U.S. patent application number 11/232294 was filed with the patent office on 2007-03-22 for lubricant compositions including gas to liquid base oils.
Invention is credited to Ian Macpherson.
Application Number | 20070066495 11/232294 |
Document ID | / |
Family ID | 37529413 |
Filed Date | 2007-03-22 |
United States Patent
Application |
20070066495 |
Kind Code |
A1 |
Macpherson; Ian |
March 22, 2007 |
Lubricant compositions including gas to liquid base oils
Abstract
A lubricant composition, uses for the lubricant composition, and
methods of lubricating devices using the lubricant composition. The
lubricant composition includes base oil component having a first
base oil derived from a gaseous source, and optionally, a second
base oil derived from a liquid petroleum source. The base oil
component of the lubricant composition includes from about 5 to
about 100 percent by weight of the base oil derived from a gaseous
source. An additive and a solubilizing agent selected from the
group consisting of an adipate ester, a polyol ester, an alkylated
naphthalene, an alkylated sulfone, a naphthenic base oil, an
aromatic base oil, an akylated benzene, and a combination of two or
more of the foregoing agents are also included in the lubricant
composition.
Inventors: |
Macpherson; Ian; (Richmond,
VA) |
Correspondence
Address: |
NEW MARKET SERVICES CORPORATION;(FORMERLY ETHYL CORPORATION)
330 SOUTH 4TH STREET
RICHMOND
VA
23219
US
|
Family ID: |
37529413 |
Appl. No.: |
11/232294 |
Filed: |
September 21, 2005 |
Current U.S.
Class: |
508/192 ;
508/287; 508/293; 508/469; 508/485; 508/496; 508/568; 508/591 |
Current CPC
Class: |
C10M 2203/1045 20130101;
C10M 2215/223 20130101; C10N 2010/12 20130101; C10M 2207/126
20130101; C10M 2207/2835 20130101; C10M 2215/08 20130101; C10M
2223/04 20130101; C10M 2223/047 20130101; C10N 2020/02 20130101;
C10N 2020/071 20200501; C10M 2207/144 20130101; C10M 2203/106
20130101; C10M 2229/02 20130101; C10M 2203/06 20130101; C10N
2060/14 20130101; C10M 2205/223 20130101; C10M 2215/04 20130101;
C10N 2060/12 20130101; C10M 2219/0406 20130101; C10N 2040/252
20200501; C10M 2207/283 20130101; C10M 2219/068 20130101; C10M
2203/104 20130101; C10M 2219/04 20130101; C10M 2207/024 20130101;
C10M 2223/049 20130101; C10N 2010/02 20130101; C10M 2207/262
20130101; C10M 2215/065 20130101; C10M 2219/046 20130101; C10N
2040/253 20200501; C10M 2207/26 20130101; C10M 2223/043 20130101;
C10M 2207/122 20130101; C10M 2215/28 20130101; C10M 2209/084
20130101; C10M 2207/026 20130101; C10M 2205/026 20130101; C10M
2207/028 20130101; C10M 2203/065 20130101; C10M 2205/22 20130101;
C10M 2207/027 20130101; C10M 2223/042 20130101; C10N 2020/04
20130101; C10N 2040/25 20130101; C10M 2215/064 20130101; C10M
2219/044 20130101; C10N 2010/04 20130101; C10M 169/04 20130101;
C10M 2203/1065 20130101; C10M 2207/289 20130101; C10M 2207/10
20130101; C10M 2207/2825 20130101; C10M 2207/282 20130101; C10M
2205/173 20130101; C10M 2215/042 20130101; C10M 2219/022
20130101 |
Class at
Publication: |
508/192 ;
508/485; 508/287; 508/568; 508/496; 508/469; 508/591; 508/293 |
International
Class: |
C10M 141/00 20060101
C10M141/00; C10M 169/04 20060101 C10M169/04 |
Claims
1. A lubricant composition, comprising: a first base oil component
comprising a first base oil derived from a gaseous source, said
first base oil having a viscosity index of greater than about 115,
less than about 0.3 weight percent sulfur, and from about 95 to
about 100 percent by weight branched alkanes, and optionally, a
second base oil derived from a liquid petroleum source; from about
1 to about 30 percent or more by weight of a solubilizing agent
selected from the group consisting of an adipate ester, a polyol
ester, an alkylated naphthalene, an alkylated sulfone, a naphthenic
base oil, an aromatic base oil, an akylated benzene, and a
combination of two or more of the foregoing agents; and an additive
component, wherein the base oil component contains from about 5 to
about 100 percent by weight of the first base oil.
2. The lubricant composition of claim 1, wherein the additive
component comprises from about 0.5 to about 25 weight percent,
based on the total weight of the lubricant composition, of a
detergent/inhibitor package.
3. The lubricant composition of claim 1, wherein the additive
component is selected from the group consisting of viscosity index
improvers, dispersants, friction modifiers, corrosion inhibitors,
rust inhibitors, antioxidants, detergents, seal swell agents,
extreme pressure additives, anti-wear additives, pour point
depressants, deodorizers, defoamers, demulsifiers, dyes, thickening
agents, fluorescent coloring agents, and combinations of two or
more of the foregoing.
4. The lubricant composition of claim 2, wherein lubricant
composition comprises from about 5 to about 15 percent by weight of
the solubilizing agent.
5. The lubricant composition of claim 1, wherein the additive
component comprises from about 0.1 to about 40 weight percent,
based on the total weight of the lubricant composition, of at least
one polymer selected from the group consisting of olefin (co)
polymer(s), polyalkyl (meth) acrylate(s) and mixtures thereof.
6. The lubricant composition of claim 5, wherein the olefin polymer
comprises polyisobutylene having a weight average molecular weight
ranging from about 700 to about 2,500.
7. The lubricant composition of claim 1, wherein the additive
component comprises a detergent/inhibitor package.
8. The lubricant composition of claim 1, wherein the additive
component comprises a friction modifier selected from the group
consisting of aliphatic fatty amines, ether amines, alkoxylated
aliphatic fatty amines, alkoxylated ether amines, oil-soluble
aliphatic carboxylic acids, polyol esters, fatty acid amides,
imidazolines, tertiary amines, hydrocarbyl succinimides reacted
with ammonia or a primary amine, and organic molybdenum
compounds.
9. The lubricant composition of claim 1, wherein the additive
component comprises an antioxidant selected from the group
consisting of bis-alkylated diphenyl amines, phenyl alpha or beta
napthyl amines, sterically hindered phenols, bisphenols, cinnamic
acid derivatives, and sulfurized olefins.
10. The lubricant composition of claim 1, wherein the additive
component comprises an antiwear agent selected from the group
consisting of phosphate esters and salts thereof, phosphite esters
and salts thereof, dialkyldithiophosphoric acid esters and salts
thereof, and dithiocarbamic acid esters and salts thereof.
11. The lubricant composition of claim 1, wherein the additive
component comprises an antifoam agent selected from the group
consisting of silicones and polyacrylates.
12. The lubricant composition of claim 1, wherein the additive
component comprises a seal swell agent selected from the group
consisting of an acrylate, an alkylated sulofone, and a silicon
containing compound.
13. The lubricant composition of claim 1, wherein the additive
component comprises a detergent selected from the group consisting
of neutral and overbased sodium sulfonates, sodium carboxylates,
sodium salicylates, sodium phenates, sulfurized sodium phenates,
lithium sulfonates, lithium carboxylates, lithium salicylates,
lithium phenates, sulfurized lithium phenates, magnesium
sulfonates, magnesium carboxylates, magnesium salicylates,
magnesium phenates, sulfurized magnesium phenates, potassium
sulfonates, potassium carboxylates, potassium salicylates,
potassium phenates, sulfurized potassium phenates, zinc sulfonates,
zinc carboxylates, zinc salicylates, zinc phenates, and sulfurized
zinc phenates.
14. The lubricant composition of claim 1, wherein the additive
component comprises a dispersant derived from a hydrocarbyl
succinic acid or anhydride having a number average molecular weight
ranging from about 200 to about 2100 as determined by gel
permeation chromatography, and ammonia or a primary amine.
15. The lubricant composition of claim 14, wherein the dispersant
is derived from polyisobutenyl succinic anhydride (PIBSA) and a
polyalkylene polyamine having a ratio of PIBSA to amine ranging
from about 1:1 to about 3:1.
16. The lubricant composition of claim 15, wherein the dispersant
comprises a post-treated succinimide dispersant.
17. The lubricant composition of claim 16, wherein the post-treated
succinimide dispersant is post treated with a member selected from
the group consisting of phosphorus-based acids, boron-based acids,
carboxylic acids, alkylphenol/aldehyde mixtures, and mixtures of
two or more of the foregoing.
18. The lubricant composition of claim 1, wherein the second base
oil comprises a liquid base oil selected from the group consisting
of a natural oil, a mixture of natural oils, a synthetic oil, a
mixture of synthetic oils, or a mixture of natural and synthetic
oils.
19. A finished lubricant comprising the lubricant composition of
claim 1.
20. The finished lubricant of claim 19, wherein the additive
component comprises a pour point depressant, a viscosity index
improver, a foam inhibitor, and, optionally, a thickening
agent.
21. A quench fluid comprising the finished lubricant of claim
19.
22. An automatic transmission fluid comprising the finished
lubricant composition of claim 1.
23. The automatic transmission fluid of claim 22, wherein the
additive component comprises a viscosity index improver, an
antiwear additive, a metal deactivator, and a seal swell agent.
24. A gear oil composition comprising the finished lubricant
composition of claim 1.
25. An engine selected from the group consisting of stationary
engines, passenger vehicle engines, truck engines, and heavy duty
engines comprising the lubricant composition of claim 1.
26. A power transmission selected from the group consisting of
automatic transmissions, manual transmissions, continuously
variable transmissions comprising the lubricant composition of
claim 1.
27. A vehicle axle comprising the lubricant composition of claim
1.
28. A hydraulic system comprising the lubricant composition of
claim 1.
29. A rotating machine selected from the group consisting of gas
turbines, compressors, wind turbines, and pumps comprising the
lubricant composition of claim 1.
30. An industrial gear transmission comprising the lubricant
composition of claim 1.
31. A grease composition comprising: a base oil component including
a first base oil derived from a gaseous source, said first base oil
having a viscosity index of greater than about 115, less than about
0.3 weight percent sulfur, and from about 95 to about 100 percent
by weight branched alkanes, and, optionally, a second base oil
derived from a liquid petroleum source; from about 5 to about 20
weight percent, based on the total weight of the grease
composition, of at least one soap selected from the group
consisting of lithium, lithium complex, calcium, sodium, magnesium,
and aluminum soaps; and from about 1 to about 30 percent or more by
weight based on the total weight of the grease composition of a
solubilizing agent selected from the group consisting of an adipate
ester, a polyol ester, an alkylated naphthalene, an alkylated
sulfone, a naphthenic base oil, an aromatic base oil, an akylated
benzene, and a combination of two or more of the foregoing agents,
wherein the base oil component contains from about 5 to about 100
percent by weight of the first base oil.
32. The grease composition of claim 31, wherein the composition
further comprises from about 0.5 to about 25 weight percent, based
on the total weight of the grease composition, of a
detergent/inhibitor package.
33. The grease composition of claim 32, wherein the composition an
additive component selected from the group consisting of viscosity
index improvers, dispersants, friction modifiers, corrosion
inhibitors, rust inhibitors, antioxidants, detergents, seal swell
agents, extreme pressure additives, anti-wear additives, pour point
depressants, deodorizers, defoamers, demulsifiers, dyes, thickening
agents, fluorescent coloring agents, and combinations of two or
more of the foregoing.
34. The grease composition of claim 31, wherein composition
comprises from about 5 to about 15 percent by weight of the
solubilizing agent.
35. The grease composition of claim 31, wherein the composition
further comprises from about 0.1 to about 40 weight percent, based
on the total weight of the lubricant composition, of at least one
polymer selected from the group consisting of olefin (co)
polymer(s), polyalkyl (meth) acrylate(s) and mixtures thereof.
36. The grease composition of claim 32, wherein the
detergent/inhibitor package comprises a component selected from the
group consisting of a viscosity index improver, an anti-foam agent,
a pour point depressant, a seal swell agent, a friction modifier, a
dispersant, a detergent, an antioxidant, an antiwear agent, a
corrosion inhibitor, and a combination of two or more of the
foregoing.
37. A metal-working fluid comprising: a base oil component
including a first base oil derived from a gaseous source having a
viscosity index of greater than about 115, less than about 0.3
weight percent sulfur, and from about 95 to about 100 percent by
weight branched alkanes, and, optionally, a second base oil derived
from a liquid petroleum source; from about 0.1 to about 5 weight
percent, based on the total weight of the metal-working fluid, of
at least one emulsifier selected from the group consisting of
succinates or sulfonates; and from 0.5 to 5 weight percent, based
on the total weight of the metal working fluid, of a biocide or
fungicide, wherein the base oil component contains from about 5 to
about 100 percent by weight of the first base oil.
38. The metal-working fluid of claim 37, wherein the fluid further
comprises a solubilizing agent selected from the group consisting
of an adipate ester, a polyol ester, an alkylated naphthalene, an
alkylated sulfone, a naphthenic base oil, an aromatic base oil, an
akylated benzene, and a combination of two or more of the foregoing
agents.
39. The metal-working fluid of claim 38, wherein the fluid
comprises from about 1 to about 30 percent or more by weight of the
solubilizing agent.
40. The metal-working fluid of claim 38, wherein fluid comprises
from about 5 to about 15 percent by weight of the solubilizing
agent.
41. A method of lubricating a power transmission, the method
comprising introducing into a power transmission a lubricant
composition comprising: a base oil component comprising a first
base oil derived from a gaseous source, said first base oil having
a viscosity index of greater than about 115, less than about 0.3
weight percent sulfur, and from about 95 to about 100 percent by
weight branched alkanes, and, optionally, a second base oil derived
from a liquid petroleum source; a solubilizing agent selected from
the group consisting of an adipate ester, a polyol ester, an
alkylated naphthalene, an alkylated sulfone, a naphthenic base oil,
an aromatic base oil, an akylated benzene, and a combination of two
or more of the foregoing agents; and from about 0.1 to about 40
weight percent, based on the total weight of the lubricant
composition, of at least one polymer selected from the group
consisting of olefin (co) polymer(s), polyalkyl (meth) acrylate(s)
and mixtures thereof, wherein the base oil component contains from
about 5 to about 100 percent by weight of the first base oil.
42. The method of claim 41, wherein the lubricant composition
further comprises from 0.5 to 25 weight percent, based on the total
weight of the lubricant composition, of a detergent/inhibitor
package.
43. The method of claim 41, wherein the lubricant composition
comprises from about 1 to about 30 percent or more by weight of the
solubilizing agent.
44. The method of claim 41, wherein lubricant composition comprises
from about 5 to about 15 percent by weight of the solubilizing
agent.
45. The method of claim 42, wherein the detergent/inhibitor package
comprises a component selected from the group consisting of a
viscosity index improver, an anti-foam agent, a pour point
depressant, a seal swell agent, a friction modifier, a dispersant,
a detergent, an antioxidant, an antiwear agent, a corrosion
inhibitor, and a combination of two or more of the foregoing.
46. A method of lubricating a gear device, the method comprising
introducing into the gear device a lubricant composition
comprising: a base oil component comprising a first base oil
derived from a gaseous source, said first base oil having a
viscosity index of greater than about 115, less than about 0.3
weight percent sulfur, and from about 95 to about 100 percent by
weight branched alkanes, and, optionally, a second base oil derived
from a liquid petroleum source; from about 0.1 to about 40 weight
percent, based on the total weight of the lubricant composition, of
at least one polymer selected from the group consisting of olefin
(co) polymer(s), polyalkyl (meth) acrylate(s) and mixtures thereof;
and a solubilizing agent selected from the group consisting of an
adipate ester, a polyol ester, an alkylated naphthalene, an
alkylated sulfone, a naphthenic base oil, an aromatic base oil, an
akylated benzene, and a combination of two or more of the foregoing
agents, wherein the base oil component contains from about 5 to
about 100 percent by weight of the first base oil.
47. The method of claim 46, wherein the lubricant composition
further comprises from about 0.5 to about 25 weight percent, based
on the total weight of the lubricant composition, of a
detergent/inhibitor package.
48. The method of claim 46, wherein the lubricant composition
comprises from about 1 to about 30 percent or more by weight of the
solubilizing agent.
49. The method of claim 46, wherein lubricant composition comprises
from about 5 to about 15 percent by weight of the solubilizing
agent.
50. The method of claim 47, wherein the detergent/inhibitor package
comprises a component selected from the group consisting of a
viscosity index improver, an anti-foam agent, a pour point
depressant, a seal swell agent, a friction modifier, a dispersant,
a detergent, an antioxidant, an antiwear agent, a corrosion
inhibitor, and a combination of two or more of the foregoing.
51. A method of lubricating a motor vehicle, the method comprising
introducing into the crankcase of a motor vehicle a lubricant
composition comprising: a base oil component comprising a first
base oil derived from a gaseous source, said first base oil having
a viscosity index of greater than about 115, less than about 0.3
weight percent sulfur, and from about 95 to about 100 percent by
weight branched alkanes, and, optionally, a second base oil derived
from a liquid petroleum source; from about 0.1 to about 40 weight
percent, based on the total weight of the lubricant composition, of
at least one polymer selected from the group consisting of olefin
(co) polymer(s), polyalkyl (meth) acrylate(s) and mixtures thereof;
and a solubilizing agent selected from the group consisting of an
adipate ester, a polyol ester, an alkylated naphthalene, an
alkylated sulfone, a naphthenic base oil, an aromatic base oil, an
akylated benzene, and a combination of two or more of the foregoing
agents, wherein the base oil component contains from about 5 to
about 100 percent by weight of the first base oil.
52. The method of claim 51, wherein the lubricant composition
further comprises from about 0.5 to about 25 weight percent, based
on the total weight of the lubricant composition, of a
detergent/inhibitor package.
53. The method of claim 51, wherein the lubricant composition
comprises from about 1 to about 30 percent or more by weight of the
solubilizing agent.
54. The method of claim 51, wherein lubricant composition comprises
from about 5 to about 15 percent by weight of the solubilizing
agent.
55. The method of claim 52, wherein the detergent/inhibitor package
comprises a component selected from the group consisting of
viscosity index improver, an anti-foam agent, a pour point
depressant, a seal swell agent, a friction modifier, a dispersant,
a detergent, an antioxidant, an antiwear agent, a corrosion
inhibitor, and a combination of two or more of the foregoing.
Description
FIELD
[0001] The present disclosure relates to lubricant compositions and
in particular to lubricants containing gas to liquid base oils as a
basestock component.
BACKGROUND AND SUMMARY
[0002] Liquid petroleum reserves continue to decline as the demand
for gasoline and liquid petroleum products continues to increase.
Because of ever increasing energy demands, more of such reserves
may be used for the production of gasoline and fuel oil products
with less of such reserves being directed to the production of
lubricant basestocks. For example, methods for converting
C.sub.1-C.sub.3 alkanes into liquid petroleum basestocks have been
devised.
[0003] However, a variety of gaseous sources may be used to provide
components that may be converted into liquid petroleum products,
including but not limited to, land fill gases, off-gases from
petroleum drilling operations, methane, natural gas, and the like.
In view of such new sources for lubricant basestocks having
characteristics that are different from conventional basestocks,
there is a need for additive compositions that may be added to the
basestocks to provide lubricants suitable for specific
applications.
[0004] With regard to the foregoing, exemplary embodiments of the
disclosure provide a lubricant composition, uses for the lubricant
composition, and methods of lubricating devices using the lubricant
composition. The lubricant composition includes a first base oil
component comprising a first base oil derived from a gaseous
source. The first base oil has a viscosity index of greater than
about 115, contains less than about 0.3 weight percent sulfur, and
is characterized as having from about 95 to about 100 percent by
weight branched alkanes. A second base oil derived from a liquid
petroleum source may optionally be included with the first base
oil, wherein the base oil component of the lubricant composition
includes from about 5 to about 100 percent by weight of the first
base oil. The lubricant composition also includes from about 1 to
about 30 percent or more by weight of a solubilizing agent selected
from the group consisting of an adipate ester, a polyol ester, an
alkylated naphthalene, an alkylated sulfone, a naphthenic base oil,
an aromatic base oil, an akylated benzene, and a combination of two
or more of the foregoing agents. An additive component is also
provided in the first base oil.
[0005] Unlike conventional lubricant compositions, the compositions
described herein include a primary base oil component that is
derived from a gaseous source. Such a base oil enables reallocation
of liquid hydrocarbon sources to the production of fuels such as
gasoline, fuel oil, jet fuel and the like. Conversion of gaseous
sources to liquid lubricant products may also reduce the flaring of
by-product and off-gases that cannot be used for fuel applications.
Such base oils typically exhibit an extremely high viscosity index,
excellent oxidation resistance and good pour points. Other benefits
of the lubricant compositions described herein may be evident from
the detailed description of exemplary embodiments of the
disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
[0006] As used herein, the term "hydrocarbyl substituent" or
"hydrocarbyl group" is used in its ordinary sense, which is
well-known to those skilled in the art. Specifically, it refers to
a group having a carbon atom directly attached to the remainder of
a molecule and having a predominantly hydrocarbon character.
Examples of hydrocarbyl groups include:
[0007] (1) hydrocarbon substituents, that is, aliphatic (e.g.,
alkyl or alkenyl), alicyclic (e.g., cycloalkyl, cycloalkenyl)
substituents, and aromatic-, aliphatic-, and alicyclic- substituted
aromatic substituents, as well as cyclic substituents wherein the
ring is completed through another portion of the molecule (e.g.,
two substituents together form an alicyclic radical);
[0008] (2) substituted hydrocarbon substituents, that is,
substituents containing non-hydrocarbon groups which, in the
context of the description herein, do not alter the predominantly
hydrocarbon substituent (e.g., halo (especially chloro and fluoro),
hydroxy, alkoxy, mercapto, alkylmercapto, nitro, nitroso, and
sulfoxy);
[0009] (3) hetero-substituents, that is, substituents which, while
having a predominantly hydrocarbon character, in the context of
this description, contain other than carbon in a ring or chain
otherwise composed of carbon atoms. Hetero-atoms include sulfur,
oxygen, nitrogen, and encompass substituents such as pyridyl,
furyl, thienyl and imidazolyl. In general, no more than two,
usually no more than one, non-hydrocarbon substituent will be
present for every ten carbon atoms in the hydrocarbyl group;
typically, there will be no non-hydrocarbon substituent in the
hydrocarbyl group.
Base Oil Component:
[0010] The base oil component of the lubricant compositions
described herein includes a first base oil derived from a gaseous
source. Gaseous sources include a wide variety of materials such as
natural gas, methane, C.sub.1-C.sub.3 alkanes, landfill gases, and
the like. Such gases may be converted to liquid hydrocarbon
products suitable for use as lubricant base oils by a gas to liquid
(GTL) process, such as the process described in U.S. Pat. No.
6,497,812, the disclosure of which is incorporated herein by
reference. For the purposes of this disclosure, a "gas" or "gaseous
source" means a material that is in the gaseous state at room
temperature and atmospheric pressure. A "liquid" means a material
that is predominantly in a liquid or fluid state at room
temperature and atmospheric pressure.
[0011] The GTL process includes two primary steps, (1) conversion
of a material existing in the gaseous state into a synthesis gas
consisting primarily of carbon monoxide and hydrogen, and the
conversion of the synthesis gas into a synthetic crude in a
reaction based on a Fischer-Tropsch reaction. Direct conversion of
gaseous hydrocarbon sources using various catalysts and/or
catalytic systems may also be used as the GTL process.
[0012] Base oils derived from a gaseous source, hereinafter
referred to as "GTL base oils," typically have a viscosity index of
greater than about 130, a sulfur content of less than about 0.3
percent by weight, contain greater than about 90 percent by weight
saturated hydrocarbons (isoparaffins), typically from about 95 to
about 100 wt. % branched aliphatic hydrocarbons, have a pour point
of below -15 to -20.degree. C., and have a NOACK volatility of less
than about 15 weight percent, and in another embodiment a NOACK
volatility of less than about 10 weight percent. Other
characteristics of the GTL base oil may be within the range of
conventional lubricant base oils. The base oil component of the
lubricant composition, as described herein, may include from about
5 to about 100 percent by weight of the GTL base oil with the
balance of the base oil component being a conventional base oil.
Because of the characteristically high content of branched alkanes
in the GTL base oils, finished lubricant formulations made with
such GTL base oils include a solubilizing agent that aids in
solublizing additives and degradation products in the finished
lubricant formulation. Suitable solublizing agents are described
below.
[0013] Conventional base oils that may optionally be combined with
the GTL base oil to provide a lubricant composition include natural
and synthetic base oils in Groups I-V as specified in the American
Petroleum Institute (API) Base Oil Interchangeability Guidelines.
Such base oil groups are as follows: TABLE-US-00001 Base Oil Sulfur
Saturates Viscosity Group.sup.1 (wt. %) (wt. %) Index Group I
>0.03 and/or <90 80 to 120 Group II .ltoreq.0.03 And
.gtoreq.90 80 to 120 Group II .ltoreq.0.03 And .gtoreq.90
.gtoreq.120 Group IV all polyalphaolefins (PAOs) Group V all others
not included in Groups I-IV .sup.1Groups I-III are mineral oil base
stocks.
[0014] The detergent/inhibitor (DI) package useful in the exemplary
embodiments disclosed herein may contain one or more conventional
additives selected from the group consisting of viscosity index
improvers, dispersants, friction modifiers, corrosion inhibitors,
rust inhibitors, antioxidants, detergents, seal swell agents,
extreme pressure additives, anti-wear additives, pour point
depressants, deodorizers, defoamers, demulsifiers, dyes, thickening
agents, and fluorescent coloring agents. The DI package is
typically present in an amount of from 0.5 to 25 weight percent,
based on the total weight of the lubricating oil composition.
Solubilizing Agents:
[0015] Solubilizing agents may be used in the disclosed lubricant
compositions.
[0016] Suitable solubilizing agents include, but are not limited
to, oil-soluble esters and diesters, alkylated naphthalenes,
alkylated sulfones, naphthenic type base oils, aromatic type base
oils, and alkylated benzenes. Other solubilizing agents known in
the art are also contemplated herein. The esters and diesters that
may be used as solublizing agents include, for example, adipate
esters and polyol esters. Exemplary diesters include the adipates,
azelates, and sebacates of C.sub.8-C.sub.13 alkanols (or mixtures
thereof), the phthalates of C.sub.4-C.sub.13 alkanols (or mixtures
thereof). Mixtures of two or more different types of diesters
(e.g., dialkyl adipates and dialkyl azelates, etc.) may also be
used. Examples of such materials include the n-octyl, 2-ethylhexyl,
isodecyl, and tridecyl diesters of adipic acid, azelaic acid, and
sebacic acid, and the n-butyl, isobutyl, pentyl, hexyl, heptyl,
octyl, nonyl, decyl, undecyl, dodecyl, and tridecyl diesters of
phthalic acid. The amount of solublizing agent in a finished
lubricant formulation may range, in one embodiment, from about 1 to
about 30 percent by weight of the finished lubricant formulation,
typically from about 5 to about 15 percent by weight of the
finished lubricant formulation.
Viscosity Index Improvers:
[0017] Viscosity index improvers for use in finished lubricant
compositions as described herein may be selected from olefin
(co)polymer(s), polyalkyl(meth)acrylates, and mixtures thereof. A
suitable viscosity index improver may include a mixture of polymers
comprising at least one olefin (co)polymer and at least one
polyalkyl(meth)acrylate in a ratio of from 20:1 to 1:2 olefin
(co)polymer to polyalkyl(meth)acrylate. A fully formulated
lubricant composition as described herein may contain 0.1 to 40 wt.
% olefin (co)polymer and 0.1 to 20 wt %
polyalkyl(meth)acrylate.
[0018] The olefin (co)polymer which may be used is a homopolymer,
copolymer, or terpolymer resulting from the polymerization of
C.sub.2-C.sub.10 olefins having a number average molecular weight
of from 1,000 to 10,000, for example, 1,000 to 3,000, as determined
by gel permeation chromatography (GPC). The C.sub.2-C.sub.10
olefins include ethylene, propylene, 1-butene, isobutylene,
2-butene, isoprene, 1-octene, and 1-decene. Exemplary (co)polymers
include polypropylene, polyisobutylene, ethylene/propylene
copolymers, styrene/isoprene copolymers, and 1-butene/isobutylene
copolymers, and mixtures of the polymers thereof.
[0019] The polyalkyl(meth)acrylates which may be used are prepared
by the polymerization of C.sub.1-C.sub.30 (meth)acrylates.
Preparation of these polymers may further include the use of
acrylic monomers having nitrogen-containing functional groups,
hydroxy groups and/or alkoxy groups which provide additional
properties to the polyalkyl(meth)acrylates such as improved
dispersancy. The polyalkyl(meth)-acrylates may have a number
average molecular weight of from 10,000 to 250,000, for example,
20,000 to 200,000. The polyalkyl(meth)acrylates may be prepared by
conventional methods of free-radical or anionic polymerization.
Dispersants
[0020] The dispersants useful in the lubricant compositions
described herein include at least one oil-soluble ashless
dispersant having a basic nitrogen and/or at least one hydroxyl
group in the molecule. Suitable dispersants include alkenyl
succinimides, alkenyl succinic acid esters, alkenyl succinic
ester-amides, Mannich bases, hydrocarbyl polyamines, or polymeric
polyamines.
[0021] The alkenyl succinimides in which the succinic group
contains a hydrocarbyl substituent containing at least 30 carbon
atoms are described for example in U.S. Pat. Nos. 3,172,892;
3,202,678; 3,216,936; 3,219,666; 3,254,025; 3,272,746; and
4,234,435. Such alkenyl succinimides may be derived from
polyisobutenyl succinic anhydride (PIBSA) having a number average
molecular weight ranging from about 200 to about 2100 as determined
by gel permeation chromatography. Alkenyl succinic acid esters and
diesters of polyhydric alcohols containing 2-20 carbon atoms and
2-6 hydroxyl groups can be used in forming the
phosphorus-containing ashless dispersants. Representative examples
are described in U.S. Pat. Nos. 3,331,776; 3,381,022; and
3,522,179. The alkenyl succinic portion of these esters corresponds
to the alkenyl succinic portion of the succinimides described
above.
[0022] Suitable alkenyl succinic ester-amides for forming
phosphorylated ashless dispersant are described for example in U.S.
Pat. Nos. 3,184,474; 3,576,743; 3,632,511; 3,804,763; 3,836,471;
3,862,981; 3,936,480; 3,948,800; 3,950,341; 3,957,854; 3,957,855;
3,991,098; 4,071,548; and 4,173,540.
[0023] Hydrocarbyl polyamine dispersants that may be phosphorylated
are generally produced by reacting an aliphatic or alicyclic halide
(or mixture thereof) containing an average of at least about 40
carbon atoms with one or more amines, typically polyalkylene
polyamines. Examples of such hydrocarbyl polyamine dispersants are
described in U.S. Pat. Nos. 3,275,554; 3,394,576; 3,438,757;
3,454,555; 3,565,804;
[0024] 3,671,511; and 3,821,302.
[0025] In general, the hydrocarbyl-substituted polyamines are high
molecular weight hydrocarbyl-N-substituted polyamines containing
basic nitrogen in the molecule. The hydrocarbyl group typically has
a number average molecular weight in the range of about 750-10,000
as determined by GPC, more usually in the range of about
1,000-5,000, and is derived from a suitable polyolefin. Exemplary
hydrocarbyl-substituted amines or polyamines are prepared from
polyisobutenyl chlorides and polyamines having from 2 to about 12
amine nitrogen atoms and from 2 to about 40 carbon atoms.
[0026] The Mannich base dispersants are usually a reaction product
of an alkyl phenol, typically having a long chain alkyl substituent
on the ring, with one or more aliphatic aldehydes containing from 1
to about 7 carbon atoms (especially formaldehyde and derivatives
thereof), and polyamines (especially polyalkylene polyamines).
Examples of Mannich condensation products, and methods for their
production are described in U.S. Pat. Nos. 2,459,112; 2,962,442;
2,984,550; 3,036,003; 3,166,516; 3,236,770; 3,368,972; 3,413,347;
3,442,808; 3,448,047; 3,454,497; 3,459,661; 3,493,520; 3,539,633;
3,558,743; 3,586,629; 3,591,598; 3,600,372; 3,634,515; 3,649,229;
3,697,574; 3,703,536; 3,704,308; 3,725,277; 3,725,480; 3,726,882;
3,736,357; 3,751,365; 3,756,953; 3,793,202; 3,798,165; 3,798,247;
3,803,039; 3,872,019; 3,904,595; 3,957,746; 3,980,569; 3,985,802;
4,006,089; 4,011,380; 4,025,451; 4,058,468; 4,083,699; 4,090,854;
4,354,950; and 4,485,023.
[0027] Polymeric polyamine dispersants suitable for use as ashless
dispersants are polymers containing basic amine groups and oil
solubilizing groups (for example, pendant alkyl groups having at
least about 8 carbon atoms). Such materials are illustrated by
interpolymers formed from various monomers such as decyl
methacrylate, vinyl decyl ether or relatively high molecular weight
olefins, with aminoalkyl acrylates and aminoalkyl acrylamides.
Examples of polymeric polyamine dispersants are set forth in U.S.
Pat. Nos. 3,329,658; 3,449,250; 3,493,520; 3,519,565; 3,666,730;
3,687,849; and 3,702,300.
[0028] The various types of ashless dispersants described above can
be phosphorylated by procedures described in U.S. Pat. Nos.
3,184,411; 3,342,735; 3,403,102; 3,502,607; 3,511,780; 3,513,093;
3,513,093; 4,615,826; 4,648,980; 4,857,214 and 5,198,133.
[0029] The dispersants of the present disclosure may be boronated.
Methods for boronating (borating) the various types of ashless
dispersants described above are described in U.S. Pat. Nos.
3,087,936; 3,254,025; 3,281,428; 3,282,955; 2,284,409; 2,284,410;
3,338,832; 3,344,069; 3,533,945; 3,658,836; 3,703,536; 3,718,663;
4,455,243; and 4,652,387.
[0030] Suitable procedures for phosphorylating and boronating
ashless dispersants such as those referred to above are set forth
in U.S. Pat. Nos. 4,857,214 and 5,198,133.
[0031] The amount of ashless dispersant on an "active ingredient
basis" (i.e., excluding the weight of impurities, diluents and
solvents typically associated therewith) is generally within the
range of about 0.5 to about 7.5 weight percent (wt %), typically
within the range of about 0.5 to 5.0 wt %, notably within the range
of about 0.5 to about 3.0 wt %, and usually within the range of
about 2.0 to about 3.0 wt %, based on the finished oil.
Friction Modifiers:
[0032] For certain applications it may be desirable to use one or
more friction modifiers in preparing the finished lubricating oil
formulation. Suitable friction modifiers include such compounds as
aliphatic amines or ethoxylated aliphatic amines, aliphatic fatty
acid amides, aliphatic carboxylic acids, aliphatic carboxylic
esters, aliphatic carboxylic ester-amides, aliphatic phosphonates,
aliphatic phosphates, aliphatic thiophosphonates, aliphatic
thiophosphates, organic molybdenum compounds, or mixtures thereof.
The aliphatic group typically contains at least about eight carbon
atoms so as to render the compound suitably oil soluble. Also
suitable are aliphatic substituted succinimides formed by reacting
one or more aliphatic succinic acids or anhydrides with
ammonia.
[0033] One exemplary group of friction modifiers is comprised of
the N-aliphatic hydrocarbyl-substituted diethanol amines in which
the N-aliphatic hydrocarbyl-substituent is at least one straight
chain aliphatic hydrocarbyl group free of acetylenic unsaturation
and having in the range of about 14 to about 20 carbon atoms.
[0034] Exemplary friction modifier mixtures include a combination
of at least one N-aliphatic hydrocarbyl-substituted diethanol amine
and at least one N-aliphatic hydrocarbyl-substituted trimethylene
diamine in which the N-aliphatic hydrocarbyl-substituent is at
least one straight chain aliphatic hydrocarbyl group free of
acetylenic unsaturation and having in the range of about 14 to
about 20 carbon atoms. Further details concerning this friction
modifier system are set forth in U.S. Pat. Nos. 255,372,735 and
5,441,656.
[0035] Another suitable mixture of friction modifiers is based on
the combination of (i) at least one di(hydroxyalkyl) aliphatic
tertiary amine in which the hydroxyalkyl groups, being the same or
different, each contain from 2 to about 4 carbon atoms, and in
which the aliphatic group is an acyclic hydrocarbyl group
containing from about 10 to about 25 carbon atoms, and (ii) at
least one hydroxyalkyl aliphatic imidazoline in which the
hydroxyalkyl group contains from 2 to about 4 carbon atoms, and in
which the aliphatic group is an acyclic hydrocarbyl group
containing from about 10 to about 25 carbon atoms. For further
details concerning this friction modifier system, reference should
be had to U.S. Pat. No. 5,344,579.
[0036] The use of friction modifiers is optional. However, in
applications where friction modifiers are used, finished lubricant
formulations may contain up to about 1.25 wt %, and usually from
about 0.05 to about 1 wt % of one or more friction modifiers.
Inhibitors:
[0037] Finished lubricant compositions as described herein
typically will contain some inhibitors. The inhibitor components
serve different functions including rust inhibition, corrosion
inhibition and foam inhibition. The inhibitors may be introduced in
a pre-formed additive package that may contain in addition one or
more other components used in the finished lubricant compositions.
Alternatively these inhibitor components may be introduced
individually or in various sub-combinations. While amounts of
inhibitors used may be varied within reasonable limits, the
finished lubricant compositions of this disclosure will typically
have a total inhibitor content in the range of about 0 to about 15
wt %, on an "active ingredient basis", i.e., excluding the weight
of inert materials such as solvents or diluents normally associated
therewith.
[0038] Foam inhibitors form one type of inhibitor suitable for use
as an inhibitor component in the finished lubricant compositions.
Useful foam inhibitors include silicones, polyacrylates,
surfactants, and the like.
[0039] Copper corrosion inhibitors constitute another class of
additives suitable for inclusion in the finished lubricant
compositions. Such compounds include thiazoles, triazoles and
thiadiazoles. Examples of such compounds include benzotriazole,
tolyltriazole, octyltriazole, decyltriazole, dodecyltriazole,
2-mercapto benzothiazole, 2,5-dimercapto-1,3,4-thiadiazole,
2-mercapto-5-hydrocarbylthio-1,3,4-thiadiazoles,
2-mercapto-5-hydrocarbyldithio-1,3,4-thiadiazoles,
2,5-bis(hydrocarbylthio)-1,3,4-thiadiazoles, and
2,5-bis(hydrocarbyldithio)-1,3,4-thiadiazoles. In one embodiment
the compounds are the 1,3,4-thiadiazoles, a number of which are
available as articles of commerce, and also combinations of
triazoles such as tolyltriazole with a 1,3,5-thiadiazole such as a
2,5-bis(alkyldithio)-1,3,4-thiadiazole. The 1,3,4-thiadiazoles are
generally synthesized from hydrazine and carbon disulfide by known
procedures. See, for example, U.S. Pat. Nos. 2,765,289; 2,749,311;
2,760,933; 2,850,453; 2,910,439; 3,663,561; 3,862,798; and
3,840,549.
[0040] Rust or corrosion inhibitors comprise another type of
inhibitor additive for use in finished lubricant compositions. Such
materials include monocarboxylic acids and polycarboxylic acids.
Examples of suitable monocarboxylic acids are octanoic acid,
decanoic acid and dodecanoic acid. Suitable polycarboxylic acids
include dimer and trimer acids such as are produced from such acids
as tall oil fatty acids, oleic acid, linoleic acid, or the
like.
[0041] Another useful type of rust inhibitor for use in the
disclosed lubricant compositions is comprised of the alkenyl
succinic acid and alkenyl succinic anhydride corrosion inhibitors
such as, for example, tetrapropenylsuccinic acid,
tetrapropenylsuccinic anhydride, tetradecenylsuccinic acid,
tetradecenylsuccinic anhydride, hexadecenylsuccinic acid,
hexadecenylsuccinic anhydride, and the like. Also useful are the
half esters of alkenyl succinic acids having 8 to 24 carbon atoms
in the alkenyl group with alcohols such as the polyglycols. Other
suitable rust or corrosion inhibitors include ether amines; acid
phosphates; amines; polyethoxylated compounds such as ethoxylated
amines, ethoxylated phenols, and ethoxylated alcohols;
imidazolines; aminosuccinic acids or derivatives thereof, and the
like. Materials of these types are available as articles of
commerce. Mixtures of such rust or corrosion inhibitors can be
used.
Antioxidants:
[0042] Antioxidants may also be present in the finished lubricant
formulations of the disclosure. Suitable antioxidants include
phenolic antioxidants, aromatic amine antioxidants, sulfurized
phenolic antioxidants, and organic phosphites, among others.
Examples of phenolic antioxidants include 2,6-di-tert-butylphenol,
liquid mixtures of tertiary butylated phenols,
2,6-di-tert-butyl-4-methylphenol,
4,4'-methylenebis(2,6-di-tert-butylphenol),
2,2'-methylenebis(4-methyl-6-tert-butylphenol), mixed
methylene-bridged polyalkyl phenols, and
4,4'-thiobis(2-methyl-6-tert-butylphenol).
N,N'-di-sec-butyl-p-phenylenediamine, 4-isopropylaminodiphenyl
amine, phenyl-naphthyl amine, phenyl-naphthyl amine, and
ring-alkylated diphenylamines serve as examples of aromatic amine
antioxidants. In one embodiment, the antioxidants are the
sterically hindered tertiary butylated phenols, the ring alkylated
diphenylamines, and combinations thereof.
[0043] The amounts of the inhibitor components and antioxidants
used to provide the finished lubricant compositions will depend to
some extent upon the composition of the component and its
effectiveness when used in the finished lubricant. However,
generally speaking, the finished lubricant composition will
typically contain the following concentrations in weight percent of
the inhibitor components and antioxidants on an active ingredient
basis: TABLE-US-00002 Inhibitor Typical Range Usual Range Foam
inhibitor 0 to 0.1 0.01 to 0.08 Copper corrosion inhibitor 0 to 1.5
0.01 to 1.0 Rust inhibitor 0 to 0.5 0.01 to 0.3 Antioxidant 0 to
1.0 0.1 to 0.6
Detergents:
[0044] Metal-containing or ash-forming detergents function both as
detergents to reduce or remove deposits and as acid neutralizers or
rust inhibitors, thereby reducing wear and corrosion and extending
engine life for lubricant formulations used in crankcase
applications. Detergents generally comprise a polar head with a
long hydrophobic tail where the polar head comprises a metal salt
of an acidic organic compound. The salts may contain a
substantially stoichiometric amount of the metal, in which case
they are usually described as normal or neutral salts, and would
typically have a total base number or TBN (as measured by ASTM
D2896) of from 0 to less than 150. Large amounts of a metal base
may be included by reacting an excess of a metal compound such as
an oxide or hydroxide with an acidic gas such as carbon dioxide.
The resulting overbased detergent comprises micelles of neutralized
detergent surrounding a core of inorganic metal base (e.g.,
hydrated carbonates). Such overbased detergents may have a TBN of
150 or greater, and typically ranging from 250 to 450 or more.
[0045] Detergents that may be used include oil-soluble neutral and
overbased sulfonates, phenates, sulfurized phenates, and
salicylates of a metal, particularly the alkali or alkaline earth
metals, e.g., sodium, potassium, lithium, calcium, and magnesium.
The most commonly used metals are calcium and magnesium, which may
both be present. Mixtures of calcium and/or magnesium with sodium
are also useful. Particularly convenient metal detergents are
neutral and overbased calcium or magnesium sulfonates having a TBN
of from 20 to 450 TBN, neutral and overbased calcium or magnesium
phenates and sulfurized phenates having a TBN of from 50 to 450,
and neutral or overbased calcium or magnesium salicylates having a
TBN of from 130 to 350. Mixtures of such salts may also be used.
When used, the presence of at least one overbased detergent is
desirable.
[0046] Sulfonates may be prepared from sulfonic acids which are
typically obtained by the sulfonation of alkyl substituted aromatic
hydrocarbons such as those obtained from the fractionation of
petroleum or by the alkylation of aromatic hydrocarbons. Examples
include those obtained by alkylating benzene, toluene, xylene,
naphthalene, diphenyl or their halogen derivatives such as
chlorobenzene, chlorotoluene and chloronaphthalene. The alkylation
may be carried out in the presence of a catalyst with alkylating
agents having from 3 to more than 70 carbon atoms. The alkaryl
sulfonates usually contain from 9 to 80 or more carbon atoms,
typically from 16 to 60 carbon atoms per alkyl substituted aromatic
moiety.
[0047] The oil-soluble sulfonates or alkaryl sulfonic acids may be
neutralized with oxides, hydroxides, alkoxides, carbonates,
carboxylate, sulphides, hydrosulfides, nitrates, borates and ethers
of the alkali metal. The amount of metal compound is chosen having
regard to the desired TBN of the final product but typically ranges
from 100 to 220 wt % (desirably at least 125 wt %) of that
stoichiometrically required.
[0048] Metal salts of alkyl phenols and sulfurized alkyl phenols
are prepared by reaction with an appropriate metal compound such as
an oxide, hydroxide or alkoxide, and overbased products may be
obtained by methods well known in the art. Sulfurized alkyl phenols
may be prepared by reacting an alkyl phenol with sulphur or a
sulphur-containing compound such as hydrogen sulphide, sulphur
monohalide or sulphur dihalide, to form products which are
generally mixtures of compounds in which 2 or more phenols are
bridged by sulphur-containing bridges. The starting alkyl phenol
may contain one or more alkyl substituents. These may be branched
or unbranched, and depending on the number of substituents may have
from 1 to 30 carbon atoms (provided the resulting alkyl phenol is
oil-soluble), with from 9 to 18 carbon atoms being particularly
suitable. Mixtures of alkyl phenols with different alkyl
substituents may be used.
[0049] Metal salts of carboxylic acids (including salicylic acids)
may be prepared in a number of ways: for example, by adding a basic
metal compound to a reaction mixture comprising the carboxylic acid
(which may be part of a mixture with another organic acid such as a
sulfonic acid) or its metal salt and promoter, and removing free
water from the reaction mixture to form an metal salt, then adding
more basic metal compound to the reaction mixture and removing free
water from the reaction mixture. The carboxylate is then overbased
by introducing the acidic material such as carbon dioxide to the
reaction mixture while removing water. This can be repeated until a
product of the desired TBN is obtained.
[0050] The overbasing process is well known in the art and
typically comprises reacting acidic material with a reaction
mixture comprising the organic acid or its metal salt, a metal
compound. That acidic material may be a gas such as carbon dioxide
or sulphur dioxide, or it may be boric acid. Processes for the
preparation of overbased alkali metal sulfonates and phenates are
described in U.S. Pat. No. 4,839,094. A process suitable for
overbased sodium sulfonates is described in EP-A-235929. A process
for making overbased salicylates is described in U.S. Pat. No.
5,451,331.
[0051] The overbased metal detergents may also be borated. The
boron may be introduced by using boric acid as the acidic material
used in the overbasing step.
[0052] However a desirable alternative is to borate the overbased
product after formation by reacting a boron compound with the
overbased metal salt. Boron compounds include boron oxide, boron
oxide hydrate, boron trioxide, boron trifluoride, boron tribromide,
boron trichloride, boron acid such as boronic acid, boric acid,
tetraboric acid and metaboric acid, boron hydrides, boron amides
and various esters of boron acids. Generally, the overbased metal
salt may be reacted with a boron compound at from 50.degree. C. to
250.degree. C., in the presence of a solvent such as mineral oil or
xylene. The borated, overbased alkali metal salt comprises at least
0.5%, and typically from 1% to 5%, by weight boron.
[0053] The amount of detergent in a finished lubricant composition
according to the disclosed embodiments may range from about 0.1 to
about 15 percent by weight based on the total weight of the
finished lubricant composition.
Antiwear and Extreme Pressure Agents:
[0054] Various types of sulfur-containing antiwear and/or extreme
pressure agents may be used in the finished lubricant formulations
described herein. Examples include dihydrocarbyl polysulfides;
sulfurized olefins; sulfurized fatty acid esters of both natural
and synthetic origins; trithiones; sulfurized thienyl derivatives;
sulfurized terpenes; sulfurized oligomers of C.sub.2-C.sub.8
monoolefins; and sulfurized Diels-Alder adducts such as those
disclosed in U.S. Pat. No. Re 27,331. Specific examples include
sulfurized polyisobutene, sulfurized isobutylene, sulfurized
diisobutylene, sulfurized triisobutylene, dicyclohexyl polysulfide,
diphenyl polysulfide, dibenzyl polysulfide, dinonyl polysulfide,
and mixtures of di-tert-butyl polysulfide such as mixtures of
di-tert-butyl trisulfide, di-tert-butyl tetrasulfide and
di-tert-butyl pentasulfide, among others. Combinations of such
categories of sulfur-containing antiwear and/or extreme pressure
agents may also be used, such as a combination of sulfurized
isobutylene and di-tert-butyl trisulfide, a combination of
sulfurized isobutylene and dinonyl trisulfide, a combination of
sulfurized tall oil and dibenzyl polysulfide.
[0055] Use may also be made of a wide variety of
phosphorus-containing oil-soluble antiwear and/or extreme pressure
additives such as the oil-soluble organic phosphates, organic
phosphites, organic phosphonates, organic phosphonites, etc., and
their sulfur analogs. Also useful as the phosphorus-containing
antiwear and/or extreme pressure additives that may be used in the
disclosed lubricant compositions include those compounds that
contain both phosphorus and nitrogen. Phosphorus-containing
oil-soluble antiwear and/or extreme pressure additives useful in
the disclosed embodiments include those compounds taught in U.S.
Pat. Nos. 5,464,549; 5,500,140; and 5,573,696, the disclosures of
which are hereby incorporated by reference.
[0056] The phosphorus-containing antiwear agents may include an
organic ester of phosphoric acid, phosphorous acid, or an amine
salt thereof. For example, phosphorus-containing antiwear agent may
include one or more of a dihydrocarbyl phosphite, a trihydrocarbyl
phosphite, a dihydrocarbyl phosphate, a trihydrocarbyl phosphate,
any sulfur analogs thereof, and any amine salts thereof.
[0057] The phosphorus-containing antiwear agent may be present in
an amount sufficient to provide about 10 to about 500 parts per
million by weight of phosphorus in the finished lubricant
composition. As a further example, the phosphorus-containing
antiwear agent may be present in an amount sufficient to provide
about 150 to about 300 parts per million by weight of phosphorus in
the finished lubricant composition.
[0058] One such type of phosphorus- and nitrogen-containing
antiwear and/or extreme pressure additives which may be used are
the phosphorus- and nitrogen-containing compositions of the type
described in G.B. 1,009,913; U.S. Pat. No. 3,197,405 and/or U.S.
Pat. No. 3,197,496. In general, these compositions are formed by
forming an acidic intermediate by the reaction of a
hydroxy-substituted triester of a phosphorothioic acid with an
inorganic phosphorus acid, phosphorus oxide or phosphorus halide,
and neutralizing a substantial portion of said acidic intermediate
with an amine or hydroxy-substituted amine. Other types of
phosphorus- and nitrogen-containing antiwear and/or extreme
pressure additive that may be used in the lubricant compositions
described herein include the amine salts of hydroxy-substituted
phosphetanes or the amine salts of hydroxy-substituted
thiophosphetanes and the amine salts of partial esters of
phosphoric and thiophosphoric acids.
Pour Point Depressants:
[0059] The detergent/inhibitor package may also contain one or more
pour point depressants. Pour point depressants may be used in
compositions described herein to improve low temperature properties
of the compositions. Examples of useful pour point depressants are
polymethacrylates; polyacrylates; polyacrylamides; condensation
products of haloparaffin waxes and aromatic compounds; vinyl
carboxylate polymers; and terpolymers of dialkylfumarates, vinyl
esters of fatty acids and alkyl vinyl ethers. Pour point
depressants useful for the purposes of this disclosure and
techniques for their preparation are described in U.S. Pat. Nos.
2,387,501; 2,015,748; 2,655,479; 1,815,022; 2,191,498; 2,666,746;
2,721,877; 2,721,878; and 3,250,715 which are herein incorporated
by reference for their relevant disclosures.
[0060] In one embodiment, the pour point depressant is represented
by the general structural formula:
Ar(R)--(Ar.sup.1(R.sup.1)--Ar.sup.2, wherein the Ar, Ar.sup.1 and
Ar.sup.2 are aromatic groups of up to about 12 carbon atoms, (R)
and (R.sup.1) are independently an alkylene group containing 1 to
100 carbon atoms with the proviso that at least one of (R) or
(R.sup.1) is CH.sub.2, and n is 0 to about 1000 with the proviso
that if n is 0, then (R) is CH.sub.2 and at least one aromatic
moiety has at least one substituent, the substituents being
selected from the group consisting of a substituent derived from an
olefin containing about 8 to about 30 carbon atoms, and a
substituent derived from a chlorinated hydrocarbon usually
containing about 8 to about 50 carbon atoms and about 2.5 chlorine
atoms for each 24 carbon atoms.
Seal Swell Agents:
[0061] Seal swell agents may be included in the finished lubricant
compositions of the disclosed embodiments particularly when the
lubricant compositions are used as power transmission fluids.
Suitable seal swell agents may be selected from oil-soluble
diesters, oil-soluble sulfones, silicon containing organic
compounds, and mixtures thereof. Generally speaking the most
suitable diesters include the adipates, azelates, and sebacates of
C.sub.8-C.sub.13 alkanols (or mixtures thereof), and the phthalates
of C.sub.4-C.sub.13 alkanols (or mixtures thereof). Mixtures of two
or more different types of diesters (e.g., dialkyl adipates and
dialkyl azelates, etc.) may also be used. Examples of such
materials include the n-octyl, 2-ethylhexyl, isodecyl, and tridecyl
diesters of adipic acid, azelaic acid, and sebacic acid, and the
n-butyl, isobutyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl,
undecyl, dodecyl, and tridecyl diesters of phthalic acid. Other
esters which may give generally equivalent performance are polyol
esters.
[0062] Suitable sulfone seal swell agents are described in U.S.
Pat. Nos. 3,974,081 and 4,029,587. Typically these products are
employed at levels in the range of about 0.25 to about 1 wt % in
the finished transmission fluid.
[0063] In one embodiment, the seal swell agents are the oil-soluble
dialkyl esters of (i) adipic acid, (ii) sebacic acid, or (iii)
phthalic acid. The adipates and sebacates should be used in amounts
in the range of from about 4 to about 15 wt % in the finished
fluid. In the case of the phthalates, the levels in the
transmission fluid should fall in the range of from about 1.5 to
about 10 wt %. Generally speaking, the higher the molecular weight
of the adipate, sebacate or phthalate, the higher should be the
treat rate within the foregoing ranges.
Thickening Agents:
[0064] A wide variety of thickening agents may be used for
providing lubricants and greases containing the base oil component.
Included among the thickening agents are alkali and alkaline earth
metal soaps of fatty acids and fatty materials having from about 12
to about 30 carbon atoms per molecule. The metal cations of the
metal soaps are typified by sodium, lithium, calcium, magnesium,
and barium. Fatty materials are illustrated by stearic acid,
hydroxystearic acid, stearin, cottonseed oil acids, oleic acid,
palmitic acid, myristic acid and hydrogenated fish oils.
[0065] Other thickening agents include salt and salt-soap complexes
such as calcium stearate-acetate (U.S. Pat. No. 2,197,263), barium
stearate acetate (U.S. Pat. No. 2,564,561), calcium
stearate-caprylate-acetate complexes (U.S. Pat. No. 2,999,065),
calcium-caprylate-acetate (U.S. Pat. No. 2,999,066), and calcium
salts and soaps of low-, intermediate- and high-molecular weight
acids and of nut oil acids.
[0066] Another group of thickening agents comprises substituted
ureas, phthalocyanines, indanthrene, pigments such as perylimides,
pyromellitdiimides, ammeline, and hydrophobic clays.Some of the
additive components described above may be supplied in the form of
solutions of active ingredient(s) in an inert diluent or solvent,
such as a diluent oil. Unless expressly stated to the contrary, the
amounts and concentrations of each additive component are expressed
in terms of active additive, i.e., the amount of solvent or diluent
that may be associated with such component as received is
excluded.
[0067] Additives used in formulating the compositions described
herein may be blended into the base oil component individually or
in various sub-combinations. However, it is preferable to blend all
of the components concurrently using an additive concentrate (i.e.,
additives plus a diluent, such as a hydrocarbon solvent). The use
of an additive concentrate takes advantage of the mutual
compatibility afforded by the combination of ingredients when in
the form of an additive concentrate. Also, the use of a concentrate
reduces blending time and lessens the possibility of blending
errors.
[0068] Exemplary embodiments of the disclosure include use of
finished lubricant compositions as described herein in a wide
variety of applications, including but not limited to,
metal-working fluids, quench fluids, greases, crankcase lubricants,
power transmission fluids, vehicle axle applications, hydraulic
systems, heavy duty gear oils, and rotating machinery such as
stationary engines, pumps, gas turbines, compressors, wind
turbines, and the like, and for a wide variety of applications
associated with the automotive, tractor, airline, and railroad
industries including engines, transmissions, and the like.
Stationary engines include fuel and gas powered engines that are
not associated with the automotive, tractor, airline, and railroad
industries.
[0069] In one embodiment, the finished lubricating oil composition
is an automatic transmission fluid (ATF). An ATF composition uses
components proportioned such that the kinematic viscosity of the
composition at 100.degree. C. is in the range of from about 4 to
about 10 cSt, usually at least 15.9 cSt. An exemplary ATF
composition contains the base oil component, a solubilizing agent,
from about 0.5 to about 1.5 wt. % viscosity index improver, from
about 1.5 to about 2.5 wt. % ashless dispersant, from about 0.05 to
about 1 wt. % friction modifier, from about 0.01 to about 0.5 wt. %
corrosion inhibitor, from about 0.1 to about 0.4 wt. % antiwear
additive, from about 0.005 to about 5 wt. % metal deactivator, from
about 0.1 to about 15 wt. % metallic detergent, from about 0.25 to
about 1 wt. % seal swell agent, and from about 0.01 to about 0.5
wt. % pour point depressant.
[0070] In one embodiment, the finished lubricating oil composition
is a manual transmission oil. An exemplary manual transmission
lubricating oil formulation contains the base oil component (which
includes at least one GTL base oil), a solubilizing agent, a
viscosity index improver, and a DI package comprising an ashless
dispersant, at least one antioxidant and at least one inhibitor.
Typically, the DI package provides 0.2-5 wt % ashless dispersant(s)
to the finished lubricant composition, 0-1.0 wt %, typically from
about 0.2-1.0 wt %, antioxidant(s) to the finished lubricant
composition, and 0.01-2 wt % inhibitor(s) selected from the group
consisting of copper corrosion inhibitors, rust inhibitors and
mixtures thereof, to the lubricant composition. The manual
transmission lubricating oil formulation usually contains from 0-5
wt. % sulfur and from 30 to 5000 ppm phosphorus, based on the total
finished lubricant composition.
[0071] In another embodiment of the disclosure, the finished
lubricating oil composition is an axle lubricating oil. An
exemplary axle lubricating oil formulation contains the GTL base
oil component, a solubilzing agent, a viscosity index improver, a
DI package comprising an sulfur containing extreme pressure agent,
at least one phosphorus containing anti-wear agent, at least one
ashless dispersant and at least one inhibitor. Usually, the DI
package provides 3-15 wt % sulfur containing extreme pressure
agent(s), 2-10 wt % phosphorus containing anti-wear agent(s), 0.2-5
wt % ashless dispersant(s) and 0.01-2 wt % inhibitor(s) selected
from the group consisting of copper corrosion inhibitors, rust
inhibitors and mixtures thereof, to the finished lubricant
composition. The axle lubricating oil formulation may contain from
0.5-5 wt % sulfur and from 200 to 5000 ppm phosphorus, based on the
finished lubricant composition.
[0072] The power transmission fluids disclosed herein may include
fluids suitable for any power transmitting application, such as a
step automatic transmission or a manual transmission used for
automotive, truck, or tractor applications. Further, the power
transmission fluids of the disclosed embodiments may be used in
transmissions with a slipping torque converter, a lock-up torque
converter, a starting clutch, and/or one or more shifting clutches.
Such transmissions include four-, five-, six-, and seven-speed
transmissions, and continuously variable transmissions (chain,
belt, or disk type). They may also be used in manual transmissions,
including automated manual and dual-clutch transmissions.
[0073] A crankcase lubricant composition in accordance with another
embodiment of the disclosure may include the GTL base oil
component, a solubilizing agent, a viscosity index improver, and a
DI package including a detergent, a dispersant, an anti-wear agent,
a friction modifier, an antioxidant, a corrosion inhibitor, a pour
point depressant, and an anti-foam agent. Such DI package includes
from about 1.3 to about 3.0 wt. % dispersant, from about 0.1 to
about 15 wt. % detergent, from about 0 to about 5 wt. % corrosion
inhibitor, from about 0 to about 5 wt. % antioxidant, from about 0
to about 5 wt. % anti-foam agent, from about 0 to about 5 wt. %
friction modifier, from about 0.01 to about 6 wt. % viscosity index
improver, from about 0.1 to about 6 wt. % antiwear agent, and from
about 0.01 to about 5 wt. % pour point depressant.
[0074] Oil compositions described herein may also be used in quench
fluid applications to provide a slower rate of cooling for
hardening metals such as steel. Quench fluid performance may be
modified by introducing one or more of the foregoing additives
and/or compositions to improve wettability, cooling rates, oil
stability life, and to reduce deposit forming tendencies of the
quench fluids. At numerous places throughout this specification,
reference has been made to a number of U.S. patents. All such cited
documents are expressly incorporated in full into this disclosure
as if fully set forth herein.
[0075] Other embodiments of the disclosure will be apparent to
those skilled in the art from consideration of the specification
and practice of the embodiments disclosed herein. As used
throughout the specification and claims, "a" and/or "an" may refer
to one or more than one. Unless otherwise indicated, all numbers
expressing quantities of ingredients, properties such as molecular
weight, percent, ratio, reaction conditions, and so forth used in
the specification and claims are to be understood as being modified
in all instances by the term "about." Accordingly, unless indicated
to the contrary, the numerical parameters set forth in the
specification and claims are approximations that may vary depending
upon the desired properties sought to be obtained by the disclosed
embodiments. At the very least, and not as an attempt to limit the
application of the doctrine of equivalents to the scope of the
claims, each numerical parameter should at least be construed in
light of the number of reported significant digits and by applying
ordinary rounding techniques. Notwithstanding that the numerical
ranges and parameters setting forth the broad scope of the
exemplary embodiments are approximations, the numerical values set
forth in the specific examples are reported as precisely as
possible. Any numerical value, however, inherently contains certain
errors necessarily resulting from the standard deviation found in
their respective testing measurements. It is intended that the
specification and examples be considered as exemplary only, with a
true scope and spirit of the disclosure being indicated by the
following claims.
* * * * *