Note: Descriptions are shown in the official language in which they were submitted.
CA 02496921 2012-10-26
Synthetic Lubricant Additive
Disclosure
BACKGROUND OF THE INVENTION:
Over the years a host of terms has arisen to identify additives and briefly
denote the intended use
and limited function. Thus the trade recognizes improvements when the
synthetic lubricant
additive is used such as an improved anti-oxidant (oxidation inhibitor),
corrosion inhibitor,
extreme pressure agent, anti-foaming agent, anti-wear agency, V.I. improver,
pour point
depressant, improved detergency and dispersant, anti-squawk agent in automatic
transmissions
and anti chatter agent when added to automatic transmission. The synthetic
lubricant additive
has beneficial results when used as directed in gasoline and diesel engines,
gear boxes, automatic
transmission, limited slip differential, steam and gas turbines, railroad and
marine diesel engines,
stationary piston engines, gasoline, diesel or steam, 2-cycle air-cooled and
water cooled engines,
hydraulic pumps and rams, cutting oils and industrial and marine reduction
gear units. The
synthetic lubricant additives contributes to many engineering advances, which
contribute to
quieter operation (reduce decibels), improved horsepower and torque, reduced
wear, friction
(energy consumption) heat and harmful emissions.
This invention relates to the use of a synthetic lubricant additive
(invention) that can be added at
various ratios to enhance most forms of lubricants from the simplest of
lubrication oils such as
automotive, truck, marine, locomotive, automatic and standard transmissions,
differentials
including limited slip, power steering fluid, hydraulic fluids, metal cutting,
drilling, tapping and
boring to the more advanced turbine engines such as steam, jet and gas. Reduce
friction, heat
emissions and wear take place when a motor oil composition consisting of 85 to
95 volume
percent solvent refined mineral based motor oil and 15 to 10 the volume
percent synthetic
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lubricant additive or a motor oil composition consisting of 85 to 90 volume
percent synthetic
motor oil and 15 to 10 volume percent synthetic lubricant additive.
Current and previous extreme pressure additives commonly used to enhance
certain
characteristics of the lubricant include zinc-phosphorus compounds, fatty
acids, active sulfur
compounds, lead, moly-disulfide, polymers, sulfur-phosphorus compound,
carboxylic
acid/esters, oxyphosphite compounds, polyisobutlyene, copolymers,
polymethacrylate, styrene
esters, chlorine concentrates and phosphorus. Further lubricants have relied
upon additives to
improve lubricity, improve shelf life and reduce oxidation, principle cause of
additive component
breakdown, rendering the oil having little value other than a coolant. Typical
patents relating to
"lubricants" and their "additives" includes Canadian Patent 1,185,962, United
States Patents
6,756,348, 6,001,782, 5,652,201, 4,081,390, 4,788,361, 6,232,279, 6,846,782,
6,503,872,
3,115,463 and 4,652,385.
The invention incorporates the use of the most advanced synthetic alpha-
olefins (understood in
the art to refer to polymerized alpha-olefins or PA0s), hydroisomerized high
viscosity index
hydro-treated, severe hydro-cracked (viscosity grade ISO 32) base oils and new
synthetic
sulfonates and liquefied polytetrafluoroethylene, comprising a stable aqueous
dispersion of
polytetrafluoroethylene particles in oil/solvent components and when combined
in a specific
sequence forms a finished product that exceeds any new product on the market
today. Each
component is required to be blended in a specific sequence to maintain
stability and it
effectiveness as a multi-purpose synthetic lubricant additive. The results of
the accurate
blending procedure and temperature control allows for the finished product to
effectively blend
with synthetic, chemical, vegetable and solvent extracted mineral based
lubricants. With
reference to the aspect of the invention, our invention incorporates similar
characteristics as cited
in United States Patent, 5,972,853 dated October 26, 1999, Boffa et al
references within the
invention through Claims 1,4,5,9 and 12; "a lubricating oil composition
comprising of poly-
alpha-olefins". Additional typical patents relating to the terms alpha-
olefins, poly-alpha-olefins
and or oligomers of alpha-olefins in referencing the term "synthetic
lubricant" include United
States Patents 5,364,994, 5,631,211, 5,681,797, 4,218,330, 4,956,122,
5,136,118, and 5,202,040.
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Hydroisomerized hydro-treated base oil is referenced within this typical
patent relating to
hydroisomerized base oils include United States Patent 6,288,296, September
11, 2001, Miller et
al. And liquefied polytetrafluoroethylene components and when combined in a
specific
sequence forms a finished product that exceeds any product on the market
today. Each
component is required to be blended in a specific sequence to maintain
stability and its
effectiveness as a multi-purpose synthetic lubricant additive. The results of
the accurate
blending procedure and temperature control allows for the finished product to
effectively blend
with synthetic, chemical, vegetable and solvent extracted mineral based
lubricants.
As previously indicated, the blend of components when blended in a very
specific sequence
under specific conditions, will result in one of the finest forms of synthetic
lubricant additive that
can be effectively used with any form of lubricating products while not
limited to just liquids but
can be used in semi-liquids, pastes and solids to substantially enhance
lubrication, reducing
energy consumption, wear on moving or sliding components while substantially
reducing both
heat and wear in both boundary and hydrodynamic lubrication situations. The
blending is via a
combination of accurately controlled shearing and homogenization of the
components resulting
in a long-term stable blend. In Addition, typical patents relating to
controlled shearing and
homogenization include United States Patents 5,863,301, 5,511,877, 4,886,368,
4,793,713 and
US R.F.30,281. Once blended in a specific sequence, simple purification or
physical separation,
such as distillation or freezing, does not constitute synthesis.
The finished product is a combination of:
Poly-alpha-olefins;
Hydroisomerized high viscosity index hydro-treated, severe hydro-cracked
(viscosity grade ISO
32) base oil;
Synthetic sulfonates;
Vacuum distilled non-aromatic solvents (-0.5% aromatic). Typical patents
relating to non-
aromatic solvents include United States Patent 6,391,833;
Liquefied polytetrafluoroethylene.
Synthetic lubricants have been successfully used for some time as a jet engine
lubricant,
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lubricants for extreme cold (arctic) conditions in a limited number of motor
oils and fire resistant
hydraulic fluids. Despite their higher cost, they do offer advantages over
distilled mineral based
petroleum lubricants to the consumer such as; reduced oil consumption,
extended oil life,
improved cold weather starting and some reduction in fuel consumption.
Vegetable based
synthetic lubricants such as corn; castor bean and jahba bean oil were used
primarily as machine
oils with very limited lubricity advantages. Most synthetic oils on the market
today lack in
ability to resist meta-to-metal wear under extreme pressure situations and
allow metal-to-metal
contact or galling under such conditions.
Component Structure:
It is important to maintain a blend of components that fall within the
following percentages:
a) Alpha-olefins: 20-60 volume percent. Preferable 55 volume percent;
b) Hydroisomerized high viscosity index hydro-treated severe hydro-treated
(viscosity grade ISO
32) base oil between 20-55 volume percent. Preferable 21 volume percent;
c) Synthetic sulfonates 6477-C: 300TBN; 0.5-10 volume percent. Preferred 2
volume percent;
d) Vacuum distilled non-aromatic solvent (-0.5% Aromatic) 10-40 volume
percent. Preferred
21.55 volume percent;
e) Liquefied polytetrafluoroethylene .001-10% volume percent. Preferable 0.45
volume percent.
Stabilized liquefied polytetrafluroroethylene must be used to avoid
agglomeration.
Sequence of Blending Components:
It is necessary to blend the components in a specific manner to ensure optimum
shelf life,
freedom of separation and the most optimum advantage in the application of the
product as an
extreme pressure lubricant additive. The flow of product must blend for a
minimum of six (6)
hours through a series of homogenizers and sheering pumps. The flow of the
various
components will follow a sequence which allows the process whereas the
chemical conversion or
transformation of one very complex mixture of the molecular structure to
another complex
mixture of molecules. The blending process allows this complex change to take
place. It is
recommended that the mixture should process at a minimum of approximately 140
degrees
Fahrenheit or 60 degrees Celsius yet should not exceed 170 degrees Fahrenheit
or 77 degrees
Celsius while in the processing tanks. The time and temperature sequence
ensure that the
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molecular change takes place systematically without adverse modification of
the viscosity or
color. The minimum temperature grid will ensure maximum expansion of the
molecules prior to
sheering of the blend of components. During this process, solvent must be
injected into the
blend to eliminate air entrapment.
Blending Equipment:
The (process) sequence involves a series of blending and holding tanks such as
cited by United
States Patent, 4,997,759, dated March 05, 1991 where as Cibulskus et al
references within the
invention; "fermentation is usually carried out in stainless steel equipment
i.e. mixing and
blending tanks", where the product can be pumped through control valves to
maintain consistent
flow and pressure. Typical patents relating to blending and holding tanks
include United States
Patents 3,948,998, 5,804,676, 6,464,385. The components will be initially
blended via a high
frequency homogenization prior to processing at the sheering pumps. The effect
of the sheering
will not take place until the temperature meets or exceed the prescribed
minimum temperature.
Electrical banding of the tanks with temperature-controlled thermostats can be
used to speed the
procedure providing the mixture is under constant movement and strict monitor
of the liquid is
maintained. Size or volume of the tanks is not an important factor in the
blending process.
Universal Use of Invention:
In the many tests conducted, the product shows compatibility with conventional
motor oils, gear
oils, hydraulic fluids, (not brake fluids) along with the various blends of
synthetic lubricants.
Tests were conducted to establish stability of the additive when blended with
various host
lubricants, to analysis oxidation, viscosity change, resistance to extreme
pressure and effect on
power and torque output. The invention performed admirably and impressed all
the technical
folks involved in the many test completed.
The invention has proven to have far reaching value as the additive can be
used as a base
component to develop a host of valued effective products such as fuel
conditioners, gasoline,
diesel, kerosene, bunker-c along with soluble and non-soluble cutting oils,
form oil for concrete
application, corrosion inhibitors on electric terminals while at the same time
reducing electrical
resistance, at electrical terminal yet providing over 34 KV of dielectric
strength.
The invention has been tested on a variety of metal skins including jet
turbine blades and
fiberglass gel coatings to demonstrate a successful reduction of both
oxidation and wind and
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water resistance. Research has further shown that the overlying possibilities
for use of this
product, is far reaching and will have enormous benefits for consumers world-
wide from
reducing harmful emissions to overall reduced energy consumption.
Testing Procedures:
ASTM D testing of the product through the use of the Block-on-Ring Tester and
the Seta Shell
Four Ball Test machine can demonstrate the product for its effect as an
extreme pressure
additive. Each of these test machines incorporate a rotating steel surface
applied against a fixed
steel surface while submerged in a bath of lubricant. Pressure is applied and
noted as KGF
(kilogram force) applied to the mating surface while the rotate is set for a
fixed RPM (revolution
per minutes).
Further numerous qualified engine tests were completed including small
engines, 2-cycle, steam
turbines, jet turbines, gasoline and the CRC L-38. Once again these test have
demonstrated the
ability of the lubricant to perform on a universal application. Further to
demonstrate the
protective coating left on the treated metal. Test four cylinder engines have
been stripped of
valve covers, oil pans, oil-pumps/filters and with only the molecular thin
film of product on the
moving component and distributor parts have successfully run without either
oil or water coolant
both on the bench stand and while completely submerged under water. These test
have been run
repeatedly and recorded before of professional engineers. The engines have
been recorded to run
in excess of 25 minutes while completely submerged under water. The motors
were later
stripped and the components reviewed and re-weighed with little sign of wear.
Further tests
were conducted and recorded with a selection of test recorded below.
Test Results From Various Test Programs
Test #1
CRC L-38:
Testing has been completed on a CRC L-38 Engine Stand ASTM D 5119-90 (American
Standard Testing Methods)
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This rigorous test was conducted at the prestigious PerkinElmer Fluid Science
Automotive
Research Center (formerly EG&G Automotive Research) and is located at 5404
Bandera Road,
San Antonio, Texas.
PerkinElmer is one of the largest independent automotive testing organizations
in the world.
PerkinElmer has been providing testing to the automotive manufacturers and
petrochemical
industry since 1953. Their customer are world wide, and include Shell Oil,
Mobil Oil, Chevron,
Exxon, Castro!, Pennzoil, Petro-Canada etc., along with automotive OEM's,
heavy-duty engine
OEM, OEM suppliers and fuel and lubricant companies. PerkinElmer was
designated as the
United States Petroleum Task force to regulate and e control the quality and
acceptance of
regulated additives.
PerkinElmer was contracted to test the Synthetic Lubricant Additive
(invention) when combined
with an off the shelf motor oil. The reference oil used in the test was rated
as a licensed API
(American Petroleum Institute) spec motor oil, having some degree in the test.
The test is a
grueling 40 hours of severe running conditions plus 13 hours of run up and run
down time. The
engine is run under full load at a maximum RPM (3150 revolutions per minute)
extreme oil
temperatures of 290 degrees Fahrenheit (143.3 degrees Celsius) with fuel to
run abnormally rich
at 4.5 lbs per hour.
The test is designed to break the oil down, prematurely wearing away the
piston rod bearings
while have an adverse effect on the viscosity of the engine oil. The reduced
viscosity of the oil
can create excessive wear and increased amount of sludge and varnish.
Results From Test #1
The scoring is based on a reference oil test on a particular machine. The
reference oil must have
passed the test on one of the many test machines. As all the test engines are
not equal so each
engine is pre-tested for the reference comparison. The maximum allowable
bearing loss is 40mg
of copper for the piston rod bearing. Sludge and varnish deposits are scored
best out of 10
points, with 10 being perfect or a total of 60 points for each test.
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The test engine assigned was rated as the toughest engine to pass on. The
reference oil scored a
weight loss of 27.7-mg. of copper while the oil with the synthetic lubricant
additive (invention)
lost a total of 9.0 mg. The engineer overseeing the test commented that it was
one of if not the
best test he has seen in over 10 years of service with PerkinElmer. Further
the results of
viscosity, sludge and varnish were near perfect score. Out of a total of 60
possible points, the
test with the synthetic lubricant additive (invention) scored 58.30 and 58.80
respectively in
varnish and sludge.
Test #2
Oil Analysis:
Sample oil was drawn from the running engine every 10 hours and analyzed to
compare the used
oil with the oil prior to running.
New 10 Hours 20 Hours 30 Hours 40 Hours
Acid Number 2.00 2.90 3.50 3.80 4.00
Viscosity cSt 40C 102.90 101.90 101.60 101.50 102.10
Viscosity cSt 100C 14.13 13.89 13.82 13.79 13.84
Viscosity Increase
CSt 40C -0.97 -1.26 -1.36 -0.78
Viscosity Increase
CSt 100C -1.70 -2.19 -2.41 -2.05
Test #3
Primary Parameter of Engine Deviations:
Tests were conducted on the various engine components on the completion of the
test to evaluate
any changes the test oil with the added invention may have had on the engine.
Percentage Permitted Deviation Calculated Deviation
Engine Oil Gallery Temperature 2.5 % 0.0
Engine Coolant Outlet Temperature 2.5% 0.0
Engine Coolant Delta Temperature 2.5% 0.0
Fuel Flow 2.5% 0.0
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Crankcase Off Gas Std FT (3) h 2.5% 0.0
Oil Pressure, PSI 2.5% 0.0
Engine Speed, RPM 5.0% 0.0
AFR 5.0% 0.0
Exhaust, in Hg. 5.0 % 0.0
Test #4
Seta-Shell Four Ball Extreme Pressure Test (ASTM D-2783-82):
In this test three steel test balls are locked in a holding cup while a fourth
ball is fixed in a
rotating chuck. Lubricant is applied to the container holding the fixed and
rotating bearings.
Pressure is loaded on the force arm and electric motor is started. The
electric DC motor is set to
run at a specified RPM for a specified time such as 10.0 seconds in this test.
Test Sample Load K.G.F Time/Seconds A/Temp Scar Length Width
Invention 500 10.0 76 0.803 1.064
Invention 780 10.0 76 1.043 1.337
TexacoTm 10W30 780 10.0 65 2.940 2.440
Plus 10% SLA 780 10.0 65 2.160 2.020
EssoTM 10W30 780 10.0 65 2.910 2.510
Plus 10% SLA 780 10.0 65 2.210 2.160
Motor MasterTM 30 780 10.0 72 5.00 3.857
Plus 10% SLA 780 10.0 72 2.074 1.951
Hydraulic AW46TM 780 10.0 72 2.900 2.320
Plus 10% SLA 780 10.0 72 1.240 1.220
Notes:
K.G.F.= Kilogram Force
Weld or Failure = Score of 4.00 or greater
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SLA = Synthetic Lubricant Additive (Invention)
Test #5
Analytical Report:
A sample of the invention has been identified and tested with the analytical
results posted below:
Flash Point 342F 172.2 C ASTM D 92
Specific Gravity 1.036 ASTM D 1298
Total Base No.
Mg KOH/g 1.6 ASTM D 2896
Copper Corrosion 1A No Corrosion ASTM D 130
Pour Point -40 F -40 C ASTM D 97
Viscosity
104 F 40 C 914 ASTM D 88
212 F 100 C 78 ASTM D 88
Kinetic cST 200 ASTM D 445
Kinetic cSt 15.2 ASTM D 445
Ash Content 0.277 ASTM D 482
Test #6
Metal Analysis:
A sample of the invention was subjected to a metal analysis with the results
posted below.
Aluminum ND
Barium ND
Copper ND
Chromium ND
Iron ND
Lead ND
Molybdenum ND
Nickel ND
Zinc ND
Silver ND
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Tin ND
Vanadium ND
Test # 7
Block on Ring Test:
Block on Ring Machine. Ring O.D. = 40mm (1.57") at 800 RPM (329 FPM) on this
test. 1700
RPM (699FPM) is maximum speed, but is not used to avoid heat build up. No
cooling
arrangement.
Oil Specimen flows at 50m1/min. (.013209 GPM, 3.05127 Cu. In./Min.) Std.
Roller bearing with
outer race of AISI 52100 steel. Mating blocks may be white metal, bronze on
steel C 0.9, Mn
1.2, Cr 0.5, W 0.5, V 0.1 (2510 AFNOR 90 MCW5 Case Hdn. To 58HRC) Load on
different
blocks: steel/steel = 1075 RPM, bronze/steel = 358 RPM, white metal/Steel =
179 RPM.
Test Routine:
First adjust the speed, and then load is steadily increased to maximum
permitted, within 5
minutes. Each test was then run for V2 hour. Recordings made for maximum
friction force,
minimum friction force after run-in period. Stable curve at end of test and
maximum temperature
recorded.
After completion of over 80 tests, SEM (Scanning Electron Microscope) studies,
for material
reference and wear track studies.
Friction Reduction:
10% Addition of Synthetic Lubricant Additive (SLA) Invention
Mineral Base Oil Plus SLA -10.6 %
Synthetic Base Oil plus 15% SLA -10.6%
15% Addition of Synthetic Lubricant Additive (SLA) Invention
Mineral Base Oil Plus SLA -14.9%
Synthetic Base Oil Plus SLA -48.9%
1')
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Temperature Reduction:
% Addition of Synthetic Lubricant Additive (SLA) Invention
Mineral Base Oil Plus SLA -26.5%
Synthetic Base oil plus SLA -17.0%
15% Addition of Synthetic Lubricant Additive (SLA) Invention
Mineral Base Oil Plus SLA -36.0%
Synthetic Base Oil plus SLA -38.7%
Wear Reduction:
10% Addition of Synthetic Lubricant Additive (SLA) Invention
Mineral Base Oil Plus SLA -60.6%
Synthetic Base Oil Plus SLA -40.3%
15% Addition of Synthetic Lubricant Additive (SLA) Invention
Mineral Base Oil Plus SLA -78.8%
Synthetic Base Oil Plus SLA -50.7%
SLA = Invention
Test # 8
Engine Stand Testing
A brand new NASCARTM engines was provided for testing on a dynamometer. The
engine was
run in on Kendall Racing Oil TM and numerous pulls were performed. The
invention was then
added to the Kendall Racing Oil TM at a 10% ratio (20 parts oil to 2 parts
invention). The test is
posted as below.
Dynamometer Test on 358 Cu. In. GM Engine (5.8 Liter)
The NASCARTM Engine was set up and run in to full operating temperature at
speeds to 6900
RPM.
After multiple runs with Kendall Racing 20W50 Racing Oil TM, the maximum
results were
CA 02496921 2012-10-26
recorded in both horsepower and torque.
The invention was then added at a 10% ratio and the tests repeated with
maximum results
recorded.
Results:
STPPwr-Chp Kendall Maximum Horsepower = 494
STPPwr-Chp with 10% Invention added to Kendall , Horsepower = 508
STPTrq-C1b-ft Kendall Maximum Torque = 399
STPTrq-C1b-ft Kendall plus 10% Invention added, Torque = 411
Test # 9
Copper Corrosion Test: ASTA D 130
The tests were carried out on polished copper blanks are submerged for 3 hours
at al 00 degrees
C on both the invention (concentrated synthetic lubricant additive) and a
number of its blended
by-products. The blanks are withdrawn, washed in Stoddard's solvent and the
colors of the
blanks compared with the chart. The results of the tests consistently revealed
1-A, No Corrosion.
Test # 10
Rheological Evaluation:
Rheological evaluation was performed on the invention when blended with
various conventional
motor oils. The test is to examine the effect the invention can have when
blended with the host
oil.
The samples oils tested with 10% and 15% addition of the invention, displayed
Newtonian
behavior at all temperatures tested. The treated oils displayed a substantial
improvement of
thermal degradation with the addition of the invention. Using standard
regression techniques the
variations of oil viscosities with each temperature was found to follow the
Arrhenius model,
AE/RT (n = Ae).
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