Note: Descriptions are shown in the official language in which they were submitted.
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LUBRICANTS WITH CALCIUM-CONTAINING DETERGENT AND THEIR USE
FOR IMPROVING LOW SPEED PRE-IGNITION
TECHNICAL FIELD
[0001] The
disclosure relates to lubricant compositions containing one or more oil
soluble additives and the use of such lubricating oil compositions to improve
low speed pre-
ignition.
BACKGROUND
[0002] Turbocharged
or supercharged engines (i.e. boosted internal combustion
engines) may exhibit an abnormal combustion phenomenon known as stochastic pre-
ignition
or low-speed pre-ignition (or "LSPI-). LSPI is a pre-ignition event that may
include very
high pressure spikes, early combustion during an inappropriate crank angle,
and knock. All
of these, individually and in combination, have the potential to cause
degradation and/or
severe damage to the engine. However, because LSPI events occur only
sporadically and in
an uncontrolled fashion, it is difficult to identify the causes for this
phenomenon and to
develop solutions to suppress it.
[0003] Pre-ignition
is a form of combustion that results of ignition of the air-fuel
mixture in the combustion chamber prior to the desired ignition of the air-
fuel mixture by the
igniter. Pre-ignition has typically been a problem during high speed engine
operation since
heat from operation of the engine may heat a part of the combustion chamber to
a sufficient
temperature to ignite the air-fuel mixture upon contact. This type of pre-
ignition is
sometimes referred to as hot-spot pre-ignition.
[0004] More
recently, intermittent abnormal combustion has been observed in
boosted internal combustion engines at low speeds and medium-to-high loads.
For example,
during operation of the engine at 3,000 rpm or less, under load, with a brake
mean effective
pressure (BMEP) of at least 10 bar, low-speed pre-ignition (LSPI) may occur in
a random and
stochastic fashion. During low speed engine operation, the compression stroke
time is
longest.
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[0005] Several
published studies have demonstrated that turbocharger use, engine
design, engine coatings, piston shape, fuel choice, and/or engine oil
additives may contribute
to an increase in LSPI events. One theory suggests that auto-ignition of
engine oil droplets
that enter the engine combustion chamber from the piston crevice (the space
between the
piston ring pack and cylinder liner) may be one cause of LSPI events.
Accordingly, there is a
need for engine oil additive components and/or combinations that are effective
to reduce or
eliminate LSPI in boosted internal combustion engines.
SUMMARY AND TERMS
[0006] The present
disclosure relates to a lubricating oil composition and method of
operating a boosted internal combustion engine. The lubricating oil
composition includes
greater than 50 wt.% of a base oil of lubricating viscosity, at least 0.3 wt.%
of an overbased
detergent having a total base number (TBN) greater than 225 mg KOH/g, and at
least 0.2
wt.% of a low-based/neutral detergent having a TBN less than or equal to 175
mg KOH/g,
wherein a total amount of calcium from the overbased and low-based/neutral
detergent ranges
from greater than 1100 ppm by weight to less than 2400 ppm by weight based on
a total
weight of the lubricating oil composition. The lubricating oil composition may
be effective
to reduce low-speed pre-ignition events in the boosted internal combustion
engine lubricated
with the lubricating oil composition.
[0007] In another
embodiment, the disclosure provides a method for reducing low-
speed pre-ignition events in a boosted internal combustion engine. The method
includes a
step of lubricating the boosted internal combustion engine with a lubricating
oil composition
including greater than 50 wt. ./0 of a base oil of lubricating viscosity, at
least 0.3 wt.% of an
overbased detergent having a TBN greater than 225 mg KOH/g, and at least 0.2
wt.% of a
low-based/neutral detergent having a TBN up to 175 mg KOH/g. A total amount of
calcium
from the overbased and low-based/neutral detergent ranges from greater than
1100 ppm by
weight to less than 2400 ppm by weight based on a total weight of the
lubricating oil
composition. The boosted internal combustion engine is operated and lubricated
with the
lubricating oil composition whereby the low-speed pre-ignition events in the
engine
lubricated with the lubricating oil composition may be reduced.
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[0008] In any of
the foregoing embodiments, the overbased detergent may include an
overbased calcium-containing detergent. The overbased calcium-containing
detergent may
be selected from an overbased calcium sulfonate detergent and an overbased
calcium phenate
detergent. In each of the embodiments, the overbased detergent may be a
calcium-containing
detergent or a mixture of two or more overbased calcium containing detergents.
In each of the
foregoing embodiments, the one or more overbased calcium-containing
detergent(s) may
provide from about 900 to about 2000 ppm by weight calcium to the lubricating
oil
composition based on a total weight of the lubricating oil composition.
[0009] In any of
the foregoing embodiments, the low-based/neutral detergent may be
a calcium containing detergent and the low-based/neutral calcium-containing
detergent may
be a detergent selected from a calcium sulfonate detergent and a calcium
phenate detergent.
In the foregoing embodiments, at least 4 wt.% of the total detergent in the
lubricating oil
composition may be from a low-based/neutral detergent. In each of the
foregoing
embodiments, the lubricating oil composition may have a total mmol metal (M)
to total base
number (TBN) ratio ranging from greater than 4.5 to about 10.0 or from greater
than 8 to
about 10.
[0010] In each of
the foregoing embodiments, the reduction of low-speed pre-ignition
(LSPI) events may be expressed as a ratio of LSPI events of a test oil
relative to LSPI events
of a reference oil (hereinafter "the LSPI Ratio"), wherein the reference oil R-
1 includes an
overbased calcium-containing detergent as the sole detergent in the
lubricating oil
composition in an amount that provides about 2400 ppm calcium to the
lubricating oil
composition. In the foregoing embodiments, the LSPI events may be expressed as
LSPI
counts during 25,000 engine cycles, wherein the engine is operated at 2000
revolutions per
minute (RPM) with a brake mean effective pressure (BMEP) of 18,000 kPA.
[0011] In each of
the foregoing embodiments, the base oil may be selected from
Group I, Group II, Group III, Group IV, or Group V base oils, and a
combination of two or
more of the foregoing. In other embodiments, the greater than 50 wt.% of base
oil is selected
from the group consisting of Group 11. Group III, Group IV, or Group V base
oils, and a
combination of two or more of the foregoing. wherein the greater than 50 wt.%
of base oil is
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other than diluent oils that arise from provision of additive components or
viscosity index
improvers in the composition.
[0012] In each of
the foregoing embodiments, the lubricating oil composition may
include one or more components selected from friction modifiers, antiwear
agents,
dispersants, antioxidants, and viscosity index improvers.
[0013] In the
foregoing embodiments of the method described herein, the engine, in
operation may generate a brake mean effective pressure level of greater than
1,500 Oa
(BMEP) at an engine speed of less than 3000 rotations per minute (rpm) or a
BMEP of 1,800
kPa at an engine speed of 2000 rpm.
[0014] In each of
the foregoing embodiments, the lubricating oil composition may be
effective to pass a TEOST 33 bench oxidation test.
[0015] In each of
the foregoing embodiments, the low-based/neutral detergent may
include a low-based/neutral calcium-containing detergent and a ratio of ppm
calcium by
weight provided to the lubricating oil composition by the low-based/neutral
calcium-
containing detergent to ppm of calcium by weight provided to the lubricating
oil composition
by the overbased calcium-containing detergent may be from 0.05 to 1Ø
[0016] In each of
the foregoing embodiments, the total calcium provided to the
lubricating oil composition by the overbased detergent may be from 1100 ppm to
1800 ppm,
by weight, based on the total weight of the lubricating oil composition.
[0017] In each of
the foregoing embodiments, the total calcium provided to the
lubricating oil composition by the low-based/neutral calcium-containing
detergent may be
from 50 ppm to 1000 ppm, by weight, based on the total weight of the
lubricating oil
composition
[0018] In each of
the foregoing embodiments, the lubricating oil composition may
comprise not more than 10 wt.% of a Group IV base oil, a Group V base oil, or
a combination
thereof In each of the foregoing embodiments, the lubricating oil compositions
comprises
less than 5 wt.% of a Group V base oil.
[0019] In each of
the foregoing embodiments, the overbased calcium-containing
detergent may be an overbased calcium sulfonate detergent.
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[0020] In each of
the foregoing embodiments, the overbased calcium-containing
detergent may optionally exclude overbased calcium salicylate detergents.
[0021] In each of
the foregoing embodiments, the lubricating oil composition may
optionally exclude any magnesium-containing detergents or the lubricating oil
composition
may be free of magnesium.
[0022] In each of
the foregoing embodiments, the lubricating oil composition may not
contain any Group IV base oils.
[0023] In each of
the foregoing embodiments, the lubricating oil composition may not
contain any Group V base oils.
[0024] The
following definitions of terms are provided in order to clarify the
meanings of certain terms as used herein.
[0025] The terms
"oil composition." "lubrication composition," "lubricating oil
composition,- "lubricating oil,- "lubricant composition,- "lubricating
composition,- "fully
formulated lubricant composition," "lubricant," "crankcase oil," "crankcase
lubricant,"
"engine oil," "engine lubricant," "motor oil," and "motor lubricant" are
considered
synonymous, fully interchangeable terminology referring to the finished
lubrication product
comprising greater than 50 wt.% of a base oil plus a minor amount of an
additive
composition.
[0026] As used
herein, the terms "additive package," "additive concentrate,"
-additive composition," "engine oil additive package," -engine oil additive
concentrate,"
"crankcase additive package," "crankcase additive concentrate," "motor oil
additive
package," "motor oil concentrate," are considered synonymous, fully
interchangeable
terminology referring the portion of the lubricating oil composition excluding
the greater than
50 wt.% of base oil stock mixture. The additive package may or may not include
the
viscosity index improver or pour point depressant.
[0027] The term
"overbased" relates to metal salts, such as metal salts of sulfonates,
carboxylates, salicylates, and/or phenates, wherein the amount of metal
present exceeds the
stoichiometric amount. Such salts may have a conversion level in excess of
100% (i.e., they
may comprise more than 100% of the theoretical amount of metal needed to
convert the acid
to its "normal,- "neutral" salt). The expression "metal ratio," often
abbreviated as MR, is
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used to designate the ratio of total chemical equivalents of metal in the
overbased salt to
chemical equivalents of the metal in a neutral salt according to known
chemical reactivity and
stoichiometry. In a normal or neutral salt, the metal ratio is one and in an
overbased salt,
MR, is greater than one. They are commonly referred to as overbased,
hyperbased, or
superbased salts and may be salts of organic sulfur acids, carboxylic acids,
salicylates, and/or
phenols. In the present disclosure, the overbased detergent has a TBN of
greater than 225 mg
KOH/g. The overbased detergent may be a combination of two or more overbased
detergents
each having a TBN of greater than 225 mg KOH/g.
[0028] In the
present disclosure, the low-based/neutral detergent has a TBN of up to
175 mg KOH/g. The low-based/neutral detergent may be a combination of two or
more low-
based and/or neutral detergents each having a TBN up to 175 mg KOH/g. In some
instances,
"overbased" may be abbreviated "OB" and in some instances, -low-based/neutral"
may be
abbreviated "LB/N.-
[0029] The term
"total metal" refers to the total metal, metalloid or transition metal in
the lubricating oil composition including the metal contributed by the
detergent component(s)
of the lubricating oil composition.
[0030] 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:
(a) hydrocarbon substituents, that is, aliphatic (e.g., alkyl or alkenyl),
alicyclic (e.g.,
cycloalkyl, cycloalkenyl) substituents, and aromatic-, aliphatic-, and
alicyclic-
substituted aromatic substituents, as well as cyclic substituents wherein the
ring is
completed through another portion of the molecule (e.g., two substituents
together
form an alicyclic moiety);
(b) substituted hydrocarbon substituents, that is, substituents containing non-
hydrocarbon groups which, in the context of this disclosure, do not alter the
predominantly hydrocarbon substituent (e.g., halo (especially chloro and
fluoro),
hydroxy, alkoxy, mercapto, alkylmercapto, nitro, nitroso, amino, alkylamino,
and
sulfoxy); and
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(c) hetero substituents, that is, substituents which, while having a
predominantly
hydrocarbon character, in the context of this disclosure, contain other than
carbon in a
ring or chain otherwise composed of carbon atoms. Heteroatoms may include
sulfur,
oxygen, and nitrogen, and encompass substituents such as pyridyl, furyl,
thienyl, and
imidazolyl. In general, no more than two, for example, no more than one, non-
hydrocarbon substituent will be present for every ten carbon atoms in the
hydrocarbyl
group: typically, there will be no non-hydrocarbon substituents in the
hydrocarbyl
group.
[0031] As used
herein, the term "percent by weight", unless expressly stated
otherwise, means the percentage the recited component represents to the weight
of the entire
composition.
[0032] The terms
"soluble," "oil-soluble," or "dispersible" used herein may, but does
not necessarily, indicate that the compounds or additives are soluble,
dissolvable, miscible, or
capable of being suspended in the oil in all proportions. The foregoing terms
do mean,
however, that they are, for instance, soluble, suspendable, dissolvable, or
stably dispersible in
oil to an extent sufficient to exert their intended effect in the environment
in which the oil is
employed. Moreover, the additional incorporation of other additives may also
permit
incorporation of higher levels of a particular additive, if desired.
[0033] The term
"TBN" as employed herein is used to denote the Total Base Number
in mg KOH/g composition as measured by the method of ASTM D2896.
[0034] The term
"alkyl" as employed herein refers to straight, branched, cyclic,
and/or substituted saturated chain moieties of from about 1 to about 100
carbon atoms.
[0035] The term
"alkenyl" as employed herein refers to straight, branched, cyclic,
and/or substituted unsaturated chain moieties of from about 3 to about 10
carbon atoms.
[0036] The term
"aryl" as employed herein refers to single and multi-ring aromatic
compounds that may include alkyl, alkenyl, alkylaryl, amino, hydroxyl, alkoxy,
halo
substituents, and/or heteroatoms including, but not limited to, nitrogen,
oxygen, and sulfur.
[0037] Lubricants,
combinations of components, or individual components of the
present description may be suitable for use in various types of internal
combustion engines.
Suitable engine types may include, but are not limited to heavy duty diesel,
passenger car,
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light duty diesel, medium speed diesel, marine engines, or motorcycle engines.
An internal
combustion engine may be a diesel fueled engine, a gasoline fueled engine, a
natural gas
fueled engine, a bio-fueled engine, a mixed dieselibiofuel fueled engine, a
mixed
gasoline/biofuel fueled engine, an alcohol fueled engine, a mixed
gasoline/alcohol fueled
engine, a compressed natural gas (CNG) fueled engine, or mixtures thereof A
diesel engine
may be a compression ignited engine. A diesel engine may be a compression
ignited engine
with a spark-ignition assist. A gasoline engine may be a spark-ignited engine.
An internal
combustion engine may also be used in combination with an electrical or
battery source of
power. An engine so configured is commonly known as a hybrid engine. The
internal
combustion engine may be a 2-stroke, 4-stroke, or rotary engine. Suitable
internal
combustion engines include marine diesel engines (such as inland marine),
aviation piston
engines, low-load diesel engines, and motorcycle, automobile, locomotive, and
truck engines.
[0038] The internal
combustion engine may contain components of one or more of an
aluminum-alloy, lead, tin, copper, cast iron, magnesium, ceramics, stainless
steel,
composites, and/or mixtures thereof The components may be coated, for example,
with a
diamond-like carbon coating, a lubricated coating, a phosphorus-containing
coating,
molybdenum-containing coating, a graphite coating, a nano-particle-containing
coating,
and/or mixtures thereof. The aluminum-alloy may include aluminum silicates,
aluminum
oxides, or other ceramic materials. In one embodiment the aluminum-alloy is an
aluminum-
silicate surface. As used herein, the term "aluminum alloy" is intended to be
synonymous
with "aluminum composite" and to describe a component or surface comprising
aluminum
and another component intermixed or reacted on a microscopic or nearly
microscopic level,
regardless of the detailed structure thereof This would include any
conventional alloys with
metals other than aluminum as well as composite or alloy-like structures with
non-metallic
elements or compounds such with ceramic-like materials.
[0039] The
lubricating oil composition for an intemal combustion engine may be
suitable for any engine irrespective of the sulfur, phosphorus, or sulfated
ash (ASTM D-874)
content. The sulfur content of the engine oil lubricant may be about 1 wt% or
less, or about
0.8 wt% or less, or about 0.5 wt% or less, or about 0.3 wt% or less, or about
0.2 wt% or less.
In one embodiment the sulfur content may be in the range of about 0.001 wt% to
about 0.5
8
wt%, or about 0.01 wt% to about 0.3 wt%. The phosphorus content may be about
0.2 wt% or
less, or about 0.1 wt% or less, or about 0.085 wt% or less, or about 0.08 wt%
or less, or even
about 0.06 wt% or less, about 0.055 wt% or less, or about 0.05 wt% or less. In
one
embodiment the phosphorus content may be about 50 ppm to about 1000 ppm, or
about 325
ppm to about 850 ppm. The total sulfated ash content may be about 2 wt% or
less, or about
1.5 wt% or less, or about 1.1 wt% or less, or about 1 wt% or less, or about
0.8 wt% or less, or
about 0.5 wt% or less. In one embodiment the sulfated ash content may be about
0.05 wt% to
about 0.9 wt%, or about 0.1 wt% or about 0.2 wt% to about 0.45 wt%. In another
embodiment, the sulfur content may be about 0.4 wt% or less, the phosphorus
content may be
about 0.08 wt% or less, and the sulfated ash is about 1 wt% or less. In yet
another
embodiment the sulfur content may be about 0.3 wt% or less, the phosphorus
content is about
0.05 wt% or less, and the sulfated ash may be about 0.8 wt% or less.
[0040] In one embodiment the lubricating oil composition is an engine oil,
wherein
the lubricating oil composition may have (i) a sulfur content of about 0.5 wt%
or less, (ii) a
phosphorus content of about 0.1 wt% or less, and (iii) a sulfated ash content
of about 1.5 wt%
or less.
[0041] In some embodiments, the lubricating oil composition is suitable for
use with
engines powered by low sulfur fuels, such as fuels containing about 1 to about
5% sulfur.
Highway vehicle fuels contain about 15 ppm sulfur (or about 0.0015% sulfur).
The
lubricating oil composition is suitable for use with boosted internal
combustion engines
including turbocharged or supercharged internal combustion engines.
[0042] Further, lubricants of the present description may be suitable to
meet one or
more industry specification requirements such as ILSAC GF-3, GF-4, GF-5, GF-6,
PC-11,
CI-4, CJ-4, ACEA Al/B1, A2/B2, A3/B3, A3/B4, A5/135, Cl, C2, C3, C4, C5,
E4/E6/E7/E9,
Euro 5/6,Jaso DL-1, Low SAPS, Mid SAPS, or original equipment manufacturer
specifications such as DexosTM 1, DexosTm 2, MB-Approval 229.51/229.31, VWTM
502.00,
503.00/503.01, 504.00, 505.00, 506.00/506.01, 507.00, 508.00, 509.00, BMWTm
Longlife-04,
PorscheTM C30, PeugeotTM Citroen Automobiles B71 2290, B71 2296, B71 2297, B71
2300,
B71 2302, B71 2312, B71 2007, B71 2008, FordTM WSS-M2C153-H, WSS-M2C930-A,
WSS-M2C945-A, WSS-M2C913A, WSS-M2C913-B, WSS-M2C913-C, GM 6094-M, ChryslerTm
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MS-6395, or any past or future PCMO or HDD specifications not mentioned
herein. In some
embodiments for passenger car motor oil (PCMO) applications, the amount of
phosphorus in
the finished fluid is 1000 ppm or less or 900 ppm or less or 800 ppm or less.
[0043] Other
hardware may not be suitable for use with the disclosed lubricant. A
"functional fluid- is a term which encompasses a variety of fluids including
but not limited to
tractor hydraulic fluids, power transmission fluids including automatic
transmission fluids,
continuously variable transmission fluids and manual transmission fluids,
hydraulic fluids,
including tractor hydraulic fluids, some gear oils, power steering fluids,
fluids used in wind
turbines, compressors, some industrial fluids, and fluids related to power
train components. It
should be noted that within each of these fluids such as, for example,
automatic transmission
fluids, there are a variety of different types of fluids due to the various
transmissions having
different designs which have led to the need for fluids of markedly different
functional
characteristics. This is contrasted by the term "lubricating fluid- which is
not used to
generate or transfer power.
[0044] With respect
to tractor hydraulic fluids, for example, these fluids are all-
purpose products used for all lubricant applications in a tractor except for
lubricating the
engine. These lubricating applications may include lubrication of gearboxes,
power take-off
and clutch(es), rear axles, reduction gears, wet brakes, and hydraulic
accessories.
[0045] When a
functional fluid is an automatic transmission fluid, the automatic
transmission fluids must have enough friction for the clutch plates to
transfer power.
However, the friction coefficient of fluids has a tendency to decline due to
the temperature
effects as the fluid heats up during operation. It is important that the
tractor hydraulic fluid or
automatic transmission fluid maintain its high friction coefficient at
elevated temperatures,
otherwise brake systems or automatic transmissions may fail. This is not a
function of an
engine oil.
[0046] Tractor
fluids, and for example Super Tractor Universal Oils (STU0s) or
Universal Tractor Transmission Oils (UTT0s), may combine the performance of
engine oils
with transmissions, differentials, final-drive planetary gears, wet-brakes,
and hydraulic
performance. While many of the additives used to formulate a UTTO or a STUO
fluid are
similar in functionality, they may have deleterious effect if not incorporated
properly. For
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example, some anti-wear and extreme pressure additives used in engine oils can
be extremely
corrosive to the copper components in hydraulic pumps. Detergents and
dispersants used for
gasoline or diesel engine performance may be detrimental to wet brake
performance. Friction
modifiers specific to quiet wet brake noise, may lack the thermal stability
required for engine
oil perfoimance. Each of these fluids, whether functional, tractor, or
lubricating, are designed
to meet specific and stringent manufacturer requirements.
[0047] The present
disclosure provides novel lubricating oil blends formulated for use
as automotive crankcase lubricants. Embodiments of the present disclosure may
provide
lubricating oils suitable for crankcase applications and having improvements
in the following
characteristics: air entrainment, alcohol fuel compatibility, anti oxi dancy,
anti wear
performance, biofuel compatibility, foam reducing properties, friction
reduction, fuel
economy, pre-ignition prevention, rust inhibition, sludge and/or soot
dispersability, piston
cleanliness, deposit formation, and water tolerance.
[0048] Engine oils
of the present disclosure may be formulated by the addition of one
or more additives, as described in detail below, to an appropriate base oil
formulation. The
additives may be combined with a base oil in the form of an additive package
(or concentrate)
or, alternatively, may be combined individually with a base oil (or a mixture
of both). The
fully formulated engine oil may exhibit improved performance properties, based
on the
additives added and their respective proportions.
[0049] Additional
details and advantages of the disclosure will be set forth in part in
the description which follows, and/or may be learned by practice of the
disclosure. The
details and advantages of the disclosure may be realized and attained by means
of the
elements and combinations particularly pointed out in the appended claims. It
is to be
understood that both the foregoing general description and the following
detailed description
are exemplary and explanatory only and are not restrictive of the disclosure,
as claimed.
DETAILED DESCRIPTION
[0050] Various
embodiments of the disclosure provide a lubricating oil composition
and methods that may be used for reducing low-speed pre-ignition events (LSPI)
in a boosted
internal combustion engine. In particular, boosted internal combustion engines
of the present
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disclosure include turbocharged and supercharged internal combustion engines.
The boosted
internal combustion engines include spark-ignited, direct injection and/or
port-fuel injection
engines. The spark-ignited internal combustion engines may be gasoline
engines.
[0051] The
composition of the invention includes a lubricating oil composition
containing a base oil of lubricating viscosity and a particular additive
composition. The
methods of the present disclosure employ the lubricating oil composition
containing the
additive composition. As described in more detail below the lubricating oil
composition may
be surprisingly effective for use in reducing low-speed pre-ignition events in
a boosted
internal combustion engine lubricated with the lubricating oil composition.
[0052] In another
embodiment, the disclosure provides a method for reducing low-
speed pre-ignition events in a boosted internal combustion engine. The method
includes a
step of lubricating the boosted internal combustion engine with a lubricating
oil composition
including greater than 50 wt.% of a base oil of lubricating viscosity, at
least 0.3 wt.% of an
overbased detergent having a TBN greater than 225 mg KOH/g, and at least 0.2
wt.cYci of a
low-based/neutral detergent having a TBN up to 175 mg KOH/g. A total amount of
calcium
from the overbased and low-based/neutral detergent ranges from greater than
1100 ppm by
weight to less than 2400 ppm by weight based on a total weight of the
lubricating oil
composition. The boosted internal combustion engine is operated and lubricated
with the
lubricating oil composition whereby the low-speed pre-ignition events in the
engine
lubricated with the lubricating oil composition may be reduced.
[0053] In some
embodiments, the combustion chamber or cylinder walls of a spark-
ignited direct injection engine or port fuel injected intemal combustion
engine provided with
a turbocharger or a supercharger is operated and lubricated with the
lubricating oil
composition whereby the low-speed pre-ignition events in the engine lubricated
with the
lubricating oil composition may be reduced.
[0054] Optionally,
the methods of the present invention may include a step of
measuring low speed pre-ignition events of the internal combustion engine
lubricated with
the lubricating oil. In such methods, the internal combustion engine the
reduction of LSPI
events is a 50% or greater reduction, or, more preferably, a 75% or greater
reduction and the
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LSPI events are LSPI counts during 25,000 engine cycles, wherein the engine is
operated at
2000 revolutions per minute with brake mean effective pressure of 18,000 kPa.
[0055] As described
in more detail below, embodiments of the disclosure may
provide significant and unexpected improvement in reducing LSPI events while
maintaining
a relatively high calcium detergent concentration in the lubricating oil
composition.
Embodiments of the disclosure may also provide unexpected improvement in TEOST
33 test
while also reducing LSPI events.
[0056] In the
embodiments of the disclosure, the lubricating oil composition may also
pass a TEOST 33 test.
Detergents
[0057] The
lubricating oil composition comprises one or more overbased detergents
and one or more low-based/neutral detergents. Suitable detergent substrates
include
phenates, sulfur containing phenates, sulfonates, calixarates, salixarates,
salicylates,
carboxylic acids, phosphorus acids, mono- and/or di-thiophosphoric acids,
alkyl phenols,
sulfur coupled alkyl phenol compounds, or methylene bridged phenols. Suitable
detergents
and their methods of preparation are described in greater detail in numerous
patent
publications, including US 7,732,390 and references cited therein. The
detergent substrate
may be salted with an alkali or alkaline earth metal such as, but not limited
to, calcium,
magnesium, potassium, sodium, lithium, barium, or mixtures thereof In some
embodiments,
the detergent is free of barium. A suitable detergent may include alkali or
alkaline earth
metal salts of petroleum sulfonic acids and long chain mono- or di-
alkylarylsulfonic acids
with the aryl group being benzyl, tolyl, and xylyl. Examples of suitable
additional detergents
include, but are not limited to, calcium phenates, calcium sulfur containing
phenates, calcium
sulfonates, calcium calixarates, calcium salixarates, calcium salicylates,
calcium carboxylic
acids, calcium phosphorus acids, calcium mono- and/or di-thiophosphoric acids,
calcium
alkyl phenols, calcium sulfur coupled alkyl phenol compounds, calcium
methylene bridged
phenols, magnesium phenates, magnesium sulfur containing phenates, magnesium
sulfonates,
magnesium calixarates, magnesium salixarates, magnesium salicylates, magnesium
carboxylic acids, magnesium phosphorus acids, magnesium mono- and/or di-
thiophosphoric
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acids, magnesium alkyl phenols, magnesium sulfur coupled alkyl phenol
compounds,
magnesium methylene bridged phenols, sodium phenates, sodium sulfur containing
phenates,
sodium sulfonates, sodium calixarates, sodium salixarates, sodium salicylates,
sodium
carboxylic acids, sodium phosphorus acids, sodium mono- and/or di-
thiophosphoric acids,
sodium alkyl phenols, sodium sulfur coupled alkyl phenol compounds, or sodium
methylene
bridged phenols.
[0058] Overbased
detergents are well known in the art and may be alkali or alkaline
earth metal overbased detergent. Such detergents may be prepared by reacting a
metal oxide
or metal hydroxide with a substrate and carbon dioxide gas. The substrate is
typically an
acid, for example, an acid such as an aliphatic substituted sulfonic acid, an
aliphatic
substituted carboxylic acid, or an aliphatic substituted phenol.
[0059] The
terminology "overbased" relates to metal salts, such as metal salts of
sulfonates, carboxylates, and phenates, wherein the amount of metal present
exceeds the
stoichiometric amount. Such salts may have a conversion level in excess of
100% (i.e., they
may comprise more than 100% of the theoretical amount of metal needed to
convert the acid
to its -normal," -neutral" salt). The expression "metal ratio," often
abbreviated as MR, is
used to designate the ratio of total chemical equivalents of metal in the
overbased salt to
chemical equivalents of the metal in a neutral salt according to known
chemical reactivity and
stoichiometry. In a normal or neutral salt, the metal ratio is one and in an
overbased salt,
MR, is greater than one. They are commonly referred to as overbased,
hyperbased, or
superbased salts and may be salts of organic sulfur acids, carboxylic acids,
or phenols.
[0060] An overbased
detergent has a TBN of greater 225 mg KOH/gram, or as further
examples, a TBN of about 250 mg KOH/gram or greater, or a TBN of about 300 mg
KOR'gram or greater, or a TBN of about 350 mg KOHigram or greater, or a TBN of
about
375 mg KOH/gram or greater, or a TBN of about 400 mg KOH/gram or greater.
[0061] Examples of
suitable overbased detergents include, but are not limited to,
overbased calcium phenates, overbased calcium sulfur containing phenates,
overbased
calcium sulfonates, overbased calcium calixarates, overbased calcium
salixarates, overbased
calcium salicylates, overbased calcium carboxylic acids, overbased calcium
phosphorus
acids, overbased calcium mono- and/or di-thiophosphoric acids, overbased
calcium alkyl
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phenols, overbased calcium sulfur coupled alkyl phenol compounds, overbased
calcium
methylene bridged phenols, overbased magnesium phenates, overbased magnesium
sulfur
containing phenates, overbased magnesium sulfonates, overbased magnesium
calixarates,
overbased magnesium salixarates, overbased magnesium salicylates, overbased
magnesium
carboxylic acids, overbased magnesium phosphorus acids, overbased magnesium
mono-
and/or di-thiophosphoric acids, overbased magnesium alkyl phenols, overbased
magnesium
sulfur coupled alkyl phenol compounds, or overbased magnesium methylene
bridged
phenols.
[0062] The
overbased detergent may have a metal to substrate ratio of from 1.1:1, or
from 2:1, or from 4:1, or from 5:1, or from 7:1, or from 1 0: 1 .
[0063] In some
embodiments, a detergent is effective at reducing or preventing rust in
an engine.
[0064] The
detergent may be present at up to 10 wt%, or about about up to 8 wt%, or
up to about 4 wt%, or greater than about 4 wt% to about 8 wt% based on a total
weight of the
lubricating oil composition.
[0065] The
detergent may be present in an amount to provide from about 1100 to
about 3500 ppm metal to the finished fluid. In other embodiments, the
detergent may provide
from about 1100 to about 3000 ppm of metal, or about 1150 to about 2500 ppm of
metal, or
about 1200 to about 2400 ppm of metal to the finished fluid.
[0066] The
lubricating oil compositions of the present disclosure include at least one
overbased detergent having a TBN of greater than 225 mg KOH/gram and at least
one
neutral/low-based detergent having a TBN of up to 175 mg KOH/gram. The present
disclosure also includes methods of using such lubricating oil compositions in
a method or
lubricating an engine by lubricating the engine with the lubricating oil
composition and
operating the engine.
[0067] The
lubricating oil composition of the disclosure has a total amount of calcium
from the overbased and low-based/neutral detergent that ranges from greater
than 1100 ppm
by weight to less than 2400 ppm by weight based on a total weight of the
lubricating oil
composition.
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[0068] The
overbased detergent may be an overbased calcium-containing detergent.
The overbased calcium-containing detergent may be selected from an overbased
calcium
sulfonate detergent, an overbased calcium phenate detergent, and an overbased
calcium
salicylate detergent. In certain embodiments, the overbased calcium-containing
detergent
comprises an overbased calcium sulfonate detergent. In certain embodiments,
the overbased
detergent is one or more calcium-containing detergents, preferably the
overbased detergent is
a calcium sulfonate detergent.
[0069] In certain
embodiments, the one or more overbased calcium-containing
detergents provide from about 900 to about 2400 ppm calcium to the finished
fluid. As a
further example, the one or more overbased calcium-containing detergents may
be present in
an amount to provide from about 900 to about 2000 ppm calcium, or from about
900 to about
1800 ppm calcium, or from about 1100 to 1600 ppm calcium, or from about 1200
to 1500
ppm calcium to the finished fluid.
[0070] The low-
based/neutral detergent has a TBN of up to 175 mg KOH/g, or up to
150 mg KOH/g. The low-based/neutral detergent may include a calcium-containing
detergent. The low-based neutral calcium-containing detergent may be selected
from a
calcium sulfonate detergent, a calcium phenate detergent and a calcium
salicylate detergent.
In some embodiments, the low-based/neutral detergent is a calcium-containing
detergent or a
mixture of calcium-containing detergents. In some embodiments, the low-
based/neutral
detergent is a calcium sulfonate detergent or a calcium phenate detergent.
[0071] The low-
based/neutral detergent comprises at least 2.5 wt.% of the total
detergent in the lubricating oil composition. In some embodiments, at least 4
wt.%, or at
least 6 wt %, or at least 8 wt.%, or at least 10 wt.% or at least 12 wt.% or
at least 20 wt.% of
the total detergent in the lubricating oil composition is a low-based/neutral
detergent which
may optionally be a low-based/neutral calcium-containing detergent.
[0072] In certain
embodiments, the one or more low-based/neutral calcium-
containing detergents provide from about 50 to about 1000 ppm calcium by
weight to the
lubricating oil composition based on a total weight of the lubricating oil
composition. In
some embodiments, the one or more low-based/neutral calcium-containing
detergents provide
from 75 to less than 800 ppm, or from 100 to 600 ppm, or from 125 to 500 ppm
by weight
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calcium to the lubricating oil composition based on a total weight of the
lubricating oil
composition.
[0073] In some
embodiments, the lubricating oil composition has a ratio of total
millimoles metal (M) to TBN of the lubricating oil composition ranging from
greater than 4.5
to about 10Ø In some embodiments the ratio of total millimoles metal (M) to
TBN of the
lubricating oil composition ranges from greater than 8 to less than 10.0 or
from 8 to 9.5 or
from 8.1 to 9Ø
[0074] In some
embodiments the ratio of the ppm of calcium, by weight, provided to
the lubricating oil composition by the low-based/neutral detergent to the ppm
of calcium, by
weight, provided to the lubricating oil composition by the overbased calcium
detergent, is
from about 0.01 to about 1, or from about 0.03 to about 0.7, or from about
0.05 to about 0.5,
or from about 0.08 to about 0.4.
[0075] The
overbased calcium-containing detergent may be an overbased calcium
sulfonate detergent. The overbased calcium-containing detergent may optionally
exclude
overbased calcium salicylate detergents. The lubricating oil may optionally
exclude any
magnesium-containing detergents or be free of magnesium. In any of the
embodiments of the
disclosure, the amount of sodium in the lubricating composition may be limited
to not more
than 150 ppm of sodium, based on a total weight of the lubricating oil
composition.
Base Oil
[0076] The base oil
used in the lubricating oil compositions herein may be selected
from any of the base oils in Groups I-V as specified in the American Petroleum
Institute
(API) Base Oil Interchangeability Guidelines. The five base oil groups are as
follows:
Table 1
Base oil Category Sulfur (%) Saturates (9/0) Viscosity Index
Group I > 0.03 and/or <90 80 to 120
Group II <0.03 and >90 80 to 120
Group III <0.03 and >90 >120
All polyalphaolefins
Group IV
(PA0s)
All others not
Group V included in Groups
1, II. III, or IV
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[0077] Groups I,
II, and III are mineral oil process stocks. Group IV base oils contain
true synthetic molecular species, which are produced by polymerization of
olefinically
unsaturated hydrocarbons. Many Group V base oils are also true synthetic
products and may
include diesters, polyol esters, polyalkylene glycols, alkylated aromatics,
polyphosphate
esters, polyvinyl ethers, and/or polyphenyl ethers, and the like, but may also
be naturally
occurring oils, such as vegetable oils. It should be noted that although Group
ITT base oils are
derived from mineral oil, the rigorous processing that these fluids undergo
causes their
physical properties to be very similar to some true synthetics, such as PAOs.
Therefore, oils
derived from Group III base oils may be referred to as synthetic fluids in the
industry.
[0078] The base oil
used in the disclosed lubricating oil composition may be a
mineral oil, animal oil, vegetable oil, synthetic oil, or mixtures thereof
Suitable oils may be
derived from hydrocracking, hydrogenation, hydrofinishing, unrefined, refined,
and re-
refined oils, and mixtures thereof
[0079] Unrefined
oils are those derived from a natural, mineral, or synthetic source
without or with little further purification treatment. Refined oils are
similar to the unrefined
oils except that they have been treated in one or more purification steps,
which may result in
the improvement of one or more properties. Examples of suitable purification
techniques are
solvent extraction, secondary distillation, acid or base extraction,
filtration, percolation, and
the like. Oils refined to the quality of an edible may or may not be useful.
Edible oils may
also be called white oils. In some embodiments, lubricating oil compositions
are free of
edible or white oils.
[0080] Re-refined
oils are also known as reclaimed or reprocessed oils. These oils are
obtained similarly to refined oils using the same or similar processes. Often
these oils are
additionally processed by techniques directed to removal of spent additives
and oil
breakdown products.
[0081] Mineral oils
may include oils obtained by drilling or from plants and animals
or any mixtures thereof For example such oils may include, but are not limited
to, castor oil,
lard oil, olive oil, peanut oil, corn oil, soybean oil, and linseed oil, as
well as mineral
lubricating oils, such as liquid petroleum oils and solvent-treated or acid-
treated mineral
lubricating oils of the paraffinic, naphthenic or mixed paraffinic-naphthenic
types. Such oils
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may be partially or fully hydrogenated, if desired. Oils derived from coal or
shale may also
be useful.
[0082] Useful
synthetic lubricating oils may include hydrocarbon oils such as
polymerized, oligomerized, or interpolymerized olefins (e.g., polybutylenes,
polypropylenes,
propylene/isobutylene copolymers); poly(1-hexenes), poly(1-octenes), trimers
or oligomers
of 1 -decene, e.g., poly(1-decenes), such materials being often referred to as
a-olefins, and
mixtures thereof, alkyl-benzenes (e.g. dodecylbenzenes, tetradecylbenzenes,
dinonylbenzenes, di-(2-ethylhexyl)-benzenes); polyphenyls (e.g., biphenyls,
terphenyls,
alkylated polyphenyls), diphenyl alkanes, alkylated diphenyl alkanes,
alkylated diphenyl
ethers and alkylated diphenyl sulfides and the derivatives, analogs and
homologs thereof or
mixtures thereof Polyalphaolefins are typically hydrogenated materials.
[0083] Other
synthetic lubricating oils include polyol esters, diesters, liquid esters of
phosphorus-containing acids (e.g., tricresyl phosphate, trioctyl phosphate,
and the diethyl
ester of decane phosphonic acid), or polymeric tetrahydrofurans. Synthetic
oils may be
produced by Fischer-Tropsch reactions and typically may be hydroisomerized
Fischer-
Tropsch hydrocarbons or waxes. In one embodiment oils may be prepared by a
Fischer-
Tropsch gas-to-liquid synthetic procedure as well as other gas-to-liquid oils.
[0084] The greater
than 50 wt.% of base oil included in a lubricating composition
may be selected from the group consisting of Group I, Group II, a Group III, a
Group IV, a
Group V. and a combination of two or more of the foregoing, and wherein the
greater than 50
wt.% of base oil is other than base oils that arise from provision of additive
components or
viscosity index improvers in the composition. In another embodiment, the
greater than 50
wt.% of base oil included in a lubricating composition may be selected from
the group
consisting of Group II, a Group III, a Group IV, a Group V, and a combination
of two or
more of the foregoing, and wherein the greater than 50 wt.% of base oil is
other than diluent
oils that arise from provision of additive components or viscosity index
improvers in the
composition.
[0085] The amount
of the oil of lubricating viscosity present may be the balance
remaining after subtracting from 100 wt% the sum of the amount of the
performance
additives inclusive of viscosity index improver(s) and/or pour point
depressant(s) and/or
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other top treat additives. For example, the oil of lubricating viscosity that
may be present in a
finished fluid may be a major amount, such as greater than about 50 wt%,
greater than about
60 wt%, greater than about 70 wt%, greater than about 80 wt%, greater than
about 85 wt%, or
greater than about 90 wt%.
[0086] The
lubricating oil composition may comprise not more than 10 wt.% of a
Group IV base oil, a Group V base oil, or a combination thereof. In each of
the foregoing
embodiments, the lubricating oil compositions comprises less than 5 wt.% of a
Group V base
oil. The lubricating oil composition does not contain any Group IV base oils.
The
lubricating oil composition does not contain any Group V base oils.
[0087] The
lubricating oil composition may also include one or more optional
components selected from the various additives set forth below.
Antioxidants
[0088] The
lubricating oil compositions herein also may optionally contain one or
more antioxidants. Antioxidant compounds are known and include for example,
phenates,
phenate sulfides, sulfurized olefins, phosphosulfurized terpenes, sulfurized
esters, aromatic
amines, alkylated diphenvlamines (e.g., nonyl diphenylamine, di-nonyl
diphenylamine, octyl
diphenylamine, di-octyl diphenylamine), phenyl-alpha-naphthylamines, alkylated
phenyl-
alpha-naphthylamines, hindered non-aromatic amines, phenols, hindered phenols,
oil-soluble
molybdenum compounds, macromolecular antioxidants, or mixtures thereof
Antioxidant
compounds may be used alone or in combination.
[0089] The hindered
phenol antioxidant may contain a secondary butyl and/or a
tertiary butyl group as a sterically hindering group. The phenol group may be
further
substituted with a hydrocarbyl group and/or a bridging group linking to a
second aromatic
group. Examples of suitable hindered phenol antioxidants include 2,6-di-tert-
butylphenol, 4-
methy1-2,6-di-tert-butylphenol, 4-ethyl-2,6-
di-tert-butylphenol, .. 4-propy1-2,6-di-tert-
butylphenol or 4-butyl-2,6-di-tert-butylphenol, or 4-dodecy1-2,6-di-tert-
butylphenol. In one
embodiment the hindered phenol antioxidant may be an ester and may include,
e.g.,
IRGANOXTM L-135 available from BASF or an addition product derived from 2,6-di-
tert-
butylphenol and an alkyl acrylate, wherein the alkyl group may contain about 1
to about 18,
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or about 2 to about 12, or about 2 to about 8, or about 2 to about 6, or about
4 carbon atoms.
Another commercially available hindered phenol antioxidant may be an ester and
may
include ETHANOXTm 4716 available from Albemarle Corporation.
[0090] Useful
antioxidants may include diarylamines and high molecular weight
phenols. In an embodiment, the lubricating oil composition may contain a
mixture of a
diarylamine and a high molecular weight phenol, such that each antioxidant may
be present
in an amount sufficient to provide up to about 5%, by weight, based upon the
final weight of
the lubricating oil composition. In an embodiment, the antioxidant may be a
mixture of about
0.3 to about 1.5% diarylamine and about 0.4 to about 2.5% high molecular
weight phenol, by
weight, based upon the final weight of the lubricating oil composition.
[0091] Examples of
suitable olefins that may be sulfurized to form a sulfurized olefin
include propylene, butylene, isobutylene, polyisobutylene, pentene, hexene,
heptene, octene,
nonene, decene, undecene, dodecene, tridecene, tetradecene, pentadecene,
hexadecene,
heptadecene, octadecene, nonadecene, eicosene or mixtures thereof In one
embodiment,
hexadecene, heptadecene, octadecene, nonadecene, eicosene or mixtures thereof
and their
dimers, trimers and tetramers are especially useful olefins. Alternatively,
the olefin may be a
Diels-Alder adduct of a diene such as 1,3-butadiene and an unsaturated ester,
such as,
butylacrylate.
[0092] Another
class of sulfurized olefin includes sulfurized fatty acids and their
esters. The fatty acids are often obtained from vegetable oil or animal oil
and typically
contain about 4 to about 22 carbon atoms. Examples of suitable fatty acids and
their esters
include triglycerides, oleic acid, linoleic acid, palmitoleic acid or mixtures
thereof. Often, the
fatty acids are obtained from lard oil, tall oil, peanut oil, soybean oil,
cottonseed oil,
sunflower seed oil or mixtures thereof Fatty acids and/or ester may be mixed
with olefins,
such as a-olefins.
[0093] The one or
more antioxidant(s) may be present in ranges about 0 wt% to about
20 wt%, or about 0.1 wt% to about 10 wt%, or about 1 wt% to about 5 wt%, of
the
lubricating oil composition.
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Antiwear Agents
[0094] The
lubricating oil compositions herein also may optionally contain one or
more antiwear agents. Examples of suitable antiwear agents include, but are
not limited to, a
metal thiophosphate; a metal dialkyldithiophosphate; a phosphoric acid ester
or salt thereof; a
phosphate ester(s); a phosphite; a phosphorus-containing carboxylic ester,
ether, or amide; a
sulfurized olefin; thiocarbamate-containing compounds including, thiocarbamate
esters,
alkylene-coupled thiocarbamates, and bis(S-alkyldithiocarbamyl)disulfides; and
mixtures
thereof A suitable antiwear agent may be a molybdenum dithiocarbamate. The
phosphorus
containing antiwear agents are more fully described in European Patent 612
839. The metal
in the dialkyl dithio phosphate salts may be an alkali metal, alkaline earth
metal, aluminum,
lead, tin, molybdenum, manganese, nickel, copper, titanium, or zinc. A useful
antiwear agent
may be zinc dialkylthiophosphate.
[0095] Further
examples of suitable antiwear agents include titanium compounds,
tartrates, tartrimides, oil soluble amine salts of phosphorus compounds,
sulfurized olefins,
phosphites (such as dibutyl phosphite), phosphonates, thiocarbamate-containing
compounds,
such as thiocarbamate esters, thiocarbamate amides, thiocarbamic ethers,
alkylene-coupled
thiocarbamates, and bis(S-alkyldithiocarbamyl) disulfides. The tartrate or
tartrimide may
contain alkyl-ester groups, where the sum of carbon atoms on the alkyl groups
may be at least
8. The antiwear agent may in one embodiment include a citrate.
[0096] The antiwear
agent may be present in ranges including about 0 wt% to about
15 wt%, or about 0.01 wt% to about 10 wt%, or about 0.05 wt% to about 5 wt%,
or about 0.1
wt% to about 3 wt% of the lubricating oil composition.
[0097] An antiwear
compound may be a zinc dihydrocarbyl dithiophosphate (ZDDP)
having a P:Zn ratio of from about 1:0.8 to about 1:1.7.
Boron-Containing Compounds
[0098] The
lubricating oil compositions herein may optionally contain one or more
boron-containing compounds.
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[0099] Examples of
boron-containing compounds include borate esters, borated fatty
amines, borated epoxides, borated detergents, and borated dispersants, such as
borated
succinimide dispersants, as disclosed in U.S. Patent No. 5,883,057.
[00100] The boron-
containing compound, if present, can be used in an amount
sufficient to provide up to about 8 wt%, about 0.01 wt% to about 7 wt%, about
0.05 wt% to
about 5 wt%, or about 0.1 wt% to about 3 wt% of the lubricating oil
composition.
Dispersants
[0010i] The
lubricating oil composition may optionally further comprise one or more
dispersants or mixtures thereof Dispersants are often known as ashless-type
dispersants
because, prior to mixing in a lubricating oil composition, they do not contain
ash-forming
metals and they do not normally contribute any ash when added to a lubricant.
Ashless type
dispersants are characterized by a polar group attached to a relatively high
molecular weight
hydrocarbon chain. Typical ashless dispersants include N-substituted long
chain alkenyl
succinimides. Examples of N-substituted long chain alkenyl succinimides
include
polyisobutylene succinimide with number average molecular weight of the
polyisobutylene
substituent in the range about 350 to about 50,000, or to about 5,000, or to
about 3,000.
Succinimide dispersants and their preparation are disclosed, for instance in
U.S. Pat. No.
7,897,696 or U.S. Pat. No. 4,234,435. The polyolefin may be prepared from
polymerizable
monomers containing about 2 to about 16, or about 2 to about 8, or about 2 to
about 6 carbon
atoms. Succinimide dispersants are typically the imide formed from a
polyamine, typically a
poly (ethy leneamine).
[00102] In an
embodiment the present disclosure further comprises at least one
polyisobutylene succinimide dispersant derived from polyisobutylene with
number average
molecular weight in the range about 350 to about 50,000, or to about 5000, or
to about 3000.
The polyisobutylene succinimide may be used alone or in combination with other
dispersants.
[00103] In some
embodiments, polyisobutylene, when included, may have greater than
50 mol%, greater than 60 mol%, greater than 70 mol%, greater than 80 mol%, or
greater than
90 mol% content of terminal double bonds. Such PIB is also referred to as
highly reactive
PIB ("HR-PIB"). HR-PIB having a number average molecular weight ranging from
about
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800 to about 5000 is suitable for use in embodiments of the present
disclosure. Conventional
PIB typically has less than 50 mol%, less than 40 mol%, less than 30 mol%,
less than 20
mol%, or less than 10 mol% content of terminal double bonds.
[00104] An HR-PIB
having a number average molecular weight ranging from about
900 to about 3000 may be suitable. Such FIR-PIB is commercially available, or
can be
synthesized by the polymerization of isobutene in the presence of a non-
chlorinated catalyst
such as boron trifluoride, as described in US Patent No. 4,152,499 to Boerzel,
et al. and U.S.
Patent No. 5,739,355 to Gateau, et al. When used in the aforementioned thermal
ene
reaction. HR-PIB may lead to higher conversion rates in the reaction, as well
as lower
amounts of sediment formation, due to increased reactivity. A suitable method
is described in
U.S. Patent No. 7,897,696.
[00105] In one
embodiment the present disclosure further comprises at least one
dispersant derived from polyisobutylene succinic anhydride ("PIBSA-). The
PIBSA may
have an average of between about 1.0 and about 2.0 succinic acid _moieties per
polymer.
[00106] The %
actives of the alkenyl or alkyl succinic anhydride can be determined
using a chromatographic technique. This method is described in column 5 and 6
in U.S. Pat.
No. 5,334,321.
[00107] The percent
conversion of the polyolefin is calculated from the % actives
using the equation in column 5 and 6 in U.S. Pat. No. 5,334,321.
[00108] Unless
stated otherwise, all percentages are in weight percent and all
molecular weights are number average molecular weights.
[00109] In one
embodiment, the dispersant may be derived from a polyalphaolefin
(PAO) succinic anhydride.
[00110] In one
embodiment, the dispersant may be derived from olefin maleic
anhydride copolymer. As an example, the dispersant may be described as a poly-
PIBSA.
[00111] In an
embodiment, the dispersant may be derived from an anhydride which is
grafted to an ethylene-propylene copolymer.
[00112] One class of
suitable dispersants may be Mannich bases. Mannich bases are
materials that are formed by the condensation of a higher molecular weight,
alkyl substituted
24
phenol, a polyalkylene polyamine, and an aldehyde such as formaldehyde.
Mannich bases
are described in more detail in U.S. Patent No. 3,634,515.
[00113] A suitable class of dispersants may be high molecular weight esters
or half
ester amides.
[00114] A suitable dispersant may also be post-treated by conventional
methods by a
reaction with any of a variety of agents. Among these are boron, urea,
thiourea,
dimercaptothiadiazoles, carbon disulfide, aldehydes, ketones, carboxylic
acids, hydrocarbon-
substituted succinic anhydrides, maleic anhydride, nitriles, epoxides,
carbonates, cyclic
carbonates, hindered phenolic esters, and phosphorus compounds. US 7,645,726;
US
7,214,649; and US 8,048,831.
[00115] In addition to the carbonate and boric acids post-treatments both
the
compounds may be post-treated, or further post-treatment, with a variety of
post-treatments
designed to improve or impart different properties. Such post-treatments
include those
summarized in columns 27-29 of U.S. Pat. No. 5,241,003. Such treatments
include,
treatment with:
Inorganic phosphorous acids or anhydrates (e.g., U.S. Pat. Nos. 3,403,102 and
4,648,980);
Organic phosphorous compounds (e.g., U.S. Pat. No. 3,502,677);
Phosphorous pentasulfides;
Boron compounds as already noted above (e.g., U.S. Pat. Nos. 3,178,663 and
4,652,387);
Carboxylic acid, polycarboxylic acids, anhydrides and/or acid halides (e.g.,
U.S. Pat.
Nos. 3,708,522 and 4,948,386);
Epoxides, polyepoxides or thioexpoxides (e.g., U.S. Pat. Nos. 3,859,318 and
5,026,495);
Aldehyde or ketone (e.g., U.S. Pat. No. 3,458,530);
Carbon disulfide (e.g., U.S. Pat. No. 3,256,185);
Glycidol (e.g., U.S. Pat. No. 4,617,137);
Urea, thourea or guanidine (e.g., U.S. Pat. Nos. 3,312,619; 3,865,813; and
British
Patent GB 1,065,595);
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Organic sulfonic acid (e.g., U.S. Pat. No. 3,189,544 and British Patent GB
2,140,811);
Alkenyl cyanide (e.g., U.S. Pat. Nos. 3,278,550 and 3,366,569);
Diketene (e.g., U.S. Pat. No. 3,546,243);
A diisocyanate (e.g., U.S. Pat. No. 3,573,205);
Alkane sultone (e.g., U.S. Pat. No. 3,749,695);
1,3-Dicarbonyl Compound (e.g., U.S. Pat. No. 4,579,675);
Sulfate of alkoxylated alcohol or phenol (e.g., U.S. Pat. No. 3,954,639);
Cyclic lactone (e.g., U.S. Pat. Nos. 4,617,138; 4,645,515; 4,668,246;
4,963,275: and
4,971,711);
Cyclic carbonate or thiocarbonate linear monocarbonate or polycarbonate, or
chloroformate (e.g., U.S. Pat. Nos. 4,612,132; 4,647,390; 4,648,886;
4,670,170);
Nitrogen-containing carboxylic acid (e.g., U.S. Pat. 4,971,598 and British
Patent GB
2,140,811);
Hydroxy-protected chlorodicarbonyloxy compound (e.g., U.S. Pat. No.
4,614,522);
Lactam, thiolactam, thiolactone or ditholactone (e.g., U.S. Pat. Nos.
4,614,603 and
4,666,460);
Cyclic carbonate or thiocarbonate, linear monocarbonate or polycarbonate, or
chloroformate (e.g., U.S. Pat. Nos. 4,612,132; 4,647,390; 4,646,886; and
4,670,170);
Nitrogen-containing carboxylic acid (e.g., U.S. Pat. No. 4,971,598 and British
Patent
GB 2,440,811);
Hydroxy-protected chlorodicarbonyloxy compound (e.g., U.S. Pat. No.
4,614,522);
Lactam, thiolactam, thiolactone or dithiolactone (e.g., U.S. Pat. Nos.
4,614,603, and
4,666,460);
Cyclic carbamate, cyclic thiocarbamate or cyclic dithiocarbamate (e.g., U.S.
Pat. Nos.
4,663,062 and 4,666,459);
Hydroxyaliphatic carboxylic acid (e.g., U.S. Pat. Nos. 4,482,464; 4,521,318;
4,713,189);
Oxidizing agent (e.g., U.S. Pat. No. 4,379,064);
Combination of phosphorus pentasulfide and a polyalkvlene polyamine (e.g.,
U.S.
Pat. No. 3,185,647);
26
Combination of carboxylic acid or an aldehyde or ketone and sulfur or sulfur
chloride
(e.g., U.S. Pat. Nos. 3,390,086; 3,470,098);
Combination of a hydrazine and carbon disulfide (e.g. U.S. Pat. No.
3,519,564);
Combination of an aldehyde and a phenol (e.g., U.S. Pat. Nos. 3,649,229;
5,030,249;
5,039,307);
Combination of an aldehyde and an 0-diester of dithiophosphoric acid (e.g.,
U.S. Pat.
No. 3,865,740);
Combination of a hydroxyaliphatic carboxylic acid and a boric acid (e.g., U.S.
Pat.
No. 4,554,086);
Combination of a hydroxyaliphatic carboxylic acid, then formaldehyde and a
phenol
(e.g., U.S. Pat. No. 4,636,322);
Combination of a hydroxyaliphatic carboxylic acid and then an aliphatic
dicarboxylic
acid (e.g., U.S. Pat. No. 4,663,064);
Combination of formaldehyde and a phenol and then glycolic acid (e.g., U.S.
Pat. No.
4,699,724);
Combination of a hydroxyaliphatic carboxylic acid or oxalic acid and then a
diisocyanate (e.g. U.S. Pat. No.4,713,191);
Combination of inorganic acid or anhydride of phosphorus or a partial or total
sulfur
analog thereof and a boron compound (e.g., U.S. Pat. No. 4,857,214);
Combination of an organic diacid then an unsaturated fatty acid and then a
nitrosoaromatic amine optionally followed by a boron compound and then a
glycolating agent (e.g., U.S. Pat. No. 4,973,412);
Combination of an aldehyde and a triazole (e.g., U.S. Pat. No. 4,963,278);
Combination of an aldehyde and a triazole then a boron compound (e.g., U.S.
Pat. No.
4,981,492);
Combination of cyclic lactone and a boron compound (e.g., U.S. Pat. No.
4,963,275
and 4,971,711).
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[00116] The TBN of a
suitable dispersant may be from about 10 to about 65 on an oil-
free basis, which is comparable to about 5 to about 30 TBN if measured on a
dispersant
sample containing about 50% diluent oil.
[00117] The
dispersant, if present, can be used in an amount sufficient to provide up to
about 20 wt%, based upon the final weight of the lubricating oil composition.
Another
amount of the dispersant that can be used may be about 0.1 wt% to about 15
wt%, or about
0.1 wt% to about 10 wt%, or about 3 wt% to about 10 wt%, or about 1 wt% to
about 6 wt%,
or about 7 wt% to about 12 wt%, based upon the final weight of the lubricating
oil
composition. In some embodiments, the lubricating oil composition utilizes a
mixed
dispersant system. A single type or a mixture of two or more types of
dispersants in any
desired ratio may be used.
Friction Modifiers
[00118] The
lubricating oil compositions herein also may optionally contain one or
more friction modifiers. Suitable friction modifiers may comprise metal
containing and
metal-free friction modifiers and may include, but are not limited to,
imidazolines, amides,
amines, succinimides, alkoxylated amines, alkoxylated ether amines, amine
oxides,
amidoamines, nitriles, betaines, quaternary amines, imines, amine salts, amino
guanadine,
alkanolamides, phosphonates, metal-containing compounds, glycerol esters,
sulfurized fatty
compounds and olefins, sunflower oil other naturally occurring plant or animal
oils,
dicarboxylic acid esters, esters or partial esters of a polyol and one or more
aliphatic or
aromatic carboxylic acids, and the like.
[00119] Suitable
friction modifiers may contain hydrocarbyl groups that are selected
from straight chain, branched chain, or aromatic hydrocarbyl groups or
mixtures thereof, and
may be saturated or unsaturated. The hydrocarbyl groups may be composed of
carbon and
hydrogen or hetero atoms such as sulfur or oxygen. The hydrocarbyl groups may
range from
about 12 to about 25 carbon atoms. In some embodiments the friction modifier
may be a
long chain fatty acid ester. In another embodiment the long chain fatty acid
ester may be a
mono-ester, or a di-ester, or a (tri)glyceride. The friction modifier may be a
long chain fatty
28
amide, a long chain fatty ester, a long chain fatty epoxide derivatives, or a
long chain
imidazo line.
[00120] Other suitable friction modifiers may include organic, ashless
(metal-free),
nitrogen-free organic friction modifiers. Such friction modifiers may include
esters formed
by reacting carboxylic acids and anhydrides with alkanols and generally
include a polar
terminal group (e.g. carboxyl or hydroxyl) covalently bonded to an oleophilic
hydrocarbon
chain. An example of an organic ashless nitrogen-free friction modifier is
known generally
as glycerol monooleate (GMO) which may contain mono-, di-, and tri-esters of
oleic acid.
Other suitable friction modifiers are described in U.S. Pat. No. 6,723,685.
[00121] Aminic friction modifiers may include amines or polyamines. Such
compounds can have hydrocarbyl groups that are linear, either saturated or
unsaturated, or a
mixture thereof and may contain from about 12 to about 25 carbon atoms.
Further examples
of suitable friction modifiers include alkoxylated amines and alkoxylated
ether amines. Such
compounds may have hydrocarbyl groups that are linear, either saturated,
unsaturated, or a
mixture thereof. They may contain from about 12 to about 25 carbon atoms.
Examples
include ethoxylated amines and ethoxylated ether amines.
[00122] The amines and amides may be used as such or in the form of an
adduct or
reaction product with a boron compound such as a boric oxide, boron halide,
metaborate,
boric acid or a mono-, di- or tri-alkyl borate. Other suitable friction
modifiers are described
in U.S. Pat. No. 6,300,291.
[00123] A friction modifier may optionally be present in ranges such as
about 0 wt% to
about 10 wt%, or about 0.01 wt% to about 8 wt%, or about 0.1 wt% to about 4
wt%.
Molybdenum-containing component
[00124] The lubricating oil compositions herein also may optionally contain
one or
more molybdenum-containing compounds. An oil-soluble molybdenum compound may
have
the functional performance of an antiwear agent, an antioxidant, a friction
modifier, or
mixtures thereof. An oil-soluble molybdenum compound may include molybdenum
dithiocarbamates, molybdenum dialkyldithiophosphates, molybdenum
dithiophosphinates,
29
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amine salts of molybdenum compounds, molybdenum xanthates, molybdenum
thioxanthates,
molybdenum sulfides, molybdenum carboxylates, molybdenum alkoxides, a
trinuclear
organo-molybdenum compound, and/or mixtures thereof. The molybdenum sulfides
include
molybdenum disulfide. The molybdenum disulfide may be in the form of a stable
dispersion.
In one embodiment the oil-soluble molybdenum compound may be selected from the
group
consisting of molybdenum dithiocarbamates, molybdenum dialkyldithiophosphates,
amine
salts of molybdenum compounds, and mixtures thereof. In one embodiment the oil-
soluble
molybdenum compound may be a molybdenum dithiocarbamate.
[00125] Suitable examples of molybdenum compounds which may be used include
commercial materials sold under the trade names such as Molyvan 822TM,
MolyvanTM A,
Molyvan 2000TM and Molyvan 855TM from R. T. Vanderbilt Co., Ltd., and
SakuraLubeTM S-
165, S-200, S-300, S-310G, S-525, S-600, S-700, and S-710 available from Adeka
Corporation, and mixtures thereof. Suitable molybdenum components are
described in US
5,650,381; US RE 37,363 El; US RE 38,929 El; and US RE 40,595 El.
[00126] Additionally, the molybdenum compound may be an acidic molybdenum
compound. Included are molybdic acid, ammonium molybdate, sodium molybdate,
potassium molybdate, and other alkaline metal molybdates and other molybdenum
salts, e.g.,
hydrogen sodium molybdate, Mo0C14, MoO2Br2, Mo203Cl6, molybdenum trioxide or
similar
acidic molybdenum compounds. Alternatively, the compositions can be provided
with
molybdenum by molybdenum/sulfur complexes of basic nitrogen compounds as
described,
for example, in U.S. Pat. Nos. 4,263,152; 4,285,822; 4,283,295; 4,272,387;
4,265,773;
4,261,843; 4,259,195 and 4,259,194; and US Patent Publication No.
2002/0038525.
[00127] Another class of suitable organo-molybdenum compounds are
trinuclear
molybdenum compounds, such as those of the formula Mo3SkLnQz and mixtures
thereof,
wherein S represents sulfur, L represents independently selected ligands
having organo
groups with a sufficient number of carbon atoms to render the compound soluble
or
dispersible in the oil, n is from 1 to 4, k varies from 4 through 7, Q is
selected from the group
of neutral electron donating compounds such as water, amines, alcohols,
phosphines, and
CA 2991769 2020-02-06
ethers, and z ranges from 0 to 5 and includes non-stoichiometric values. At
least 21 total
carbon atoms may be present among all the ligands' organo groups, such as at
least 25, at
least 30, or at least 35 carbon atoms. Additional suitable molybdenum
compounds are
described in U.S. Pat. No. 6,723,685.
[00128] The oil-soluble molybdenum compound may be present in an amount
sufficient to provide about 0.5 ppm to about 2000 ppm, about 1 ppm to about
700 ppm, about
1 ppm to about 550 ppm, about 5 ppm to about 300 ppm, or about 20 ppm to about
250 ppm
of molybdenum.
Titanium-containing compounds
[00129] Another class of additives includes oil-soluble titanium compounds.
The oil-
soluble titanium compounds may function as antiwear agents, friction
modifiers,
antioxidants, deposit control additives, or more than one of these functions.
In an
embodiment the oil soluble titanium compound may be a titanium (IV) alkoxide.
The
titanium alkoxide may be formed from a monohydric alcohol, a polyol, or
mixtures thereof.
The monohydric alkoxides may have 2 to 16, or 3 to 10 carbon atoms. In an
embodiment, the
titanium alkoxide may be titanium (IV) isopropoxide. In an embodiment, the
titanium
alkoxide may be titanium (IV) 2-ethylhexoxide. In an embodiment, the titanium
compound
may be the alkoxide of a 1,2-diol or polyol. In an embodiment, the 1,2-diol
comprises a fatty
acid mono-ester of glycerol, such as oleic acid. In an embodiment, the oil
soluble titanium
compound may be a titanium carboxylate. In an embodiment the titanium (IV)
carboxylate
may be titanium neodecanoate.
[00130] In an embodiment the oil soluble titanium compound may be present
in the
lubricating oil composition in an amount to provide from zero to about 1500
ppm titanium by
weight or about 10 ppm to 500 ppm titanium by weight or about 25 ppm to about
150 ppm.
Transition metal-containing compounds
[00131] In another embodiment, the oil-soluble compound may be a transition
metal
containing compound or a metalloid. The transition metals may include, but are
not limited
to, titanium, vanadium, copper, zinc, zirconium, molybdenum, tantalum,
tungsten, and the
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like. Suitable metalloids include, but are not limited to, boron, silicon,
antimony, tellurium,
and the like.
[00132] In one
embodiment, the oil-soluble compound that may be used in a weight
ratio of Ca/M ranging from about 0.8:1 to about 70:1 is a titanium containing
compound,
wherein M is the total metal in the lubricant composition as described above.
The titanium-
containing compounds may function as antiwear agents, friction modifiers,
antioxidants,
deposit control additives, or more than one of these functions. Among the
titanium
containing compounds that may be used in, or which may be used for preparation
of the oils-
soluble materials of, the disclosed technology are various Ti (IV) compounds
such as
titanium (IV) oxide; titanium (IV) sulfide; titanium (IV) nitrate; titanium
(W) alkoxides such
as titanium methoxide, titanium ethoxide, titanium propoxide, titanium
isopropoxide,
titanium butoxide, titanium 2-ethylhexoxide; and other titanium compounds or
complexes
including but not limited to titanium phenates; titanium carboxylates such as
titanium (IV) 2-
ethyl-1 -3-hexanedioate or titanium citrate or titanium oleate; and titanium
(IV)
(triethanolaminato)isopropoxide. Other forms of titanium encompassed within
the disclosed
technology include titanium phosphates such as titanium dithiophosphates
(e.g.,
dialkyldithiophosphates) and titanium sulfonates (e.g.,
alkylbenzenesulfonates), or, generally,
the reaction product of titanium compounds with various acid materials to form
salts, such as
oil-soluble salts. Titanium compounds can thus be derived from, among others,
organic
acids, alcohols, and glycols. Ti compounds may also exist in dimeric or
oligomeric form,
containing Ti--0--Ti structures. Such titanium materials are commercially
available or can
be readily prepared by appropriate synthesis techniques which will be apparent
to the person
skilled in the art. They may exist at room temperature as a solid or a liquid,
depending on the
particular compound. They may also be provided in a solution form in an
appropriate inert
solvent.
[00133] In one
embodiment, the titanium can be supplied as a Ti-modified dispersant,
such as a succinimide dispersant. Such materials may be prepared by forming a
titanium
mixed anhydride between a titanium alkoxide and a hydrocarbyl-substituted
succinic
anhydride, such as an alkenyl- (or alkyl) succinic anhydride. The resulting
titanate-succinate
intermediate may be used directly or it may be reacted with any of a number of
materials,
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such as (a) a polyamine-based succinimide/amide dispersant having free,
condensable --NH
functionality; (b) the components of a polyamine-based succinimide/amide
dispersant, i.e., an
alkenyl- (or alkyl-) succinic anhydride and a polyamine, (c) a hydroxy-
containing polyester
dispersant prepared by the reaction of a substituted succinic anhydride with a
polyol,
aminoalcohol, polyamine, or mixtures thereof
Alternatively, the titanate-succinate
intermediate may be reacted with other agents such as alcohols, aminoalcohols,
ether
alcohols, polyether alcohols or polyols, or fatty acids, and the product
thereof either used
directly to impart Ti to a lubricant, or else further reacted with the
succinic dispersants as
described above. As an example, 1 part (by mole) of tetraisopropyl titanate
may be reacted
with about 2 parts (by mole) of a polyisobutene-substituted succinic anhydride
at 140-150 C
for 5 to 6 hours to provide a titanium modified dispersant or intermediate.
The resulting
material (30 g) may be further reacted with a succinimide dispersant from
polyisobutene-
substituted succinic anhydride and a polyethylenepolyamine mixture (127 grams
+ diluent
oil) at 150 C for 1.5 hours, to produce a titanium-modified succinimide
dispersant.
[00134] Another
titanium containing compound may be a reaction product of titanium
alkoxide and C6 to C25 carboxylic acid. The reaction product may be
represented by the
following formula:
0
2
Ti -(0 ¨C¨R)n
wherein n is an integer selected from 2, 3 and 4, and R is a hydrocarbyl group
containing
from about 5 to about 24 carbon atoms, or by the formula:
0
II 2
C-R
0 0 0
3
14¨ C 0-11¨ O C¨R
0
4
CF
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wherein each of RI, R2, R3, and R4 are the same or different and are selected
from a
hydrocarbyl group containing from about 5 to about 25 carbon atoms. Suitable
carboxylic
acids may include, but are not limited to caproic acid, caprylic acid, lauric
acid, myristic acid,
palmitic acid, stearic acid, arachidic acid, oleic acid, erucic acid, linoleic
acid, linolenic acid,
cyclohexanecarboxylic acid, phenylacetic acid, benzoic aicd, neodecanoic acid,
and the like.
[00135] In an
embodiment the oil soluble titanium compound may be present in the
lubricating oil composition in an amount to provide from 0 to 3000 ppm
titanium by weight
or 25 to about 1500 ppm titanium by weight or about 35 ppm to 500 ppm titanium
by weight
or about 50 ppm to about 300 ppm.
Viscosity Index Improvers
[00136] The
lubricating oil compositions herein also may optionally contain one or
more viscosity index improvers. Suitable viscosity index improvers may include
polyolefins,
olefin copolymers, ethylene/propylene copolymers, polyisobutenes, hydrogenated
styrene-
isoprene polymers, styrene/maleic ester copolymers, hydrogenated
styrene/butadiene
copolymers, hydrogenated isoprene polymers, alpha-olefin maleic anhydride
copolymers,
polymethacrylates, polyacrylates, polyalkyl styrenes, hydrogenated alkenyl
aryl conjugated
diene copolymers, or mixtures thereof. Viscosity index improvers may include
star polymers
and suitable examples are described in US Patent No. 8,999,905 B2.
[00137] The
lubricating oil compositions herein also may optionally contain one or
more dispersant viscosity index improvers in addition to a viscosity index
improver or in lieu
of a viscosity index improver. Suitable viscosity index improvers may include
functionalized
polyolefins, for example, ethylene-propylene copolymers that have been
functionalized with
the reaction product of an acylating agent (such as maleic anhydride) and an
amine;
polymethacrylates functionalized with an amine, or esterified maleic anhydride-
styrene
copolymers reacted with an amine.
[00138] The total
amount of viscosity index improver and/or dispersant viscosity index
improver may be about 0 wt% to about 20 wt%, about 0.1 wt% to about 15 wt%,
about 0.1
wt% to about 12 wt%. or about 0.5 wt% to about 10 wt%, of the lubricating oil
composition.
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Other Optional Additives
[00139] Other additives may be selected to perform one or more functions
required of
a lubricating fluid. Further, one or more of the mentioned additives may be
multi-functional
and provide functions in addition to or other than the function prescribed
herein.
[00140] A lubricating oil composition according to the present disclosure
may
optionally comprise other performance additives. The other performance
additives may be in
addition to specified additives of the present disclosure and/or may comprise
one or more of
metal deactivators, viscosity index improvers, ashless TBN boosters, friction
modifiers,
antiwear agents, corrosion inhibitors, rust inhibitors, dispersants,
dispersant viscosity index
improvers, extreme pressure agents, antioxidants, foam inhibitors,
demulsifiers, emulsifiers,
pour point depressants, seal swelling agents and mixtures thereof Typically,
fully-
formulated lubricating oil will contain one or more of these performance
additives.
[00141] Suitable metal deactivators may include derivatives of
benzotriazoles
(typically tolyltriazole), dimercaptothiadiazole derivatives, 1,2,4-triazoles,
benzimidazoles, 2-
alkyldithiobenzimidazoles, or 2-alkyldithiobenzothiazoles; foam inhibitors
including
copolymers of ethyl acrylate and 2-ethylhexylacrylate and optionally vinyl
acetate;
demulsifiers including trialkyl phosphates, polyethylene glycols, polyethylene
oxides,
polypropylene oxides and (ethylene oxide-propylene oxide) polymers; pour point
depressants
including esters of maleic anhydride-styrene, polymethacrylates, polyacrylates
or
poly acrylamid es.
[00142] Suitable foam inhibitors include silicon-based compounds, such as
siloxane.
[00143] Suitable pour point depressants may include a
polymethylmethacrylates or
mixtures thereof Pour point depressants may be present in an amount sufficient
to provide
from about 0 wt% to about 1 wt%, about 0.01 wt% to about 0.5 wt%, or about
0.02 wt% to
about 0.04 wt% based upon the final weight of the lubricating oil composition.
[00144] Suitable rust inhibitors may be a single compound or a mixture of
compounds
having the property of inhibiting corrosion of ferrous metal surfaces. Non-
limiting examples
of rust inhibitors useful herein include oil-soluble high molecular weight
organic acids, such
as 2-ethylhexanoic acid, lauric acid, mvristic acid, palmitic acid, oleic
acid, linoleic acid,
linolenic acid, behenic acid, and cerotic acid, as well as oil-soluble
polycarboxylic acids
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including dimer and trimer acids, such as those produced from tall oil fatty
acids, oleic acid,
and linoleic acid. Other suitable corrosion inhibitors include long-chain
alpha, omega-
dicarboxylic acids in the molecular weight range of about 600 to about 3000
and
alkenylsuccinic acids in which the alkenyl group contains about 10 or more
carbon atoms
such as, tetrapropenylsuccinic acid, tetradecenylsuccinic acid, and
hexadecenylsuccinic acid.
Another useful type of acidic corrosion inhibitors are the half esters of
alkenyl succinic acids
having about 8 to about 24 carbon atoms in the alkenyl group with alcohols
such as the
polyglycols. The corresponding half amides of such alkenyl succinic acids are
also useful. A
useful rust inhibitor is a high molecular weight organic acid. In some
embodiments, an
engine oil is devoid of a rust inhibitor.
[00145] The rust
inhibitor, if present, can be used in an amount sufficient to provide
about 0 wt% to about 5 wt%, about 0.01 wt% to about 3 wt%, about 0.1 wt% to
about 2 wt%,
based upon the final weight of the lubricating oil composition.
[00146] In general
terms, a suitable crankcase lubricant may include additive
components in the ranges listed in the following table.
Table 2
Component Wt. % Wt. %
(Broad) (Typical)
Dispersant(s) 0.0 - 10% 1.0 -8.5%
Antioxidant(s) 0.0 - 5.0 0.01 - 3.0
Metal Detergent(s) 0.1 - 15.0 0.2- 8.0
Ashless TBN booster(s) 0.0 - 1.0 0.01 - 0.5
Corrosion Inhibitor(s) 0.0 - 5.0 0.0 - 2.0
Metal dihydrocarbyl dithiophosphate(s) 0.1 - 6.0 0.1 - 4.0
Ash-free amine phosphate salt(s) 0.0- 3.0 0.0- 1.5
Antifoaming agent(s) 0.0 - 5.0 0.001 -0.15
Antiwear agent(s) 0.0 - 10.0 0.0 - 5.0
Pour point depressant(s) 0.0 - 5.0 0.01 - 1.5
Viscosity index improver(s) 0.0 -20.00 0.25 - 10.0
Dispersant viscosity index improver(s) 0.0 - 10.0 0.0 - 5.0
Friction modifier(s) 0.01 - 5.0 0.05 - 2.0
Base oil(s) Balance Balance
Total 100 100
36
[00147] The percentages of each component above represent the weight
percent of
each component, based upon the weight of the final lubricating oil
composition. The
remainder of the lubricating oil composition consists of one or more base
oils.
[00148] Additives used in formulating the compositions described herein may
be
blended into the base oil individually or in various sub-combinations.
However, it may be
suitable to blend all of the components concurrently using an additive
concentrate (i.e.,
additives plus a diluent, such as a hydrocarbon solvent). Additives used in
formulating the
compositions described herein may be blended into the base oil individually or
in various
sub-combinations. However, it may be suitable to blend all of the components
concurrently
using an additive concentrate (i.e., additives plus a diluent, such as a
hydrocarbon solvent).
[00149] The present disclosure provides novel lubricating oil blends
specifically
formulated for use as automotive engine lubricants. Embodiments of the present
disclosure
may provide lubricating oils suitable for engine applications that provide
improvements in
one or more of the following characteristics: low-speed pre-ignition events,
antioxidancy,
antiwear performance, rust inhibition, fuel economy, water tolerance, air
entrainment, seal
protection, deposit reduction, i.e. passing the TEOST 33 test, and foam
reducing properties.
[00150] Fully formulated lubricants conventionally contain an additive
package,
referred to herein as a dispersant/inhibitor package or DI package, that will
supply the
characteristics that are required in the formulations. Suitable DI packages
are described for
example in U.S. Patent Nos. 5,204,012 and 6,034,040 for example. Among the
types of
additives included in the additive package may be dispersants, seal swell
agents, antioxidants,
foam inhibitors, lubricity agents, rust inhibitors, corrosion inhibitors,
demulsifiers, viscosity
index improvers, and the like. Several of these components are well known to
those skilled
in the art and are generally used in conventional amounts with the additives
and compositions
described herein.
[00151] The following examples are illustrative, but not limiting, of the
methods and
compositions of the present disclosure. Other suitable modifications and
adaptations of the
variety of conditions and parameters normally encountered in the field, and
which are
obvious to those skilled in the art, are within the spirit and scope of the
disclosure.
37
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EXAMPLES
[00152] Fully
formulated lubricating oil compositions containing conventional
additives were made and the low-speed pre-ignition events of the lubricating
oil compositions
were measured. Each of the lubricating oil compositions contained a major
amount of a base
oil, a base conventional dispersant inhibitor (DI) package plus a viscosity
index improver(s),
wherein the base DI package (less the viscosity index improver) provided about
8 to 12
percent by weight of the lubricating oil composition. The base DI package
contained
conventional amounts of dispersant(s), antiwear additive(s), antifoam
agent(s), and
antioxidant(s) as set forth in Table 3 below. Specifically, the base DI
package contained a
succinimide dispersant, a borated succinimide dispersant, a molybdenum-
containing
compound in an amount to deliver about 80 ppm molybdenum to the lubricating
oil
composition, an organic friction modifier, one or more antioxidants, and one
or more
antiwear agents (unless specified otherwise). The base DI package was also
blended with
about 5 to about 10 wt% of one or more viscosity index improvers. Group I base
oil was
used as a diluent. The major amount of base oil (about 78 to about 87 wt%) was
a Group III
base oil. The components that were varied are specified in the Tables and
discussion of the
Examples below. All the values listed are stated as weight percent of the
component in the
lubricating oil composition (i.e., active ingredient plus diluent oil, if
any), unless specified
otherwise.
38
CA 2991769 2020-02-06
Table 3 ¨ Base DI Package Composition
_Component Wt. %
Antioxidant(s) 0.5 to
2.5
Antiwear agent(s), including any metal dihydrocarbyl dithiophosphate 0.7 to
5.0
Antifoaming agent(s) 0.001
to 0.01
Detergent(s)* 0.0
Dispersant (s) 2.0 to
6.0
Metal-containing friction modifier(s) 0.05
to 1.25
Metal free friction modifier(s) 0.01 to
0.5
Pour point depressant(s) 0.05
to 0.5
Process oil 0.25
to 1.0
*Detergent is varied in the following experiments, so for purposes of the base
formulation,
the detergent amount is set to zero.
[00153] Low
Speed Pre-Ignition (LSPI) events were measured in a GM 2.0 Liter, 4
cylinder EcotecTM turbocharged gasoline direct injection (GDI) engine. One
complete LSPI
fired engine test consisted of 4 test cycles. Within a single test cycle, two
operational stages
or segments are repeated in order to generate LSPI events. In stage A, when
LSPI is most
likely to occur, the engine is operated at about 2000 rpm and about 18,000 kPa
brake mean
effective pressure (BMEP). In stage B, when LSPI is not likely to occur, the
engine is
operated at about 1500 rpm and about 17,000 kPa BMEP. For each stage, data is
collected
over 25,000 engine cycles. The structure of a test cycle is as follows: stage
A ¨ stage A ¨
stage B ¨ stage B ¨ stage A ¨ stage A. Each stage is separated by an idle
period. Because
LSPI is statistically significant during stage A, the LSPI event data that was
considered in the
present examples only included LSPI generated during stage A operation. Thus,
for one
complete LSPI fired engine test, data was typically generated over a total of
16 stages and
was used to evaluate performance of comparative and inventive oils.
[00154] LSPI
events were determined by monitoring peak cylinder pressure (PP) and
when 2% of the combustible material in the combustion chamber burns (MFB02).
The
threshold for peak cylinder pressure is calculated for each cylinder and for
each stage and is
typically 65,000 to 85,000 kPa. The threshold for MFB02 is calculated for each
cylinder and
for each stage and typically ranges from about 3.0 to about 7.5 Crank Angle
Degree (CAD)
After Top Dead Center (ATDC). An LSPI was recorded when both the PP and MFB02
thresholds were exceeded in a single engine cycle. LSPI events can be reported
in many
39
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ways. In order to remove ambiguity involved with reporting counts per engine
cycles, where
different fired engine tests can be conducted with a different number of
engine cycles, the
relative LSPI events of comparative and inventive oils was reported as an
"LSPI Ratio". In
this way improvement relative to some standard response is clearly
demonstrated.
[00155] All of the
reference oils are commercially available engine oils that meet all
ILSAC OF-5 performance requirements, including passage of the TEOST 33 test
discussed
below.
[00156] In the
following examples, combinations of an overbased calcium detergent
and a neutral/low based calcium detergent were tested with the base
formulation. The LSPI
Ratio was reported as a ratio of the LSPI events of a test oil relative to the
LSPI events of
Reference Oil -R-1". R-1 was a lubricating oil composition formulated with the
base DI
package and an overbased calcium detergent in an amount to provide about 2400
ppm Ca to
the lubricating oil composition. More detailed formulation information for
reference oil R-1
is given below. Considerable improvement in LSPI is recognized when there is
greater than
50% reduction in LSPI events relative to R-1 (an LSPI Ratio of less than 0.5).
A further
improvement in LSPI is recognized when there is greater than 70% reduction in
LSPI events
(an LSPI Ratio of less than 0.3), an even further improvement in LSPI is
recognized when
there is greater than 75% reduction in LSPI events (an LSPI Ratio of less than
0.25), and an
even further improvement in LSPI is recognized when there is greater than 80%
reduction in
LSPI events relative to R-1 (an LSPI Ratio of less than 0.20), and an even
further
improvement in LSPI is recognized when there is greater than 90% reduction in
LSPI events
relative to R-1(an LSPI Ratio of less than 0.10). The LSPI Ratio for the R-1
reference oil is
thus deemed to be 1.00.
[00157] The TEOST-33
test is a bench test that may be used to evaluate oxidative
degradation and/or thermal coking of engine oil. According to the test, about
100 mL of test
oil is used in a 12 cycle/2 hour test. The test results in bulk oxidation of
the oil (about 100
grams) on a hollow heated rod (TEOST depositor rod) that will accumulate the
deposits over
the test period. The test oil flows over the rod at about 0.5 grams per minute
while the test
piece is cycled 12 times over a temperature ranging from 200-480 C. The total
deposit is the
performance parameter measured. The total deposit is the sum of the deposit on
the rod and
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the deposit in the oil which is removed by filtration. The more deposit
measured indicates
poorer performance of the additive composition. Specifically, a test oil
having a weight gain
of 30 mg or less passes the TEOST 33 test.
[00158] TBN
measurements given in the tables below were based on ASTM D2896.
TBN measurements were used to report mmol total metal:TBN of the fully
formulated
example fluid in Table 4 below.
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AFTON-1507WC1
Tablet
Component R-1 R-2 C-1 C-2 C-3 1-1 1-2 1-3
1-4 1-5
OB Ca sulfonate, ppmw Ca 2400 1600 1100 0 1625 1375
1200 1500 1450
(TBN = 30(1 mg KOHIg)
LB/N Ca sulfonate, ppmw Ca 0 0 0 0 125 125 500
(TBN = 45 mg KOH/g)
LB/N Ca phenate, ppmw Ca 125
(TBN = 15(1 mg KOH/g)
LB/N Na sulfonate, ppm Na 91
(TBN <5 mg KOH/g)
Total Ca, ppmw 2400 2300* 1600 1100 0 1750 1500
1700 1625 1450
LSPI Ratio 1.00 1.38 0.22 0.05 0 0.19 0.15
0,06 0.25 0,35
TEOST 33, total deposit in mg Pass Pass Fail Fail Fail
Pass Pass Pass Pass Pass
Ratio of mmol total Metal 8.0 8.6 7.9 8.2 2.3 8.2 8,2
9.0 8,1 7.9
TBN of the lubricating oil
Ratio ppm LB/N Ca to ppm 013 0 0 0 0 0.08 0.09 0.4
0.08
Ca
*Measured value using ICP analysis
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[00159] Commercial
oils, R-1 and R-2, are included as reference oils to demonstrate
the current state of the art. Reference oil R-1 was formulated from about 80.7
wt.% of a
Group III base oil, 12.1 wt.% of HiTECk 11150 PCMO Additive Package available
from
Afton Chemical Corporation and 7.2 wt.% of a 35 SSI ethylene/propylene
copolymer
viscosity index improver. HiTECk 11150 passenger car motor oil additive
package is an API
SN, ILSAC-GF-5, and ACEA A5/B5 qualified DI package. R-1 also showed the
following
and properties and partial elemental analysis:
Reference Oil R-1
10.9 Kinematic Viscosity at 100 C. (mm2/sec)
3.3 TBS, APPARENT VISCOSITY, cPa
2438 calcium (ppmw)
<10 magnesium (ppmw)
80 molybdenum (ppmw)
772 phosphorus (ppmw)
855 zinc (ppmw)
9.0 Total Base Number ASTM D-2896 (mg KOH/g)
165 Viscosity Index
[00160] R-2 contains
only calcium-containing detergents at a higher calcium loading
than the tested inventive oils. R-1 and R-2 meet all performance requirements
for ILSAC
GF-5 and, as such, would demonstrate passing performance in the TEOST-33 bench
oxidation test. Comparative examples C-1, C-2, C-3, and C-4 are not
commercially available
fluids but are designed to demonstrate technical problems experienced by one
skilled in the
art when the detergent system is modified to meet LSPI performance needs.
[00161] As shown in
Table 4, there is a significant improvement in LSPI performance
when the amount of calcium from an overbased ("OB") detergent is decreased
from about
2400 to about 1600 ppm calcium. Comparing R-1 to C-1, the LSPI Ratio was
reduced by
about 78% but performance in TEOST-33 test went from passing to failing as
calcium was
decreased. If the amount of calcium from an OB detergent is further reduced to
1100 ppm
(C-2), the LSPI Ratio is even more significantly improved; however,
performance in the
TEOST-33 test is still poor at this level of calcium. In C-3, the detergent
system is
completely removed demonstrating that without detergent. LSPI is improved
100%.
43
However, again, the TEOST 33 test performance is sacrificed. Example 1-5
utilizes a low
based sodium sulfonate instead of the low based calcium sulfonate used in
inventive
examples I-1, 1-2, 1-3, and 1-4 and shows that a significant reduction in LSPI
Ratio can be
obtained using a sodium-containing low-based/neutral detergent instead of a
calcium-
containing low-based/neutral detergent.
[00162] An unexpected improvement in LSPI can be obtained by combining a
low
base or neutral ("LB/N") calcium detergent (I-1 to 1-4) with an OB calcium
detergent without
sacrificing performance in the TEOST-33 bench oxidation test. Inventive
Example I-1 passes
the TEOST-33 test while delivering a more significant improvement in LSPI
events with an
almost 81% reduction in the LSPI Ratio relative to R-1. Inventive Examples 1-2
and 1-3
provide an even greater reduction in the LSPI Ratio without loss of
performance in the
TEOST-33 test. Example 1-4 demonstrates the use of a LB/N calcium phenate in
place of the
LB/N calcium sulfonate. 1-4 also shows a significant improvement in the LSPI
Ratio as well
as passing TEOST 33 test. The examples presented in Table 4 clearly
demonstrate that the
amount of calcium from an OB calcium detergent may be maintained at a higher
level by
adding additional calcium from a LB/N calcium detergent while still passing
the TEOST 33
test and ensuring a significant reduction in LSPI Ratio. Further,
unexpectedly, the results
obtained in the TEOST 33 test may be improved even in the absence of high
amounts of OB
calcium detergent. In fact, off-setting the OB calcium detergent with LB/N
calcium
detergent, unexpectedly and surprisingly improved TEOST 33 test while also
reducing the
LSPI Ratio.
[00163] The present data shows that off-setting OB Ca sulfonate with LB/N
Ca
sulfonate in an amount of greater than 8 % LB/N Ca Sulfonate in the total
detergent provides
an improvement in LSPI while maintaining performance in TEOST 33 test.
[00164]
[00165] Other embodiments of the present disclosure will be apparent to
those skilled
in the art from consideration of the specification and practice of the
embodiments disclosed
herein. As used throughout the specification and claims, "a" and/or "an" may
refer to one or
44
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more than one. Unless otherwise indicated, all numbers expressing quantities
of ingredients,
properties such as molecular weight, percent, ratio, reaction conditions, and
so forth used in
the specification and claims are to be understood as being modified in all
instances by the
term "about,- whether or not the term "about- is present. Accordingly, unless
indicated to
the contrary, the numerical parameters set forth in the specification and
claims are
approximations that may vary depending upon the desired properties sought to
be obtained by
the present disclosure. At the very least, and not as an attempt to limit the
application of the
doctrine of equivalents to the scope of the claims, each numerical parameter
should at least be
construed in light of the number of reported significant digits and by
applying ordinary
rounding techniques. Notwithstanding that the numerical ranges and parameters
setting forth
the broad scope of the disclosure are approximations, the numerical values set
forth in the
specific examples are reported as precisely as possible. Any numerical value,
however,
inherently contains certain errors necessarily resulting from the standard
deviation found in
their respective testing measurements. It is intended that the specification
and examples be
considered as exemplary only, with a true scope and spirit of the disclosure
being indicated
by the following claims.
[00166] The
foregoing embodiments are susceptible to considerable variation in
practice. Accordingly, the embodiments are not intended to be limited to the
specific
exemplifications set forth hereinabove. Rather, the foregoing embodiments are
within the
spirit and scope of the appended claims, including the equivalents thereof
available as a
matter of law.
[00167] The
patentees do not intend to dedicate any disclosed embodiments to the
public, and to the extent any disclosed modifications or alterations may not
literally fall
within the scope of the claims, they are considered to be part hereof under
the doctrine of
equivalents.
[00168] It is to be
understood that each component, compound, substituent or
parameter disclosed herein is to be interpreted as being disclosed for use
alone or in
combination with one or more of each and every other component, compound,
substituent or
parameter disclosed herein.
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[00169] It is also
to be understood that each amount/value or range of amounts/values
for each component, compound, substituent or parameter disclosed herein is to
be interpreted as
also being disclosed in combination with each amount/value or range of
amounts/values
disclosed for any other component(s), compounds(s), substituent(s) or
parameter(s) disclosed
herein and that any combination of amounts/values or ranges of amounts/values
for two or
more component(s), compounds(s), substituent(s) or parameters disclosed herein
are thus also
disclosed in combination with each other for the purposes of this description.
[00170] It is
further understood that each range disclosed herein is to be interpreted as
a disclosure of each specific value within the disclosed range that has the
same number of
significant digits. Thus, a range of from 1-4 is to be interpreted as an
express disclosure of the
values 1, 2, 3 and 4.
[00171] It is
further understood that each lower limit of each range disclosed herein is
to be interpreted as disclosed in combination with each upper limit of each
range and each
specific value within each range disclosed herein for the same component,
compounds,
substituent or parameter. Thus, this disclosure to be interpreted as a
disclosure of all ranges
derived by combining each lower limit of each range with each upper limit of
each range or
with each specific value within each range, or by combining each upper limit
of each range
with each specific value within each range.
[00172]
Furthermore, specific amounts/values of a component, compound, substituent
or parameter disclosed in the description or an example is to be interpreted
as a disclosure of
either a lower or an upper limit of a range and thus can be combined with any
other lower or
upper limit of a range or specific amount/value for the same component,
compound, substituent
or parameter disclosed elsewhere in the application to form a range for that
component,
compound, substituent or parameter.
46
