Plate-like magnetite particles and process for producing the same

Abstract: Poreless plate-like magnetite particles useful as the magnetic material for magnetic recording media have an average particle diameter of from 0.1 to 1.5 µm and a plate ratio of from 11:1 to 50:1 and which are discrete from each other. These particles are prepared by a process comprising: (i) reacting a ferrous salt solution containing from 0.1 to 5.5 mol% of a ferric salt, calculated as Fe(III), based on Fe(II), with an amount of an aqueous alkali carbonate such that the equivalent ratio of the alkali carbonate to the Fe(II) and Fe(III) in the aqueous ferrous salt solution is not less than 1:1 and the following general formula is satisfied: (ii) oxidizing the suspension containing FeCO₃ thus obtained by passing an oxygen-containing gas therethrough.

Description: The present invention relates to a process for producing poreless plate-like magnetite particles which have a large plate ratio (average particle diameter:thickness) and are discrete from each other, directly from an aqueous solution and to plate-like magnetite particles. Such plate-like magnetite particles are chiefly used for electromagnetic wave absorbers, shields, anticorrosive coatings and toners and in dampers, sound insulators and magnetic recording materials. Plate-like magnetite particles are expected to be used in various technical fields by utilizing various properties such as the shape and the magnetic characteristics thereof. This fact is described in JP-A-63-41853 (1988): "There is a possibility of using lamella magnetic iron oxide particles for a magnetic recording material such as magnetic tape, card and disk", and "Hexagonal lamella iron oxide particles having a magnetite or maghemite crystalline structure are also used for other purposes. In a coating material, very remarkable parallel orientation of each particle is produced with respect to each other. Therefore, it is possible to obtain very high packing density, and as a result, for example, the anticorrosive effect and the screening effect on electromagnetic interference increase, and the conductivity is enhanced". JP-A-61-138959 (1986) states: "It has been found that when small plate-like or scale-like magnetizable particles are used as a magnetic component of one-component toner, it is scarcely by the intrinsic colour of the magnetic component itself but mainly by the colouring agent having a strong colour which is added thereto that the colour of the toner is decided", and "It is possible to immediately convert the state of these particles into a good dispersed state in a binder or a binder solution merely by stirring them without consuming any special classifying energy". Magnetite particles are generally dispersed in and mixed with a vehicle so as to be used as a coating, or are kneaded with and dispersed in a resin and molded so as to be used as a molded product. In dispersing and mixing magnetite particles in and with a vehicle, or kneading and dispersing magnetite particles with and in a resin, the particles are required to have as good a dispersibility as possible in order to improve the properties and the working efficiency. For this purpose, magnetite particles are required not only to be in the form of a plate but also to have as large a plate ratio (average particle diameter:thickness) as possible, to be discrete each other and to be poreless. As processes for producing plate-like magnetite particles there are, for example, a process of producing plate-like hematite particles from an aqueous solution by autoclaving an alkaline suspension containing ferric hydroxide or goethite and heat-treating the plate-like hematite particles in a reducing gas [refer to JP-A-51-28700 (1976) and JP-B-63-41853 (1988)], a process of producing goethite particles by rapidly oxidizing an alkaline suspension containing ferrous hydroxide with a strong oxidizing agent or a process of producing goethite particles by reacting ferric iron with an alkali in an aqueous medium to produce ferric hydroxide and autoclaving the ferric hydroxide, thereby forming plate-like goethite particles from an aqueous solution, and the heat-treating the goethite particles in a reducing gas after dehydrating the plate-like goethite particles under heating, if necessary [refer to JP-A-61-266311 (1986) and JP-A-55-104923 (1980)], and a process of producing plate-like magnetite particles directly from an aqueous solution [refer to JP-A-62-34141]. Poreless plate-like magnetite particles which have as large a plate ratio (average particle diameter:thickness) as possible and which are discrete each other, are now strongly demanded, but particles having satisfactory properties have not been obtained by the above-described known methods. In a process of producing plate-like hematite particles from an aqueous solution and heat-treating these particles, sintering of the particles and between the particles occurs in the heat-treating process, which makes it difficult to disperse the particles in a vehicle or a resin. In the case of producing plate-like goethite particles from an aqueous solution and after, if necessary, dehydrating the particles under heating, the obtained plate-like magnetite particles have many pores on the particle surface and inside the particle as a result of dehydration in the goethite crystal particles, and sintering of the particles and between the particles occurs when they are heated. If such porous magnetite particles are dispersed in a vehicle or a resin, other fine particles are attracted to the portion at which surface magnetic poles are generated. As a result, a multiplicity of particles agglomerate and large agglomerated lumps are produced, which make dispersion difficult. EP-A-279,626 describes a process for producing plate-like magnetite particles directly from an aqueous solution and the particles obtained are discrete from each other and poreless. The plate ratio (average particle diameter:thickness) of the particles is 2:1 to 10:1, preferably 3:1 to 8:1. Particles having a large plate ratio have not been obtained. The present invention provides poreless plate-like magnetite particles which have an average particle diameter of from 0.1 to 0.5 µm and which are discrete from each other, said particles having: a) a plate ratio of from 11:1 to 20:1 and a specific surface area of from 2.0 to 30.0 m²/g; or b) a plate ratio of from 21:1 to 50:1 and a specific surface area of from 3.0 to 30.0 m²/g. The present invention also provides a process for producing poreless, plate-like magnetite particles having a plate ratio of from 11:1 to 20:1, a specific surface area of from 2.0 to 30.0 m²/g and an average particle diameter of from 0.1 to 1.5µm and which are discrete from each other, which process comprises, (i) reacting a ferrous salt solution containing from 0.1 to 5.5 mol% of a ferric salt, calculated as Fe(III), based on Fe(II), with an amount of an aqueous alkali carbonate at a temperature of not lower than 75°C, such that the equivalent ratio of the alkali carbonate to the Fe(II) and Fe(III) in the aqueous ferrous salt solution is not less than 1:1 and the following general formula is satisfied: and (ii) oxidizing the suspension containing FeCO₃ thus obtained by passing an oxygen-containing gas therethrough. The present invention additionally provides a process for producing poreless, plate-like magnetite particles having a plate ratio of from 21:1 to 50:1, a specific surface area of from 3.0 to 30 m²/g and an average particle diameter of from 0.1 to 1.5µm and which are discrete from each other, which process comprises, (i) reacting a ferrous salt solution containing from 0.1 to 5.5 mol% of a ferric salt, calculated as Fe(III), based on Fe(II), with an amount of an aqueous alkali carbonate at a temperature of not lower than 75°C, such that the equivalent ratio of the alkali carbonate to the Fe(II) and Fe(III) in the aqueous ferrous salt solution is not less than 1:1 and the following general formula is satisfied: in which from 0.01 to 8.0 mol% of a water-soluble organic compound having a -COONa or -COOK group, based on the Fe(II) and Fe(III), are added to the aqueous ferrous salt solution, to the aqueous alkali carbonate solution or to the suspension containing FeCO₃ before oxidation; and (ii) oxidizing the suspension containing FeCO₃ thus obtained by passing an oxygen-containing gas therethrough. The particles produced by the process of the present invention may, for example, have an average particle diameter of from 0.1 to 0.5µm. The present invention also provides a magnetic medium, coating or molded product wherein the magnetic material is as defined above or is produced by a process as defined above. In the accompanying drawings: Figs. 1, 3, 4 and 6 to 8 are electron micrographs, wherein: Figs. 1, 3 and 6 to 8 show the structure of the plate-like magnetite particles obtained in Example 1, Example 3, Example 8, Example 10 and Example 12, respectively, and Fig. 4 shows the structure of the mixed particles of the plate-like magnetite particles and spindle-like hematite particles obtained in Comparative Example 1; Figs. 2 and 5 are X-ray diffraction patterns of the plate-like magnetite particles obtained in Example 1 and the mixed particles of the plate-like magnetite particles and spindle-like hematite particles obtained in Comparative Example 1, respectively, wherein the peak A indicates the magnetite particles and the peak B indicates the hematite particles. Plate-like magnetite particles obtained by the first process of the present invention have an average particle diameter of from 0.1 to 1.5 µm and a plate ratio (average particle diameter/thickness) of from 11: 1 to 20 : 1, and are discrete each other. Since these particles are poreless, the specific surface area thereof is as small as from 2.0 to 30.0 m²/g. By adding a specified amount of water-soluble organic compound having a -COONa or -COOK group to the aqueous ferrous salt solution, to the aqueous alkali carbonate solution or to the suspension containing FeCO₃ before the oxidation, it is possible to produce plate-like magnetite particles having a larger plate ratio (average particle diameter:thickness) directly from the aqueous solution. The particles thus obtained have an average particle diameter of from 0.1 to 1.5 µm and a plate ratio (average particle diameter:thickness) of from 21:1 to 50:1, and are discrete each other. Since these particles are poreless, the specific surface area thereof is as small as from 3.0 to 30.0 m²/g. As the aqueous ferrous salt solution used in the present invention, an aqueous ferrous sulfate solution or an aqueous ferrous chloride solution are, for example, usable. As an aqueous ferric salt solution used in the present invention, an aqueous ferric sulfate solution or an aqueous ferric chloride solution may for example, be used. The amount of ferric salt is from 0.1 to 5.5 mol%, preferably from 0.2 to 5.0 mol%, calculated as Fe(III), based on the Fe(II) in the aqueous ferrous salt solution. If it is less than 0.1 mol%, it is difficult to obtain plate-like magnetite particles having a large plate ratio (average particle diameter:thickness), which is the object of the present invention. If it exceeds 5.5 mol%, spindle-like hematite particles get mixed in the plate-like magnetite particles. As an alkali carbonate in the present invention, sodium carbonate, potassium carbonate and ammonium carbonate for example may be used, singly or in the form of a mixture. The mixing order of the aqueous ferrous salt solution and the aqueous alkali carbonate solution is not specified; either may be added to the other or both may be mixed with each other simultaneously. The reaction temperature in the present invention is preferably from 75 to 100°C. If it is lower than 75°C, spindle-like hematite particles or acicular goethite particles get mixed in the plate-like magnetite particles. If it exceeds 100°C, the object of the present invention can be achieved, but it is uneconomic because special equipment such as an autoclave is required. The amount of alkali carbonate used in the present invention is so controlled that the equivalent ratio of the alkali carbonate to the Fe(II) and Fe(III) in the aqueous ferrous salt solution is not less than 1:1 and the following general formula is satisfied: If the amount exceeds the above-described specified range, spindle-like hematite particles get mixed in the plate-like magnetite particles. When productivity is taken into consideration, the concentration of iron is preferably not less than about 0.1 mol/ℓ. As the water-soluble organic compound having a -COONa or -COOK group used in the present invention, sodium acetate, potassium acetate, sodium tartrate, potassium tartrate, sodium citrate, potassium citrate, sodium propionate, potassium propionate are, for example, usable. The amount of water-soluble organic compound having a -COONa or -COOK group added in the present invention is from 0.01 to 8.0 mol%, preferably from 0.01 to 7.0 mol%, based on the Fe(II) and Fe(III) in the aqueous ferrous salt solution. If it is less than 0.01 mol%, it is difficult to obtain plate-like magnetite particles having a large plate ratio (average particle diameter:thickness). If it exceeds 8.0 mol%, spindle-like hematite particles get mixed in the plate-like magnetite particles. Since the water-soluble organic compound having a -COONa or -COOK group in the present invention influences the form of the particles produced, such as the plate ratio, it is necessary to add the water-soluble organic compound before the production reaction of the plate-like magnetite particles. The water-soluble organic compound may be added to any of the aqueous ferrous salt solution, the aqueous alkali carbonate solution and the suspension containing FeCO₃ before being oxidized by passing an oxygen-containing gas therethrough. As the oxygen-containing gas, air is preferable. The amount of oxygen-containing gas supplied and the supplying time are not specified and an ordinary method is adopted. The plate-like magnetite particles obtained by a method according to the present invention, that is, (1) plate-like magnetite particles which have an average particle diameter of from 0.1 to 0.5 µm and a plate ratio of from 11:1 to 20:1, which are discrete each other, and which have a specific surface area of from 2.0 to 30.0 m²/g, preferably from 5.0 to 30.0 m²/g due to porelessness, when the concentration of Fe(II) and Fe(III) in the suspension is preferably less than 0.3 mol/ℓ, and (2) plate-like magnetite particles which have an average particle diameter of from 0.1 to 0.5 µm and a plate ratio of from 21:1 to 50:1, preferably from 21:1 to 40:1, which are discrete each other, and which have a specific surface area of from 3.0 to 30.0 m²/g, preferably from 6.0 to 30.0 m²/g due to porelessness, when the concentration of Fe(II) and Fe(III) in the suspension is preferably not less than 0.3 mol/ℓ, are novel and have a high packing density in a vehicle or a resin, excellent dispersibility and orientation properties and a high contacting ratio between the particles, so that these particles are useful as a material for an electromagnetic wave absorber, shield, anticorrosive coating, toner, damper, sound insulator or magnetic recording material. According to the method of the present invention, it is possible to obtain particles which are in the form of a plate, and have a large plate ratio such as not less than 11 : 1. In addition, since the particles are produced directly from an aqueous solution, the particles are discrete each other and poreless, so that the packing density in a vehicle or a resin is high, the dispersibility and orientation properties are excellent and the amount of contact between the particles is also high. Thus, these particles are useful as a material for an electromagnetic wave absorber, shield, anticorrosive coating, toner, damper, sound insulator or magnetic recording material. EXAMPLES The present invention is now further explained in more detail in the following Examples. The average particle diameter in the following Examples and Comparative Examples are values obtained by measurement from an electron micrograph. The specific surface area was measured by a BET method, and the thickness and the plate ratio were expressed by the values obtained from the specific surface area measured by the BET method and the average particle diameter. The magnetism was measured by a vibrating sample magnetometer model VSMP-1 (produced by Toei Kogyo Co., Ltd.) under a measuring magnetic field of 10 KOe. Example 1 An aqueous solution of 0.34 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel. To 44.3 ℓ of the thus-prepared aqueous solution, 5.7 ℓ of the aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.009 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 0.5 mol% of Fe(II)) was added (CO₃/Fe = 1.5 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.2 mol/ℓ). N₂ gas was continuously blown into the aqueous solution containing FeCO₃ at a rate of 50 ℓ per minute at 90°C for 60 minutes so as to age the aqueous solution. Thereafter, air was passed through the aqueous solution at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. The obtained plate-like particles had an average particle diameter of 0.13 µm, and a plate ratio (average particle diameter:thickness) of 11 : 1, as shown in the transmission electron micrograph (x 50,000) of Fig. 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 24.2 m²/g, the coercive force (Hc) was 115 Oe, the saturation magnetization (σs) was 85.7 emu/g, and the squareness (σr/σs) was 0.093. Fig. 2 is an X-ray diffraction pattern of the particles. In Fig. 2, the peak A indicates magnetite particles and the obtained particles are therefore seen to be magnetite particles. Example 2 An aqueous solution of 1.09 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel. To 41.4 ℓ of the thus-prepared aqueous solution, 8.6 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.035 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 2.0 mol% of Fe(II)) was added (CO₃/Fe = 3.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.31 mol/ℓ). N₂ gas was continuously blown into the aqueous solution containng FeCO₃ at a rate of 50 ℓ per minute at 90°C for 60 minutes so as to age the aqueous solution. Thereafter, air was passed through the aqueous solution at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained plate-like particles had an average particle diameter of 0.56 µm, and a plate ratio (average particle diameter:thickness) of 15 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 7.4 m²/g, the coercive force (Hc) was 93 Oe, the saturation magnetization (σs) was 87.6 emu/g, and the squareness (σr/σs) was 0.105. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 3 An aqueous solution of 1.64 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel and 22.1 g of sodium citrate was added to the obtained aqueous solution of Na₂CO₃ so that 0.5 mol% of sodium citrate was contained on the basis of the Fe in the aqueous ferrous sulfate solution. To 41.4 ℓ of the thus-prepared aqueous solution of Na₂CO₃, 8.6 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.026 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 4.0 mol% of Fe(II)) was added (CO₃/Fe = 4.5 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.32 mol/ℓ). Air was passed through the aqueous solution containing FeCO₃ at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. The obtained plate-like particles had an average particle diameter of 0.62 µm, and a plate ratio (average particle diameter:thicknes) of 26 : 1, as shown in the transmission electron micrograph (x 30,000) of Fig. 3. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 8.6 m²/g, the coercive force (Hc) was 82 Oe, the saturation magnetization (σs) was 88.9 emu/g, and the squareness (σr/σs) was 0.098. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 4 Particles were produced in the same way as in Example 3 except that 30.6 g of sodium acetate was used instead of sodium citrate so that 1.5 mol% of sodium acetate was contained on the basis of the Fe in the aqueous ferrous sulfate solution (the concentration of Fe(II) and Fe(III) therein was 0.32 mol/ℓ). The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained plate-like particles had an average particle diameter of 0.72 µm, and a plate ratio (average particle diameter:thickness) of 23 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 6.8 m²/g, the coercive force (Hc) was 87 Oe, the saturation magnetization (σs) was 88.2 emu/g, and the squareness (σr/σs) was 0.101. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 5 An aqueous solution of 1.09 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel and 173 g of sodium tartrate was added to the obtained aqueous solution of Na₂CO₃ so that 5.0 mol% of sodium tartrate was contained on the basis of the Fe in the aqueous ferrous sulfate solution. To 41.4 ℓ of the aqueous solution of Na₂CO₃, 8.6 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.026 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 1.5 mol% of Fe(II)) was added (CO₃/Fe = 3.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.31 mol/ℓ). N₂ gas was continuously blown into the aqueous solution containing FeCO₃ at a rate of 50 ℓ per minute at 90°C for 60 minutes so as to age the aqueous solution. Thereafter, air was passed through the aqueous solution containing FeCO₃ at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope it was found that the obtained plate-like particles had an average particle diameter of 0.53 µm, and a plate ratio (average particle diameter:thickness) of 34 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 11.2 m²/g, the coercive force (Hc) was 80 Oe, the saturation magnetization (σs) was 89.1 emu/g, and the squareness (σr/σs) was 0.101. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Comparative Example 1 Particles were produced from an aqueous solution in the same way as in Example 1 except for using 8.6 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.105 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 6.0 mol% of Fe(II)). The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. The obtained particles were a mixture of plate-like particles and spindle-shaped particles, as shown in the transmission electron micrograph (x 20,000) of Fig. 4. As a result of X-ray diffraction, the peak indicating magnetite particles and the peak indicating hematite particles were observed, as shown in Fig. 5. In Fig. 5, the peak A indicates magnetite particles and the peak B indicates hematite particles. Comparative Example 2 Particles were produced from an aqueous solution in the same way as in Example 3 except for changing the amount of sodium citrate to 443 g (equivalent to 10 mol% of the Fe in the aqueous ferrous sulfate solution). The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained particles were a mixture of plate-like particles and granular particles. As a result of X-ray diffraction, it was observed that hematite particles were mixed with magnetite particles. Example 6 An aqueous solution of 0.51 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel. To 43.6 ℓ of the thus-prepared aqueous solution of Na₂CO₃, 6.4 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.018 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 1.0 mol% of Fe(II)) was added (CO₃/Fe = 2.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.23 mol/ℓ). N₂ gas was continuously blown into the aqueous solution containing FeCO₃ at a rate of 50 ℓ per minute so as to age the aqueous solution at 90°C for 30 minutes. Thereafter, air was passed through the aqueous solution at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained plate-like particles had an average particle diameter of 0.18 µm, and a plate ratio (average particle diameter:thickness) of 13 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 21.8 m²/g, the coercive force (Hc) was 110 Oe, the saturation magnetization (σs) was 85.8 emu/g, and the squareness (σr/σs) was 0.101. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 7 An aqueous solution of 0.72 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel. To 42.9 ℓ of the thus-prepared aqueous solution of Na₂CO₃, 7.1 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.035 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 2.0 mol% of Fe(II)) was added (CO₃/Fe = 2.5 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.25 mol/ℓ). N₂ gas was continuously blown into the aqueous solution containing FeCO₃ at a rate of 50 ℓ per minute at 90°C for 30 minutes so as to age the aqueous solution. Thereafter, air was passed through the aqueous solution at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained plate-like particles had an average particle diameter of 0.33 µm, and a plate ratio (average particle diameter:thickness) of 14 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 13.8 m²/g, the coercive force (Hc) was 92 Oe, the saturation magnetization (σs) was 87.1 emu/g, and the squareness (σr/σs) was 0.095. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 8 An aqueous solution of 1.17 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel. To 42.9 ℓ of the thus-prepared aqueous solution of Na₂CO₃, 7.1 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.07 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 4.0 mol% of Fe(II)) was added (CO₃/Fe = 4.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.26 mol/ℓ). N₂ gas was continuously blown into the aqueous solution containing FeCO₃ at a rate of 50 ℓ per minute at 90°C for 30 minutes so as to age the aqueous solution. Thereafter, air was passed through the aqueous solution at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron micrograph, it was found that the obtained plate-like particles had an average particle diameter of 0.47 µm, and a plate ratio (average particle diameter:thickness) of 18 : 1, as shown in the transmission electron micrograph (x 30,000) of Fig. 6. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 9.8 m²/g, the coercive force (Hc) was 81 Oe, the saturation magnetization (σs) was 88.1 emu/g, and the squareness (σr/σs) was 0.100. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 9 An aqueous solution of 0.45 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel and 14.7 g of sodium citrate was added to the obtained aqueous solution of Na₂CO₃ so that 0.5 mol% of sodium citrate was contained on the basis of the Fe in the aqueous ferrous sulfate solution. To 44.3 ℓ of the aqueous solution of Na₂CO₃, 5.7 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.009 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 0.5 mol% of Fe(II) was added (CO₃/Fe = 2.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.2 mol/ℓ). Air was passed through the aqueous solution containing FeCO₃ at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained plate-like particles had an average particle diameter of 0.12 µm, and a plate ratio (average particle diameter:thickness) of 21 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 25.6 m²/g, the coercive force (Hc) was 111 Oe, the saturation magnetization (σs) was 85.9 emu/g, and the squareness (σr/σs) was 0.111. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 10 An aqueous solution of 0.72 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel and 14.7 g of sodium citrate was added to the obtained aqueous solution of Na₂CO₃ so that 0.5 mol% of sodium citrate was contained on the basis of the Fe in the aqueous ferrous sulfate solution. To 42.9 ℓ of the aqueous solution of Na₂CO₃, 7.1 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.018 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 1.0 mol% of Fe(II)) was added (CO₃/Fe = 2.5 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.25 mol/ℓ). Air was passed through the aqueous solution containing FeCO₃ at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron micrograph, it was found that the obtained plate-like particles had an average particle diameter of 0.23 µm, and a plate ratio (average particle diameter:thickness) of 25 : 1, as shown in the transmission electron micrograph (x 30,000) of Fig. 7. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 19.1 m²/g, the coercive force (Hc) was 102 Oe, the saturation magnetization (σs) was 86.1 emu/g, and the squareness (σr/σs) was 0.098. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 11 An aqueous solution of 1.00 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel and 20.6 g of sodium citrate was added to the obtained aqueous solution of Na₂CO₃ so that 0.5 mol% of sodium citrate was contained on the basis of the Fe in the aqueous ferrous sulfate solution. To 42.0 ℓ of the aqueous solution of Na₂CO₃, 8.0 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.009 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 0.5 mol% of Fe(II)) was added (CO₃/Fe = 3.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.28 mol/ℓ). Air was passed through the aqueous solution containing FeCO₃ at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron microscope, it was found that the obtained plate-like particles had an average particle diameter of 0.31 µm, and a plate ratio (average particle diameter:thickness) of 28 : 1. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 17.5 m²/g, the coercive force (Hc) was 93 Oe, the saturation magnetization (σs) was 86.4 emu/g, and the squareness (σr/σs) was 0.103. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles. Example 12 An aqueous solution of 1.47 mol/ℓ of Na₂CO₃ was prepared in a reaction vessel and 34.8 g of sodium tartrate was added to the obtained aqueous solution of Na₂CO₃ so that 1.0 mol% of sodium tartrate was contained on the basis of the Fe in the aqueous ferrous sulfate solution. To 42.0 ℓ of the aqueous solution of Na₂CO₃, 8.0 ℓ of an aqueous solution of 1.75 mol/ℓ of ferrous sulfate containing 0.035 mol/ℓ of ferric sulfate (the amount of Fe(III) is equivalent to 2.0 mol% of Fe(II)) was added (CO₃/Fe = 4.0 equivalents) in a stream of N₂ gas at a temperature of 90°C, thereby producing FeCO₃ (the concentration of Fe(II) and Fe(III) therein was 0.29 mol/ℓ). Air was passed through the aqueous solution containing FeCO₃ at a rate of 60 ℓ per minute at 90°C for 10 hours, thereby producing particles. The particles produced were filtered, washed with water, dried and disaggregated by an ordinary method. From observation through a transmission electron micrograph, it was found that the obtained plate-like particles had an average particle diameter of 0.43 µm, and a plate ratio (average particle diameter:thickness) of 31 : 1, as shown in the transmission electron micrograph (x 20,000) of Fig. 8. No pores existed on the surface or the interior of the particles. The BET specific surface area of the obtained particles was 12.1 m²/g, the coercive force (Hc) was 88 Oe, the saturation magnetization (σs) was 86.9 emu/g, and the squareness (σr/σs) was 0.106. As a result of X-ray diffraction, only the peak indicating magnetite particles was observed and it was thus seen that the obtained particles were magnetite particles.

Claims: Poreless plate-like magnetite particles which have an average particle diameter of from 0.1 to 0.5 µm and which are discrete from each other, said particles having: a) a plate ratio of from 11:1 to 20:1 and a specific surface area of from 2.0 to 30.0 m²/g; or b) a plate ratio of from 21:1 to 50:1 and a specific surface area of from 3.0 to 30.0 m²/g. Particles according to claim 1 which have a plate ratio of from 21:1 to 50:1 and a specific surface area of from 6.0 to 30.0 m²/g. Particles according to claim 1 or 2 which have a plate ratio of from 21:1 to 40:1. Particles according to claim 1 which have a plate ratio of from 11:1 to 20:1 and a specific surface area of from 5.0 to 30.0 m²/g. A process for producing poreless, plate-like magnetite particles having a plate ratio of from 11:1 to 20:1, a specific surface area of from 2.0 to 30.0 m²/g and an average particle diameter of from 0.1 to 1.5µm and which are discrete from each other, which process comprises, (i) reacting a ferrous salt solution containing from 0.1 to 5.5 mol% of a ferric salt, calculated as Fe(III), based on Fe(II), with an amount of an aqueous alkali carbonate at a temperature of not lower than 75°C, such that the equivalent ratio of the alkali carbonate to the Fe(II) and Fe(III) in the aqueous ferrous salt solution is not less than 1:1 and the following general formula is satisfied: and (ii) oxidizing the suspension containing FeCO₃ thus obtained by passing an oxygen-containing gas therethrough. A process for producing poreless, plate-like magnetite particles having a plate ratio of from 21:1 to 50:1, a specific surface area of from 3.0 to 30 m²/g and an average particle diameter of from 0.1 to 1.5µm and which are discrete from each other, which process comprises, (i) reacting a ferrous salt solution containing from 0.1 to 5.5 mol% of a ferric salt, calculated as Fe(III), based on Fe(II), with an amount of an aqueous alkali carbonate at a temperature of not lower than 75°C, such that the equivalent ratio of the alkali carbonate to the Fe(II) and Fe(III) in the aqueous ferrous salt solution is not less than 1:1 and the following general formula is satisfied: in which from 0.01 to 8.0 mol% of a water-soluble organic compound having a -COONa or -COOK group, based on the Fe(II) and Fe(III), are added to the aqueous ferrous salt solution, to the aqueous alkali carbonate solution or to the suspension containing FeCO₃ before oxidation; and (ii) oxidizing the suspension containing FeCO₃ thus obtained by passing an oxygen-containing gas therethrough. A process according to claim 6, wherein the water-soluble organic compound having a -COONa group is selected from sodium acetate, sodium tartrate, sodium citrate and sodium propionate. A process according to any one of claims 5 to 7, in which the ferrous salt solution contains from 0.2 to 5.0 mol% of a ferric salt, calculated as Fe(III), based on Fe(II). A process according to any one of claims 5 to 8, wherein the reaction temperature of the aqueous ferrous salt solution and the aqueous alkali carbonate solution is from 75 to 100°C. A process according to any one of claims 5 to 9, wherein the particles produced are as defined in any one of claims 1 to 4. A magnetic medium, coating or molded product wherein the magnetic material is poreless plate-like magnetic particles as claimed in any one of claims 1 to 4 or as produced by a process as claimed in any one of claims 5 to 9.

Inventors: HONMYO TORAYUKI, HONMYO, TORAYUKI,
Applicants: TODA KOGYO CORP, TODA KOGYO CORP.
Application year: 1990
Main classification: C01G49
IPC codes: G11B5, C01G49