Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
STABILIZED BLENDS CONTAINING FRICTION MODIFIERS
BACKGROUND OF THE INVENTION
[0001] The present invention relates to functional fluid compositions
con-
taining friction modifiers, and specifically stable compositions containing
friction modifiers with limited solubility in and/or limited compatibility
with the
functional fluids with which they are used.
[0002] Friction modifiers and their importance to various types of
functional
fluids are known. However, many friction modifiers may only be used in
limited ways due to solubility and/or compatibility issues with the functional
fluids in which they are used. Many friction modifiers, and specifically those
derived from hydroxy-carboxylic acids, have limited solubility in functional
fluids, such as engine oils and gear oils. These friction modifiers, when used
at
levels above their solubility and/or compatibility limits, may fall out of the
functional fluid composition over time and/or cause the composition to appear
hazy or cloudy.
[0003] These are serious issues in the manufacturing and blending
processes
of the fluids as well as in the field. For example, a functional fluid
additive
manufacturer would sell a homogeneous additive package of performance
chemicals, which may then be added to a base oil to give a final lubricant,
which
in turn is sold in tanks, drums, cans and plastic containers for final
delivery of
the lubricant to the equipment to be lubricated. To maintain assurance of
performance of the final lubricant, or any other functional fluid, in the
equip-
ment in which it is used, the concentrate and the lubricant must remain homoge-
neous throughout these steps. In other words, all of the additives present
must
be compatible with each of the various materials it comes into contact with
and/or finds itself, from the additive package to the concentrate to the final
fluid. This stringent standard greatly limits the choices of and available
treat-
ment levels for many additives, including the friction modifiers discussed
herein. These friction modifiers could provide improved performance to a
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functional fluid but not widely used and/or are not used at the optimal level
because the additive does not meet the solubility and/or compatibility require-
ments discussed above.
[0004] In the field, functional fluid compositions that drop out one or
more
components over time may not perform properly unless they are well-mixed
before use, or may be removed by filters associated with the equipment in
which
the functional fluid is used. The haziness and/or cloudiness of a functional
fluid, which may be measured as the fluid's turbidity, is often seen as a sign
the
composition is not stable, or may be in an early stage of separation and/or
component drop out. Such conditions are not desired in functional fluid compo-
sitions, for both performance and aesthetic related reasons. This reality has
created constraints on the use of various friction modifiers, such as
effective
maximum treat rates.
[0005] Without these solubility and/or compatibility limitations on the
use of
these friction modifiers, greater performance and equipment protection might
be
achievable, including for example extended life of a lubricant or a lubricated
piece of equipment such as engines, automatic transmissions, gear assemblies
and the like. Improved fuel economy and viscosity stability might be
achievable
as well. Greater performance may even be achievable with lesser amounts of
chemical as well as greater amounts, depending on the selection of the more
effective, but otherwise not suitable chemicals from a compatibility or
solubility
standpoint when delivered in a conventional manner.
[0006] There is a need for functional fluid compositions that contain
higher
amounts of friction modifiers while still remaining stable and/or clear. There
is
particularly a need for functional fluid compositions, such as engine oil
compo-
sitions, that contain friction modifiers derived from a hydroxy-carboxylic
acid,
at levels that would otherwise cause the composition to be unstable and/or
hazy,
as described above. The compositions and methods of the present invention
overcome these constraints and thus allow the use of these friction modifiers
at
levels not otherwise possible while still maintaining the stability and/or
clarity
of the functional fluid composition.
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SUMMARY OF THE INVENTION
[0007] Functional fluid compositions have been discovered that may
contain
high amounts of friction modifiers, and particularly friction modifiers with
limited solubility in and/or compatibility with the functional fluid
compositions
in which they are used, allowing for the use of higher amounts of such
friction
modifiers in these functional fluid compositions, while maintaining the
stability,
clarity, and/or compatibility of the overall composition.
[0008] The present invention provides a composition that includes: (a)
a
medium, which may include a solvent, a functional fluid, or combinations
thereof; and (b) a friction modifier component that includes a phosphorus-
containing compound that is not fully soluble in the medium; and (c) a
stabiliz-
ing component that is soluble in (a) and that interacts with (b) such that
(b)'s
solubility in (a) is improved, or perhaps more accurately, (b)'s solubility in
the
combination of (a) and (b) is improved over (b)'s solubility in (a) where the
stabilizing component includes a compound having at least one hydrogen-
donating group, a least one hydrogen-accepting group, and at least one hydro-
carbyl group, where the hydrogen-donating group and the hydrogen-accepting
group are not separated by more than 8 covalent and ionic bonds. Components
(b) and (c) may be present in component (a) in the form of dispersed particles
having an average diameter of less than 10 microns.
[0009] The invention provides for the compositions described herein
where
the turbidity of the overall composition is improved, as defined by visual
clarity
ratings (such as shown in Tables 1-3 below), or a lower JTU and/or NTU value
compared to the same composition that does not contain (c), the stabilizing
component. In some embodiments the compositions of the present invention
have a maximum JTU and/or NTU value of 100.
[0010] The present invention also provides for a process of preparing a
clear
and stable composition, as described herein, said method including the steps
of:
(I) adding components (b) and (c) to component (a); and (II) mixing the compo-
nents so that particles of components (b) and (c), or in some embodiments
particles of component (b) alone, have an average diameter of less than 10
microns, or in other embodiments and more specifically, no more than 10
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percent by weight of the particles have a diameter of more than 0.5 microns.
In
addition, component (b) may be present in the overall composition at a mini-
mum amount, such as no less than 0.15 percent by weight.
[0011] The invention also provides the use of the compatibilizers and
com-
positions described herein to improve the solubility and/or compatibility
and/or
stability of compositions containing the friction modifiers described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Various preferred features and embodiments will be described
below
by way of non-limiting illustration.
[0013] The present invention provides compositions and methods that allow
for the use of certain friction modifiers in functional fluid compositions
that
could not otherwise be used, and/or could not be used at the levels allowed
for
by the present invention, without resulting in unstable, unclear, and/or hazy
compositions.
[0014] The types of functional fluids in and with which the compositions
and
methods of the present invention may be used can include: gear oils, transmis-
sion oils, hydraulic fluids, engine oils, two cycle oils, metalworking fluids,
fuels
and the like. In one embodiment the functional fluid is engine oil. In another
embodiment the functional fluid is gear oil. In another embodiment the func-
tional fluid is a transmission fluid. In another embodiment the functional
fluid
is a hydraulic fluid. In another embodiment the functional fluid is a fuel. In
another embodiment the functional fluid is a grease.
[0015] In some embodiments the present invention does not include the
use
of a delivery device, for example a device that acts to contain the friction
modifier and contact it with the functional fluid with which it is to be
added. In
some embodiments the present invention does not included the use of either a
gel composition or a solid composition, where such compositions slow release
one or more components into a functional fluid. Rather the present invention
provides a means for incorporating friction modifiers into functional fluids,
by
use of a combination of components, which result in a functional fluid with
the
high level of friction modifier while still being stable, clear and/or non-
hazy.
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[0016] In some embodiments the present invention provides a composition
that is more stable, clearer, and/or less hazy than a composition that is
identical
except for it missing one or more components. In some embodiments the
missing component is the stabilizing component. In other embodiments the
compositions of the present invention have a lower turbidity compared to
compositions that are identical except for them missing the stabilizing compo-
nent of the present invention. In some of these embodiments, the compositions'
turbidity is expressed as a visual clarity rating such as in Tables 1-3 or a
JTU
and/or NTU value. In other embodiments the compositions of the present
invention have a maximum JTU and/or NTU value of 100, of 90 or even of 80.
[0017] JTU and NTU values may be measured US EPA method 180.1. JTU
and NTU values may also be measured without any further dilution in Jackson
Turbidity Units (JTU's) by using a Monitek Model 151 Turbidimeter.
The Medium
[0018] The compositions of the present invention include a medium. The
medium may be a solvent and/or diluent, a functional fluid, an additive concen-
trate, or combinations thereof.
[0019] Suitable solvents include aliphatic hydrocarbons, aromatic
hydrocar-
bons, oxygen containing compositions, or mixtures thereof. The oxygen con-
taming composition can include an alcohol, a ketone, an ester of a carboxylic
acid, a glycol and/or a polyglycol, or a mixture thereof. Suitable solvents
also
include oils of lubricating viscosity, naphtha, toluene, xylene, or
combinations
thereof The oil of lubricating viscosity can comprise natural oils, synthetic
oils, or mixtures thereof. The oil of lubricating viscosity can be an API
(Ameri-
can Petroleum Institute) Group II, III, IV, V base oil or mixture thereof.
Exam-
ples of commercially available aliphatic hydrocarbon solvents or diluents, to
include oils of lubricating viscosity, are PilotTM 140 and PilotTM 299 and
PilotTM
900 available from Petrochem Carless, PetroCanadaTM 100N, NexbaseTM,
YubaseTM, and 4 to 6 cSt poly(alpha-olefins).
[0020] Suitable functional fluids include any of the functional fluids
listed
above, including mixtures of such fluids. In many embodiments the functional
fluids, or other materials used as the medium, contain additional additives in
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addition to components (b) and (c) described in detail below. These additional
additives are described in greater detail below.
[0021] In one embodiment of the invention the medium and/or the overall
composition is substantially free of or free of at least one member selected
from
the group consisting of sulphur, phosphorus, sulfated ash, and combinations
thereof, and in other embodiments the fuel composition contains less than 20
ppm, less than 15 ppm, less than 10 ppm, or less than 1 ppm of at least one
member selected from the group consisting of sulphur, phosphorus, sulfated
ash,
and combinations thereof.
[0022] In one embodiment, the medium and the stabilizing component may
be the same material. That is one material may perform the functions of both
components. For example when the invention is in the form of a concentrate the
medium present may act as a stabilizing component and vice versa. This con-
centrate may then be added to a functional fluid as a top treat and/or
additive
package, resulting in a stable and homogeneous functional fluid which would
otherwise be cloudy or incompatible in the absence of stabilizer compo-
nent/medium material.
The Friction Modifier
[0023] The compositions of the present invention include a friction
modifier
component. The friction modifier component may include a least one friction
modifier that is not fully soluble and/or compatible in the medium and/or
functional fluid in which it is to be used. By not fully soluble and/or
compati-
ble, it is meant that the friction modifier does not stay dissolved and/or
suspend-
ed in the fluid to which it is added, causes the fluid to appear hazy and/or
cloudy, have sediments, or any combination thereof. In some embodiments, the
friction modifier causes the fluid in which it is used to have hazy appearance
or
solid drop-out, or an NTU and/or JTU value above 80, 90 or even 100. In some
embodiments this fluid is a functional fluid composition such as a finished
lubricant or an additive concentrate.
[0024] In some embodiments the friction modifier of the present invention
is
soluble and/or compatible with a fluid at low concentrations, but becomes less
than soluble and/or compatible at higher concentrations. In some embodiments
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friction modifiers suitable for use in the present invention are not fully
soluble
and/or compatible, as defined above, when present in a fluid at concentrations
of
or more than 0.1, 0.15, 0.2, 0.3, 0.5, or 1.0 percent by weight.
[0025] The friction modifier component may include a phosphorus contain-
ing additive, such as an amine salt of a hydrocarbyl phosphate, a hydrocarbyl
thiophosphate, a hydrocarbyl dithiophosphate, or combinations thereof. Such
additives are generally prepared by reacting one or more phosphorus acids,
such
as a phosphoric, thiophosphoric, including dithiophosphoric, acids, with an
unsaturated amide, such as an acrylamide, and also include amine salts of full
or
partial esters of phosphoric or thiophosphoric acids.
[0026] Phosphorus-containing acids suitable for use in preparing the
friction
modifier component of the present invention include phosphorus acid esters
prepared by reacting one or more phosphorus acids or anhydrides with an
alcohol.
The alcohol used may contain up to about 30, 24, 12 or even 3 carbon atoms.
The
phosphorus acid or anhydride may be an inorganic phosphorus reagent, such as
phosphorus pentoxide, phosphorus trioxide, phosphorus tetraoxide, phosphorus
acid,
phosphorus halide, lower phosphorus esters, or a phosphorus sulfide, including
phosphorus pentasulfide. In some embodiments the phosphorus acid or anhydride
is
phosphorus pentoxide, phosphorus pentasulfide, phosphorus trichloride, or
combina-
tions thereof. The phosphorus acid ester may be a mono- or diester of
phosphoric
acid or mixtures thereof.
[0027] Examples of commercially available alcohols include Alfol 810 (a
mix-
ture of primarily straight chain, primary alcohols having from 8 to 10 carbon
atoms);
Alfol 1218 (a mixture of synthetic, primary, straight-chain alcohols
containing 12 to
18 carbon atoms); Alfol 20+ alcohols (mixtures of C18-C28 primary alcohols
having
mostly Cm); and Alfol 22+ alcohols (C18-C28 primary alcohols containing
primarily
C22 alcohols).
[0028] In another embodiment, the phosphorus-containing acid is a
thiophospho-
rus acid ester and may be a mono- or dithiophosphorus acid ester.
Thiophosphorus
acid esters are also referred to as thiophosphoric acids. The thiophosphorus
acid
ester may be prepared by reacting a phosphorus sulfide, such as those
described
above, with any of the alcohols described above. Monothiophosphoric acid
esters, or
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monothiophosphates, may be prepared by the reaction of a sulfur source, such
as
elemental sulfur, with a dihydrocarbyl phosphite. The sulfur source may also
be an
organosufide, such as a sulfur coupled olefin or dithiophosphate. Monothiophos-
phates may also be formed in the lubricant blend by adding a dihydrocarbyl
phos-
phite to a lubricating composition containing a sulfur source, such as a
sulfurized
olefin.
[0029] Dithiophosphoric acids, or phosphorodithioic acids, may be
reacted with
an epoxide or a glycol and further reacted with a phosphorus acid, anhydride,
or
lower ester. The epoxide may be an aliphatic epoxide or a styrene oxide, such
as
ethylene oxide, propylene oxide, butene oxide, octene oxide, dodecene oxide,
and
styrene oxide. In one embodiment propylene oxide is used. The glycols may be
aliphatic glycols having from 1 or 2 to 12, 6 or 3 carbon atoms. These
materials may
be reacted with P205. The resulting materials, as well as the other described
herein
may then be reacted with an amine to forma salt.
[0030] As noted above, the acidic phosphoric acid esters described above
may be
reacted with ammonia or an amine compound to form an ammonium salt. The salts
may be formed separately and then the salt of the phosphorus acid ester may be
added to the lubricating composition. Alternately, the salts may also be
formed in
situ when the acidic phosphorus acid ester is blended with other components to
form
a fully formulated lubricating composition.
[0031] Suitable amines include monoamines and polyamines, including
those
described above. The amines may be primary amines, secondary amines or
tertiary
amines. Useful monoamines may contain from 1 to 24, 14 or 8 carbon atoms,
including methylamine, ethylamine, propylamine, butylamine, octylamine, and
dodecylamine, dimethylamine, diethylamine, dipropylamine, dibutylamine, methyl
butylamine, ethyl hexylamine, trimethylamine, tributylamine, methyl
diethylamine,
ethyl dibutylamine and the like.
[0032] In one embodiment, the amine may be a fatty (C4_30) amine that
include
but are not limited to n-hexylamine, n-octylamine, n-decylamine, n-
dodecylamine, n-
tetradecylamine, n-hexadecylamine, n-octadecylamine, oleylamine and the like.
Some examples are commercially available fatty amines such as "Armeen" amines
(products available from Armak Chemicals, Chicago, Illinois), such as Armak's
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Armeen-C, Armeen-O, Armeen-OL, Armeen-T, Armeen-HT, Armeen S and Armeen
SD, wherein the letter designation relates to the fatty group, such as cocoa,
oleyl,
tallow, or soya groups.
[0033] A useful amine is a C12-14 branched tertiary alkyl primary amine
sup-
plied by Rohm and Haas under the trade name Primene 81R. In one embodiment,
the
stabilizing component is an amine salt of a mixture of phosphoric acids and
esters
and/or an amine salt of a mixture of dithiophosphoric acids and esters, where
the
mixtures are salted with Primene 81R or a similar amine or mixture of amines.
[0034] The preparation of these phosphorus containing additives,
including
the amine salts of the acids and esters described above, is discussed in
greater
detail in US Pat. No. 6617287.
[0035] In some embodiments the phosphorus containing additive of compo-
nent (c) includes a phosphate, a phosphite, a thiophosphate, an amine salt of
any
of these materials, or any combination thereof. In some embodiments component
(c) includes: (i) a hydrocarbyl phosphoric acid or acid ester; (ii) an amine
salt
thereof; or combinations thereof. In still other embodiments component (c)
includes a compound represent by the following formula:
(X 1 =)a.13(X2b-R)3
or a salted version thereof wherein: each X1 is independently 0 or S, a is 0
or 1,
each X2 is independently 0 or S, b is 0 or 1, and R is H or a hydrocarbyl
group,
and in some embodiments with the proviso that at least one of the R groups is
a
hydrocarbyl group containing at least 1 carbon atom. In some embodiments the
phosphorus containing additive is salted with an amine.
[0036] The friction modifier may be present in the compositions of the
present invention at levels of at least 0.05, 0.1, 0.15, 0.2, 0.3, 0.5 or even
1.0
percent by weight. The friction modifier may be present at amounts up to, or
even less than, 10, 9, 8, 7.5, 5, or even 4 or 3 percent by weight.
[0037] The compositions of the present invention, and specifically the
friction modifier component, may optionally include one or more additional
friction modifiers. These additional friction modifiers may or may not have
the
solubility and/or compatibility issues of the friction modifiers described
above.
These additional friction modifiers may include esters of polyols such as
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glycerol monooleates, as well as there borated derivatives; fatty phosphites;
borated fatty epoxides; sulfurized olefins; compounds derived from a hydroxy-
carboxylic acid such as oleyl tartrimide, stearyl tartrimide, and 2-ethylhexyl
tartrate; imidazolines derived from fatty acids and ethylene diamine
derivatives
such as that derived from oleic acid and aminoethyl ethanolamine and mixtures
thereof
[0038] Esters of polyols include fatty acid esters of glycerol. These
can be prepared
by a variety of methods well known in the art. Many of these esters, such as
glycerol
monooleate and glycerol mono-tallowate, are manufactured on a commercial
scale. The
esters useful for this invention are oil-soluble and are preferably prepared
from C8 to C22
fatty acids or mixtures thereof such as are found in natural products. The
fatty acid may
be saturated or unsaturated. Certain compounds found in acids from natural
sources
may include licanic acid which contains one keto group. Useful C8 to C22 fatty
acids are
those of the formula R-COOH wherein R is alkyl or alkenyl.
[0039] The fatty acid monoester of glycerol is useful. Mixtures of mono and
diesters may be used. Mixtures of mono- and diester can contain at least about
40% of
the monoester. Mixtures of mono- and diesters of glycerol containing from
about 40%
to about 60% by weight of the monoester can be used. For example, commercial
glycerol monooleate containing a mixture of from 45% to 55% by weight
monoester
and from 55% to 45% diester can be used.
[0040] Useful fatty acids for making these fatty acid esters include
oleic, stearic,
isostearic, palmitic, myristic, palmitoleic, linoleic, lauric, linolenic, and
eleostearic, and
the acids from the natural products tallow, palm oil, olive oil, peanut oil.
[0041] Fatty acid amides have been discussed in detail in U.S. Pat. No.
4,280,916.
Suitable amides are C8-C24 aliphatic monocarboxylic amides and are well known.
Reacting the fatty acid base compound with ammonia produces the fatty amide.
The
fatty acids and amides derived there from may be either saturated or
unsaturated.
Important fatty acids include lauric acid (C12), palmitic acid (C16), and
stearic acid (CO.
Other important unsaturated fatty acids include oleic, linoleic and linolenic
acids, all of
which are C18. In one embodiment, the fatty amides of the instant invention
are those
derived from the C18 unsaturated fatty acids.
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[0042] The fatty amines and the diethoxylated long chain amines such as
N,N-bis-
(2-hydroxyethyl)-tallowamine themselves are generally useful as components of
this
invention. Both types of amines are commercially available. Fatty amines and
ethox-
ylated fatty amines are described in greater detail in U.S. Patent 4,741,848.
[0043] Friction modifiers derived from a hydroxy-carboxylic acid may be
formed by the reaction of the acid with an alcohol and/or an amine. Suitable
hydroxy-carboxylic acid include those represented by the formula:
7 0 \
µC ____________________________________ X ¨(- OR2 )
b
\R1¨Y /a
wherein: a and b may be independently integers of 1 to 5, or 1 to 2; X may be
an
aliphatic or alicyclic group, or an aliphatic or alicyclic group containing an
oxygen atom in the carbon chain, or a substituted group of the foregoing
types,
said group containing up to 6 carbon atoms and having a+b available points of
attachment; each Y may be independently -0-, >NH, or >NR3 or two Y's
together representing the nitrogen of an imide structure R1-N< formed between
two carbonyl groups; and each R1 and R3 may be independently hydrogen or a
hydrocarbyl group, provided that at least one R1 and R3 group may be a
hydrocarbyl group; each R2 may be independently hydrogen, a hydrocarbyl
group or an acyl group, further provided that at least one -0R2 group is
located
on a carbon atom within X that is a or 0 to at least one of the -C(0)-Y-R1
groups.
[0044] In one embodiment the acid is represented by the formula:
0
R4o: HOH
O
R40
wherein each R4 is independently H or a hydrocarbyl group, or wherein the R4
groups together form a ring. In one embodiment the friction modifier is
borated. In another embodiment the friction modifier is not borated.
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[0045] In any of the embodiments above, the hydroxy-carboxylic acid may
be tartaric acid, citric acid, or combinations thereof, and may also be a
reactive
equivalent of such acids (including esters, acid halides, or anhydrides). The
resulting friction modifiers may include imide, di-ester, di-amide, or ester-
amide
derivatives of tartaric acid, citric acid, or mixtures thereof. In one
embodiment
the derivative of hydroxycarboxylic acid includes an imide, a di-ester, a di-
amide, or an ester-amide derivative of tartaric acid.
[0046] The amines used in the preparation of the friction modifier may
have
the formula RR'NH wherein R and R' each independently represent H, a
hydrocarbon-based radical of 1 or 8 to 30 or 150 carbon atoms, that is, 1 to
150
or 8 to 30 or 1 to 30 or 8 to 150 atoms. Amines having a range of carbon atoms
with a lower limit of 2, 3, 4, 6, 10, or 12 carbon atoms and an upper limit of
120, 80, 48, 24, 20, 18, or 16 carbon atoms may also be used. In one
embodiment, each of the groups R and R' has 8 or 6 to 30 or 12 carbon atoms.
In one embodiment, the sum of carbon atoms in R and R' is at least 8. R and R'
may be linear or branched. In one embodiment R and R' are linear and have at
least 12 carbons. In such embodiments the groups may include some
unsaturation.
[0047] The alcohols useful for preparing the friction modifier will
similarly
contain 1 or 8 to 30 or 150 carbon atoms. Alcohols having a range of carbon
atoms from a lower limit of 2, 3, 4, 6, 10, or 12 carbon atoms and an upper
limit
of 120, 80, 48, 24, 20, 18, or 16 carbon atoms may also be used. In certain
embodiments the number of carbon atoms in the alcohol-derived group may be 8
to 24, 10 to 18, 12 to 16, or 13 carbon atoms.
[0048] The alcohols and amines may be linear or branched, and, if branched,
the branching may occur at any point in the chain and the branching may be of
any length. In some embodiments the alcohols and/or amines used include
branched compounds, and in still other embodiments, the alcohols and amines
used are at least 50%, 75% or even 80% branched.
[0049] In some embodiments, the alcohol and/or amine used includes
branched C6_18 Or C8_18 alcohols, branched C12-16 alcohols, 2-ethylhexanol,
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isotridecyl alcohol, linear C6-18 Or C8-18 alcohols, linear C12-16 alcohols,
or
combinations thereof.
[0050] In one embodiment the hydroxy-acid derived friction modifier can
be
represented by a compound of the formula:
0 0
R5 Y 11 (X),,. ( 11 Y' R)m
wherein: n' is 0 to 10; p is 1 to 5; Y and Y' are independently -0-, >NH,
>NR7,
or an imide group formed by the linking of the Y and Y' groups forming a Ri-
N< group between two >C=0 groups; R5 and R6 are independently hydrocarbyl
groups, typically containing 1, 4 or 6 to 150, 30 or 24 carbon atoms; m is 0
or 1,
and X is independently -CH2-, >CHR8 or >CR8R9, >CHOR10, or >C(CO2R10)2,
-CH3, -CH2R8 or -CHR8R9, -CH20R10, or -CH(CO2R10)2, or mixtures thereof
wherein: R7 is a hydrocarbyl group; R8 and R9 are independently keto-
containing groups (such as acyl groups), ester groups or hydrocarbyl groups;
and R1 is independently hydrogen or a hydrocarbyl group, typically containing
1 to 150 carbon atoms.
[0051] In some embodiments the compounds represent by Formula IV have
at least one X that is hydroxyl-containing (e.g., >CHOR10, wherein R1 is
hydrogen). When X is hydroxyl-containing, the compound may be derived from
hydroxy-carboxylic acids such as tartaric acid, citric acid, or mixtures
thereof
In one embodiment the compound is derived from citric acid and R5 and R6
contain at least 6 or 8 carbon atoms up to 150, or 6 or 8 to 30 or 24 carbon
atoms. In one embodiment the compound is derived from tartaric acid and R5
and R6 contain 4 or 6 to 30 or 24 carbon atoms. When X is not hydroxyl-
containing, the compound may be derived from malonic acid, oxalic acid,
chlorophenyl malonic acid, reactive equivalents thereof such as esters, or
mixtures
thereof
[0052] In some embodiments the compositions of the present invention do
not include any of these optional friction modifiers and in other embodiments,
one or more of any of the optional friction modifiers listed herein are not
present in the compositions of the present invention.
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[0053] In
other embodiments an additional friction modifier is present, and
that friction modifier is derived from a hydroxy-acid. In other embodiments
the
additional friction modifier is oleyl tartrimide, stearyl tartrimide, 2-
ethylhexyl
tartrimide, or combinations thereof.
[0054] The
additional friction modifier may be present in the compositions
of the present invention at levels of at least 0.05, 0.1, 0.15, 0.2, 0.3, 0.5
or even
1.0 percent by weight. The additional friction modifier may be present at less
than 10, 7.5, 5, or even 4 or 3 percent by weight.
[0055] In
some embodiments the compositions of the invention are free of
hydroxy-acid derived friction modifiers such as those described above. In some
embodiments the compositions of the invention are free of fatty amide friction
modifiers such as those described above. In
other embodiments the
compositions of the invention are essentially free of or even free of any
secondary friction modifiers.
The Stabilizing Component
[0056] The
compositions of the present invention include a stabilizing
component. The stabilizing component of the present invention is soluble in
medium and that interacts with the friction modifier such that its solubility
in
the medium and/or overall composition is improved. This may be accomplished
by an association of the stabilizing component and the friction modifier,
result-
ing in suspended particles of the associated molecules, that remain suspended,
dispersed and/or dissolved in the medium and/or overall composition to an
extent greater than obtained by the friction modifier alone.
[0057] The
stabilizing component of the present invention is an additive that,
when combined with the friction modifier in the medium, results in an im-
provement in the turbidity of the composition, compared to the same composi-
tion that does not contain the stabilizing component. The stabilizing
component
comprises a compound having at least one hydrogen-donating group, a least one
hydrogen-accepting group, and at least one hydrocarbyl group, where the
hydrogen-donating group and the hydrogen-accepting group are not separated
by more than 8 covalent and ionic bonds.
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[0058] In some embodiments the stabilizing component includes a
quaternary
salt comprising the reaction product of (a) hydrocarbyl-substituted compound
having a tertiary amino group and (b) a quaternizing agent suitable for
convert-
ing the tertiary amino group of (a) to a quaternary nitrogen, wherein the
quater-
nizing agent is selected from the group consisting of dialkyl sulfates, benzyl
halides, hydrocarbyl substituted carbonates; hydrocarbyl epoxides in combina-
tion with an acid or mixtures thereof.
[0059] The quaternary salt may include the reaction product of: (i) at
least
one compound selected from the group consisting of: (a) the condensation
product of a hydrocarbyl-substituted acylating agent and a compound having an
oxygen or nitrogen atom capable of condensing with said acylating agent and
said condensation product further having a tertiary amino group; (b) a polyal-
kene-substituted amine having at least one tertiary amino group; and (c) a
Mannich reaction product having a tertiary amino group, said Mannich reaction
product being prepared from the reaction of a hydrocarbyl-substituted phenol,
an aldehyde, and an amine; and (ii) a quaternizing agent suitable for
converting
the tertiary amino group of compound (i) to a quaternary nitrogen, wherein the
quaternizing agent is selected from the group consisting of dialkyl sulfates,
benzyl halides, hydrocarbyl substituted carbonates; hydrocarbyl epoxides in
combination with an acid or mixtures thereof
[0060] In one embodiment the quaternary salt comprises the reaction
product
of (i) at least one compound selected from the group consisting of: a polyal-
kene-substituted amine having at least one tertiary amino group and/or a Man-
nich reaction product having a tertiary amino group; and (ii) a quaternizing
agent.
[0061] In another embodiment the quaternary salt comprises the reaction
product of (i) the reaction product of a succinic anhydride and an amine; and
(ii)
a quaternizing agent. In such embodiments, the succinic anhydride may be
derived from polyisobutylene and an anhydride, where the polyisobutylene has a
number average molecular weight of about 800 to about 1600. In some embod-
iments the succinic anhydride is chlorine free.
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[0062] In some embodiments, the hydrocarbyl substituted acylating agent
of
component (i)(a) described above is the reaction product of a long chain hydro-
carbon, generally a polyolefin substituted with a monounsaturated carboxylic
acid reactant such as (1) monounsaturated C4 to Ci0 dicarboxylic acid such as
fumaric acid, itaconic acid, maleic acid.; (2) derivatives of (1) such as anhy-
drides or Ci to C5 alcohol derived mono- or di-esters of (1); (3)
monounsaturat-
ed C3 to Ci0monocarboxylic acid such as acrylic acid and methacrylic acid.; or
(iv4 derivatives of (3) such as Ci to C5 alcohol derived esters of (3) with
any
compound containing an olefinic bond represented by the general formula:
(R1)(R1)C=C(R1)(CH(R1)(R1))
wherein each R1 is independently hydrogen or a hydrocarbyl group.
[0063] Olefin polymers for reaction with the monounsaturated carboxylic
acids can include polymers comprising a major molar amount of C2 to C20, e.g.
C2 to C5 monoolefin. Such olefins include ethylene, propylene, butylene,
isobutylene, pentene, octene-1, or styrene. The polymers can be homopolymers
such as polyisobutylene, as well as copolymers of two or more of such olefins
such as copolymers of; ethylene and propylene; butylene and isobutylene;
propylene and isobutylene. Other copolymers include those in which a minor
molar amount of the copolymer monomers e.g., 1 to 10 mole % is a C4 to C18
diolefin, e.g., a copolymer of isobutylene and butadiene; or a copolymer of
ethylene, propylene and 1,4-hexadiene.
[0064] In one embodiment, at least one R of formula describe ding the
compound containing an olefinic bond provided above is derived from poly-
butene, that is, polymers of C4 olefins, including 1-butene, 2-butene and
isobu-
tylene. C4 polymers can include polyisobutylene. In another embodiment, at
least one R of the formula is derived from ethylene-alpha olefin polymers,
including ethylene-propylene-diene polymers. Ethylene-alpha olefin copoly-
mers and ethylene-lower olefin-diene terpolymers are described in numerous
patent documents, including European patent publication EP0279863 and the
following United States patents: 3,598,738; 4,026,809; 4,032,700; 4,137,185;
4,156,061; 4,320,019; 4,357,250; 4,658,078; 4,668,834; 4,937,299; 5,324,800
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each of which are incorporated herein by reference for relevant disclosures of
these ethylene based polymers.
[0065] In another embodiment, the olefinic bonds of the compound
contain-
ing an olefinic bond described above are predominantly vinylidene groups,
represented by the following formulas:
-(H)C=C(R2)(R2)
wherein R2 is a hydrocarbyl group, and in some embodiments both R2 groups are
methyl groups, and
-(H)(R3)C(C(CH3)=CH2)
wherein R3 is a hydrocarbyl group.
[0066] In one embodiment, the vinylidene content of the compound
contain-
ing an olefinic bond described above can comprise at least about 30 mole %
vinylidene groups, at least about 50 mole % vinylidene groups, or at least
about
70 mole % vinylidene groups. Such material and methods for preparing them
are described in U.S. Pat. Nos. 5,071,919; 5,137,978; 5,137,980; 5,286,823,
5,408,018, 6,562,913, 6,683,138, 7,037,999 and U.S. Publication Nos.
20040176552A1, 20050137363 and 20060079652A1, which are expressly
incorporated herein by reference, such products are commercially available by
BASF, under the tradename GLISSOPALO and by Texas Petrochemicals LP,
under the tradename TPC 11O5TM and TPC 595TM
[0067] Methods of making hydrocarbyl substituted acylating agents from
the
reaction of the monounsaturated carboxylic acid reactant and the compound
containing an olefinic bond described above are well know in the art and dis-
closed in the following patents: U.S. Pat. Nos. 3,361,673 and 3,401,118 to
cause
a thermal "ene" reaction to take place; U.S. Pat. Nos. 3,087,436; 3,172,892;
3,272,746, 3,215,707; 3,231,587; 3,912,764; 4,110,349; 4,234,435; 6,077,909;
6,165,235 and are hereby incorporated by reference.
[0068] In another embodiment, the hydrocarbyl substituted acylating
agent
can be made from the reaction of at least one carboxylic reactant represented
by
the following formulas:
(R40 C (0)(R5)õC (0))R4
and
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R4
144--(R5)11-C(0)01i4
wherein each R4 is independently H or a hydrocarbyl group, and each R5 is a
divalent
hydrocarbylene group and n is 0 or 1 with any compound containing an olefin
bond
as described above. Compounds and the processes for making these compounds are
disclosed in U.S. Pat. Nos. 5,739,356; 5,777,142; 5,786,490; 5,856,524;
6,020,500;
and 6,114,547 which are hereby incorporated by reference.
[0069] Other methods of making the hydrocarbyl substituted acylating
agent
can be found in the following reference, U.S. Pat. Nos. 5,912,213; 5,851,966;
and 5,885,944 which are hereby incorporated by reference.
[0070] The compound having an oxygen or nitrogen atom capable of con-
densing with the acylating agent and further having a tertiary amino group can
be represented by the following formulas:
H R6
N /
N ¨X ¨N
/ N
R6 R6
wherein X is an alkylene group containing about 1 to about 4 carbon atoms; and
wherein each R6 is independently a hydrocarbyl group, and R6' can be hydrogen
or a hydrocarbyl group.
)R7
HO¨X ¨ N
NR7
wherein X is an alkylene group containing about 1 to about 4 carbon atoms; and
wherein each R7 is independently a hydrocarbyl group.
[0071] Examples of the nitrogen or oxygen contain compounds capable of
condensing with the acylating agent and further having a tertiary amino group
can include but are not limited to: ethylenediamine, 1,2-propylenediamine, 1,3-
propylene diamine, the isomeric butylenediamines, pentanediamines, hexanedi-
amines, heptanediamines, diethylenetriamine, dipropylenetriamine, dibutylene-
triamine, triethylenetetraamine, tetraethylenepentaamine, pentaethylenehex-
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aamine, hexamethylenetetramine, and bis(hexamethylene) triamine, the dia-
minobenzenes, the diaminopyridines or mixtures thereof. In addition, nitrogen
or oxygen contain compounds which may be alkylated to contain a tertiary
amino group may also used. Examples of the nitrogen or oxygen contain
compounds capable of condensing with the acylating agent after being alkylated
to having a tertiary amino group can include but are not limited to: dimethyla-
minopropylamine, N,N-dimethyl-aminopropylamine, N,N-
diethyl-
aminopropylamine, N,N-dimethyl-aminoethylamine or mixtures thereof. The
nitrogen or oxygen containing compounds capable of condensing with the
acylating agent and further having a tertiary amino group can further include
aminoalkyl substituted heterocyclic compounds such as
1 -(3 -aminopropyl)imidazole and 4 -
(3 -aminopropyl)morpholine,
1 -(2 -amino ethyl)piperidine, 3,3 -
diamino -N-methyl diprop ylamine,
3'3-aminobis(N,N-dimethylpropylamine). Another type of nitrogen or oxygen
containing compounds capable of condensing with the acylating agent and
having a tertiary amino group include alkanolamines including but not limited
to
triethanolamine, N,N- dimethylaminoprop anol, N,N-
diethylaminoprop anol,
N,N-diethylaminobutanol, N,N,N-tris(hydroxyethyl)amine, or mixtures thereof
[0072] The
acid used with the quaternizing agent may be an organic acid
represented by the general formula R-COOH where R is a hydrocarbyl group.
In some embodiments the hydrocarbyl group of the acid contains from 1 to 10, 1
to 6 or even 1 to 4 carbons atoms. In some embodiments the acid may be acetic
acid, propionic acid, butyric acid, or pentanoic acid.
[0073]
Examples of quaternary ammonium salt and methods for preparing
the same are described in the following patents, which are hereby incorporated
by reference, US 4,253,980, US 3,778,371, US 4,171,959, US 4,326,973, US
4,338,206, and US 5,254,138.
[0074] The
quaternary salts of the invention may also comprise a polyester
quaternary ammonium salt which may be derived from the reaction of a polyes-
ter that contains a tertiary amino group and a quaternizing agent suitable for
converting the tertiary amino group to a quaternary nitrogen.
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[0075] The polyester containing a tertiary amino group used in the
prepara-
tion of the additives of the invention may also be described as a non-
quaternized
polyester containing a tertiary amino group.
[0076] In some embodiments the polyester is the reaction product of a
fatty
carboxylic acid containing at least one hydroxyl group and a compound having
an oxygen or nitrogen atom capable of condensing with said acid and further
having a tertiary amino group. Suitable fatty carboxylic acids that may used
in
the preparation of the polyesters described above may be represented by the
formula:
OH 0
R1- ---R2 OH
where R1 is a hydrogen or a hydrocarbyl group containing from 1 to 20 carbon
atoms and R2 is a hydrocarbylene group containing from 1 to 20 carbon atoms.
In some embodiments R1 contains from 1 to 12, 2 to 10, 4 to 8 or even 6 carbon
atoms, and R2 contains from 2 to 16, 6 to 14, 8 to 12, or even 10 carbon
atoms.
[0077] In some embodiments the fatty carboxylic acid used in the prepara-
tion of the polyester is 12-hydroxystearic acid, ricinoleic acid, 12-hydroxy
dodecanoic acid, 5-hydroxy dodecanoic acid, 5-hydroxy decanoic acid, 4-
hydroxy decanoic acid, 10-hydroxy undecanoic acid, or combinations thereof.
[0078] The compound having an oxygen or nitrogen atom capable of con-
densing with said acid and further having a tertiary amino group may include
any of the materials described above as compounds having an oxygen or nitro-
gen atom capable of condensing with the acylating agent. Suitable materials
may be represented by the formula:
R3 H
NI I
Xi
R4 R5
where R3 is a hydrocarbyl group containing from 1 to 10 carbon atoms; R4 is a
hydrocarbyl group containing from 1 to 10 carbon atoms; R5 is a hydrocarbylene
group containing from 1 to 20 carbon atoms; and X1 is 0 or NR6 where R6 is a
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hydrogen or a hydrocarbyl group containing from 1 to 10 carbon atoms. In
some embodiments R3 contains from 1 to 6, 1 to 2, or even 1 carbon atom, R4
contains from 1 to 6, 1 to 2, or even 1 carbon atom, R5 contains from 2 to 12,
2
to 8 or even 3 carbon atoms, and R6 contains from 1 to 8, or 1 to 4 carbon
atoms. In some of these embodiments, the compound becomes:
R3 R6 R3
NI
NI H NI
NH2
R4 R5 R4 R5
or
where the various definitions provided above still apply.
[0079] Examples of nitrogen or oxygen containing compounds capable of
condensing with the polyester agents include all of those listed above as exam-
ples of materials that are capable of condensing with the acylating agents.
[0080] The quaternized polyester salt can be a quaternized polyester
amide
salt. In such embodiments the polyester containing a tertiary amino group used
to prepare the quaternized polyester salt is a polyester amide containing a
tertiary amino group. In some of these embodiments the amine or amino alcohol
is reacted with a monomer and then the resulting material is polymerized with
additional monomer, resulting in the desired polyester amide which may then be
quaternized.
[0081] In some embodiments the quaternized polyester salt includes an
anion
represented by the following formula:
R1 0
R5 X2
R7 _________________________________________ OR2N N
- - n I RI \4
R6
where R1 is a hydrogen or a hydrocarbyl group containing from 1 to 20 carbon
atoms and R2 is a hydrocarbylene group containing from 1 to 20 carbon atoms;
R3 is a hydrocarbyl group containing from 1 to 10 carbon atoms; R4 is a hydro-
carbyl group containing from 1 to 10 carbon atoms; R5 is a hydrocarbylene
group containing from 1 to 20 carbon atoms; R6 is a hydrogen or a hydrocarbyl
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group containing from 1 to 10 carbon atoms; n is a number from 1 to 10; R7 is
hydrogen, a hydrocarbonyl group containing from 1 to 22 carbon atoms, or a
hydrocarbyl group containing from 1 to 22 carbon atoms; and X2 is a group
derived from the quaternizing agent. In some embodiments R6 is hydrogen.
[0082] As above, in some embodiments R1 contains from 1 to 12, 2 to 10, 4
to 8 or even 6 carbon atoms, and R2 contains from 2 to 16, 6 to 14, 8 to 12,
or
even 10 carbon atoms, R3 contains from 1 to 6, 1 to 2, or even 1 carbon atom,
R4
contains from 1 to 6, 1 to 2, or even 1 carbon atom, R5 contains from 2 to 12,
2
to 8 or even 3 carbon atoms, and R6 contains from 1 to 8, or 1 to 4 carbon
atoms. In any of these embodiments n may be from 2 to 9, or 3 to 7, and R7
may contain from 6 to 22, or 8 to 20 carbon atoms.
[0083] In these embodiments the quaternized polyester salt is
essentially
capped with a C1-22, or a C8-20, fatty acid. Examples of suitable acids
include
oleic acid, palmitic acid, stearic acid, erucic acid, lauric acid, 2-
ethylhexanoic
acid, 9,11-linoleic acid, 9,12-linoleic acid, 9,12,15-linolenic acid, abietic
acid,
or combinations thereof
[0084] The number average molecular weight (Mn) of the quaternized
polyester salts of the invention may be from 500 to 3000, or from 700 to 2500.
[0085] The polyester useful in the present invention can be obtained by
heating one or more hydroxycarboxylic acids or a mixture of the hydroxycar-
boxylic acid and a carboxylic acid, optionally in the presence of an
esterification
catalyst. The hydroxycarboxylic acids can have the formula HO-X-COOH
wherein X is a divalent saturated or unsaturated aliphatic radical containing
at
least 8 carbon atoms and in which there are at least 4 carbon atoms between
the
hydroxy and carboxylic acid groups, or from a mixture of such a hydroxycar-
boxylic acid and a carboxylic acid which is free from hydroxy groups. This
reaction can be carried out at a temperature in the region of 160 C to 200 C,
until the desired molecular weight has been obtained. The course of the
esterifi-
cation can be followed by measuring the acid value of the product, with the
desired polyester, in some embodiments, having an acid value in the range of
10
to 100 mg KOH/g or in the range of 20 to 50 mg KOH/g. The indicated acid
value range of 10 to 100 mg KOH/g is equivalent to a number average molecu-
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lar weight range of 5600 to 560. The water formed in the esterification
reaction
can be removed from the reaction medium, and this can be conveniently done by
passing a stream of nitrogen over the reaction mixture or, by carrying out the
reaction in the presence of a solvent, such as toluene or xylene, and
distilling off
the water as it is formed.
[0086] The resulting polyester can then be isolated in conventional
manner;
however, when the reaction is carried out in the presence of an organic
solvent
whose presence would not be harmful in the subsequent application, the result-
ing solution of the polyester can be used.
[0087] In the said hydroxycarboxylic acids the radical represented by X may
contain from 12 to 20 carbon atoms, optionally where there are between 8 and
14 carbon atoms between the carboxylic acid and hydroxy groups. In some
embodiments the hydroxy group is a secondary hydroxy group.
[0088] Specific examples of such hydroxycarboxylic acids include
ricinoleic
acid, a mixture of 9- and 10-hydroxystearic acids (obtained by sulphation of
oleic acid followed by hydrolysis), and 12-hydroxystearic acid, and especially
the commercially available hydrogenated castor oil fatty acid which contains
in
addition to 12-hydroxystearic acid minor amounts of stearic acid and palmitic
acid.
[0089] The carboxylic acids which can be used in conjunction with the
hydroxycarboxylic acids to obtain these polyesters are preferably carboxylic
acids of saturated or unsaturated aliphatic compounds, particularly alkyl and
alkenyl carboxylic acids containing a chain of from 8 to 20 carbon atoms. As
examples of such acids there may be mentioned lauric acid, palmitic acid,
stearic acid and oleic acid.
[0090] In one embodiment the polyester is derived from commercial 12-
hydroxy-stearic acid having a number average molecular weight of about 1600.
Polyesters such as this are described in greater detail in U.K. Patent
Specifica-
tion Nos. 1373660 and 1342746.
[0091] In some embodiments the components used to prepare the additives
described above are substantially free of, essentially free of, or even
completely
free of, non-polyester-containing hydrocarbyl substituted acylating agents
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and/or non-polyester-containing hydro carbyl substituted diacylating agents,
such as for example polyisobutylene. In some embodiments these excluded
agents are the reaction product of a long chain hydrocarbon, generally a
polyole-
fin reacted with a monounsaturated carboxylic acid reactant, such as, (i) a,I3-
monounsaturated C4 to Cio dicarboxylic acid, such as, fumaric acid, itaconic
acid, maleic acid.; (ii) derivatives of (i) such as anhydrides or Ci to C5
alcohol
derived mono- or di-esters of (i); (iii) a,13-monounsaturated C3 to C10
monocar-
boxylic acid such as acrylic acid and methacrylic acid.; or (iv) derivatives
of
(iii), such as, C1 to C5 alcohol derived esters of (iii) with any compound con-
taming an olefinic bond represented by the general formula
(R9)(R10)c c,¨
11( )(CH(R7)(R8)) wherein each of R9 and R1 is independently
hydrogen or a hydrocarbon based group; each of R11, R7 and R8 is independently
hydrogen or a hydrocarbon based group and preferably at least one is a hydro-
carbyl group containing at least 20 carbon atoms. In one embodiment, the
excluded hydrocarbyl-substituted acylating agent is a dicarboxylic acylating
agent. In some of these embodiments, the excluded hydrocarbyl-substituted
acylating agent is polyisobutylene succinic anhydride.
[0092] By substantially free of, it is meant that the components of the
pre-
sent invention are primarily composed of materials other than hydrocarbyl
substituted acylating agents described above such that these agents are not
significantly involved in the reaction and the compositions of the invention
do
not contain significant amounts of additives derived from such agents. In some
embodiments the components of the invention, or the compositions of the
invention, may contain less than 10 percent by weight of these agents, or of
the
additives derived from these agents. In other embodiments the maximum
allowable amount may be 5, 3, 2, 1 or even 0.5 or 0.1 percent by weight. One
of
the purposes of these embodiments is to allow the exclusion of agents such as
polyisobutylene succinic anhydrides from the reactions of the invention and
so,
to also allow the exclusion of quaternized salt detergent additive derived
from
agents such as polyisobutylene succinic anhydrides. The focus of this
invention
is on polyester, or hyperdispersant, quaternary salt detergent additives.
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[0093] The quaternizing agents useful in preparing the quaternized
polyester
salts described above include any of the quaternizing agents described above
with regards to the other quaternized salts. In one embodiment, the
quaternizing
agent can be a hydrocarbyl epoxide in combination with an acid. Examples of
hydrocarbyl epoxides include: ethylene oxide, propylene oxide, butylene oxide,
styrene oxide and combinations thereof. In one embodiment the quaternizing
agent does not contain any styrene oxide.
[0094] In some embodiments the acid used with the hydrocarbyl epoxide
may be a separate component, such as acetic acid. In other embodiments, for
example when the hydrocarbyl acylating agent is a dicarboxylic acylating
agent,
no separate acid component is needed. In such embodiments, the detergent may
be prepared by combining reactants which are essentially free of, or even free
of, a separate acid component, such as acetic acid, and rely on the acid group
of
the hydrocarbyl acylating agent instead. In other embodiments, a small amount
of an acid component may be present, but at <0.2 or even <0.1 moles of acid
per
mole of hydrocarbyl acylating agent.
[0095] In some embodiments the quaternizing agent of the invention does
not contain any substituent group that contains more than 20 carbon atoms. In
other words, in some embodiments the long substituent group that allows for
the
resulting additive to be organic soluble and thus useful for the purposes of
this
invention is not provided by the quaternizing agent but instead is brought to
the
additive by the non-quaternized detergents described above.
[0096] In certain embodiments the molar ratio of detergent having an
amine
functionality to quaternizing agent is 1:0.1 to 2, or 1:1 to 1.5, or 1:1 to
1.3.
[0097] In some embodiments the hydrocarbyl-substituted compound having a
tertiary amino group used to prepare the quaternary salt includes: (1) the
conden-
sation product of a hydrocarbyl-substituted acylating agent and a compound
having an oxygen or nitrogen atom capable of condensing with said acylating
agent and said condensation product further having a tertiary amino group; (2)
a
polyalkene-substituted amine having at least one tertiary amino group; (3) a
Mannich reaction product having a tertiary amino group, said Mannich reaction
product being prepared from the reaction of a hydrocarbyl-substituted phenol,
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an aldehyde, and an amine; (4) a polyester containing a tertiary amino group;
or
any combination thereof.
[0098] In some embodiments the stabilizing component includes a
poly(hydroxycarboxylic acid) amide salt derivative represented by the formula
[Y-00[0-A-00].-Zr-R]mpXq- wherein Y is hydrogen or a substituted or non-
substituted hydrocarbyl group for example a hydroxy substituted hydrocarbyl
group, A is a divalent hydrocarbyl group, n is from 1 to 100, m is from 1 to
4, q
is from 1 to 4 and p is an integer such that pq=m, Z is a divalent bridging
group
which is attached to the carbonyl group through a nitrogen atom, r is 0 or 1,
R'
is an ammonium group and Xq- is an anion. In some embodiments the A in the
formula of the poly(hydroxycarboxylic acid) amide salt derivative is fully
saturated.
[0099] In some embodiments these stabilizing components are represented
by the formula [Y40-A-00].-Zr-R ]mpXq- wherein Y is hydrogen, a hydro-
carbonyl group (e.g. H-A-00-), a hydrocarbyl group optionally substituted
(e.g.
H-A- or HO-A-) for example a hydroxy substituted hydrocarbyl or hydrocar-
bonyl group (e.g. HO-A-00-), A is a divalent hydrocarbyl group, n is from 1 to
100, m is from 1 to 4, q is from 1 to 4 and p is an integer such that pq=m, Z
is a
divalent bridging group which is attached to the carbonyl group through a
nitrogen atom, r is 0 or 1, R is an ammonium group and Xq- is an anion. In
some embodiments the A in the formula of the poly(hydroxycarboxylic acid)
amide salt derivative is fully saturated.
[00100] In still other embodiments these stabilizing components are repre-
sented by the formula [H40-A-00](.+1)-Zr-R+LipXq- wherein A is a divalent
hydrocarbyl group, n is from 1 to 100, m is from 1 to 4, q is from 1 to 4 and
p is
an integer such that pq=m, Z is a divalent bridging group which is attached to
the carbonyl group through a nitrogen atom, r is 0 or 1, R+ is an ammonium
group and Xq- is an anion. In some embodiments the A in the formula of the
poly(hydroxycarboxylic acid) amide salt derivative is fully saturated.
[00101] The poly(hydroxycarboxylic acid) amide salt derivatives described
above may also be referred to as hyperdispersants. The R+ group in the formu-
las above may be a primary, secondary, tertiary or quaternary ammonium group.
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In some embodiments R is a quaternary ammonium group. In some embodi-
ments R' in the hyperdispersant formula above is represented by formula ¨
N'(R2)(R3)(R4) wherein R2, R3 and R4 may be selected from hydrogen and alkyl
groups such as methyl.
[00102] In the hyperdispersant formulas above A may be a divalent straight
chain or branched hydrocarbyl group. A may be a substituted aromatic, aliphat-
ic or cycloaliphatic straight chain or branched divalent hydrocarbyl group. In
some embodiments A is an arylene, alkylene or alkenylene group, in particular
an arylene, alkylene or alkenylene group containing in the range of from 4 to
25,
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with the heteroatoms (e.g., oxygen, nitrogen and sulphur) generally
representing
only a minority, about 33% or less, of the total non-hydrogen atoms present.
Those skilled in the art will appreciate that functional groups such as
hydroxy,
halo, alkoxy, nitro and cyano in a substituted hydrocarbyl group Y will
displace
one of the hydrogen atoms of the hydrocarbyl, whilst functional groups such as
carbonyl, carboxyl, tertiary amino (-N-), oxy, sulphonyl and sulphoxyl in a
substituted hydrocarbyl group will displace a -CH- or -CH2- moiety of the
hydrocarbyl. In some embodiments Y is unsubstituted or substituted by a group
selected from hydroxy, halo or alkoxy group, for example a Ci_4 alkoxy group.
In still further embodiments Y is a stearyl group, 12-hydroxystearyl group, an
oleyl group or a 12-hydroxyoley1 group, and that derived from naturally occur-
ring oil such as tall oil fatty acid.
[00105] In the hyperdispersant formulas above Z may be an optionally substi-
tuted divalent bridging group represented by the formula: -N(R1)-B- wherein R1
is hydrogen or a hydrocarbyl group and B is an optionally substituted alkylene
group. Examples of hydrocarbyl groups that may represent R1 include methyl,
ethyl, n-propyl, n-butyl and octadecyl. Examples of optionally substituted
alkylene groups that may represent B include ethylene, trimethylene, tetrameth-
ylene and hexamethylene. Examples of Z moieties include -NHCH2CH2-5
-NHCH2C(CH3)2CH2- and -NH(CH2)3-.
[00106] In the hyperdispersant formulas above r is preferably 1, i.e. the
poly(hydroxycarboxylic acid) amide salt derivative must contain the optionally
substituted divalent bridging group Z.
[00107] The anion Xq- in the hyperdispersant formulas above is not critical
and can be any anion (or mixture of anions) suitable to balance the positive
charge of the poly(hydroxycarboxylic acid) amide cation. The anion Xq- may be
a sulphur-containing anion, such as sulphate and sulphonate anions. However,
in some embodiments the anion Xq- is a non-sulphur-containing anion such as a
non-sulphur-containing organic anion or inorganic anion. Non-limiting exam-
ples of suitable anions are OH-, CH-, NH3-, HCO3-, HC00-, CH3C00-, H-,
Dv 3 3-5 rAJ 3 2-5 213 r 2 5 FR r 2-5 r 2v q 2-5 LC 2r 4 5 N v 2 5 NO2, N 3-
5 Ki2 5 V 5 022,
BeF3-, F, Na-, [Al(H20)2(OH)4] 5 Si035 SiF6 H2PO4-5 P3-5 P043-, HP042-, Cl-,
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C103, C104, C10, K0, Sb0116 5 SnC162 5 [SnTe4]4 5 Cr042 5 Cr2072 5 Mnal. 5
:,-,1 2- ri, ,,,,,-, \ trvi_j\ 1 ,-, 3- Th,
NIA_ 16 5 Lk_11(.k.._ ki3)2-111)2_14-5 AS \-/LI. 5 _or 5 Br03, 103, 1, CN 5
OCN 5 etc. Suita-
ble anions may also include anions derived from compounds containing a
carboxylic acid group (e.g. a carboxylate anion), anions derived from com-
pounds containing a hydroxyl group (e.g. an alkoxide, phenoxide or enolate
anion), nitrogen based anions such as nitrate and nitrite, phosphorus based
anions such as phosphates and phosphonates, or mixtures thereof. Non-limiting
examples of suitable anions derived from compounds containing a carboxylic
acid group include acetate, oleate, salicylate anions, and mixtures thereof.
Non-
limiting examples of suitable anions derived from compounds containing a
hydroxyl group include phenate anions, and mixtures thereof. In some embodi-
ments the anion VI- is a non-sulfur-containing anion selected from the group
consisting of OH, a phenate group, a salicylate group, an oleate group and an
acetate group, and in still other embodiments the anion is OH.
[00108] The one or more poly(hydroxycarboxylic acid) amide salt derivatives
may be obtained by reaction of an amine and a poly(hydroxycarboxylic acid) of
formula Y-00[0-A-00].-OH wherein Y is hydrogen or optionally substituted
hydrocarbyl group, A is a divalent optionally substituted hydrocarbyl group
and
n is from 1 to 100, with an acid or a quaternizing agent. The Y, A and n in
the
poly(hydroxycarboxylic acid) formula may be defined as above for the
poly(hydroxycarboxylic acid) amide salt derivative formula.
[00109] As used herein, the term "hydrocarbyl" represents a radical formed by
removal of one or more hydrogen atoms from a carbon atom of a hydrocarbon
(not necessarily the same carbon atoms in case more hydrogen atoms are re-
moved). Hydrocarbyl groups may be aromatic, aliphatic, acyclic or cyclic
groups. Preferably, hydrocarbyl groups are aryl, cycloalkyl, alkyl or alkenyl,
in
which case they may be straight-chain or branched-chain groups. Representa-
tive hydrocarbyl groups include phenyl, naphthyl, methyl, ethyl, butyl,
pentyl,
methylpentyl, hexenyl, dimethylhexyl, octenyl, cyclooctenyl, methylcy-
clooctenyl, dimethylcyclooctyl, ethylhexyl, octyl, isooctyl, dodecyl, hexade-
cenyl, eicosyl, hexacosyl, triacontyl and phenylethyl. The phrase "optionally
substituted hydrocarbyl" is used to describe hydrocarbyl groups optionally
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containing one or more "inert" heteroatom-containing functional groups. By
"inert" is meant that the functional groups do not interfere to any
substantial
degree with the function of the compound.
[00110] In one embodiment at least one, or all of the poly(hydroxycarboxylic
acid) amide salt derivatives are sulphur-containing derivatives. In such an
embodiment, said derivatives may have a sulphur content of at most 2.5 wt. %
for example from 0.1 to 2.0 wt. % or from 0.6 to 1.2 wt. % sulphur, as
measured
by ICP-AES, based on the total weight of said derivatives. In another embodi-
ment of the present invention, the one or more poly(hydroxycarboxylic acid)
amide salt derivatives are non-sulphur-containing derivatives.
[00111] The group (--0-A-00--) in the poly(hydroxycarboxylic acid)s and
amide salt derivatives thereof described above may be a 12-oxystearyl group,
12-oxyoley1 group or a 6-oxycaproyl group.
[00112] The amines which react with poly(hydroxycarboxylic acid)s to form
poly(hydroxycarboxylic acid) amide intermediates may include those defined in
WO 97/41092. The amine reactant may be a diamine, a triamine or a polyam-
ine. Suitable examples include diamines selected from ethylenediamine, N,N-
dimethy1-1,3-propanediamine, triamines and polyamines selected from diethy-
lenetri amine, triethylenetetramine, tetraethylenepentamine, p entaethylenehex
a-
mine and tris(2-aminoethyl)amine.
[00113] The amidation between the amine reactant and the
(poly(hydroxycarboxylic acid) may be carried out according to methods known
to those skilled in the art, by heating the poly(hydroxycarboxylic acid) with
the
amine reactant, optionally in a suitable hydrocarbon solvent such as toluene
or
xylene, and azeotroping off the formed water. Said reaction may be carried out
in the presence of a catalyst such as p-toluenesulphonic acid, zinc acetate,
zirconium naphthenate or tetrabutyl titanate.
[00114] The poly(hydroxycarboxylic acid) amide intermediate formed from
reaction of the amine and the poly(hydroxycarboxylic acid) is reacted with an
acid or a quaternizing agent to form a salt derivative, according to well-
known
methods. Acids that may be used to form the salt derivative may be selected
from organic or inorganic acids. Said acids are conveniently selected from
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carboxylic acids, nitrogen-containing organic and inorganic acids, sulphur-
containing organic or inorganic acids (such as sulphuric acid,
methanesulphonic
acid and benzenesulphonic acid).
[00115] Quaternizing agents that may be used to form the salt derivative may
be selected from dimethyl sulfate, a dialkyl sulphate having from 1 to 4
carbon
atoms, an alkyl halide such as methyl chloride, methyl bromide, aryl halide
such
as benzyl chloride. In one embodiment the quaternizing agent is a sulphur-
containing quaternizing agent, in particular dimethyl sulfate or a dialkyl sul-
phate having from 1 to 4 carbon atoms, for example dimethyl sulphate. Quater-
nization is a well-known method in the art. For example, quaternization using
dimethyl sulphate is described in U.S. Pat. No. 3,996,059, U.S. Pat. No.
4,349,389 and GB 1 373 660.
[00116] In some embodiments the poly(hydroxycarboxylic acid) amide salt
derivatives have a TBN (total base number) value of less than 10 or even less
than 5 or less than 2 mg KOH per gram, as measured by ASTM D 4739. Exam-
ples of poly(hydroxycarboxylic acid) amide salt derivatives that are available
commercially include that available from Lubrizol under the trade designation
"SOLSPERSE 17000" (a reaction product of poly(12-hydroxystearic acid) with
N,N-dimethyl-1,3-propanediamine and dimethyl sulphate) and those available
under the trade designations "CH-5" and "CH-7" from Shanghai Sanzheng
Polymer Company.
[00117] In some embodiments the stabilizing component includes a high
molecular weight polyetheramine, which may be prepared by reacting one unit
of a hydroxy-containing hydrocarbyl compound with two or more units of
butylene oxide to form a polyether intermediate, and aminating the polyether
intermediate by reacting the polyether intermediate with an amine or with
acrylonitrile and hydrogenating the reaction product of the polyether
intermedi-
ate and acrylonitrile.
[00118] Suitable polyetheramines may contain two or more ether units and is
generally prepared from a polyether intermediate. The polyether intermediate
can be a reaction product of one unit of a hydroxy-containing hydrocarbyl
compound with two or more units of butylene oxide. The hydroxy-containing
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hydrocarbyl compound can be an alcohol or an alkyl-substituted phenol where
the alcohol or alkyl substituent of the phenol can have 1 to 50 carbon atoms,
6
to 30 carbon atoms in a second instance, and 8 to 24 carbon atoms in a third
instance. The alcohol or alkyl substituent of the phenol can have a straight
carbon chain, branched carbon chain, or a mixture thereof. The hydroxy-
containing hydrocarbyl compound can contain one or more hydroxyl groups.
[00119] The polyether intermediate from the reaction of a hydroxy-containing
hydrocarbyl compound and butylene oxide can have 2 to 100 repeating butylene
oxide units, 5 to 50 repeating butylene oxide units in a second embodiment,
and
15 to 30 repeating butylene oxide units in a third embodiment. U.S. Patent No.
5,094,667 provides reaction conditions for preparing a polyether intermediate.
[00120] The high molecular weight polyetheramine of the present invention
can be prepared from the above described polyether intermediate that is pre-
pared from butylene oxide.
[00121] In one embodiment of the invention the polyetheramine is prepared
by reacting the polyether intermediate derived from butylene oxide with acrylo-
nitrile to form a nitrile that is then hydrogenated to form a 3-aminopropyl
terminated polyether as described in U.S. Patent No. 5,094,667.
[00122] In another embodiment of the invention the polyetheramine is pre-
pared by reacting the polyether intermediate derived from butylene oxide with
an amine in an amination reaction to give an aminated polyether as described
in
European Publication No. EP310875. The amine can be a primary or secondary
monoamine, a polyamine containing an amino group with a reactive N-H bond,
or ammonia.
[00123] The high molecular weight polyetheramine of the present invention
can have a number average molecular weight of 300 or 350 to 5000, in another
instance of 400 to 3500, and in further instances of 450 to 2500 and 1000 to
2000.
[00124] In another embodiment of the invention the high molecular weight
polyetheramine of the present invention can be represented by the formula
R(OCH2CHR1)xA where R is a C6 to C30 alkyl group or a C6 to C30 alkyl-
substituted phenyl group; R1 is ethyl; x is a number from 5 to 50; and A is
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OCH2CH2CH2NH2 or -NR2 R3 wherein R2 and R3 are independently hydrogen, a
hydrocarbyl group, or ¨(R4 NR5)yR6 wherein R4 is an alkylene group having 2 to
carbon atoms, R5 and R6 are independently hydrogen or a hydrocarbyl group,
and y is a number from 1 to 7. Throughout this application an alkylene group
is
5 a divalent alkane group. In a further embodiment of the polyetheramine of
the
invention, R is a C8 to C24 alkyl group, x is a number from 15 to 30, and A is
¨OCH2 CH2 CH2 NH2.
[00125] In some embodiments the high molecular weight polyetheramine is
represented by the formula R(OCH2CHR1)xA wherein R is a C6 to C30 alkyl
10 group or a C6 to C30 alkyl-substituted phenyl group; R1 is ethyl; x is a
number
from 5 to 50; and A is -OCH2CH2CH2NH2 or ¨NR2R3 wherein R2 and R3 are
independently hydrogen, a hydrocarbyl group, or ¨(R4NR5)yR6 wherein R4 is an
alkylene group having 2 to 10 carbon atoms, R5 and R6 are independently
hydrogen or a hydrocarbyl group, and y is a number from 1 to 7.
[00126] In some embodiments the stabilizing component includes an alka-
nolamine substituted phenol where the phenol contains a hydrocarbyl substitu-
ent. Suitable materials may be represented by the formula:
OH
2
R3-0R4
10 Rz
1\1/
\R3-0R4
R1
where R1 is a hydrocarbyl group, R2 is a hydrocarbylene group, each R3 is
independently a hydrocarbylene group, and each R4 is independently a hydrogen
or a hydrocarbylene group. In some embodiments R1 contains from 1 to 20, 8 to
20, 8 to 16, 10 to 14 or even about 12 carbon atoms; R2 contains from 1 to 8,
1
to 6, 1 to 4, at least 1 carbon atom, or even about 1 carbon atom; each R3
group
contain from 1 to 8, 1 to 6, 1 to 4, 2 to 4, at least 2 carbon atoms, or even
about
2 carbon atoms and may be identical; and each R4 group is hydrogen or a hydro-
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carbylene group that contains from 1 to 8, 1 to 6, 1 to 4, 2 to 4, at least 2
carbon
atoms, or even about 2 carbon atoms and may be identical.
[00127] In some embodiments the stabilizing component includes a low
molecular weight acylated nitrogen compound derived from an alkyl succinic
anhydride and an alkanolamine.
[00128] The stabilizing component may be a low molecular weight acylated
nitrogen compound, which in some embodiments may be described as an amino
ester or an amino ester salt. These materials may be prepared from the
reaction
of an alkyl succinic anhydride and an alkanolamine combined at a ratio of 1:10
to 10:1, 1:5 to 5:1, 3:5 to 5:3, 1:2 to 2:1, 1:1. The alkyl group of the alkyl
succinic anhydride can be a hydrocarbyl group containing from about 4 to about
18 carbon atoms; from about 6 to about 18 carbon atoms, from about 9 to about
18 carbon atoms and particularly from about 12 to about 18 carbon atoms. The
alkyl group of the alkyl succinic anhydride can be saturated, unsaturated,
branched, linear or mixtures thereof. In some embodiments the alkyl group is
linear.
[00129] The alkyl succinic anhydride can be the reaction product of a
branched or linear olefin having about 4 to about 18 carbon atoms; from about
6
to about 18 carbon atoms, from about 9 to about 18 carbon atoms and particular-
ly from about 12 to about 18 carbon atoms and maleic anhydride. This reaction
is well known to those skilled in the art. Suitable examples of the alkyl
succinic
anhydride include dodecenyl succinic anhydride, pentadecenyl succinic anhy-
dride, hexadecenyl succinic anhydride, octadecenyl succinic anhydride, hepta-
decenyl succinic anhydride, and the like.
[00130] The alkanolamine component of the acylated nitrogen compound of
the present invention can be an amino alcohol, such as, an ethanolamine
(includ-
ing mono, di and tri ethanolamines), or a propanol amines (including mono, di
and tri ethanolamines) in which nitrogen is attached directly to the carbon of
the
alkyl alcohol. Examples of the alkanolamine component of the acylated nitro-
gen compounds can include: monoethanolamine, triethanolamine, methylethano-
lamine, methyldiethanolamine, dimethylethanolamine, diethylethanolamine,
dibutylethanolamine, monoisopropanolamine, diisopropanolamine, triisopro-
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panolamine. The examples of these alkanolamines are well known to those
skilled in the art. In some embodiments the alkanolamine used in the
preparation
of the compatibilizer is triethanolamine, N,N-dimethylaminopropanol, N,N-
diethylaminopropanol, N,N-dimethylethanol amine, N,N-diethylaminobutanol,
N,N,N-tris(hydroxyethyl)amine, or a mixture thereof
[00131] The reaction products of the alkyl succinic anhydride or its acid or
ester derivative and the alkanolamine include amides, imides, esters, amine
salts, ester- amides, ester-amine salts, amide-amine salts, acid-amides, acid-
esters and mixtures thereof. The reaction and the resulting products of the
alkyl
succinic anhydride and the alkanolamine are readily known to those skilled in
the art.
[00132] The stabilizing component may be an aromatic carboxylic acid/amine
salt or an abietic acid/amine salt, that is a salt of an aromatic carboxylic
acid
and/or an abietic acid with an amine, such as a fatty amine. However in other
embodiments, these moderately performing stabilizing compounds may be
excluded from the compositions of the invention, or at least required in
higher
amounts than some of the other stabilizing compounds described in order to
provide comparable performance. This is some embodiments these materials
are part of the invention and in other embodiments these materials may be
treated more as comparative examples, at least where more consistent perfor-
mance is required and/or at lower concentration levels.
[00133] The aromatic carboxylic acid may include an aliphatic moiety contain-
ing the carboxylic acid group, and the aliphatic moiety may contain from 1 to
26 or
more carbon atoms, or from 1 to 10 carbon atoms. Alternatively, the aromatic
carboxylic acid may be one in which the carboxylic group is bonded directly to
the
aromatic moiety, for example benzoic acid. Suitable aromatic carboxylic adds
include benzoic acid, phenylacetic acid, phenylpropionic acid, phenylbutyric
acid,
phenylpentanoic acid, phenylhexanoic acid, phenylheptanoic acid,
phenyloctanoic
acid, phenylnonanoic acid, phenyldecanoic acid, phenyldodecanoic acid, phenyl-
tetradecanoic acid, phenylbexadecanoic acid, and phenyloctadecanoic acid.
[00134] The aromatic carboxylic acid may also include phenyl versions of any
of the acids described above, where a hydroxy group is present on the aromatic
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ring, generally adjacent to the aliphatic moiety containing the carboxylic
acid
group. Examples of acids include salicylic acid.
[00135] The acid moiety of the amine salt may contain a hydroxy group, an oxy
group, or it may contain an ester moiety. Hydroxy carboxylic acids include
phenyl
hydroxy carboxylic acids having a hydroxy alkyl group which may contain from 3
to 26 carbon atoms. The phenyl or other aryl ring or rings may include one or
more
substituents attached thereto including alkyl groups of 1 to 12 or 10 more
carbon
atoms, alkoxy groups containing from 1 to 12 carbon atoms, hydroxy, carbamyl,
carboalkoxy, amido or amino alkyl groups.
[00136] When one substituent group is present, not counting the hydroxy group
of
a phenyl ring as a substituent if present, it may generally be in a position
para to the
carboxylic acid moiety. When two or more substituents are present, they may
generally be in a position 3,4 or 3,5 on a phenyl ring. Illustrative examples
include
meta or para toluic acid, meta- or para-hydroxybenzoic acid, anisic acid and
gallic
acid.
[00137] The amine suitable for use in the preparation of the salt are not
overly
limited and may include any alkyl amine, though generally are fatty acid
amines
derived from fatty carboxylic acids. The alkyl group present in the amine may
contain from 10 to 30 carbon atoms, or from 12 to 18 carbon atoms, and may be
linear or branched. In some embodiments the alkyl group is linear and unsatu-
rated. Typical amines include pentadecylamine, octadecylamine, cetylamine,
oleylamine, decylamine, do decylamine, dimethyldo decylamine, tridecylamine,
heptadecylamine, octadecylamine, stearylamine, and any combination thereof
In some embodiments the fatty acid derived amine salt of a salicylic acid of
oleylamine.
[00138] The salt is prepared in any suitable manner and generally includes
mixing
the amines and acid under conditions designed to avoid conversion to the
amide,
ester, or other condensation products. In one embodiment, substantially equal
molar
proportions of the mine and acid are used. However, when desired, an excess of
the
amine may be employed, in which case the proportions may be in the range of
from
about 1.0 to about 1.2 mole proportions of amine per mole proportion of acid.
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[00139] In some embodiments the stabilizing component is a fatty acid amino
salicylate, that is a fatty amine salt of salicylic acid where the fatty amine
used
in the preparation of the salt is derived from a fatty acid.
[00140] Amines suitable for use in the preparation of the amino salicylate are
not overly limited and may include any alkyl amine, though generally are fatty
acid amines derived from fatty carboxylic acids. The alkyl group present in
the
amine may contain from 10 to 30 carbon atoms, or from 12 to 18 carbon atoms,
and may be linear or branched. In some embodiments the alkyl group is linear
and unsaturated. Typical amines include pentadecylamine, octadecylamine,
cetylamine, oleylamine, decylamine, dodecylamine, dimethyldodecylamine,
tridecylamine, heptadecylamine, octadecylamine, stearylamine, and any combi-
nation thereof. In some embodiments the fatty acid derived amine salt of a
salicylic acid of oleylamine.
[00141] In some embodiments the stabilizing component includes a nitrogen-
containing dispersant or borated version thereof. The nitrogen-containing
dispersant may be a reaction product of a hydrocarbyl-substituted succinic
acylating agent and a polyamine, which may optionally be borated. Such
materials are described in US Pat. No. 4,234,435. In related embodiments the
stabilizing component can be (i) a nitrogen-containing dispersant; (ii) a
borated
nitrogen-containing dispersant; (iii) an alkyl imidazoline; (iv) the reaction
product of a polyethylene polyamine and a fatty acid; or combinations thereof.
[00142] The hydrocarbyl-substituted succinic acylating agents can include
succinic acids, halides, esters, and anhydrides. In some embodiments the
agents
are succinic anhydrides. In one embodiment, the hydrocarbyl groups of the
agents are derived from polyalkenes having an Mn (number average molecular
weight) of from 500, 750, or 850 up to 5000, 3000, 2000, or 1600, and the
polydispersity, (Mw/Mn), that is, the ratio of the weight average molecular
weight over the number average molecular weight is from 1.5, 1.8, or 2, or to
2.5, 3.6, or 3.2. In some embodiments, the nitrogen free dispersant of the
present invention is derived from a hydrocarbon polymer, such as polyisobutyl-
ene (PIB), that substantially free of polymer having a Mn of more than 1600,
or
from 1600 to 3000.
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[00143] The PIB may be conventional PIB or highly reactive and/or high
vinylidene PIB. In one embodiment the PIB used is conventional PIB, in
another embodiment the PIB used is highly reactive PIB, and in still another
embodiment the PIB used is a mixture of conventional and highly reactive PIB.
[00144] The amine which reacts with the succinic acylating agent may be a
polyamine. The polyamine may be aliphatic, cycloaliphatic, heterocyclic or
aromatic. Examples of the polyamines include alkylene polyamines, hydroxy
containing polyamines, aromatic polyamines, and heterocyclic polyamines.
Such alkylenepolyamines include ethylenepolyamines, butylenepolyamines,
propylenepolyamines, pentylenepolyamines, etc. The higher homologs and
related heterocyclic amines such as piperazines and N-aminoalkyl-substituted
piperazines are also included. Specific examples of such polyamines are eth-
ylenediamine, diethylenetriamine (DETA), triethylenetetramine (TETA), tris-(2-
aminoethyl)amine, propylenediamine, trimethylenediamine, tripropylenetetra-
mine, tetraethylenepentamine (TEPA), hexaethyleneheptamine, pentaethylene-
hexamine, and mixtures thereof.
[00145] Suitable polyamines also include ethylenepolyamines, as described
under the heading Ethylene Amines in Kirk Othmer's "Encyclopedia of Chemi-
cal Technology", 2d Edition, Vol. 7, pages 22-37, Interscience Publishers, New
York (1965). These materials are a complex mixture of polyalkylenepolyamines
including cyclic condensation products such as the aforedescribed piperazines.
[00146] Other useful types of polyamine mixtures are those resulting from
stripping the above-described polyamine mixtures to leave a residue often
termed "polyamine bottoms". In general, alkylenepolyamine bottoms can be
characterized as having less than two, usually less than 1%, (by weight)
material
boiling below 200 C. A typical sample of such ethylene polyamine bottoms
obtained from the Dow Chemical Company of Freeport, Texas designated
"E-100" has a specific gravity at 15.6 C of 1.0168, a percent nitrogen by
weight
of 33.15 and a viscosity at 40 C of 121 centistokes. Gas chromatography
analysis of such a sample contains 0.93% "Light Ends" (most probably DETA),
0.72% TETA, 21.74% TEPA and 76.61% pentaethylenehexamine and higher (by
weight). These alkylenepolyamine bottoms include cyclic condensation prod-
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ucts such as piperazine and higher analogs of diethylenetriamine,
triethylenetet-
ramine and the like. These alkylenepolyamine bottoms can be reacted with the
acylating agent alone or can be used with other amines and/or polyamines.
[00147] In some embodiments the nitrogen-containing dispersant is derived
from the reaction of one or more of the amines described above and a fatty
carboxylic acid. Suitable fatty carboxylic acids include both mono and di
carboxylic acids with a hydrocarbyl containing from 6, 10 or 12 to 100, 60,
30,
or 24 carbon atoms. The hydrocarbyl group may be linear or branched, and in
some embodiments contains a single methyl branch at the end of the hydro-
carbyl chain. Specific examples of suitable acids include dodecanoic acid,
tetradecanoic acid, palmitic acid, stearic acid (including isostearic acid),
icosa-
noic acid, and the like. Smaller acids can be used in combination with those
described above, such as adipic acid, succinic acid, octanedioic acid, and the
like. In some embodiments these nitrogen-containing dispersant are prepared
from isostearic acid and an alkylene polyamine such as DETA, TETA and/or
TEPA.
[00148] The nitrogen-containing dispersants may also be borated. Typically,
the borated dispersant contains from 0.1% to 5%, or from 0.5% to 4%, or from
0.7% to 3% by weight boron. In one embodiment, the borated dispersant is a
borated acylated amine, such as a borated succinimide dispersant. Borated
dispersants are described in U.S. Pat. Nos. 3,000,916; 3,087,936; 3,254,025;
3,282,955; 3,313,727; 3,491,025; 3,533,945; 3,666,662 and 4,925,983. Borated
dispersant are prepared by reaction of one or more dispersants with one or
more
boron compounds. Any of the dispersants described herein may be borated,
either during the reaction of the hydrocarbyl substituted acylating agent and
the
amine or after.
[00149] In one embodiment, the boron compound is an alkali or mixed alkali
metal and alkaline earth metal borate. These metal borates are generally
hydrat-
ed particulate metal borates which are known in the art. Alkali metal borates
include mixed alkali and alkaline metal borates. U.S. Pat. Nos. 3,997,454;
3,819,521; 3,853,772; 3,907,601; 3,997,454; and 4,089,790 disclose suitable
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alkali and alkali metal and alkaline earth metal borates and their methods of
manufacture. In one embodiment the boron compound is boric acid.
[00150] The nitrogen-containing dispersants of the present invention may also
be post-treated by reaction with any of a variety of agents besides borating
agents. Among these are urea, thiourea, dimercaptothiadiazoles, carbon disul-
fide, aldehydes, ketones, carboxylic acids, hydrocarbon-substituted succinic
anhydrides, nitriles, epoxides, and phosphorus compounds. References detailing
such treatment are listed in U.S. Pat. No. 4,654,403.
[00151] In one embodiment, the nitrogen-containing dispersant of the present
invention is borated and may also be derived from PIB having an Mn of less
than 1600, or from 850 or 900 to 1500 or 1200.
[00152] In one embodiment, the nitrogen-containing dispersant of the present
invention is any one or more of the following: a borated succinimide
dispersant
derived from the reaction of boric acid, a mixture of polyethylene polyamines
and/or bottoms, and a polyisobutenyl succinic anhydride derived from conven-
tional PIB; a borated succinimide dispersant derived from the reaction of
boric
acid, a mixture of polyethylene polyamines and/or bottoms, and a polyisobu-
tenyl succinic anhydride derived from high vinylidene PIB; a borated
dispersant
derived from the reaction of a polyisobutenyl succinimide dispersant and boric
acid where the dispersant is derived from a mixture of polyethylene polyamines
and/or bottoms, and a polyisobutenyl succinic anhydride derived from conven-
tional PIB; a non-borated polyisobutenyl succinimide dispersant derived from a
polyisobutenyl succinic anhydride derived from high vinylidene PIB and TEPA;
a non-borated alkyl imidazoline derived from a polyalkylene amine and a fatty
mono-carboxylic acid.
[00153] In still other embodiments, the nitrogen containing dispersant used in
the stabilizing component of the present invention includes at least one hydro-
carbyl group containing from 10, 20 or 40 to 500, 400 or 250 carbon atoms.
The dispersant may also have a TBN (as defined below and as measured by
ASTM D4739) of at least 9, 10, 15 or 20. In the case where the dispersant is
borated, its TBN may be at least 9. In the case where the dispersant is not
borated, its TBN may be at least 20. In further embodiments, where the disper-
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sant is borated, it may contain at least 0.1, 0.2, 0.4 percent by weight
boron.
The borated dispersant may contain from 0.1, 0.2 or 0.4 to 4 or 2 percent by
weight boron. In still other embodiments, the dispersant may have an N:CO
ratio of greater than 0.7:1. The N:CO ratio of a dispersant is the ratio of
the
equivalents of amino groups to carboxylic groups within the dispersant mole-
cule. In the case where the dispersant is borated, its N:CO ratio may be at
least
0.7:1 or at least 0.75:1. In the case where the dispersant is not borated, the
N:CO ratio may have a higher limit, for example the N:CO ratio may be at least
1:1 or 1.3:1, or even at least 1.6:1. The N:CO ratio of the dispersants is
general-
ly not higher than 4:1, 3:1 or 2:1. Any one of the features describe above may
be used in combination with the others.
[00154] Any of the stabilizing components described above may be used
alone, even to the exclusion of one or more the components listed, while in
other embodiments they may be used in any combination of two or more there-
of.
[00155] Useful compatibilizers may be described more generally as a com-
pound having at least one hydrogen-donating group, a least one hydrogen-
accepting group, and at least one hydrocarbyl group, where the hydrogen-
donating group and the hydrogen-accepting group are not separated by more
than 8 bonds, where the bond counted may include covalent bonds or ionic
bonds, and generally both types of bonds combined.
[00156] In some embodiments the hydrocarbyl group of the compatibilizer
compound is sufficient to impart solubility to the compatibilizer in the
medium
in which it is used, while in other embodiments it contains at least 8, 10, 14
or
even 20 carbon atoms. Is still other embodiments the hydrocarbyl group of the
compatibilizer compound may be any of the hydrocarbyl groups defined above
related to the compatibilizer component.
[00157] A hydrogen-donating group is a substituent group or atom capable of
donating a proton to another compound. The group may itself be described as a
hydrogen donor group. Suitable examples of hydrogen-donating groups which
are included in the invention are: -OH, -OR, -C(0)0H, -C(0)0R, -SH, -NRH, -
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NH2, -NR2H, -NRH2, and -NH3, where each R is independently a hydrocarbyl
group. Suitable examples may have a positive charge.
[00158] A hydrogen-accepting group is a substituent group or atom capable of
accepting a proton. The group may itself be described as a hydrogen acceptor
group. Suitable examples of hydrogen-accepting groups which are included in
the invention are: =0, -C(0)0H, -C(0)0R, =S, -NRH, -NRR, -NHH where each
R is independently a hydrocarbyl group; a carboxylic acid derivative such as a
carboxylate anion, an imide, an amide, an imidazoline, an anhydride or an
ester;
or a phosphate or thiophosphate. Additional examples of hydrogen- accepting
groups include the anions described above. Suitable examples may have a
negative charge.
[00159] In other embodiments the accepting and donating groups discussed
above are separated by at least 1 to no more than 4, 6, 7 or 8 bonds, at least
2 or
even 3 to no more than 6, 7 or 8, and even no less than 2 up to no more than 4
bonds. In some embodiments the compatibilizer compound contains at least one
set of groups, that is at least one acceptor group and at least one donating
group,
but in other embodiments the compatibilizer compounds may contain multiple
sets of groups. For example the compatibilizer compounds may include at least
two acceptor groups and at least two donating groups, or even more. Useful
compatibilizer compounds may include 1 set of accepting and donating groups,
two sets, or even three sets of groups. While not wishing to be bound by
theory
it is believed that the greater the number of sets of accepting and donating
groups, the better a compounds performance as a compatibilizer, however the
distance between the groups, as measured by the number of bonds between the
groups also has an impact on compatibilizer performance. In addition it is
believed that the functionality of the accepting and donating groups can be
impaired if they are sterically hindered.
[00160] Suitable compatibilizers may contain: (i) a single hydrogen-acceptor
group and a single hydrogen-donating groups; (ii) a single hydrogen-acceptor
group and two or more hydrogen-donating groups; (iii) two or more hydrogen-
acceptor groups and one hydrogen-donating group; or (iv) two or more hydro-
gen-acceptor groups and two or more hydrogen-donating groups.
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[00161] In some embodiments the compatibilizer component includes (i) a
compound having at least one set of accepting and donating groups separated by
less than 4 bonds, where bonds include both covalent and ionic bonds, (ii) a
compound having at least one hydrogen-acceptor group such as a nitrogen atom
and at least two, or even three hydrogen-donating groups, such as ¨OH groups,
separated by 1 to 8 bonds, (iii) a compound having at least two sets of
accepting
and donating groups where the groups of each set are separated by 1 to 8
bonds,
where bonds include both covalent and ionic bonds, or any combination thereof.
[00162] In some embodiments component (c), the stabilizing component, is
essentially free or even free of compounds represented by the formula:
Xi
R3 N R1
I
R4 R2
or salted versions thereof wherein: X1 is 0 or NR5 where R1 and R5 can option-
ally link to form a ring; R3 is H or a hydrocarbyl; R4 is H, a hydrocarbyl
group,
¨CH2C(0)-X2 where X2 is ¨OH, or where R4 is linked with R2 to form a ring
where the linked -R4-R2-
group is ¨CH2C(0)¨; and wherein each R1 is inde-
pendently H, a hydrocarbyl group or -(CH2CH2NH).-H where n is an integer
from 1 to 10; where each R2 is independently H, a hydrocarbyl group or -
(CH2CH2NH).-H where n is 1 to 10, or where R2 is linked with R4 to form a
ring where the linked -R4-R2- group is ¨CH2C(0)¨; and R5 is a hydrocarbyl
group; with the proviso that at least one of R1, R2, R3, R4, or R5 is a
hydrocarbyl
group and wherein the entire compound contains at least 10 carbon atoms. In
some embodiments at least one of R1, R2, R3, R4, or R5 is a hydrocarbyl group
that contains at least 10 carbon atoms.
[00163] In still further embodiments component (c), the stabilizing compo-
nent, is free of compounds represented by one or more of the following formu-
las:
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0
/ N
N- X3
R6 _________________________________________ R6 0 \
----- N>
I X3 / R6N /
n
X3 H
Or or
wherein each R6 is independently a hydrocarbyl group; each X3 is independently
a nitrogen containing group derived from a polyethylene polyamine; and n may
be an integer from 1 to 10.
[00164] In some embodiments the stabilizing component excludes certain
nitrogen-containing dispersants or borated version thereof. For example the
computerize component of the invention may be essentially free or even free of
nitrogen-containing dispersants, or borated versions thereof, which are the
reaction product of a hydrocarbyl-substituted succinic acylating agent and a
polyamine but which do not contain a quaternized nitrogen atom.
[00165] In one embodiment, component (c), the stabilizing component, is free
of borated non-quaternized succinimide dispersants derived from the reaction
of
boric acid, a mixture of polyethylene polyamines and/or bottoms, and a polyiso-
butenyl succinic anhydride derived from conventional PIB; borated succinimide
non-quaternized dispersants derived from the reaction of boric acid, a mixture
of
polyethylene polyamines and/or bottoms, and polyisobutenyl succinic anhy-
drides derived from high vinylidene PIB; borated non-quaternized dispersants
derived from the reaction of a polyisobutenyl succinimide dispersant and boric
acid where the dispersant is derived from a mixture of polyethylene polyamines
and/or bottoms, and a polyisobutenyl succinic anhydride derived from conven-
tional PIB; a non-borated non-quaternized polyisobutenyl succinimide disper-
sant derived from a polyisobutenyl succinic anhydride derived from high vinyli-
dene PIB and TEPA; a non-borated alkyl imidazoline derived from a poly-
alkylene amine and a fatty mono-carboxylic acid.
[00166] In some embodiments the stabilizing component is free of overbased
detergents. In some embodiments the stabilizing component is free of phospho-
rus containing additives, such as an amine salt of a hydrocarbyl phosphate, a
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hydrocarbyl thiophosphate, a hydrocarbyl dithiophosphate, or combinations
thereof
[00167] In some embodiments the stabilizing component of the present
invention is essentially free to free of compounds represented by the formula:
Ix11111)43,
11
wherein: X1 is an oxygen atom, a sulfur atom, or >NR2; X2 is an oxygen atom or
a sulfur atom; X3 is a carbon atom, S=0, or P(0R2); Y1 is ¨R2, ¨0R2, ¨0-
'NHR1(R2)2, ¨s_+NHR1(R2)25 - K 1=s a hydrocarbylene group; R2 is a hydrocarbyl
group or ¨H; and each n is independently 0 or 1.
[00168] In still further embodiments, the stabilizer component of the inven-
tion is free of: (i) a borated succinimide dispersant derived from the
reaction of
boric acid, a mixture of polyethylene polyamines and/or bottoms, and a polyiso-
butenyl succinic anhydride derived from conventional PIB; (ii) a borated
succin-
imide dispersant derived from the reaction of boric acid, a mixture of polyeth-
ylene polyamines and/or bottoms, and a polyisobutenyl succinic anhydride
derived from high vinylidene PIB; (iii) a borated dispersant derived from the
reaction of a polyisobutenyl succinimide dispersant and boric acid where the
dispersant is derived from a mixture of polyethylene polyamines and/or bot-
toms, and a polyisobutenyl succinic anhydride derived from conventional PIB;
(iv) a non-borated polyisobutenyl succinimide dispersant derived from a poly-
isobutenyl succinic anhydride derived from high vinylidene PIB and TEPA; (v)
a calcium sulfonate overbased detergent derived from a sulfonic acid; (vi) an
overbased detergent derived from an alkylated phenol; (vii) an amine salt of a
mixture of phosphoric acids and esters; (viii) an amine salt of a mixture of
dithio-
phosphoric acids and esters; or mixtures thereof While the friction modifier
com-
prises any of the friction modifiers described above. In some embodiments the
friction modifier component includes oleyl tartrimide, stearyl tartrimide, 2-
ethylhexyl
tartrimide, or combinations thereof; and may also include any of the other
friction
modifiers described above, particularly the additional friction modifiers that
do not
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have compatibility and/or solubility issues in the medium and/or functional
fluid
compositions described herein.
Industrial Application
[00169] The present invention includes a process of preparing a composition
that includes combining: (a) a medium comprising a solvent, a functional
fluid,
or combinations thereof; (b) a friction modifier component that includes a
phosphorus-containing compound that is not fully soluble in the medium; and
(c) a stabilizing component that is soluble in (a) and that interacts with (b)
such
that (b)'s solubility in (a) is improved where the stabilizing component
includes
a compound having at least one hydrogen-donating group, a least one hydrogen-
accepting group, and at least one hydrocarbyl group, where the hydrogen-
donating group and the hydrogen-accepting group are not separated by more
than 8 covalent and ionic bonds. The processes of the present invention
involve
adding components (b) and (c) to component (a) and mixing the components so
that particles of components (b) and (c) have an average diameter of less than
10
microns. The processes of the present invention results in a mixture that is
clear
and/or stable in that the friction modifier does not drop out of solution,
does not
make the mixture appear cloudy or hazy, stays suspended, dispersed and/or
dissolved in the mixture, or combinations thereof, or that at least shows im-
provement in one or more of these areas when compared to an identical compo-
sition that does not contain the stabilizing component.
[00170] While not wishing to be bound by theory, it is believed that in at
least
some embodiments the compositions of the present invention improve the
stability and/or compatibility of the friction modifier component in the
overall
composition due to the friction modifier component being solubilized in a
complex with the compatibilizer.
[00171] In some embodiments the processes of the present invention result in
a mixture with an improved clarity, as defined by a lower JTU and/or NTU
value, compared to the same composition that does not contain the stabilizing
component.
[00172] In some embodiments the compositions of the present invention
and/or the compositions that result from the processes of the present
invention
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include both finished functional fluids and additive concentrates. Finished
functional fluids are fluids that are ready for use. Additive concentrates are
compositions that may contain all of the additives required for a finished
fluid,
but in concentrated form. This makes shipment and handling easier. At the
appropriate time, the additive concentrate may be blended with a fluid,
solvent
such as oil, or similar diluent, as well as additional additives, to produce a
finished functional fluid that is ready for use.
[00173] As noted above, components (b) and (c), or (b) alone, may be present
in component (a) in the form of dispersed particles having an average diameter
of less than 10 microns. In some embodiments the particles have an average
diameter of less than 10, 5 or 3 microns. In other embodiments, the particles
have an average diameter of from 0.01, 0.02, 0.03 or 0.09 to 10, 6, 5 or 3 mi-
crons. In some embodiments 80% of the particles meet one or more of the size
limitations described above. In other embodiments 90%, 95%, 99% or even
100% of the particles meet the size limits. That is, in some embodiments no
more than 10% by weight of the particles have a diameter of more than 10, 5,
3,
1 or even 0.5 microns. The means by which the particles are formed is not
overly limited, and may include the mixing of components (a), (b) and (c)
using
conventional equipment and/or techniques.
[00174] When referring to finished functional fluids, the compositions in-
volved with the present invention may include: from 1, 3 or 10 to 99, 80 or 70
percent by weight of component (a), the medium; from 0.1, 0.15, 0.2, 0.3, 0.5
or
1.0 to 10, 7.5, 5, 4 or 3 percent by weight of component (b), the friction
modifi-
er; and from 0.1, 0.2, 0.3, 0.5 or 2.0 to 20, 10, 8, 5, 4 or 2 percent by
weight of
component (c), the stabilizing component.
[00175] When referring to additive concentrates, the compositions involved
with the present invention may include: from 0.1, 1, 3 or 10 to 90, 60, 50,
30, or
20 percent by weight of component (a), the medium; from 0.1, 0.15, 0.5, 1, 5
or
8 to 60, 30, 20 or 10 percent by weight of component (b), the friction
modifier;
and from 0.1, 0.2, 0.3, 0.5 or 2.0 to 20, 10, 8, 5, 4 or 2 percent by weight
of
component (c), the stabilizing component. As noted above in some embodi-
ments the medium and the stabilizing component may be the same material, in
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which case the duel functioning material may be present in any of the ranges
provided above for either component (a) or (c).
[00176] In some embodiments the compositions of the present invention are
formed by mixing components (b) and (c) into component (a) such that component
(b) forms small particles within component (a) and component (c) acts to
stabilize
these particles. In some embodiments component (c) and component (b) form
mixed
particles in component (a). In some embodiments some or all of the particles
formed
are within the sizes described above. In other embodiments, some or even all
of the
particles are larger than those described above.
[00177] In some embodiments the components of the present invention are mixed
by conventional means. The amount of mixing required varies from composition
to
composition and is that sufficient to produce the particles of the desired
size and/or
stability. In some embodiments the mixing may be accomplished by milling the
components and in still other embodiments the mixing may be accomplished by
milling the components at low temperature.
[00178] The mixing may be in the form of a milling process using conventional
milling equipment and techniques. However, in some embodiments the milling is
completed at low temperatures, in some embodiments from at less than 30
degrees C
and in other embodiments from -10, 0 or 5 to 30, 25 or 20 degrees C. The low
temperature milling may be achieved by cooled milling equipment, pre-cooled
components, adding a chilling agent such as dry ice (solid carbon dioxide) to
the
components during milling, or a combination thereof The resulting compositions
in
some embodiments may be described as stable dispersions and in other
embodiments
may be described as solubilized solutions, or even combinations thereof, where
the
main difference between such embodiments may be the size of the particles
involved.
[00179] In other embodiments the compositions of present invention are not
formed by milling or any other high-energy input methods, but rather are
formed
with simple mixing and very little energy input.
[00180] In some embodiments the functional fluid with which the compositions
of
the invention are used is a fuel. The fuel compositions of the present
invention
comprise the stabilized compositions described above and a liquid fuel, and is
useful in fueling an internal combustion engine or an open flame burner. These
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compositions may also contain one or more additional additives described
herein. In some embodiments, the fuels suitable for use in the present
invention
include any commercially available fuel, and in some embodiments any com-
mercially available diesel fuel and/or biofuel.
[00181] The description that follows of the types of fuels suitable for use in
the present invention refer to the fuel that may be present in the additive
con-
taining compositions of the present invention as well as the fuel and/or fuel
additive concentrate compositions to which the additive containing composi-
tions may be added.
[00182] Fuels suitable for use in the present invention are not overly
limited.
Generally, suitable fuels are normally liquid at ambient conditions e.g., room
temperature (20 to 30 C) or are normally liquid at operating conditions. The
fuel can be a hydrocarbon fuel, non-hydrocarbon fuel, or mixture thereof.
[00183] The hydrocarbon fuel can be a petroleum distillate, including a
gasoline as defined by ASTM specification D4814, or a diesel fuel, as defined
by ASTM specification D975. In one embodiment the liquid fuel is a gasoline,
and in another embodiment the liquid fuel is a non-leaded gasoline. In another
embodiment the liquid fuel is a diesel fuel. The hydrocarbon fuel can be a
hydrocarbon prepared by a gas to liquid process to include for example hydro-
carbons prepared by a process such as the Fischer-Tropsch process. In some
embodiments, the fuel used in the present invention is a diesel fuel, a
biodiesel
fuel, or combinations thereof
[00184] Suitable fuels also include heavier fuel oils, such as number 5 and
number 6 fuel oils, which are also referred to as residual fuel oils, heavy
fuel
oils, and/or furnace fuel oils. Such fuels may be used alone or mixed with
other,
typically lighter, fuels to form mixtures with lower viscosities. Bunker fuels
are
also included, which are generally used in marine engines. These types of
fuels
have high viscosities and may be solids at ambient conditions, but are liquid
when heated and supplied to the engine or burner it is fueling.
[00185] The non-hydrocarbon fuel can be an oxygen containing composition,
often referred to as an oxygenate, which includes alcohols, ethers, ketones,
esters of a carboxylic acids, nitroalkanes, or mixtures thereof. Non-
hydrocarbon
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fuels can include methanol, ethanol, methyl t-butyl ether, methyl ethyl
ketone,
transesterified oils and/or fats from plants and animals such as rapeseed
methyl
ester and soybean methyl ester, and nitromethane.
[00186] Mixtures of hydrocarbon and non-hydrocarbon fuels can include, for
example, gasoline and methanol and/or ethanol, diesel fuel and ethanol, and
diesel fuel and a transesterified plant oil such as rapeseed methyl ester and
other
bio-derived fuels. In one embodiment the liquid fuel is an emulsion of water
in
a hydrocarbon fuel, a non-hydrocarbon fuel, or a mixture thereof
[00187] In several embodiments of this invention the liquid fuel can have a
sulphur content on a weight basis that is 50,000 ppm or less, 5000 ppm or
less,
1000 ppm or less, 350 ppm or less, 100 ppm or less, 50 ppm or less, or 15 ppm
or less.
[00188] The liquid fuel of the invention is present in a fuel composition in a
major amount that is generally greater than 95% by weight, and in other embod-
iments is present at greater than 97% by weight, greater than 99.5% by weight,
greater than 99.9% by weight, or greater than 99.99% by weight.
[00189] The compositions described above may also include one or more addi-
tional additives. Such additives include oxidation inhibitors and
antioxidants,
antiwear agents, corrosion inhibitors, or viscosity modifiers, as well as
disper-
sant and detergents. These additional additives may be present in the medium,
particularly when the medium includes a functional fluid. When present, these
additional additives may represent from 0, 0.1, 0.5 or 1 to 2, 5, 10 or 15
percent
of the overall composition, when considering a finished fluid, and from 0,
0.5, 1
or 2 to 4, 10, 20 or 40 percent of the overall composition, when considering
an
additive concentrate.
[00190] As allowed for by the ranges above, in one embodiment, the additive
concentrate may comprise the additives of the present invention and be substan-
tially free of any additional solvent. In these embodiments the additive
concen-
trate containing the additives of the present invention is neat, in that it
does not
contain any additional solvent added to improve the material handling
character-
istics of the concentrate, such as its viscosity.
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[00191] 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: hydrocarbon substituents, that is,
aliphatic (e.g., alkyl or alkenyl), alicyclic (e.g., cycloalkyl, cycloalkenyl)
substituents, and aromatic-, aliphatic-, and alicyclic-substituted aromatic
sub-
stituents, as well as cyclic substituents wherein the ring is completed
through
another portion of the molecule (e.g., two substituents together form a ring);
substituted hydrocarbon substituents, that is, substituents containing non-
hydrocarbon groups which, in the context of this invention, do not alter the
predominantly hydrocarbon nature of the substituent (e.g., halo (especially
chloro and fluoro), hydroxy, alkoxy, mercapto, alkylmercapto, nitro, nitroso,
and sulfoxy); 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,
preferably
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. The term hydrocarbyl
and/or hydrocarbylene may also have the definition provided in the sections
above.
[00192] It is known that some of the materials described above may interact in
the final formulation, so that the components of the final formulation may be
different from those that are initially added. For instance, metal ions (of,
e.g., a
detergent) can migrate to other acidic or anionic sites of other molecules. In
addition the acylating agents and/or substituted hydrocarbon additives of the
present invention may form salts or other complexes and/or derivatives, when
interacting with other components of the compositions in which they are used.
The products formed thereby, including the products formed upon employing
the composition of the present invention in its intended use, may not be
suscep-
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tible of easy description. Nevertheless, all such modifications and reaction
products are included within the scope of the present invention; the present
invention encompasses the composition prepared by admixing the components
described above.
[00193] Unless otherwise indicates all percent values and ppm values herein
are weight percent values and/or calculated on a weight basis.
EXAMPLES
[00194] The invention will be further illustrated by the following examples,
which sets forth particularly advantageous embodiments. While the examples
are provided to illustrate the present invention, they are not intended to
limit it.
Example Set A
[00195] A set of samples is prepared by adding a specific friction modifier to
specific mediums where the friction modifier is known to have compatibility
issues in such compositions. The friction modifier used in this testing is a
dialkyl hydrogen phosphonate (FM-1). The mediums used in this testing in-
clude: a Group I base oil hydraulic fluid (MEDIUM-1), a Group IV base oil
hydraulic fluid (MEDIUM-2), and a Group I base oil industrial gear oil fluid
(MEDIUM-3). The compatibilizers used in this testing include: a quaternary
ammonium salt derived from a 1000 number average molecular weight polyiso-
butylene derived succinic anhydride and a polyalkylene polyamine, quaternized
using an alkylene epoxide in combination with an acid where the compounds
has a hydrogen-donating group within two bonds of two hydrogen-accepting
groups and a second hydrogen-donating group separated by one bond from a
hydrogen-accepting group (COMPAT-1), a low molecular weight acylated
nitrogen compound that includes a hydrogen-accepting group within three bonds
of two hydrogen-donating groups (COMPAT-2), a borated succinimide disper-
sant prepared from polyisobutenylsuccinic anhydride, itself prepared from
polyisobutylene have a number average molecular weight of about 1000, and
polyalkyl polyamines where the N:CO ratio of the compound is >1.6 (COM-
PAT-3), a non-borated succinimide dispersant prepared from polyisobutenylsuc-
cinic anhydride, itself prepared from polyisobutylene have a number average
molecular weight of about 1000, and a polyalkyl polyamine where the N:CO
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ratio of the compound is >1.4 (COMPAT-4), a hydroxyalkyl-alkenyl imidazo-
line (COMPAT-5), and a fatty acid derived amine salt of a salicylic acid (COM-
PAT-6), and a non-inventive mineral oil for comparative examples (COMPAT-
7).
[00196] Each example is prepared by mixing the components in the amounts
specified in the tables below. A sample of each example is stored at 65
degrees
C, room temperature, 0 degrees C, and -18 degrees C. The clarity of each
sample is checked at the time of mixing, and then at set time intervals. Each
example is visually evaluated to check for cloudiness, haziness and even for
drop out of the friction modifier. The samples stored at cold temperatures are
rated at temperature and then allowed to warm to room temperature at which
point another rating is taken.
[00197] The results from the example set are provided in the tables below:
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Table 1 ¨ Formulationsl and Results2 in Neat Compositions
Comp Comp Inv Inv Inv Inv Inv
Ex 1-1 Ex 1-2 Ex 1-3 Ex 1-4 Ex 1-5 Ex 1-6 Ex 1-7
MEDIUM-1 100 99 98 98 98 98 98
MEDIUM-2
MEDIUM-3
FM-1 1 1 1 1 1 1
COMPAT -1 1
COMPAT-2 1
COMPAT-3 1
COMPAT-4 1
COMPAT-5 1
Store Rate
TIME Ex 1-1 Ex 1-2 Ex 1-3 Ex 1-4 Ex 1-5 Ex 1-6 Ex 1-7
Temp Temp
WK 0 RT RT Clear Clear Clear Clear Clear
Clear Clear
Trace of
65C 65 Clear Clear Clear Clear Clear Clear
Sediment
Haze &
RT RT Clear Clear Clear Clear Clear Clear
Trace Sed
Slight Slight
OC OC Clear Clear Clear Clear Clear
WK 1 Haze Haze
-18C -18C SOLID Haze Haze SOLID SOLID SOLID SOLID
Slight Slight
OC RT Clear Clear Clear Clear Clear
Haze Haze
-18C RT Clear SlightClear Clear Clear Clear Clear
Haze
Light
65C 65 Clear Clear Clear Clear Clear Clear
Sediment
Haze & Haze &
RT RT Clear Clear Clear Clear Clear
Trace Sed Trace Sed
Slight Slight
OC OC Clear Clear Clear Clear Clear
WK 2 Haze Haze
-18C -18C SOLID GEL GEL SOLID GEL GEL GEL
Haze & Trace
of
OC RT Clear Clear Clear Clear Clear
Trace Sed
Sediment
-18C RT Clear SlightClear Clear Clear Clear Clear
Haze
Light
65C 65 Clear Clear Clear Clear Clear Clear
Sediment
Haze & Haze & Haze &
RT RT Clear Clear Clear Clear
Trace Sed Trace Sed Trace
Sed
Haze &
WK 3
OC OC Clear Trace Sed Clear Clear Clear Clear
GEL
-18C -18C SOLID GEL GEL SOLID GEL GEL GEL
Haze & Trace
of
OC RT Clear Clear Clear Clear Clear
Trace Sed
Sediment
-18C RT Clear SlightClear Clear Clear Clear Clear
Haze
1 ¨All formulation values in Table I are percent by weight. The
compatibilizers tested may contain
an inherent amount of diluent such as a diluent oil.
2 ¨ Empty cells indicate no rating was taken for that sample at that time. A
rating of "SOLID"
indicates that more than half the sample does not flow within 30 seconds of
being inverted. A rating
on sediments with no comment on haze indicates the sample is otherwise clear.
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Table 2 ¨ Formulationsl and Results2 in Neat Compositions
Comp Comp Inv Inv Inv Inv Inv
Ex 2-1 Ex 2-2 Ex 2-3 Ex 2-4 Ex 2-5 Ex 2-6 Ex 2-7
MEDIUM-1
MEDIUM-2 100 99 98 98 98 98 98
MEDIUM-3
FM-1 1 1 1 1 1 1
COMPAT -1 1
COMPAT-2 1
COMPAT-3 1
COMPAT-4 1
COMPAT-5 1
Store Rate
TIME Ex 2-1 Ex 2-2 Ex 2-3 Ex 2-4 Ex 2-5 Ex 2-6 Ex 2-7
Temp Temp
WK 0 RT RT Clear Clear Clear Clear Clear Clear
Clear
Haze &
65C 65 Clear Clear Clear Clear Clear Clear
Light Sed
RT RT Clear Clear Clear SlightClear Clear Clear
Haze
Haze &
OC OC Clear Clear Clear Clear
Clear Clear
Trace Sed
WK 1
Haze & Haze & Haze & Haze & Haze &
-18C -18C Clear Haze
Trace Sed Trace Sed Trace Sed Light Sed Light Sed
Trace
OC RT Clear Clear Clear Clear
Clear Clear
Sediment
Trace Trace Trace Trace
-18C RT Clear Clear Clear
Sediment Sediment Sediment Sediment
Haze &
65C 65 Clear Clear Clear Clear Clear Clear
Trace Sed
Haze &
RT RT Clear Clear Clear Clear
Clear Clear
Suspension
Haze &
WK 2
OC OC Clear Clear Clear Separation Clear Clear Clear
Haze & Haze & Haze & Haze & Haze &
-18C -18C Clear Haze
Trace Sed Trace Sed Trace Sed Trace Sed Trace Sed
OC RT Clear Clear Clear Suspension Clear Clear Clear
Trace Trace Light Trace Trace
-18C RT Clear Clear
Sediment Sediment Sediment Sediment Sediment
Haze &
65C 65 Clear Clear Clear Clear Clear Clear
Light Sed
Trace
RT RT Clear Clear Clear Clear
Clear Clear
Sediment
Haze & Trace
OC OC Clear Clear Clear Clear Clear
Separation Sediment
WK 3 Haze &
Haze & Haze & Haze & Haze &
-18C -18C Clear Heavy Haze
Trace Sed Trace Sed Trace Sed Light Sed
Sed
Trace
OC RT Clear Clear Clear Suspension Clear Clear
Sediment
-18C RT Clear Clear
Sediment Sediment Sediment Sediment Sediment
1 ¨All formulation values in Table I are percent by weight. The
compatibilizers tested may contain
an inherent amount of diluent such as a diluent oil.
2 ¨ Empty cells indicate no rating was taken for that sample at that time. A
rating of "SOLID"
indicates that more than half the sample does not flow within 30 seconds of
being inverted. A rating
on sediments with no comment on haze indicates the sample is otherwise clear.
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Table 3 ¨ Formulationsl and Results2 in Neat Compositions
Comp Inv Inv
Ex 3-1 Ex 3-2 Ex 3-3
MEDIUM-1
MEDIUM-2
MEDIUM-3 58.15 58.15 58.15
FM-1 14.28 14.28 14.28
COMPAT-2 28.57
COMPAT-6 28.57
COMPAT-7 28.57
TIME Store Temp Rate Temp Ex 3-1 Ex 3-2 Ex 3-3
WK 0 RT RT Clear Clear Clear
65C 65 Clear Clear Clear
RT RT Clear Clear Clear
WK
OC OC Trace Sediment Clear Clear
1
-18C -18C Slight Haze Slight Haze Slight Haze
OC RT Trace Sediment Clear Clear
-18C RT Clear Clear Clear
65C 65 Clear Clear Clear
RT RT Clear Clear Clear
WK 2 OC OC Trace Sediment Clear Clear
-18C -18C Slight Haze Clear Slight Haze
OC RT Trace Sediment Slight Haze Clear
-18C RT Clear Clear Clear
65C 65 Clear Clear Fine Susp Trace Sed
RT RT Clear Clear Clear
WK 3 OC OC Trace Sediment Clear Clear
-18C -18C Slight Haze Clear Slight Haze
OC RT Trace Sediment Slight Haze Clear
-18C RT Clear Clear Clear
1 ¨All formulation values in Table I are percent by weight. The
compatibilizers tested may contain
an inherent amount of diluent such as a diluent oil.
2 ¨Empty cells in the results section indicate no rating was taken for that
sample at that time.
[00198] The results show that the inventive compatibilizers of the invention
improve the compatibility of FM-1 in neat additive concentrates (where the
medium of each example is the diluent inherently present in the compatibilizer
itself), in solvent diluted compositions, and in gasoline compositions where
the
lack of compatibility of the friction modifier is evident in the comparative
example even at very low concentrations.
[00199] Each of the documents referred to above is incorporated herein by
reference. Except in the Examples, or where otherwise explicitly indicated,
all
numerical quantities in this description specifying amounts of materials, reac-
tion conditions, molecular weights, number of carbon atoms, and the like, are
to
be understood as modified by the word "about."
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[00200] Unless otherwise indicated, each chemical or composition
referred to
herein should be interpreted as being a commercial grade material which may
contain the isomers, by-products, derivatives, and other such materials which
are normally understood to be present in the commercial grade. However, the
amount of each chemical component is presented exclusive of any solvent or
diluent, which may be customarily present in the commercial material, unless
otherwise indicated. It is to be understood that the upper and lower amount,
range, and ratio limits set forth herein may be independently combined. Simi-
larly, the ranges and amounts for each element of the invention can be used
together with ranges or amounts for any of the other elements. As used herein,
the expression "consisting essentially of' permits the inclusion of substances
that do not materially affect the basic and novel characteristics of the
composi-
tion under consideration. As used herein the term polyisobutenyl means a
polymeric alkenyl group derived from polyisobutylene, which may be a saturat-
ed or unsaturated group.
57
