Magnetic Tape Abrasive Distribution for Head Chipping Prevention
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Solution Overview
Problem
Magnetic tapes with reduced non-magnetic and magnetic layer thicknesses suffer from deteriorated electromagnetic conversion characteristics during repeated running in low temperature and high humidity environments, due to spacing loss caused by head attachment and partial chipping, which complicates maintaining reliable data storage performance.
Innovation Solution
A magnetic tape design featuring a non-magnetic support with a non-magnetic layer and a magnetic layer, where the magnetic layer includes ferromagnetic hexagonal ferrite powder with a specific abrasive distribution and orientation, ensuring the abrasive is present in a fine state to prevent partial chipping and maintain effective head attachment removal, thus maintaining electromagnetic conversion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the total thickness of the non-magnetic layer and magnetic layer is decreased to increase recording capacity, then the total length of magnetic tape accommodated in one reel increases, but electromagnetic conversion characteristics deteriorate during repeated running in low temperature and high humidity environments
Solution Approach 1:
The patent changes the physical and chemical parameters of the magnetic layer by controlling abrasive particle size distribution (d10-d90 ratio of 0.70 or more), abrasive content (0.01-10 mass%), and magnetic particle characteristics (saturation magnetization 80-200 emu/g, specific surface area 0.1-10 μm²). These parameter optimizations enable thin magnetic layers (total thickness ≤0.60 μm) to maintain reliable electromagnetic conversion characteristics during repeated running in low temperature and high humidity environments while increasing recording capacity.
2Reliability
If abrasion properties of the magnetic layer surface are increased to remove head attached materials, then spacing loss caused by head attached materials is reduced, but partial chipping of the head occurs more easily
Solution Approach 1:
The patent applies local quality by creating different abrasive particle size distributions at different locations within the magnetic layer. The abrasive particles are distributed such that finer particles are present throughout the layer while coarser particles provide surface abrasion properties. This local differentiation enables the surface to effectively remove head attached materials while the overall structure prevents head chipping.
Solution Approach 2:
The magnetic layer is designed as a composite material containing multiple components: ferromagnetic particles (providing magnetic recording properties), abrasive particles (providing surface abrasion properties), and binding agents. This composite structure integrates the functions of data storage and head contamination removal while maintaining head integrity through proper particle size distribution and material selection.
3Object-generated harmful factors
If abrasive particles are present in a fine state to prevent head chipping, then partial chipping of the head is prevented, but abrasion properties of the magnetic layer surface are deteriorated
Solution Approach 1:
The abrasive particle population is segmented into different size ranges with specific proportions. The patent specifies a particle size distribution where d10-d90 ratio is 0.70 or more, meaning there is a deliberate segmentation between finer particles (which prevent head chipping) and coarser particles (which provide abrasion properties). This segmentation allows both functions to coexist effectively.
Solution Approach 2:
The patent optimizes the parameter of abrasive particle size distribution by controlling the d10-d90 ratio to be 0.70 or more and setting the average particle size between 0.01-1.0 μm. It also controls the abrasive content at 0.01-10 mass% of the magnetic layer. These parameter changes enable the magnetic layer to have sufficient abrasion properties while preventing head chipping.
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 magnetic tape maintains excellent electromagnetic conversion characteristics even with reduced thickness, preventing spacing loss and ensuring reliable data storage performance in low temperature and high humidity environments by effectively managing abrasive distribution and orientation within the magnetic layer.
Implementation Method 1
the magnetic layer includes ferromagnetic hexagonal ferrite powder
Implementation Method 2
an abrasive has been included in the magnetic layer, in order to impart a function of removing the head attached materials to the surface of the magnetic layer
Data Source
AI summary
A magnetic tape is provided in which the total thickness of the non-magnetic layer and the magnetic layer is equal to or smaller than 0.60 μm. The magnetic layer includes ferromagnetic hexagonal ferrite powder and an abrasive. The percentage of a plan view maximum area of the abrasive confirmed in a region having a size of 4.3 μm×6.3 μm of the surface of the magnetic layer by plane observation using a scanning electron microscope, with respect to the total area of the region, is equal to or greater than 0.02% and less than 0.06%. Further, the tilt cos θ of the ferromagnetic hexagonal ferrite powder with respect to a surface of the magnetic layer acquired by cross section observation performed by using a scanning transmission electron microscope is 0.85 to 1.00.