Oxidation resistant compositions for use with rare earth magnets

Claim 2

An oxidation resistant coated rare earth magnet or magnet material, comprising: a rare earth magnet or magnet material coated by an oxidation resistant composition, said oxidation resistant composition comprising a mixture of (1) an amino containing silane, (2) an epoxy silane, and (3) an epoxy resin, said amino containing silane being an aminosilane or a polyaminosilane having the formula ##STR3## wherein said R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, 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 ##STR4## wherein said R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphtic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof, and the amount of said amino containing silane and said epoxy silane in said coating composition each being from about 5 to about 70 parts by weight per 100 parts by weight of said coating 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 coating composition.

Claim 3

An oxidation resistant coated rare earth magnet or magnet material according to claim 1, wherein said R 1 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 R 2 and R 3 of said amino containing silane and said epoxy silane compound independently is an aliphatic having from 1 to 11 carbon atoms.

Claim 4

An oxidation resistant coated rare earth magnet or magnet material according to claim 2, wherein R 1 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 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.

Claim 5

An oxidation resistant coated rare earth magnet or magnet material according to claim 3, wherein said R 1 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 R 2 and R 3 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 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 resin is from about 20 parts to about 40 parts by weight.

Claim 6

An oxidation resistant coated rare earth magnet or magnet material according to claim 1, 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)ethyltrimethoxysilane and [2-(3,4-epoxy-4-methylcyclohexyl)propyl]methyldiethoxy silane.

Claim 7

An oxidation resistant coated rare earth magnet or magnet material according to claim 1, 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 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 the amount of said epoxy resin is from about 10 to about 50 parts by weight.

Claim 8

An oxidation resistant coated rare earth magnet or magnet material according to claim 1, including from about 0.1 to about 10 parts by weight of an oxymetallic inhibitor for every 100 parts by weight of said coating composition.

Claim 9

An oxidation resistant coated rare earth magnet or magnet material according to claim 3, including from about 0.1 to about 10 parts by weight of an oxymetallic inhibitor for every 100 parts by weight of said coating composition, wherein said oxymetallic compound is K 3 PO 4 , Ma 2 MoO 4 , Kr 2 Cr 2 O 7 , MCr 2 O 7 , or MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 10

An oxidation resistant coated rare earth magnet or magnet material according to claim 6, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said coating composition, wherein said oxymetallate compound is MCr 2 O 7 , MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 11

An oxidation resistant coated rare earth magnet or magnet material, comprising: a rare earth magnet or magnetic material coating composition, said coating composition comprising a mixture of (1) an amino containing silane; and (2) an epoxy silane or an epoxy resin, said amino containing silane being an aminosilane or a polyaminosilane having the formula ##STR5## wherein said R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, wherein Y and Z indepedently 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 ##STR6## wherein said R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphtic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof, the amount of said amino containing silane being from about 20 parts to about 80 parts by weight based upon the total weight of said amino containing silane and said epoxy silane or said epoxy resin, and the amount of said epoxy silane or said epoxy resin being from about 80 parts to about 20 parts by weight based upon the total weight of said epoxy silane or said epoxy resin and said amino containing silane compound.

Claim 12

An oxidation resistant coated rare earth magnet or magnet material, comprising: a rare earth magnet or magnetic material coating composition, said coating composition comprising a mixture of (1) an amino containing silane; and (2) an epoxy silane or an epoxy resin, said amino containing silane being an aminosilane or a polyaminosilane having the formula ##STR5## wherein said R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, wherein Y and Z indepedently 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 ##STR6## wherein said R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphtic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof, the amount of said amino containing silane being from about 20 parts to about 80 parts by weight based upon the total weight of said amino containing silane and said epoxy silane or said epoxy resin, and the amount of said epoxy silane or said epoxy resin being from about 80 parts to about 20 parts by weight based upon the total weight of said epoxy silane or said epoxy resin and said amino containing silane compound.

Claim 13

An oxidation resistant coated rare earth magnet or magnet material according to claim 10, wherein said R 1 of said amino containing silane compound and said epoxy silane compound independently is an aliphatic having from 1 to 20 carbon atoms, or an aromatic or an alkyl substituted aromatic having from 6 to 30 carbon atoms, and wherein R 2 and R 3 of said amino containing silane and said epoxy silane compound independently is an aliphatic having from 1 to 11 carbon atoms.

Claim 14

An oxidation resistant coated rare earth magnet or magnet material according to claim 11, wherein R 1 of said amino containing silane and said epoxy silane independently is an aliphatic containing from 1 to 11 carbon atoms, or an aromatic or an alkyl substituted aromatic containing from 7 to 16 carbon atoms, wherein the amount of said amino containing silane is from about 30 to about 70 parts by weight, and wherein the amount of said epoxy silane or said epoxy resin is from about 70 parts to about 30 parts by weight.

Claim 15

An oxidation resistant coated rare earth magnet or magnet material according to claim 12, wherein said R 1 of said amino containing silane compound and said epoxy silane compound independently is an alkyl containing 3 or 4 carbon atoms, or an aromatic or an alkyl substituted aromatic containing from 7 to 9 carbon atoms, wherein R 2 and R 3 is an alkyl having from 1 to 2 carbon atoms, and wherein said Y aminoalkyl group contains at least one secondary or primary amine moiety.

Claim 16

An oxidation resistant coated rare earth magnet or magnet material according to claim 10, wherein said amino containing silane compound is 4-aminobutyltriethoxysilane, (aminoethylaminomethyl)phenethyltrimethoxysilane, N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane, 3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, N-2-aminoethyl-3-aminoproyltrimethoxysilane, 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(polyethyenimine), 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 17

An oxidation resistant coated rare earth magnet or magnet material according to claim 10, 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, and wherein said epoxy is the reaction product of bisphenol A and epichlorohydrin.

Claim 18

An oxidation resistant coated rare earth magnet or magnet material according to claim 10, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said coating composition.

Claim 19

An oxidation resistant coated rare earth magnet or magnet material according to claim 12, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said coating composition, wherein said oxymetallate compound is K 3 PO 4 , Na 2 MoO 4 , K 2 Cr 2 O 7 , MCr 2 O 7 , or MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 20

An oxidation resistant coated rare earth magnet or magnet material 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 coating composition, wherein said oxymetallate compound is MCr 2 O 7 , MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 21

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, an epoxy silane, and an epoxy resin, the amount of said amino containing silane and said epoxy silane being from about 5 to about 70 parts by weight per 100 parts by weight of said oxidation resistant 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 oxidation resistant composition.

Claim 22

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, an epoxy silane, and an epoxy resin, the amount of said amino containing silane and said epoxy silane being from about 5 to about 70 parts by weight per 100 parts by weight of said oxidation resistant 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 oxidation resistant composition.

Claim 23

A composite rare earth magnet or magnet material according to claim 19, 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 ##STR7## wherein R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, 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 ##STR8## wherein R 1 is an aliphatic, an aromatic, or combinations thereof, having from 1 to 30 carbon atoms, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof.

Claim 24

A composite rare earth magnet or magnet material according to claim 20, 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 R 1 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 R 2 and R 3 of said amino containing silane and said epoxy silane compound independently is an aliphatic having from 1 to 11 carbon atoms.

Claim 25

A composite rare earth magnet or magnet material according to claim 21, wherein R 1 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 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 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 oxidation resistant composition and said rare earth magnet or magnet material.

Claim 26

A composite rare earth magnet or magnet material according to claim 22, wherein said rare earth magnet or magnet material is at least substantially encapsulated by said oxidation resistant composition, wherein said R 1 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 R 2 and R 3 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 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 resin is from about 20 parts to about 40 parts by weight.

Claim 27

A composite rare earth magnet or magnet material according to claim 19, wherein said amino containing silane compound is 4-aminobutyltriethoxysilane, (aminoethylaminoethyl)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(methoxy-ethoxyethoxy)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]methyldiethoxysilane.

Claim 28

A composite rare earth magnet or magnet material according to claim 19, 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 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 the amount of said epoxy resin is from about 10 to about 50 parts by weight.

Claim 29

A composite rare earth magnet or magnet material according to claim 19, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said oxidation resistant composition.

Claim 30

A composite rare earth magnet or magnet material according to claim 23, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said oxidation resistant composition, wherein said oxymetallate compound is K 3 PO 4 , Na 2 MoO 4 , K 2 Cr 2 O 7 , MCr 2 O 7 , or MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 31

A composite rare earth magnet or magnet material according to claim 24, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said oxidation resistant composition, wherein said oxymetallate compound is MCr 2 O 7 , MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 32

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 an epoxy silane or an epoxy resin, the amount of said amino containing silane being from about 20 parts to about 80 parts by weight based upon the total weight of said amino-containing silane and said epoxy silane or said epoxy resin, and the amount of said epoxy silane or said epoxy resin being from about 80 parts to about 20 parts by weight based upon the total weight of said epoxy silane or said epoxy resin and said amino-containing silane.

Claim 33

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 an epoxy silane or an epoxy resin, the amount of said amino containing silane being from about 20 parts to about 80 parts by weight based upon the total weight of said amino-containing silane and said epoxy silane or said epoxy resin, and the amount of said epoxy silane or said epoxy resin being from about 80 parts to about 20 parts by weight based upon the total weight of said epoxy silane or said epoxy resin and said amino-containing silane.

Claim 34

A composite rare earth magnet or magnet material according to claim 29, 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 ##STR9## wherein R 1 group has from 1 to 30 carbon atoms, wherein said R 1 group is an aliphatic, an aromatic, or combinations thereof, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, 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 ##STR10## wherein R 1 is an aliphatic, an aromatic, or combinations thereof, having from 1 to 30 carbon atoms, wherein n is 1 or 0, wherein R 2 and R 3 , independently, is an aliphatic, an aromatic, or combinations thereof, having from 1 to 20 carbon atoms, and wherein T is an epoxycyclohexyl group, a glycidoxy group, or an alkyl derivative thereof.

Claim 35

A composite rare earth magnet or magnet material according to claim 30, 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 R 1 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 R 2 and R 3 of said amino containing silane and said epoxy silane compound independently is an aliphatic having from 1 to 11 carbon atoms.

Claim 36

A composite rare earth magnet or magnet material according to claim 31, wherein R 1 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 the amount of said amino containing silane is from about 30 to about 70 parts by weight, and wherein the amount of said epoxy silane or said epoxy resin is from about 70 parts to about 30 parts by weight, and 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 oxidation resistant composition and said rare earth magnet or magnet material.

Claim 37

A composite rare earth magnet or magnet material according to claim 32, wherein said rare earth magnet or magnet material is at least substantially encapsulated by said oxidation resistant composition, wherein said R 1 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 R 2 and R 3 is an alkyl having from 1 to 2 carbon atoms, wherein said Y aminoalkyl group contains at least one secondary or primary amine moiety.

Claim 38

A composite rare earth magnet or magnet material according to claim 29, 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)triemthoxysilane, 3-aminophenyltrimethoxysilane, 3-(1-aminopropoxy)-3,3-dimethyl-1-propenyltrimethoxysilane, 3-aminopropyltris(methoxy-ethoxyethoxy)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]methyldiethoxysilane.

Claim 39

A composite rare earth magnet or magnet material according to claim 29, wherein the amount of said hinder 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.

Claim 40

A composite rare earth magnet or magnet material according to claim 29, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said oxidation resistant composition.

Claim 41

A composite rare earth magnet or magnet material according to claim 33, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitor for every 100 parts by weight of said oxidation resistant composition, wherein said oxymetallate compound is K 3 PO 4 , Na 2 MoO 4 , K 2 Cr 2 O 7 , MCr 2 O 7 , or MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.

Claim 42

A composite rare earth magnet or magnet material according to claim 34, including from about 0.1 to about 10 parts by weight of an oxymetallate inhibitors for every 100 parts by weight of said oxidation resistant composition, wherein said oxymetallate compound is MCr 2 O 7 , MCrO 4 , or combinations thereof, and where M is H, Li, Na, or K.