Process for production of ferromagnetic powder

Claim 2

In a process for producing a ferromagnetic metal powder by reducing, in a solution, a salt of a metal capable of forming a ferromagnetic metal powder with a reducing agent, the improvement comprising separating the ferromagnetic powder from the reaction bath, washing the ferromagnetic metal powder with water until the conductivity of the water after the washing is about 50 mυ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.

Claim 3

The process according to claim 1, wherein the anionic surface active agent is an aliphatic carboxylate salt.

Claim 4

The process according to claim 1, wherein the anionic surface active agent is the alkali metal salt of an aliphatic carboxylic acid containing 11 to 18 carbon atoms.

Claim 5

The process according to claim 3, wherein the aliphatic acid is an unsaturated aliphatic carboxylic acid.

Claim 6

The process according to claim 4, wherein the alkali metal salt of the unsaturated aliphatic carboxylic acid is sodium oleate.

Claim 7

The process according to claim 1, wherein the solution reduction process is carried out using an acid or salt of a phosphinic acid as the reducing agent.

Claim 8

The process according to claim 1, wherein the solution reduction is carried out using a boron hydride compound or a derivative thereof as the reducing agent.

Claim 9

The process according to claim 1, wherein the ferromagnetic metal powder comprises at least about 75% by weight of the metal, and wherein the ferromagnetic metal comprises a member selected from group consisting Fe, Co, Ni, and combinations thereof.

Claim 10

The process according to claim 8, wherein the ferromagnetic metal powder further contains about 20% by weight of a non-magnetic metal selected from the group consisting of Al, Si, S, Sc, Ti, Vi, Cr, Mn, Zn, Y, Mo, Rh, Pd, Ag, Sn, Sb, Te, Ba, Ta, W, Re, Au, Hg, Pb, Bi, La, Ce, Pr, Nd, B, P and combinations thereof.

Claim 11

The process according to claim 8 wherein the ferromagnetic metal powder further contains 15% by weight or less of a member selected from the group consisting of water, oxygen, hydroxyl groups, or combinations thereof.

Claim 12

A ferromagnetic metal powder comprising at least about 75% by weight of a ferromagnetic metal selected from the group consisting of Fe, Co, Ni and combinations thereof; about 20% by weight of a non-magnetic metal selected from the group consisting of Al, Si, S, Sc, Ti, Vi, Cr, Mn, Zn, Y, Mo, Rh, Pd, Ag, Sn, Sb, Te, Ba, Ta, W, Re, Au, Hg, Pb, Bi, La, Ce, Pr, Nd, B, P and combinations thereof; and 15% by weight or less of a member selected from the group consisting of water, oxygen, hydroxyl groups, and combinations thereof; said ferromagnetic metal powder being produced by reducing, in a solution, a salt of said metal capable of forming a ferromagnetic metal powder and a salt of said non-magnetic metal with a reducing agent, and separating the ferromagnetic powder from the reaction bath, washing the ferromagnetic powder with water until the conductivity of the water after the washing is 50 m μ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.

Claim 13

A ferromagnetic metal powder comprising at least about 75% by weight of a ferromagnetic metal selected from the group consisting of Fe, Co, Ni and combinations thereof; about 20% by weight of a non-magnetic metal selected from the group consisting of Al, Si, S, Sc, Ti, Vi, Cr, Mn, Zn, Y, Mo, Rh, Pd, Ag, Sn, Sb, Te, Ba, Ta, W, Re, Au, Hg, Pb, Bi, La, Ce, Pr, Nd, B, P and combinations thereof; and 15% by weight or less of a member selected from the group consisting of water, oxygen, hydroxyl groups, and combinations thereof; said ferromagnetic metal powder being produced by reducing, in a solution, a salt of said metal capable of forming a ferromagnetic metal powder and a salt of said non-magnetic metal with a reducing agent, and separating the ferromagnetic powder from the reaction bath, washing the ferromagnetic powder with water until the conductivity of the water after the washing is 50 m μ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.

Claim 14

A magnetic recording member comprising a support having thereon a magnetic recording layer comprising the ferromagnetic powder of claim 11 in a binder.

Claim 15

A ferromagnetic metal powder comprising at least 75% by weight of Co and about 25% by weight or less of P and a member selected from the group consisting of Ni, Cr, Ti, Pb, Sn, Sb, S, Pd and combinations thereof, and about 10% by weight or less of at least one member selected from the group consisting of water, oxygen, hydroxyl groups, and combinations thereof; said ferromagnetic metal powder being produced by reducing a solution containing a metal capable of forming a ferromagnetic powder with phosphinic acid or a salt thereof, separating the ferromagnetic powder from the reaction bath, washing the ferromagnetic powder with water until the conductivity of the water after the washing is about 50 m μ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.

Claim 16

A ferromagnetic metal powder comprising at least 75% by weight of Co and about 25% by weight or less of P and a member selected from the group consisting of Ni, Cr, Ti, Pb, Sn, Sb, S, Pd and combinations thereof, and about 10% by weight or less of at least one member selected from the group consisting of water, oxygen, hydroxyl groups, and combinations thereof; said ferromagnetic metal powder being produced by reducing a solution containing a metal capable of forming a ferromagnetic powder with phosphinic acid or a salt thereof, separating the ferromagnetic powder from the reaction bath, washing the ferromagnetic powder with water until the conductivity of the water after the washing is about 50 m μ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.

Claim 17

A ferromagnetic metal powder comprising at least 75% by weight Fe, about 25% by weight or less of B and a member selected from the group consisting of Co, Ni, Cr, Ti, Pb, Sn, Sb, S and combinations thereof, and about 10% by weight or less of a member selected from the group consisting of water, oxygen, hydroxyl groups and combinations thereof, said ferromagnetic metal powder being produced by reducing in a solution a salt of a metal capable of forming a ferromagnetic metal powder with a boron hydride compound or a derivative thereof, separating the ferromagnetic metal powder from the reaction bath, washing the ferromagnetic powder with water until the conductivity of the water after the washing is about 50 mμ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.

Claim 18

A ferromagnetic metal powder comprising at least 75% by weight Fe, about 25% by weight or less of B and a member selected from the group consisting of Co, Ni, Cr, Ti, Pb, Sn, Sb, S and combinations thereof, and about 10% by weight or less of a member selected from the group consisting of water, oxygen, hydroxyl groups and combinations thereof, said ferromagnetic metal powder being produced by reducing in a solution a salt of a metal capable of forming a ferromagnetic metal powder with a boron hydride compound or a derivative thereof, separating the ferromagnetic metal powder from the reaction bath, washing the ferromagnetic powder with water until the conductivity of the water after the washing is about 50 mμ/cm or less, and then treating said ferromagnetic metal powder with an aqueous solution containing at least one anionic surface active agent.