Acicular ferromagnetic alloy particles for magnetic recording and process for producing the same

Claim 2

Acicular ferromagnetic alloy particles for magnetic recording, comprising the acicular ferromagnetic alloy particles containing Si, Cr, Ni and P impregnated with phosphorus compound and silicon compound.

Claim 3

Acicular ferromagnetic alloy particles for magnetic recording according to claim 1, wherein said acicular ferromagnetic alloy particles containing Si, Cr, Ni and P further contain Mg.

Claim 4

A process for producing acicular ferromagnetic alloy particles for magnetic recording, comprising the steps of oxidizing Fe(OH) 2 in an aqueous suspension by blowing an oxygen-containing gas into said aqueous suspension of Fe(OH) 2 of pH of higher than 11 obtained by reacting an aqueous solution of a ferrous salt with an aqueous solution of an alkali metal hydroxide thereby obtaining acicular particles of alpha-FeOOH containing Si, Cr and Ni, a water-soluble silicate being added into said aqueous solution of an alkali metal hydroxide or into said aqueous suspension of Fe(OH) 2 before blowing said oxygen-containing gas in an amount of 0.1 to 1.7 atomic % (calculated as Si) to Fe of said ferrous salt and a water-soluble chromium salt and a water-soluble nickel salt being added into said aqueous solution of the ferrous salt, said aqueous solution of the alkali metal hydroxide, said aqueous suspension of Fe(OH) 2 before blowing the oxygen-containing gas thereinto, or said aqueous suspension of Fe(OH) 2 during oxidizing by blowing the oxygen-containing gas thereinto, in the respective amount of 0.1 to 5.0 atomic % (calculated as Cr) and 0.1 to 7.0 atomic % (calculated as Ni) to Fe of said ferrous salt, after collecting said acicular particles of alpha-FeOOH containing Si, Cr and Ni from the mother liquor and suspending the thus obtained particle in water, adding 0.1 to 2% by weight of a salt of phosphoric acid (calculated as PO 3 ) to said acicular particles of alpha-FeOOH containing Si, Cr and Ni in the thus formed aqueous suspension of pH of higher than 8, further adding 0.1 to 7.0% by weight of a water-soluble silicate (calculated as SiO 2 ) thereinto, and adjusting the pH of the thus prepared aqueous suspension to 3 to 7, thereby obtaining the acicular particles of alpha-FeOOH containing Si, Cr and Ni coated with a phosphorus compound and a silicon compound, after collecting said acicular particles by filtering and drying said acicular particles, subjecting the thus dried acicular particles of alpha-FeOOH containing Si, Cr and Ni coated with said phosphorus compound and said silicon compound to thermal treatment in a non-reducing atmosphere, thereby obtaining the acicular particles of alpha-Fe 2 O 3 containing Si, Cr and Ni impregnated with said phosphorus compound and said silicon compound, subjecting the thus obtained acicular particles of alpha-Fe 2 O 3 containing Si, Cr and Ni impregnated with said phosphorus compound and said silicon compound to thermal reduction in a reducing gas thereby obtaining acicular ferromagnetic alloy particles containing Si, Cr, Ni and P impregnated with phosphorus compound and silicon compound.

Claim 5

A process for producing acicular ferromagnetic alloy particles for magnetic recording, comprising the steps of oxidizing Fe(OH) 2 in an aqueous suspension by blowing an oxygen-containing gas into said aqueous suspension of Fe(OH) 2 of pH of higher than 11 obtained by reacting an aqueous solution of a ferrous salt with an aqueous solution of an alkali metal hydroxide thereby obtaining acicular particles of alpha-FeOOH containing Si, Cr and Ni, a water-soluble silicate being added into said aqueous solution of an alkali metal hydroxide or into said aqueous suspension of Fe(OH) 2 before blowing said oxygen-containing gas in an amount of 0.1 to 1.7 atomic % (calculated as Si) to Fe of said ferrous salt and a water-soluble chromium salt and a water-soluble nickel salt being added into said aqueous solution of the ferrous salt, said aqueous solution of the alkali metal hydroxide, said aqueous suspension of Fe(OH) 2 before blowing the oxygen-containing gas thereinto, or said aqueous suspension of Fe(OH) 2 during oxidizing by blowing the oxygen-containing gas thereinto, in the respective amount of 0.1 to 5.0 atomic % (calculated as Cr) and 0.1 to 7.0 atomic % (calculated as Ni) to Fe of said ferrous salt, after collecting said acicular particles of alpha-FeOOH containing Si, Cr and Ni from the mother liquor and suspending the thus obtained particle in water, adding 0.1 to 2% by weight of a salt of phosphoric acid (calculated as PO 3 ) to said acicular particles of alpha-FeOOH containing Si, Cr and Ni in the thus formed aqueous suspension of pH of higher than 8, further adding 0.1 to 7.0% by weight of a water-soluble silicate (calculated as SiO 2 ) thereinto, and adjusting the pH of the thus prepared aqueous suspension to 3 to 7, thereby obtaining the acicular particles of alpha-FeOOH containing Si, Cr and Ni coated with a phosphorus compound and a silicon compound, after collecting said acicular particles by filtering and drying said acicular particles, subjecting the thus dried acicular particles of alpha-FeOOH containing Si, Cr and Ni coated with said phosphorus compound and said silicon compound to thermal treatment in a non-reducing atmosphere, thereby obtaining the acicular particles of alpha-Fe 2 O 3 containing Si, Cr and Ni impregnated with said phosphorus compound and said silicon compound, subjecting the thus obtained acicular particles of alpha-Fe 2 O 3 containing Si, Cr and Ni impregnated with said phosphorus compound and said silicon compound to thermal reduction in a reducing gas thereby obtaining acicular ferromagnetic alloy particles containing Si, Cr, Ni and P impregnated with phosphorus compound and silicon compound.

Claim 6

A process for producing acicular ferromagnetic alloy particles for magnetic recording according to claim 3, wherein a water-soluble magnesium salt is further added to said aqueous solution of said ferrous salt, said aqueous solution of said alkali metal hydroxide, said aqueous suspension of Fe(OH) 2 before blowing said oxygen containing gas therein, or said aqueous suspension of Fe(OH) 2 during blowing said oxygen-containing gas thereinto in an amount of 0.1 to 15.0 atomic % as Mg to Fe corresponding to said ferrous salt in said aqueous suspension of Fe(OH) 2 , thereby oxidizing said ferrous salt into acicular particles of alpha-FeOOH containing Si, Cr, Ni and Mg, after collecting said acicular particles of alpha-FeOOH containing Si, Cr, Ni and Mg from the mother liquor and doping the surface thereof with both said phosphorus compound and said silicon compound, the thus obtained acicular particles of alpha-FeOOH containing Si, Cr, Ni and Mg coated with said phosphorus compound and said silicon compound are subjected to the thermal treatment, thereby obtaining the acicular particles of alpha-Fe 2 O 3 containing Si, Cr, Ni and Mg impregnated with said phosphorus compound and silicon compound and the thus obtained acicular particles of alpha-Fe 2 O 3 containing Si, Cr, Ni and Mg impregnated with said phosphorus compound and said silicon compound are subjected to thermal reduction in a reducing gas, thereby obtaining acicular ferromagnetic alloy particles containing Si, Cr, Ni, Mg and P impregnated with phosphorus compound and silicon compound.

Claim 7

A process for producing acicular ferromagnetic alloy particles for magnetic recording according to claim 3 or 4, wherein the temperature in said thermal reduction in said non-reducing atmosphere is in the range of 500° to 900° C.

Claim 8

A process for producing acicular ferromagnetic alloy particles for magnetic recording according to claim 3 or 4, wherein the temperature in said thermal reduction in said reducing gas is in the range of 350° to 600° C.