Note: Descriptions are shown in the official language in which they were submitted.
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LUBRICATING OIL COMPOSITONS
TECHNICAL FIELD
[0001] The disclosed technology relates to lubricants for internal
combustion engines,
particularly those for compression ignition engines.
BACKGROUND OF THE DISCLOSURE
[0002] Automobile spark ignition and diesel engines have valve train
systems
including, for example, valves, cams and rocker arms, which present special
lubrication
concerns. It is important that the lubricant, i.e., the engine oil, provides
oxidation stability
and suppresses the production of deposits in the engines to keep engine parts
clean and
extend engine life and oil drain intervals. Such deposits are produced from
non-combustibles
and incomplete combustion of hydrocarbon fuels (e.g., gasoline and diesel fuel
oil) and by
the deterioration of the engine oil employed. It is also important that the
lubricant protects
these parts from wear.
[0003] Engine oils typically use a mineral oil or a synthetic oil as a
base oil.
However, simple base oils alone do not provide the necessary properties to
provide the
necessary oxidation stability, deposit control, etc., required to protect
internal combustion
engines. Thus, base oils are formulated with various additives, for imparting
auxiliary
functions, such as ashless dispersants, metallic detergents (i.e., metal-
containing detergents),
antiwear agents, and antioxidants, to provide a formulated oil (i.e., a
lubricating oil
composition).
[0004] A number of such engine oil additives are known and employed in
practice.
For example, detergents are usually contained in the commercially available
internal
composition engine oils, especially those used for automobiles, for their
detergency and
antioxidant properties. One such example of detergents includes phenates. Low
molecular
weight alkylphenols such as tetrapropenyl phenol (TPP) have been used as a raw
material by
producers of sulfurized, overbased phenates. However, there is still a need to
improve wear
performance, such that oxidation performance is not impacted.
[0005] Accordingly, despite the advances in lubricant oil formulation
technology,
there still exists a need for retaining the antiwear properties while also
improving oxidation
performance of the engine oils.
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SUMMARY OF THE DISCLOSURE
[0006] In accordance with one illustrative embodiment, a lubricating oil
composition
is provided which comprises:
[0007] (a) a major amount of an oil of lubricating viscosity having a
kinematic
viscosity at 100 C in a range of about 2 to about 50 mm2/s,
[0008] (b) an overbased metal salt of an alkyl-substituted phenate
detergent, wherein
the alkyl group is derived from an isomerized normal alpha olefin having from
about 10 to
about 40 carbon atoms per molecule and having an isomerization level (I) of
the normal alpha
olefin of from about 0.1 to about 0.4,
[0009] (c) one or more boron-containing detergents having about 50 to
about 500
ppm of boron, based on the total weight of the lubricating oil composition,
and
[0010] (d) one or more zinc dialkyl dithiophosphate compounds derived from
a
primary alcohol.
[0011] In accordance with another illustrative embodiment, a method is
provided
comprising the step of operating an internal combustion engine with a
lubricating oil
composition comprising (a) a major amount of an oil of lubricating viscosity
having a
kinematic viscosity at 100 C in a range of about 2 to about 50 mm2/s,
[0012] (b) an overbased metal salt of an alkyl-substituted phenate
detergent, wherein
the alkyl group is derived from an isomerized normal alpha olefin having from
about 10 to
about 40 carbon atoms per molecule and having an isomerization level (I) of
the normal alpha
olefin of from about 0.1 to about 0.4,
[0013] (c) one or more boron-containing detergents having about 50 to
about 500
ppm of boron, based on the total weight of the lubricating oil composition,
and
[0014] (d) one or more zinc dialkyl dithiophosphate compounds derived from
a
primary alcohol.
[0015] The lubricating oil compositions of the present disclosure
advantageously
improve the oxidation properties, detergency, and thermal stability of the
lubricating oil
performance of the present disclosure while retaining the wear reducing
properties of the
lubricating oil compositions.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0016] To facilitate the understanding of the subject matter disclosed
herein, a
number of terms, abbreviations or other shorthand as used herein are defined
below. Any
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term, abbreviation or shorthand not defined is understood to have the ordinary
meaning used
by a skilled artisan contemporaneous with the submission of this application.
[0017] Definitions:
[0018] In this specification, the following words and expressions, if and
when used,
have the meanings given below.
[0019] A "major amount" means in excess of 50 wt. % of a composition.
[0020] "Active ingredients" or "actives" refer to additive material that
is not diluent
or solvent.
[0021] All percentages reported are weight % on an active ingredient basis
(i.e.,
without regard to carrier or diluent oil) unless otherwise stated.
[0022] The term "ppm" means parts per million by weight, based on the
total weight
of the lubricating oil composition.
[0023] Kinematic viscosity at 100 C (KVioo) was determined in accordance
with
ASTM D445.
[0024] The term "metal" refers to alkali metals, alkaline earth metals, or
mixtures
thereof
[0025] The term "alkali metal" refers to lithium, sodium, potassium,
rubidium, and
cesium.
[0026] The term "alkaline earth metal" refers to calcium, barium,
magnesium, and
strontium.
[0027] The term "Total Base Number" or "TBN" refers to the amount of base
equivalent to milligrams of KOH in one gram of sample. Thus, higher TBN
numbers reflect
more alkaline products, and therefore a greater alkalinity. TBN was determined
using ASTM
D 2896 test.
[0028] Boron, calcium, phosphorus, and sulfur contents were determined in
accordance with ASTM D5185.
[0029] The term "olefins" refers to a class of unsaturated aliphatic
hydrocarbons
having one or more carbon-carbon double bonds, obtained by a number of
processes. Those
containing one double bond are called mono-alkenes, and those with two double
bonds are
called dienes, alkyldienes, or diolefins. Alpha olefins are particularly
reactive because the
double bond is between the first and second carbons, e.g., 1-octene and 1-
octadecene, and are
used as the starting point for medium-biodegradable surfactants. Linear and
branched olefins
are also included in the definition of olefins.
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[0030] The term "Normal Alpha Olefins" refers to olefins which are
straight chain,
non-branched hydrocarbons with carbon-carbon double bond present in the alpha
or primary
position of the hydrocarbon chain.
[0031] The term "Isomerized Normal Alpha Olefin" refers to an alpha olefin
that has
been subjected to isomerization conditions which results in an alteration of
the distribution of
the olefin species present and/or the introduction of branching along the
alkyl chain. The
isomerized olefin product may be obtained by isomerizing a linear alpha olefin
containing
from about 10 to about 40 carbon atoms, or from about 20 to about 28 carbon
atoms, or from
about 20 to about 24 carbon atoms
[0032] The term "Cio-40 Normal Alpha Olefins" defines a fraction of normal
alpha
olefins wherein the carbon numbers below 10 have been removed by distillation
or other
fractionation methods.
[0033] The present disclosure is directed to a lubricating oil composition
comprising
(a) a major amount of an oil of lubricating viscosity having a kinematic
viscosity at 100 C in
a range of about 2 to about 50 mm2/s, (b) an overbased metal salt of an alkyl-
substituted
phenate detergent, wherein the alkyl group is derived from an isomerized
normal alpha olefin
having from about 10 to about 40 carbon atoms per molecule and having an
isomerization
level (I) of the normal alpha olefin of from about 0.1 to about 0.4, (c) one
or more boron-
containing detergents having about 50 to about 500 ppm of boron, based on the
total weight
of the lubricating oil composition, and (d) one or more zinc dialkyl
dithiophosphate
compounds derived from a primary alcohol.
[0034] In general, the level of sulfur in the lubricating oil compositions
of the present
disclosure is less than or equal to about 0.7 wt. %, based on the total weight
of the lubricating
oil composition, e.g., a level of sulfur of about 0.01 wt. % to about 0.70 wt.
%, or about 0.01
wt. % to about 0.6 wt. %, or about 0.01 wt. % to about 0.5 wt. %, or about
0.01 wt. % to
about 0.4 wt. %, or about 0.01 wt. % to about 0.3 wt. %, or about 0.01 wt. %
to about 0.2 wt.
%, or about 0.01 wt. % to about 0.10 wt. %, based on the total weight of the
lubricating oil
composition. In one embodiment, the level of sulfur in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.60 wt. %, or less than or
equal to about 0.50
wt. %, or less than or equal to about 0.40 wt. %, or less than or equal to
about 0.30 wt. %, or
less than or equal to about 0.28 wt. %, or less than or equal to about 0.20
wt. %, or less than
or equal to about 0.10 wt. % based on the total weight of the lubricating oil
composition.
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[0035] In one embodiment, the level of phosphorus in the lubricating oil
compositions
of the present disclosure is less than or equal to about 0.12 wt. %, based on
the total weight of
the lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt.
% to about 0.12
wt. %. In one embodiment, the level of phosphorus in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.11 wt. %, based on the
total weight of the
lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt. %
to about 0.11 wt.
%. In one embodiment, the level of phosphorus in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.10 wt. %, based on the
total weight of the
lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt. %
to about 0.10 wt.
%. In one embodiment, the level of phosphorus in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.099 wt. %, based on the
total weight of the
lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt. %
to about 0.099 wt.
%. In one embodiment, the level of phosphorus in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.08 wt. %, based on the
total weight of the
lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt. %
to about 0.08 wt.
%. In one embodiment, the level of phosphorus in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.07 wt. %, based on the
total weight of the
lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt. %
to about 0.07 wt.
%. In one embodiment, the level of phosphorus in the lubricating oil
compositions of the
present disclosure is less than or equal to about 0.05 wt. %, based on the
total weight of the
lubricating oil composition, e.g., a level of phosphorus of about 0.01 wt. %
to about 0.05 wt.
A.
[0036] In one embodiment, the level of sulfated ash produced by the
lubricating oil
compositions of the present disclosure is less than or equal to about 1.60 wt.
% as determined
by ASTM D 874, e.g., a level of sulfated ash of from about 0.10 wt. % to about
1.60 wt. % as
determined by ASTM D 874. In one embodiment, the level of sulfated ash
produced by the
lubricating oil compositions of the present disclosure is less than or equal
to about 1.00 wt. %
as determined by ASTM D 874, e.g., a level of sulfated ash of from about 0.10
wt. % to about
1.00 wt. % as determined by ASTM D 874. In one embodiment, the level of
sulfated ash
produced by the lubricating oil compositions of the present disclosure is less
than or equal to
about 0.80 wt. % as determined by ASTM D 874, e.g., a level of sulfated ash of
from about
0.10 wt. % to about 0.80 wt. % as determined by ASTM D 874. In one embodiment,
the
level of sulfated ash produced by the lubricating oil compositions of the
present disclosure is
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less than or equal to about 0.60 wt. % as determined by ASTM D 874, e.g., a
level of sulfated
ash of from about 0.10 wt. % to about 0.60 wt. % as determined by ASTM D 874.
In another
embodiment, the level of sulfated ash produced by the lubricating oil
compositions of the
present disclosure is less than or equal to about 1.1 to 1.2 wt. % as
determined by ASTM D
874.
[0037] The lubricating oil composition in accordance with the present
disclosure
includes an oil of lubricating viscosity (sometimes referred to as "base
stock" or "base oil").
The expression "base oil" as used herein shall be understood to mean a base
stock or blend of
base stocks which is a lubricant component that is produced by a single
manufacturer to the
same specifications (independent of feed source or manufacturer's location);
that meets the
same manufacturer's specification; and that is identified by a unique formula,
product
identification number, or both. The oil of lubricating viscosity is the
primary liquid
constituent of a lubricant, into which additives and possibly other oils are
blended, for
example to produce a final lubricant (or lubricant composition). A base oil is
useful for
making concentrates as well as for making lubricating oil compositions
therefrom, and may
be selected from natural and synthetic lubricating oils and combinations
thereof
[0038] Natural oils include animal and vegetable oils, liquid petroleum
oils and
hydrorefined, solvent-treated mineral lubricating oils of the paraffinic,
naphthenic and mixed
paraffinic-naphthenic types. Oils of lubricating viscosity derived from coal
or shale are also
useful base oils.
[0039] Synthetic lubricating oils include hydrocarbon oils such as
polymerized and
interpolymerized olefins (e.g., polybutylenes, polypropylenes, propylene-
isobutylene
copolymers, chlorinated polybutylenes, poly(1-hexenes), poly(1-octenes), and
poly(1-
decenes)); alkylbenzenes (e.g., dodecylbenzenes, tetradecylbenzenes,
dinonylbenzenes, and
di(2-ethylhexyl)benzenes); alkylated naphthalene; polyphenols (e.g.,
biphenyls, terphenyls,
alkylated polyphenols); and alkylated diphenyl ethers and alkylated diphenyl
sulfides and the
derivatives, analogues and homologues thereof
[0040] Another suitable class of synthetic lubricating oils comprises the
esters of
dicarboxylic acids (e.g., malonic acid, alkyl malonic acids, alkenyl malonic
acids, succinic
acid, alkyl succinic acids and alkenyl succinic acids, maleic acid, fumaric
acid, azelaic acid,
suberic acid, sebacic acid, adipic acid, linoleic acid dimer, and phthalic
acid) with a variety of
alcohols (e.g., butyl alcohol, hexyl alcohol, dodecyl alcohol, 2-ethylhexyl
alcohol, ethylene
glycol, diethylene glycol monoether, and propylene glycol). Specific examples
of these esters
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include dibutyl adipate, di(2-ethylhexyl) sebacate, di-n-hexyl fumarate,
dioctyl sebacate,
diisooctyl azelate, diisodecyl azelate, dioctyl phthalate, didecyl phthalate,
dieicosyl sebacate,
the 2-ethylhexyl diester of linoleic acid dimer, and the complex ester formed
by reacting one
mole of sebacic acid with two moles of tetraethylene glycol and two moles of 2-
ethylhexanoic acid.
[0041] Esters useful as synthetic oils also include those made from C5 to
C12
monocarboxylic acids and polyols, and polyol ethers such as neopentyl glycol,
trimethylolpropane, pentaerythritol, dipentaerythritol and tripentaerythritol.
[0042] The base oil may be derived from Fischer-Tropsch synthesized
hydrocarbons.
Fischer-Tropsch synthesized hydrocarbons are made from synthesis gas
containing H2 and
CO using a Fischer-Tropsch catalyst. Such hydrocarbons typically require
further processing
in order to be useful as the base oil. For example, the hydrocarbons may be
hydroisomerized;
hydrocracked and hydroisomerized; dewaxed; or hydroisomerized and dewaxed;
using
processes known to those skilled in the art.
[0043] Unrefined, refined and re-refined oils can be used in the present
lubricating oil
composition. Unrefined oils are those obtained directly from a natural or
synthetic source
without further purification treatment. For example, a shale oil obtained
directly from
retorting operations, a petroleum oil obtained directly from distillation or
ester oil obtained
directly from an esterification process and used without further treatment
would be unrefined
oil. Refined oils are similar to the unrefined oils except they have been
further treated in one
or more purification steps to improve one or more properties. Many such
purification
techniques, such as distillation, solvent extraction, acid or base extraction,
filtration and
percolation are known to those skilled in the art.
[0044] Re-refined oils are obtained by processes similar to those used to
obtain
refined oils applied to refined oils which have been already used in service.
Such re-refined
oils are also known as reclaimed or reprocessed oils and often are
additionally processed by
techniques for approval of spent additive and oil breakdown products.
[0045] Hence, the base oil which may be used to make the present
lubricating oil
composition 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 (API
Publication
1509). Such base oil groups are summarized in Table 1 below:
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TABLE 1
Base Oil Properties
Group(a) Saturate e) , wt. % SUlfUr(c) , wt. %
Viscosity Index'
Group I <90 and/or >0.03 80 to <120
Group II >90 <0.03 80 to <120
Group III >90 <0.03 >120
Group IV Polyalphaolefins (PA0s)
Group V All other base stocks not included in Groups I, II, III or
IV
(a) Groups I-III are mineral oil base stocks.
(b) Determined in accordance with ASTM D2007.
(c) Determined in accordance with ASTM D2622, ASTM D3120, ASTM D4294 or
ASTM D4927.
(d) Determined in accordance with ASTM D2270.
[0046] Base oils suitable for use herein are any of the variety
corresponding to API
Group II, Group III, Group IV, and Group V oils and combinations thereof,
preferably the
Group III to Group V oils due to their exceptional volatility, stability,
viscometric and
cleanliness features.
[0047] The oil of lubricating viscosity for use in the lubricating oil
compositions of
this disclosure, also referred to as a base oil, is typically present in a
major amount, e.g., an
amount of greater than 50 wt. %, or greater than about 70 wt. %, or great than
about 80%,
based on the total weight of the lubricating oil composition. In one
embodiment, the oil of
lubricating viscosity can be present in the lubricating oil composition of
this disclosure in an
amount of less than about 90 wt. % or less than about 85 wt. %, based on the
total weight of
the lubricating oil composition. The base oil for use herein can be any
presently known or
later-discovered oil of lubricating viscosity used in formulating lubricating
oil compositions
for engine oils. Additionally, the base oils for use herein can optionally
contain viscosity
index improvers, e.g., polymeric alkylmethacrylates; olefinic copolymers,
e.g., an ethylene-
propylene copolymer or a styrene-butadiene copolymer; and the like and
mixtures thereof
The topology of viscosity modifier could include, but is not limited to,
linear, branched,
hyperbranched, star, or comb topology.
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[0048] As one skilled in the art would readily appreciate, the viscosity
of the base oil
is dependent upon the application. Accordingly, the viscosity of a base oil
for use herein will
ordinarily range from about 2 to about 2000 centistokes (cSt) at 100
Centigrade (C.).
Generally, individually the base oils used as engine oils will have a
kinematic viscosity range
at 100 C of about 2 cSt to about 30 cSt, or about 3 cSt to about 16 cSt, or
about 4 cSt to about
12 cSt and will be selected or blended depending on the desired end use and
the additives in
the finished oil to give the desired grade of engine oil, e.g., a lubricating
oil composition
having an SAE Viscosity Grade of OW, OW-8, OW-12, OW-16, OW-20, OW-26, OW-30,
OW-
40, 0W-50, OW-60, 5W, 5W-20, 5W-30, 5W-40, 5W-50, 5W-60, 10W, 10W-20, 10W-30,
10W-40, 10W-50, 15W, 15W-20, 15W-30, 15W-40, 30, 40 and the like.
[0049] The lubricating oil composition in accordance with the present
disclosure
further includes an overbased metal salt of an alkyl-substituted phenate
detergent, wherein
the alkyl group is derived from an isomerized normal alpha olefin having from
about 10 to
about 40 carbon atoms per molecule having an isomerization level (I) of the
normal alpha
olefin of from about 0.1 to about 0.4. In general, isomerized phenate
detergents are useful for
their detergency and antioxidant properties. In addition, metal salts of
isomerized phenate
detergents made from isomerized normal alpha olefin, have a reduced content of
unreacted
TPP, which in a recent reproductive toxicity study in rats sponsored by the
Petroleum
Additives Panel of the American Chemistry Counsel showed that in high
concentrations
unreacted TPP may cause adverse effects in male and female reproductive
organs.
[0050] In one aspect of the present disclosure, the phenate detergent is
an alkylated
phenate detergent wherein the alkyl group is derived from an isomerized normal
alpha olefin
having from about 10 to about 40 carbon atoms per molecule.
[0051] In one aspect of the present disclosure, the alkyl group of the
alkylated
phenate detergent is derived from an isomerized normal alpha olefin having
from about 14 to
about 30, or from about 16 to about 30, or from about 18 to about 30, or from
about 20 to
about 28, or from about 20 to about 24, or from about 18 to about 28 carbon
atoms per
molecule.
[0052] In one aspect of the present disclosure, an isomerization level (I)
of the normal
alpha olefin of the alkylated phenate detergent is between from about 0.10 to
about 0.40, or
from about 0.10 to about 0.30, or from about 0.12 to about 0.30, or from about
0.22 to about
0.30.
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[0053] In another embodiment, the isomerization level of the normal alpha
olefin is
about 0.26, and the normal alpha olefin has from about 20 to about 24 carbon
atoms.
[0054] In one aspect of the present disclosure, the overbased metal salt
of an alkyl-
substituted phenate detergent has a TBN of from about 100 to about 600, or
from about 150
to about 500, or from about 150 to about 450, or from about 200 to about 450,
or from about
250 to about 450, or from about 300 to about 450, or from about 350 to about
450, or from
about 300 to about 425, or from about 325 to about 425, or from about 350 to
about 425 mg
KOH/gram, on an oil free basis.
[0055] In one aspect of the present disclosure, the overbased metal salt
of an alkyl-
substituted phenate detergent is a calcium phenate detergent.
[0056] In one aspect of the present disclosure, the overbased metal salt
of an alkyl-
substituted phenate detergent is a calcium non-sulfurized phenate detergent.
[0057] In one aspect of the present disclosure, the overbased metal salt
of an alkyl-
substituted phenate detergent can be prepared as described in, for example,
U.S. Patent No.
8,580,717 which is herein incorporated in its entirety.
[0058] In general, the overbased metal salt of an alkyl-substituted
phenate detergent is
present in the lubricating oil composition in an amount of about 10 ppm to
about 5000 ppm
of metal, e.g., calcium, based on the total weight of the lubricating oil
composition. In one
embodiment, an overbased metal salt of an alkyl-substituted phenate detergent
is present in
the lubricating oil composition in an amount of about 50 ppm to about 4000 ppm
of metal,
based on the total weight of the lubricating oil composition. In one
embodiment, an
overbased metal salt of an alkyl-substituted phenate detergent is present in
the lubricating oil
composition in an amount of about 100 ppm to about 3000 ppm of metal, based on
the total
weight of the lubricating oil composition. In other embodiments, the overbased
metal salt of
an alkyl-substituted phenate detergent is present in the lubricating oil
composition in an
amount of from about 150 ppm to about 2500 ppm of metal, from about 250 ppm to
about
1500 ppm of metal, from about 350 ppm to about 1500 ppm of metal, from about
500 ppm to
about 1500 ppm of metal, from about 600 ppm to about 1400 ppm of metal, from
about 700
ppm to about 1400 ppm of metal, from about 750 ppm to about 1350 ppm of metal,
from
about 800 ppm to about 1350 ppm of metal, from about 850 ppm to about 1300 ppm
of metal,
from about 950 ppm to about 1300 ppm of metal, from about 1000 ppm to about
1300 ppm of
metal, from about 1050 ppm to about 1300 ppm of metal, from about 1100 ppm to
about
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1300 ppm of metal, from about 1150 ppm to about 1300 ppm of metal, from about
1200 ppm
to about 1300 ppm of metal, based on the total weight of the lubricating oil
composition.
[0059]
[0060] In one embodiment, the overbased metal salt of an alkyl-substituted
phenate
detergent is present in the lubricating oil composition in an amount of about
0.1 wt. % to
about 3 wt. %, based on the total weight of the lubricating oil composition.
In one
embodiment, the overbased metal salt of an alkyl-substituted phenate detergent
is present in
the lubricating oil composition in an amount of about 0.2 wt. % to about 2 wt.
%, based on
the total weight of the lubricating oil composition. In one embodiment, the
overbased metal
salt of an alkyl-substituted phenate detergent is present in the lubricating
oil composition in
an amount of about 0.5 wt. % to about 1.4 wt. %, based on the total weight of
the lubricating
oil composition.
[0061] The lubricating oil composition in accordance with the present
disclosure
further includes at least about 50 to about 500 ppm of boron from one or more
boron-
containing detergents. Suitable one or more boron-containing detergents
include, for
example, oil-soluble borated sulfonates, non-sulfur containing borated
phenates, sulfurized
berated phenates, borated salixarates, borated salicylates, borated
saligenins, complex borated
detergents and borated naphthenate detergents and other oil-soluble borated
alkylhydroxybenzoates of a metal, such as alkali or alkaline earth metals,
e.g., barium,
sodium, potassium, lithium, calcium, and magnesium. The most commonly used
metals are
calcium and magnesium, which may both be present in detergents used in a
lubricant, and
mixtures of calcium and/or magnesium with sodium. In one embodimeni, one or
more
boron-containing detergents includes a berated sultbnate and a boratcd
salicylate.
[0062] In one embodiment, borated sulfonates include, for example, borated
alkaline
earth metal sulfonates obtained by (a) reacting in the presence of a
hydrocarbon solvent (i) at
least one of an oil-soluble sulfonic acid or alkaline earth sulfonate salt or
mixtures thereof;
(ii) at least one source of an alkaline earth metal; (iii) at least one source
of boron, and (iv)
from 0 to less than 10 mole percent, relative to the source of boron, of an
overbasing acid,
other than the source of boron; and (b) heating the reaction product of (a) to
a temperature
above the distillation temperature of the hydrocarbon solvent to distill the
hydrocarbon
solvent and water from the reaction. Suitable borated alkaline earth metal
sulfonates include
those disclosed in, for example, U.S. Patent Application Publication No.
20070123437, the
contents of which are incorporated by reference herein.
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[0063] In one embodiment, borated salicylates include, for example,
borated alkaline
earth metal salicylates obtained by (a) reacting in the presence of a
hydrocarbon solvent (i) at
least one of an oil-soluble salicylic acid or alkaline earth salicylate salt
or mixtures thereof;
(ii) at least one source of an alkaline earth metal; (iii) at least one source
of boron, and (iv)
from 0 to less than 10 mole percent, relative to the source of boron, of an
overbasing acid,
other than the source of boron; and (b) heating the reaction product of (a) to
a temperature
above the distillation temperature of the hydrocarbon solvent to distill the
hydrocarbon
solvent and water from the reaction.
[0064] In one aspect of the present disclosure, the one or more boron-
containing
detergents are one or more overbased boron-containing detergents. In one
embodiment, the
one or more boron-containing detergents are one or more boron-containing
detergents having
a TBN (oil free basis) of 0 to about 60. In another embodiment, the one or
more boron-
containing detergents are one or more boron-containing detergents having a TBN
(oil free
basis) of greater than 60 to about 200. In another embodiment, the one or more
boron-
containing detergents are one or more boron-containing detergents having a TBN
(oil free
basis) of greater than about 200 to about 600.
[0065] In general, the one or more boron-containing detergents provide the
lubricating oil compositions of the present disclosure with from about 50 to
about 500 ppm,
or from about 60 to about 500 ppm, or from about 70 to about 500 ppm, or from
about 80 to
about 500 ppm, or from about 90 to about 500 ppm, or from about 100 to about
500 ppm, or
from about 110 to about 500 ppm of boron, or from about 120 to about 500 ppm,
or from
about 130 to about 500 ppm, or from about 140 to about 500 ppm, or from about
150 to about
500 ppm, or from about 160 to about 500 ppm, or from about 170 to about 500
ppm, or from
about 180 to about 500 ppm, or from about 190 to about 500 ppm, or from about
200 to about
500 ppm of boron, based upon the total mass of the composition.
[0066] The lubricating oil composition in accordance with the present
disclosure
further includes one or more zinc dialkyl dithiophosphate compounds derived
from a primary
alcohol. Suitable primary alcohols include those alcohols containing from 1 to
18 carbon
atoms such as methanol, ethanol, propanol, butanol, pentanol, hexanol,
heptanol, octanol,
nonanol, decanol, dodecanol, octadecanol, propenol, butenol, and 2-
ethylhexanol. In one
embodiment, a zinc dialkyl dithiophosphate (ZnDTP) derived from a primary
alcohol can be
represented by a structure of formula (I):
Zn[S¨P(=S)(OR')(0R2)12 (I)
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wherein RI and R2 may be the same or different alkyl radicals having from 1 to
18 carbon
atoms or 2 to 12 carbon atoms or from 2 to 8 carbon atoms. The R' and R2
groups of the zinc
dialkyl dithiophosphate are derived from a primary alcohol as described above.
In order to
obtain oil solubility, the total number of carbon atoms (i.e., Ri+R2) will be
at least 5.
[0067] In one
embodiment, a mixture can be used comprising one or more zinc
dialkyl dithiophosphate compounds derived from a primary alcohol and one or
more zinc
dialkyl dithiophosphate compounds derived from a secondary alcohol, wherein
the molar
ratio of the primary alcohol to the secondary alcohol is from about 100:0 to
about 0:100.
Suitable secondary alcohols include those alcohols containing from 3 to 18
carbon atoms
such as isopropyl alcohol, secondary butyl alcohol, isobutanol, 3-methylbutan-
2-ol, 2-
pentanol, 4-methyl-2-pentanol, 2-hexanol, 3-hexanol, and amyl alcohol. In one
embodiment,
a zinc dialkyl dithiophosphate (ZnDTP) derived from a secondary alcohol can be
represented
by a structure of formula (II):
Zn[S¨P(=S)(0R1)(0R2)12 (II)
wherein RI and R2 may be the same or different alkyl radicals having from 3 to
18 carbon
atoms or 3 to 12 carbon atoms or from 3 to 8 carbon atoms. The R' and R2
groups of the zinc
dialkyl dithiophosphate can be derived from the foregoing secondary alcohols.
In order to
obtain oil solubility, the total number of carbon atoms (i.e., RLFR2) will be
at least 5.
[0068] In one
embodiment, the molar ratio of the primary alcohol to the secondary
alcohol in the mixture of the one or more zinc dialkyl dithiophosphate
compounds derived
from a primary alcohol and one or more zinc dialkyl dithiophosphate compounds
derived
from a secondary alcohol can range from about 20:80 to about 80:20. In one
embodiment,
the molar ratio of the primary alcohol to the secondary alcohol in the mixture
of the one or
more zinc dialkyl dithiophosphate compounds derived from a primary alcohol and
one or
more zinc dialkyl dithiophosphate compounds derived from a secondary alcohol
can range
from about 30:70 to about 70:30. In one embodiment, the molar ratio of the
primary alcohol
to the secondary alcohol in the mixture of the one or more zinc dialkyl
dithiophosphate
compounds derived from a primary alcohol and one or more zinc dialkyl
dithiophosphate
compounds derived from a secondary alcohol can range from about 40:60 to about
60:40.
[0069] In
general, the one or more zinc dialkyl dithiophosphate compounds derived
from a primary alcohol and/or one or more zinc dialkyl dithiophosphate
compounds derived
from a secondary alcohol can be present in the lubricating oil composition of
the present
disclosure in an amount of about 3 wt. % or less, based on the total weight of
the lubricating
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oil composition, e.g., an amount of about 0.1 wt. % to about 3 wt. %. In one
embodiment, the
one or more zinc dialkyl dithiophosphate compounds derived from a primary
alcohol and/or
one or more zinc dialkyl dithiophosphate compounds derived from a secondary
alcohol can
be present in the lubricating oil composition of the present disclosure in an
amount of about
0.1 to about 1.5 wt. %, based on the total weight of the lubricating oil
composition. In one
embodiment, the one or more zinc dialkyl dithiophosphate compounds derived
from a
primary alcohol and/or one or more zinc dialkyl dithiophosphate compounds
derived from a
secondary alcohol can be present in the lubricating oil composition of the
present disclosure
in an amount of about 0.5 to about 1.5 wt. %, based on the total weight of the
lubricating oil
composition. In one embodiment, the one or more zinc dialkyl dithiophosphate
compounds
derived from a primary alcohol and/or one or more zinc dialkyl dithiophosphate
compounds
derived from a secondary alcohol can be present in the lubricating oil
composition of the
present disclosure in an amount of about 1.0 to about 1.4 wt. %, based on the
total weight of
the lubricating oil composition. In one embodiment, the one or more zinc
dialkyl
dithiophosphate compounds derived from a primary alcohol and/or one or more
zinc dialkyl
dithiophosphate compounds derived from a secondary alcohol can be present in
the
lubricating oil composition of the present disclosure in an amount of about
1.2 to about 1.4
wt. %, based on the total weight of the lubricating oil composition.
[0070] If desired, the lubricating oil composition of the present
disclosure can further
contain one or more additional detergents. In one embodiment, the lubricating
oil
compositions of the present disclosure further contain one or more alkali
metal or alkaline
earth metal sulfonates. For example, the lubricating oil composition of the
present disclosure
can contain one or more calcium sulfonates. In one embodiment, a calcium
sulfonate is one
or more overbased calcium detergents. In one embodiment, a calcium sulfonate
is an
overbased calcium detergent having a TBN (oil free basis) of 0 to about 60. In
another
embodiment, the calcium sulfonate is an overbased calcium detergent having a
TBN (oil free
basis) of greater than 60 to about 200. In another embodiment, the calcium
sulfonate is an
overbased calcium detergent having a TBN (oil free basis) of greater than
about 200 to about
800.
[0071] The lubricating oil compositions of the present disclosure may also
contain
other conventional additives that can impart or improve any desirable property
of the
lubricating oil composition in which these additives are dispersed or
dissolved. Any additive
known to a person of ordinary skill in the art may be used in the lubricating
oil compositions
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disclosed herein. Some suitable additives have been described in Mortier et
al., "Chemistry
and Technology of Lubricants", 2nd Edition, London, Springer, (1996); and
Leslie R.
Rudnick, "Lubricant Additives: Chemistry and Applications", New York, Marcel
Dekker
(2003), both of which are incorporated herein by reference. For example, the
lubricating oil
compositions can be blended with antioxidants, rust inhibitors, dehazing
agents, demulsifying
agents, metal deactivating agents, friction modifiers, pour point depressants,
antifoaming
agents, co-solvents, corrosion-inhibitors, ashless dispersants,
multifunctional agents, dyes,
extreme pressure agents and the like and mixtures thereof. A variety of the
additives are
known and commercially available. These additives, or their analogous
compounds, can be
employed for the preparation of the lubricating oil compositions of the
disclosure by the usual
blending procedures.
[0072] In the preparation of lubricating oil formulations, it is common
practice to
introduce the additives in the form of about 10 to about 80 wt. % active
ingredient
concentrates in hydrocarbon oil, e.g. mineral lubricating oil, or other
suitable solvent.
[0073] Usually these concentrates may be diluted with about 3 to about
100, e.g.,
about 5 to about 40, parts by weight of lubricating oil per part by weight of
the additive
package in forming finished lubricants, e.g. crankcase motor oils. The purpose
of
concentrates, of course, is to make the handling of the various materials less
difficult and
awkward as well as to facilitate solution or dispersion in the final blend.
[0074] Each of the foregoing additives, when used, is used at a
functionally effective
amount to impart the desired properties to the lubricant. Thus, for example,
if an additive is a
friction modifier, a functionally effective amount of this friction modifier
would be an
amount sufficient to impart the desired friction modifying characteristics to
the lubricant.
[0075] In general, the concentration of each of the additives in the
lubricating oil
composition, when used, may range from about 0.001 wt. % to about 20 wt. %, or
from about
0.005 wt. % to about 15 wt. %, or from about 0.01 wt. % to about 10 wt. %, or
from about 0.1
wt. % to about 5 wt. %, or from about 0.1 wt. % to about 2.5 wt. %, based on
the total weight
of the lubricating oil composition. Further, the total amount of the additives
in the lubricating
oil composition may range from about 0.001 wt.% to about 20 wt.%, or from
about 0.01 wt.%
to about 10 wt.%, or from about 0.1 wt.% to about 5 wt.%, based on the total
weight of the
lubricating oil composition.
[0076] The following examples are presented to exemplify embodiments of
the
disclosure but are not intended to limit the disclosure to the specific
embodiments set forth.
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Specific details described in each example should not be construed as
necessary features of
the disclosure. The following examples are intended for illustrative purposes
only and do not
limit in any way the scope of the present disclosure. All numerical values are
approximate.
When numerical ranges are given, it should be understood that embodiments
outside the
stated ranges may still fall within the scope of the disclosure.
[0077] The isomerization level was measured by an NMR method as follows.
[0078] isomerization level (I) and NMR method,
[0079] The isomerization level (I) of the olefin was determined b:).[
hydrogen-1 (1I-I)
NNW. The NMR spectra were obtained on a Bruker Ultrashield Plus 400 in
chloroform-di at
400 MI-12 using TopSpin 32 spectral processing software.
[0080] The isomerization level (I) represents the relative amount of
methyl groups
(CI-I3) (chemical shift 0.30-1.01 ppm) attached to the methylene backbone
groups (-CI-I2-)
(chemical shift 1.01-1.38 ppm) and is defined by Equation (1) as shown below,
[0081] 1= m/(m+n) Equation (1) where m is NMR integral for methyl groups
with
chemical shifts between 0.30 0.03 to 1.01 0.03 ppm, and n is NMR integral
for methylene
groups with chemical shifts between 1.01 0.03 to 1.38 0.10 ppm.
EXAMPLE 1
[0082] A lubricating oil composition was prepared that contained a major
amount of a
base oil of lubricating viscosity and the following additives, to provide a
finished oil having
an SAE viscosity of 15W-40:
[0083] an ethylene carbonate post-treated bis-succinimide;
[0084] 120 ppm in terms of boron content, of a middle overbased borated
calcium
sulfonate detergent;
[0085] a mixture of a low overbased calcium sulfonate detergent and a high
overbased calcium sulfonate detergent;
[0086] 1280 ppm of Ca of a 400 TBN (oil free basis) calcium alkylated
phenate
detergent, wherein the alkyl group is derived from a C2c, to C24 isomerized
normal alpha
olefin and wherein the isomerization level of the alpha olefin is about 0.26;
[0087] 990 ppm in terms of phosphorus content, of a mixture of primary and
secondary zinc dialkyldithiophosphate in a 50:50 molar ratio of primary to
secondary
alcohols;
[0088] a molybdenum succinimide antioxidant;
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[0089] an alkylated diphenylamine;
[0090] 5 ppm in terms of silicon content, of a foam inhibitor;
[0091] a non-dispersant olefin copolymer viscosity modifier; and
[0092] the remainder, a Group II base oil having a kinematic viscosity of
6.4 cSt at
100 C.
COMPARATIVE EXAMPLE 2
[0093] A lubricating oil composition was prepared similar to Example 1
except the
ratio for the molar ratio of primary to secondary zinc that contained a major
amount of a base
oil of lubricating viscosity. In this example there was 990 ppm in terms of
phosphorus
content, of an all secondary zinc dialkyldithiophosphate.
EXAMPLE 3
[0094] A lubricating oil composition was prepared similar to Example 1
except the
ratio for the molar ratio of primary to secondary zinc, that contained a major
amount of a base
oil of lubricating viscosity. In this example there was 990 ppm in terms of
phosphorus
content, of a mixture of primary and secondary zinc dialkyldithiophosphate in
a 20:80 molar
ratio of primary to secondary.
EXAMPLE 4
[0095] A lubricating oil composition was prepared similar to Example 1
except the
ratio for the molar ratio of primary to secondary zinc, that contained a major
amount of a base
oil of lubricating viscosity. In this example there was 990 ppm in terms of
phosphorus
content, of a mixture of primary and secondary zinc dialkyldithiophosphate in
a 80:20 molar
ratio of primary to secondary.
EXAMPLE 5
[0096] A lubricating oil composition was prepared similar to Example 1
except the
ratio for the molar ratio of primary to secondary zinc, that contained a major
amount of a base
oil of lubricating viscosity. In this example there was 990 ppm in terms of
phosphorus
content, of a an all primary zinc dialkyldithiophosphate.
EXAMPLE 6
[0097] A lubricating oil composition was prepared similar to Example 3
except there
was 60 ppm in terms of boron content, of a middle overbased borated calcium
sulfonate
detergent.
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EXAMPLE 7
[0098] A lubricating oil composition was prepared similar to Example 3
except there
was 150 ppm in terms of boron content, of a middle overbased borated calcium
sulfonate
detergent.
EXAMPLE 8
[0099] A lubricating oil composition was prepared similar to Example 3
except there
was 320 ppm in terms of boron content, of a middle overbased borated calcium
sulfonate
detergent.
EXAMPLE 9
[00100] A lubricating oil composition was prepared similar to Example 3
except there
was 430 ppm in terms of boron content, of a middle overbased borated calcium
sulfonate
detergent.
[00101] The lubricating oil composition of Examples 1, 3-9 and Comparative
Example
2 were subjected to a Komatsu Hot Tube Test and TEOST MHT4 as described below.
The
results of these tests are set forth below in Table 2.
[00102] Komatsu Hot Tube Test (KHTT)
[00103] The Komatsu Hot Tube Test (KHTT) is used for screening and quality
control
of deposit formation performance for engine oils and other oils subjected to
high
temperatures.
[00104] Detergency and thermal and oxidative stability are performance
areas that are
generally accepted in the industry as being essential to satisfactory overall
performance of a
lubricating oil. The Komatsu Hot Tube test is a lubrication industry bench
test (JPI 5S-55-
99) that measures the detergency and thermal and oxidative stability of a
lubricating oil.
During the test, a specified amount of test oil is pumped upwards through a
glass tube that is
placed inside an oven set at a certain temperature. Air is introduced in the
oil stream before
the oil enters the glass tube, and flows upward with the oil. Evaluations of
the lubricating
oils were conducted at a temperature of 280 C. The test result is determined
by comparing
the amount of lacquer deposited on the glass test tube to a rating scale
ranging from 1.0 (very
black) to 10.0 (perfectly clean).
[00105] TEOST MI-1T4
[00106] TEOST MHT4 (ASTM D7097-16a) is designed to predict the deposit-
forming
tendencies of engine oil in the piston ring belt and upper piston crown area.
Correlation has
been shown between the TEOST MHT procedure and the TU3MH Peugeot engine test
in
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deposit formation. This test determines the mass of deposit formed on a
specially constructed
test rod exposed to repetitive passage of 8.5 g of engine oil over the rod in
a thin film under
oxidative and catalytic conditions at 285 C. Deposit-forming tendencies of an
engine oil
under oxidative conditions are determined by circulating an oil-catalyst
mixture comprising a
small sample (8.4 g) of the oil and a very small (0.1 g) amount of an organo-
metallic catalyst.
This mixture is circulated for 24 hours in the TEOST MHT instrument over a
special wire-
wound depositor rod heated by electrical current to a controlled temperature
of 285 C at the
hottest location on the rod. The rod is weighed before and after the test.
Deposit weight of
45 mg is considered as pass/fail criteria.
[00107] A copy of this test method can be obtained from ASTM International
at 100
Barr Harbor Drive, PO Box 0700, West Conshohocken, Pa. 19428-2959 and is
herein
incorporated for all purposes.
TABLE 2
Comp. Ex. Ex. 4 Ex.5 Ex. 6 Ex. 7 Ex. 8 Ex. 9
Ex. 1
2 3
TEOST MHT4
48.8 63.2 49.1 43.7 28.1 48.7 47 44.8 44.8
deposits (mg)
KHT (Merit
8.5 5.5 7 9 9.5 7 7 6.5 6.5
Rating)
[00108] The data in Table 2 show clear detergency, and thermal and
oxidative stability
benefits of the lubricating oil performance of the present disclosure
(Examples 1, and 3 to 9)
over Comparative Example 2.
[00109] It will be understood that various modifications may be made to the
embodiments disclosed herein. Therefore, the above description should not be
construed as
limiting, but merely as exemplifications of preferred embodiments. For
example, the
functions described above and implemented as the best mode for operating the
present
disclosure are for illustration purposes only. Other arrangements and methods
may be
implemented by those skilled in the art without departing from the scope and
spirit of this
disclosure. Moreover, those skilled in the art will envision other
modifications within the
scope and spirit of the claims appended hereto.
