Oxidation resistant compositions for use with rare earth magnets

Claim 2

An oxidation resistant composition for a rare earth magnet or magnet materials, comprising: an amino containing silane, and at least one of the following two compounds, (1) an epoxy silane, (2) an epoxy resin, the amount of any one of said three compounds in said two component composition being from about 20 parts to about 80 parts by weight based upon the total parts by weight of said two component composition, and wherein the amount of said remaining compound is from about 80 parts to about 20 parts by weight, based upon 100 parts by weight of said two component composition; and the amount of said amino containing silane and said epoxy silane in said three component composition being from about 5 to about 70 parts by weight per 100 parts by weight of said three component composition, and the amount of said epoxy compound being from about 5 parts to about 90 parts by weight per every 100 parts by weight of said three component composition.

Claim 3

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 1, wherein said amino containing silane is an aminosilane or a polyaminosilane having the formula wherein R¹ is a hydrocarbon group having from 1 to 30 carbon atoms, wherein said hydrocarbon group is an ali­phatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R² and R³, independently, is a hydro­carbon group having from 1 to 20 carbon atoms, wherein Y and Z independently is a hydrogen atom, an aminoalkyl group, a polyaminoalkyl group, an aryl group, an alkyl­alkoxysilane group, or an aminoalkylalkoxysilane group wherein said alkyl group has from 1 to 12 carbon atoms and said alkoxy group has from 1 to 6 carbon atoms, wherein said epoxy silane compound has the formula wherein R¹ is a hydrocarbon group having from 1 to 30 carbon atoms, wherein said hydrocarbon group is an ali­phatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R² and R³, independently, is a hydro­carbon group having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof.

Claim 4

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 2, wherein said R¹ of said amino containing silane com­pound and said epoxy silane compound independently is an aliphatic having from 1 to 20 carbon atoms, an aromatic or an alkyl substituted aromatic having from 6 to 30 carbon atoms, and wherein R² and R³ of said amino con­taining silane and said epoxy silane compound indepen­dently is an aliphatic having from 1 to 11 carbon atoms.

Claim 5

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 3, wherein R¹ of said amino containing silane and said epoxy silane independently is an aliphatic containing from 1 to 11 carbon atoms, an aromatic or an alkyl sub­stituted aromatic containing from 7 to 16 carbon atoms, wherein in said ternary system the amount of said amino containing silane is from about 20 to about 60 parts by weight, wherein the amount of said epoxy silane is from about 10 to about 55 parts by weight, wherein said epoxy resin is from about 10 to about 50 parts by weight, and wherein in said binary system, the amount of each said component is from about 30 parts to about 70 parts by weight.

Claim 6

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 4, wherein said R¹ of said amino containing silane com­pound and said epoxy silane compound independently is an alkyl containing 3 or 4 carbon atoms, an aromatic or an alkyl substituted aromatic containing from 7 to 9 carbon atoms, wherein R² and R³ is an alkyl having from 1 to 2 carbon atoms, wherein said Y aminoalkyl group contains at least one secondary or primary amine moiety, wherein in said ternary composition the amount of said amino containing silane is from about 35 to about 50 parts by weight, wherein the amount of said epoxy silane is from about 10 parts to about 40 parts by weight, and wherein the amount of said epoxy is from about 20 parts to about 40 parts by weight.

Claim 7

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 2, wherein said amino containng silane compound is 4-­aminobutyltriethoxysilane, (aminoethylaminomethyl)phen­ethyltrimethoxysilane, N-(2-aminoethyl)-3-aminopropyl­methyldimethoxysilane, 3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, N-2-aminoethyl-3-amino­propyltrimethoxysilane, N-2-aminoethyl-3-aminopropyl­ tris(2-ethylhexoxy)silane, 6-(aminohexylaminopropyl)tri­methoxysilane, 3-aminophenyltrimethoxysilane, 3-(1-aminopropoxy)-3,3-dimethyl-1-propenyltrimethoxysilane, 3-aminopropyltris(methoxyethoxyethoxy)silane, 3-amino­propylmethyldiethoxysilane, bis[3-(trimethoxysilyl)pro­pyl]ethylenediamine, n-phenylaminopropyltrimethoxysilane, trimethoxysilylpropyldiethylenetriamine, ω -aminoundecyl­trimethoxysilane, bis[3-(triethoxysilyl)propyl]amine, dimethoxymethylsilylpropyl (polyethyleneimine), tri­methoxysilylpropyl(polyethylenimine), and wherein said epoxy silane is (3-glycidoxypropyl)methyldiethoxysilane, (3-glycidoxypropyl)trimethoxysilane, 2-(3,4-epoxycyclo­hexyl)ethylmethyldimethoxysilane, 2-(3,4-epoxycyclo­hexyl)ethyltrimethoxysilane and [2-(3,4-epoxy-4-methyl­cyclohexyl)propyl]methyldiethoxy silane.

Claim 8

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 2, wherein said amino containing silane is 3-aminopropyl­triethoxysilane, 3-aminopropyltrimethoxysilane, or N-2-­aminoethyl-3-aminopropyltrimethoxysilane, wherein said epoxy silane compound is (3-glycidoxypropyl)-trimethoxy­silane, wherein said epoxy is the reaction product of bisphenol A and epichlorohydrin, wherein in said ternary system the amount of said amino containing silane is from about 20 to about 60 parts by weight, wherein the amount of said epoxy silane is from about 10 to about 55 parts by weight, and wherein said epoxy resin is from about 10 to about 50 parts by weight, and wherein in said binary system, the amount of each said component is from about 30 parts to about 70 parts by weight.

Claim 9

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 2, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composition.

Claim 10

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 4, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composition, wherein said oxymetallate compound is K₃PO₄, Na₂MoO₄, K₂Cr₂O₇, MCr₂O₇, or MCrO₄, and combinations thereof, and where M is H, Li, Na, or K.

Claim 11

An oxidation resistant composition for a rare earth magnet or magnet materials according to Claim 7, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composition, wherein said oxymetallate compound is MCr₂O₇, MCrO₄, or combinations thereof, and where M is H, Li, Na, or K.

Claim 12

A rare earth magnet or magnet materials coated with an oxidation resistant composition, said composition comprising: an amino containing silane and at least one of the following two compounds, (1) an epoxy silane, (2) an epoxy resin, the amount of any one of said three compounds in said two component composition being from about 20 parts to about 80 parts by weight based upon the total parts by weight of said two component composition, and wherein the amount of said remaining compound is from about 80 parts to about 20 parts by weight, based upon 100 parts by weight of said two component composition; and the amount of said amino containing silane and said epoxy silane in said three component composition being from about 5 to about 70 parts by weight per 100 parts by weight of said three component composition, and the amount of said epoxy compound being from about 5 parts to about 90 parts by weight per every 100 parts by weight of said three component composition.

Claim 13

A rare earth magnet or magnet materials coated with an oxidation resistant composition, said composition comprising: an amino containing silane and at least one of the following two compounds, (1) an epoxy silane, (2) an epoxy resin, the amount of any one of said three compounds in said two component composition being from about 20 parts to about 80 parts by weight based upon the total parts by weight of said two component composition, and wherein the amount of said remaining compound is from about 80 parts to about 20 parts by weight, based upon 100 parts by weight of said two component composition; and the amount of said amino containing silane and said epoxy silane in said three component composition being from about 5 to about 70 parts by weight per 100 parts by weight of said three component composition, and the amount of said epoxy compound being from about 5 parts to about 90 parts by weight per every 100 parts by weight of said three component composition.

Claim 14

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 11, wherein the amount of said rare earth magnet or magnet material is from about 40 percent to about 90 percent by volume based upon the total volume of said rare earth magnet or magnet materials and said oxidation resistant composition, wherein said amino containing silane is an aminosilane or a polyaminosilane having the formula wherein R¹ is a hydrocarbon group having from 1 to 30 carbon atoms, wherein said hydrocarbon group is an ali­phatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R² and R³, independently, is a hydro­carbon group having from 1 to 20 carbon atoms, wherein Y and Z independently is a hydrogen atom, an aminoalkyl group, an aryl group, a polyaminoalkyl group, an alkyl­alkoxysilane group, or an aminoalkylalkoxysilane group, wherein said alkyl group has from 1 to 12 carbon atoms and said alkoxy group has from 1 to 6 carbon atoms, wherein said epoxy silane compound has the formula wherein R¹ is a hydrocarbon group having from 1 to 30 carbon atoms, wherein said hydrocarbon group is an ali­phatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R² and R³, independently, is a hydro­carbon group having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group or a glycidoxy group.

Claim 15

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 12, wherein said R¹ of said amino containing silane compound and said epoxy silane compound indepen­dently is an aliphatic having from 1 to 20 carbon atoms, an aromatic or an alkyl substituted aromatic having from 6 to 30 carbon atoms, and wherein R² and R³ of said amino containing silane and said epoxy silane compound independently is an aliphatic having from 1 to 11 carbon atoms.

Claim 16

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 13, wherein R¹ of said amino containing silane and said epoxy silane independently is an aliphatic containing from 1 to 11 carbon atoms, an aromatic or an alkyl substituted aromatic containing from 7 to 16 carbon atoms, wherein in said ternary system the amount of said amino containing silane is from about 20 to about 60 parts by weight, wherein the amount of said epoxy silane is from about 10 to about 55 parts by weight, and wherein said epoxy resin is from about 10 to about 50 parts by weight, and wherein in said binary system, the amount of each said component is from about 30 parts to about 70 parts by weight.

Claim 17

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 14, wherein the amount of said rare earth magnet or magnetic material is from about 55 to about 70 per­cent by volume, wherein said R¹ of said amino containing silane compound and said epoxy silane compound independently is an alkyl containing 3 or 4 carbon atoms, an aromatic or an alkyl substituted aromatic containing from 7 to 9 carbon atoms, wherein R² and R³ is an alkyl having from 1 to 2 carbon atoms, wherein said Y amino­alkyl group ontains at least one secondary or primary amine moiety, wherein said ternary composition the amount of said amino containng silane is from about 35 to about 50 parts by weight, wherein the amount of said epoxy silane is from about 10 parts to about 40 parts by weight, and wherein the amount of said epoxy is from about 20 parts to about 40 parts by weight.

Claim 18

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 12, wherein said amino containing silane com­pound is 4-aminobutyltriethoxysilane, (aminoethylamino­methyl)phenethyltrimethoxysilane, N-(2-aminoethyl)-3-­aminopropylmethyldimethoxysilane, 3-aminopropyltriethoxy­silane, 3-aminopropyltrimethoxysilane, N-2-aminoethyl-3-­aminopropyltrimethoxysilane, N-2-aminoethyl-3-amino­propyltris(2-ethylhexoxy)silane, 6-(aminohexylamino­propyl)trimethoxysilane, 3-aminophenyltrimethoxysilane, 3-(1-aminopropoxy)-3,3-dimethyl-1-propenyltrimethoxysilane, 3-aminopropyltris(methoxyethoxyethoxy)silane, 3-amino­propylmethyldiethoxysilane, bis[3-(trimethoxysilyl)pro­pyl]ethylenediamine, n-phenylaminopropyltrimethoxysilane, trimethoxysilylpropyldiethylenetriamine, ω -aminoundecyl­trimethoxysilane, bis[3-(triethoxysilyl)propyl]amine, dimethoxymethylsilylpropyl (polyethyleneimine), tri­ methoxysilylpropyl(polyethyleneimine), and wherein said epoxy silane is (3-glycidoxypropyl)methyldiethoxysilane, (3-glycidoxypropyl)trimethoxysilane, 2-(3,4-epoxycyclo­hexyl)ethylmethyldimethoxysilane, 2-(3,4-epoxycyclo­hexyl)ethyltrimethoxysilane and [2-(3,4-epoxy-4-methyl­cyclohexyl)propyl]methyldiethoxysilane.

Claim 19

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 12, wherein said amino containing silane is 3-­aminopropyltriethoxysilane, 3-aminopropyltrimethoxy­silane, or N-2-aminoethyl-3-aminopropyltrimethoxysilane, wherein said epoxy silane compound is (3-glycidoxypro­pyl)-trimethoxysilane, wherein said epoxy is the reaction product of bisphenol A and epichlorohydrin, wherein in said ternary system the amount of said amino containing silane is from about 20 to about 60 parts by weight, wherein the amount of said epoxy silane is from about 10 to about 55 parts by weight, and wherein said epoxy resin is from about 10 to about 50 parts by weight, and wherein in said binary system, the amount of each said component is from about 30 parts to about 70 parts by weight.

Claim 20

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 11, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composi­tion.

Claim 21

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 15, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composi­ tion, and wherein said oxymetallate compound is K₃PO₄, Na₂MoO₄, K₂Cr₂O₇, MCr₂O₇, and MCrO₄, and combinations thereof, where M is H, Li, Na, or K.

Claim 22

A rare earth magnet or magnet material coated with an oxidation resistant composition according to Claim 17, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composi­tion, and wherein said oxymetallate compound is MCr₂O₇, MCrO₄, or combinations thereof, and where M is H, Li, Na, or K.

Claim 23

A composite rare earth magnet or magnet material, comprising: the rare earth magnet or magnet material, an oxidation resistant composition, and a binder, said oxidation resistant composition comprising an amino-­containing silane, and at least one of the following two compounds, (1) an epoxy silane, (2) an epoxy resin, the amount of any one of said three compounds in said two component composition being from about 20 parts to about 80 parts by weight based upon the total parts by weight of said two component composition, and wherein the amount of said remaining compound is from about 80 parts to about 20 parts by weight, based upon 100 parts by weight of said two component composition; and the amount of said amino containing silane and said epoxy silane in said three component composition being from about 5 to about 70 parts by weight per 100 parts by weight of said three component composition, and the amount of said epoxy compound being from about 5 parts to about 90 parts by weight per every 100 parts by weight of said three component composition.

Claim 24

A composite rare earth magnet or magnet material, comprising: the rare earth magnet or magnet material, an oxidation resistant composition, and a binder, said oxidation resistant composition comprising an amino-­containing silane, and at least one of the following two compounds, (1) an epoxy silane, (2) an epoxy resin, the amount of any one of said three compounds in said two component composition being from about 20 parts to about 80 parts by weight based upon the total parts by weight of said two component composition, and wherein the amount of said remaining compound is from about 80 parts to about 20 parts by weight, based upon 100 parts by weight of said two component composition; and the amount of said amino containing silane and said epoxy silane in said three component composition being from about 5 to about 70 parts by weight per 100 parts by weight of said three component composition, and the amount of said epoxy compound being from about 5 parts to about 90 parts by weight per every 100 parts by weight of said three component composition.

Claim 25

A composite rare earth magnet or magnet material according to Claim 21, wherein the amount of said binder is from about 2 percent to about 60 percent by volume based upon the total volume of said binder, said rare earth magnet or magnet material, and said oxidation resistant composition, wherein said amino-containing silane is an aminosilane or a polyaminosilane having the formula wherein R¹ is a hydrocarbon group having from 1 to 30 carbon atoms, wherein said hydrocarbon group is an ali­phatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R² and R³, independently, is a hydro­carbon group having from 1 to 20 carbon atoms, wherein Y and Z independently is a hydrogen atom, an aminoalkyl group, a polyaminoalkyl group, an aryl group, an alkyl­alkoxysilane group, or an aminoalkylalkoxysilane group wherein said alkyl group has from 1 to 12 carbon atoms and said alkoxy group has from 1 to 6 carbon atoms, wherein said epoxy silane compound has the formula wherein R¹ is a hydrocarbon group having from 1 to 30 carbon atoms, wherein said hydrocarbon group is an ali­phatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R² and R³, independently, is a hydro­carbon group having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof.

Claim 26

A composite rare earth magnet or magnet material according to Claim 22, wherein the amount of said rare earth magnet or magnet material is from about 40 percent to about 90 percent by volume based upon the total volume of said magnet or magnet material and said oxidation resistant composition, wherein R¹ of said amino-containing silane compound and said epoxy silane compound independently is an aliphatic having from 1 to 20 carbon atoms, an aromatic or an alkyl substituted aromatic having from 6 to 30 carbon atoms, and wherein R² and R³ of said amino containing silane and said epoxy silane compound independently is an aliphatic having from 1 to 11 carbon atoms.

Claim 27

A composite rare earth magnet or magnet material according to Claim 23, wherein R¹ of said amino containing silane and said epoxy silane independently is an aliphatic containing from 1 to 11 carbon atoms, an aromatic or an alkyl substituted aromatic containing from 7 to 16 carbon atoms, wherein in said ternary system the amount of said amino containing silane is from about 20 to about 60 parts by weight, wherein the amount of said epoxy silane is from about 10 to about 55 parts by weight, wherein said epoxy resin is from about 10 to about 50 parts by weight, and wherein in said binary system, the amount of each said component is from about 30 parts to about 70 parts by weight.

Claim 28

A composite rare earth magnet or magnet material according to Claim 24, wherein said rare earth magnet or magnet material is at least substantially encapsulated by said oxidation resistant composition, wherein said R¹ of said amino containing silane compound and said epoxy silane compound independently is an alkyl containing 3 or 4 carbon atoms, an aromatic or an alkyl substituted aromatic containing from 7 to 9 carbon atoms, wherein R² and R³ is an alkyl having from 1 to 2 carbon atoms, wherein said Y aminoalkyl group contains at least one secondary or primary amine moiety, wherein in said ternary composition the amount of said amino containing silane is from about 35 to about 50 parts by weight, wherein the amount of said epoxy silane is from about 10 parts to about 40 parts by weight, and wherein the amount of said epoxy is from about 20 parts to about 40 parts by weight.

Claim 29

A composite rare earth magnet or magnet material according to Claim 21, wherein said amino con­taining silane compound is 4-aminobutyltriethoxysilane, (aminoethylaminomethyl)phenethyltrimethoxysilane, N-(2-­aminoethyl)-3-aminopropylmethyldimethoxysilane, 3-amino­propyltriethoxysilane, 3-aminopropyltrimethoxysilane, N-­2-aminoethyl-3-aminopropyltrimethoxysilane, N-2-amino­ethyl-3-aminopropyltris(2-ethylhexoxy)silane, 6-(amino­hexylaminopropyl)trimethoxysilane, 3-aminophenyltri­methoxysilane, 3-(1-aminopropoxy)-3,3-dimethyl-1-­propenyltrimethoxysilane, 3-aminopropyltris(methoxy­ethoxyethoxy)silane, 3-aminopropylmethyldiethoxysilane, bis[3-(trimethoxysilyl)propyl]ethylenediamine, n-phenyl­aminopropyltrimethoxysilane,trimethoxysilylpropyldiethyl­enetriamine, ω -aminoundecyltrimethoxysilane, bis[3-(tri­ethoxysilyl)propyl]amine, dimethoxymethylsilylpropyl (polyethyleneimine), trimethoxysilylpropyl(polyethyleni­mine), and wherein said epoxy silane is (3-glycidoxy­propyl)methyldiethoxysilane, (3-glycidoxypropyl)tri­methoxysilane, 2-(3,4-epoxycyclohexyl)ethylmethyldi­methoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxy­ silane and [2-(3,4-epoxy-4-methylcyclohexyl)propyl]­methyldiethoxysilane.

Claim 30

A composite rare earth magnet or magnet material according to Claim 21, wherein the amount of said binder is from about 25 percent to about 40 percent by volume based upon the total volume of said binder, said rare earth magnet or magnet material, and said oxidation resistant composition, wherein said amino containing silane is 3-aminopropyltriethoxysilane, 3-­aminopropyltrimethoxysilane, or N-2-aminoethyl-3-amino­propyltrimethoxysilane, wherein said epoxy silane com­pound is (3-glycidoxypropyl)-trimethoxysilane, wherein said epoxy is the reaction product of bisphenol A and epichlorohydrin, wherein in said ternary system the amount of said amino containing silane is from about 20 to about 60 parts by weight, wherein the amount of said epoxy silane is from about 10 to about 55 parts by weight, and wherein said epoxy resin is from about 10 to about 50 parts by weight, and wherein in said binary system, the amount of each said component is from about 30 parts to about 70 parts by weight.

Claim 31

A composite rare earth magnet or magnet material according to Claim 21, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composition.

Claim 32

A composite rare earth magnet or magnet material according to Claim 25, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composition, wherein said oxymetallate compound is K₃PO₄, Na₂MoO₄, K₂Cr₂O₇, MCr₂O₇ or MCrO₄, and combina­tions thereof, and where M is H, Li, Na, or K.

Claim 33

A composite rare earth magnet or magnet material according to Claim 26, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said ternary or said binary composition, wherein said oxymetallate compound is MCr₂O₇, MCrO₄, or combinations thereof, and where M is H, Li, Na, or K.