U.S. patent application number 11/210616 was filed with the patent office on 2007-03-01 for controlled release of additive gel(s) for functional fluids.
Invention is credited to Mark R. Baker, Bryan A. Grisso, Jennifer M. Ineman, Brian M. O'Connor.
Application Number | 20070049505 11/210616 |
Document ID | / |
Family ID | 37564422 |
Filed Date | 2007-03-01 |
United States Patent
Application |
20070049505 |
Kind Code |
A1 |
Baker; Mark R. ; et
al. |
March 1, 2007 |
Controlled release of additive gel(s) for functional fluids
Abstract
The invention provides a method of lubricating containing: (a)
employing a first functional fluid, (b) adding or contacting the
first functional fluid with a controlled release gel wherein the
controlled release gel has the desired additives to be released
imparting the desired properties into the first functional fluid
which is for lubricating a mechanical device; and/or adding a
delivery system with the desired additives for a second functional
fluid; (c) releasing the desired additives from the delivery system
into the first functional fluid resulting in the first functional
fluid changing into a second functional fluid, with the proviso
that the second functional fluid is different from the first
functional fluid.
Inventors: |
Baker; Mark R.; (Lyndhurst,
OH) ; O'Connor; Brian M.; (Hudson, OH) ;
Grisso; Bryan A.; (Wickliffe, OH) ; Ineman; Jennifer
M.; (Greer, SC) |
Correspondence
Address: |
Teresan W. Gilbert;The Lubrizol Corporation
Patent Dept./Mail Drop 022B
29400 Lakeland Blvd.
Wickliffe
OH
44092-2298
US
|
Family ID: |
37564422 |
Appl. No.: |
11/210616 |
Filed: |
August 24, 2005 |
Current U.S.
Class: |
508/270 |
Current CPC
Class: |
C10M 2207/129 20130101;
C10M 2207/26 20130101; C10N 2030/06 20130101; C10N 2040/08
20130101; C10N 2050/08 20130101; C10N 2040/25 20130101; C10N
2050/12 20200501; C10M 2223/043 20130101; C10N 2040/042 20200501;
C10N 2010/04 20130101; C10N 2050/10 20130101; C10M 2207/028
20130101; C10N 2040/04 20130101; C10M 2207/262 20130101; C10M
177/00 20130101; C10N 2070/00 20130101; C10M 2215/28 20130101; C10M
2219/046 20130101; C10M 163/00 20130101; C10N 2040/044 20200501;
C10N 2040/26 20130101; C10M 2219/089 20130101; C10N 2040/20
20130101; C10N 2070/02 20200501; C10N 2010/02 20130101 |
Class at
Publication: |
508/270 |
International
Class: |
C10L 1/26 20060101
C10L001/26 |
Claims
1. A method of lubricating comprising: (a) employing a first
functional fluid, wherein the first functional fluid is selected
from the group consisting of an oil of lubricating viscosity, a
gear oil including automotive and/or industrial, a manual
transmission oil, an automatic transmission oil, a hydraulic fluid,
an engine oil, a two cycle oil, a metalworking fluid and an axle
fluid; (b) contacting the first functional fluid with a delivery
system wherein the delivery system has the desired additives to be
released imparting the desired properties into the first functional
fluid which is for lubricating a mechanical device; (c) releasing
the desired additives from the delivery system into the first
functional fluid resulting in the first functional fluid changing
into a second functional fluid selected from the group consisting
of a gear oil, a manual transmission oil, an automatic transmission
oil, a hydraulic fluid, an engine oil, a two cycle oil, a
metalworking fluid and an axle fluid, with the proviso that the
second functional fluid is different from the first functional
fluid.
2. The method of claim 1, wherein the delivery system comprises at
least one of a liquids, solids, controlled release additive gel,
capsules (for example melamine or urea formaldehyde
microencapsulation polymers), linear low density polyolefin bags,
perforated sheets, baffles, injectors, polymers which are
oil-permeable at elevated temperatures, particles which are
oil-insoluble but oil wettable, oil-soluble solid polymers capable
of functioning as viscosity improvers, or mixtures thereof.
3. The method of claim 1, wherein the delivery system comprises a
controlled release additive gel.
4. The method of claim 1, wherein the first and/or second
functional fluid comprises an antiwear/EP agent present from about
0.1 wt % to about 5 wt %.
5. The method of claim 3, wherein the controlled release gel
composition comprises i.) at least two additives selected from the
group comprising detergents, dispersants, acids, bases, over based
detergent, succinated polyolefins or mixtures thereof wherein the
selected additives when combined form a gel; ii.) optionally at
least one additive comprising viscosity modifier(s), friction
modifier(s), detergent(s), cloud point depressant(s), pour point
depressant(s), demulsifier(s), flow improver(s), anti static
agent(s), dispersant(s), antioxidant(s), antifoam(s),
corrosion/rust inhibitor(s), extreme pressure/antiwear agent(s),
seal swell agent(s), lubricity aid(s), antimisting agent(s), or
mixtures thereof; resulting in a controlled release gel that over
time releases at least one desired additive into a functional fluid
when the gel is contacted with the functional fluid.
6. The method of claim 3, wherein the controlled release gel
composition has a ratio of detergent to dispersant is from about
10:1 to about 1:10 and the detergent is an over based detergent
having a TBN of at least 200.
7. The method of claim 6, wherein the dispersant is selected from
the group consisting of ashless type dispersants, polymeric
dispersants, Mannich dispersants, carboxylic dispersants, amine
dispersants, high molecular weight esters, esterified maleic
anhydride styrene copolymers, maleated ethylene diene monomer
copolymers, surfactants, functionalized derivatives, and
combinations thereof and where the dispersant is present in a range
of about 0.01 wt. % to about 95% of the additive gel, and wherein
the detergent is selected from the group consisting of over based
sulfonates, phenates, salicylates, carboxylates, over based calcium
sulfonate detergents, overbased detergents containing metals such
as Mg, Ba, Sr, Na, C and K and mixtures thereof and wherein the
detergents are in the range from about 0.01 wt. % to about 99% by
wt. of the additive gel.
8. The method of claim 5, wherein component i) is present in the
range from about 0.01 wt. % to about 95 wt. % of the additive gel
and wherein component ii) is present in the range of about 0% to
about 95% by wt. of the additive gel.
9. The method of claim 6, wherein optionally at least one other
component can be added to the additive gel composition which is
selected from the group consisting of base stock oils, inert
carriers, dyes, bacteriostatic agents, solid particulate additives
and mixtures thereof.
10. The method of claim 3, wherein the gel comprises an over based
detergent, a succinimide dispersant and an anti-foam agent
resulting in a controlled release gel that over time releases an
antifoam additive into the functional fluid so as to reduce the
foaming tendency and to improve stability of the fluid.
11. The method of claim 3, wherein the gel comprises an over based
detergent, a succinimide dispersant, an ashless anti-oxidant and a
polysuccinated polyolefin resulting in a controlled release gel
that over time releases an antioxidant additive into the functional
fluid of an engine.
12. The method of claim 3 comprising an over based detergent, a
succinimide dispersant, a friction modifier and a polysuccinated
polyolefin resulting in a controlled release gel that over time
releases the friction modifier into the functional fluid so as to
reduce the coefficient friction between metal parts.
13. The method of claim 12 further comprising an antiwear
agent/extreme pressure agent.
14. The method of claim 13, wherein the antiwear agent/extreme
pressure agent comprises an amine salt of a phosphorus ester
acid.
15. The method of claim 14, wherein the phosphorus ester acid is
selected from the group consisting of phosphoric acid esters and
salts thereof; dialkyldithiophosphoric acid esters and salts
thereof; phosphites; and phosphorus-containing carboxylic esters,
ethers, and amides; and mixtures thereof.
16. The method of claim 1, wherein the first functional fluid is a
manual transmission fluid; and wherein the second functional fluid
is an axle fluid.
17. A method for lubricating a mechanical device comprising: (a)
employing one or more delivery systems, wherein the delivery
systems may be the same, similar, different or combinations thereof
and wherein the composition of the delivery systems depends on the
desired additives to be added into a first functional fluid or to
change the first functional fluid into a second functional fluid;
(b) contacting the first functional fluid with one or more delivery
systems wherein the functional fluid may be of more than one type,
and wherein the delivery systems comprises at least one additive
comprising detergents, dispersants, acids, bases, over based
detergent, succinated polyolefins, viscosity modifier(s), friction
modifier(s), detergent(s), cloud point depressant(s), pour point
depressant(s), demulsifier(s), flow improver(s), anti static
agent(s), dispersant(s), antioxidant(s), antifoam(s),
corrosion/rust inhibitor(s), extreme pressure/antiwear agent(s),
seal swell agent(s), lubricity aid(s), antimisting agent(s), or
mixtures thereof; resulting in changing the first functional fluid
into the second functional fluid when the delivery systems are
contacted with the first functional fluid.
18. The method of claim 17, wherein the delivery systems comprise a
controlled release additive gel.
19. The method of claim 18, wherein the controlled release gel
composition comprises i.) at least two additives selected from the
group comprising detergents, dispersants, acids, bases, over based
detergent, succinated polyolefins or mixtures thereof wherein the
selected additives when combined form a gel; ii.) optionally at
least one additive comprising viscosity modifier(s), friction
modifier(s), detergent(s), cloud point depressant(s), pour point
depressant(s), demulsifier(s), flow improver(s), anti static
agent(s), dispersant(s), antioxidant(s), antifoam(s),
corrosion/rust inhibitor(s), extreme pressure/antiwear agent(s),
seal swell agent(s), lubricity aid(s), antimisting agent(s), or
mixtures thereof; resulting in a controlled release gel that over
time releases at least one desired additive into a functional fluid
when the gel is contacted with the functional fluid.
20. The method of claim 17, wherein the mechanical device comprises
one first functional fluid contacting multiple delivery systems
resulting in changing the first functional fluid into multiple
second functional fluids.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a delivery system for
providing one or more functional fluids with desired additives. The
invention further relates to the systems use in lubricant
technology.
BACKGROUND OF THE INVENTION
[0002] Modern mechanical equipment such as a transmission,
hydraulic, engine or gear all require a functional fluid to possess
a number of different properties. These properties allow the
equipment to operate in a range of equipment environments,
including various regimes of soot/sludge formation, friction,
corrosion, thermal decomposition, oxidation, extreme pressure and
wear. In many instances these different properties are unique to a
component of the mechanical device. The unique properties may
depend on chemical interactions between additives (for example,
synergistic effects or antagonists competing for same reactive
sites), component design, as well as the materials used.
Consequently, a number of functional fluids are required to
lubricate various components within the mechanical equipment.
Having a number of functional fluids may result in difficulties
such as in handling or storage and confusion of application for the
operator. Confusion of application may result in improper use
resulting in equipment down time.
[0003] Furthermore, functional fluids degrade over time through
use. The additives in the functional fluids deplete or change over
the lifetime of the fluid in an engine or other mechanical device.
Replenishment of additives in a functional fluid by a slow release
additive package in the form of a gel is disclosed in US Patent
Application 2004/0014614. Other time release additives include
coatings or polymers as disclosed in U.S. Patent Application
2004/0154304A1; and U.S. Pat. Nos. 4,075,098; and 4,066,559.
[0004] Accordingly, it is desirable to provide a delivery system
for additives and a method of lubricating a mechanical device with
the delivery system. The delivery system and method of lubricating
allows for improved storage or handling of functional fluids as
well as reduced confusion of application. The present invention
provides a delivery system and a method of lubricating capable of
improving at least one of replenishing additives in a lubricating
oil, storage and handling of functional fluids.
SUMMARY OF THE INVENTION
[0005] The invention provides a method for lubricating a
comprising:
[0006] (a) employing a first functional fluid, wherein the first
functional fluid is selected from the group consisting of an oil of
lubricating viscosity, a gear oil including automotive and/or
industrial, a manual transmission oil, an automatic transmission
oil, a hydraulic fluid, an engine oil, a two cycle oil, a
metalworking fluid and an axle fluid;
[0007] (b) contacting the first functional fluid with a delivery
system wherein the delivery system has the desired additives to be
released imparting the desired properties into the first functional
fluid which is for lubricating a mechanical device;
[0008] (c) releasing the desired additives from the delivery system
into the first functional fluid resulting in the first functional
fluid changing into a second functional fluid selected from the
group consisting of a gear oil, a manual transmission oil, an
automatic transmission oil, a hydraulic fluid, an engine oil, a two
cycle oil, a metalworking fluid and an axle fluid, with the proviso
that the second functional fluid is different from the first
functional fluid.
[0009] In another embodiment the invention is a method for
lubricating a mechanical device comprising:
[0010] (a) employing one or more delivery systems, wherein the
delivery systems may be the same, similar, different or
combinations thereof and wherein the composition of the delivery
systems depends on the desired additives to be added into a first
functional fluid or to change the first functional fluid into a
second functional fluid;
[0011] (b) contacting the first functional fluid with one or more
delivery systems wherein the functional fluid may be of more than
one type, and wherein the delivery systems comprises at least one
additive comprising detergents, dispersants, acids, bases, over
based detergent, succinated polyolefins, viscosity modifier(s),
friction modifier(s), detergent(s), cloud point depressant(s), pour
point depressant(s), demulsifier(s), flow improver(s), anti static
agent(s), dispersant(s), antioxidant(s), antifoam(s),
corrosion/rust inhibitor(s), extreme pressure/antiwear agent(s),
seal swell agent(s), lubricity aid(s), antimisting agent(s), or
mixtures thereof;
[0012] resulting in changing the first functional fluid into the
second functional fluid when the delivery systems are contacted
with the first functional fluid.
[0013] The present invention provides a process for supplying one
or more desired additives to a functional fluid by contacting the
functional fluid with the additized controlled release gel.
DETAILED DESCRIPTION
[0014] In one embodiment the invention provides a method for
lubricating a mechanical device comprising the methods disclosed
above.
[0015] The delivery system comprises at least one of liquids,
solids, a controlled release additive gel, capsules (for example
melamine or urea formaldehyde microencapsulation polymers), polymer
bags (e.g. linear low density polyethylene), perforated sheets,
baffles, injectors, polymers which are oil-permeable at elevated
temperatures (as defined in U.S. Pat. No. 4,066,559), particles
which are oil-insoluble but oil wettable (as defined in U.S. Pat.
No. 5,478,463), oil-soluble solid polymers capable of functioning
as viscosity improvers (as defined in U.S. Pat. No. 4,014,794), or
mixtures thereof. Typically the oil-soluble solid polymers are
delivered from within an oil filter, but any means by which the
delivery system can be brought into contact with the functional
fluid can be used e.g., container/delivery device within the oil
pan, or within a fluid by-pass loop.
[0016] In accordance with one embodiment of the present invention,
a controlled release additive gel is provided for a fluid
conditioning device(s). The present invention provides a process
for supplying one or more desired additives to a functional fluid
by contacting the functional fluid with the additized controlled
release gel.
[0017] The present invention of a delivery system can be used in
any fluid conditioning device including internal combustion engines
which include mobile and stationary applications; hydraulic
systems; automatic transmissions; gear boxes which include manual
transmissions and differentials (e.g. front and rear drive axles
and industrial speed increasers or reducers); metalworking fluids;
pumps; suspension systems; other lubricated mechanical systems; and
the like. The fluid conditioning devices that can use the additive
gel include, 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; lubricated mechanical systems such as gear
boxes, automatic transmissions, differentials, hydraulic systems
and the like.
[0018] In one preferred embodiment, the first functional fluid is
not a gear oil because difficulties may be encountered transforming
the gear oil into a second functional fluid. The reason for this is
believed to be the presence of excessive amounts of antiwear/EP
agent additives based on sulphurised olefins. In some instances
where the amount of sulphurised olefin is reduced it may be
possible to change a first functional fluid derived from a gear oil
into a different second functional fluid.
[0019] The functional fluid becomes diminished and depleted of its
additives over time. The additive delivery system is specifically
formulated to meet the desired performance requirements of the
functional fluid system and to condition the fluid. The present
invention provides for the use of an additive delivery system to
increase the performance of the functional fluid by replenishing
the depleted desired additives or introducing new desired additives
to the functional fluid. Thus the functional fluid can add and/or
maintain consistent performance over the functional fluid's life
because the device should perform closer to optimum for a longer
period of time.
[0020] The functional fluids useful to be readditized through the
additized delivery system include gear oil, transmission oil,
hydraulic fluid, engine oil, two cycle oil, metalworking fluid and
the like. In one embodiment the preferred functional fluid is an
engine oil. In another embodiment the preferred functional fluid is
a gear oil. In another embodiment the preferred functional fluid is
a transmission fluid. In another embodiment the preferred
functional fluid is a hydraulic fluid.
[0021] In one embodiment the additive delivery system dissolves
into the functional fluid by contacting the additive delivery
system with the functional fluid in the system. The additive
delivery system is positioned anywhere the additive delivery system
will be in contact with the functional fluid. In one embodiment,
the additive delivery system is positioned anywhere that the
circulating functional fluid contacts the additive delivery system.
In one embodiment the functional fluid is an engine oil and the
additive delivery system is positioned in the engine oil system
which includes the lubricating system, 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, oil lines and the like. In one
embodiment the functional fluid is a gear oil and the additive
delivery system is located in the gear system which includes oil
drain pan, sump, filters, a full flow or bypass oil line, lines,
loop and/or filter, canisters, mesh, other spaces within the device
in which a delivery system might be contained and the like. In one
embodiment the functional fluid is transmission fluid and the
additive delivery system is located in the transmission system
which includes the space such as a hole within a transmission
magnet, the oil pan, oil lines, lines, canisters, mesh and the
like. In one embodiment the additive delivery system is located in
the engine oil line, which includes a full flow filter, a by-pass
filter, the oil pan, and the like. In one embodiment, the
functional fluid is a hydraulic fluid and the additive delivery
system is located in the hydraulic cylinder, sump, filter, oil
lines, pan, full flow or by pass oil loop, line and/or filter,
canister, mesh, other spaces in the system and the like.
[0022] One or more locations in a line, loop and/or the functional
fluid system can contain the additive delivery system. Further, if
more than one additive delivery system for the functional fluid is
used the additive delivery system can be identical, similar and/or
a different additive delivery system composition.
[0023] In one embodiment the method for lubricating a mechanical
device comprises employing one or more additive delivery systems in
a container.
[0024] In one embodiment the properties imparted by the desired
additives include dispersancy, antioxidancy, corrosion inhibition,
wear prevention, scuffing prevention, pitting prevention including
micro and macro pitting, friction modifying properties including
increased and/or decreased friction coefficients, detergency,
viscosity control using viscosity modifiers, foam control or
mixtures thereof.
[0025] In one embodiment the mechanical device comprises axles,
gear boxes, automatic transmissions, manual transmissions,
differentials or mixtures thereof.
[0026] In one embodiment of the invention the first functional
fluid is changed into the second functional fluid different from
the first functional fluid. Changing the first functional fluid
into the second functional fluid may be attained by releasing the
desired additives from a delivery system in an amount sufficient to
provide a different ratio of additives.
[0027] The first functional fluid may be changed into the second
functional fluid by adding and/or modifying the ratio of additives
in the first functional fluid. Modifying the ratio of additives by
the addition the desired additives is obtained by adding or
contacting the first functional fluid with a delivery system
composition of the desired additives. The desired additives
controlled released into the first functional fluid resulting in
the first functional fluid changing into the second functional
fluid. The change from the first functional fluid to the second
functional fluid occurs when the desired additives are released
from the delivery system and providing the desired properties to
the second functional fluid.
[0028] In one embodiment the first functional fluid is a manual
transmission fluid additized with a sufficient amount of an
antiwear agent/extreme pressure agent and other additives including
dispersants and/or detergent to form the second functional fluid,
an axle fluid.
[0029] In one embodiment the functional fluid system comprises
additive delivery systems suitable for forming a functional fluid
for an axle. The compositions of the additive delivery systems
suitable forming a functional fluid for an axle and/or gear oil in
one embodiment contains reduced amounts of a sulfurized olefin
antiwear agent in the presence of a sulfonate detergent. In another
embodiment the functional fluid for an axle and/or gear oil
contains reduced amounts of sulfonate detergent in the presence of
a sulfurized olefin antiwear agent. In another embodiment the
sulfonate detergent in the delivery system is substantially
retained, thus reducing the amount of detergent in a functional
fluid for an axle and/or gear oil. In one embodiment, it is
desirable that the sulfonate detergent in the delivery system does
not release in a gear oil applications.
[0030] In one embodiment the line, loop and/or the functional fluid
system contains two or more different additive delivery systems
located at two or more locations. The different compositions of the
additive delivery systems provide the first functional fluid with
desired additives to be control released to change to a second
functional fluid that lubricates the mechanical device.
[0031] In one embodiment, the mechanical device contains two or
more first functional fluids which are contacted with one or more,
for example two or three additive delivery systems. After
contacting the additives delivery systems, the first functional
fluids are changed into second functional fluids (which can be the
same or different depending on the delivery systems) with two or
more compositions that are employed to provide appropriate
lubricating properties to various components within the mechanical
device.
[0032] In one embodiment the mechanical device comprises one first
functional fluid contacting multiple delivery systems resulting in
changing the first functional fluid into multiple second functional
fluids.
[0033] In one embodiment the mechanical device comprises multiple
first functional fluids contacting multiple delivery systems
resulting in changing the first functional fluids into multiple
second functional fluids.
[0034] In one embodiment it is desirable to provide a container to
hold the additive delivery system, such as a housing, a canister or
a structural mesh anywhere in the functional fluid system, for
example, a canister within a bypass loop of a stationary gas engine
for power generation. The necessary design feature for the
container is that at least a portion of the additive delivery
system is in contact with the functional fluid.
[0035] In one embodiment the delivery system is a controlled
release gel. The gel comprises; [0036] i.) at least two additives
selected from the group comprising detergents, dispersants, acids,
bases, over based detergent, succinated polyolefins or mixtures
thereof wherein the selected additives when combined form a gel;
[0037] ii.) optionally at least one additive comprising viscosity
modifier(s), friction modifier(s), detergent(s), cloud point
depressant(s), pour point depressant(s), demulsifier(s), flow
improver(s), anti static agent(s), dispersant(s), antioxidant(s),
antifoam(s), corrosion/rust inhibitor(s), extreme pressure/antiwear
agent(s), seal swell agent(s), lubricity aid(s), antimisting
agent(s), or mixtures thereof.
[0038] The additive gel needs to be in contact with the functional
fluid. In one embodiment the additive gel is in contact with the
functional fluid in the range of about 100% to about 1% of the
functional fluid in the system, in another embodiment the additive
gel is in contact with the functional fluid in the range of about
75% to about 25% of the functional fluid in the system and in
another embodiment the additive gel is in contact with the
functional fluid in the range of about 50% of the functional fluid
in the system. As the flow rate decreases there is less dissolution
of the additive gel and as the flow rate increases there is greater
dissolution of the additive gel.
[0039] In one embodiment, the additive gel is positioned in the
functional fluid system so that the additive gel and/or spent
additive gel can easily be removed, and then replaced with a new
and/or recycled additive gel.
[0040] The additive gel is added to the system by any known method
depending on the total amount of gel that is desired to be released
over time, the desired form of the additive gel (e.g. stiffness,
consistency, homogeneity and the like), the desired overall
dissolution of the gel, the desired release rates of a specific
component, the desired mode of operation and/or any combinations of
the above.
[0041] The release rate of the additive gel is determined primarily
by the additive gel formulation. The release rate is also dependent
on the mode of addition of the additive gel, the location of
additive gel, flow rate of the functional fluid, the form of the
additive gel (e.g., stiffness, consistency, homogeneity and the
like) and the like. The additive gel is positioned in a location
desirable for the specified and desirable dissolution rate of the
additive gel components.
[0042] The additive gel's formulation may be composed of one or
more components that selectively dissolve or a portion of one or
more components remain till the end of its service life or
combinations thereof. In general, the components in category ii
will typically dissolve faster than the components in i) as defined
above. This allows a desired component(s) ii) as defined above to
be selectively released into the functional fluid while other
components remain undissolved or less dissolved. Thus depending on
the fluid conditioning device and its functional fluid, the gel
would contain the desired component(s) in category ii to dissolve
into the functional fluid to replace or introduce the desired
additive.
[0043] In one embodiment, it has been found that the gel slowly
dissolves its component additive parts into the functional fluid
when exposed to heated fluid with no or limited flow over the
surface of the gel. The rate of dissolution of additive gel under
these conditions is controlled to be slow, and because the gel
dissolves into its component additives, it effectively achieves
slow and selective release of the desired additives into the
functional fluid. If exposure to the hot fluid is continued beyond
the point that certain additive(s) are selectively released, the
gel will continue to dissolve over time so that the other
additives, i.e. b i) components, continue to be released. These
release rates can be optimized, using the parameters described
above, so that the desired gel component(s) are released over a
substantial portion to all of the functional fluid's useful
life.
[0044] The gel can be used as is, without an inert carrier or a non
additive matrix, such as a polymeric membrane or complicated
mechanical systems needed in earlier systems for achieving
controlled release of additives over time.
[0045] The gel is a mixture of two or more additives from category
i component that when combined form a gel and further contain at
least one additive from category ii components. The gel exists in a
semi-solid state more like a solid than a liquid, see Parker,
Dictionary of Scientific and Technical Terms, Fifth Edition, McGraw
Hill, .COPYRGT. 1994. See, also, Larson, "The Structure and
rheology of Complex Fluids", Chapter 5, Oxford University Press,
New York, N.Y., .COPYRGT. 1999, each which is incorporated herein
by reference. The rheological properties of a gel can be measured
by small amplitude oscillatory shear testing. This technique
measures the structural character of the gel and produces a term
called the storage modulus which represents storage of elastic
energy and the loss modulus which represents the viscous
dissipation of that energy. The ratio of the loss modulus/storage
modulus, which is called the loss tangent, or "tan delta", is >1
for materials that are liquid-like and <1 for materials that are
solid-like. The additive gels have tan delta values in one
embodiment of about .ltoreq.0.75, in another embodiment of about
.ltoreq.0.5 and in another embodiment of about .ltoreq.0.3. The
gels have tan delta values in one embodiment of about .ltoreq.1, in
one embodiment of about .ltoreq.0.75, in one embodiment of about
.ltoreq.0.5 or in one embodiment of about .ltoreq.0.3.
[0046] The additive gel contains a combination of gelling additives
of i) components in the range of about 0.01% to about 95%, in one
embodiment in the range of about 0.1% to 80% and in another
embodiment in the range of about 1% to about 50% of the total
weight of the gel.
[0047] The additive gel contains a combination of optional
additives of the ii) components in the range of about 0.1% to about
95%, in one embodiment in the range of about 0.1% to 90%, in
another embodiment in the range of about 0.1% to about 80%, and in
another embodiment in the range of about 0.5% to about 50% of the
total weight of the additives and/or base oil of the delivery
system (i.e. excluding the weight of the mechanical device).
[0048] In accordance with the present invention, any delivery
system formed from the combination of two or more additives
comprising detergents, dispersants, acids, bases, over based
detergents, succinated polyolefins, and the like can be used to
make the additive gel. The additive gel comprises at least two
additives selected from the group including detergents,
dispersants, acids, bases, over based detergent, succinated
polyolefins or mixtures thereof wherein such selected additives
when combined form a gel. Further in one embodiment the additive
gel includes combining dispersants, or combining a dispersant and
an acid, or combining a dispersant and a base, or a dispersant and
an over based detergent, and the like.
[0049] In one embodiment, a category of gel which finds particular
use are those in which gellation occurs through the combination of
an overbased detergent and an ashless succinimide dispersant. In
one embodiment, the ratio of the detergent to the dispersant is
from about 10:1 to about 1:10, in another embodiment from about 5:1
to about 1:5, form about 4:1 to about 1:1 and in another embodiment
from about 4:1 to about 2:1. In addition, the TBN of the overbased
detergent which participates in the gel-forming matrix, is normally
at least 200, more typically at 300-1,000 and most typically 350 to
650. Where mixtures of overbased detergents are used, at least one
should have a TBN value within these ranges. However, the average
TBN of these mixtures may also correspond to these values.
[0050] The dispersant includes dispersants; ashless type
dispersants such as Mannich dispersants; polymeric dispersants;
carboxylic dispersants; amine dispersants, high molecular weight
(Cn wherein n.ltoreq.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. In one embodiment the preferred dispersant
ispolyisobutenyl succinimide dispersant.
[0051] The dispersants includes ashless-type dispersants, polymeric
dispersants, Mannich dispersants, high molecular weight (Cn wherein
n.gtoreq.12) esters, carboxylic dispersants, amine dispersants and
combinations thereof. The dispersant may be used alone or in
combination.
[0052] The dispersant includes but is not limited to an ashless
dispersant 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 amino groups per molecule.
[0053] 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: ##STR1## and/or ##STR2## wherein each R.sup.1
is independently an alkyl group, frequently a polysiobutyl group
with a molecular weight of 500-5000, and R.sup.2 are alkenylene
groups, commonly ethylene (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
delivery systems in accordance with the present invention.
[0054] The Mannich dispersant 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 polyanines). Mannich bases having the
following general structure (including a variety of different
isomers and ##STR3## the like) are especially interesting. and/or
##STR4##
[0055] Another class of dispersants is carboxylic dispersants.
Examples of these "carboxylic dispersants" are described in Patent
U.S. Pat. No. 3,219,666.
[0056] 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.
[0057] 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., amino alkyl 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.
[0058] Dispersants can also be post-treated by reaction with any of
a variety of agents. Among these are urea, thiourea,
dimercaptothiazoles, carbon disulfide, aldehydes, ketones,
carboxylic acids, hydrocarbon-substituted succinic anhydrides,
nitriles, epoxides, boron compounds, and phosphorus compounds.
[0059] Dispersants can be used alone or in combination. The
dispersant is present in the range from about 0 wt % or 0.01 wt %
to about 95 wt % gel, in another embodiment in the range from about
1 wt % to about 70 wt % gel, and preferably in another embodiment
in the range from about 5 wt % to about 50 wt % total weight of the
additives and/or base oil of the delivery system.
[0060] The detergents include overbased sulfonates, phenates,
salicylates, carboxylates, overbased calcium sulfonate detergents
which are commercially-available, overbased detergents containing
metals such as Mg, Ba, Sr, Na, Ca and K and mixtures thereof and
the like.
[0061] Detergents are described, for example, in U.S. Pat. No.
5,484,542 which is incorporated herein by reference. 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.
[0062] The detergents may be used alone or in combination. The
detergents are present in the range from about 0 wt % or 0.01 wt %
to about 99 wt %, in one embodiment in the range from about 1 wt %
to about 70 wt % and in another embodiment in the range from about
5 wt % to about 50 wt % total weight of the additives and/or base
oil of the delivery system.
[0063] Typically the additive gel further contains at least one
desired additive for controlled release into the functional fluid.
The additive gel desired components include viscosity modifier(s),
friction modifier(s), detergent(s), cloud point depressant(s), pour
point depressant(s), demulsifier(s), flow improver(s), anti static
agent(s), dispersant(s), antioxidant(s), antifoam(s),
corrosion/rust inhibitor(s), extreme pressure/antiwear agent(s),
seal swell agent(s), lubricity aid(s), antimisting agent(s), and
mixtures thereof; resulting in a controlled release gel that over
time releases the desired additive(s) into a functional fluid when
the gel is contacted with the functional fluid. The desired
additive component is further determined by the functional fluid
formulation, performance characteristics, function and the like and
what additive is desired to be added for depleted additives and/or
added new depending on the desired functions.
[0064] Antioxidants include 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,
bis-nonylated diphenylamine, nonyl diphenylamine, octyl
diphenylamine, bis-octylated diphenylamine, bis-decylated
diphenylamine, decyl diphenylamine and mixtures thereof.
[0065] The antioxidant function includes sterically hindered
phenols and includes but is not limited to 2,6-di-tert-butylphenol,
4-methyl-2,6-di-tert-butylphenol, 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-butylphenol,
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-butyl-o-cresol),
4,4-methylenebis(2-tert-amyl-o-cresol),
2,2-methylenebis(4-metyl-6-tert-butylphenol),
4,4-methylene-bis(2,6-di-tertbutylphenol) and mixtures thereof.
[0066] 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 based conditions,
such as aqueous KOH.
[0067] Antioxidants may be used alone or in combination. The
antioxidants are typically present in the range of about 0 wt % or
0.01 wt % to about 95 wt %, in one embodiment in the range from
about 0.01 wt % to 95 wt %, and in another embodiment in the range
from about 1 wt % to about 70 wt % and in another embodiment in the
range from about 5 wt % to about 60 wt % total weight of the
additives and/or base oil of the delivery system.
[0068] The extreme pressure/anti-wear agents include 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 amine salts of phosphorus acid acid, 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 dipentene, 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.
[0069] In one embodiment the antiwear agent/extreme pressure agent
comprises an amine salt of a phosphorus ester acid. The amine salt
of a phosphorus ester acid includes phosphoric acid esters and
salts thereof; dialkyldithiophosphoric acid esters and salts
thereof; phosphites; and phosphorus-containing carboxylic esters,
ethers, and amides; and mixtures thereof.
[0070] In one embodiment the phosphorus compound further comprises
a sulfur atom in the molecule. In one embodiment the amine salt of
the phosphorus compound is ashless, i.e., metal-free (prior to
being mixed with other components).
[0071] The amines which may be suitable for use as the amine salt
include primary amines, secondary amines, tertiary amines, and
mixtures thereof. The amines include those with at least one
hydrocarbyl group, or, in certain embodiments, two or three
hydrocarbyl groups. The hydrocarbyl groups may contain about 2 to
about 30 carbon atoms, or in other embodiments about 8 to about 26
or about 10 to about 20 or about 13 to about 19 carbon atoms.
[0072] Primary amines include ethylamine, propylamine, butylamine,
2-ethylhexylamine, octylamine, and dodecylamine, as well as such
fatty amines as n-octylamine, n-decylamine, n-dodecylamine,
n-tetradecylamine, n-hexadecylamine, n-octadecylamine and
oleylamine. Other useful fatty amines include commercially
available fatty amines such as "Armeen.RTM." amines (products
available from Akzo Chemicals, Chicago, Ill.), such as Armeen C,
Armeen O, Armeen O L, Armeen T, Armeen H T, Armeen S and Armeen S
D, wherein the letter designation relates to the fatty group, such
as coco, oleyl, tallow, or stearyl groups.
[0073] Examples of suitable secondary amines include dimethylamine,
diethylamine, dipropylamine, dibutylamine, diamylamine,
dihexylamine, diheptylamine, methylethylamine, ethylbutylamine and
ethylamylamine. The secondary amines may be cyclic amines such as
piperidine, piperazine and morpholine.
[0074] The amine may also be a tertiary-aliphatic primary amine.
The aliphatic group in this case may be an alkyl group containing
about 2 to about 30, or about 6 to about 26, or about 8 to about 24
carbon atoms. Tertiary alkyl amines include monoamines such as
tert-butylamine, tert-hexylamine, 1-methyl-1-amino-cyclohexane,
tert-octylamine, tert-decylamine, tert-dodecylamine,
tert-tetradecylamine, tert-hexadecylamine, tert-octadecylamine,
tert-tetracosanylamine, and tert-octacosanylamine.
[0075] Mixtures of amines may also be used in the invention. In one
embodiment a useful mixture of amines is "Primene.RTM. 81R" and
"Primene.RTM. JMT." Primene.RTM. 81R and Primene.RTM. JMT (both
produced and sold by Rohm & Haas) are mixtures of C11 to C14
tertiary alkyl primary amines and C18 to C22 tertiary alkyl primary
amines respectively.
[0076] Suitable hydrocarbyl amine salts of alkylphosphoric acid of
the invention may be represented by the following formula: ##STR5##
wherein R.sup.3 and R.sup.4 are independently hydrogen or
hydrocarbyl groups such as alkyl groups; for the phosphorus ester
acid, at least one of R.sup.3 and R.sup.4 will be hydrocarbyl.
R.sup.3 and R.sup.4 may contain about 4 to about 30, or about 8 to
about 25, or about 10 to about 20, or about 13 to about 19 carbon
atoms. R.sup.5, R.sup.6 and R.sup.7 may be independently hydrogen
or hydrocarbyl groups, such as alkyl branched or linear alkyl
chains with 1 to about 30, or about 4 to about 24, or about 6 to
about 20, or about 10 to about 16 carbon atoms. These R.sup.5,
R.sup.6 and R.sup.7 groups may be branched or linear groups, and in
certain embodiments at least one, or alternatively two of R.sup.5,
R.sup.6 and R.sup.7 are hydrogen. Examples of alkyl groups suitable
for R.sup.5, R.sup.6 and R.sup.7 include butyl, sec-butyl,
isobutyl, tert-butyl, pentyl, n-hexyl, sec-hexyl, n-octyl,
2-ethylhexyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl,
pentadecyl, hexadecyl, heptadecyl, octadecyl, octadecenyl,
nonodecyl, eicosyl groups and mixtures thereof.
[0077] In one embodiment the hydrocarbyl amine salt of an
alkylphosphoric acid ester is the reaction product of a C14 to C18
alkylated phosphoric acid with Primene 81R.TM. (produced and sold
by Rohm & Haas) which is a mixture of C11 to C14 tertiary alkyl
primary amines.
[0078] Similarly, hydrocarbyl amine salts of
dialkyldithiophosphoric acid esters of the invention used in the
rust inhibitor package may be represented by the formula: ##STR6##
wherein the various R groups are as defined above, although
typically both R groups are hydrocarbyl or alkyl. Examples of
hydrocarbyl amine salts of dialkyldithiophosphoric acid esters
include the reaction product(s) of hexyl, heptyl or octyl or nonyl,
4-methyl-2-pentyl or 2-ethylhexyl, isopropyl dithiophosphoric acids
with ethylene diamine, morpholine, or Primene 81R.TM., and mixtures
thereof.
[0079] In one embodiment the dithiophosphoric acid may be reacted
with an epoxide or a glycol. This reaction product is further
reacted with a phosphorus acid, anhydride, or lower ester. The
epoxide includes an aliphatic epoxide or a styrene oxide. Examples
of useful epoxides include ethylene oxide, propylene oxide, butene
oxide, octene oxide, dodecene oxide, styrene oxide and the like. In
one embodiment the epoxide is Propylene oxide. The glycols may be
aliphatic glycols having from 1 to about 12, or from about 2 to
about 6, or about 2 to about 3 carbon atoms. The dithiophosphoric
acids, glycols, epoxides, inorganic phosphorus reagents and methods
of reacting the same are described in U.S. Pat. Nos. 3,197,405 and
3,544,465. The resulting acids may then be salted with amines. An
example of suitable dithiophosphoric acid is prepared by adding
phosphorus pentoxide (about 64 grams) at about 58.degree. C. over a
period of about 45 minutes to about 514 grams of hydroxypropyl
O,O-di(4-methyl-2-pentyl)phosphorodithioate (prepared by reacting
di(4-methyl-2-pentyl)-phosphorodithioic acid with about 1.3 moles
of propylene oxide at about 25.degree. C.). The mixture is heated
at about 75.degree. C. for about 2.5 hours, mixed with a
diatomaceous earth and filtered at about 70.degree. C. The filtrate
contains about 11.8% by weight phosphorus, about 15.2% by weight
sulfur, and an acid number of 87 (bromophenol blue).
[0080] The EP/antiwear agent can be used alone or in
combination.
[0081] In one embodiment the EP/antiwear agent may be in the
delivery system from about 0 wt % or 0.05 wt % to about 10 wt % or
about 0.1 wt % to about 5 wt %.
[0082] The EP/antiwear agents are present in the range of about 0
wt % to about 20 wt %, in one embodiment in the range from about
0.25 wt % to about 10 wt % and in another embodiment in the range
from about 0.5 wt % to about 25 wt % total weight of the additives
and/or base oil of the delivery system.
[0083] The antifoams include organic silicones such as poly
dimethyl siloxane, poly ethyl siloxane, polydiethyl siloxane,
polyacrylates and polymethacrylates,
trimethyl-triflouro-propylmethyl siloxane and the like.
[0084] The antifoams may be used alone or in combination. The
antifoams are used in the range of about 0 wt % to about 20 wt %,
in one embodiment in the range of about 0.02 wt % to about 10 wt %
and in another embodiment in the range of 0.05 wt % to about 2.5 wt
% total weight of the additives and/or base oil of the delivery
system.
[0085] The viscosity modifier provides both viscosity improving
properties and dispersant properties. Examples of
dispersant-viscosity modifiers include 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.
[0086] 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
maleic 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 (polyisobutylene), methacrylate,
polyalkystyrene, ethylene/propylene and
ethylene/propylene/1,4-hexadiene polymers and maleic
anhydride-styrene interpolymer and derivatives thereof, can also be
used as viscosity index improvers. The viscosity modifiers are
known and commercially available.
[0087] The viscosity modifiers may be used alone or in combination.
The viscosity modifiers are present in the range of about 0 wt % to
20 wt %, in one embodiment in the range from about 0.25 wt % to
about 10 wt % and in another embodiment in the range from about 0.5
wt % to about 2.5 wt % total weight of the additives and/or base
oil of the delivery system.
[0088] The friction modifiers include organo-molybdenum compounds,
including molybdenum dithiocarbamates, and fatty acid based
materials, including those based on oleic acid, including glycerol
mono oleate (GMO), those based on stearic acid, and the like.
[0089] In one embodiment, the friction modifier is a phosphate
ester or salt including a monohydrocarbyl, dihydrocarbyl or a
trihydrocarbyl phosphate, wherein each hydrocarbyl group is
saturated. In several embodiments, each hydrocarbyl group contains
from about 8 to about 30, or from about 12 up to about 28, or from
about 14 up to about 24, or from about 14 up to about 18 carbons
atoms. In another embodiment, the hydrocarbyl groups are alkyl
groups. Examples of hydrocarbyl groups include tridecyl,
tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl groups and
mixtures thereof.
[0090] In one embodiment, the phosphate salts may be prepared by
reacting an acidic phosphate ester with an amine compound or a
metallic base to form an amine or a metal salt. The amines may be
monoamines or polyamines. Useful amines include those amines
disclosed in U.S. Pat. No. 4,234,435 at Col. 21, line 4 to Col. 27,
line 50.
[0091] Useful amines include primary ether amines, such as those
represented by the formula, R''(OR').sub.x--NH.sub.2, wherein R' is
a divalent alkylene group having about 2 to about 6 carbon atoms; x
is a number from one to about 150, or from about one to about five,
or one; and R'' is a hydrocarbyl group of about 5 to about 150
carbon atoms.
[0092] The phosphate salt may be derived from a polyamine. The
polyamines include alkoxylated diamines, fatty polyamine diamines,
alkylenepolyamines, hydroxy containing polyamines, condensed
polyamines, arylpolyamines, and heterocyclic polyamines.
[0093] The metal salts of the phosphorus acid esters are prepared
by the reaction of a metal base with the acidic phosphorus ester.
The metal base may be any metal compound capable of forming a metal
salt. Examples of metal bases include metal oxides, hydroxides,
carbonates, borates, or the like. Suitable metals include alkali
metals, alkaline earth metals and transition metals. In one
embodiment, the metal is a Group IIA metal, such as calcium or
magnesium, Group IIB metal, such as zinc, or a Group VIIB metal,
such as manganese. Examples of metal compounds which may be reacted
with the phosphorus acid include zinc hydroxide, zinc oxide, copper
hydroxide or copper oxide.
[0094] In one embodiment, the friction modifier is a phosphite and
may be a monohydrocarbyl, dihydrocarbyl or a trihydrocarbyl
phosphite, wherein each hydrocarbyl group is saturated. In several
embodiments each hydrocarbyl group independently contains from
about 8 to about 30, or from about 12 up to about 28, or from about
14 up to about 24, or from about 14 up to about 18 carbons atoms.
In one embodiment, the hydrocarbyl groups are alkyl groups.
Examples of hydrocarbyl groups include tridecyl, tetradecyl,
pentadecyl, hexadecyl, heptadecyl, octadecyl groups and mixtures
thereof.
[0095] In one embodiment, the friction modifier is a fatty
imidazoline comprising fatty substituents containing from 8 to
about 30, or from about 12 to about 24 carbon atoms. The
substituent may be saturated or unsaturated, preferably saturated.
In one aspect, the fatty imidazoline may be prepared by reacting a
fatty carboxylic acid with a polyalkylenepolyamine, such as those
discussed above. A suitable fatty imidazoline includes those
described in U.S. Pat. No. 6,482,777.
[0096] The friction modifiers can be used alone or in combination.
The friction reducing agents are present in the range of about 0 wt
% to 10 wt %, or from about 0.25 wt % to about 10 wt %, or from
about 0.5 wt % to about 2.5 wt % total weight of the additives
and/or base oil of the delivery system.
[0097] The anti-misting agents include 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 propane sulfonic acid (also known as
AMPS.RTM.), or derivatives thereof, and the like.
[0098] The anti-misting agents can be used alone or in combination.
The anti-misting agents are present in the range of about 0 wt % to
10 wt %, or from about 0.25 wt % to about 10 wt %, or from about
0.5 wt % to about 2.5 wt % total weight of the additives and/or
base oil of the delivery system.
[0099] The corrosion inhibitors include alkylated succinic acids
and anhydrides derivatives thereof, organo phosphonates and the
like. The rust inhibitors may be used alone or in combination. The
rust inhibitors are present in the range of about 0 wt % to about
90 wt %, and in one embodiment in the range from about 0.0005 wt %
to about 50 wt % and in another embodiment in the range from about
0.0025 wt % to about 30 wt % total weight of the additives and/or
base oil of the delivery system.
[0100] The metal deactivators include derivatives of benzotriazoles
such as tolyltriazole,
N,N-bis(heptyl)-ar-methyl-1H-benzotriazole-1-methanamine,
N,N-bis(nonyl)-ar-methyl-1H-Benzotriazole-1-methanamine,
N,N-bis(decyl)ar-methyl-1H-Benzotriazole-1-methanamine,
N,N-(undecyl)ar-methyl-1H-benzotriazole-1-methanamine,
N,N-bis(dodecyl)ar-methyl-1H-Benzotriazole-1-methanamine
N,N-bis(2-ethylhexyl)-ar-methyl-1H-Benzotriazole-1-methanamine and
mixtures thereof. In one embodiment the metal deactivator is
N,N-bis(1-ethylhexyl)ar-methyl-1H-benzotriazole-1-methanamine;
1,2,4-triazoles, benzimidazoles, 2-alkyldithiobenzimidazoles;
2-alkyldithiobenzothiazoles;
2-N,N-dialkyldithio-carbamoyl)benzothiazoles;
2,5-bis(alkyl-dithio)-1,3,4-thiadiazoles such as
2,5-bis(tert-octyldithio)-1,3,4-thiadiazole
2,5-bis(tert-nonyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-decyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-undecyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-dodecyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-tridecyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-tetradecyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-octadecyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-nonadecyldithio)-1,3,4-thiadiazole,
2,5-bis(tert-eicosyldithio)-1,3,4-thiadiazole and mixtures thereof;
2,5-bis(N,N-dialkyldithiocarbamoyl)-1,3,4-thiadiazoles;
2-alkydithio-5-mercapto thiadiazoles; and the like.
[0101] The metal deactivators may be used alone or in combination.
The metal deactivators are present in the range of about 0 wt % to
about 90 wt %, or from about 0.0005 wt % to about 50 wt %, or from
about 0.0025 wt % to about 30 wt % total weight of the additives
and/or base oil of the delivery system.
[0102] The demulsifiers include polyethylene and polypropylene
oxide copolymers and the like. The demulsifiers may be used alone
or in combination. The demulsifiers are present in the range of
about 0 wt % to about 90 wt %, or from about 0.0005 wt % to about
50 wt %, or from about 0.0025 wt % to about 30 wt % total weight of
the additives and/or base oil of the delivery system.
[0103] The lubricity aids include glycerol mono oleate, sorbitan
mono oleate and the like. The lubricity additives may be used alone
or in combination. The lubricity additives are present in the range
of about 0 wt % to about 90 wt %, or from about 0.0005 wt % to
about 50 wt %, or from about 0.0025 wt % to about 30 wt % total
eight of the additives and/or base oil of the delivery system.
[0104] The flow improvers include ethylene vinyl acetate copolymers
and the like. The flow improvers may be used alone or in
combination. The flow improvers are present in the range of about 0
wt % to about 90 wt %, or from about 0.0005 wt % to about 50 wt %,
or from about 0.0025 wt % to about 30 wt % total weight of the
additives and/or base oil of the delivery system.
[0105] The cloud point depressants include alkylphenols and
derivatives thereof, ethylene vinyl acetate copolymers and the
like. The cloud point depressants may be used alone or in
combination. The cloud point depressants are present in the range
of about 0 wt % to about 90 wt %, or from about 0.0005 wt % to
about 50 wt %, or from about 0.0025% to about 30 wt % total weight
of the additives and/or base oil of the delivery system.
[0106] The pour point depressants include alkylphenols and
derivatives thereof, ethylene vinyl acetate copolymers and the
like. The pour point depressant may be used alone or in
combination. The pour point depressant are present in the range of
about 0 wt % to about 90 wt %, or from about 0.0005 wt % to about
50 wt %, or from about 0.0025 wt % to about 30 wt % total weight of
the additives and/or base oil of the delivery system.
[0107] The seal swell agents include organo sulfur compounds such
as thiophene, 3-(decyloxy)tetrahydro-1,1-dioxide, phthalates and
the like. The seal swell agents may be used alone or in
combination. The seal swell agents are present in the range of
about 0 wt % to about 90 wt %, or from about 0.0005 wt % to about
50 wt %, or from about 0.0025 wt % to about 30 wt % total weight of
the additives and/or base oil of the delivery system.
[0108] Optionally, other components can be added to the delivery
system includes base stock oils, inert carriers, dyes,
bacteriostatic agents, solid particulate additives, and the like so
long as these components do not have a detrimental effect on the
delivery system.
[0109] When the delivery system is a gel, typically the gel
contains small amounts (about 5-40 wt %) of base stock oils, which
include but are not limited to mineral-based, synthetic (including
Fischer-Tropsch gas-to-liquid synthetic procedure as well as other
gas-to-liquid oils) or mixtures thereof.
[0110] Optionally, an inert carrier can be used if desired.
Furthermore, other active ingredients, which provide a beneficial
and desired function 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.
[0111] Optionally, dyes can be used and include halo-alkanes and
the like. The dyes may be used alone or in combination. The dyes
are present in the range of about 0 wt % to about 90 wt %, or from
about 0.0005 wt % to about 50 wt %, or from about 0.0025 wt % to
about 30 wt % total weight of the additives and/or base oil of the
delivery system.
[0112] Optionally, bacteriostatic agents can be used and include
formaldehyde, gluteraldehyde and derivatives, kathan and the like.
The bacteriostatic agents may be used alone or in combination. The
bacteriostatic agents are present in the range of about 0 wt % to
about 90 wt %, or from about 0.0005% to about 50 wt %, or from
about 0.0025% to about 30 wt % total weight of the additives and/or
base oil of the delivery system.
[0113] The components are mixed together sequentially or all
together to form a mixture. After mixing of the components of the
gel, a cure may be required in order for gelation to occur. If a
cure is required, it is typically done in the range of about
20.degree. C. to about 165.degree. C. for about 1 min to about 60
days, or about 50.degree. C. to about 120.degree. C. for about 1 to
about 24 hours, or about 85.degree. C. to about 115.degree. C. for
about 4 to about 12 hours.
SPECIFIC EMBODIMENT
[0114] For all the examples the components listed in each example
in the specification were mixed together to form the gel. The gels
were cured at about 100.degree. C. for about 8 hours.
Example 1
Controlled Release of Antiwear Agent in Manual Transmission
Fluid
[0115] Antiwear agents such as amine salts of a phosphorus acid
esters are well known as being suitable for a gear oil,
transmission fluid or axle fluid.
[0116] Controlled release of an antiwear agent can be accomplished
using a gel composed of: [0117] a. about 45 wt % of an overbased
detergent, [0118] b. about 10 wt % of a 2000 MW polyisobutenyl
succan; [0119] c. about 15 wt % of a succinimide dispersant, and
[0120] d. about 30 wt % of an amine salt of a phosphorus ester
acid.
[0121] A manual transmission fluid is passed over the controlled
release gel containing the antiwear agent. The resulting
composition contains an acceptable amount of antiwear agent to
allow the fluid to be used as an axle fluid.
[0122] A FZG scuffing test is carried out on the manual
transmission fluid (MTF) and the manual transmission fluid
containing antiwear agent from the controlled release gel (MTFGAW).
The FZG scuffing test is carried out using "A10" type gears of
about 10 mm face width, at a pitchline velocity of about 16.6 m/s
in reverse direction and at about 120.degree. C. (test also
referred to as A10/16.6R/120 test). The results obtained are shown
in Table 1. TABLE-US-00001 TABLE 1 Sample Load Stage Fail MTF 5
MTFGAW 7
[0123] The results indicate that the controlled release gel is
capable of modifying a lubricant designed for one mechanical device
and providing desired additional additives to provide a lubricant
with a different composition with acceptable properties in another
mechanical device requiring a different lubricant additive
composition.
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