neutralizing the mixture with an aqueous alkaline solution or an aqueous acid solution, if necessary, filtering out the particles and drying the thus obtained particles. The amount of aluminum coating the particle surfaces is 1.0 to 10.0 mol%, preferably 1.0 to 5 mol% based on Fe (calculated as Aℓ). If it is less than 1.0 mol%, the wetting property with a resin is not sufficient, thereby making it difficult to obtain acicular magnetic iron based alloy particles having a sufficient resin adsorption, or it is difficult to obtain acicular magnetic iron based alloy particles having a large specific surface area. If it is more than 10.0 mol%, the magnetic characteristics such as the coercive force and the saturation magnetization of the acicular magnetic iron based alloy particles obtained are greatly reduced. Examples of the nickel compound are nickel sulfate, nickel nitrate, nickel chloride and nickel hydroxide. The coating of acicular goethite particles with a nickel compound is preferably carried out by mixing an aqueous solution containing nickel with the acicular goethite particles, stirring the mixture, neutralizing the mixture with an aqueous alkaline solution or an aqueous acid solution, if necessary, filtering out the particles and drying the thus obtained particles. The amount of nickel coating the particle surfaces is 0.3 to 10.0 mol% based on Fe (calculated as Ni). If it is less than 0.3 mol%, the reducing·temperature lowering-effect is not obtained, and since the deagglomeration property of the particles is insufficient, the improvement of the initial dispersibility, which is one of the objects of the present invention, is insufficient. If it is more than 10.0 mol%, the magnetic crystalline anisotropy becomes smaller, thereby making it difficult to obtain acicular magnetic iron based alloy particles having a high coercive force, and the saturation magnetization is apt to be lowered. Examples of the silicon compound are colloidal silica, water glass, aqueous silicic acid and silica sol. The coating of acicular geothite particles with a silicon compound is preferably carried out by mixing an aqueous solution containing a silicon compound with the acicular goethite particles, stirring the mixture, neutralizing the mixture with an aqueous alkaline solution or an aqueous acid solution, if necessary, filtering out the particles and drying the thus obtained particles. The amount of silicon coating the particle surfaces is 1.0 to 10.0 mol% based on Fe (calculated as SiO₂). If it is less than 1.0 mol%, it is difficult to obtain the iron based alloy particles having a large specific surface area. If it is more than 10.0mol%, the saturation magnetization of the acicular magnetic iron based alloy particles obtained is unfavorably lowered. When the surfaces of acicular goethite particles are coated with a boron compound, cobalt compound, aluminium compound, nickel compound, and silicon compound, the order of coating may be selected as desired, or the coating of such compounds may be carried out simultaneously. The heat-treating temperature in the present invention is 300 to 600°C. If it is lower than 300°C, since high densification of the particles is difficult, it is difficult to retain the shapes of the particles at the time of heat-treating in the subsequent reduction process, thereby lowering the coercive force of the acicular magnetic iron based alloy particles, and it is also difficult to provide an S.F.D. value of not more than 0.5. The reason why the S.F.D. value is not improved is that when the heat-treating temperature is lower than 300°C, recrystallization is insufficient, resulting in the nonuniformity in the shape anisotropy due to the distribution of the shapes of the particles after reduction and the nonuniformity in the crystalline anisotropy due to the structural distribution of Fe, B and Co. If the heat-treating temperature is higher than 600°C, sintering of particles and sintering between particles is caused, thereby destroying the particle shapes. The heat-treating temperature in a reducing atmosphere in the present invention is 300 to 500°C. If it is lower than 300°C, the reduction is insufficient for obtaining acicular magnetic iron based alloy particles having a large saturation magnetization. If it is higher than 500°C, sintering of the particles and sintering between the particles is caused, thereby destroying the particle shapes and lowering the coercive force of the acicular magnetic iron based alloy particles obtained. The acicular magnetic iron based alloy particles of the present invention preferably have a particle length of 0.1 to 0.4 µm, and an aspect ratio of 5 : 1 to 15 : 1. The acicular magnetic iron based alloy particles after reduction in the process of the present invention can be taken out into air by a known method such as a method of dipping the acicular magnetic iron based alloy particles in an organic solvent such as toluene and a method of replacing the atmosphere after reduction with an inert gas and gradually increasing the oxygen content in the inert gas to provide gradual oxidization of the inert gas by air. The acicular magnetic iron based alloy particles according to the present invention obtained in this way have: (1) a coercive force not less than 1,400 Oe, preferably not less than 1450 Oe; a saturation magnetization of not less than 125 emu/g, preferably not less than 130 emu/g; a change of saturation magnetization of not more than 15%, preferably not more than 10 %; and an S.F.D. value of not more than 0.50, preferably not more than 0.47; (2) a gloss of not less than 100%, preferably not less than 110 %, at a dispersion time of 50%; a gloss of not less than 120%; preferably not less than 130 %, at a dispersion time of 100%; and a resin adsorption of not less than 1.1 g, preferably not less than 1.4 g; in addition to the properties described in (1); or (3) a specific surface area of not less than 45.0 m²/g, preferably not less than 48 m²/g, in addition to the properties described in (1). The acicular magnetic iron based alloy particles of the present invention having the above-described properties are suitable for use as the magnetic particles for high-density and high-output recording which are now in the strongest demand. The present invention is further described in the following Examples. Examples In each of the following Examples and Comparative Examples; (i) The particle length and the aspect ratio of the acicular magnetic iron based alloy particles are expressed as average values measured from electron microphotographs. (ii) The magnetic characteristics of the acicular magnetic iron based alloy particles are measured by a vibrating sample magnetometer VSM-3S-15, produced by Toei Kogyo K.K. and applying an external magnetic field up to 10 KOe. (iii) The stability against oxidation is expressed as Δσs/σs(%) which shows the change of saturation magnetization (%) of a sample allowed to stand for 7 days at a temperature of 60°C and a relative humidity of 90%. (iv) The S.F.D. value is obtained using a sheet test piece having a squareness ratio of 0.85 obtained by the following method. The differentiation curve of the magnetization major roop around coercivity of the sample was obtained using a differentiation circuit of the magnetometer, the half power width of the differentiation curve was measured and the half power width was divided by the coercive force of the peak value of the curve. A magnetic coating was prepared by charging the following components into a 100-cc plastic bottle in the following amounts and dispersing them with a paint conditioner for 8 hours. A sheet test piece was obtained by applying the magnetic coating to a polyethylene film of 25 µm thickness to a thickness of 50 µm using an applicator, and drying the coated film in a magnetic field of 3 to 5 KGauss. (v) The resin adsorption is expressed by the difference between the weight of the resin concentration of the resin liquid having the following composition and the weight of the resin concentration of the supernatant liquid of the coating obtained by charging 20 g of acicular magnetic iron based alloy particles, 56 g of the resin liquid and 120 g of 3-mmø stainless steel balls into a 100-mℓ plastic bottle and dispersing them with a paint conditioner for 60 minutes and subjected to centrifugal separation. The weights of both resin concentrations were measured as the nonvolatile matter. (vi) The dispersibility is expressed by the gloss of the coated film obtained by applying a coating to a PET film by an applicator. The coating was produced by charging 15 g of acicular magnetic iron based alloy particles, the resin liquid having the following composition and 120 g of 3-mmø stainless steel balls into a 100-mℓ plastic bottle and dispersing them with a paint conditioner for a predetermined time. The dispersing time required for the saturation of the gloss was assumed to be 100%, and the gloss at that time is expressed as the criterion of the dispersibility. The gloss at a dispersion time of 50% is expressed as the criterion of the initial dispersibility. The gloss of the coated film was measured by a glossmeter produced by Nihon Denshoku Kogyo K.K. at an incident angle of 60°C, and the value is expressed by % on the assumption that the gloss of the standard sheet was 89.0%. Production of acicular hematite particles Examples 1 to 10 Comparative Examples 1 to 9 Example 1 100 g of acicular goethite particles having a particle length of 0.21 µm and an aspect ratio (major axis : minor axis) of 12 : 1 was suspended in 1 ℓ of water. To the suspension, 10.0 g (equivalent to 10.0 wt% based on the acicular goethite particles) of H₃BO₃ and 13.0 g (equivalent to 13.0 wt% based on the acicular goethite particles) of Co(CH₃COO)₂·4H₂O were added and the suspension was stirred for 10 minutes. The pH of the suspension was 6.2. NH₄OH was then added until the pH of the suspension became 9.3. The acicular α-FeOOH particles were filtered out and dried, thereby obtaining the acicular α-FeOOH particles coated with boron and cobalt. 50 g of the thus obtained acicular goethite particles coated with boron and cobalt were heat-treated at 400°C in air to obtain acicular hematite particles coated with a boron oxide and a cobalt oxide. According to the observation of the electron microphotographs, the particles had an average particle length of 0.19 µm and an average aspect ratio (major axis : minor axis) of 11 : 1. Examples 2 to 10, Comparative Examples 1 to 9 Acicular hematite particles were obtained in the same way as in Example 1 except that the kind of the acicular goethite particles, the kind and the content of a boron compound and the time for mixing the boron compound, the kind and the content of a cobalt compound and the time of existence of the cobalt compound and the temperature in the heat-treating process were varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Table 1. Production of acicular magnetic iron based alloy particles Examples 11 to 20 Comparative Examples 10 to 20 Example 11 20 g of the acicular hematite particles coated with boron oxide and cobalt oxide obtained in Example 1 were reduced by a hydrogen gas at 410°C for 6 hours, thereby obtaining acicular magnetic iron based alloy particles. The surfaces of the acicular magnetic iron based alloy particles obtained by reduction were coated with a stable oxide film so as to prevent rapid oxidation when they were taken out into air. As a result of X-ray fluorometry, it was found that the particles contained 4.7 mol% of B based on Fe and 4.5 mol% of Co based on Fe. According to the observation of the electron microphotographs, the particles had an average particle length of 0.15 µm and an average aspect ratio (major axis : minor axis) of 7 : 1. As to the magnetic characteristics, the coercive force (Hc) was 1,530 Oe, the saturation magnetization (σs) was 133 emu/g, the change of saturation magnetization was 8.0% and the S.F.D. value was 0.43. Examples 12 to 20, Comparative Examples 10 to 20 Acicular magnetic iron based alloy particles were obtained in the same way as in Example 11 except that the kind of the acicular hematite particles, and the time and the temperature in the heat-treating process were varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Table 2. Surface coating of acicular goethite particles Examples 21 to 39 Reference Examples 1 to 4 Example 21 100 g of acicular goethite particles having an average particle length of 0.21 µm and an average aspect ratio (major axis : minor axis) of 12 : 1 was suspended in 1 ℓ of water. To the suspension, 10.0 g (equivalent to 10.0 wt% based on the acicular goethite particles) of H₃BO₃, 13.0 g (equivalent to 13.0 wt% based on the acicular goethite particles) of Co(CH₃COO)₂·4H₂O and 12 g (equivalent to 12 wt% based on the acicular goethite particles) of Aℓ (NO₃)₃·9H₂O were added and the suspension was stirred for 10 minutes. The pH of the suspension was 4.4. NH₄OH was then added until the pH of the suspension became 9.3. The acicular α-FeOOH particles were filtered out and dried, thereby obtaining the acicular α-FeOOH particles coated with boron compound, cobalt compound and aluminium compound. Examples 22 to 39, Reference Examples 1 to 4 Acicular α-FeOOH particles coated with various compounds were obtained in the same way as in Example 21 except that the kind of the acicular goethite particles, the kind and the content of a boron compound, the kind and the content of a cobalt compound and the kind and the content of an aluminium compound or a nickel compound or the kinds and the contents of both alumina and nickel compounds were varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Tables 3 and 4. Production of acicular hematite particles Examples 40 to 58 Comparative Examples 5 to 8 Example 40 50 g of the acicular goethite particles coated with boron, cobalt and aluminium obtained in Example 21 were heat-treated at 400°C in air to obtain acicular hematite particles coated with a boron oxide, a cobalt oxide and an aluminium oxide. According to the observation of the electron microphotographs, the particles had an average particle length of 0.19 µm and an average aspect ratio (major axis : minor axis) of 11 : 1 by average value. Examples 41 to 58, Reference Examples 5 to 8 Acicular hematite particles were obtained in the same way as in Example 40 except that the temperature in the heat-treating process was varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Tables 5 and 6. Production of acicular magnetic iron based alloy particles Examples 59 to 77 Reference Examples 9 to 12 Example 59 20 g of the acicular hematite particles coated with a boron oxide, a cobalt oxide and an aluminium oxide obtained in Example 40 were reduced by a hydrogen gas at 420°C for 6 hours, thereby obtaining acicular magnetic iron based alloy particles. The surfaces of the acicular magnetic iron based alloy particles obtained by reduction were coated with a stable oxide film so as to prevent rapid oxidation when they were taken out into air. As a result of X-ray fluorometry, it was found that the particles contained 4.7 mol% of B based on Fe, 4.5 mol% of Co based on Fe and 2.6 mol% of Aℓ based on Fe. According to the observation of the electron microphotographs, the particles had an average particle length of 0.15 µm and an average aspect ratio (major axis : minor axis) of 7 : 1. As to the magnetic characteristics, the coercive force (Hc) was 1,540 Oe, the saturation magnetization (σs) was 133 emu/g, the oxidative stability was 8.0% and the S.F.D. value was 0.42. The resin adsorption content was 1.4. As to the dispersibility, the gloss at a dispersion time of 50% was 110% and the gloss at a dispersion time of 100% was 120%. Examples 60 to 77, Reference Examples 9 to 12 Acicular magnetic iron based alloy particles were obtained in the same way as in Example 59 except that the kind of the acicular hematite particles and the temperature in the heat-treating process were varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Tables 7 and 8. Surface coating of acicular goethite particles Examples 78 to 90 Reference Examples 13 to 14 Example 78 100 g of acicular goethite particles having an average particle length of 0.20 µm and an average aspect ratio (major axis : minor axis) of 13 : 1 was suspended in 1 ℓ of water. To the suspension, 10.0 g (equivalent to 10.0 wt% based on the acicular goethite particles) of H₃BO₃, 13.0 g (equivalent to 13.0 wt% based on the acicular goethite particles) of Co(CH₃COO)₂·4H₂O and 9.5 g (equivalent to 9.5 wt% based on the acicular goethite particles) of colloidal silica were added and the suspension was stirred for 10 minutes. The pH of the suspension was 6.1. NH₄OH was then added until the pH of the suspension became 9.3. The acicular α-FeOOH particles were filtered out and dried, thereby obtaining the acicular α-FeOOH particles coated with boron compound, cobalt compound and silicon compound. Examples 79 to 90, Reference Example 13 and 14 Acicular α-FeOOH particles coated with various compounds were obtained in the same way as in Example 78 except that the kind of the acicular goethite particles, the kind and the content of a boron compound, the kind and the content of a cobalt compound, the kind and the content of a silicon compound and the kind or the content of an aluminium compound, if any, were varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Tables 9 and 10. In the case of using water glass as the silicon compound for coating the acicular goethite particles, after the water glass was added to the suspension with the pH adjusted to 9.3, the suspension was stirred for 10 minutes, and then acetic acid was added to adjust the pH of the suspension to 7.0 to 7.5. Production of acicular hematite particles Examples 91 to 105 Comparative Examples 15 to 16 Example 91 50 g of the acicular goethite particles coated with boron compound, cobalt compound and silicon compound obtained in Example 78 were heat-treated at 400°C in air to obtain acicular hematite particles coated with a boron oxide, a cobalt oxide and a silicon oxide. According to the observation of the electron microphotographs, the particles had an average particle length of 0.19 µm and an average aspect ratio (major axis : minor axis) of 11 : 1. Examples 92 to 105, Reference Examples 15 and 16 Acicular hematite particles were obtained in the same way as in Example 91 except that the temperature in the heat-treating process was varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Tables 11 and 12. Production of acicular magnetic iron based alloy particles Examples 106 to 120 Reference Examples 17 and 18 Example 106 20 g of the acicular hematite particles coated with a boron oxide, a cobalt oxide and an aluminium oxide obtained in Example 91 were reduced by a hydrogen gas at 410°C for 6 hours, thereby obtaining acicular magnetic iron based alloy particles. The surfaces of the acicular magnetic iron based alloy particles obtained by reduction were coated with a stable oxide film so as to prevent rapid oxidation when they were taken out into air. As a result of X-ray fluorometry, it was found that the particles contained 4.7 mol% of B based on Fe, 4.5 mol% of Co based on Fe and 2.4 mol% of Si based on Fe (calculated as SiO₂). According to the observation of the electron microphotographs, the particles proved to have an average particle length of 0.15 µm and an average aspect ratio (major axis : minor axis) of 7 : 1. As to the magnetic characteristics, the coercive force (Hc) was 1,560 Oe, the saturation magnetization (σs) was 133 emu/g the changes of saturation magnetization was 8.0% and the S.F.D. was 0.43. Examples 107 to 120, Comparative Examples 17 and 18 Acicular magnetic iron based alloy particles were obtained in the same way as in Example 106 except that the kind of the acicular hematite particles and the temperature in the heat-treating process were varied. The main conditions for producing these particles and the properties of these particles obtained are shown in Tables 13 and 14.

Claims: Acicular magnetic iron-based alloy particles suitable for use in magnetic recording media, which (a) comprise a coating containing B and Co in respective amounts of, based on the amount of Fe in the said particles, from 1.5 to 10 mol% of B (calculated as B) and from 1.5 to 10 mol% of Co (calculated as Co); (b) have a saturation magnetization of not less than 125 Am²/kg (125 emu/g); (c) have a Switching Field Distribution (S.F.D.) value of not more than 0.50; (d) have a coercive force of not less than 1,400 Oe; and (e) have a change in saturation magnetization of not more than is 15 %. Acicular particles according to claim 1, wherein the coating further contains from 1.0 to 10 mol% of Al (calculated as Al) based on the amount of Fe. Acicular particles according to claim 1 or 2, wherein the coating further contains from 0.3 to 10 mol% of Ni (calculated as Ni) based on the amount of Fe. Acicular particles according to claim 1 or 2, wherein the coating further contains Si in an amount of from 1.0 to 10 mol% (calculated as SiO₂) based on the amount of Fe. A process for producing acicular magnetic iron based alloy particles, suitable for use in magnetic recording media, containing boron and cobalt in the vicinity of the surfaces of the particles and having an saturation magnetization of not less than 125 Am²/kg (125 emu/g) and a S.F.D. value of not more than 0.50, comprising: (i) coating the surfaces of acicular goethite particles with a boron compound and a cobalt compound; (ii) heat-treating the coated particles in air at a temperature of from 300 to 600°C to obtain thereby acicular hematite particles coated with a boron oxide and a cobalt oxide; and (iii) heat-treating the said acicular hematite particles at a temperature of from 300 to 500°C in a reducing atmosphere. A process according to claim 5, further comprising coating the surfaces of the acicular goethite particles in step (i) with an aluminium compound and/or a nickel compound. A process according to claim 5, further comprising coating the surfaces of the acicular goethite particles in step (i) with silicon compound and, optionally also, an aluminium compound. A process according to any one of claims 5 to 7, wherein the boron compound is selected from KBO₂, H₃BO₃, HBO₂ and B₂O₃ and the cobalt compound is selected from cobalt sulfate, cobalt nitrate, cobalt acetate, cobalt chloride and cobalt hydroxide. A magnetic recording medium in which the magnetic particles are acicular particles as claimed in any one of claims 1 to 4 or which have been produced by a process as claimed in any one of claims 5 to 8.

Inventors: IKEMOTO KUNIO, KAWASAKI HIROFUMI, MISHIMA AKIO, MORI KOHJI, NAGAI NORIMICHI, OKINAKA KENJI, OTA YASUTAKA, TAMARI KOUSAKU, TANIHARA MAMORU, IKEMOTO, KUNIO, KAWASAKI, HIROFUMI, MISHIMA, AKIO, MORI, KOHJI, NAGAI, NORIMICHI, OKINAKA, KENJI, OTA, YASUTAKA, TAMARI, KOUSAKU, TANIHARA, MAMORU
Applicants: TODA KOGYO CORP, TODA KOGYO CORP.
Application year: 1989
Main classification: G11B5
IPC codes: G11B5