Patent Grant
11430478
This application claims priority under 35 U.S.C 119 to Japanese Patent Application No. 2018-246873 filed on Dec. 28, 2018. The above application is hereby expressly incorporated by reference, in its entirety, into the present application.
The present invention relates to a magnetic tape, a magnetic tape cartridge, and a magnetic tape apparatus.
Magnetic recording media are divided into tape-shaped magnetic recording media and disk-shaped magnetic recording media, and tape-shaped magnetic recording media, that is, magnetic tapes are mainly used for storage such as data back-up.
As the magnetic tapes, a magnetic tape including a back coating layer on a surface side of a non-magnetic support opposite to a surface side provided with a magnetic layer has been disclosed in JP1997-190623A (JP-H09-190623A).
A magnetic tape is generally accommodated in a magnetic tape cartridge in a state of being wound around a reel. The recording of information on the magnetic tape and the reproducing thereof are generally performed by setting a magnetic tape cartridge in a magnetic tape apparatus called a drive, and causing the magnetic tape to run in the magnetic tape apparatus, and causing a surface of the magnetic tape (surface of a magnetic layer) and a magnetic head to come into contact with each other for sliding.
The magnetic tape is used in a data center in which a temperature and humidity are controlled. In addition, a temperature and humidity of a storage environment before shipping of the magnetic tape cartridge accommodating the magnetic tape are also controlled.
Meanwhile, in the data center, power saving is required for cost reduction. In order to realize the power saving, it is desirable to further alleviate the controlling conditions of a usage environment of the magnetic tape in the data center than current conditions or make the control unnecessary. This viewpoint applies to the storage environment of the magnetic tape cartridge.
However, it is assumed that, in a case where the controlling conditions of the usage environment and/or the storage environment are alleviated or the controlling thereof is not performed, the magnetic tape is exposed to an environmental change due to a change in the weather, a change of the season, and the like. As an aspect of such an environmental change, a temperature change from a high temperature to a low temperature under low humidity is considered. However, from the studies of the inventor, it is determined that, in a magnetic tape including a back coating layer on a surface side of a non-magnetic support opposite to a surface side provided with a magnetic layer, in a case where sliding between a surface of the magnetic tape and a magnetic head is repeated after a temperature change from a high temperature to a low temperature under low humidity, a phenomenon in which electromagnetic conversion characteristics deteriorate occurs.
An aspect of the invention provides for a magnetic tape including a back coating layer on a surface side of a non-magnetic support opposite to a surface side provided with a magnetic layer, in which deterioration of electromagnetic conversion characteristics is hardly caused, even in a case where sliding between a surface of the magnetic tape and a magnetic head is repeated after a temperature change from a high temperature to a low temperature under low humidity.
According to an aspect of the invention, there is provided a magnetic tape comprising: a non-magnetic support; a magnetic layer including ferromagnetic powder and a binding agent on one surface side of the non-magnetic support; and a back coating layer including non-magnetic powder and a binding agent on the other surface side of the non-magnetic support, in which an isoelectric point of a surface zeta potential of the magnetic layer is equal to or greater than 5.5, and an isoelectric point of a surface zeta potential of the back coating layer is equal to or greater than 4.5.
In an aspect, the isoelectric point of the surface zeta potential of the magnetic layer may be 5.5 to 7.0.
In an aspect, the isoelectric point of the surface zeta potential of the back coating layer may be 4.5 to 6.0.
In an aspect, the binding agent of the magnetic layer may be a binding agent including an acidic group.
In an aspect, the binding agent of the back coating layer may be a binding agent including an acidic group.
In an aspect, the acidic group may include at least one kind of acidic group selected from the group consisting of a sulfonic acid group and a salt thereof.
In an aspect, the magnetic tape may further comprise a non-magnetic layer including non-magnetic powder and a binding agent between the non-magnetic support and the magnetic layer.
According to another aspect of the invention, there is provided a magnetic tape cartridge comprising: the magnetic tape described above.
According to still another aspect of the invention, there is provided a magnetic tape apparatus comprising: the magnetic tape described above; and a magnetic head.
According to an aspect of the invention, it is possible to provide a magnetic tape including a non-magnetic support, a magnetic layer on one surface side of the non-magnetic support, and a back coating layer on the other surface side of the non-magnetic support, in which deterioration of electromagnetic conversion characteristics is hardly caused, even in a case where sliding between a surface of the magnetic tape and a magnetic head is repeated after a temperature change from a high temperature to a low temperature under low humidity, a magnetic tape cartridge, and a magnetic tape apparatus including this magnetic tape.
Magnetic Tape
According to an aspect of the invention, there is provided a magnetic tape comprising: a non-magnetic support; a magnetic layer including ferromagnetic powder and a binding agent on one surface side of the non-magnetic support; and a back coating layer including non-magnetic powder and a binding agent on the other surface side of the non-magnetic support, in which an isoelectric point of a surface zeta potential of the magnetic layer is equal to or greater than 5.5, and an isoelectric point of a surface zeta potential of the back coating layer is equal to or greater than 4.5.
Hereinafter, the magnetic tape will be described more specifically. In the invention and the specification, a “surface of the magnetic layer” is identical to the surface of the magnetic tape on the magnetic layer side, and a “surface of the back coating layer” is identical to the surface of the magnetic tape on the back coating layer side.
Isoelectric Point of Surface Zeta Potential
In the magnetic tape, the isoelectric point of the surface zeta potential of the magnetic layer is equal to or greater than 5.5, and the isoelectric point of the surface zeta potential of the back coating layer is equal to or greater than 4.5. In the invention and the specification, the isoelectric point of the surface zeta potential of each layer is a value of pH, in a case where a surface zeta potential measured by a flow potential method (also referred to as a flow current method) becomes zero. A sample is cut out from the magnetic tape which is a measurement target, and the sample is disposed in a measurement cell so that the surface of a layer which is a target for obtaining the surface zeta potential (that is, surface of magnetic layer or back coating layer) comes into contact with an electrolyte. Pressure in the measurement cell is changed to flow the electrolyte and a flow potential at each pressure is measured, and then, the surface zeta potential is obtained by the following calculation expression.
Calculation Expression
[ζ: surface zeta potential, p: pressure, I: flow potential, η: viscosity of electrolyte, ε: relative dielectric constant of electrolyte, ε0: dielectric constant in a vacuum state, L: length of channel (flow path between two electrodes), A: area of cross section of channel]
The pressure is changed in a range of 0 to 400,000 Pa (0 to 400 mbar). The calculation of the surface zeta potential by flowing the electrolyte to the measurement cell and measuring a flow potential is performed by using electrolytes having different pH (from pH of 9 to pH of 3 at interval of approximately 0.5). A total number of measurement points is 13 from the measurement point of pH 9 to the 13th measurement points of pH 3. By doing so, the surface zeta potential of each measurement point of pH is obtained. As pH decreases, the surface zeta potential decreases. Thus, two measurement points at which polarity of the surface zeta potential changes (a change from a positive value to a negative value) may appear, while pH decreases from 9 to 3. In a case where such two measurement points appear, pH, in a case where the surface zeta potential is zero, is obtained by interpolation by using a straight line (linear function) showing a relationship between the surface zeta potential and pH of each of the two measurement points. Meanwhile, in a case where all of the surface zeta potentials obtained during the decrease of pH from 9 to 3 is positive value, pH, in a case where the surface zeta potential is zero, is obtained by extrapolation by using a straight line (linear function) showing a relationship between the surface zeta potential and pH of the 13th measurement point (pH of 3) which is the final measurement point and the 12th measurement point. On the other hand, in a case where all of the surface zeta potentials obtained during the decrease of pH from 9 to 3 is negative value, pH, in a case where the surface zeta potential is zero, is obtained by extrapolation by using a straight line (linear function) showing a relationship between the surface zeta potential and pH of the first measurement point (pH of 9) which is the initial measurement point and the 12th measurement point. By doing so, the value of pH, in a case where the surface zeta potential measured by the flow potential method is zero, is obtained.
The above measurement is performed three times in total at room temperature by using different samples cut out from the same magnetic tape (magnetic tape which is a measurement target), and pH, in a case where the surface zeta potential in each measurement is zero, is obtained. For the viscosity and the relative dielectric constant of the electrolyte, a measurement value at room temperature is used. The room temperature is set as 20° C. to 27° C. Regarding the magnetic layer, an arithmetic mean of three pHs obtained as described above is an isoelectric point of the surface zeta potential of the magnetic layer of the magnetic tape which is a measurement target. In addition, regarding the back coating layer, an arithmetic mean of three pHs obtained as described above is an isoelectric point of the surface zeta potential of the back coating layer of the magnetic tape which is a measurement target. As the electrolyte having pH of 9, an electrolyte obtained by adjusting pH of a KCl aqueous solution having a concentration of 1 mmol/L to 9 by using a KOH aqueous solution having a concentration of 0.1 mol/L is used. As the electrolyte having other pH, an electrolyte obtained by adjusting pH of the electrolyte having pH of 9, which is adjusted as described above, by using an HCl aqueous solution having a concentration of 0.1 mol/L is used.
The isoelectric point of the surface zeta potential measured by the method described above is an isoelectric point obtained regarding the surface of the magnetic layer or the back coating layer. As a result of the intensive studies, the inventor has newly found that, in the magnetic tape including the magnetic layer and the back coating layer, by setting the isoelectric point of the surface zeta potential of the magnetic layer to be equal to or greater than 5.5 and setting the isoelectric point of the surface zeta potential of the back coating layer to be equal to or greater than 4.5, it is possible to suppress deterioration of electromagnetic conversion characteristics caused by repeated sliding between the surface of the magnetic tape and the magnetic head after a temperature change from a high temperature to a low temperature under low humidity. The inventor has surmised that a reason is that the isoelectric point of the surface zeta potential of each of the magnetic layer and the back coating layer being in a region of nearly neutral to basic pH, that is, the isoelectric point of the surface zeta potential of each of the magnetic layer and the back coating layer being in the above range contributes to a reduction of an influence of a precipitate precipitated on the surface of the magnetic layer and/or the surface of the back coating layer by a temperature change from a high temperature to a low temperature under low humidity on electromagnetic conversion characteristics. However, it is merely a surmise.
The isoelectric point of the surface zeta potential of the magnetic layer is equal to or greater than 5.5, from a viewpoint of further suppressing deterioration of the electromagnetic conversion characteristics, is preferably equal to or greater than 5.7, and more preferably equal to or greater than 6.0. As will be described later in detail, the isoelectric point of the surface zeta potential of the magnetic layer can be controlled by the kind of a component used for forming the magnetic layer, a formation step of the magnetic layer, and the like. From a viewpoint of availability of the controlling, the isoelectric point of the surface zeta potential of the magnetic layer is preferably equal to or smaller than 7.0, more preferably equal to or smaller than 6.7, and even more preferably equal to or smaller than 6.5.
The isoelectric point of the surface zeta potential of the back coating layer is equal to or greater than 4.5, from a viewpoint of further suppressing deterioration of the electromagnetic conversion characteristics, is preferably equal to or greater than 4.7, and more preferably equal to or greater than 5.0. In addition, as will be described later in detail, the isoelectric point of the surface zeta potential of the back coating layer can be controlled by the kind of a component used for forming the back coating layer, a formation step of the back coating layer, and the like. From a viewpoint of availability of the controlling, the isoelectric point of the surface zeta potential of the back coating layer is preferably equal to or smaller than 6.0, more preferably equal to or smaller than 5.8, and even more preferably equal to or smaller than 5.5.
Next, the magnetic layer, the back coating layer, and the like of the magnetic tape will be described more specifically.
Magnetic Layer
Ferromagnetic Powder
As the ferromagnetic powder included in the magnetic layer, ferromagnetic powder normally used in the magnetic layer of various magnetic recording media can be used. It is preferable to use ferromagnetic powder having a small average particle size, from a viewpoint of improvement of recording density of the magnetic tape. From this viewpoint, ferromagnetic powder having an average particle size equal to or smaller than 50 nm is preferably used, and ferromagnetic powder having an average particle size equal to or smaller than 40 nm is more preferably used, as the ferromagnetic powder. Meanwhile, the average particle size of the ferromagnetic powder is preferably equal to or greater than 5 nm, more preferably equal to or greater than 10 nm, even more preferably equal to or greater than 15 nm, and still preferably equal to or greater than 20 nm, from a viewpoint of stability of magnetization.
As a preferred specific example of the ferromagnetic powder, hexagonal ferrite powder can be used. The hexagonal ferrite powder may be barium ferrite, strontium ferrite, calcium ferrite, lead ferrite, or the like, or may be a mixed crystal of two or more kinds of these. For details of the hexagonal ferrite powder, descriptions disclosed in paragraphs 0012 to 0030 of JP2011-225417A, paragraphs 0134 to 0136 of JP2011-216149A, paragraphs 0013 to 0030 of JP2012-204726A, and paragraphs 0029 to 0084 of JP2015-127985A can be referred to, for example.
As a preferred specific example of the ferromagnetic powder, metal powder can also be used. For details of the metal powder, descriptions disclosed in paragraphs 0137 to 0141 of JP2011-216149A and paragraphs 0009 to 0023 of JP2005-251351A can be referred to, for example.
As a preferable specific example of the ferromagnetic powder, ε-iron oxide powder can also be used. As a manufacturing method of the ε-iron oxide powder, a manufacturing method from a goethite, a reverse micelle method, and the like are known. All of the manufacturing methods are well known. In addition, regarding a method of manufacturing the ε-iron oxide powder in which a part of Fe is substituted with substitutional atoms such as Ga, Co, Ti, Al, or Rh, a description disclosed in J. Jpn. Soc. Powder Metallurgy Vol. 61 Supplement, No. S1, pp. S280 to S284, J. Mater. Chem. C, 2013, 1, pp. 5200 to 5206 can be referred, for example. However, the manufacturing method of the ε-iron oxide powder capable of being used as the ferromagnetic powder in the magnetic layer is not limited.
In the invention and the specification, average particle sizes of various powder such as the ferromagnetic powder are values measured by the following method with a transmission electron microscope, unless otherwise noted.
The powder is imaged at a magnification ratio of 100,000 with a transmission electron microscope, the image is printed on photographic printing paper so as to have the total magnification of 500,000 to obtain an image of particles configuring the powder. A target particle is selected from the obtained image of particles, an outline of the particle is traced with a digitizer, and a size of the particle (primary particle) is measured. The primary particle is an independent particle which is not aggregated.
The measurement described above is performed regarding 500 particles randomly extracted. An arithmetic mean of the particle size of 500 particles obtained as described above is an average particle size of the powder. As the transmission electron microscope, a transmission electron microscope H-9000 manufactured by Hitachi, Ltd. can be used, for example. In addition, the measurement of the particle size can be performed by well-known image analysis software, for example, image analysis software KS-400 manufactured by Carl Zeiss. The average particle size shown in examples which will be described later is a value measured by using transmission electron microscope H-9000 manufactured by Hitachi, Ltd. as the transmission electron microscope, and image analysis software KS-400 manufactured by Carl Zeiss as the image analysis software, unless otherwise noted. In the invention and the specification, the powder means an aggregate of a plurality of particles. For example, the ferromagnetic powder means an aggregate of a plurality of ferromagnetic particles. The aggregate of the plurality of particles not only includes an aspect in which particles configuring the aggregate are directly in contact with each other, but also includes an aspect in which a binding agent or an additive which will be described later is interposed between the particles. A term “particles” is also used for describing the powder.
As a method of collecting sample powder from the magnetic tape in order to measure the particle size, a method disclosed in a paragraph 0015 of JP2011-048878A can be used, for example.
In the invention and the specification, unless otherwise noted, (1) in a case where the shape of the particle observed in the particle image described above is a needle shape, a fusiform shape, or a columnar shape (here, a height is greater than a maximum long diameter of a bottom surface), the size (particle size) of the particles configuring the powder is shown as a length of a long axis configuring the particle, that is, a long axis length, (2) in a case where the shape of the particle is a planar shape or a columnar shape (here, a thickness or a height is smaller than a maximum long diameter of a plate surface or a bottom surface), the particle size is shown as a maximum long diameter of the plate surface or the bottom surface, and (3) in a case where the shape of the particle is a sphere shape, a polyhedron shape, or an unspecified shape, and the long axis configuring the particles cannot be specified from the shape, the particle size is shown as an equivalent circle diameter. The equivalent circle diameter is a value obtained by a circle projection method.
In addition, regarding an average acicular ratio of the powder, a length of a short axis, that is, a short axis length of the particles is measured in the measurement described above, a value of (long axis length/short axis length) of each particle is obtained, and an arithmetic mean of the values obtained regarding 500 particles is calculated. Here, unless otherwise noted, in a case of (1), the short axis length as the definition of the particle size is a length of a short axis configuring the particle, in a case of (2), the short axis length is a thickness or a height, and in a case of (3), the long axis and the short axis are not distinguished, thus, the value of (long axis length/short axis length) is assumed as 1, for convenience.
In addition, unless otherwise noted, in a case where the shape of the particle is specified, for example, in a case of definition of the particle size (1), the average particle size is an average long axis length, and in a case of the definition (2), the average particle size is an average plate diameter. In a case of the definition (3), the average particle size is an average diameter (also referred to as an average particle diameter).
The content (filling percentage) of the ferromagnetic powder of the magnetic layer is preferably 50% to 90% by mass and more preferably 60% to 90% by mass. The components other than the ferromagnetic powder of the magnetic layer are at least a binding agent and one or more kinds of additives may be further randomly included. A high filling percentage of the ferromagnetic powder in the magnetic layer is preferable from a viewpoint of improvement recording density.
Binding Agent and Curing Agent
The magnetic tape is a coating type magnetic tape and includes a binding agent in the magnetic layer. The binding agent is one or more kinds of resin. As the binding agent, various resins normally used as a binding agent of a coating type magnetic recording medium can be used. For example, as the binding agent, a resin selected from a polyurethane resin, a polyester resin, a polyamide resin, a vinyl chloride resin, an acrylic resin obtained by copolymerizing styrene, acrylonitrile, or methyl methacrylate, a cellulose resin such as nitrocellulose, an epoxy resin, a phenoxy resin, and a polyvinylalkylal resin such as polyvinyl acetal or polyvinyl butyral can be used alone or a plurality of resins can be mixed with each other to be used. Among these, a polyurethane resin, an acrylic resin, a cellulose resin, and a vinyl chloride resin are preferable. These resins may be homopolymers or copolymers. These resins can be used as the binding agent even in the non-magnetic layer and/or a back coating layer which will be described later.
For the binding agent described above, description disclosed in paragraphs 0028 to 0031 of JP2010-024113A can be referred to. An average molecular weight of the resin used as the binding agent can be, for example, 10,000 to 200,000 as a weight-average molecular weight. The weight-average molecular weight of the invention and the specification is a value obtained by performing polystyrene conversion of a value measured by gel permeation chromatography (GPC) under the following measurement conditions. The weight-average molecular weight of the binding agent shown in examples which will be described later is a value obtained by performing polystyrene conversion of a value measured under the following measurement conditions.
GPC device: HLC-8120 (manufactured by Tosoh Corporation)
Column: TSK gel Multipore HXL-M (manufactured by Tosoh Corporation, 7.8 mmID (inner diameter)×30.0 cm)
Eluent: Tetrahydrofuran (THF)
In an aspect, as the binding agent, a binding agent including an acidic group can be used. The acidic group of the invention and the specification is used as a meaning including a form of a group capable of emitting H+ in water or a solvent including water (aqueous solvent) to be dissociated into anions and a salt thereof. As specific examples of the acidic group, a form of a sulfonic acid group, a sulfate group, a carboxyl group, a phosphate group, and a salt thereof can be used. For example, a form of a salt of a sulfonic acid group (—SO3H) means a group represented by —SO3M, where M represents a group representing an atom (for example, alkali metal atom or the like) which may be cations in water or in an aqueous solvent. The same applies to the form of each of salts of the various groups described above. As an example of the binding agent including the acidic group, a resin including at least one kind of acidic group selected from the group consisting of a sulfonic acid group and a salt thereof (for example, a polyurethane resin or a vinyl chloride resin) can be used. However, the resin included in the magnetic layer is not limited to these resins. In addition, in the binding agent including the acidic group, a content of the acidic group can be, for example, 0.03 to 0.50 meq/g. The unit “eq” represents equivalent, and is a unit that cannot be converted into an SI unit. The content of various functional groups such as the acidic group included in the resin can be obtained by a well-known method in accordance with the kind of the functional group. The amount of the binding agent used in a magnetic layer forming composition can be, for example, 1.0 to 30.0 parts by mass with respect to 100.0 parts by mass of the ferromagnetic powder.
In regards to the controlling of the isoelectric point of the surface zeta potential of the magnetic layer, the inventor has surmised that formation of the magnetic layer so as to decrease the amount of an acidic component present in a surface portion of the magnetic layer contributes to an increase in value of the isoelectric point. In addition, the inventor has surmised that increasing the amount of a basic component present in the surface portion of the magnetic layer also contributes to an increase in value of the isoelectric point. The acidic component is used as a meaning including a form of a component capable of emitting H+ in water or an aqueous solvent to be dissociated into anions and a salt thereof. The basic component is used as a meaning including a form of a component capable of emitting OH− in water or an aqueous solvent to be dissociated into cations and a salt thereof. For example, it is considered that, in a case of using the acidic component, a process of, after unevenly distributing the acidic component in a surface portion of a coating layer of the magnetic layer forming composition, decreasing the amount of the acidic component of the surface portion leads to an increase in value of the isoelectric point of the surface zeta potential of the magnetic layer to control the isoelectric point to be equal to or greater than 5.5. For example, the inventor has considered that, in a step of applying a magnetic layer forming composition onto a non-magnetic support directly or through a non-magnetic layer, the applying which is performed in an alternating magnetic field by applying an alternating magnetic field leads to uneven distribution of the acidic component in the surface portion of the coating layer of the magnetic layer forming composition. Furthermore, the inventor has surmised that performing a burnish treatment thereafter contributes to a removal of at least a part of the unevenly distributed acidic component. The burnish treatment is a treatment of rubbing a surface to be treated with a member (for example, an abrasive tape or a grinding tool such as a grinding blade or a grinding wheel). Details of a magnetic layer forming step including the burnish treatment will be described later. As the acidic component, for example, a binding agent including an acidic group can be used.
In addition, a curing agent can also be used together with the resin which can be used as the binding agent. As the curing agent, in an aspect, a thermosetting compound which is a compound in which a curing reaction (crosslinking reaction) proceeds due to heating can be used, and in another aspect, a photocurable compound in which a curing reaction (crosslinking reaction) proceeds due to light irradiation can be used. At least a part of the curing agent is included in the magnetic layer in a state of being reacted (crosslinked) with other components such as the binding agent, by proceeding the curing reaction in the magnetic layer forming step. This point also applies to a layer formed by using a composition, in a case where the composition used for forming the other layer includes the curing agent. The preferred curing agent is a thermosetting compound, polyisocyanate is suitable. For details of the polyisocyanate, descriptions disclosed in paragraphs 0124 and 0125 of JP2011-216149A can be referred to, for example. The amount of the curing agent can be, for example, 0 to 80.0 parts by mass with respect to 100.0 parts by mass of the binding agent in the magnetic layer forming composition, and is preferably 50.0 to 80.0 parts by mass, from a viewpoint of improvement of hardness of the magnetic layer.
Additives
The magnetic layer includes ferromagnetic powder and the binding agent, and may include one or more kinds of additives, if necessary. As the additives, the curing agent described above is used as an example. In addition, examples of the additive included in the magnetic layer include non-magnetic powder (for example, inorganic powder or carbon black), a lubricant, a dispersing agent, a dispersing assistant, an antibacterial agent, an antistatic agent, and an antioxidant. As the non-magnetic powder, non-magnetic powder which can function as an abrasive, non-magnetic powder (for example, non-magnetic colloid particles) which can function as a projection formation agent which forms projections suitably protruded from the surface of the magnetic layer, and the like can be used. An average particle size of colloidal silica (silica colloid particles) shown in the examples which will be described later is a value obtained by a method disclosed in a measurement method of an average particle diameter in a paragraph 0015 of JP2011-048878A. As the additives, a commercially available product can be suitably selected according to the desired properties or manufactured by a well-known method, and can be used with any amount. As an example of the additive which can be used in the magnetic layer including the abrasive, a dispersing agent disclosed in paragraphs 0012 to 0022 of JP2013-131285A can be used as a dispersing agent for improving dispersibility of the abrasive. For example, for the lubricant, descriptions disclosed in paragraphs 0030 to 0033, 0035, and 0036 of JP2016-126817A can be referred to. The non-magnetic layer may include a lubricant. For the lubricant which may be included in the non-magnetic layer, descriptions disclosed in paragraphs 0030, 0031, 0034, 0035, and 0036 of JP2016-126817A can be referred to. For the dispersing agent, a description disclosed in paragraphs 0061 and 0071 of JP2012-133837A can be referred to. The dispersing agent may be included in the non-magnetic layer. For the dispersing agent which can be included in the non-magnetic layer, a description disclosed in a paragraph 0061 of JP2012-133837A can be referred to.
The magnetic layer described above can be provided on the surface of the non-magnetic support directly or indirectly through the non-magnetic layer.
Back Coating Layer
The back coating layer at least includes non-magnetic powder and a binding agent. As the non-magnetic powder included in the back coating layer, any one or both of carbon black and non-magnetic powder other than carbon black can be used. As the non-magnetic powder other than carbon black, powder of an inorganic substance (inorganic powder) can be used. Specific examples thereof include inorganic powder of iron oxide such as α-iron oxide, titanium oxide such as titanium dioxide, cerium oxide, tin oxide, tungsten oxide, ZnO, ZrO2, SiO2, Cr2O3, α-alumina, β-alumina, γ-alumina, goethite, corundum, silicon nitride, titanium carbide, magnesium oxide, boron nitride, molybdenum disulfide, copper oxide, MgCO3, CaCO3, BaCO3, SrCO3, BaSO4, and silicon carbide. For the non-magnetic powder included in the back coating layer, the description regarding the non-magnetic powder included in the non-magnetic layer which will be described later can also be referred to.
A shape of the non-magnetic powder other than carbon black may be any of a needle shape, a sphere shape, a polyhedron shape, and a planar shape. An average particle size of the non-magnetic powder is preferably 0.01 to 0.20 μm and more preferably 0.01 to 0.15 μm. In addition, a specific surface area of the non-magnetic powder obtained by a Brunauer-Emmett-Teller (BET) method (BET specific surface area) is preferably 1 to 100 m2/g, more preferably 5 to 70 m2/g, and even more preferably 10 to 65 m2/g. Meanwhile, an average particle size of carbon black is, for example, 5 to 80 nm, preferably 10 to 50 nm, and more preferably 10 to 40 nm. For the content (filling percentage) of the non-magnetic powder in the back coating layer, the description regarding the non-magnetic powder of the non-magnetic layer which will be described later can be referred to.
The back coating layer further includes a binding agent and can randomly include well-known additives. The amount of the binding agent used in a back coating layer forming composition can be, for example, 1.0 to 30.0 parts by mass with respect to 100.0 parts by mass of the non-magnetic powder.
In an aspect, as the binding agent of the back coating layer, a binding agent including an acidic group can be used. For details of the binding agent including the acidic group, the above description can be referred to.
For other details of the binding agent, additives, and the like of the back coating layer, a well-known technique regarding the back coating layer can be applied, and a well-known technique regarding the magnetic layer and/or the non-magnetic layer can be applied. For example, for the back coating layer, descriptions disclosed in paragraphs 0018 to 0020 of JP2006-331625A and page 4, line 65, to page 5, line 38, of U.S. Pat. No. 7,029,774B can be referred to.
In regards to the controlling of the isoelectric point of the surface zeta potential of the back coating layer, the inventor has surmised that formation of the back coating layer so as to decrease amount of an acidic component present in a surface portion of the back coating layer contributes to an increase in value of the isoelectric point. In addition, the inventor has surmised that increasing the amount of a basic component present in the surface portion of the back coating layer also contributes to an increase in value of the isoelectric point. For example, it is considered that, in a case of using the acidic component, a process of, after unevenly distributing the acidic component in a surface portion of a coating layer of a back coating layer forming composition, decreasing the amount of the acidic component of the surface portion leads to an increase in value of the isoelectric point of the surface zeta potential of the back coating layer to control the isoelectric point to be equal to or greater than 4.5. For example, the inventor has considered that, in a step of applying a back coating layer forming composition onto a non-magnetic support, the applying which is performed in an alternating magnetic field by applying an alternating magnetic field leads to uneven distribution of the acidic component in the surface portion of the coating layer of the back coating layer forming composition. Furthermore, the inventor has surmised that performing a burnish treatment thereafter contributes to a removal of at least a part of the unevenly distributed acidic component. Details of a back coating layer forming step including the burnish treatment will be described later. As the acidic component, for example, a binding agent including an acidic group can be used.
Non-Magnetic Layer
Next, the non-magnetic layer will be described. The magnetic tape may include a magnetic layer directly on the surface of the non-magnetic support or may include a magnetic layer on the surface of the non-magnetic support directly or indirectly through the non-magnetic layer including the non-magnetic powder and the binding agent. The non-magnetic powder used in the non-magnetic layer may be inorganic powder or organic powder. In addition, carbon black and the like can be used. Examples of the inorganic powder include powder of metal, metal oxide, metal carbonate, metal sulfate, metal nitride, metal carbide, and metal sulfide. These non-magnetic powder can be purchased as a commercially available product or can be manufactured by a well-known method. For details thereof, descriptions disclosed in paragraphs 0146 to 0150 of JP2011-216149A can be referred to. For carbon black which can be used in the non-magnetic layer, descriptions disclosed in paragraphs 0040 and 0041 of JP2010-024113A can be referred to. The content (filling percentage) of the non-magnetic powder of the non-magnetic layer is preferably 50% to 90% by mass and more preferably 60% to 90% by mass.
In regards to other details of a binding agent or additives of the non-magnetic layer, the well-known technique regarding the non-magnetic layer can be applied. In addition, in regards to the type and the content of the binding agent, and the type and the content of the additive, for example, the well-known technique regarding the magnetic layer can be applied.
In the invention and the specification, the non-magnetic layer also includes a substantially non-magnetic layer including a small amount of ferromagnetic powder as impurities or intentionally, together with the non-magnetic powder. Here, the substantially non-magnetic layer is a layer having a residual magnetic flux density equal to or smaller than 10 mT, a layer having coercivity equal to or smaller than 7.96 kA/m (100 Oe), or a layer having a residual magnetic flux density equal to or smaller than 10 mT and coercivity equal to or smaller than 7.96 kA/m (100 Oe). It is preferable that the non-magnetic layer does not have a residual magnetic flux density and coercivity.
Non-Magnetic Support
Next, the non-magnetic support (hereinafter, also simply referred to as a “support”) will be described. As the non-magnetic support, well-known components such as polyethylene terephthalate, polyethylene naphthalate, polyamide, polyamide imide, and aromatic polyamide subjected to biaxial stretching are used. Among these, polyethylene terephthalate, polyethylene naphthalate, and polyamide are preferable. Corona discharge, plasma treatment, easy-bonding treatment, or heat treatment may be performed with respect to these supports in advance.
Various Thicknesses
A thickness of the non-magnetic support is preferably 3.00 to 20.00 μm, more preferably 3.00 to 10.00 μm, and even more preferably 3.00 to 6.00 μm.
A thickness of the magnetic layer can be optimized according to a saturation magnetization amount of a magnetic head used, a head gap length, a recording signal band, and the like. The thickness of the magnetic layer is normally 0.01 μm to 0.15 μm, and is preferably 0.02 μm to 0.12 μm and more preferably 0.03 μm to 0.10 μm from a viewpoint of realization of high-density recording. The magnetic layer may be at least one layer, or the magnetic layer can be separated into two or more layers having different magnetic properties, and a configuration regarding a well-known multilayered magnetic layer can be applied. A thickness of the magnetic layer which is separated into two or more layers is a total thickness of these layers.
A thickness of the non-magnetic layer is, for example, 0.10 to 1.50 μm and is preferably 0.10 to 1.00 μm.
A thickness of the back coating layer is preferably equal to or smaller than 0.90 μm and more preferably 0.10 to 0.70 μm.
The thicknesses of various layers of the magnetic tape and the non-magnetic support can be acquired by a well-known film thickness measurement method. As an example, a cross section of the magnetic tape in a thickness direction is, for example, exposed by a well-known method of ion beams or microtome, and the exposed cross section is observed with a scanning electron microscope. In the cross section observation, various thicknesses can be acquired as a thickness acquired at one portion of the cross section, or an arithmetic mean of thicknesses acquired at a plurality of portions of two or more portions, for example, two portions which are randomly extracted. In addition, the thickness of each layer may be acquired as a designed thickness calculated according to the manufacturing conditions.
Manufacturing Method of Magnetic Tape
Each composition for forming the magnetic layer, the back coating layer, and the non-magnetic layer which is randomly provided, normally includes a solvent, together with various components described above. As the solvent, various organic solvents generally used for manufacturing a coating type magnetic recording medium can be used. The amount of the solvent in each layer forming composition is not particularly limited, and can be set to be the same as that of each layer forming composition of a typical coating type magnetic recording medium. Steps of preparing the composition for forming each layer generally includes at least a kneading step, a dispersing step, and a mixing step provided before and after these steps, if necessary. Each step may be divided into two or more stages. The components used in the preparation of each layer forming composition may be added at an initial stage or in a middle stage of any step. In addition, each raw material may be separately added in two or more steps.
In order to prepare each layer forming composition, a well-known technique can be used. In the kneading step, an open kneader, a continuous kneader, a pressure kneader, or a kneader having a strong kneading force such as an extruder is preferably used. The details of the kneading processes of these kneaders are disclosed in JP1989-106338A (JP-H01-106338A) and JP1989-079274A (JP-1101-079274A). In addition, in order to disperse each layer forming composition, as a dispersion medium, at least one or more kinds of dispersion beads selected from the group consisting of glass beads and other dispersion beads can be used. As such dispersion beads, zirconia beads, titania beads, and steel beads which are dispersion beads having high specific gravity are suitable. These dispersion beads can be used by optimizing a particle diameter (bead diameter) and a filling percentage. As a disperser, a well-known disperser can be used. Each layer forming composition may be filtered by a well-known method before performing the coating step. The filtering can be performed by using a filter, for example. As the filter used in the filtering, a filter having a hole diameter of 0.01 to 3 μm (for example, filter made of glass fiber or filter made of polypropylene) can be used, for example.
The magnetic layer can be formed by directly applying the magnetic layer forming composition onto the surface of the non-magnetic support and drying or performing multilayer coating with the non-magnetic layer forming composition in order or at the same time and drying. The back coating layer can be formed by applying the back coating layer forming composition onto the surface of the non-magnetic support where the magnetic layer is formed or the surface thereof on a side opposite to the surface where the magnetic layer is to be formed. For details of the coating for forming each layer, a description disclosed in a paragraph 0066 of JP2010-231843A can be referred to.
The coating of the magnetic layer forming composition performed in an alternating magnetic field can contribute to the controlling of the isoelectric point of a surface zeta potential of the magnetic layer to be equal to or greater than 5.5. The inventor has surmised that this is because, an acidic component (for example, the binding agent including an acidic group) is easily unevenly distributed in a surface portion of a coating layer of the magnetic layer forming composition due to the applied alternating magnetic field, and thus, by drying this coating layer, a magnetic layer in which the acidic component is unevenly distributed in the surface portion is obtained. Furthermore, the inventor has surmised that performing a burnish treatment thereafter contributes to a removal of at least a part of the unevenly distributed acidic component to control the isoelectric point of the surface zeta potential of the magnetic layer to be equal to or greater than 5.5.
In addition, the coating of the back coating layer forming composition performed in an alternating magnetic field can contribute to the controlling of the isoelectric point of a surface zeta potential of the back coating layer to be equal to or greater than 4.5. The inventor has surmised that this is because, an acidic component (for example, the binding agent including an acidic group) is easily unevenly distributed in a surface portion of a coating layer of the back coating layer forming composition due to the applied alternating magnetic field, and thus, by drying this coating layer, a back coating layer in which the acidic component is unevenly distributed in the surface portion is obtained. Furthermore, the inventor has surmised that performing a burnish treatment thereafter contributes to a removal of at least a part of the unevenly distributed acidic component to control the isoelectric point of the surface zeta potential of the back coating layer to be equal to or greater than 4.5.
The applying of the alternating magnetic field can be performed by disposing a magnet in a coating device so that the alternating magnetic field is applied vertically to the surface of the coating layer of the magnetic layer forming composition or the back coating layer forming composition. A magnetic field strength of the alternating magnetic field can be, for example, set as approximately 0.05 to 3.00 T. However, there is no limitation to this range. The “vertical” in the invention and the specification does not mean only a vertical direction in the strict sense, but also includes a range of errors allowed in the technical field of the invention. For example, the range of errors means a range of less than ±10° from an exact vertical direction.
The burnish treatment is a treatment of rubbing a surface to be treated with a member (for example, an abrasive tape or a grinding tool such as a grinding blade or a grinding wheel), and can be performed in the same manner as a well-known burnish treatment for manufacturing a coating type magnetic recording medium. The burnish treatment can be preferably carried out by performing one or both of rubbing (polishing) a surface of the coating layer to be treated with an abrasive tape and rubbing (grinding) a surface of the coating layer to be treated with a grinding tool. As the abrasive tape, a commercially available product may be used or an abrasive tape manufactured by a well-known method may be used. As the grinding tool, a well-known grinding blade such as a fixed blade, a diamond wheel, or a rotary blade, a grinding wheel, or the like can be used. In addition, a wiping treatment of wiping off the surface of the coating layer rubbed by the abrasive tape and/or the grinding tool with a wiping material may be performed. For details of the preferred abrasive tape, grinding tool, burnish treatment, and wiping treatment, descriptions disclosed in paragraphs 0034 to 0048 and FIG. 1 of JP1994-052544 (JP-H06-52544A) and examples thereof can be referred to. It is considered that the more the burnish treatment is strengthened, the more the acidic component unevenly distributed in the surface portion of the coating layer of the magnetic layer forming composition or the back coating layer forming composition by performing the applying in an alternating magnetic field can be removed. The burnish treatment can be strengthened as an abrasive having high hardness is used as the abrasive contained in the abrasive tape, and can be strengthened as the amount of the abrasive in the abrasive tape is increased. In addition, the burnish treatment can be strengthened as a grinding tool having high hardness is used as the grinding tool. In regards to the burnish treatment conditions, the burnish treatment can be strengthened as a sliding speed between the surface of the coating layer to be processed and the member (for example, an abrasive tape or a grinding tool) is increased. The sliding speed can be increased by increasing one or both of the speed for moving the member and the speed for moving the magnetic tape to be treated. Although the reason is not clear, the isoelectric point of the surface zeta potential of the magnetic layer may tend to increase after the burnish treatment as the amount of the binding agent containing an acidic group in the coating layer of the magnetic layer forming composition is increased. The same applies to the back coating layer.
In a case where the magnetic layer forming composition contains a curing agent, it is preferable to perform a curing treatment at any stage of the steps for forming the magnetic layer. The burnish treatment is preferably performed at least before the curing treatment. The burnish treatment may be further performed after the curing treatment. The inventor has considered that it is preferable to perform the burnish treatment before the curing treatment in order to increase a removal efficiency for removing the acidic component from the surface portion of the coating layer of the magnetic layer forming composition. The curing treatment can be performed by a treatment such as heat treatment or light irradiation according to the kind of the curing agent contained in the magnetic layer forming composition. The curing treatment conditions are not particularly limited, and may be appropriately set according to the list of the magnetic layer forming composition, the kind of curing agent, the thickness of the coating layer, and the like. For example, in a case where the coating layer is formed using the magnetic layer forming composition containing polyisocyanate as the curing agent, the curing treatment is preferably the heat treatment.
Even in a case where the back coating layer forming composition contains a curing agent, it is preferable to perform a curing treatment at any stage of the steps for forming the back coating layer. The burnish treatment is preferably performed at least before the curing treatment. The burnish treatment may be further performed after the curing treatment. The inventor has considered that it is preferable to perform the burnish treatment before the curing treatment in order to increase a removal efficiency for removing the acidic component from the surface portion of the coating layer of the back coating layer forming composition. The curing treatment can be performed by a treatment such as heat treatment or light irradiation according to the kind of the curing agent contained in the back coating layer forming composition. The curing treatment conditions are not particularly limited, and may be appropriately set according to the list of the back coating layer forming composition, the kind of curing agent, the thickness of the coating layer, and the like. For example, in a case where the coating layer is formed using the back coating layer forming composition containing polyisocyanate as the curing agent, the curing treatment is preferably the heat treatment.
Preferably, a surface smoothing treatment can be performed before the curing treatment. The surface smoothing treatment is a treatment performed for increasing the smoothness of the surface of the magnetic layer and/or the surface of the back coating layer, and is preferably performed by a calender process. For details of the calender process, descriptions disclosed in a paragraph 0026 of JP2010-231843A can be referred to, for example.
For various other steps for manufacturing the magnetic tape, a well-known technique can be applied. For details of the various steps, descriptions disclosed in paragraphs 0067 to 0070 of JP2010-231843A can be referred to, for example. It is preferable that the coating layer of the magnetic layer forming composition is subjected to an alignment process, while this coating layer is wet (not dried). For the alignment process, various well-known techniques such as a description disclosed in a paragraph 0067 of JP2010-231843A can be used. For example, a homeotropic alignment process can be performed by a well-known method such as a method using a polar opposing magnet. In an alignment zone, it is possible to control a drying speed of the coating layer by a temperature of dry air, an air flow, and/or a transportation speed of the magnetic tape in the alignment zone. In addition, the coating layer may be preliminarily dried before being transported to the alignment zone. In a case of performing the alignment process, it is preferable to apply a magnetic field (for example, DC magnetic field) for aligning the ferromagnetic powder with respect to the coating layer of the magnetic layer forming composition applied in the alternating magnetic field.
As described above, it is possible to obtain the magnetic tape according to an aspect of the invention. The magnetic tape is normally accommodated in a magnetic tape cartridge and the magnetic tape cartridge is mounted in a magnetic tape apparatus (generally referred to as a “drive”). A servo pattern can also be formed on the magnetic layer of the magnetic tape by a well-known method, in order to allow head tracking servo to be performed in the drive. For example, the servo pattern can be formed on a direct current (DC) demagnetized magnetic layer. The direction of demagnetization can be a longitudinal direction or a vertical direction of the magnetic tape. In addition, the direction of magnetization in a case of forming the servo pattern (that is, magnetized region) can be a longitudinal direction or a vertical direction of the magnetic tape.
According to the magnetic tape, it is possible to suppress deterioration of electromagnetic conversion characteristics caused by the repeated sliding between the surface of the magnetic tape and the magnetic head after a temperature change from a high temperature to a low temperature under low humidity, it is possible to decrease the generation frequency of the missing pulse. In an aspect, low humidity can be environment of relative humidity of approximately 0% to 30%, for example. A high temperature can be, for example, approximately 30° C. to 50° C., a low temperature can be, for example, approximately higher than 0° C. and equal to or lower than 15° C., and a temperature change from a high temperature to a low temperature can be, for example, a temperature change approximately from 15° C. to 50° C.
Magnetic Tape Cartridge
An aspect of the invention relates to a magnetic tape cartridge including the magnetic tape.
In the magnetic tape cartridge, the magnetic tape is generally accommodated in a cartridge main body in a state of being wound around a reel. The reel is rotatably provided in the cartridge main body. As the magnetic tape cartridge, a single reel type magnetic tape cartridge including one reel in a cartridge main body and a twin reel type magnetic tape cartridge including two reels in a cartridge main body are widely used. In a case where the single reel type magnetic tape cartridge is mounted in the magnetic tape apparatus (drive) in order to record and/or reproduce information (magnetic signals) on the magnetic tape, the magnetic tape is drawn from the magnetic tape cartridge and wound around the reel on the drive side. A magnetic head is disposed on a magnetic tape transportation path from the magnetic tape cartridge to a winding reel. Sending and winding of the magnetic tape are performed between a reel (supply reel) on the magnetic tape cartridge side and a reel (winding reel) on the drive side. In the meantime, the magnetic head comes into contact with and slides on the surface of the magnetic layer of the magnetic tape, and accordingly, the recording and/or reproduction of information is performed. With respect to this, in the twin reel type magnetic tape cartridge, both reels of the supply reel and the winding reel are provided in the magnetic tape cartridge. The magnetic tape cartridge may be any of single reel type magnetic tape cartridge and twin reel type magnetic tape cartridge. The magnetic tape cartridge may include the magnetic tape according to an aspect of the invention, and a well-known technique can be applied for other configurations.
Magnetic Tape Apparatus
An aspect of the invention relates to a magnetic tape apparatus including the magnetic tape and a magnetic head.
In the invention and the specification, the “magnetic tape apparatus” means a device capable of performing at least one of the recording of information on the magnetic tape or the reproducing of information recorded on the magnetic tape. Such an apparatus is generally called a drive. The magnetic tape apparatus can be a sliding type magnetic tape apparatus. The sliding type apparatus is an apparatus in which the surface of the magnetic layer comes into contact with and slides on the magnetic head, in a case of performing the recording of information on the magnetic tape and/or reproducing of the recorded information.
The magnetic head included in the magnetic tape apparatus can be a recording head capable of performing the recording of information on the magnetic tape, or can be a reproducing head capable of performing the reproducing of information recorded on the magnetic tape. In addition, in an aspect, the magnetic tape apparatus can include both of a recording head and a reproducing head as separate magnetic heads. In another aspect, the magnetic head included in the magnetic tape can also have a configuration of comprising both of a recording element and a reproducing element in one magnetic head. As the reproducing head, a magnetic head (MR head) including a magnetoresistive (MR) element capable of sensitively reading information recorded on the magnetic tape as a reproducing element is preferable. As the MR head, various well-known MR heads can be used. In addition, the magnetic head which performs the recording of information and/or the reproducing of information may include a servo pattern reading element. Alternatively, as a head other than the magnetic head which performs the recording of information and/or the reproducing of information, a magnetic head (servo head) comprising a servo pattern reading element may be included in the magnetic tape apparatus.
In the magnetic tape apparatus, the recording of information on the magnetic tape and/or the reproducing of information recorded on the magnetic tape can be performed by bringing the surface of the magnetic layer of the magnetic tape into contact with the magnetic head and sliding. The magnetic tape apparatus may include the magnetic tape according to an aspect of the invention and well-known techniques can be applied for other configurations.
Hereinafter, the invention will be described with reference to examples. However, the invention is not limited to aspects shown in the examples. “Parts” and “%” in the following description mean “parts by mass” and “% by mass”, unless otherwise noted. In addition, steps and evaluations described below are performed in an environment of an atmosphere temperature of 23° C.±1° C., unless otherwise noted.
A “binding agent A” described below is a SO3Na group-containing polyurethane resin (weight-average molecular weight: 70,000, SO3Na group: 0.20 meq/g).
A “binding agent B” described below is a vinyl chloride copolymer (product name: MR110, SO3K group-containing vinyl chloride copolymer, SO3K group: 0.07 meq/g) manufactured by Kaneka Corporation.
Manufacturing of Magnetic Tape
(1) Preparation of Alumina Dispersion
3.0 parts of 2,3-dihydroxynaphthalene (manufactured by Tokyo Chemical Industry Co., Ltd.), 31.3 parts of a 32% solution (solvent is a mixed solvent of methyl ethyl ketone and toluene) of a SO3Na group-containing polyester polyurethane resin (UR-4800 (SO3Na group: 0.08 meq/g) manufactured by Toyobo Co., Ltd.), and 570.0 parts of a mixed solvent of methyl ethyl ketone and cyclohexanone (mass ratio of 1:1) as a solvent were mixed with 100.0 parts of alumina powder (HIT-80 manufactured by Sumitomo Chemical Co., Ltd.) having a gelatinization ratio of approximately 65% and a BET specific surface area of 20 m2/g, and dispersed in the presence of zirconia beads by a paint shaker for 5 hours. After the dispersion, the dispersion liquid and the beads were separated by a mesh and an alumina dispersion was obtained.
(2) Magnetic Layer Forming Composition List
(3) Non-Magnetic Layer Forming Composition List
(4) Back Coating Layer Forming Composition List
(5) Preparation of Each Layer Forming Composition
The non-magnetic layer forming composition was prepared by the following method.
The magnetic liquid was prepared by dispersing (beads-dispersing) each component by using a batch type vertical sand mill for 24 hours. Zirconia beads having a bead diameter of 0.5 mm were used as the dispersion beads.
The prepared magnetic liquid, the abrasive solution, and other components (silica sol, other components, and finishing additive solvent) were mixed with each other and beads-dispersed for 5 minutes by using the sand mill, and the treatment (ultrasonic dispersion) was performed with a batch type ultrasonic device (20 kHz, 300 W) for 0.5 minutes. After that, the obtained mixed solution was filtered by using a filter having a hole diameter of 0.5 μm, and the magnetic layer forming composition was prepared.
The non-magnetic layer forming composition was prepared by the following method.
Various components described above excluding the lubricant (stearic acid, stearic acid amide, and butyl stearate), cyclohexanone, and methyl ethyl ketone were dispersed by using batch type vertical sand mill for 24 hours to obtain a dispersion liquid. Zirconia beads having a bead diameter of 0.5 mm were used as the dispersion beads. After that, the remaining components were added into the obtained dispersion liquid and stirred with a dissolver. The dispersion liquid obtained as described above was filtered with a filter having a hole diameter of 0.5 μm and a non-magnetic layer forming composition was prepared.
The back coating layer forming composition was prepared by the following method.
Each component excluding polyisocyanate and cyclohexanone was kneaded by an open kneader and diluted, and were subjected to a dispersion process of 12 passes, with a transverse beads mill disperser and zirconia beads having a bead diameter of 1 mm, by setting a bead filling percentage as 80 volume %, a circumferential speed of rotor distal end as 10 m/sec, and a retention time for 1 pass as 2 minutes. After that, the remaining components were added into the obtained dispersion liquid and stirred with a dissolver. The dispersion liquid obtained as described above was filtered with a filter having a hole diameter of 1 μm and a back coating layer forming composition was prepared.
(6) Manufacturing Method of Magnetic Tape
The non-magnetic layer forming composition prepared in the section (5) was applied to a surface of a support made of polyethylene naphthalate having a thickness of 5.00 μm so that the thickness after the drying becomes 1.00 μm and was dried to form a non-magnetic layer.
Then, in a coating device disposed with a magnet for applying an alternating magnetic field, the magnetic layer forming composition prepared in the section (5) was applied onto the surface of the non-magnetic layer so that the thickness after the drying becomes 0.10 μm, while applying an alternating magnetic field (magnetic field strength: 0.15 T), to form a coating layer. The applying of the alternating magnetic field was performed so that the alternating magnetic field was applied vertically to the surface of the coating layer. After that, a homeotropic alignment process was performed by applying a magnetic field having a DC magnetic field strength of 0.30 T in a vertical direction with respect to a surface of a coating layer, while the coating layer of the magnetic layer forming composition is wet (not dried). After that, the coating layer was dried to form a magnetic layer.
After that, the back coating layer forming composition prepared in the section (5) was applied to the surface of the support made of polyethylene naphthalate on a side opposite to the surface where the non-magnetic layer and the magnetic layer were formed, so that the thickness after the drying becomes 0.50 mm, and was dried to form a coating layer of the back coating layer forming composition. The coating of the back coating layer forming composition was performed while applying the alternating magnetic field (magnetic field strength: 0.15 T) vertically to the surface of the coating layer of the back coating layer forming composition, in a coating device disposed with a magnet for applying the alternating magnetic field.
After the magnetic tape obtained as described above was slit to have a width of ½ inches (0.0127 meters), the burnish treatment and the wiping treatment of the surface of the coating layer of the magnetic layer forming composition were performed.
After that, the burnish treatment and the wiping treatment of the surface of the coating layer of the back coating layer forming composition were performed.
The burnish treatment and the wiping treatment were performed by using a commercially available abrasive tape (product name MA22000 manufactured by FUJIFILM Corporation, abrasive: diamond/Cr2O3/bengala) as the abrasive tape, using a commercially available sapphire blade (manufactured by KYOCERA Corporation, width of 5 mm, length of 35 mm, tip angle of 60 degrees) as the grinding blade, and using a commercially available wiping material (product name WRP736 manufactured by KURARAY CO., LTD.) as the wiping material, in the processing apparatus having the configuration shown in FIG. 1 of JP1994-052544 (JP-H06-52544A). As the treatment conditions, the treatment conditions in Example 12 of JP1994-052544 (JP-H06-52544A) were adopted.
After the burnish treatment and the wiping treatment, a surface smoothing treatment (calender process) was performed by using a calender roll configured of only a metal roll, at a speed of 100 m/min, linear pressure of 294 kN/m (300 kg/cm), and a calender temperature (surface temperature of a calender roll) of 100° C.
After that, the heat treatment (curing treatment) was performed in an environment of the atmosphere temperature of 70° C. for 36 hours, and then a servo pattern was formed on the magnetic layer by a commercially available servo writer.
By doing so, a magnetic tape of Example 1 was manufactured.
A magnetic tape was manufactured by the same method as in Example 1, except that various conditions were changed as shown in Table 1.
As shown in Table 1, in Examples 2 to 5, the same magnetic tape manufacturing method as in Example 1 was performed. That is, the application of the alternating magnetic field was performed during the coating of the magnetic layer forming composition and the coating of the back coating layer forming composition, and the burnish treatment and the wiping treatment were performed on the coating layer of the magnetic layer forming composition and the coating layer of the back coating layer forming composition in the same manner as in Example 1.
With respect to this, in Comparative Examples 1 to 4, 7, and 8, the same magnetic tape manufacturing method as in Example 1 was performed, except that the application of the alternating magnetic field was not performed during the coating of the magnetic layer forming composition and the coating of the back coating layer forming composition, and the burnish treatment and the wiping treatment were not performed on the coating layer of the magnetic layer forming composition and the coating layer of the back coating layer forming composition.
In Comparative Example 5, the same magnetic tape manufacturing method as in Example 1 was performed, except that the burnish treatment and the wiping treatment were not performed on the coating layer of the magnetic layer forming composition and the coating layer of the back coating layer forming composition.
In Comparative Example 6, the same magnetic tape manufacturing method as in Example 1 was performed, except that the application of the alternating magnetic field was not performed during the coating of the magnetic layer forming composition and the coating of the back coating layer forming composition.
In Comparative Example 9, the same magnetic tape manufacturing method as in Example 1 was performed, except that the application of the alternating magnetic field was not performed during the coating of the back coating layer forming composition, and the burnish treatment and the wiping treatment were not performed on the coating layer of the back coating layer forming composition.
In Comparative Example 10, the same magnetic tape manufacturing method as in Example 1 was performed, except that the application of the alternating magnetic field was not performed during the coating of the magnetic layer forming composition, and the burnish treatment and the wiping treatment were not performed on the coating layer of the magnetic layer forming composition.
Evaluation of Magnetic Tape
(1) Isoelectric Point of Surface Zeta Potential of Magnetic Layer
Six samples for isoelectric point measurement were cut out from each magnetic tape of the examples and the comparative examples and disposed in the measurement cell of two samples in one measurement. In the measurement cell, a sample installing surface and a surface of the back coating layer of the sample were bonded to each other by using a double-sided tape in upper and lower sample table (size of each sample installing surface is 1 cm×2 cm) of the measurement cell. In a case where an electrolyte flows in the measurement cell after disposing two samples as described above, the surface of the magnetic layer of the two samples bonded to each other on the upper and lower sample table of the measurement cell comes into contact with the electrolyte, and thus, the surface zeta potential of the magnetic layer can be measured. The measurement was performed three times in total by using two samples in each measurement, and the isoelectric points of the surface zeta potential of the magnetic layer were obtained. An arithmetic mean of the three values obtained by three times of the measurement is shown in Table 1, as the isoelectric point of the surface zeta potential of the magnetic layer of each magnetic tape. As a surface zeta potential measurement device, SurPASS manufactured by Anton Paar was used. The measurement conditions were set as follows. Other details of the method of obtaining the isoelectric point are as described above.
Measurement cell: variable gap cell (20 mm×10 mm)
Measurement mode: Streaming Current
Gap: approximately 200 μm
Measurement temperature: room temperature
Ramp Target Pressure/Time: 400,000 Pa (400 mbar)/60 seconds
Electrolyte: KCl aqueous solution having concentration of 1 mmol/L (adjusted pH to 9)
pH adjusting solution: HCl aqueous solution having concentration of 0.1 mol/L or KOH aqueous solution having concentration of 0.1 mol/L
Measurement pH: pH 9 pH 3 (measured at 13 measurement points in total at interval of approximately 0.5)
(2) Isoelectric Point of Surface Zeta Potential of Back Coating Layer
Six samples for isoelectric point measurement were cut out from each magnetic tape of the examples and the comparative examples and disposed in the measurement cell of two samples in one measurement. In the measurement cell, a sample installing surface and a surface of the magnetic layer of the sample were bonded to each other by using a double-sided tape in upper and lower sample table (size of each sample installing surface is 1 cm×2 cm) of the measurement cell. In a case where an electrolyte flows in the measurement cell after disposing two samples as described above, the surface of the back coating layer of the two samples bonded to each other on the upper and lower sample table of the measurement cell comes into contact with the electrolyte, and thus, the surface zeta potential of the back coating layer can be measured. The measurement was performed three times in total by using two samples in each measurement, and the isoelectric points of the surface zeta potential of the back coating layer were obtained. An arithmetic mean of the three values obtained by three times of the measurement is shown in Table 1, as the isoelectric point of the surface zeta potential of the back coating layer of each magnetic tape. As a surface zeta potential measurement device, the device disclosed in the section (1) was used, and the measurement conditions were set as shown in the section (1). Other details of the method of obtaining the isoelectric point are as described above.
(3) Signal-to-Noise-Ratio (SNR) Decrease
Each magnetic tape (total length of magnetic tape: 500 m) of the examples and the comparative examples was stored in a thermo box in which a temperature was maintained to be 32° C. and relative humidity was maintained to be 10%, for 3 hours. After that, the magnetic tape was extracted from the thermo box (a temperature of the outside air was 23° C. and relative humidity was 50%) and put in a thermo room in which a temperature was maintained to be 10° C. and relative humidity was maintained to be 10%, within 1 minute, and then 2000 passes of the recording and the reproducing were performed in this thermo room and a difference between the SNR of the 1st pass and the SNR of 2000th pass (SNR of 2000th pass-SNR of first pass) was calculated as an SNR decrease.
The SNR was measured by the following method using a ½ inches (0.0127 meters) reel tester to which the magnetic head was fixed.
A relative speed between the magnetic tape and the magnetic head is 8 m/sec, and the recording was performed by using a metal-in-gap (MIG) head (gap length 0.15 μm, track width 1.0 μm) as the recording head and setting a recording current to an optimum recording current for each magnetic tape. The reproducing was performed by using a giant-magnetoresistive (GMR) head (element thickness 15 nm, shield interval 0.1 μm, lead width 0.5 μm) as the reproducing head. A signal with a linear recording density of 300 kfci was recorded, and a reproducing signal was measured by a spectrum analyzer manufactured by Shibasoku Co., Ltd. The unit kfci is a unit of the linear recording density (cannot be converted into SI unit system). As the signal, a portion where the signal was sufficiently stable after the start of running of the magnetic tape was used. The recording and the reproducing were performed under the above conditions, and the SNR (Broadband-SNR) was obtained as a relative value when a ratio of an output value of a carrier signal and an integrated noise of an entire spectrum band was SNR and the SNR of the 1st pass in Comparative Example 1 was a reference (0 dB).
The results of the above evaluation are shown in Table 1 (Table 1-1 and Table 1-2).
As shown in Table 1, even in a case where the magnetic tapes of the examples were exposed to a temperature change from a high temperature to a low temperature under low humidity, the SNR decrease was small compared to the magnetic tapes of the comparative examples.
An aspect of the invention is effective in the technical fields of various magnetic recording media for data storage.
| Number | Date | Country | Kind |
|---|---|---|---|
| JP2018-246873 | Dec 2018 | JP | national |
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| 2002-329605 | Nov 2002 | JP |
| 2002-347197 | Dec 2002 | JP |
| 2002-367142 | Dec 2002 | JP |
| 2002-367318 | Dec 2002 | JP |
| 2002-373414 | Dec 2002 | JP |
| 2003-77116 | Mar 2003 | JP |
| 2003-296918 | Oct 2003 | JP |
| 2003-323710 | Nov 2003 | JP |
| 2004-5793 | Jan 2004 | JP |
| 2004-005820 | Jan 2004 | JP |
| 2004-55137 | Feb 2004 | JP |
| 2004-103186 | Apr 2004 | JP |
| 2004-114492 | Apr 2004 | JP |
| 2004-133997 | Apr 2004 | JP |
| 2004-185676 | Jul 2004 | JP |
| 2005-029656 | Feb 2005 | JP |
| 2005-038579 | Feb 2005 | JP |
| 2005-209265 | Aug 2005 | JP |
| 2005-243063 | Sep 2005 | JP |
| 2005-243162 | Sep 2005 | JP |
| 2006-54018 | Feb 2006 | JP |
| 2006-92672 | Apr 2006 | JP |
| 2006-234835 | Sep 2006 | JP |
| 2006-257434 | Sep 2006 | JP |
| 2006-286114 | Oct 2006 | JP |
| 2007-265555 | Oct 2007 | JP |
| 2007-273039 | Oct 2007 | JP |
| 2007-287310 | Nov 2007 | JP |
| 2007-297427 | Nov 2007 | JP |
| 2007-305197 | Nov 2007 | JP |
| 2008-047276 | Feb 2008 | JP |
| 2008-243317 | Oct 2008 | JP |
| 2009-32338 | Feb 2009 | JP |
| 2009-093738 | Apr 2009 | JP |
| 2009-245515 | Oct 2009 | JP |
| 2009-283082 | Dec 2009 | JP |
| 2010-036350 | Feb 2010 | JP |
| 2010-49731 | Mar 2010 | JP |
| 2011-48878 | Mar 2011 | JP |
| 2011-134372 | Jul 2011 | JP |
| 2011-138566 | Jul 2011 | JP |
| 2011-187142 | Sep 2011 | JP |
| 2011-210288 | Oct 2011 | JP |
| 2011-225417 | Nov 2011 | JP |
| 2012-38367 | Feb 2012 | JP |
| 2012-043495 | Mar 2012 | JP |
| 2012-203955 | Oct 2012 | JP |
| 2012-203956 | Oct 2012 | JP |
| 2013-25853 | Feb 2013 | JP |
| 2013-77360 | Apr 2013 | JP |
| 2013-164889 | Aug 2013 | JP |
| 2014-15453 | Jan 2014 | JP |
| 2014-179149 | Sep 2014 | JP |
| 2015-39801 | Mar 2015 | JP |
| 2015-111484 | Jun 2015 | JP |
| 2015-201241 | Nov 2015 | JP |
| 2016-15183 | Jan 2016 | JP |
| 2016-502224 | Jan 2016 | JP |
| 2016-051493 | Apr 2016 | JP |
| 2016-071912 | May 2016 | JP |
| 2016-71926 | May 2016 | JP |
| 2016-110680 | Jun 2016 | JP |
| 2016-126817 | Jul 2016 | JP |
| 2016-139451 | Aug 2016 | JP |
| 2016-177851 | Oct 2016 | JP |
| 2017-16732 | Jan 2017 | JP |
| 2017-041291 | Feb 2017 | JP |
| 2017-041296 | Feb 2017 | JP |
| 2017-174475 | Sep 2017 | JP |
| 2017-228328 | Dec 2017 | JP |
| 2017-228331 | Dec 2017 | JP |
| 2018-73454 | May 2018 | JP |
| 2018-92693 | Jun 2018 | JP |
| 2019-08847 | Jan 2019 | JP |
| 2019065199 | Apr 2019 | WO |
| 2019065200 | Apr 2019 | WO |
| Entry |
|---|
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| Number | Date | Country | |
|---|---|---|---|
| 20200211593 A1 | Jul 2020 | US |
