U.S. patent application number 11/417343 was filed with the patent office on 2007-05-10 for lubricant composition.
Invention is credited to David J. DeGonia, Chip Hewette, Ronald L. Phillips.
Application Number | 20070105728 11/417343 |
Document ID | / |
Family ID | 37671933 |
Filed Date | 2007-05-10 |
United States Patent
Application |
20070105728 |
Kind Code |
A1 |
Phillips; Ronald L. ; et
al. |
May 10, 2007 |
Lubricant composition
Abstract
A lubricating composition including an ester; a viscosity index
improver; and at least one of a sterically hindered
sulfur-containing, phosphorus-containing compound, and its
salt.
Inventors: |
Phillips; Ronald L.;
(Richmond, VA) ; DeGonia; David J.; (Midlothian,
VA) ; Hewette; Chip; (Richmond, VA) |
Correspondence
Address: |
NEW MARKET SERVICES CORPORATION;(FORMERLY ETHYL CORPORATION)
330 SOUTH 4TH STREET
RICHMOND
VA
23219
US
|
Family ID: |
37671933 |
Appl. No.: |
11/417343 |
Filed: |
May 3, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60734757 |
Nov 9, 2005 |
|
|
|
Current U.S.
Class: |
508/187 ;
508/189; 508/422; 508/423; 508/463; 508/591 |
Current CPC
Class: |
C10M 2207/2815 20130101;
C10M 2223/043 20130101; C10M 169/044 20130101; F16H 57/04 20130101;
C10N 2020/02 20130101; C10M 2207/10 20130101; C10M 169/04 20130101;
C10M 2205/028 20130101; C10M 161/00 20130101; C10M 2207/2805
20130101; C10M 2223/047 20130101; C10N 2030/06 20130101; C10M
2207/28 20130101; C10M 2205/173 20130101; C10M 2207/281 20130101;
C10M 2219/044 20130101; C10N 2060/14 20130101; C10N 2030/54
20200501; C10M 2205/0285 20130101; C10N 2040/04 20130101; C10M
2215/00 20130101; C10M 2223/02 20130101 |
Class at
Publication: |
508/187 ;
508/423; 508/422; 508/591; 508/189; 508/463 |
International
Class: |
C10M 137/02 20060101
C10M137/02; C10M 141/10 20060101 C10M141/10 |
Claims
1. A lubricating composition comprising: an ester; a viscosity
index improver; and at least one of a sulfur-containing,
phosphorus-containing compound and a salt of the sulfur-containing,
phosphorus-containing compound.
2. The composition of claim 1, wherein the ester has a viscosity
less than or equal to about 2 cSt at 100.degree. C.
3. The composition of claim 1, wherein the ester has the formula
RCO.sub.2R.sup.1, wherein R comprises an alkyl radical having from
about 4 to about 9 carbon atoms and R.sup.1 comprises an alkyl
radical having from about 4 to about 15 carbon atoms.
4. The composition of claim 1, wherein the ester comprises at least
one of isononyl 2-ethylhexanoate, isooctyl 2-ethylhexanoate,
2-ethylhexyl 2-ethylhexanoate, isononyl heptanoate, isononyl
isopentanoate, isooctyl heptanoate, isononyl pentanoate, isooctyl
isopentanoate, isooctyl pentanoate, octyl pentanoate, nonyl
pentanoate, decyl pentanoate, octyl heptanoate, nonyl heptanoate,
decyl heptanoate and mixtures thereof.
5. The composition of claim 1, wherein the viscosity index improver
is a polyalphaolefin.
6. The composition of claim 5, wherein the polyalphaolefins has a
viscosity of from about 40 to about 1000 cSt at 100.degree. C.
7. The composition of claim 1, wherein the sterically hindered
sulfur-containing, phosphorus-containing compound is at least one
of a compound of formulae (II) and (V): ##STR6## wherein n is an
integer from 1 to 5; and wherein R.sup.1, R.sup.2, R.sup.3,
R.sup.4, R.sup.5, R.sup.6, R.sup.10, and R.sup.11 are independently
selected from the group consisting of hydrogen, cyano, and
hydrocarbyl groups comprising from about 1 to about 30 carbon
atoms.
8. The composition of claim 7, wherein in formula (II) R.sup.1 and
R.sup.2 are methyl and R.sup.3, R.sup.4, R.sup.5, and R.sup.6 are
hydrogen.
9. The composition of claim 1, wherein the salt of the
sulfur-containing, phosphorus-containing compound is at least one
of a compound of formulae (III) and (VI): ##STR7## wherein n is an
integer from 1 to 5; and wherein R.sup.1, R.sup.2, R.sup.3,
R.sup.4, R.sup.6, R.sup.7, R.sup.8, R.sup.9, R.sup.10, and R.sup.11
are independently selected from the group consisting of hydrogen,
cyano, and hydrocarbyl groups comprising from about 1 to about 30
carbon atoms.
10. The composition of claim 9, wherein in formula (III) R.sup.3,
R.sup.4, R.sup.5, R.sup.6, R.sup.7 and R.sup.8 are hydrogen;
R.sup.1 and R.sup.2 are methyl; and R.sup.9 is a tertiary
C.sub.12-14 alkyl group.
11. The composition of claim 9, wherein in formula (VI) R.sup.1,
R.sup.2, R.sup.3, R.sup.4, R.sup.5, R.sup.6, R.sup.7 and R.sup.8
are hydrogen; R.sup.9 is a tertiary C.sub.12-14 alkyl group; and
R.sup.10 and R.sup.11 are alkyl groups comprising from about 1 to
about 6 carbon atoms.
12. The composition of claim 1, further comprising a synthetic base
oil.
13. The composition of claim 12, wherein the synthetic base oil
comprises a polyalphaolefins.
14. The composition of claim 12, wherein the viscosity index of the
combination of the synthetic base oil, the viscosity index
improver, and the ester is about 200 or greater.
15. The composition of claim 1, further comprising a gas-to-liquid
base oil.
16. The composition of claim 1, further comprising a
boron-containing compound.
17. The composition of claim 16, wherein the boron-containing
compound is present in the composition in an amount to provide
about 5 ppm to about 500 ppm boron.
18. The composition of claim 16, wherein the boron-containing
compound is a borated nitrogen-containing compound.
19. The composition of claim 16, wherein the boron-containing
compound is a borated phosphorus-containing compound.
20. The composition of claim 1, further comprising an acid and a
nitrogen-containing compound, wherein at least one of the acid and
the nitrogen-containing compound is a friction modifier.
21. The composition of claim 20, wherein the acid is a friction
modifier chosen from at least one of an organic carboxylic acid,
organic phosphorus acid, organic sulfonic acid, inorganic
phosphorus acid, and a mixture thereof.
22. The composition of claim 21, wherein the organic phosphorus
acid is at least one of dialkyl phosphorus acid, monoalkyl
phosphorus acid, dialkyl dithiophosphorus acid, dialkyl
thiophosphorus acid, amyl acid phosphate, 2-ethylhexyl acid
phosphate, and a mixture thereof.
23. The composition of claim 20, wherein the nitrogen-containing
compound is a friction modifier and is a mixture of C.sub.8-16
tertiary primary alkyl amine.
24. A method of lubricating an automotive gear comprising using as
the lubricant the composition of claim 1.
25. A method of improving antiwear protection in an automotive gear
comprising placing a composition according to claim 1 in the
automotive gear.
26. A method of improving fuel efficiency in an automotive gear
comprising placing a composition according to claim 1 in an
automotive gear.
27. A method of lubricating an axle comprising using as the
lubricant the composition of claim 1.
28. A method of improving antiwear protection in an axle comprising
placing a composition according to claim 1 in the axle.
29. A method of improving fuel efficiency in an axle comprising
placing a composition according to claim 1 in the axle.
30. A method of lubricating a stationary gearbox comprising using
as the lubricant the composition of claim 1.
31. A method of improving antiwear protection in a stationary
gearbox comprising placing a composition according to claim 1 in
the stationary gearbox.
32. A method of improving fuel efficiency in a stationary gearbox
comprising placing a composition according to claim 1 in the
stationary gearbox.
33. A method of passing ASTM D5704 comprising lubricating a gear
with a composition according to claim 1.
34. A method of passing ASTM D6121 with lubricated and
nonlubricated gear sets comprising lubricating a gear with a
composition according to claim 1.
35. A method of passing ASTM D6121 with nonlubricated gear sets at
least about 325.degree. F. for at least about 16 hours comprising
lubricating a gear with a composition according to claim 1.
36. A method of maintaining GL-5 and/or SAE J2360 performance
comprising lubricating a gear with a composition according to claim
1.
37. A lubricating composition comprising an ester; a viscosity
index improver; and a reaction product of a sulfur-containing
compound, a phosphorus-containing compound, and a
nitrogen-containing compound.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S.
Provisional Application No. 60/734,757, filed on Nov. 9, 2005.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to a composition comprising
an ester; a viscosity index improver; and at least one of a
sulfur-containing, phosphorus-containing compound and its salt.
Methods of using the composition are also disclosed.
BACKGROUND OF THE DISCLOSURE
[0003] Lubricant compositions, such as gear oils, typically are
subjected to elevated temperatures and therefore it would be
beneficial to provide a thermally stable compound that would not
prematurely decompose at higher temperatures. A thermally stable
compound would therefore remain in the lubricant composition for an
extended period of time and provide the property, e.g., antiwear,
to the composition over an extended period of time. What is needed
is a compound that has the proper thermal stability to sustain its
antiwear property.
[0004] Moreover, as automobile manufacturers continue to make
bigger trucks with larger more powerful engines the amount of
torque on the axles has increased. Unfortunately, the axles of
these trucks have not been updated to account for the increased
torque because of cost. So, the manufacturers have become
increasingly reliant on improved lubricant compositions to extend
the life of the axles, which is the cheapest solution to the
problem. In particular, what is needed is a lubricant composition
with at least one of improved antiwear, thermal stability, and
oxidative stability in axles that are "green," i.e., have not been
broken in for some time period or distance. Moreover, there is need
for a lubricant composition as discussed above that can be used in
axles that are subjected to low and high temperature and variable
load conditions. Further, there is needed a lubricant composition
that can provide at least one of improved antiwear and fuel
efficiency.
SUMMARY OF THE DISCLOSURE
[0005] In accordance with the present disclosure, a lubricating
composition may comprise an ester; a viscosity index improver; and
at least one of a sterically hindered sulfur-containing,
phosphorus-containing compound and a salt of the sulfur-containing,
phosphorus-containing compound.
[0006] In an aspect, there is disclosed a lubricating composition
comprising an ester; a viscosity index improver; and a reaction
product of a sulfur-containing compound, a phosphorus-containing
compound and a nitrogen-containing compound.
[0007] Additional objects and advantages of the disclosure will be
set forth in part in the description which follows, and/or can be
learned by practice of the disclosure. The objects and advantages
of the disclosure will be realized and attained by means of the
elements and combinations particularly pointed out in the appended
claims.
[0008] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the disclosure, as
claimed.
DESCRIPTION OF THE EMBODIMENTS
[0009] 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
the molecule and having predominantly hydrocarbon character.
Examples of hydrocarbyl groups include:
[0010] (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);
[0011] (2) substituted hydrocarbon substituents, that is,
substituents containing non-hydrocarbon groups which, in the
context of this invention, do not alter the predominantly
hydrocarbon substituent (e.g., halo (especially chloro and fluoro),
hydroxy, alkoxy, mercapto, alkylmercapto nitro, nitroso, and
sulfoxy);
[0012] (3) hetero substituents, that is, substituents which, while
having a predominantly hydrocarbon character, in the context of
this invention, contain other than carbon in a ring or chain
otherwise composed of carbon atoms. Heteroatoms include sulfur,
oxygen, nitrogen, and encompass substituents as pyridyl, furyl,
thienyl and imidazolyl. In general, no more than two, for example
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 substituents in the hydrocarbyl
group.
[0013] As used herein, the term "percent by weight", unless
expressly stated otherwise, means the percentage the recited
component represents to the weight of the entire composition.
[0014] In an aspect, there is provided a composition providing at
least one of improved antiwear and fuel efficiency to a gear, such
as a hypoid gear axle while maintaining GL-5 and/or SAE J2360
performance. The composition can comprise several compounds and/or
components that form compounds in situ that can comprise steric
hindrance to minimize and/or prevent decomposition of the compound
at high temperatures. The steric hindrance can be present in any
form, such as branching of hydrocarbyl chains. For example, a beta
branched hindered dialkyl acid phosphite and/or the sulfurized
analogous phosphoric acid salt can be present in the disclosed
composition. It is believed, without being limited to any
particular theory, that a sterically hindered phosphorus-containing
compound; a sterically hindered, sulfur-containing,
phosphorus-containing compound and/or a salt of a sterically
hindered, sulfur-containing, phosphorus-containing compound can
improve the ASTM D5704 (L60) performance of a lubricant composition
relative to linear and branched phosphites. The lubricant
composition can be suitably used with any friction material such as
paper, steel or carbon fiber.
[0015] The composition disclosed herein can comprise a
phosphorus-containing compound, such as a phosphite or a phosphate.
Methods of making both phosphites and phosphates are known. In an
aspect, the phosphite can be a di- or tri-hydrocarbyl phosphite.
Each hydrocarbyl group can have from about 1 to about 24 carbon
atoms, or from 1 to about 18 carbon atoms, or from about 2 to about
8 carbon atoms. Each hydrocarbyl group can be independently alkyl,
alkenyl, aryl, and mixtures thereof. When the hydrocarbyl group is
an aryl group, then it contains at least about 6 carbon atoms; or
from about 6 to about 18 carbon atoms. Examples of the alkyl or
alkenyl groups include propyl, butyl, hexyl, heptyl, octyl, oleyl,
linoleyl, stearyl, etc. Examples of aryl groups include phenyl,
naphthyl, heptylphenol, etc. In an aspect, each hydrocarbyl group
can be independently methyl, propyl, butyl, pentyl, hexyl, heptyl,
oleyl or phenyl, for example methyl, butyl, oleyl or phenyl, and as
a further example methyl, butyl, oleyl, or phenyl.
[0016] Non-limiting examples of useful phosphites include dibutyl
hydrogen phosphonate, diisobutyl hydrogen phosphonate, dioleyl
hydrogen phosphonate, di(C.sub.14-18) hydrogen phosphonate,
triphenyl phosphite, a dihydrocarbyl phosphite such as a compound
of formula (I), and a polymeric phosphite, such as a compound of
formula (IV) shown below. ##STR1##
[0017] wherein n is an integer from about 1 to about 5; and
[0018] wherein R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5,
R.sup.6, R.sup.10, and R.sup.11 can be independently selected from
the group consisting of hydrogen, cyano, and hydrocarbyl groups
comprising from about 1 to about 30 carbon atoms, for example from
about 1 to about 20 carbon atoms, and as a further example from
about 1 to about 10 carbon atoms. In an aspect, if n is an integer
greater than about 5, it is believed, without being limited to any
particular theory, that the repeating unit will not completely
sulfurize.
[0019] In an aspect, in the compound of formula (I), R.sup.3,
R.sup.4, R.sup.5, and R.sup.6 can be hydrogen; and R.sup.1 and
R.sup.2 can be methyl. This compound is commonly referred to as
neopentyl glycol phosphite (NPGP) and is registered with Chemical
Abstracts Select under the designation CAS #4090-60-2
(5,5-dimethyl-1,3,2-dioxaphosphorinan-2-one). In an aspect, in the
compound of formula (IV), R.sup.1 and R.sup.2 can be methyl;
R.sup.3, R.sup.4, R.sup.5, and R.sup.6 can be hydrogen; and
R.sup.10 and R.sup.11 can be alkyl groups having from about 1 to
about 6 carbon atoms.
[0020] The phosphorus-containing compound can also be at least one
of a phosphoric acid ester or salt thereof, a reaction product of a
phosphorus acid or anhydride and an unsaturated compound, and
mixtures of two or more thereof.
[0021] A metal dithiophosphate can be prepared by reacting a metal
base with at least one thiophosphorus acids, which can be mono- or
dithiophosphorus acids.
[0022] The phosphorus acid or anhydride can be reacted with an
unsaturated compound, including but not limited to, amides, esters,
acids, anhydrides, and ethers.
[0023] In an aspect, the phosphorus-containing compound, such as a
phosphite, can comprise various functional groups that increase the
steric hindrance of the compound and therefore increase its
resistance to thermal decomposition. In an aspect, the
phosphorus-containing compound can be branched at the position beta
to the oxygen atom in the hydrocarbyl chain. It is believed that
branching at this beta carbon can change, e.g., can improve, the
thermal stability of the phosphorus-containing compound in a
lubricant composition.
[0024] Moreover, the phosphorus-containing compound can be made
using components that would increase the resultant compound's
steric hindrance. For example, the alcohol used to make, for
example, the phosphite can be a beta-branched alcohol. Non-limiting
examples of beta branched alcohols include isobutanol,
2-ethylhexanol, neopentyl glycol, neopentyl alcohol, pristanol, and
methyl isobutyl carbinol (MIBC).
[0025] The disclosed phosphorus-containing compound can be used as
a starting material to yield a sulfur-containing,
phosphorus-containing compound. In an aspect, a sulfur-containing
compound can be mixed, blended, and/or reacted with a
phosphorus-containing compound, such as those described above, and
a nitrogen-containing compound to yield the sulfur-containing,
phosphorus-containing compound. In an aspect, there is contemplated
a composition comprising a reaction product of a
phosphorus-containing compound, a nitrogen-containing compound, and
a sulfur-containing compound. The sulfur-containing,
phosphorus-containing compound can provide improved antiwear
properties as compared to a non-sulfur-containing,
phosphorus-containing compound.
[0026] The sulfur-containing compound can be any compound that
comprises free and/or active sulfur. Non-limiting examples of
sulfur-containing compounds include sulfurized animal or vegetable
fats or oils, sulfurized animal or vegetable fatty acid esters,
fully or partially esterified esters of trivalent or pentavalent
acids of phosphorus, sulfurized olefins, dihydrocarbyl
polysulfides, sulfurized Diels-Alder adducts, sulfurized
dicyclopentadiene, sulfurized or co-sulfurized mixtures of fatty
acid esters and monounsaturated olefin, co-sulfurized blends of
fatty acid, fatty acid ester and .alpha.-olefin,
functionally-substituted dihydrocarbyl polysulfides,
thio-aldehydes, thio-ketones and derivatives thereof (e.g., acids,
esters, imines, or lactones), epithio compounds, sulfur-containing
acetal derivatives, co-sulfurized blends of terpene and acyclic
olefins, polysulfide olefin products, and elemental sulfur.
[0027] In an aspect, the sulfur-containing compound can be made by
reacting an olefin, such as isobutene, with sulfur. The product,
e.g., sulfurized isobutylene or sulfurized polyisobutylene,
typically has a sulfur content of about 10 to about 55%, for
example about 30 to about 50% by weight. A wide variety of other
olefins or unsaturated hydrocarbons, e.g., isobutene dimer or
trimer, can be used to form such sulfur-containing compounds.
[0028] In another aspect, polysulfides composed of one or more
compounds represented by the formula: R.sup.20--S.sub.x --R.sup.21
where R.sup.20 and R.sup.21 can be hydrocarbyl groups each of which
can contain from about 3 to about 18 carbon atoms and x can be in
the range of from about 2 to about 8, for example in the range of
from about 2 to about 5, and as a further example can be 3. The
hydrocarbyl groups can be of widely varying types such as alkyl,
cycloalkyl, alkenyl, aryl, or aralkyl. Tertiary alkyl polysulfides
such as di-tert-butyl trisulfide, and mixtures comprising
di-tert-butyl trisulfide (e.g., a mixture composed principally or
entirely of the tri, tetra-, and pentasulfides) can be used.
Examples of other useful dihydrocarbyl polysulfides include the
diamyl polysulfides, the dinonyl polysulfides, the didodecyl
polysulfides, and the dibenzyl polysulfides.
[0029] The sulfur-containing compound can be used in at least an
equimolar or greater amount per equivalent of phosphorus-containing
compound to yield a sulfur-containing, phosphorus-containing
compound. In an aspect, from about 1 to about 1.5 molar equivalents
of the sulfur-containing compound can be used.
[0030] The sulfur-containing compound can also be present in a
finished lubricant composition in an amount ranging from about 0.5
wt. % to about 10 wt. %, for example from about 2 to about 6 wt. %,
and as further example from about 5 wt. % relative to the total
weight of the finished lubricant composition.
[0031] As disclosed above, a nitrogen-containing compound can be
present in the disclosed composition. In an aspect, the
nitrogen-containing compound can be used to yield a
sulfur-containing, phosphorus-containing compound, and/or its
analogous salt. Moreover, as disclosed below, in another aspect,
the nitrogen-containing compound can be combined with an acid,
wherein at least one of the acid and the nitrogen-containing
compound is a friction modifier. Further, as disclosed below, in a
further aspect, the nitrogen-containing compound can be a
dispersant and can be optionally borated and/or phosphorylated.
[0032] The nitrogen-containing compound can be any
nitrogen-containing compound, such as an amide of the structure
R.sup.3CONR.sup.4R.sup.5 wherein R.sup.3, R.sup.4 and R.sup.5 can
be each independently hydrogen or a hydrocarbyl group containing
from about 1 to about 30 carbon atoms or an ethoxylated amide of
the structure ##STR2## wherein the sum of x and y can be from about
1 to about 50, for example from about 1 to about 20, and as a
further example from about 1 to about 10. In an aspect, when
R.sup.3, R.sup.4 and R5 are hydrocarbyl groups, they contain from
about 1 to about 18 carbon atoms and for example from about 1 to
about 6 carbon atoms.
[0033] When R.sup.3 is hydrogen and R.sup.4 and R.sup.5 are
hydrocarbyl groups, the nitrogen-containing compound is a
dihydrocarbyl formamide. Non-limiting examples of
dihydrocarbylformamides having utility herein can include:
dimethylformamide, diethylformamide, dipropylformamide,
methylethylformamide, dibutylformamide, methylbutylformamide,
ethylbutylformamide, dioleylformamide, distearylformamide,
didecylformamide, ditridecylformamide, decyltridecylformamide,
decyloleylformamide, and tridecyloleylformamide, etc.
[0034] When R.sup.3 is a hydrocarbyl group and R.sup.4 and R.sup.5
are both hydrogen, the nitrogen-containing compound is a primary
hydrocarbyl amide. Non-limiting examples of primary hydrocarbyl
amides can include acetamide, propionamide, butyramides,
valeramide, lauramide, myristamide and palmitamide. Some commercial
simple fatty acid amides are available from Armak Company: coco
fatty amide, octadecanamide, hydrogenated tallow fatty amide,
oleamide, and 13-docosenamide.
[0035] When R.sup.3 and R.sup.4 are both hydrocarbyl groups and
R.sup.5 is hydrogen, the nitrogen-containing compound is an
N-substituted amide. Non-limiting examples of N-substituted amides
can include N-methylacetamide, N-ethylacetamide,
N-methylvaleramide, N-propyllauramide, N-methyloleamide and
N-butylstearamide.
[0036] When R.sup.3, R.sup.4 and R.sup.5 are all hydrocarbyl
groups, the nitrogen-containing compound is an N,N-disubstituted
amide. Non-limiting examples of N,N-disubstituted amides can
include N,N-dimethylacetamide, N-methyl-N-ethylacetamide,
N,N-diethylpropionamide, N,N-dibutylvaleramide,
N,N-diethylstearamide, and N,N-dimethyloleamide.
[0037] Additional non-limiting examples of the nitrogen-containing
compound include N,N-bis(2-hydroxyethyl)dodecanamide,
N,N-bis(2-hydroxyethyl) coco fatty acid amide,
N,N-bis(2-hydroxyethyl)oleamide, N-2-hydroxyethylcocamide, and
N-2-hydroxyethylstearamide.
[0038] In an aspect, the sulfur-containing, phosphorus-containing
compound can be at least one of formulae (II) and (V): ##STR3##
[0039] wherein n is an integer from about 1 to about 5; and
[0040] wherein R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5,
R.sup.6, R.sup.10, and R.sup.11 can be independently selected from
the group consisting of hydrogen, cyano, and hydrocarbyl groups
comprising from about 1 to about 30 carbon atoms, for example from
about 1 to about 20 carbon atoms, and as a further example from
about 1 to about 10 carbon atoms.
[0041] In an aspect, in formula (II) R.sup.1 and R.sup.2 can be
methyl; and R.sup.3, R.sup.4, R.sup.5, and R.sup.6 can be hydrogen.
In another aspect, in formula (V), R.sup.1 and R.sup.2 can be
methyl; R.sup.3, R.sup.4, R.sup.5, and R.sup.6 can be hydrogen; and
R.sup.10 and R.sup.11 can be alkyl groups comprising from about 1
to about 6 carbon atoms.
[0042] The disclosed composition can comprise a salt of the
sulfur-containing, phosphorus containing compound. In an aspect,
the salt can be prepared by (a) providing a phosphorus-containing
compound, a sulfur-containing compound, and a nitrogen-containing
compound, such as an amide; and (b) providing the resultant
sulfur-containing, phosphorus-containing compound with an
additional nitrogen-containing compound, such as an amine to yield
the salt. In another aspect, the salt can be prepared by providing
a phosphorus-containing compound, a sulfur-containing compound, and
a nitrogen-containing compound, such as an amine.
[0043] The sulfurized neopentyl glycol phosphite and/or its salt
can have improved antiwear as compared to a non-sulfurized
neopentyl glycol phosphite.
[0044] The disclosed process can include the use of solvents. The
solvent can be any inert fluid substance in which at least one of
the reactants is soluble or the product is soluble. Non-limiting
examples include benzene, toluene, xylene, n-hexane, cyclohexane,
naphtha, diethyl ether carbitol, dibutyl ether dioxane,
chlorobenzene, nitrobenzene, carbon tetrachloride, chloroform, base
oil, such as gas-to liquid and polyalphaolefin, and process
oil.
[0045] In an aspect, the nitrogen-containing compound can help
neutralize any acids present in the disclosed composition. Any
nitrogen-containing compound can be used so long as it is
oil-soluble. Additional, non-limiting examples of the
nitrogen-containing compound can include an amide, an amine, and a
pyridine. In an aspect, the nitrogen-containing compound can be an
amine, which can be primary, secondary, or tertiary.
[0046] In an aspect, the hydrocarbyl amines can be primary
hydrocarbyl amines comprising from about 4 to about 30 carbon atoms
in the hydrocarbyl group, and for example from about 8 to about 20
carbon atoms in the hydrocarbyl group. The hydrocarbyl group can be
saturated or unsaturated. Representative examples of primary
saturated amines are those known as aliphatic primary fatty amines.
Typical fatty amines can include alkyl amines such as n-hexylamine,
n-octylamine, n-decylamine, n-dodecylamine, n-tetradecylamine,
n-pentadecylamine, n-hexadecylamine, n-octadecylamine (stearyl
amine), etc. These primary amines are available in both distilled
and technical grades. While the distilled grade can provide a purer
reaction product, amides and imides can form in reactions with the
amines of technical grade. Also suitable are mixed fatty
amines.
[0047] In an aspect, the amine salts of the disclosed compounds can
be those derived from tertiary-aliphatic primary amines having at
least about 4 carbon atoms in the alkyl group. For the most part,
they can be derived from alkyl amines having a total of less than
about 30 carbon atoms in the alkyl group.
[0048] Usually the tertiary aliphatic primary amines are monoamines
represented by the formula ##STR4## wherein R.sup.1, R.sup.2, and
R.sup.3 can be the same or different and can be a hydrocarbyl group
containing from about one to about 30 carbon atoms. Such amines are
illustrated by tertiary-butyl amine, tertiary-hexyl primary amine,
1-methyl-1-amino-cyclohexane, tertiary-octyl primary amine,
tertiary-decyl primary amine, tertiary-dodecyl primary amine,
tertiary-tetradecyl primary amine, tertiary-hexadecyl primary
amine, tertiary-octadecyl primary amine, tertiary-tetracosanyl
primary amine, and tertiary-octacosanyl primary amine.
[0049] Mixtures of amines can also be useful for the purposes of
this disclosure. Illustrative of amine mixtures of this type can be
a mixture of C.sub.8-C.sub.16 tertiary alkyl primary amines and a
similar mixture of C.sub.14-C.sub.24 tertiary alkyl primary amines.
The tertiary alkyl primary amines and methods for their preparation
are well known to those of ordinary skill in the art and,
therefore, further discussion is unnecessary. The tertiary alkyl
primary amine useful for the purposes of this disclosure and
methods for their preparation are described in U.S. Pat. No.
2,945,749, which is hereby incorporated by reference for its
teaching in this regard.
[0050] Primary amines in which the hydrocarbon chain comprises
olefinic unsaturation also can be quite useful. Thus, the R' and
R'' groups can contain at least one olefinic unsaturation depending
on the length of the chain, usually no more than one double bond
per 10 carbon atoms. Representative amines are dodecenylamine,
myristoleylamine, palmitoleylamine, oleylamine and
linoleylamine.
[0051] Secondary amines include dialkylamines having two of the
above alkyl groups including fatty secondary amines, and also mixed
dialkylamines where R' can be a fatty amine and R'' can be a lower
alkyl group (1-9 carbon atoms) such as methyl, ethyl, n-propyl,
i-propyl, butyl, etc., or R'' can be an alkyl group bearing other
non-reactive or polar substituents (CN, alkyl, carbalkoxy, amide,
ether, thioether, halo, sulfoxide, sulfone). The fatty polyamine
diamines can include mono- or dialkyl, symmetrical or asymmetrical
ethylene diamines, propane diamines (1,2, or 1,3), and polyamine
analogs of the above. Suitable fatty polyamines include
N-coco-1,3-diaminopropane, N-soyaalkyl trimethylenediamine,
N-tallow-1,3-diaminopropane, and N-oleyl-1,3-diaminopropane.
[0052] In an aspect, the nitrogen-containing compound can be
provided in an amount ranging from about 0.05 to about 2, and for
example from about 1 to about 1.5 molar equivalent per equivalent
of phosphorus-containing compound.
[0053] The sulfur-containing, phosphorus-containing compound and/or
its salt can be formed separately and then added to a lubricating
or functional fluid composition. Alternatively, the
sulfur-containing, phosphorus-containing compound and/or its salt
can be formed when the phosphorus-containing compound, such as the
disclosed phosphite, is blended, mixed and/or reacted with other
components to form the lubricating or functional fluid
composition.
[0054] The salt of a sulfur-containing, phosphorus-containing
compound can be oil-soluble, i.e., the hydrocarbyl chains of the
salt can be of sufficient length, such as at least six carbon
atoms, so that the resultant compound is soluble in a formulated
composition. The incorporation of hydrophobic groups can lead to an
increase in solubility in a non-polar media. Non-limiting examples
of a salt of a sulfur-containing, phosphorus-containing compound
include diisobutyl thiophosphoric acid C.sub.8-16 tertiary alkyl
primary amine salt, di-2-ethylhexyl-thiophosphoric acid C.sub.8-16
tertiary alkyl primary amine salt, and neopentyl glycol
thiophosphoric acid C.sub.8-16 tertiary alkyl primary amine salt.
In an aspect, there is contemplated a salt of a dithiophosphoric
acid. In another aspect, the salt of the sulfur-containing,
phosphorus-containing compound can be at least one of a compound of
formulae (III) and (VI) shown below. ##STR5##
[0055] wherein n is an integer from 1 to 5; and
[0056] wherein R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5,
R.sup.6, R.sup.7, R.sup.8, R.sup.9, R.sup.10, and R.sup.11 are
independently selected from the group consisting of hydrogen,
cyano, and hydrocarbyl groups comprising from about 1 to about 30
carbon atoms, for example from about 1 to about 20 carbon atoms,
and as a further example from about 1 to about 10 carbon atoms. In
an aspect, in formula (VI) R.sup.1 and R.sup.2 can be methyl;
R.sup.3, R.sup.4, R.sup.5, R.sup.6, R.sup.7, and R.sup.8 can be
hydrogen; R.sup.9 can be a tertiary C.sub.12-14 alkyl group; and
R.sup.10 and R.sup.11 can be alkyl groups comprising from about 1
to about 6 carbon atoms. In an aspect, in formula (III), R.sup.3,
R.sup.4, R.sup.5, R.sup.6, R.sup.7, and R.sup.8 can be hydrogen;
R.sup.1 and R.sup.2 can be methyl; and R.sup.9 can be a tertiary
C.sub.12-14 alkyl group.
[0057] In an aspect, a salt of the sulfur-containing,
phosphorus-containing compound can be present in a lubricant
composition in any amount necessary to provide at least one of
reduced high frequency reciprocating rig performance, temperature
reduction in a simulated use axle efficiency test, and reduced
temperature in a simulated trailer towing test. For example, the
salt can be present in an amount ranging from about 0.1 to about 10
wt. %, for example from about 0.3 to about 8 wt. %, and as a
further example from about 0.3 to 6 wt. % relative to the total
weight of the lubricant composition.
[0058] The disclosed composition can further comprise an acid, and
a nitrogen-containing compound, wherein at least one of the acid
and the nitrogen-containing compound is a friction modifier. A
friction modifier is understood to mean a compound comprising from
about 10 to about 24 carbon atoms. In an aspect, the composition
can comprise a friction modifying acid and a nitrogen-containing
compound. In another aspect, the composition can comprise an acid
and a friction modifying nitrogen-containing compound. In a further
aspect, the composition can comprise a friction modifying acid and
a friction modifying nitrogen-containing compound.
[0059] The acid for use in the disclosed composition can be at
least one of an organic carboxylic acid, organic phosphorus acid,
organic sulfonic acid, inorganic phosphorus acid, and a mixture
thereof. In an aspect, the organic carboxylic acid can be linear or
branched, saturated or unsaturated, and can comprise from about 5
to about 40, and for example from about 10 to about 24 carbon
atoms. The organic carboxylic acid can be aliphatic. Non-limiting
examples of the carboxylic acid include octenoic acid, isostearic
acid, steric acid, and a mixture thereof.
[0060] In an aspect, the acid can be an organic phosphorus acid,
such as those disclosed above, dialkyl phosphorus acid, monoalkyl
phosphorus acid, dialkyl dithiophosphorus acid, monoalkyl
dithiophosphorus acid, dialkyl thiophosphorus acid, monoalkyl
thiophosphorus acid, and a mixture thereof. Non-limiting examples
of the phosphorus acid can include amyl acid phosphate,
2-ethylhexyl acid phosphate, dialkyl dithiophosphorus acid, and a
mixture thereof.
[0061] The acid can be the same or different from the
phosphorus-containing compound disclosed above. Moreover, the
nitrogen-containing compound present in the disclosed composition
can be the same or different from the nitrogen-containing compound
disclosed above, which can be used to make either the
sulfur-containing, phosphorus-containing compound, and/or its
analogous salt.
[0062] In an aspect, the acid can be at least one of 2-ethylhexyl
acid phosphate and amyl acid phosphate, and the nitrogen-containing
compound can be an oleyl amine.
[0063] The lubricant composition disclosed herein can comprise two
different nitrogen-containing compounds. In an aspect, the compound
can comprise a linear amine, such as oleyl amine, and a branched
amine, such as a mixture of C.sub.11-14 tertiary alkyl primary
amine. The amines can each be present in the lubricating
composition in an amount so that the total weight percent of the
amines ranges from about 0.1 to about 5, as a further example from
about 0.3 to about 2, and as a further example from about 0.4 to
about 0.9 wt. %.
[0064] Base oils suitable for use in formulating compositions
according to the invention can include any of the synthetic oils.
In an aspect, the base oil can comprise a polyalphaolefin as
disclosed in U.S. patent application No. 2005/0059563, published
Mar. 17, 2005. In another aspect, the base oil can comprise a base
oil composition including a low viscosity basestock, an ester, and
a viscosity index improver. The base oil composition can have a
viscosity index greater than or equal to 200, for example greater
than or equal to 220, as a further example greater than or equal to
240, as a further example greater than or equal to 260, and as a
further example greater than or equal to 280. Further, oils derived
from a gas-to-liquid process are also suitable.
[0065] The base oil can be present in a major amount, wherein
"major amount" is understood to mean greater than or equal to 30%,
for example from about 40 to about 80 percent by weight of the
lubricant composition.
[0066] Non-limiting examples of synthetic basestock include
hydrocarbon oils such as polymerized and interpolymerized olefins
(e.g., polybutylenes, polypropylenes, propylene isobutylene
copolymers, etc.); polyalphaolefins; alkylbenzenes (e.g.,
dodecylbenzenes, tetradecylbenzenes, di-nonylbenzenes,
di-(2-ethylhexyl)benzenes, etc.); polyphenyls (e.g., biphenyls,
terphenyl, alkylated polyphenyls, etc.); alkylated diphenyl ethers
and alkylated diphenyl sulfides and the derivatives, analogs and
homologs thereof and the like.
[0067] Alkylene oxide polymers and interpolymers and derivatives
thereof where the terminal hydroxyl groups have been modified by
esterification, etherification, etc., constitute another class of
known synthetic basestock that can be used. Such basestock can be
exemplified by the oils prepared through polymerization of ethylene
oxide or propylene oxide, the alkyl and aryl ethers of these
polyoxyalkylene polymers (e.g., methyl-polyisopropylene glycol
ether having an average molecular weight of about 1000, diphenyl
ether of polyethylene glycol having a molecular weight of about
500-1000, diethyl ether of polypropylene glycol having a molecular
weight of about 1000-1500, etc.) or mono- and polycarboxylic esters
thereof, for example, the acetic acid esters, mixed C.sub.3-8 fatty
acid esters, or the C.sub.13 Oxo acid diester of tetraethylene
glycol.
[0068] Hence, the base oil used which can be used to make the
compositions as described herein can be selected from any of the
base oils in Groups IV and V as specified in the American Petroleum
Institute (API) Base Oil Interchangeability Guidelines. Such base
oil groups are as follows:
[0069] Group IV are polyalphaolefins (PAO); and Group V include all
other basestocks not included in Group I, II, III or IV. The
polyalphaolefins used as basestock typically have viscosities in
the range of 2 to 100 cSt at 100.degree. C., for example 4 to 8 cSt
at 100.degree. C.
[0070] Basestocks suitable for use herein can be made using a
variety of different processes including but not limited to
distillation, solvent refining, hydrogen processing,
oligomerisation, esterification, and re-refining.
[0071] The base oil can be an oil derived from Fischer-Tropsch
synthesized hydrocarbons. Fischer-Tropsch synthesized hydrocarbons
can be made from synthesis gas containing H.sub.2 and CO using a
Fischer-Tropsch catalyst. Such hydrocarbons typically require
further processing in order to be useful as the base oil. For
example, the hydrocarbons can be hydroisomerized using processes
disclosed in U.S. Pat. No. 6,103,099 or 6,180,575; hydrocracked and
hydroisomerized using processes disclosed in U.S. Pat. No.
4,943,672 or 6,096,940; dewaxed using processes disclosed in U.S.
Pat. No. 5,882,505; or hydroisomerized and dewaxed using processes
disclosed in U.S. Pat. Nos. 6,013,171; 6,080,301; or 6,165,949.
[0072] Unrefined, refined and rerefined oils, either mineral or
synthetic (as well as mixtures of two or more of any of these) of
the type disclosed hereinabove can be used in the base oils.
Unrefined oils are those obtained directly from a mineral or
synthetic source without further purification treatment. For
example, a shale oil obtained directly from retorting operations, a
petroleum oil obtained directly from primary distillation or ester
oil obtained directly from an esterification process and used
without further treatment would be an unrefined oil. Refined oils
are similar to the unrefined oils except they have been further
treated in one or more purification steps to improve one or more
properties. Many such purification techniques are known to those
skilled in the art such as solvent extraction, secondary
distillation, acid or base extraction, filtration, percolation,
etc. Rerefined oils are obtained by processes similar to those used
to obtain refined oils applied to refined oils which have been
already used in service. Such rerefined oils are also known as
reclaimed or reprocessed oils and often are additionally processed
by techniques directed to removal of spent additives, contaminants,
and oil breakdown products.
[0073] Esters suitable for use herein include the esters of
monobasic acids with either monoalkanols or polyols. Suitable ester
includes those having the formula RCO.sub.2R.sup.1, wherein R
comprises an alkyl radical having from about 4 to about 10 carbon
atoms and R.sup.1 comprises an alkyl radical having from about 4 to
about 15, for example from about 4 to about 12, and as a further
example from about 4 to about 9 carbon atoms. Specific examples of
these types of esters include isononyl 2-ethylhexanoate, isooctyl
2-ethylhexanoate, 2-ethylhexyl 2-ethylhexanoate, isononyl
heptanoate, isononyl isopentanoate, isooctyl heptanoate, isononyl
pentanoate, isooctyl isopentanoate, isooctyl pentanoate, octyl
pentanoate, nonyl pentanoate, decyl pentanoate, octyl heptanoate,
nonyl heptanoate, decyl heptanoate. Other suitable esters comprise
mixtures of esters formed by the reaction of isononyl alcohol and a
mixture of acids having from about 8 carbon atoms to about 10
carbon atoms or a mixed ester formed by the reaction of
2-ethylhexyl alcohol and a mixture of acids having from about 8
carbon atoms to about 10 carbon atoms.
[0074] Also suitable are esters of dicarboxylic acids (e.g.,
phthalic acid, succinic acid, alkyl succinic acids, alkenyl
succinic acids, maleic acid, azelaic acid, suberic acid, sebacic
acid, fumaric acid, adipic acid, linoleic acid dimer, malonic acid,
alkyl malonic acids, alkenyl malonic acids, etc.) with a variety of
alcohols (e.g., butyl alcohol, hexyl alcohol, dodecyl alcohol,
2-ethylhexyl alcohol, ethylene glycol, diethylene glycol monoether,
propylene glycol, etc.) Specific examples of these esters include
dibutyl adipate, di(2-ethylhexyl)sebacate, di-n-hexyl fumarate,
dioctyl sebacate, diisooctyl azelate, diisodecyl azelate, dioctyl
phthalate, didecyl phthalate, dieicosyl sebacate, the 2-ethylhexyl
diester of linoleic acid dimer, the complex ester formed by
reacting one mole of sebacic acid with two moles of tetraethylene
glycol and two moles of 2-ethylhexanoic acid and the like.
[0075] Also suitable for the present disclosure are esters, such as
those obtained by reacting one or more polyhydric alcohols, for
example the hindered polyols such as the neopentyl polyols, e.g.,
neopentyl glycol, with monocarboxylic acids containing from 5 to 10
carbons. The acids can be linear or branched aliphatic acids, or
mixtures thereof. Other suitable esters can be obtained by reaction
of the above described acids and di- or tri-ethylene glycol or di-
or tri-propylene glycol alcohols capped with linear hydrocarbons
having 1 to 4 carbons, for example 3 to 4 carbons.
[0076] The ester can have a viscosity of less than or equal to
about 2 cSt at 100.degree. C., for example less than or equal to
1.5, and as a further example greater than or equal to about 1 cSt
at 100.degree. C.
[0077] A suitable viscosity index improver can be a high viscosity
polyalphaolefin. High viscosity PAOs, such as known PAO materials,
which typically comprise relatively low molecular weight
hydrogenated polymers or oligomers of alphaolefins. The
alphaolefins include, but are not limited to, C.sub.2 to about
C.sub.32 alphaolefins with the C.sub.8 to about C.sub.16
alphaolefins, such as 1-octene, 1-decene, 1-dodecene and the like
being exemplary. Suitable polyalphaolefins include polypropenes,
polyisobutenes, poly-1-butenes, poly-1-hexenes poly-1-octene,
poly-1-decene, and poly-1-dodecene, although the dimers of higher
olefins in the range of C.sub.14 to C.sub.18 provide low viscosity
basestocks. Included are homopolymers, interpolymers and
mixtures.
[0078] Suitable high viscosity PAOs may be conveniently made by the
polymerization of an alphaolefin in the presence of a
polymerization catalyst such as the Friedel-Crafts catalysts
including, for example, aluminum trichloride, boron trifluoride or
complexes of boron trifluoride with water, alcohols such as
ethanol, propanol or butanol, carboxylic acids or esters such as
ethyl acetate or ethyl propionate. For example, the methods
disclosed by U.S. Pat. No. 4,149,178 or 3,382,291, the disclosures
of which are hereby incorporated by reference, may be conveniently
used herein. Other descriptions of PAO synthesis are found in the
following U.S. Pat. No. 3,742,082 (Brennan); U.S. Pat. No.
3,769,363 (Brennan); U.S. Pat. No. 3,876,720 (Heilman); U.S. Pat.
No. 4,239,930 (Allphin); U.S. Pat. No. 4,367,352 (Watts); U.S. Pat.
No. 4,413,156 (Watts); U.S. Pat. No. 4,434,408 (Larkin); U.S. Pat.
No. 4,910,355 (Shubkin); U.S. Pat. No. 4,956,122 (Watts); and U.S.
Pat. No. 5,068,487 (Theriot), the disclosures of which are hereby
incorporated by reference.
[0079] Suitable high viscosity PAOs may be prepared by the action
of a reduced chromium catalyst with the alphaolefin, such PAOs are
described in U.S. Pat. No. 4,827,073 (Wu); U.S. Pat. No. 4,827,064
(Wu); U.S. Pat. No. 4,967,032 (Ho et al.); U.S. Pat. No. 4,926,004
(Pelrine et al.); and, U.S. Pat. No. 4,914,254 (Pelrine), the
disclosures of which are hereby incorporated by reference. The
dimers of the C.sub.14 to C.sub.18 olefins are described in U.S.
Pat. No. 4,218,330, the disclosure of which is hereby incorporated
by reference.
[0080] Suitable high viscosity PAOs may include PAOs having a
viscosity of greater than or equal to about 40 cSt at 100.degree.
C. and less than or equal to about 1,000 cSt at 100.degree. C. As
another example, greater than or equal to 100 cSt at 100.degree. C.
and less than or equal to about 300 cSt at 100.degree. C. As a
further example, greater than or equal to about 100 cSt at
100.degree. C. and less than or equal to about 200 cSt at
100.degree. C. As an even further example, greater than or equal to
about 150 cSt at 100.degree. C. and less than or equal to about 200
cSt.
[0081] Group IV basestocks, i.e. polyalphaolefins (PAO) include
hydrogenated oligomers of an alpha-olefin, the most important
methods of oligomerisation being free radical processes, Ziegler
catalysis, and cationic, Friedel-Crafts catalysis.
[0082] The composition can optionally further comprise a
boron-containing compound. The boron-containing compound can be
present in the composition in an amount ranging from about 5 ppm to
about 500 ppm, for example from about 11 ppm to about 100 ppm. The
amount of boron compound employed ranges from about 0.001 mole to
about 1 mole per mole of basic nitrogen and/or hydroxyl in the
mixture.
[0083] The boron-containing compound can be an inorganic or an
organic compound. The inorganic compounds include boron acids,
anhydrides, oxides and halides. The organic boron compounds include
the boron amides and esters. Also included are borated acylated
amines and borated dispersants, borated epoxides and the borated
fatty acid esters of glycerol.
[0084] The boron-containing compounds that are useful include boron
oxide, boron oxide hydrate, boron trioxide, boron trifluoride,
boron tribromide, boron trichloride, boron acids such as boronic
acid (i.e., alkyl-B(OH).sub.2 or aryl-B(OH).sub.2), boric acid
(i.e., H.sub.3BO.sub.3), tetraboric acid (i.e.,
H.sub.2B.sub.4O.sub.7), metaboric acid (i.e., HBO.sub.2), boron
anhydrides, boron amides and various esters of such boron acids.
Complexes of boron trihalide with ethers, organic acids, inorganic
acids, or hydrocarbons can be used. Examples of such complexes
include boron-trifluoride-triethyl ester, boron
trifluoride-phosphoric acid, boron trichloride-chloroacetic acid,
boron tribromide-dioxane, and boron trifluoridemethyl ethyl
ether.
[0085] Specific examples of boronic acids include methyl boronic
acid, phenyl-boronic acid, cyclohexyl boronic acid, p-heptylphenyl
boronic acid and dodecyl boronic acid. Suitable boron-containing
compounds include, for example, boron oxides such as boron oxide,
boron oxide hydrate, and boron trioxide.
[0086] The boron acid esters include mono-, di-, and tri-organic
esters of boric acid with alcohols or phenols such as, e.g.,
methanol, ethanol, isopropanol, butanol, pentanol, hexanol,
cyclohexanol, cyclopentanol, 1-octanol, 2-octanol, dodecanol,
behenyl alcohol, oleyl alcohol, stearyl alcohol, benzyl alcohol,
2-butyl cyclohexanol, ethylene glycol, propylene glycol,
trimethylene glycol, 1,3-butanediol, 2,4-hexanediol,
1,2-cyclohexanediol, 1,3-octanediol, glycerol, pentaerythritol
diethylene glycol, carbitol, Cellosolve, triethylene glycol,
tripropylene glycol, phenol, naphthol, p-butylphenol,
o,p-diheptylphenol, n-cyclohexylphenol,
2,2-bis-(p-hydroxyphenyl)-propane, polyisobutene (molecular weight
of 1500)-substituted phenol, ethylene chlorohydrin, o-chlorophenol,
m-nitrophenol, 6-bromooctanol, and 7-keto-decanol. Lower alcohols,
1,2-glycols, and 1-3-glycols, i.e., those having less than about 8
carbon atoms can be useful for preparing the boric acid esters.
[0087] In an aspect, the boron-containing compound can be a borated
nitrogen-containing compound, including, but not limited to the
nitrogen-containing compounds disclosed above. In an aspect, a
borated nitrogen-containing compound can be a dispersant.
[0088] In another aspect, the boron-containing compound can be a
borated phosphorus-containing compound, including, but not limited
to the phosphorus-containing compounds disclosed above. In an
aspect, a borated phosphorus-containing compound can be a
dispersant. The amount of phosphorus compound employed ranges from
about 0.001 mole to 1 mole per mole of basic nitrogen and free
hydroxyl in the reaction mixture up one half of which may be
contributed by an auxiliary nitrogen compound.
[0089] The phosphorus-containing dispersants can comprise 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.
[0090] 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. The alkenyl succinimides can be formed by conventional
methods such as by heating an alkenyl succinic anhydride, acid,
acid-ester, acid halide, or lower alkyl ester with a polyamine
containing at least one primary amino group. The alkenyl succinic
anhydride can be made readily by heating a mixture of olefin and
maleic anhydride to, for example, about 180-220.degree. C. The
olefin can be a polymer or copolymer of a lower mono-olefin such as
ethylene, propylene, 1-butene, isobutene and the like and mixtures
thereof. An exemplary source of alkenyl group is from polyisobutene
having a gel permeation chromatography (GPC) number average
molecular weight of up to 10,000 or higher, for example in the
range of about 500 to about 2,500, and as a further example in the
range of about 800 to about 1,500. In an aspect, the
polyisobutylene can have a molecular weight ranging from about 700
to about 5000. The polyisobutylene succinic anhydride to amine
ratio can range from about 1.4 to about 3, and as a further example
from about 1.8 to about 2.2.
[0091] In an aspect, a capping agent can be added. For example, an
additional amount of maleic anhydride can be added to function as a
capping agent for the basic nitrogen thereby reducing the basic
nitrogen to a non-basic species.
[0092] As used herein the term "succinimide" is meant to encompass
the completed reaction product from reaction between one or more
polyamine reactants and a hydrocarbon-substituted succinic acid or
anhydride (or like succinic acylating agent), and is intended to
encompass compounds wherein the product may have amide, amidine,
and/or salt linkages in addition to the imide linkage of the type
that results from the reaction of a primary amino group and an
anhydride moiety.
[0093] The dispersants can be phosphorylated by procedures
described, for example, 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.
[0094] Methods for 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.
[0095] Procedures for phosphorylating and borating ashless
dispersants such as those referred to above are set forth in U.S.
Pat. Nos. 4,857,214 and 5,198,133.
[0096] The lubricant composition can comprise two different
nitrogen-containing dispersants, such as a succinimide dispersant,
and a borated succinimide dispersant.
[0097] Optionally, other components can be present in the lubricant
composition or additive composition. Non-limiting examples of other
components include diluents, defoamers, demulsifiers, copper
corrosion inhibitors, antioxidants, extreme pressure agent,
antiwear agent, seal swell agent, pour point depressants, rust
inhibitors and friction modifiers.
[0098] Also disclosed herein is a method of lubricating a machine,
such as an automotive gear, a stationary gearbox (including an
industrial gear), and/or an axle with the disclosed lubricating
composition. In a further aspect, there is disclosed a method of
improving at least one of antiwear protection and fuel efficiency
in a machine, such as an automotive gear, a stationary gearbox
(including an industrial gear), and/or an axle comprising placing
the disclosed lubricating composition in the machine, such as an
automotive gear, a stationary gearbox (including an industrial
gear), and/or an axle. There is also disclosed a method of passing
ASTM D6121 with lubricated and nonlubricated gear sets, for example
at least about 325.degree. F. for at least about 16 hours, and/or
ASTM D5704 and/or a method of maintaining GL-5 and/or SAE J2360
performance comprising lubricating a gear and/or axle with the
disclosed lubricating composition.
EXAMPLES
[0099] A lubricant composition was formulated as follows as shown
in Table 1: TABLE-US-00001 TABLE 1 Component Weight Percent A
Compound of Formula III 0.20-1 Base Oil with an Ester 40-90 High
Viscosity PAO VII 10-40 EP/AW Agent (s) 4-6 Pour Point Depressant
(s) 2.5-5 Dispersant (s) 0.5-4 Amine Rust Inhibitor (s) 1-2
Anti-Foam Agent (s) 0.1-2 Demulsifier (s) 0-0.5 Corrosion Inhibitor
(s) 0.1-1 Anti-oxidant (s) 0-5
[0100] A comparative lubricant composition was formulated as
follows as shown in Table 2:
[0101] Table 2 TABLE-US-00002 TABLE 2 Component Weight Percent A
compound of Formula III 0.20-1 Base Oil 40-90 Ethylene, Propylene
Olefin Copolymer VII 0-20 Seal Swell Agent (s) 0-10 EP/AW Agent (s)
4-6 Pour Point Depressant (s) 2.5-5 Dispersant (s) 0.5-4 Amine Rust
Inhibitor (s) 1-2 Anti-Foam Agent (s) 0.1-2 Demulsifier (s) 0-0.5
Corrosion Inhibitor (s) 0.1-1
[0102] The lubricant composition from Table 1 and the comparative
lubricant composition from Table 2 were subjected to the Corporate
Average Fuel Economy ("CAFE") test. This test measures the
efficiency of an axle, calculated as (total output torque X output
speed)/(input torque X input speed), at various load/speed stages
and is compared to a baseline fluid. A more efficient axle (i.e.,
greater test result value) translates into better overall fuel
economy for the vehicle. Results of the axle efficiency test are
indicative of the CAFE test. The conditions for the various load
stages are shown in Table 3. Stages A through E represents city
driving cycle whereas Stage F represents the highway driving cycle.
The baseline fluid was a full-synthetic SAE 75W-90 axle lubricant
(GM Part #9986115) for General Motors light duty vehicles.
TABLE-US-00003 TABLE 3 Pinion Pinion Pinion Power, Torque lb- Stage
Speed, rpm Torque, N-m kW ft Power, hp Warm-up 1500 67.0 10.5 49.4
14.1 A 750 13.6 1.1 10.0 1.4 B 1250 13.6 1.8 10.0 2.4 C 1000 33.9
3.5 25.0 4.8 D 1580 33.9 5.6 25.0 7.5 E 1000 54.2 5.7 40.0 7.6 F
2560 61.0 16.4 45.0 21.9
[0103] The results for the axle efficiency test are shown in Table
4. The lubricant compositions from Table 1 and Table 2 provided
better axle efficiency then the baseline fluid. The lubricant
composition from Table 1 gives the best overall results from the
axle efficiency test. TABLE-US-00004 TABLE 4 Average Axle
Efficiency at Different Load/Speed Stage Gear Oil Stage A Stage B
Stage C Stage D Stage E Stage F Table 1 comp. 86.13 84.50 93.24
93.06 95.09 95.41 Table 2 comp. 85.31 83.72 92.78 92.78 94.86 95.23
Baseline Fluid 82.16 80.45 91.33 91.63 94.02 94.89
[0104] For the purposes of this specification and appended claims,
unless otherwise indicated, all numbers expressing quantities,
percentages or proportions, and other numerical values 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 following
specification and attached claims are approximations that can vary
depending upon the desired properties sought to be obtained by the
present disclosure. 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.
[0105] It is noted that, as used in this specification and the
appended claims, the singular forms "a," "an," and "the," include
plural referents unless expressly and unequivocally limited to one
referent. Thus, for example, reference to "an antioxidant" includes
two or more different antioxidants. As used herein, the term
"include" and its grammatical variants are intended to be
non-limiting, such that recitation of items in a list is not to the
exclusion of other like items that can be substituted or added to
the listed items.
[0106] While particular embodiments have been described,
alternatives, modifications, variations, improvements, and
substantial equivalents that are or can be presently unforeseen can
arise to applicants or others skilled in the art. Accordingly, the
appended claims as filed and as they can be amended are intended to
embrace all such alternatives, modifications variations,
improvements, and substantial equivalents.
* * * * *