Magnetic Particle Surface Modification for Coating Dispersion

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Solution Overview

Problem

Existing methods for enhancing the dispersion of magnetic particles in magnetic coating liquids often result in coarse aggregates due to excessive polar groups or dispersing agents, leading to poor surface smoothness and compromised magnetic characteristics.

Innovation Solution

A method involving the use of carboxylic acid compounds with specific structural features to modify the surface of magnetic particles in an acidic water-based solvent, allowing for high dispersion in organic solvent-based coating liquids, thereby preventing aggregation and improving electromagnetic characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dispersing agents are used to enhance compatibility and improve dispersion, then dispersion is improved, but magnetic particles still aggregate strongly and are added as coarse aggregates

Engineering Contradiction:
ImprovedispersionVSAvoidparticle size uniformity
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The invention creates a composite structure by combining the binder with magnetic particles through chemical bonding. The binder contains multiple functional groups that chemically attach to magnetic particle surfaces, forming a stable composite material. This composite approach ensures uniform particle distribution and prevents aggregation, resolving the contradiction between dispersion improvement and particle size uniformity.

Inventive Principle:
Principle #40Composite materials

2Reliability

If intensive dispersing conditions are applied to break down aggregates, then dispersion is improved, but dispersion process takes a long time and causes abrasion and foreign matter contamination

Engineering Contradiction:
ImprovedispersionVSAvoiddispersion time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The invention performs preliminary action by pre-modifying the magnetic particle surfaces with binder molecules before the actual dispersion process. The binder's functional groups chemically bond to the particle surfaces in advance, creating a protective layer that prevents aggregation. This preliminary surface modification eliminates the need for intensive dispersing conditions, significantly reducing dispersion time and avoiding mechanical damage to particles.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If microparticulate magnetic material is employed, then dispersion should be improved, but microparticles aggregate strongly and are added as coarse aggregates

Engineering Contradiction:
Improveparticle sizeVSAvoiddispersion
Core Design Contradiction:
Manufacturing precisionVSReliability

Solution Approach 1:

The invention creates a composite material where binder molecules are chemically bonded to microparticulate magnetic material surfaces. The binder's functional groups (carboxyl, hydroxyl, or amine) form stable chemical bonds with the particle surfaces, creating a composite structure that maintains the small particle size while preventing aggregation. This composite approach ensures that microparticles remain dispersed and are added to the coating liquid in their microparticulate form, not as coarse aggregates.

Inventive Principle:
Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method achieves a highly dispersed state of magnetic particles, reducing the dispersion load and enhancing electromagnetic characteristics in magnetic recording media, while preventing overdispersion and maintaining magnetic properties.

Implementation Method 1

cause a compound capable of functioning as a dispersing agent in an organic solvent-based coating liquid to adsorb to the surface (i.e., to modify the surface) of the magnetic particles in the acidic water-based solvent

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 2

magnetic particles develop a positive surface charge in acidic water-based solvents because protons adsorb onto the magnetic particles

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 3

the repulsive force between positive charges enables the existence of a high state of dispersion

Methodology Applied
Scientific EffectElectrostatic repulsion: Ion Repulsion/Attraction

Data Source

PatentUS9202502B2Magnetic particles and method of manufacturing the same, and usage thereof
Publication Date: 2015.12.01 FUJIFILM CORP

AI summary

An aspect of the present invention relates to a method of manufacturing magnetic particles, which comprises adding a carboxylic acid compound to a water-based magnetic liquid, wherein the water-based magnetic liquid comprises magnetic particles dispersed in an acidic water-based solvent, and the carboxylic acid compound is selected from the group consisting of aromatic compounds and aliphatic compounds having one or more carboxylic acid (salt) groups denoted by:—COOMwherein M denotes a hydrogen atom or an alkali metal atom, when the number of the carboxylic acid (salt) group contained within the molecule thereof is 1, the number of carbon atoms, excluding the carboxylic acid (salt) group portion, ranges from 1 to 13; and then collecting the magnetic particles from the water-based magnetic liquid to obtain the magnetic particles the surfaces of which have been modified by being coated with the carboxylic acid compound.