Patent ID: 8313801

Claim:
A process of making a liquid-coated rapidly solidified rare earth-transition metal-boron magnet material, the process comprising: providing a homogeneous solution comprising a solvent, one or more of an organotitanate or organozirconate coupling agents, an epoxy resin, a hardener, an accelerator, and a lubricant; combining a rare earth-transition metal-boron magnet powder with said homogeneous solution to form a slurry mixture; stirring said slurry mixture periodically; and maintaining said slurry mixture at a temperature between 40-60° C., such that said solvent evaporates and a coating is formed on the magnet powder; wherein the coupling agent has a general form of (RO—) n (Ti or Zr)(—OR′Y) 4-n where R is a neopentyl(diallyl), dioctyl, or (2,2-diallyloxymethyl)butyl group, Ti or Zr has a coordination number of 4, R′ is a phosphito, pyrophosphato or cyclic pyrophosphato segment, and Y is a dioctyl or ditridecyl end group, with 1≦n≦4; and wherein the amount of the coupling agent in the coating that is formed is about 0.1 weight percent to about 1 weight percent of the coated magnet powder.