Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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INDUSTRIAL GEAR OILS IMPARTING REDUCED
GEARBOX OPERATING TEMPERATURES
Field of the Invention
[0001] The invention relates to improved gear oil compositions that
substantially
reduce the operating temperature of a gearbox in which the gear oil
compositions are
used. The reduced operating temperature provided by the described compositions
leads
to improved equipment performance. The invention also relates to methods of
making
the described gear oil compositions and methods of using the same.
Background of the Invention
[0002] Industrial gearboxes see extreme operating conditions that can
lead to
damage, for example, wear to the internal components of the gearbox. This
damage
reduces the life of the industrial gearbox and can lead to costly and
prolonged
maintenance, repair costs, unscheduled downtime for the equipment that
contains the
industrial gearbox, and similar problems.
[0003] There is an on-going need for improved industrial gearbox
lubricants that can
provide better performance in and protection of industrial gearboxes, thus
extending the
service life of the industrial gearboxes and the equipment that contains them.
[0004] One means of protecting an industrial gearbox and extending the
life of the
fluid lubricating them is to reduce the temperature at which it operates. It
is generally
known that extended exposure to the high temperatures that industrial
gearboxes
commonly operate under increases the wear and tear on the parts of the
gearboxes,
eventually leading to part failure. This negative impact of high operating
temperature is
the result of multiple forces, including but not limited to the fact that the
high
temperatures can accelerate the break-down of the protective additives and
increase the
oxidation of the base fluid present in the industrial gearbox lubricant, thus
leaving the
parts of the gearbox less protected over time. Reducing the operating
temperature of an
industrial gearbox will result in improved performance over time.
[0005] One means of reducing the operating temperature of an industrial
gearbox is
by use of an external cooler or the addition of radiating fins. However, such
approaches
have limitations and can involve costly and time consuming modifications to
existing
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equipment. There is a need for an approach that reduces the operating
temperature of an
industrial gearbox in existing equipment without the need for such
modifications.
[0006] An alternative to reducing gearbox operating temperature would
be to operate
the equipment at a lower level (lower load, lower power, lower speed, etc.).
However,
this approach generally leads to a reduction in production and/or efficiency
and so is not
an attractive option to equipment operators trying to maintain productivity.
Instead,
there is a need for industrial gearbox lubricants that can reduce the
operating temperature
of an industrial gearbox without sacrificing operation levels (equipment load,
power,
speed, etc.).
[0007] It has now been found that the industrial gearbox lubricant
compositions of
the present invention can provide a reduction in industrial gearbox operating
temperature
with no other changes to equipment operating conditions.
Summary of the Invention
[0008] The invention provides an industrial gear composition
comprising: (a) an oil
of lubricating viscosity; (b) an industrial gear lubricant additive package;
and (c) a fatty
phosphite present at no less than 1.0 percent by weight of the overall
composition. The
present invention is not directed to automotive gear compositions and/or
lubricants, but
rather is focused on industrial gear oil compositions and/or lubricants
dealing with the
unique problems seen in industrial gearbox applications.
[0009] The invention provides for the described compositions where
component (b),
the industrial gear lubricant additive package, may include one or more
antiwear
additives and/or extreme pressure agents, one or more rust and/or corrosion
inhibitors,
one or more foam inhibitors, one or more demulsifiers, or any combination
thereof.
Component (b), the industrial gear lubricant additive package, may also
further include
one or more friction modifiers.
[0010] The invention further provides for component (b), the industrial
gear lubricant
additive package, to further include: one or more sulfurized olefins or
polysulfides; one
or more phosphorus amine salts; one or more thiophosphate esters, one or more
thiadiazoles, tolyltriazoles, polyethers, and/or alkenyl amines; one or more
ester
copolymers; one or more carboxylic esters; one or more succinimide
dispersants,
detergents, or any combination thereof.
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[0011] The invention provides for concentrate compositions as well as
lubricant
compositions. The described industrial gear additive concentrates may contain
up to 49
percent by weight of component (a). The described industrial gear lubricants
may
contain at least 80 percent by weight of component (a). Component (b) may be
present
from 1 to 5 percent by weight of the overall industrial gear lubricant; and
component (c)
may be present from 1.0 to 5.0 percent by weight of the overall industrial
gear lubricant.
[0012] The invention further provides a method of reducing the
operating
temperature of an industrial gearbox, said method comprising the steps of: (1)
adding to
an industrial gear oil lubricant a fatty phosphite such that the lubricant
contains at least
1.0 percent by weight fatty phosphite, and (II) operating the industrial
gearbox while
supplying the industrial gear oil lubricant to the industrial gearbox.
[0013] The invention further provides a method of reducing the
operating
temperature of an industrial gearbox, said method comprising the steps of: (I)
supplying
to an industrial gearbox the lubricant composition described herein, and (II)
operating the
industrial gearbox. In any of these embodiments, the fatty phosphite may be
added to the
industrial gear oil lubricant before the lubricant is supplied to the
industrial gearbox, or
wherein at least a portion of the fatty phosphite is added to the industrial
gear oil
lubricant after the lubricant is supplied to the industrial gearbox.
[0014] The invention provides the use of the described fatty phosphite
in an
industrial gear lubricant composition to reduce the operating temperature of
an industrial
gearbox in which the lubricant composition is used. The invention also
provides the use
of the described industrial gear lubricant composition to reduce the operating
temperature of an industrial gearbox in which the lubricant composition is
used.
Detailed Description of the Invention
[0015] Various features and embodiments of the invention will be described
below
by way of non-limiting illustration.
[0016] The industrial gear compositions of the invention include: (a)
an oil of
lubricating viscosity; (b) an industrial gear lubricant additive package; and
(c) a fatty
phosphite present at no less than 1.0 percent by weight of the overall
composition. In
some embodiments the industrial gear lubricant additive package may include a
demulsifier, a dispersant, and a metal deactivator. The 1.0 percent by weight
minimum
of the fatty phosphite is included as it is believed that, in at least some
embodiments, at
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least this amount of fatty phosphite is necessary to see the described
benefits in the
industrial gear oil compositions, namely the reduced gearbox operating
temperature. The
extent to which the benefits of the invention are seen are expected to vary
and/or be
dependent somewhat on the base fluid used.
The Oil of Lubricating Viscosity
[0017] The oil of lubricating viscosity can be present in a major
amount, for a
lubricant composition, or in a concentrate forming amount, for a concentrate
and/or
additive composition.
[0018] Suitable oils include natural and synthetic lubricating oils and
mixtures
thereof. In a fully formulated lubricant, the oil of lubricating viscosity is
generally
present in a major amount (i.e. an amount greater than 50 percent by weight).
Typically,
the oil of lubricating viscosity is present in an amount of 75 to 98 percent
by weight, and
often greater than 80 percent by weight of the overall composition.
[0019] The oil of lubricating viscosity may include natural and
synthetic oils, oil
derived from hydro cracking, hydrogenation, and hydrofinishing, unrefined,
refined and
re-refined oils or mixtures thereof Unrefined oils are those obtained directly
from a
natural or synthetic source generally without (or with little) further
purification
treatment. 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.
Purification
techniques are known in the art and include solvent extraction, secondary
distillation,
acid or base extraction, filtration, percolation and similar processes. Re-
refined oils are
also known as reclaimed or reprocessed oils, and are obtained by processes
similar to
those used to obtain refined oils. Re-refined oils are often are processed by
techniques
directed to removal of spent additives and oil breakdown products.
[0020] Natural oils useful as the oil of lubricating viscosity include
animal oils and
vegetable oils (e.g., castor oil, lard oil), 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 and oils derived from coal or
shale or
mixtures thereof.
[0021] Synthetic oils of lubricating viscosity include hydrocarbon oils
such as
polymerized and interpolymerised olefins (e.g., polybutylenes, polypropylenes,
propyleneisobutylene copolymers); poly(1 -hex enes), poly(1-octenes), poly(1-
decenes),
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and mixtures thereof; alkyl-benzenes (e.g., dodecylbenzenes,
tetradecylbenzenes,
dinonylbenzenes, di-(2-ethylhexyl)-benzenes); polyphenyls (e.g., biphenyls,
terphenyls,
alkylated polyphenyls); alkylated biphenyl ethers and alkylated biphenyl
sulfides and the
derivatives, analogs and homologs thereof or mixtures thereof In some
embodiments
the oil of lubricating viscosity used in the invention is a synthetic oil that
includes
polymerized polyisobutylene, and in some embodiments the oil of lubricating
viscosity
used in the invention is a synthetic oil that includes polymerized
polyisobutylene and a
polyalphaol efin
[0022] Another synthetic oil of lubricating viscosity includes polyol
esters other than
the hydrocarbyl-capped polyoxyalkylene polyol as disclosed herein,
dicarboxylic esters,
liquid esters of phosphorus-containing acids (e.g., tricresyl phosphate,
trioctyl phosphate,
and the diethyl ester of decane phosphonic acid), or polymeric
tetrahydrofurans.
Synthetic conventional oil of lubricating viscosity also includes those
produced by
Fischer-Tropsch reactions and typically may be hydroisomerised Fischer-Tropsch
hydrocarbons or waxes. In one embodiment, the oil of lubricating viscosity may
be
prepared by a Fischer-Tropsch gas-to-liquid synthetic procedure as well as
other gas-to-
liquid oils.
[0023] Oils of lubricating viscosity may further be defined as
specified in the
American Petroleum Institute (API) Base Oil Interchangeability Guidelines. The
five
base oil groups are as follows: Group 1 (sulfur content >0.03 percent by
weight, and/or
<90 percent by weight saturates, viscosity index 80-120); Group II (sulfur
content <0.03
percent by weight and >90 percent by weight saturates, viscosity index 80-
120); Group
III (sulfur content <0.03 percent by weight and >90 percent by weight
saturates,
viscosity index >120); Group IV (all polyalphaolefins, or PAO, such as PA0-2,
PA0-4,
PA0-5, PA0-6, PA0-7 or PA0-8); and Group V (which encompasses "all others").
The
oil of lubricating viscosity includes API Group I, Group II, Group III, Group
IV, Group
V oil or mixtures thereof. In one embodiment, the oil of lubricating viscosity
is an API
Group I, Group II, Group III, Group IV oil or mixtures thereof Alternatively,
the oil of
lubricating viscosity is often an API Group II, Group III or Group IV oil or
mixtures
thereof
[0024] In some embodiments, the lubricating oil component of the
present invention
includes a Group II or Group III base oil, or a combination thereof The oil
can also be
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derived from the hydroisomerization of wax, such as slack wax or a Fischer-
Tropsch
synthesized wax. Such "Gas-to-Liquid" oils are typically characterized as
Group III.
[0025] The compositions of the present invention may include some
amount of
Group I base oils, and even Group IV and Group V base oils. However, in some
embodiments, the lubricating oil component of the invention contains no more
than 20,
10, 5, or even 1 percent by weight Group 1 base oil. These limits may also
apply to
Group IV or Group V base oils. In other embodiments, the lubricating oil
present in the
compositions of the invention is at least 60, 70, 80, 90, or even 98 percent
by weight
Group II and/or Group III base oil. In some embodiments, the lubricating oil
present in
the compositions of the invention is essentially only Group II and/or Group
III base oil,
where small amounts of other types of base oils may be present but not in
amounts that
significantly impact the properties or performance of the overall composition.
[0026] In some embodiments, the compositions of the invention include
some
amount of Group I and/or Group II base oils. In other embodiments, the
compositions of
the invention are lubricating compositions where the oil of lubricating
viscosity is
primarily Group I and/or Group II base oils, or even essentially Group I
and/or Group II
base oils, or even exclusively Group I and/or Group II base oils.
[0027] In some embodiments, the invention provides a Group II
composition, that is
the oil of lubricating viscosity includes Group II oil, and can even be
primarily if not
exclusively Group II oil, while still providing synthetic oil composition
performance.
This is one of the benefits of the present invention.
[0028] The various described oils of lubricating viscosity may be used
alone or in
combinations. The oil of lubricating viscosity may be used in the described
industrial
gear lubricants in the range of about 80 percent by weight to about 98 percent
by weight,
or from 80, 85, 90, 95, 97 or even 97.5 or 98 percent by weight oil or up to
90, 95, 97,
97.5, or even 98 percent by weight oil. The oil of lubricating viscosity may
be used as
diluent in the described industrial gear additive concentrates in the range of
about 1
percent by weight to about 49 percent by weight, or from 1, 5, even 10 percent
by weight
oil up to 10, 20, 30, 40, or even 45 or 49 percent by weight oil.
The Industrial Gear Lubricant Additive Package
[0029] The compositions of the invention include an industrial gear
additive
package. In other words, the compositions of the invention are designed to be
industrial
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gear lubricants, or additive packages for making the same. The present
invention does
not relate to automotive gear lubricants or other lubricating compositions.
[0030] In some embodiments, the industrial gear lubricant additive
package includes
a demulsifier, a dispersant, and a metal deactivator. Any combination of
conventional
additive packages designed for industrial gear application may be used. The
invention
inherently assumes such additive packages are essentially free of the fatty
phosphites of
the present invention, or at least do not contain the type of fatty phosphites
specified by
the invention in the amounts specified.
[0031] The additives which may be present in the industrial gear
additive package
include a foam inhibitor, a demulsifier, a pour point depressant, an
antioxidant, a
dispersant, a metal deactivator (such as a copper deactivator), an antiwear
agent, an
extreme pressure agent, a viscosity modifier, or some mixture thereof. The
additives
may each be present in the range from 50, 75, 100 or even 150 ppm up to 5, 4,
3, 2 or
even 1.5 percent by weight, or from 75 ppm to 0.5 percent by weight, from 100
ppm to
0.4 percent by weight, or from 150 ppm to 0.3 percent by weight, where the
percent by
weight values are with regards to the overall lubricating oil composition.
However,
it is noted that some additives, including viscosity modifying polymers, which
may
alternatively be considered as part of the base fluid, may be present in
higher
amounts including up to 30, 40, or even 50% by weight when considered separate
from the base fluid. The additives may be used alone or as mixtures thereof
[0032] Antifoams, also known as foam inhibitors, are known in the art
and include
but are not limited to organic silicones and non-silicon foam inhibitors.
Examples of
organic silicones include dimethyl silicone and polysiloxanes. Examples of non-
silicon
foam inhibitors include but are not limited to polyethers, polyacrylates and
mixtures
thereof as well as copolymers of ethyl acrylate, 2-ethylhexylacrylate, and
optionally
vinyl acetate. In some embodiments, the antifoam is a polyacrylate. Antifoams
may be
present in the composition from 0.001 to 0.012 or 0.004 pbw or even 0.001 to
0.003
pbw.
[0033] Demulsifiers are known in the art and include but are not
limited to
derivatives of propylene oxide, ethylene oxide, polyoxyalkylene alcohols,
alkyl amines,
amino alcohols, diamines or polyamines reacted sequentially with ethylene
oxide or
substituted ethylene oxides or mixtures thereof. Examples of demulsifiers
include
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polyethylene glycols, polyethylene oxides, polypropylene oxides, (ethylene
oxide-
propylene oxide) polymers and mixtures thereof. In some embodiments, the
demulsifiers
are polyethers. Demulsifiers may be present in the composition from 0.002 to
0. 2 pbw.
[0034] Pour point depressants are known in the art and include but are
not limited to
esters of maleic anhydride-styrene copolymers, polymethacrylates;
polyacrylates;
polyacrylamides; condensation products of haloparaffin waxes and aromatic
compounds;
vinyl carboxylate polymers; and terpolymers of dialkyl fumarates, vinyl esters
of fatty
acids, ethylene-vinyl acetate copolymers, alkyl phenol formaldehyde
condensation
resins, alkyl vinyl ethers and mixtures thereof.
[0035] The compositions of the invention may also include a rust inhibitor,
other
than some of the additives described above. Suitable rust inhibitors include
hydrocarbyl
amine salts of dialkyldithiophosphoric acid, hydrocarbyl amine salts of
hydrocarbyl
arenesulphonic acid, fatty carboxylic acids or esters thereof, an ester of a
nitrogen-
containing carboxylic acid, an ammonium sulfonate, an imidazoline, mono-thio
phosphate salts or esters, or any combination thereof; or mixtures thereof.
Examples of
hydrocarbyl amine salts of dialkyldithiophosphoric acid of the invention
include but are
not limited to those described above, as well as the reaction product(s) of
diheptyl or
dioctyl or dinonyl dithiophosphoric acids with ethylenediamine, morpholine or
PrimcneTM 81R or mixtures thereof. Suitable hydrocarbyl amine salts of
hydrocarbyl
arenesulphonic acids used in the rust inhibitor package of the invention are
represented
by the formula:
\*,õ144
(R1)Cy__Sey
(V)
wherein Cy is a benzene or naphthalene ring. R1 is a hydrocarbyl group with
about 4 to
about 30, preferably about 6 to about 25, more preferably about 8 to about 20
carbon
atoms. z is independently 1, 2, 3, or 4 and most preferably z is 1 or 2. R2,
R3 and R4 are
the same as described above. Examples of hydrocarbyl amine salts of
hydrocarbyl
arenesulphonic acid of the invention include but are not limited to the
ethylenediamine
salt of dinonylnaphthalene sulfonic acid. Examples of suitable fatty
carboxylic acids or
esters thereof include glycerol monooleate and oleic acid. An example of a
suitable ester
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of a nitrogen-containing carboxylic acid includes oleyl sarcosine. The rust
inhibitors
may be present in the range from 0.02 to 0.2, from 0.03 to 0.15, from 0.04 to
0.12, or
from 0.05 to 0.1 percent by weight of the lubricating oil composition. The
rust
inhibitors of the invention may be used alone or in mixtures thereof.
[00361 The
compositions of the invention may also include a metal deactivator.
Metal deactivators are used to neutralise the catalytic effect of metal for
promoting
oxidation in lubricating oil. Suitable metal deactivators include but are not
limited to
triazoles, tolyltriazoles, a thiadiazole, or combinations thereof, as well as
derivatives
thereof. Examples include derivatives of benzotriazoles other than those
described
above, benzimidazole, 2-alkyldithiobenzimidazoles, 2-
alkyldithiobenzothiazoles, 2-
(N,N' -dialkyldithio-earb amoyl)b enzothiazo les , 2,5-bis(alkyl-dithio)-1
,3,4-thiadiazo les,
2 ,5 -bis(N,N' -di alkyldithio carb amoy1)-1,3 ,4-thiadiazo les, 2 -
alkyldithio-5 -mere apto
thiadiazoles or mixtures thereof. These additives may be used from 0.01 to
0.25 percent
by weight in the overall composition. In some embodiments, the metal
deactivator is a
hydrocarbyl substituted benzotriazole compound. The benzotriazole compounds
with
hydrocarbyl substitutions include at least one of the following ring positions
1- or 2- or
4- or 5- or 6- or 7- benzotriazoles. The hydrocarbyl groups contain about 1 to
about 30,
preferably about 1 to about 15, more preferably about 1 to about 7 carbon
atoms, and
most preferably the metal deactivator is 5-methylbenzotriazole used alone or
mixtures
thereof. The metal deactivators may be present in the range from 0.001 to 0.5,
from 0.01
to 0.04 or from 0.015 to 0.03 pbw of the lubricating oil composition. Metal
deactivators may also be present in the composition from 0.002 or 0.004 to
0.02 pbw.
The metal deactivator may be used alone or mixtures thereof.
[0037]
Antioxidants may also be present including (i) an alkylated diphenylamine,
and (ii) a substituted hydrocarbyl mono-sulfide. In some embodiments, the
alkylated
diphenylamines of the invention are bis-nonylated diphenylamine and bis-
octylated
diphenylamine. In some embodiments, the substituted hydrocarbyl monosulfides
include
n-dodecy1-2-hydroxyethyl sulfide, 1-(tert-dodecylthio)-2-propanol, or
combinations
thereof. In some embodiments the substituted hydrocarbyl monosulfide is 1-
(tert-
dodecylthio)-2-propanol. The antioxidant package may also include sterically
hindered
phenols. Examples of suitable hydrocarbyl groups for the sterically hindered
phenols
include but are not limited to 2-ethylhexyl or n-butyl ester, dodecyl or
mixtures thereof.
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Examples of methylene-bridged sterically hindered phenols include but are not
limited to
4,4'-methylene-bis(6-tert-butyl o-cresol), 4,4'-methylene-bis(2-tert-amyl-o-
cresol), 2,2'-
methylene-bis(4-methy1-6-tert-butylphenol), 4,4'-methylene-bis(2,6-di-
tertbutylphenol)
or mixtures thereof
[0038] In some embodiments, the industrial gear lubricant additive package
of the
invention includes a nitrogen-containing dispersant, for example a hydrocarbyl
substituted nitrogen containing additive. Suitable hydrocarbyl substituted
nitrogen
containing additives include ashless dispersants and polymeric dispersants.
Ashless
dispersants are so-named because, as supplied, they do not contain metal and
thus do not
normally contribute to sulfated ash when added to a lubricant. However, they
may, of
course, interact with ambient metals once they are added to a lubricant which
includes
metal-containing species. Ashless dispersants are characterized by a polar
group
attached to a relatively high molecular weight hydrocarbon chain. Examples of
such
materials include succinimide dispersants, Mannich dispersants, and borated
derivatives
thereof
[0039] In some embodiments, the industrial gear lubricant additive
package of the
invention includes a sulfur-containing compound. Suitable sulfur-containing
compounds
include sulfurized olefins and polysulfides. The sulfurized olefin or
polysulfides may be
derived from isobutylene, butylene, propylene, ethylene, or some combination
thereof.
In some examples, the sulfur-containing compound is a sulfurized olefin
derived from
any of the natural oils or synthetic oils described above, or even some
combination
thereof For example, the sulfurized olefin may be derived from vegetable oil.
[0040] In some embodiments, the industrial gear additive packages
include one or
more phosphorous amine salts, but in amounts such that the additive package,
or in other
embodiments the resulting industrial gear lubricant compositions, contains no
more than
1.0 percent by weight of such materials, or even no more than 0.75 or 0.6
percent by
weight. In other embodiments, the industrial gear additive packages, or the
resulting
industrial gear lubricant compositions, are essentially free of or even
completely free of
phosphorous amine salts.
[0041] In some embodiments, component (b), the industrial gear lubricant
additive
package, comprises one or more antiwear additives and/or extreme pressure
agents, one
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or more rust and/or corrosion inhibitors, one or more foam inhibitors, one or
more
demulsifiers, or any combination thereof.
[0042] In some embodiments, the industrial gear additive packages, or
the resulting
industrial gear lubricant compositions, are essentially free of or even
completely free of
phosphorous amine salts, dispersants, or both.
[0043] In some embodiments, the industrial gear additive packages, or
the resulting
industrial gear lubricant compositions, include a demulsifier, a corrosion
inhibitor, a
friction modifier, or combination of two or more thereof. In some embodiments,
the
corrosion inhibitor includes a tolyltriazole. In still other embodiments, the
industrial
gear additive packages, or the resulting industrial gear lubricant
compositions, include
one or more sulfurized olefins or polysulfides; one or more phosphorus amine
salts; one
or more thiophosphate esters, one or more thiadiazoles, tolyltriazoles,
polyethers, and/or
alkenyl amines; one or more ester copolymers; one or more carboxylic esters;
one or
more succinimide dispersants, or any combination thereof.
[0044] The industrial gear additive package may be present in the overall
industrial
gear lubricant from 1 to 5 percent by weight, or in other embodiments from 1,
1.5, or
even 2 percent by weight up to 2, 3, 4, 5, 7 or even 10 percent by weight.
Amounts of
the industrial gear additive package that may be present in the industrial
gear concentrate
compositions of the invention are the corresponding amounts to the weight
percent
above; where the values are considered without the oil present (i.e., they may
be treated
as pbw values along with the actual amount of oil present).
The ftitly phosphite
[0045] The compositions of the invention include a fatty phosphite
present at no less
than 1.0 percent by weight of the overall lubricant composition.
[0046] Suitable phosphites include those having at least one hydrocarbyl
group with
4 or more, or 8 or more, or 12 or more, carbon atoms. Typical ranges for the
number of
carbon atoms on the hydrocarbyl group include 8 to 30, or 10 to 24, or 12 to
22, or 14 to
20, or 16 to 18. The phosphite may be a mono-hydrocarbyl substituted
phosphite, a di-
hydrocarbyl substituted phosphite, or a tri-hydrocarbyl substituted phosphite.
In one
embodiment, the phosphite is sulphur-free, i.e., the phosphite is not a
thiophosphite.
[0047] The phosphite having at least one hydrocarbyl group with 4 or
more carbon
atoms may be represented by the formulae:
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R7
R5-0 H C)
R5
0 or R6
wherein at least one of R5, R6 and R7 may be a hydrocarbyl group containing at
least 4
carbon atoms and the other may be hydrogen or a hydrocarbyl group. In one
embodiment, R5, R6 and R7 are all hydrocarbyl groups. The hydrocarbyl groups
may be
alkyl, cycloalkyl, aryl, acyclic or mixtures thereof. In the formula with all
three groups
R5, R6 and R7, the compound may be a tri-hydrocarbyl substituted phosphite
i.e., R5, R6
and R7 are all hydrocarbyl groups.
[0048] Alkyl groups may be linear or branched, typically linear, and
saturated or
unsaturated, typically saturated. Examples of alkyl groups for R5, R6 and R7
include
octyl, 2-ethylhexyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl,
pentadecyl,
hexadecyl, heptadecyl, octadecyl, octadecenyl, nonadecyl, eicosyl or mixtures
thereof
[0049] In some embodiments, the fatty phosphite component of the
invention, and/or
the composition overall, is essentially free of, or even completely free of
phosphoric acid
ester and/or amine salts thereof
[0050] In some embodiments, the fatty phosphite comprises an alkenyl
phosphite or
esters thereof, for example, esters of dimethyl hydrogen phosphite.
[0051] The fatty phosphite may be present in the overall industrial
gear lubricant
from 1.0 to 10.0 percent by weight, or in other embodiments from 1, 1.5, or
even 2
percent by weight up to 1.5, 1.9, 2, 3, 4, 5, 7 or even 10 percent by weight.
Amounts of
the industrial gear additive package that may be present in the industrial
gear concentrate
compositions of the invention are the corresponding amounts to the weight
percent
above; where the values are considered without the oil present (i.e., they may
be treated
as pbw values along with the actual amount of oil present).
[0052] In some embodiments, the ratio of the industrial gear additive
package
component (component (b)) relative to the fatty phosphite component (component
(a)),
on an oil free weight basis, is from 1:0.5 to 1:1.5. In still further
embodiments, this ratio
of components (b):(c) is 1:0.5 to 1:1.5, or 1:0.6 to 1:1.2, or 1:0.7 to 1:1.1,
or 1:0.8 to
1:1Ø
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Industrial Application
[0053] As noted above, the invention includes both industrial gear
lubricants and
industrial gear additive concentrates that may be used to make industrial gear
lubricants.
[0054] In the industrial gear lubricants of the invention: component
(a), the oil of
lubricating viscosity, may be present from 80, 85, 90, 95, 97 or even 97.5 or
98 percent
by weight oil up to 90, 95, 97, 97.5, or even 98 percent by weight; component
(b), the
industrial gear lubricant additive package, may be present from 1, 1.5, or
even 2 percent
by weight up to 2, 3, 4, 5, 7 or even 10 percent by weight; and component (c),
the fatty
phosphite, may be present from 1, 1.5, or even 2 percent by weight up to 1.5,
1.9, 2, 3, 4,
5, 7 or even 10 percent by weight.
[0055] In the industrial gear additive concentrates of the invention:
component (a),
the oil of lubricating viscosity, may be present from 1, 5, even 10 percent by
weight oil
up to 10, 20, 30, 40, or even 45 or 49 percent by weight; component (b), the
industrial
gear lubricant additive package, may be present from 20, 25, 25.5, 27.5, 30,
35, 45 or
even 45 percent by weight up to 45, 47.5, or even 49.5 percent by weight; and
component (c), the fatty phosphite, may be present from 25.5, 27.5, 30, 35, 45
or even 45
percent by weight up to 45, 47.5, or even 49.5 percent by weight
[0056] In some embodiments, the ratio of the industrial gear additive
package
component (component (b)) relative to the fatty phosphite component (component
(a)),
on an oil free weight basis, is from 1:0.5 to 1:1.5. In still further
embodiments, the ratio
of components (b):(c) is from 4:1 to 1:5, or from 2:1 to 1:5, or from 1:1 to
1:5, or from
1:0.5 to 1:1.5, or 1:0.6 to 1:1.2, or 1:0.7 to 1:1.1, or 1:0.8 to 1:1Ø These
ratios may
apply to the industrial gear lubricants of the invention and/or to the
industrial gear
additive concentrates of the invention.
[0057] The invention includes methods of making the industrial gear
lubricants
and/or the industrial gear additive concentrates described above. Such methods
include
mixing the described components together. No particular order or means of
addition is
believed to significantly impact the results.
[0058] The invention also includes a method of reducing the operating
temperature
of an industrial gearbox. The method includes the steps of: (I) adding to an
industrial
gear oil lubricant a fatty phosphite such that the lubricant contains at least
1.0 percent by
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weight fatty phosphite, and (II) operating the industrial gearbox while
supplying the
industrial gear oil lubricant to the industrial gearbox.
[0059] The method may also involve the addition of one of the
industrial gear
lubricants described herein to an industrial gearbox and then operating that
industrial
gearbox, which will result in a lower operating temperature in the industrial
gearbox
compared to the operating temperature the industrial gearbox would experience
if
operated with a similar industrial gear lubricant that does not include the
specified fatty
phosphite.
[0060] In these methods, in some embodiments at least a portion, if not
all of the
fatty phosphite is added to the industrial gear oil lubricant before the
lubricant is supplied
to the industrial gearbox. In other embodiments at least a portion, if not all
of the fatty
phosphite is added to the industrial gear oil lubricant after the lubricant is
supplied to the
industrial gearbox.
[0061] In some embodiments, the compositions of this invention are
essentially free
of, or even completely free of: copolymers comprising units derived from two
or more
methacrylic acid esters. More specifically, in some embodiments the
compositions of
this invention are essentially free of, or even completely free of: copolymers
comprising
units derived from (a) methacrylic acid esters containing from 9 to 25 carbon
atoms in
the ester group and (b) methacrylic acid esters containing from 7 to 12 carbon
atoms in
the ester group, said ester groups having 2-(C 1_4 alkyl)-substituents, and
optionally (c) at
least one monomer selected from the group consisting of methacrylic acid
esters
containing from 2 to 8 carbon atoms in the ester group atoms and which are
different
from methacrylic acid esters (a) and (b), vinyl aromatic compounds, and
nitrogen-
containing vinyl monomers with the proviso that no more than 60% by weight of
the
esters contain not more than 11 carbon atoms in the ester group.
[0062] In some embodiments, the compositions of this invention are
essentially free
of, or even completely free of: a nitrogen-containing ester derived from a
carboxy-
containing interpolymer having a reduced specific viscosity (RSV) of from
about 0.05 to
about 2, said interpolymer being derived from at least two monomers. More
specifically,
in some embodiments, the compositions of this invention are essentially free
of, or even
completely free of: a nitrogen-containing ester derived from a carboxy-
containing
interpolymer having a reduced specific viscosity (RSV) of from about 0.05 to
about 2,
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said interpolymer being derived from at least two monomers, (i) one of said
monomers
being at least one of an aliphatic olefin containing from 2 to about 30 carbon
atoms and a
vinyl aromatic monomer and (ii) the other of said monomers being at least one
alpha,
beta-unsaturated acylating agent, said ester being characterized by the
presence within its
polymeric structure of each of the following groups which arc derived from the
carboxy
groups of said interpolymer: (A) from about 20 to about 70 mole % based on
moles of
carboxyl groups in said interpolymer, of ester groups containing from about 13
to about
19 carbon atoms; (B) from about 80 to about 30 mole %, based on moles of
carboxyl
groups in said interpolymer, of ester groups containing from about 8 to about
12 carbon
atoms, optionally; (C) up to about 20 mole %, based on moles of carboxyl
groups in said
interpolymer, of ester groups containing from 2 to 7 carbon atoms; wherein
from about
93 to about 97% of the carboxy groups derived from the carboxy-containing
interpolymer are ester groups, the balance of the carboxy groups comprising
residual
carboxylic acid or anhydride groups which are then (D) reacted with at least
one amino
compound having an average of from 1 to about 1.1 primary or secondary amino
groups,
to convert from about 5 up to less than 50% of the carboxylic acid or
anhydride groups to
carbonyl-amino groups, with the unreacted carboxylic acid or anhydride groups
remaining as (E) residual carboxylic acid or anhydride groups.
Examples
[0063] The invention will be further illustrated by the following examples,
which set
forth particularly advantageous embodiments. While the examples are provided
to
illustrate the invention, they are not intended to limit it.
Example Set A
[0064] A set of examples of industrial gear lubricants is prepared in
group II base oil.
Each example uses the same base oil and the same industrial gear lubricant
additive
package. Some examples then include a supplemental additive in order to
evaluate the
impact the supplement has on the operating temperature seen when an industrial
gearbox
is operated with the prepared industrial gear lubricants. The examples are
summarized in
the table below. Different amounts of the different supplemental additives
used in the
examples reflect the different phosphorus levels of each material. Amounts
were
adjusted so the same amount of phosphorus was delivered when changing from one
supplemental additive to another.
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Table 1
Ex Ex Ex Ex Ex Ex Ex Ex Ex
A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9
Group 11 Base Oil' 98.0 97.0 96.25 95.5 96.25
95.5 96.42 95.74 95.43
IGO Add Pack2 2.0 2.0 2.0 2.0 2.0 2.0 2.0
2.0 2.0
C18 Phosphite3 1.0 1.75 2.5
C16-18 Phosphite4 1.75 2.5
C16-18 Phosphonate5 1.58 2.26
Phos acid amine salt 2.57
Gearbox Operating 149 144 144 141 149 139 146 145 147
Temperature ( C)7
Change from A-1
-- -5 -5 -8 0 -10 -3 -4 -2
Baseline ( C)7
1 ¨ All the examples in this set use a Group II ISO 150 base oil, which is a
mixture of a 600N RLOP base
oil and polyisobzitylene.
2 ¨ All the examples in this set use the same industrial gear oil additive
package which includes a
sulfurized olefin, a thiophosphate ester, a thiadiazole, a tolyltriazole, a
polyether, an alkenyl amine, an
ester copolymer, a carboxylic ester, and a succinimide dispersant.
3 The CI8 phosphite is a di-alkyl substituted phosphite with CI8 alkyl
groups.
4 ¨ The C16-18 phosphite is a di-alkyl substituted phosphite with C16-18 alkyl
groups.
5 ¨ The C16-18 phosphonate is a di-alkyl substituted phosphonate with C16-18
alkyl groups.
6 ¨ The phos acid amine salt is an amine salt of a C18 alkyl phosphoric acid.
7 ¨ Each example is tested by an internally developed procedure where "C"
profile gears are mounted in
a test rig, lubricated with the example industrial gear lubricant, operated
through a break-in period, and
then tested for two hours at 1750 rpm under a 300 Nm load. The temperature of
the gearbox is monitored
and the reported value is where the temperature stabilized during the test
period. A lower temperature
compared to the baseline indicates a reduced gearbox operation temperature.
These results have been
normalized for ambient temperature.
[0065] The results show that the industrial gear lubricants of the
present invention
provide a reduction in operating temperature in industrial gearboxes. The data
shows
this benefit is obtained using multiple fatty phosphites and that the level of
reduction
depends on the base medium used.
Example Set B
[0066] An additional set of examples of industrial gear lubricants is
prepared in
various other base oils. The examples are summarized in the table below.
17
Table 2
Ex Ex Ex Ex Ex Ex Ex Ex Ex
B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9
Synthetic Base Oil 98.0 97.0 96.25 95.5 95.5
Synthetic Base Oil 22 98.0 95.5
Synthetic Base Oil 33 96.0 94.5
IGO Add Pack4 2.0 2.0 2.0
2.0 2.0 2.0 2.0 4.0 4.0
C18 Phosphite5 1.0 1.75 2.5 2.5 1.5
C16-18 Phosphite6 2.5
Gearbox Operating
140 123 125 138 137 143 133 150 143
Temperature ( C)7
Change from A-1
-- -13 -15 -2 -3 -- -10 -- -7
Baseline ( C)7
1 ¨ Examples B-1, B-2, B-3, B-4, and B-5 use synthetic ISO 150 base oil which
is a mix of PAOs
2 ¨ Examples B-6 and B-7 use synthetic ISO 150 base oil which is a mix of PAOs
and an alkyl ester copolymer.
3¨ Examples B-8 and B-9 use synthetic ISO 320 base oil which is a mix of PAOs
and an alkyl ester copolymer.
4 ¨ All the examples in this set, except B-8 and B-9, use the same industrial
gear oil additive package used in Example
Set A. Examples B-8 and B-9 use a different industrial gear oil additive
package that contains the same components
as the package used in Example Set A but in different amounts.
5¨ The C18 phosphite is a di-alkyl substituted phosphite with C18 alkyl
groups.
6¨ The C16-18 phosphite is a di-alkyl substituted phosphite with C16-18 alkyl
groups.
7¨ Each example is tested by an internally developed procedure where "C"
profile gears are mounted in a test rig,
lubricated with the example industrial gear lubricant, operated through a
break-in period, and then tested for two
hours at 1750 rpm under a 300 Nm load. The temperature of the gearbox is
monitored and the reported value is
where the temperature stabilized during the test period. A lower temperature
compared to the baseline indicates a
reduced gearbox operation temperature.
[0067] The results show that the industrial gear lubricants of the present
invention provide a
reduction in operating temperature in industrial gearboxes. The data shows
this benefit is obtained
across multiple base oils as well as different industrial gear additive
packages.
[0068] Except in the Examples, or where otherwise indicated, all numerical
quantities in this
description specifying amounts, reaction conditions, molecular weights, number
of carbon atoms,
etc., are to be understood as modified by the word "about." Unless otherwise
indicated, all percent
and formulation values are on a weight basis. Unless otherwise indicated, all
molecular weights
are number average molecular weights. Unless otherwise indicated, each
chemical or composition
referred to herein should be interpreted as being a commercial grade material
which may contain
the isomers, by-products, derivatives, and other such materials which are
normally understood to
be
Date Recue/Date Received 2020-04-15
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present in the commercial grade. However, the amount of each chemical
component is
presented exclusive of any solvent or diluent, which may be customarily
present in the
commercial material, unless otherwise indicated. It is to be understood that
the upper
and lower amount, range, and ratio limits set forth herein may be
independently
combined. Similarly, the ranges and amounts for each element of the invention
can be
used together with ranges or amounts for any of the other elements. As used
herein, the
expression "consisting essentially of' permits the inclusion of substances
that do not
materially affect the basic and novel characteristics of the composition under
consider-
ation. All of the embodiments of the invention described herein are
contemplated from
and may be read from both an open-ended and inclusive view (i.e. using
"comprising of'
language) and a closed and exclusive view (i.e., using "consisting of'
language).
[0069] 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: (i) 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 a
ring); (ii) substituted hydrocarbon substituents, that is, substituents
containing non-
hydrocarbon groups which, in the context of this invention, do not alter the
predominantly hydrocarbon nature of the substituent (e.g., halo (especially
chloro and
fluoro), hydroxy, alkoxy, mercapto, alkylmercapto, nitro, nitroso, and
sulfoxy); (iii)
hetero substituents, that is, substituents which, while having a predominantly
hydrocarbon character, in the context of this invention, contain other than
carbon in a
ring or chain otherwise composed of carbon atoms and encompass substituents
such as
pyridyl, furyl, thienyl and imidazolyl. Heteroatoms include sulfur, oxygen,
and nitrogen.
In general, no more than two, or no more than one, non-hydrocarbon substituent
will be
present for every ten carbon atoms in the hydrocarbyl group; alternatively,
there may be
no non-hydrocarbon substituents in the hydrocarbyl group.
[0070] It is known that some of the materials described above may
interact in the
final formulation, so that the components of the final formulation may be
different from
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those that are initially added. For instance, metal ions (of, e.g., a
detergent) can migrate
to other acidic or anionic sites of other molecules. The products formed
thereby,
including the products formed upon employing the composition of the present
invention
in its intended use, may not be capable of easy description. Nevertheless, all
such
modifications and reaction products are included within the scope of the
present
invention; the present invention encompasses the composition prepared by
admixing the
components described above.
