Magnetic metal powder suitable for use in magnetic recording media and method of manufacturing the powder

Abstract

A metal magnetic powder for a magnetic recording medium is provided whose particles have a metal magnetic phase, composed mainly of Fe or Fe plus Co, and an oxide layer, wherein the average major axis length of the powder particles is 10-50 nm, the average particle volume including the oxide layer is 5,000 nm3 or less, the atomic ratio (R+Al+Si)/(Fe+Co) calculated using the content values (at. %) of the elements contained in the powder particles is 20% or less, where R is rare earth element (Y being treated as a rare earth element). The metal magnetic powder is obtained by using a complexing agent and a reducing agent to elute nonmagnetic constituents after firing. The metal magnetic powder exhibits a large saturation magnetization σs for its particle volume while maintaining weatherability comparable to the conventional level and is suitable for a coated-type magnetic recording medium.

Description

BRIEF EXPLANATION OF THE DRAWINGS

FIG. 1 is graph showing how saturation magnetization σs varied as a function of average particle volume V in metal magnetic powders obtained in Examples and Comparative Examples.

FIG. 2 is a pore size distribution graph (with cumulative volume scaled on the vertical axis) for the metal magnetic powders of pre-elution Sample 3 and Example 5.

FIG. 3 is a diagram schematically representing the states of a metal magnetic powder before and after elution processing.

Claims

1. A metal magnetic powder for a magnetic recording medium whose particles have a metal magnetic phase, composed mainly of Fe or Fe plus Co, and an oxide layer, wherein the average major axis length of the powder particles is 10-50 nm, the average particle volume including the oxide layer is 5,000 nm3 or less, and the atomic ratio (R+Al+Si)/(Fe+Co) calculated using the content values (at. %) of the elements contained in the powder particles is 20% or less, where R is rare earth element (Y being treated as a rare earth element).

2. The metal magnetic powder for a magnetic recording medium according to claim 1, wherein the total content of rare earth element (Y being treated as a rare earth element), Al and Si in the powder particles is not greater than 40 μmol/m2 per unit surface area of the powder.

3. The metal magnetic powder for a magnetic recording medium according to claim 1, wherein when its pore size distribution is measured by the mercury penetration method, the metal magnetic powder has such relationship that the cumulative volume of pores in the region where the pore size is larger than the average major axis length of the power is 1.0 mL/g or less.

4. The metal magnetic powder for a magnetic recording medium according to claim 1, which metal magnetic powder satisfies the relationship of Formula (1) between saturation magnetization σs (Am2/kg) and average particle volume including the oxide layer V (nm3) and whose rate of decrease in saturation magnetization Δσs when held for 1 week in an atmosphere of a temperature of 60° C. and humidity of 90% RH is 15% or less: σs≧0.0185V+58  (1).

5. A method of manufacturing the metal magnetic powder for a magnetic recording medium defined by claim 1, comprising: a step (elution process) of subjecting a metal magnetic powder including particles having a metal magnetic phase composed mainly of Fe or Fe plus Co and containing a nonmagnetic constituent composed of one or more of rare earth element (Y being treated as a rare earth element), Al and Si, in which step a reducing agent acts in a solution added with a complexing agent capable of forming a complex with one or more of said nonmagnetic constituent to elute the nonmagnetic constituent from the powder particles into the solution.

6. The method of manufacturing the metal magnetic powder for a magnetic recording medium according to claim 5, wherein one or both of disodium tartrate and sodium citrate is used as the complexing agent.

7. The method of manufacturing the metal magnetic powder for a magnetic recording medium according to claim 5, wherein one or more of hydrazine (N2H2), lithium aluminum hydride (LiAlH4), sodium boron hydride (NaBH4), and derivatives thereof are used as the reducing agent.

8. The method of manufacturing the metal magnetic powder for a magnetic recording medium according to claim 5, further comprising after the elution process: a step (oxidation process) for forming an oxide layer on the surfaces of the powder particles.

9. A magnetic recording medium using the metal magnetic powder according to any of claims 1 to claim 1.

10. The metal magnetic powder for a magnetic recording medium according to claim 2, wherein when its pore size distribution is measured by the mercury penetration method, the metal magnetic powder has such relationship that the cumulative volume of pores in the region where the pore size is larger than the average major axis length of the power is 1.0 mL/g or less.

11. The metal magnetic powder for a magnetic recording medium according to claim 2, which metal magnetic powder satisfies the relationship of Formula (1) between saturation magnetization σs (Am2/kg) and average particle volume including the oxide layer V (nm3) and whose rate of decrease in saturation magnetization Δσs when held for 1 week in an atmosphere of a temperature of 60° C. and humidity of 90% RH is 15% or less: σs≧0.0185V+58  (1).

12. The metal magnetic powder for a magnetic recording medium according to claim 3, which metal magnetic powder satisfies the relationship of Formula (1) between saturation magnetization σs (Am2/kg) and average particle volume including the oxide layer V (nm3) and whose rate of decrease in saturation magnetization Δσs when held for 1 week in an atmosphere of a temperature of 60° C. and humidity of 90% RH is 15% or less: σs≧0.0185V+58  (1).

13. A method of manufacturing the metal magnetic powder for a magnetic recording medium defined by claim 2, comprising: a step (elution process) of subjecting a metal magnetic powder including particles having a metal magnetic phase composed mainly of Fe or Fe plus Co and containing a nonmagnetic constituent composed of one or more of rare earth element (Y being treated as a rare earth element), Al and Si, in which step a reducing agent acts in a solution added with a complexing agent capable of forming a complex with one or more of said nonmagnetic constituent to elute the nonmagnetic constituent from the powder particles into the solution.

14. A method of manufacturing the metal magnetic powder for a magnetic recording medium defined by claim 3, comprising: a step (elution process) of subjecting a metal magnetic powder including particles having a metal magnetic phase composed mainly of Fe or Fe plus Co and containing a nonmagnetic constituent composed of one or more of rare earth element (Y being treated as a rare earth element), Al and Si, in which step a reducing agent acts in a solution added with a complexing agent capable of forming a complex with one or more of said nonmagnetic constituent to elute the nonmagnetic constituent from the powder particles into the solution.

15. A method of manufacturing the metal magnetic powder for a magnetic recording medium defined by claim 4, comprising: a step (elution process) of subjecting a metal magnetic powder including particles having a metal magnetic phase composed mainly of Fe or Fe plus Co and containing a nonmagnetic constituent composed of one or more of rare earth element (Y being treated as a rare earth element), Al and Si, in which step a reducing agent acts in a solution added with a complexing agent capable of forming a complex with one or more of said nonmagnetic constituent to elute the nonmagnetic constituent from the powder particles into the solution.

16. The method of manufacturing the metal magnetic powder for a magnetic recording medium according to claim 6, wherein one or more of hydrazine (N2H2), lithium aluminum hydride (LiAlH4), sodium boron hydride (NaBH4), and derivatives thereof are used as the reducing agent.

17. The method of manufacturing the metal magnetic powder for a magnetic recording medium according to claim 6, further comprising after the elution process: a step (oxidation process) for forming an oxide layer on the surfaces of the powder particles.

18. The method of manufacturing the metal magnetic powder for a magnetic recording medium according to claim 7, further comprising after the elution process: a step (oxidation process) for forming an oxide layer on the surfaces of the powder particles.

19. A magnetic recording medium using the metal magnetic powder according to claim 2.

20. A magnetic recording medium using the metal magnetic powder according to claim 3.

21. A magnetic recording medium using the metal magnetic powder according to claim 4.