U.S. patent application number 10/603517 was filed with the patent office on 2004-12-30 for novel additive composition that reduces soot and/or emissions from engines.
This patent application is currently assigned to The Lubrizol Corporation, a corporation of the State of Ohio. Invention is credited to Burrington, James D., George, Herman F., Martin, John R., Yodice, Richard.
Application Number | 20040266630 10/603517 |
Document ID | / |
Family ID | 33539756 |
Filed Date | 2004-12-30 |
United States Patent
Application |
20040266630 |
Kind Code |
A1 |
George, Herman F. ; et
al. |
December 30, 2004 |
Novel additive composition that reduces soot and/or emissions from
engines
Abstract
An additive composition containing an antioxidant and a
dispersant that reduces the soot content in lubricating oil in an
engine and/or the emission of an engine. Further, a process for
employing the additive composition to decrease the amount of soot
in the lubricating oil of an engine and/or decrease the emissions
from an engine.
Inventors: |
George, Herman F.; (Chardon,
OH) ; Burrington, James D.; (Mayfield Village,
OH) ; Martin, John R.; (Concord Township, OH)
; Yodice, Richard; (Mentor, OH) |
Correspondence
Address: |
THE LUBRIZOL CORPORATION
Patent Administrator
29400 Lakeland Boulevard
Mail Drop 022B
Wickliffe
OH
44092-2298
US
|
Assignee: |
The Lubrizol Corporation, a
corporation of the State of Ohio
Wickliffe
OH
44092-2298
|
Family ID: |
33539756 |
Appl. No.: |
10/603517 |
Filed: |
June 25, 2003 |
Current U.S.
Class: |
508/113 ;
508/154; 508/291 |
Current CPC
Class: |
C10N 2030/10 20130101;
C10N 2030/18 20130101; C10M 2201/103 20130101; C10M 2219/086
20130101; C10N 2030/041 20200501; C10M 2217/043 20130101; C10M
2215/064 20130101; C10N 2040/252 20200501; C10N 2070/00 20130101;
C10M 2201/062 20130101; C10M 2207/34 20130101; C10N 2040/25
20130101; C10M 2201/105 20130101; C10M 2215/08 20130101; C10M
2219/089 20130101; C10N 2030/02 20130101; C10N 2050/10 20130101;
C10M 2215/04 20130101; C10N 2010/06 20130101; C10M 2201/041
20130101; C10M 2205/04 20130101; C10M 177/00 20130101; C10N 2030/30
20200501; C10M 2207/281 20130101; C10M 2215/00 20130101; C10M
2219/046 20130101; C10M 2227/00 20130101; C10N 2010/02 20130101;
C10N 2030/06 20130101; C10N 2030/08 20130101; C10M 2207/026
20130101; C10M 2209/104 20130101; C10M 163/00 20130101; C10M
2215/28 20130101; C10M 2207/04 20130101; C10M 2207/289 20130101;
C10M 2219/024 20130101; C10N 2010/08 20130101; C10N 2030/04
20130101; C10M 2219/022 20130101; C10N 2010/04 20130101; C10M
2205/04 20130101; C10M 2207/282 20130101; C10M 2209/104 20130101;
C10M 2209/109 20130101 |
Class at
Publication: |
508/113 ;
508/154; 508/291 |
International
Class: |
C10M 141/00 |
Claims
We claim:
1. An additive composition comprising a dispersant and an
antioxidant used in an application selected from the group
comprising decreasing the amount of soot in a lubricating oil of an
engine, decreasing the amount of emissions in an engine's exhaust
and combinations thereof.
2. The composition of claim 1 wherein the emissions reduced are
selected from the group comprising soot, hydrocarbons and/or
NOx
3. The composition of claim 1 further comprises at least one
lubricant additive t selected from the group comprising detergents,
overbased detergents, carbon black, silica, alumina, titania,
magnesium oxide, calcium carbonate, lime, clay, zeolites, extreme
pressure (EP) agents, wear reduction agents, viscosity index
improvers, anti-foaming agents, friction reducing agents,
anti-misting agents, cloud-point depressants, pour-point
depressants, mineral and/or synthetic oils mixtures thereof and
combination thereof and in the range of about 0% to about 95% of
the additive composition.
4. The composition of claim 1 wherein the dispersant is in the
range of about 0.1% to about 95% and the antioxidant is in the
range of about 0.01% to about 99% of the additive composition.
5. The composition of claim 1 wherein the antioxidant is selected
from the group comprising the antioxidants include but are not
limited to alkyl-substituted phenols such as 2,6-di-tertiary
butyl-4-methyl phenol, phenate sulfides, phosphosulfurized
terpenes, sulfurized esters, aromatic amines, and hindered phenols,
is a hindered, ester-substituted phenol and combinations
thereof.
6. The composition of claim 1 wherein the dispersant is selected
from the group comprising ashless type dispersants such as Mannich
dispersants; polymeric dispersants; carboxylic dispersants amine,
dispersants, high molecular weight esters, and the like succinics;
esterfied maleic anhydride styrene copolymers; maleated ethylene
diene monomer copolymers; surfactants; emulsifiers; ashless
succinimide, polyisbutenyl succinimide, substituted long chain
alkenyl succinimides, high molecular weight esters, N-substituted
long chain alkenyl succinimides, decyl methacrylate, vinyl decyl
ether, aminoalkyl acrylates, acrylamides,
poly-(oxyethylene)-substituted acrylates, high molecular weight
olefins with monomers containing polar substitutes; functionalized
derivatives of each component listed herein; and combinations
thereof.
7. The composition of claim 1 wherein the dispersant is selected
from the group comprising ashless succinimide, polyisbutenyl
succinimide, substituted long chain alkenyl succinimides, high
molecular weight esters, mannich dispersants, N-substituted long
chain alkenyl succinimides, carboxylic dispersants, amine
dispersants, polymeric dispersants, decyl methacrylate, vinyl decyl
ether, aminoalkyl acrylates, acrylamides,
poly-(oxyethylene)-substituted acrylates, high molecular weight
olefins with monomers containing polar substitutes and mixtures
thereof; and an antioxidant selected from the group comprises
alkyl-substituted phenols, 2,6-di-teritiary butyl-4-methyl phenol,
phenate sulfides, phosphosulfurized terpenes and mixtures
thereof.
8. A process comprising contacting a portion of an engine oil with
an additive composition of claim 1 resulting in the reduction of
soot in the engine oil and/or emissions in an engine exhaust.
9. The process of claim 8 wherein the additive composition is
positioned to contact the oil in an area selected from the group
comprising full flow oil, bypass of oil, in the reservoir and
combinations thereof.
10. The process of claim 8 wherein the additive composition is
located in an area selected from the group comprising a filter, a
drain pan, an oil bypass loop, a canister, a housing, a reservoir,
a pocket of a filter, a canister in a filter, a mesh in a filter, a
canister in a bypass system, a mesh in a bypass system and
combinations thereof.
11. The process of claim 8 wherein the additive composition is in
contact with the engine oil in the range of about 100% to 1% of the
engine oil.
12. The process of claim 8 wherein the additive composition is
positioned in a location of flow rate of the engine oil in the
range of greater than 1% to about 100% of the circulating engine
oil.
13. The process of claim 8 wherein the emissions reduced in the
exhaust are selected from the group comprising soot, NOx,
hydrocarbons and combinations thereof.
14. The process of claim 8 comprising adding to the engine oil the
additive composition all at the same time, a portion of the
components over its service life, continuously to the engine oil
over the service life of the oil and combinations thereof.
15. The process of claim 8 wherein the composition further
comprises at least one lubricant additive t selected from the group
comprising detergents, overbased detergents, carbon black, silica,
alumina, titania, magnesium oxide, calcium carbonate, lime, clay,
zeolites, extreme pressure (EP) agents, wear reduction agents,
viscosity index improvers, anti-foaming agents, friction reducing
agents, anti-misting agents, cloud-point depressants, pour-point
depressants, mineral and/or synthetic oils mixtures thereof and
combination thereof.
16. The process of claim 15 wherein the dispersant is in the range
of about 0.01% to about 60%, the antioxidant is in the range of
about 0.01% to about 60% of and the lubricant additive is in the
range of about 0% to about 60% of the additive composition.
17. An oil filter for an engine oil lubricating system comprising a
housing, a filter for removing particulate matter from an oil
bypass filter and a container with an additive composition wherein
the additive composition comprises a dispersant and an antioxidant
and results in the reduction of one of the following from an engine
soot, NOx hydrocarbons or combinations thereof.
18. An additive composition containment device for an engine oil
lubricating system comprising a housing and a container with an
additive composition, and wherein the additive composition
comprises a dispersant and an antioxidant for the reduction of soot
from lubricating systems, engine emissions reduction or
combinations thereof.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a novel additive
composition that decreases the amount of soot in a lubricating oil
in an engine and/or decreases the amount of emissions particularly
soot, hydrocarbons and/or nitrogen oxides (NO, NO.sub.2, N.sub.2O,
collectively known as NOx) from an engine.
[0002] Soot may be present in any lubricating oil used in a
lubrication system of any engine that generates soot such as
internal combustion engines, spark ignited engines, stationary
engines, off and on highway engines and the like. Internal
combustion engines, in particular diesel fueled engines, generate
carbonaceous soot particles. During combustion the fuel is injected
into the combustion chamber in the form of small droplets. During
the combustion process, soot particles form from incompletely
combusted fuel droplets. The lubricating oil for the cylinders and
the rings contain the soot from the incomplete combustion process.
As the pistons move up and down in the chamber, the soot particles
that have formed go into the lubricating oil system of the pistons,
rings, through the cylinder and into the reservoir. Accordingly,
the generated soot in the engine oil contributes to problems with
engine lubrication.
[0003] Soot is also a problem in modern diesel engines with fuel
injection systems. The fuel injection system has been designed to
produce less emissions, but has increased the formation of soot in
the lubricating oil of the engine. It further requires more
frequent oil change intervals to prevent the concentration of soot
particles in the oil from exceeding acceptable limits.
[0004] The suspended soot particles in the lubricating oil have the
effect of increasing the viscosity and creating wear particles in
the lubricating oil. Accordingly, the soot acts like an abrasive
and induces wear in the engine parts. High soot levels result in
shorter drain intervals and more oil changes.
[0005] Dispersants have been used in lubricating oils to suspend
the soot build up so as to reduce the detrimental effects of the
soot on engine wear. However, an oils' capacity to protect an
engine is limited, even with the dispersants. In addition, soot
particles are small and are finely distributed in the lubricating
oil so that filters generally are not satisfactory in removing the
soot. During the course of a heavy duty diesel service interval
(15,000 to 30,000 miles), 5 to 10 pounds of soot is typically
produced. Filtration of the suspended or dispersed soot particles
in the lubricating oil is complicated by their small size of
generally less than 1 micron compared to typical automotive oil
filters, which are sized to remove particles which are 20 to 40
microns or greater in diameter. This level of a soot loading can
not be practically filtered with conventional filtration
methods.
[0006] It is desirable to decrease the concentration of particles
of soot in an engine oil using a novel additive composition. It is
further desirable to decrease the emissions of soot, hydrocarbons
and/or NOx from and engine using a novel additive composition.
[0007] It has been found that an additive composition of the
instant invention in contact with the lubricating oil of an engine
can decrease the soot content in the oil as well as also reduce the
emissions from an engine in particular soot, hydrocarbons and/or
NOx. It has been further found that an oil based additive
composition can reduce the particles of soot from the oil of an
engine and/or emissions from an engine.
SUMMARY OF THE INVENTION
[0008] In accordance with the instant invention, it has been
discovered that an oil based additive composition can reduce the
concentration of soot particles in a lubricating oil of an engine
and/or reduce emissions from an engine.
[0009] In accordance with the present invention it has been
discovered that an additive composition comprising a dispersant and
an antioxidant reduces the concentration of soot in the lubricating
oil of an engine and/or decreases the emissions from an engine. The
additive composition can optionally contain other desired lubricant
additives. The additive composition dissolves into the oil during
use of the engine. In one embodiment the release of the additive
composition components is a slow release.
[0010] In the present invention, suspended and/or dispersed soot in
engine oil is decreased by a process comprising contacting a
portion of an engine oil containing the soot with the additive
composition of the present invention. Further the present invention
decreases the emissions from an engine by a process comprising
contacting a portion of an engine oil with the additive composition
of the present invention.
[0011] The present invention provides for the use of an additive
composition to decrease the amount of suspended/dispersed soot in
lubricating oil in engines and/or to decrease the emissions in
particular soot, hydrocarbons and/or NOx from an engine. The
engines that can use the additive composition include, but are not
limited to internal combustion engines, stationary engines,
generators, diesel and/or gasoline engines, on highway and/or off
highway engines, two-cycle engines, aviation engines, piston
engines, marine engines, railroad engines, biodegradable fuel
engines and the like. In one embodiment the engine is equipped with
after treatment devices, such as exhaust gas recirculation systems,
catalytic converters, diesel particulate filters, NOx traps and the
like.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In accordance with the present invention the soot
concentration is decreased from a lubricating oil in an engine
thereby avoiding the deleterious effects on the engine from the
soot including viscosity, wear and emissions. Furthermore, the
emissions of an engine is decreased by using the additive
composition thereby improving the environment.
[0013] The additive composition is in the form of a solid, liquid,
semi-solid, gel or combinations thereof. The form of the
composition depends on the desired application, the mode of
addition, timing of addition, the speed of release and combinations
thereof.
[0014] The soot level and/or emissions level is reduced by contact
of the lubricating oil with the additive composition. The additive
composition is positioned within the lubricating system, anywhere
the additive composition will be in contact with the lubricating
oil. The additive composition is positioned anywhere that the
circulating oil contacts the additive composition such as full flow
of oil, bypass of the oil in the reservoir or combinations therein.
The location of the additive composition in the lubricating system
includes but is not limited to a filter, drain pan, oil bypass
loop, canister, housing, reservoir, pockets of a filter, canister
in a filter, mesh in a filter, canister in a bypass system, mesh in
a bypass system and the like. One or more locations can contain the
additive composition. Further, if more than one additive
composition is used it can be identical, similar and/or a different
additive composition.
[0015] In one embodiment it is desirable to provide a container to
hold the additive composition, such as a housing, a canister, a
structural mesh or the like anywhere within the lubricating oil
system, for example, a filter in a housing of an engine oil
lubricating system. The necessary design feature for the container
is that at least a portion of the additive composition is in
contact with the oil.
[0016] In one embodiment, the additive composition is positioned
anywhere in the filter. The filter is a desirable location to place
the additive composition because the additive composition and/or
spent additive composition can easily be removed, and then replaced
with a new and/or recycled additive composition.
[0017] The additive composition needs to be in contact with the
engine oil, in one embodiment the gel is in contact with the oil in
the range of about 100% to about 1% of the oil in the bypass
system, in another embodiment the additive composition is in
contact with the oil in the range of about 75% to about 25% of the
oil in the bypass system and in another embodiment the additive
composition is in contact with the oil in the range of about 50% of
the oil in the bypass system.
[0018] The release rate of the additive composition is determined
primarily by the additive composition formulation. The release rate
is also dependent on the form of the additive composition and/or
the mode of addition. The additive composition is positioned in a
location desirable for the specified and desirable dissolution rate
of the additive composition. The additive composition's formulation
maybe composed of one or more components that selectively dissolve
completely or a portion of the components remain till the end of
its service life or combinations thereof.
[0019] The additive composition is added to the lubrication system
by any known method depending on the desired form of the additive
composition, the desired speed of addition, the desired release
rate, the desired mode of operation and/or any of the combinations
of the above. In one embodiment the additive composition is in the
form of a liquid and is injected by means of a pump into the
lubricating oil system. In another embodiment the additive
composition is a gel and is added to the lubricating system by
means of an injector pump, or a container in the oil filter. In one
embodiment the additive composition is a solid and introduced into
the lubricating oil system by means of an auger. In one embodiment
the additive composition is a solid or semisolid and is added to
the lubricating system by means of a solid addition device such as
an auger.
[0020] The additive composition comprises a dispersant and an
antioxidant. Further the additive composition may optionally
contain other lubricant additives.
[0021] The additive composition contains the dispersant in the
range of about 0.1% to about 95%, in one embodiment about 5% to
about 70% and in another embodiment about 7% to about 50% of the
composition. The additive composition contains the antioxidant in
the range of about 0.1% and about 99% in one embodiment about 5% to
about 80% and in another embodiment about 10% to about 70% of the
additive composition. The additive composition contains other
lubricant additive in the range of about 0% to about 95%, in one
embodiment about 1% to about 70% and in another embodiment about 5%
to about 60% of the additive composition.
[0022] The dispersant includes but is not limited to dispersants;
ashless type dispersants such as Mannich dispersants; polymeric
dispersants; carboxylic dispersants; amine dispersants, high
molecular weight (Cn wherein n>12) esters and the like;
esterfied maleic anhydride styrene copolymers; maleated ethylene
diene monomer copolymers; surfactants; emulsifiers; functionalized
derivatives of each component listed herein and the like; and
combinations and mixtures thereof. The dispersant can be used alone
or in combination. In one embodiment the preferred dispersant is
polyisobutenyl succinimide dispersant.
[0023] The dispersant includes but is not limited to ashless type
dispersants such as a polyisobutenyl succinimide and the like.
Polyisobutenyl succinimide ashless dispersants are
commercially-available products which are typically made by
reacting together polyisobutylene having a number average molecular
weight ("Mn") of about 300 to 10,000 with maleic anhydride to form
polyisobutenyl succinic anhydride ("PIBSA") and then reacting the
product so obtained with a polyamine typically containing 1 to 10
ethylene diamine groups per molecule.
[0024] Another class of ashless dispersants includes but is not
limited to high molecular weight (Cn where n.gtoreq.12) esters,
Mannich dispersants and the like. Ashless type dispersants are
characterized by a polar group attached to a relatively high
molecular weight hydrocarbon chain. Typical ashless dispersants
include N-substituted long chain alkenyl succinimides, having a
variety of chemical structures including typically: 1
[0025] where each R.sup.1 is independently an alkyl group,
frequently a polyisobutyl group with a molecular weight of
500-5000, and R are alkenyl groups, cornmonly ethylenyl
(C.sub.2H.sub.4) groups. Succinimide dispersants are more fully
described in U.S. Pat. No. 4,234,435 which is incorporated herein
by reference. The dispersants described in this patent are
particularly effective for producing gels in accordance with the
present invention.
[0026] The Mannich dispersants are the reaction products of alkyl
phenols in which the alkyl group contains at least about 30 carbon
atoms with aldehydes (especially formaldehyde) and amines
(especially polyalkylene polyamines). Mannich bases having the
following general structure (including a variety of different
isomers and the like) are especially interesting. 2
[0027] Another class of dispersants is carboxylic dispersants.
Examples of these "carboxylic dispersants" are described in U.S.
Pat. No. 3,219,666.
[0028] Amine dispersants are reaction products of relatively high
molecular weight aliphatic halides and amines, preferably
polyalkylene polyamines. Examples thereof are described, in U.S.
Pat. No. 3,565,804.
[0029] Polymeric dispersants are interpolymers of oil-solubilizing
monomers such as decyl methacrylate, vinyl decyl ether and high
molecular weight olefins with monomers containing polar
substituents, e.g., aminoalkyl acrylates or acrylamides and
poly-(oxyethylene)-substituted acrylates. Examples of polymer
dispersants thereof are disclosed in the following U.S. Pat. Nos.
3,329,658, and 3,702,300.
[0030] Dispersants can also be post-treated by reaction with any of
a variety of agents. Among these are urea, thiourea,
dimercaptothiadiazoles, carbon disulfide, aldehydes, ketones,
carboxylic acids, hydrocarbon-substituted succinic anhydrides,
nitriles, epoxides, boron compounds, and phosphorus compounds.
[0031] Antioxidants include but are not limited to
alkyl-substituted phenols such as 2,6-di-tertiary butyl-4-methyl
phenol, phenate sulfides, phosphosulfurized terpenes, sulfurized
esters, aromatic amines, diphenyl amines, alkylated diphenyl amines
and hindered phenols.
[0032] The antioxidant includes amine antioxidants and is not
limited to bis-nonylated diphenylamine, nonyl diphenylamine, octyl
diphenylamine, bis-octylated diphenylamine, bis-decylated
diphenylamine, decyl diphenylamine and mixtures thereof.
[0033] The antioxidants include sterically hindered phenols and
includes but is not limited to 2,6-di-tert-butylphenol,
4-methyl-2,6-di-tert-butyl- phenol,
4-ethyl-2,6-di-tert-butylphenol, 4-propyl-2,6-di-tert-butylphenol,
4-butyl-2,6-di-tert-butylphenol 2,6-di-tert-butylphenol,
4-pentyl-2,6-di-tert-butylphenol, 4-hexyl-2,6-di-tert-butylphenol,
4-heptyl-2,6-di-tert-butylphenol,
4-(2-ethylhexyl)-2,6-di-tert-butylpheno- l,
4-octyl-2,6-di-tert-butylphenol, 4-nonyl-2,6-di-tert-butylphenol,
4-decyl-2,6-di-tert-butylphenol, 4-undecyl-2,6-di-tert-butylphenol,
4-dodecyl-2,6-di-tert-butylphenol,
4-tridecyl-2,6-di-tert-butylphenol,
4-tetradecyl-2,6-di-tert-butylphenol, methylene-bridged sterically
hindered phenols include but are not limited to
4,4-methylenebis(6-tert-b- utyl-o-cresol),
4,4-methylenebis(2-tert-amyl-o-cresol),
2,2-methylenebis(4-methyl-6-tert-butylphenol),
4,4-methylene-bis(2,6-di-t- ertbutylphenol) and mixtures
thereof.
[0034] Another example of an antioxidant is a hindered,
ester-substituted phenol, which can be prepared by heating a
2,6-dialkylphenol with an acrylate ester under base catalysis
conditions, such as aqueous KOH. Antioxidants may be used alone or
in combination.
[0035] The antioxidants are typically present in the range of about
0.01% to about 95%, preferably about 0.01% to 95%, and more
preferably about 1.0% to about 70% and most preferably about 5% to
about 60% by weight of the gel. (Jim is this definition of
antioxidant ok?)
[0036] The other lubricant additives include but are not limited to
dispersants, detergents, overbased detergents, carbon black,
silica, alumina, titania, magnesium oxide, calcium carbonate, lime,
clay, zeolites, extreme pressure (EP) agents, wear reduction
agents, viscosity index improvers, anti-foaming agents, friction
reducing agents, anti-misting agents, cloud-point depressants,
pour-point depressants, mineral and/or synthetic oils mixtures
thereof and combination thereof. These lubricant additives
components can be used alone or in combination.
[0037] The detergents include but are not limited to overbased
sulfonates, phenates, salicylates, carboxylates and the like. The
detergents include but are not limited to overbased calcium
sulfonate detergents which are commercially-available, overbased
detergents containing metals such as Mg, Ba, Sr, Na, Ca and K and
mixtures thereof. The detergents may be used alone or in
combination. Detergents are described, for example, in U.S. Pat.
No. 5,484,542 which is incorporated herein by reference.
[0038] The extreme pressure anti-wear additives include but are not
limited to a sulfur or chlorosulphur EP agent, a chlorinated
hydrocarbon EP agent, or a phosphorus EP agent, or mixtures
thereof. Examples of such EP agents are chlorinated wax, organic
sulfides and polysulfides, such as benzyldisulfide,
bis-(chlorobenzyl) disulfide, dibutyl tetrasulfide, sulfurized
sperm oil, sulfurized methyl ester of oleic acid sulfurized
alkylphenol, sulfurized dispentene, sulfurized terpene, and
sulfurized Diels-Alder adducts; phosphosulfurized hydrocarbons,
such as the reaction product of phosphorus sulfide with turpentine
or methyl oleate, phosphorus esters such as the dihydrocarbon and
trihydrocarbon phosphate, i.e., dibutyl phosphate, diheptyl
phosphate, dicyclohexyl phosphate, pentylphenyl phosphate;
dipentylphenyl phosphate, tridecyl phosphate, distearyl phosphate
and polypropylene substituted phenol phosphate, metal
thiocarbamates, such as zinc dioctyldithiocarbamate and barium
heptylphenol diacid, such as zinc dicyclohexyl phosphorodithioate
and the zinc salts of a phosphorodithioic acid combination may be
used and mixtures thereof. The EP agent can be used alone or in
combination.
[0039] The antifoams include but are not limited to organic
silicones such as poly dimethyl siloxane, poly ethyl siloxane, poly
diethyl siloxane and the like. The antifoams may be used alone or
in combination.
[0040] The viscosity modifiers provide both viscosity improving
properties and dispersant properties. Examples of
dispersant-viscosity modifiers include but are not limited to vinyl
pyridine, N-vinyl pyrrolidone and N,N'-dimethylaminoethyl
methacrylate are examples of nitrogen-containing monomers and the
like. Polyacrylates obtained from the polymerization or
copolymerization of one or more alkyl acrylates also are useful as
viscosity modifiers. The viscosity modifiers may be used alone or
in combination.
[0041] Functionalized polymers can also be used as viscosity
modifiers. Among the common classes of such polymers are olefin
copolymers and acrylate or methacrylate copolymers. Functionalized
olefin copolymers can be, for instance, interpolymers of ethylene
and propylene which are grafted with an active monomer such as
maleric anhydride and then derivatized with an alcohol or an amine.
Other such copolymers are copolymers of ethylene and propylene
which are reacted or grafted with nitrogen compounds. Derivatives
of polyacrylate esters are well known as dispersant viscosity index
modifiers additives. Dispersant acrylate or polymethacrylate
viscosity modifiers such as Acryloid.TM. 985 or Viscoplex.TM.
6-054, from RohMax, are particularly useful. Solid, oil-soluble
polymers such as the PIB, methacrylate, polyalkylstyrene,
ethylene/propylene and ethylene/propylene/1, 4-hexadiene polymers,
can also be used as viscosity index improvers. The viscosity
modifiers are known and commercially available.
[0042] The friction reducing agents include but are not limited to
organo-molybdenum compounds, including molybdenum dithiocarbamate.
The friction reducing agents can be used alone or in
combination.
[0043] The anti-misting agents include but are not limited to very
high (>100,000 Mn) polyolefins such as 1.5 Mn polyisobutylene
(for example the material of the trades name Vistanex.RTM.), or
polymers containing 2-(N-acrylamido), 2-methyl propanesulfonic acid
(also known as AMPS.RTM.), or derivatives thereof. The anti-misting
agents can be used alone or in combination.
[0044] The cloud point depressants include but are not limited to
alkylphenols and derivatives thereof. The cloud point depressants
can be used alone or in combination.
[0045] The pour point depressants include but are not limited to
alkylphenols and derivatives thereof. The pour point depressants
can be used alone or in combination.
[0046] The additive composition typically contains small amounts
(about 5-40%) of base stock oils, which include but are not limited
to mineral-based, synthetic or mixtures thereof.
[0047] Optionally, an inert carrier can be used if desired.
Furthermore, other active ingredients, which provide a beneficial
and desired function to the soot being decreased, can also be
included in the gel. In addition, solid, particulate additives such
as the PTFE, MoS.sub.2 and graphite can also be included.
[0048] In an embodiment of this invention, the internal combustion
engine is equipped with an exhaust after-treatment device. Exhaust
after-treatment devices are used for modern engines to meet the new
low exhaust emission standards. These systems are used to reduce
undesirable emissions in the exhaust gases of internal combustion
vehicle engines and are located in the exhaust system connected to
the engines.
[0049] In one embodiment of this invention, catalysts are employed
in the exhaust systems of internal combustion engines to convert
carbon monoxide, hydrocarbons and nitrogen oxides (NOx) produced
during engine operation into more desirable gases such as carbon
dioxide, water and nitrogen. Among the broad range of available
catalysts for this purpose, are oxidation catalysts, reduction
catalysts and the so-called three-way converters. Oxidation
catalysts can efficiently oxidize unburnt exhaust gas components
and convert them into harmless substances. Three-way converters are
able to simultaneously convert all three harmful substances
provided that the internal combustion engine is operated close to
the stoichiometirc air/fuel ratio. These catalyst systems typically
contain noble metals from the platinum group of the Periodic System
of Elements. Particular metals used are platinum, palladium and
rhodium.
[0050] In another embodiment, the exhaust after-treatment device
involves a NOx trap. NOx traps, i.e. materials that are able to
absorb nitrogen oxides during lean-burn operation and are able to
release them when the oxygen concentration in the exhaust gas is
lowered are porous support materials loaded with alkali metal or
alkaline earth metals combined with precious metal catalysts such
as platinum and the like.
[0051] In still another embodiment, the exhaust after-treatment
device contains a diesel engine exhaust particulate filter
hereinafter referred to as "DPF's". DPF's have a multiplicity of
interconnected thin porous walls that define at least one inlet
surface and one outlet surface on the filter and a multiplicity of
hollow passages or cells extending through the filter from the
inlet surface to an outlet surface. The interconnected thin porous
walls allow the fluid to pass from the inlet surface to the outlet
surface while restraining a desired portion of the solid
particulates in the fluid from passing through. DPF's are typically
installed in a housing which is inserted like a muffler or
catalytic converter into the exhaust system of diesel engine
equipped vehicle.
Specific Embodiments
[0052] In order to more thoroughly illustrate the present
invention, the following examples are provided.
[0053] Gel Preparation
[0054] A representative gel, known as Composition X is prepared by
first mixing components A and C, and then adding component B with
mixing in the proportions listed below. The resulting mixture is
heated at 120.degree. overnight to produce the final gel.
1 % wt of Composition Component Chemical Description X A
Polyisobutenyl (2000 Mn) succinimide 20% Dispersant B 400 TBN
Overbased Alkylbenzenesulfonate 60% Detergent C Nonylated
Diphenylamine Antioxidant 20%
[0055] GM 6.5 L Engine Test
[0056] Test Engine
[0057] GM 6.5 L Engine see ASTM D5966.
[0058] Test Filters
[0059] For the experimental runs, each engine was equipped with a
filter with one cup into which was placed 400 g of Composition X
additive gel and placed at the bottom of the filter. In the
comparative runs, the same filter was used without additive gel in
the cup. The additizing cup had twelve of 1/4" diameter diffusion
holes at the top of the cup above the surface of the gel.
[0060] Test Oil
[0061] A 15W40 fully qualified (SAE-C.sub.1-4) oil was used in this
test.
[0062] Procedure
[0063] The test vehicles was operated for 4 runs: 1) a baseline
with standard filters, 2) a test run with two large hole cup
filters on Truck #1 and two small-hole filters on Truck #2, 3) a
second test run with two large hole cup filters on Truck #2 and two
small-hole filters on Truck #1, and #4) a repeat baseline. For each
run, both filters was replaced with new standard filters (Runs 1
and 4) or test filters (Runs 2 and 3). A 4-ounce sample was taken
at the following mileages:
[0064] Each oil change included two flushes in which full sump
quantity of new test oil and a new filter was installed, the engine
was running for at least 15 minutes, and the oil drained for 30
minutes or until no more oil drips out (whichever occurred first).
The two flushes were performed prior to filling with the test oil
and installing a new (or test) filter, which remained on the
vehicle for the next drain interval.
[0065] Oil drain samples were taken for baselines at the mileage
intervals from 500-20,000 miles Initial (after vehicle is warmed
up) 500 miles, 3,000 miles, 6,000 miles, 9,000 miles, 12,000 miles,
and 20,000 miles.
[0066] At the 20,000-mile mark, before taking a baseline oil drain
sample, test oil was flushed and oil changed and a new filter, was
added, additized filter installed and initial additized filter
drained.
[0067] The following analysis was performed and kinematic viscosity
and 100.degree. C. (vis 100); elemental analysis by ICP, ASTM D
4739 (TBN), ASTM D664A (TAN) and percent soot by thermal
gravimetric analysis (TGA).
[0068] See Designation: D 5966-99 "Standard Test Method for
Evaluation of Engine Oils for Roller Follower Wear in Light-Duty
Diesel Engine 1, AMERICAN SOCIETY FOR TESTING AND MATERIALS, 100
Barr Harbor Dr., West Conshohocken, Pa. 19428, from the Annual Book
of ASTM Standards, copyright ASTM.
[0069] Results
[0070] The results are shown in Table 1, Table 1 summarizes
experiments in which the antioxidants withheld from the gel (1
Experimental, 1 Exp) compared to baselines (1 Comparatives, 1
Comp). Table 2 shows soot production with no gel in the filter,
with and without dosing of a 1:1 mixture of antioxidant:dispersant
throughout the 50 hr test for 2 Exp. and 2 Comp.
2TABLE 1 GM 6.5 L Test Soot Production as a Function of Dosing with
Gel Components Hours on Test Experiment 0 10 20 25 30 40 50 1 Comp
% C baseline 3 0.0% 0.4% 1.2% 1.6% 1.7% 2.2% 2.8% 1 Exp % C Gel
(-AO) in filter 0.1% 0.3% 1.2% 1.5% 1.6% 2.1% 2.7%
[0071] 100 g alkyldiphenylamine antioxidant added at beginning of
test per 7 qts of oil
3TABLE 2 GM 6.5 L Test Soot Production as a Function of Dosing with
Gel Components Hours on Test Experiment 0 10 20 25 30 40 50 2 Exp %
C 1:1 AO:Disp Dosed** 0.1% 0.8% 1.5% 1.9% 2.0% 2.6% 3.3% 2 Comp % C
Baseline 4 0.1% 0.8% 1.8% 2.2% 2.2% 3.0% 3.6% **11.3 g of 1:1 (wt)
mixture of antioxidant (AO) and dispersant (Disp) per 7 quarts of
oil added at 0, 10, 20, 30 and 40 hrs.
[0072] Mack T-8 Engine Test
[0073] Test Engine
[0074] Mack T-8 Diesel Engine.
[0075] Test Filters
[0076] For these experiment runs, the engine was equipped with an
oil pan with a 1" deep tray, into which was placed 400 g of
Composition X additive gel. In the comparative runs, an oil pan
without additive was used.
[0077] Test Oil
[0078] A 15W40 fully qualified (SAE-CI-4) oil was used in this
test.
[0079] Procedure
[0080] A Short T-8 test was used. The Short T-8 is a modified
version of the T-8/T-8E ASTM test. Conditions are shown below:
[0081] Speed (rpm): 1800 Fuel Flow (kg/hr): 63.3 Intake Manifold
Temp. (C): 43
[0082] Coolant Temp. (C): 85 Crankcase Pressure (kPa):
0.25-0.75
[0083] Inlet Air Restriction (kPa): 2.25-2.75 Exhaust Back Pressure
(kPa): 3.1
[0084] Engine Timing (BTDC): 15 degrees
[0085] The engine timing corresponds to an average soot production
rate in the 3 Comp experiment of 0.006%/hour in a 7 quart oil
sump.
[0086] Results
[0087] The results are shown in Table 3, Example 3, 3 Comparative
and 3 Experimental.
[0088] Table 3 demonstrates that the soot production rate is 3
Experimental is lower than in 3 Comparative, which is about the
same as 3 Experimental with antioxidant. The results demonstrate
that soot reduction occurs from the antioxidant and dispersant
components of the additive composition (compare 3 Comparative and 3
Experimental) further demonstrates that the antioxidant dissolution
is necessary but also the dispersant is needed.
4TABLE 3 Mack T-8 Test Stand Soot Levels (3 Comparative) without (3
Comparative) and with 3 Experimental Additive Gel Filter as a
Function of Test Hours. Hours on Test Experiment 0 7 8 10 14 20 23
24 3 Comp % C, Baseline 0.05% 0.06% 0.09% 0.14% 3 Exp % C, Gel
oilpan 0.05% 0.07% 0.08% 3A Exp % C, AO dose 0.10% 0.07% 0.15%
Hours on Test Experiment 31 32 39 40 48 56 64 3 Comp % C, Baseline
0.22% 0.28% 3 Exp % C, Gel oilpan 0.12% 0.21% 3A Exp % C, AO dose
0.38% 0.50% 0.60% 0.71%
[0089] While the invention has been explained in relation to its
preferred embodiments, it is to be understood that various
modifications thereof will become apparent to those skilled in the
art upon reading the specification. Therefore, it is to be
understood that the invention disclosed herein is intended to cover
such modifications as fall within the scope of the appended
claims.
* * * * *