Note: Descriptions are shown in the official language in which they were submitted.
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LUBRICANT WITH SPHERICAL COPPER AND BISMUTH POWDERS
PRIORITY
The present International Patent Application is related to, and claims the
priority benefit of,
U.S. Provisional Patent Application Serial No. 61/958,709, filed August 5,
2013, the contents of
which are hereby incorporated into the present disclosure in their entirety.
BACKGROUND
Combustion engines, such as those within automobiles, lawn mowers, engine-
generators,
and other machines, contain parts which move against each other causing
friction. Friction wastes
otherwise useful power by converting kinetic energy to heat. It also wears
away the moving parts,
which could lead to lower efficiency and degradation of the engine. Thus,
continuous friction in an
engine may lead to an increase in fuel consumption, decrease in power output,
and can lead to
engine failure.
Lubricating compositions, greases, and other fluids are commonly used in
combustion
engines to protect the engine by reducing wear on the moving parts. Lubricants
create a separating
film between surfaces of adjacent moving parts to minimize direct contact
between them, thereby
decreasing heat caused by friction and reducing wear, thus protecting the
engine. Lubricants also
clean, inhibit corrosion, improve sealing, and cool the engine by carrying
heat away from the
moving parts.
Many lubricants are generally composed of a base oil plus a variety of
additives to improve
certain properties. Some of the benefits of additives include increasing
viscosity, increasing
detergency to minimize sludge buildup, improving extreme pressure (EP)
performance, increasing
resistance to corrosion and oxidation, and decreasing contamination. Metal
alloys, composites and
pure metals are commonly used as additives for lubricants. For instance, lead
is a common EP
additive for lubricating oils and greases and is effective in decreasing
friction and inhibiting
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corrosion. (Richard W. Hein, Evaluation of Bismuth Napthenate as an EP
additive, Nov. 2000).
However, lead is a toxic and hazardous material and is harmful on the
environment and to human
health. Id.; European Copper Institute, September 2007; Environmental
Protection Agency (EPA),
2014. Numerous attempts have been made to create lubricants having metal
particles therein
similar to lead to improve the lubricating qualities and the wear resistance
of the lubricants in
engines and other machines. However, none have been successful to date.
Therefore, there is a
need for a non-hazardous additive replacement for lead in lubricants.
BRIEF SUMMARY
The disclosed lubricant compositions and methods for producing the same use
spherical
particles of both copper powder and bismuth powder as a replacement for lead.
When used in
internal combustible engines, such as those within automobiles, lawn mowers,
engine-generators,
and other machines, the disclosed lubricants deliver outstanding wear
resistance, improve gas
mileage, extend interval times needed for oil changes, and also reduce engine
exhaust emission.
In one embodiment, a lubricant is provided. The lubricant includes a base oil,
a grease, a
copper powder, comprising at least one spherical particle, and a bismuth
powder, comprising at
least one spherical particle. In one exemplary embodiment, the copper powder
is between 0.1% and
60% of the total weight of the lubricant. In yet another exemplary embodiment,
the bismuth
powder is between 0.1% and 60% of the total weight of the lubricant. In yet
another exemplary
embodiment, at least one spherical particle of copper powder is about 4.0 p.m
to 176.0 p.m in size.
In at least one exemplary embodiment, the D50 particle size of at least one
particle of the copper
powder is about 8 p.m to 13 p.m. In another embodiment, at least one spherical
particle of the
bismuth powder is about 0.9 p.m to 32.0 p.m in size. In yet another exemplary
embodiment, the D50
size of at least one particle of the bismuth powder is about 5.0 p.m to 15
p.m.
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In at least one exemplary embodiment, the lubricant is an engine oil. In one
embodiment
where the lubricant is an engine oil, the base oil comprises a shear stabile
polymer and at least one
additive. In at least one exemplary embodiment, the lubricant is a gear oil.
In one embodiment
where the lubricant is a gear oil, the base oil comprises a top-treat additive
package. In another at
least one exemplary embodiment, the lubricant is a grease. In one embodiment
where the lubricant
is a grease, the grease comprises a synthetic lubricating grease comprising a
lithium complex. In
yet another at least one exemplary embodiment, the lubricant is a spray
lubricant.
The disclosed embodiments also include methods for producing a lubricant. In
at least one
aspect of the present disclosure, the method includes the steps of selecting
at least one base oil,
selecting at least one grease, adding a first quantity of the at least one
base oil to a first quantity of
the at least one grease in a mixing container, adding a copper powder to the
mixing container,
wherein the copper powder comprises at least one spherical particle, adding a
bismuth powder to
the mixing container, wherein the bismuth powder comprises at least one
spherical particle, and
mixing the first quantity of the at least one base oil, the first quantity of
the at least one grease, the
copper powder, and the bismuth powder in the mixing container until well
blended to form a
lubricant composition. In at least one embodiment, the method includes the
step of mixing the first
quantity of the at least one base oil and the first quantity of the at least
one grease in the mixing
container prior to adding the copper powder and bismuth powder to the mixing
container.
In at least one embodiment, the method includes the step of mixing the
lubricant
composition with a second quantity of the base oil to form an engine or gear
oil lubricant. In at
least one exemplary embodiment, the at least one base oil and at least one
grease is mixed in the
mixing container at a high speed for 20 minutes; wherein the first quantity of
the at least one base
oil, the at least one grease, the spherical copper powder and the spherical
bismuth powder are mixed
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in the mixing container at a high speed for 45 minutes; and wherein the
lubricant and the second
quantity of the base oil are mixed in the mixing container for 20 minutes.
In yet another at least one embodiment, the method includes the step of mixing
the lubricant
composition with a second quantity of grease to form a grease lubricant. In at
least one
embodiment, the method includes the step of mixing the lubricant composition
with mineral spirits
to form a spray lubricant.
In at least one aspect of the present disclosure the method further includes
the steps of
applying the lubricant composition to an engine comprising at least one metal
surface, applying heat
and pressure within the engine to compress the lubricant composition, wherein
compressing the
lubricant composition infuses the copper powder and the bismuth powder within
the lubricant
composition to the at least one metal surface of the engine, and coating the
at least one metal
surface of the engine with the infused copper powder and bismuth powder. Other
embodiments are
also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments and other features, advantages and disclosures contained
herein, and the
manner of attaining them, will become apparent and the present disclosure will
be better understood
by reference to the following description of various exemplary embodiments of
the present
disclosure taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a flow diagram of a method for producing a lubricant that is an
engine oil.
FIG. 2 is a flow diagram of a method for producing a lubricant that is a gear
oil.
FIG. 3 is a flow diagram of a method for producing a lubricant that is a
grease.
FIG. 4 is a flow diagram of a method for producing a lubricant that is a spray
lubricant.
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DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles of the
present disclosure,
reference will now be made to the embodiments illustrated in the drawings, and
specific language
will be used to describe the same. It will nevertheless be understood that no
limitation of the scope
of this disclosure is thereby intended.
In at least one embodiment of the present disclosure, the lubricant includes a
base oil, a
grease, a copper powder, comprising at least one spherical particle, and a
bismuth powder,
comprising at least one spherical particle. An exemplary embodiment of a
lubricant of the present
disclosure is shown in FIG. 1. FIG. 1 is a flow diagram of a method 100 for
producing a lubricant
according to at least one embodiment of the present disclosure. Specifically,
the lubricant disclosed
in FIG. 1 is directed to the method of producing an engine oil lubricant 100.
In at least one
embodiment according to the present disclosure, the method 100 includes the
step of selecting at
least one base oil 102. The base oil selected 102 may comprise a shear stabile
polymer and at least
one additive. The selected base oil 102 may include, but is not limited to,
Altra Oil Treatment 250.
The Altra Oil 250 can be used in any engine oil, such as in gasoline or diesel
engines. Altra Oil 250
contains antiwear and detergent/dispersant additives. Altra Oil 250 reduces
friction, engine wear,
contains detergent/dispersant reducing deposits, neutralizes acids, compatible
with all types of
motor oil, and contains seal swell.
In at least one embodiment according to the present disclosure, the method 100
includes the
step of selecting at least one grease 104. The grease selected 104 may be
selected from, but is not
limited to: SLC HV 00 Purple (Chemtool, Inc.); Duralube EP-0 (Chemtool, Inc.);
Duralube EP-1
(Chemtool, Inc.); Duralube EP-2 (Chemtool, Inc.); and/or an Over Base Calcium
Sulfonate grease,
such as Alpha 2000 (Chemtool, Inc.). In one exemplary embodiment of the
present disclosure, the
grease selected 104 is an EP-2 grease.
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The SLC HV 00 Purple grease is a premium, lithium complex grease formulated
with
synthetic hydrocarbon fluids. It exhibits low temperature performance to
temperatures of -40
degrees Fahrenheit and has been formulated with an additive package which
insures high film
strength, EP, corrosion protection, and anti-wear properties. This grease is
used for grease filled
industrial gear cases, subject to high temperatures. Duralube EP-0, EP-1, and
EP-2 are lithium
complex greases formulated with quality base oils and fortified with rust and
oxidation inhibitors as
well as EP additives. They are water resistant greases and have a dropping
point of over 500
degrees Fahrenheit allowing them to perform at high temperatures.
The Over Base Calcium Sulfonate grease, such as Alpha 2000, may come in
different
grades, such as EP1 or EP2, etc. It is a calcium based grease that performs at
extremely high
temperatures. For instance, Alpha 2000 does not become fluid at temperatures
approaching 600 F
and after cooling to room temperature, it returns to its original grease
structure. Alpha 2000 may be
used in a variety of applications for automotive, industrial, construction,
agricultural, railroad, and
mining operations. Specific applications include all chassis points for
automotive, wheel bearings,
fifth wheels, king pins, anti-friction bearings, low and high speed journal
bearings, oven conveyors,
electric motor bearings, steel mill roller bearings, and on form and earth-
moving equipment. Alpha
2000 is also excellent for use in marine type applications where water washout
and corrosion are of
primary concern. The benefits of using an Over Base Calcium Sulfonate grease
include water
resistance and corrosion protection. It contains no heavy metals or other
harmful or
environmentally undesirable additives such as sulfur, phosphorus, chlorine,
zinc, phenols,
antimony, barium or lead.
In at least one embodiment according to the present disclosure, the method 100
includes the
step of adding a first quantity of the at least one base oil 106 to a first
quantity of the at least one
grease 108 in a mixing container 110. The mixing container may include, but is
not limited to, a
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metal or plastic drum, vat, or container. In particular, a stainless steel or
aluminum vat, drum, or
container may be used.
In at least one embodiment according to the present disclosure, the method 100
includes the
step of adding a copper powder to the mixing container, wherein the copper
powder comprises at
least one spherical particle 114. The copper powder may include, but is not
limited to, copper
powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper
Powder -
American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a
D50 in the
range of about 8.0 p.m to 13.0 p.m. The spherical shaped copper powder
particles are about 4.0 p.m
to 176.0 p.m in size. The percent of copper powder used may range from 0.1% up
to 60.0% of the
total weight of the engine oil lubricant.
In at least one embodiment according to the present disclosure, the method 100
includes the
step of adding a bismuth powder to the mixing container, wherein the bismuth
powder comprises at
least one spherical particle 116. The bismuth powder may include, but is not
limited to, bismuth
powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth
Powder -
American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of
about 5.0 p.m to
15 p.m. The spherical shaped bismuth powder particles are about 0.9 p.m to
32.0 p.m in size. The
percent of bismuth powder used may range from 0.1% up to 60.0% of the total
weight of the engine
oil lubricant.
In at least one embodiment according to the present disclosure, the method 100
includes the
step of mixing the first quantity of the at least one base oil 106 and the
first quantity of the at least
one grease 108 in the mixing container prior to adding the copper powder 114
and bismuth powder
116 to the mixing container 112. In at least one embodiment according to the
present disclosure,
the method 100 includes the step of mixing the first quantity of the at least
one base oil 106, the first
quantity of the at least one grease 108, the copper powder 114, and the
bismuth powder 116 in the
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mixing container until well blended to form a lubricant composition 118.
Mixing may occur at any
speed fast enough to disperse the copper and bismuth powders. The mixing speed
may include, but
is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature
less than 140
degrees Fahrenheit.
In at least one embodiment according to the present disclosure, the method 100
includes the
step of mixing the lubricant composition 118 with a second quantity of the
base oil 120 to form an
engine oil lubricant 122. In at least one exemplary embodiment according to
the present disclosure,
the at least one base oil 106 and at least one grease 108 is mixed in the
mixing container at a high
speed for twenty (20) minutes 112; wherein the first quantity of the at least
one base oil 106, the
first quantity of the at least one grease 108, the spherical copper powder
114, and the spherical
bismuth powder 116 are mixed in the mixing container at a high speed for forty-
five (45) minutes
118; and wherein the lubricant composition 118 and the second quantity of the
base oil 120 are
mixed in the mixing container for twenty (20) minutes 122.
In another embodiment of the present disclosure, the method 100 further
includes the step of
applying the engine oil lubricant to an engine comprising at least one metal
surface 124. In at least
one aspect of the present disclosure, the method 100 includes the step of
applying heat and pressure
within the engine to compress the engine oil lubricant, wherein compressing
the engine oil lubricant
infuses the copper powder and the bismuth powder within the engine oil
lubricant to the at least one
metal surface of the engine 126. The heat and pressure applied to the engine
include normal
temperatures and pressures as found under normal conditions of running an
engine. The types of
engines may include combustible engines, such as gasoline, diesel, propane and
natural gas engines
within automobiles, lawn mowers, engine-generators, and other machines.
Smaller engines require
a smaller dosage of the engine oil. For instance, small engines require 1
ounce per quart of engine
oil lubricant; 4 and 6 cylinder engines require 4 ounces of engine oil
lubricant; 8 cylinder engines
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require 6 ounces of engine oil lubricant; and heavy equipment, trucks, and
tractors require 16
ounces.
In at least one aspect of the present disclosure, the method 100 includes the
step of coating
the at least one metal surface of the engine with the infused copper powder
and bismuth powder
128. The application of heat and pressure within the engine to infuse the
copper powder and
bismuth powder 126 coats the at least one metal surface of the engine. After
coating the at least one
metal surface of the engine with the infused copper powder and bismuth powder
128, the at least
one metal surface of the engine has a bronze color from the impregnated
particles of copper and
bismuth. The engine oil lubricant plates the friction surfaces filling in
minor imperfections,
scratches and scars in the metal surfaces being treated, making a smooth
surface reducing friction
and reducing wear from taking place. The engine oil lubricant acts as millions
of microscopic ball
bearings providing a barrier between two metal surfaces reducing metal on
metal contact, which is
the main cause of wear and friction. It also provides a detergent/cleaning
action as it circulates
through the engine and scrubs away oil sludge and deposits built up on
components, restoring
engine cavities to like new cleanliness.
The benefits of the engine oil lubricant include, but are not limited to,
increasing fuel
economy, reducing oil consumption, reducing emissions, reducing operating
temperatures,
extending engine life and increasing reliability, reducing wear and scoring on
all component
surfaces, keeping equipment operating at peak performance, reducing friction
and providing higher
performance under load, improving compression and horsepower, neutralizing
acids to reduce oil
breakdown, providing better cold starts, and providing unique plating action
on surfaces and
protecting against lubrication starvation. The engine oil lubricant does not
contain any lead, PTFE,
chlorinated paraffins, or antimony components.
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Another exemplary embodiment of a lubricant of the present disclosure is shown
in FIG. 2.
FIG. 2 is a flow diagram of a method 200 for producing a lubricant according
to at least one
embodiment of the present disclosure. Specifically, the lubricant disclosed in
FIG. 2 is directed to
the method of producing a gear oil lubricant 200. The gear oil lubricant as
disclosed is a unique and
outstanding concentrated oil supplement for gear boxes, hydraulics,
differentials, manual
transmissions, transfer cases, power steering, and some compressors. In at
least one embodiment
according to the present disclosure, the method 200 includes the step of
selecting at least one base
oil 202. The base oil selected 202 may comprise a top-treat additive package.
The selected base oil
202 may include, but is not limited to, HiTEC 397. HiTEC 397 is a top-treat
additive for gear oils
designed to impart frictional characteristics needed by limited slip axles. It
has been optimized to
bring the required friction performance needed to minimize chatter by
promoting smooth clutch
engagement. It minimizes NVH associated with momentary cyclic torque loss,
satisfies
torque/power requirements necessary for modern vehicles, and maintains
friction coefficient level
over life of fluid for good torque transfer.
In at least one embodiment according to the present disclosure, the method 200
includes the
step of selecting at least one grease 204. The grease selected 204 may
include, but is not limited to:
SLC HV 00 Purple (Chemtool, Inc.); Duralube EP-0 (Chemtool, Inc.); Duralube EP-
1 (Chemtool,
Inc.); Duralube EP-2 (Chemtool, Inc.); and/or an Over Base Calcium Sulfonate
grease, such as
Alpha 2000 (Chemtool, Inc.). In one exemplary embodiment of the present
disclosure, the grease
selected 204 is an EP-2 grease.
The SLC HV 00 Purple grease is a premium, lithium complex grease formulated
with
synthetic hydrocarbon fluids. It exhibits low temperature performance to
temperatures of -40
degrees Fahrenheit and has been formulated with an additive package which
insures high film
strength, EP, corrosion protection, and anti-wear properties. This grease is
used for grease filled
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industrial gear cases, subject to high temperatures. Duralube EP-0, EP-1, and
EP-2 are lithium
complex greases formulated with quality base oils and fortified with rust and
oxidation inhibitors as
well as EP additives. They are water resistant greases and have a dropping
point of over 500
degrees Fahrenheit allowing them to perform at high temperatures.
The Over Base Calcium Sulfonate grease, such as Alpha 2000, may come in
different
grades, such as EP1 or EP2, etc. It is a calcium based grease that performs at
extremely high
temperatures. For instance, Alpha 2000 does not become fluid at temperatures
approaching 600 F
and after cooling to room temperature, it returns to its original grease
structure. Alpha 2000 may be
used in a variety of applications for automotive, industrial, construction,
agricultural, railroad, and
mining operations. Specific applications include all chassis points for
automotive, wheel bearings,
fifth wheels, king pins, anti-friction bearings, low and high speed journal
bearings, oven conveyors,
electric motor bearings, steel mill roller bearings, and on form and earth-
moving equipment. Alpha
2000 is also excellent for use in marine type applications where water washout
and corrosion are of
primary concern. The benefits of using an Over Base Calcium Sulfonate grease
include water
resistance and corrosion protection. It contains no heavy metals or other
harmful or
environmentally undesirable additives such as sulfur, phosphorus, chlorine,
zinc, phenols,
antimony, barium or lead.
In at least one embodiment according to the present disclosure, the method 200
includes the
step of adding a first quantity of the at least one base oil 206 to a first
quantity of the at least one
grease in a mixing container 210. The mixing container may include, but is not
limited to, a metal
or plastic drum, vat, or container. In particular, a stainless steel or
aluminum vat, drum, or container
may be used.
In at least one embodiment according to the present disclosure, the method 200
includes the
step of adding a copper powder to the mixing container, wherein the copper
powder comprises at
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least one spherical particle 214. The copper powder may include, but is not
limited to, copper
powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper
Powder -
American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a
D50 in the
range of about 8.0 p.m to 13.0 p.m. The spherical shaped copper powder
particles are about 4.0 p.m
to 176.0 p.m in size. The percent of copper powder used may range from 0.1% up
to 60.0% of the
total weight of the gear oil lubricant.
In at least one embodiment according to the present disclosure, the method 200
includes the
step of adding a bismuth powder to the mixing container, wherein the bismuth
powder comprises at
least one spherical particle 216. The bismuth powder may include, but is not
limited to, bismuth
powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth
Powder -
American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of
about 5.0 p.m to
p.m. The spherical shaped bismuth powder particles are about 0.9 p.m to 32.0
p.m in size. The
percent of bismuth powder used may range from 0.1% up to 60.0% of the total
weight of the gear
oil lubricant.
15
In at least one embodiment according to the present disclosure, the method
100 includes the
step of mixing the first quantity of the at least one base oil 206 and the
first quantity of the at least
one grease 208 in the mixing container prior to adding the copper powder 214
and bismuth powder
216 to the mixing container 212. In at least one embodiment according to the
present disclosure,
the method 200 includes the step of mixing the first quantity of the at least
one base oil 206, the first
quantity of the at least one grease 208, the copper powder 214, and the
bismuth powder 216 in the
mixing container until well blended to form a lubricant composition 218.
Mixing may occur at any
speed fast enough to disperse the copper and bismuth powders. The mixing speed
may include, but
is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature
less than 140
degrees Fahrenheit.
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In at least one embodiment according to the present disclosure, the method 200
includes the
step of mixing the lubricant composition 218 with a second quantity of the
base oil 220 to form a
gear oil lubricant 222. In at least one exemplary embodiment according to the
present disclosure,
the at least one base oil 206 and at least one grease 208 is mixed in the
mixing container at a high
speed for twenty (20) minutes 212; wherein the first quantity of the at least
one base oil 206, the
first quantity of the at least one grease 208, the spherical copper powder 214
and the spherical
bismuth powder 216 are mixed in the mixing container at a high speed for forty-
five (45) minutes
218; and wherein the lubricant composition 218 and the second quantity of the
base oil 220 are
mixed in the mixing container for twenty (20) minutes 222.
In another at least one embodiment of the present disclosure, the method 200
further
includes the step of applying the lubricant composition to an engine
comprising at least one metal
surface 224. In at least one aspect of the present disclosure, the method 200
includes the step of
applying heat and pressure within the engine to compress the lubricant
composition, wherein
compressing the lubricant composition infuses the copper powder and the
bismuth powder within
the lubricant composition to the at least one metal surface of the engine 226.
The heat and pressure
applied to the engine include normal temperatures and pressures as found under
normal conditions
of running an engine. The types of engines may include combustible engines,
such as those within
automobiles, lawn mowers, engine-generators, and other machines. For
hydraulics, a dosage of
gear oil of 1 ounce per quart is required. For regular duty gear boxes, 2
ounces per quart, and for
heavy load/high torque gear boxes, 3 ounces per quart of the gear oil
lubricant is required.
In at least one aspect of the present disclosure, the method 200 includes the
step of coating
the at least one metal surface of the engine with the infused copper powder
and bismuth powder
228. The application of heat and pressure within the engine to infuse the
copper powder and
bismuth powder 226 coats the at least one metal surface of the engine. After
coating the at least one
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metal surface of the engine with the infused copper powder and bismuth powder
228, the at least
one metal surface of the engine has a bronze color from the impregnated
particles of copper and
bismuth. The gear oil is for use in any non-friction based gear application
using oil for lubrication,
such as industrial gear boxes, hydraulics, differentials, manual
transmissions, transfer cases, power
steering, sliding ways and some compressors. The gear oil lubricant plates the
friction surfaces
filling in minor imperfections, scratches and scars in the metal surfaces
being treated, making a
smooth surface reducing friction and reducing wear from taking place. The gear
oil lubricant acts
as millions of microscopic ball bearings providing a barrier between two metal
surfaces reducing
metal on metal contact which is the main cause of wear and friction. It also
provides a
detergent/cleaning action as it circulates through the engine and scrubs away
oil sludge and deposits
built up on components, restoring engine cavities to like new cleanliness.
The benefits of the gear oil lubricant according to the present disclosure
include, but are not
limited to, reducing operating temperatures, improving power, providing better
starts, reducing
power required for startup, dramatically extending equipment life and
increasing reliability,
reducing wear and scoring on all component surfaces, keeping equipment
operating at peak
performance, reducing friction and providing high performance under load,
neutralizing acids to
reduce oil breakdown, and unique plating action on surfaces for protecting
against lubrication
starvation. The gear oil lubricant according to the present disclosure does
not contain any lead,
PTFE, chlorinated paraffins, or antimony components.
In yet another exemplary embodiment of a lubricant of the present disclosure
is shown in
FIG. 3. FIG. 3 is a flow diagram of a method 300 for producing a lubricant
according to at least one
embodiment of the present disclosure. Specifically, the lubricant disclosed in
FIG. 3 is directed to
the method of producing a grease 300. In at least one embodiment according to
the present
disclosure, the method 300 includes the step of selecting at least one base
oil 302. The base oil
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selected 302 may include, but is not limited to, Synative ES 2900. Synative ES
2900 is an ester
base oil containing highly polar ester functional groups. Synative ES 2900 is
compatible with
lithium greases and is used primarily as a dispersing oil.
In at least one embodiment according to the present disclosure, the method 300
includes the
step of selecting at least one grease 304. The grease 304 selected may
include, but is not limited to,
a synthetic lubricating grease comprising a lithium complex. The grease 304
may be selected from,
but is not limited to: SLC HV 00 Purple (Chemtool, Inc.); Duralube EP-0
(Chemtool, Inc.);
Duralube EP-1 (Chemtool, Inc.); Duralube EP-2 (Chemtool, Inc.); and/or an Over
Base Calcium
Sulfonate grease, such as Alpha 2000 (Chemtool, Inc.). In one exemplary
embodiment of the
present disclosure, the grease selected 304 is an EP-2 grease.
The SLC HV 00 Purple grease is a premium, lithium complex grease formulated
with
synthetic hydrocarbon fluids. It exhibits low temperature performance to
temperatures of -40
degrees Fahrenheit and has been formulated with an additive package which
insures high film
strength, EP, corrosion protection, and anti-wear properties. This grease is
used for grease filled
industrial gear cases, subject to high temperatures. Duralube EP-0, EP-1, and
EP-2 are lithium
complex greases formulated with quality base oils and fortified with rust and
oxidation inhibitors as
well as EP additives. They are water resistant greases and have a dropping
point of over 500
degrees Fahrenheit allowing them to perform at high temperatures.
The Over Base Calcium Sulfonate grease, such as Alpha 2000, may come in
different
grades, such as EP1 or EP2, etc. It is a calcium based grease that performs at
extremely high
temperatures. For instance, Alpha 2000 does not become fluid at temperatures
approaching 600 F
and after cooling to room temperature, it returns to its original grease
structure. Alpha 2000 may be
used in a variety of applications for automotive, industrial, construction,
agricultural, railroad, and
mining operations. Specific applications include all chassis points for
automotive, wheel bearings,
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fifth wheels, king pins, anti-friction bearings, low and high speed journal
bearings, oven conveyors,
electric motor bearings, steel mill roller bearings, and on form and earth-
moving equipment. Alpha
2000 is also excellent for use in marine type applications where water washout
and corrosion are of
primary concern. The benefits of using an Over Base Calcium Sulfonate grease
include water
resistance and corrosion protection. It contains no heavy metals or other
harmful or
environmentally undesirable additives such as sulfur, phosphorus, chlorine,
zinc, phenols,
antimony, barium or lead.
In at least one embodiment according to the present disclosure, the method 300
includes the
step of adding a first quantity of the at least one base oil 306 to a first
quantity of the at least one
grease 308 in a mixing container 310. The mixing container may include, but is
not limited to, a
metal or plastic drum, vat, or container. In particular, a stainless steel or
aluminum vat, drum, or
container may be used.
In at least one embodiment according to the present disclosure, the method 300
includes the
step of adding a copper powder to the mixing container, wherein the copper
powder comprises at
least one spherical particle 314. The copper powder may include, but is not
limited to, copper
powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper
Powder -
American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a
D50 in the
range of about 8.0 p.m to 13.0 p.m. The spherical shaped copper powder
particles are about 4.0 p.m
to 176.0 p.m in size. The percent of copper powder used may range from 0.1% up
to 60.0% of the
total weight of the grease.
In at least one embodiment according to the present disclosure, the method 300
includes the
step of adding a bismuth powder to the mixing container, wherein the bismuth
powder comprises at
least one spherical particle 316. The bismuth powder may include, but is not
limited to, bismuth
powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth
Powder -
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American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of
about 5.0 p.m to
15 p.m. The spherical shaped bismuth powder particles are about 0.9 p.m to
32.0 p.m in size. The
percent of bismuth powder used may range from 0.1% up to 60.0% of the total
weight of the grease.
In at least one embodiment according to the present disclosure, the method 300
includes the
step of mixing the first quantity of the at least one base oil 306, the first
quantity of the at least one
grease 308, the copper powder 314, and the bismuth powder 316 in the mixing
container until well
blended to form a lubricant composition 318. Mixing may occur at any speed
fast enough to
disperse the copper and bismuth powders. The mixing speed may include, but is
not limited to,
500-2000 rpm, and preferably 500-1500 rpm at a temperature less than 140
degrees Fahrenheit.
In at least one embodiment according to the present disclosure, the method 300
includes the
step of mixing the lubricant composition 318 with a second quantity of grease
320 to form a grease
lubricant 322. In another at least one embodiment of the present disclosure,
the method 300 further
includes the step of applying the grease lubricant to an engine comprising at
least one metal surface
324. In at least one aspect of the present disclosure, the method 300 includes
the step of applying
heat and pressure within the engine to compress the lubricant composition,
wherein compressing the
lubricant composition infuses the copper powder and the bismuth powder within
the lubricant
composition to the at least one metal surface of the engine 326. The heat and
pressure applied to
the engine include normal temperatures and pressures as found under normal
conditions of running
an engine. The types of engines may include combustible engines, such as those
within
automobiles, lawn mowers, engine-generators, and other machines.
In at least one aspect of the present disclosure, the method 300 includes the
step of coating
the at least one metal surface of the engine with the infused copper powder
and bismuth powder
328. The application of heat and pressure within the engine to infuse the
copper powder and
bismuth powder 326 coats the at least one metal surface of the engine. After
coating the at least one
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metal surface of the engine with the infused copper powder and bismuth powder
328, the at least
one metal surface of the engine has a bronze color from the impregnated
particles of copper and
bismuth. The grease lubricant plates the friction surfaces filling in minor
imperfections, scratches
and scars in the metal surfaces being treated, making a smooth surface
reducing friction and
reducing wear from taking place. The grease lubricant acts as millions of
microscopic ball bearings
providing a barrier between two metal surfaces reducing metal on metal
contact, which is the main
cause of wear and friction. It also provides a detergent/cleaning action as it
circulates through the
engine and scrubs away oil sludge and deposits built up on components,
restoring engine cavities to
like new cleanliness.
A Synthetic EP 00 grease lubricant as produced from the present disclosure is
a EP grease
formulated with synthetic hydrocarbon fluids. It contains a lithium complex
with EP and anti-wear
additives with a low operating temperature of -40 degrees Fahrenheit and also
operates at very high
temperatures. It provides excellent corrosion protection and extends component
life, and reduces
heat and friction to provide savings in maintenance and energy costs. This
product is ideal for
industrial gear boxes, cycloidal gear reducers, robotic gear boxes, high speed
ball or roller bearings,
wire rope and cables, mining and construction applications where semi-fluid
grease is used. It is
successful in wheel bearings where heavy weight gear oils are currently being
used. It provides
superior lubrication and mobility like a gear oil but is thick enough not to
leak out of seals.
An EP 0 grease lubricant as produced from the present disclosure is designed
as a multi-
purpose grease that is fortified with EP additives, and rust and oxidation
inhibitors. It is water
resistant and has a wide operating temperature of -67 degrees Fahrenheit to
over 302 degrees
Fahrenheit. EP 0 grease lubricants are ideal for use in severe cold
applications where superior
protection is important and there is a need for a thin grease. It is also used
in auto greasing
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applications that call for an EP 0 grease for use in any industry. It is an
ideal grease for increasing
performance and reducing maintenance and energy costs.
A resulting EP 1 grease lubricant as produced from the present disclosure is
an EP grease
designed as a multi-purpose grease fortified with EP additives and rust and
oxidation inhibitors. It
is water resistant and has a wide operating temperature of -49 degrees
Fahrenheit to over 320
degrees Fahrenheit. It is an ideal grease for increasing performance and
reducing maintenance and
energy costs. EP 1 grease may be used in cold applications where superior
protection is important
and where there is a need for a thinner grease and is applicable in any
industry, including in auto-
greasing applications.
A resulting EP 2 grease lubricant as produced from the present disclosure is
an EP grease
designed as a multi-purpose grease that is fortified with EP additives and
rust and oxidation
inhibitors. It is water resistant and has a wide operating temperature of -40
degrees Fahrenheit to
over 302 degrees Fahrenheit. It is an ideal grease for increasing performance
and reducing
maintenance and energy costs. EP 2 grease may be used in applications
including, but not limited
to, universal joints, gear boxes, wheel bearings, axles, bushings, electric
motor bearings, conveyors,
5th wheel plates, and winches. This grease can be used in industries from
domestic to industrial,
construction, mining, manufacturing, commercial, transportation, utilities,
and any application
where grease is currently used.
The benefits of the Synthetic EP 00, EP 0, EP 1, and EP 2 grease lubricants
include, but are
not limited, resistance to water washout, reducing operating temperatures,
reducing energy costs,
wide operating temperature range (from -40 degrees Fahrenheit to 450 degrees
Fahrenheit),
extending lubrication periods, protection against rust and oxidation,
extending bearing life and
increasing reliability, reducing wear and scoring on all component surfaces,
keeping equipment
operating at peak performance, reducing friction and proving higher
performance under load, and
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protecting against lubrication starvation through plating action. The greases
as taught in the present
disclosure do not contain any lead, PTFE, chlorinated paraffins, or antimony
components.
FIG. 4 shows another exemplary embodiment of an engine lubricant of the
present
disclosure. FIG. 4 is a flow diagram of a method 400 for producing an engine
lubricant according
to at least one embodiment of the present disclosure. Specifically, the engine
lubricant disclosed in
FIG. 4 is directed to the method of producing a spray lubricant 400. In at
least one embodiment
according to the present disclosure, the method 400 includes the step of
selecting at least one base
oil 402. In at least one embodiment according to the present disclosure, the
method 400 includes
the step of select at least one grease 404. In at least one embodiment
according to the present
disclosure, the method 400 includes the step of adding a first quantity of the
at least one base oil
406 to a first quantity of the at least one grease 408 in a mixing container
410. The mixing
container may include, but is not limited to, a metal or plastic drum, vat, or
container. In particular,
a stainless steel or aluminum vat, drum, or container may be used.
In at least one embodiment according to the present disclosure, the method 400
includes the
step of adding a copper powder to the mixing container, wherein the copper
powder comprises at
least one spherical particle 414. The copper powder may include, but is not
limited to, copper
powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper
Powder -
American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a
D50 in the
range of about 8.0 p.m to 13.0 p.m. The spherical shaped copper powder
particles are about 4.0 p.m
to 176.0 p.m in size. The percent of copper powder used may range from 0.1% up
to 60.0% of the
total weight of the spray lubricant.
In at least one embodiment according to the present disclosure, the method 400
includes the
step of adding a bismuth powder to the mixing container, wherein the bismuth
powder comprises at
least one spherical particle 416. The bismuth powder may include, but is not
limited to, bismuth
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powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth
Powder -
American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of
about 5.0 p.m to
15 p.m. The spherical shaped bismuth powder particles are about 0.9 p.m to
32.0 p.m in size. The
percent of bismuth powder used may range from 0.1% up to 60.0% of the total
weight of the spray
lubricant.
In at least one embodiment according to the present disclosure, the method 400
includes the
step of mixing the first quantity of the at least one base oil 402, the first
quantity of the at least one
grease 404, the copper powder 414, and the bismuth powder 416 in the mixing
container until well
blended to form a lubricant composition 418. Mixing may occur for any period
and time and at any
speed fast enough to disperse the copper and bismuth powders. The mixing speed
may include, but
is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature
less than 140
degrees Fahrenheit. The lubricant composition may comprise, but is not limited
to, either the
finished gear oil lubricant or the finished engine oil lubricant as taught in
the present disclosure.
In at least one embodiment according to the present disclosure, the method 400
includes the
step of mixing the lubricant composition with mineral spirits to form a spray
lubricant 420. In at
least one exemplary embodiment, the lubricant composition comprises 50% of the
total weight of
the spray lubricant and the mineral spirits comprise 50% of the total weight
of the spray lubricant.
The mixture must be continually mixed while filling containers with spray
lubricant. The resulting
composition may then be applied to any application requiring lubrication and
where there is metal
on metal movement in a low eight, low compression application, including but
not limited to,
hinges, overhead doors and tracks, air tools and impact wrenches, lawn mowers
chains and cables,
rusted nuts and bolts, high speed bearings rollers, bushings, moving parts on
conveyors, hand tools,
trimmers blades, etc. In addition, the spray lubricant can be used in
applications such as on a dry
film lubricant.
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The spray lubricant applies quickly and evenly to penetrate, cover and protect
against all
types of friction. The spray lubricant is a solvent, allowing the product to
reach into hard to reach
places, helping to break free metal surfaces that are seized together and
lubricates components as
they break free. When used on surfaces at a higher temperatures, the faster
the product will
penetrate. The spray lubricant significantly reduces metal wear conditions and
lowers the coefficient
of friction arising under extreme pressure conditions that cause metallic
adhesion, abrasion, contact
fatigue and fretting. The benefits of the spray lubricant include, but are not
limited to, reducing
corrosion, self-repairing worn surfaces, producing protective film deposits on
high wear parts,
reducing operating temperatures, reducing wear on all treated components,
allowing for high loads,
high speed with less effects of wear, and significantly extending equipment
life with less
maintenance. The spray lubricant does not contain any lead, PTFE, chlorinated
paraffins, or
antimony components.
The use of the lubricants according to the present disclosure in engines
delivers outstanding
wear resistance, improves gas mileage, extends interval times needed for oil
changes, and also
reduce engine exhaust emission. The use of the lubricants according to the
present disclosure result
in an extremely high Timken wear test, over 90 pounds (values higher than 35
pounds indicate the
presence of an EP additive). In addition, numerous tests have been conducted
using the disclosed
grease lubricant composition.
As shown in Table 1, regular Duralube grease was tested as a control against
Duralube made
according to the present disclosure (Duralube with Copper #1). The Duralube
with Copper #1
contains a 8.55% of total weight of Copper and a 5.70% of total weight of
Bismuth. 4-Ball wear
tests were conducted on engines using both grease lubricants. Use of the
Duralube with Copper #1
grease lubricant reduced engine wear scar from .60 to .43. This indicates that
the grease lubricant
of the present disclosure is capable of reducing wear and tear by 28.33% when
compared to normal
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grease lubricants. In additional, the 4-Ball weld test shows a 100% increase
in the load carrying
capacity, indicating a high anti-wear capability. The reduction in wear means
that operating
temperatures can be reduced to reduce friction. Moreover, use of such a grease
lubricant will
reduce energy consumption, either fuel economy or electricity, depending on
the application. These
results should be similar when used in an engine or gear box.
Table 1: Duralube EP-2 compared to sample of Duralube with Copper and Bismuth
lest Duralobe EP-2: Doralnbe with Copper 41
:Thickener Lithium Complex. Lithium Compleic
Appearance Amber Smooth Daik. Brown, Smooth
IDro:pping Point "F 456*E.
ASTM D 2265.
-Worked Penetration
.60 strokes. 4 cone 17.S. 293.
ASMI D 217.
.4-Bail. weld,
ASTM
200 Ka .40n Kk-,f
PAss
Weid 2.50 .KL:,4f .500 Kgf
4-Ball wear 0,60 nun: 0.43 :num
TAS D 2266..
A
Oil Sepatatio 24 63%. loss
AS:TM D 1742
Hegman .10 Microns. 10 l'slicron
Similarly, Table 2 shows a comparison of SLC HV 00 grease, which has a thin
consistency
and is similar to a thick oil, such as engine or gear oil. The base grease was
tested against different
compositions of the grease lubricant as taught in the present disclosure. The
Copper #1
composition contains 8.55% of the total weight of Copper and a 5.70% of the
total weight of
Bismuth. Samples 1-3 also contain different percentages of Copper and Bismuth
according to the
present disclosure. Sample 1 contains 9.0% of the total weight of Copper and
13.0% of the total
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weight of Bismuth. Sample 2 contains 4.5% of the total weight of Copper and
13.0% of the total
weight of Bismuth. Sample 3 contains 0.0% of the total weight of Copper and
13.0% of the total
weight of Bismuth. While Copper #1 and Samples 1-3 all resulted in better
results for the 4-Ball
weld and wear tests than the SLC HV 00 control, the composition of Copper #1
had the best
performance.
Table 2: SLC HV 00 Compared with Copper #1, Sample 1, Sample 2, and Sample 3
Test SIC 11V Ot) eta ppEr 41 Sample 1
Sample 2 Sample 3
Thickener Lithium Cx Lnkium ex Lithium Cx Lithium ex
Lithium ex
Appemuce Purple,z=-lmooth Dlirk Brown Dark Brown
Dark Brown Dark Brown
Worked Penetrn Eon
60 strokes ',=4' mne 427 4? ) 418 421 412
ASTM D 217
4-Ball weld
ASMID 25.96
200 Ke 400 Kgf 40') KO 400 Kgf 400 KO
Pris
Weld 250 Kgf 5C10 Kt-rf 500 Kgf 500 Kgf .-
i}0,.Kgf
4-Rall wear 059 tyilv 041 ram :': 45 nun 0.4$ anti
O48 min
ASLM D 2266
liegi.man 5 Micron IS Micron 14 Micron 18 Micron I I
Micron
A
Example 1: Engine and Gear Oil Lubricant Formulations
Raw material Wt % Lbs
Base Oil 21.0Ck I05.0CY
Cllemtool EP#2 Greasw
mumu: mummum mumum mmummumm mmmmmmmm
Bismuth 301A .:.5Q.. J.
Copper I700FPM 8 50 42 SO
Total 46.50 232.50
Remaining
Base Oil 53.50 267.50
Total 100% 500.00
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For manufacturing a volume of 500 pounds of either engine or gear oil, 105
pounds of an EP
base oil is added to a Chemtool EP#2 Grease containing a Lithium complex and
mixed at high
speed for 20 minutes. After mixing, 32.50 pounds of Bismuth 301A and 42.50
pounds of Copper
1700FPM are added to the mixture of grease and oil and mixed at high speed for
45 minutes. After
mixing, an additional 267.50 pounds of base oil is added and mixed for 20
minutes. The resulting
composition may then be bottled and used in internal combustible engines.
Example 2: Grease Lubricant Formulation
Raw material Wt % Lb s
Pre-Mix
Synative ES 2900 Oil J 28.07
NLGI #2 / 00 Grease::
Bismuth 301A
Copper I700FPIVI 8 55 68 41
Total 22.8% 182.46
Remaining
NLGI #2 / 00 Grease 77.19 617.54
Total 100% 800.00
For manufacturing a volume of 800 pounds of grease lubricant, 40.35 pounds of
NLGI #2 /
00 grease was added to 28.07 pounds of Synative ES 2900 oil, 45.61 pounds of
Bismuth 301A and
68.42 pounds of Copper 1700FPM and mixed until smooth. After mixing, an
additional 617.54
pounds of NLGI #2 / 00 grease is added and mixed until smooth. The resulting
composition may
then be bottled and used in internal combustible engines.
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Example 3: Spray Lubricant Formulation
Raw material Wt % Lbs
Gear/Engine Lubricant,50.0 250.00
Total 50.0% 500.00
For manufacturing a volume of 500 pounds of spray lubricant, 250 pounds of
either a
finished gear oil treatment or engine oil treatment as taught in the present
disclosure is added to 250
pounds of mineral spirits and mixed for 5-10 minutes. The mixture must be
continued to be mixed
while filling containers with spray lubricant. The resulting composition may
then be applied to any
application requiring lubrication.
While various embodiments of engine lubricant and methods for using the same
have been
described in considerable detail herein, the embodiments are merely offered by
way of non-limiting
examples of the disclosure described herein. It will therefore be understood
that various changes
and modifications may be made, and equivalents may be substituted for elements
thereof, without
departing from the scope of the disclosure. Indeed, this disclosure is not
intended to be exhaustive
or to limit the scope of the disclosure.
Further, in describing representative embodiments, the disclosure may have
presented a
method and/or process as a particular sequence of steps. However, to the
extent that the method or
process does not rely on the particular order of steps set forth herein, the
method or process should
not be limited to the particular sequence of steps described. Other sequences
of steps may be
possible. Therefore, the particular order of the steps disclosed herein should
not be construed as
limitations of the present disclosure. In addition, disclosure directed to a
method and/or process
should not be limited to the performance of their steps in the order written.
Such sequences may be
varied and still remain within the scope of the present disclosure.
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