FIELD OF THE INVENTION
[0001] The present invention relates to a lubricating oil.
BACKGROUND OF THE INVENTION
[0002] Polyoxyalkylene glycol derivatives are used as lubricating oils in various applications.
For example, water-soluble polyoxyalkylene glycol derivatives are used as hydraulic
oils, cutting oil, grinding oil, gear oil, etc., polymers of polyoxyalkylene glycol
(meth)acrylates are used as water-soluble lubricants (JP-A-56-47411), and compounds
obtained by esterifying alkylene oxide adducts of castor oil are used as metal-working
oils (JP-A-57-207699), while oil-soluble polyoxyalkylene glycol derivatives are used
as viscosity index improvers for mineral oils (JP-B-53-44196), a refrigerating machine
oil (JP-A-57-51795), etc. (The terms "JP-A" and "JP-B" as used herein mean an "unexamined
published Japanese patent application" and an "examined Japanese patent publication",
respectively.)
[0003] However, polymers of polyoxyalkylene glycol (meth)acrylates and derivatives of castor
oil are defective in that their performances change if they are used in the form of
an aqueous solution for a prolonged period of time, while oil-soluble polyoxyalkylene
glycols also have the problem that their applications are limited since not only they
are quite insoluble in water although quite soluble in mineral oils, but it is impossible
to emulsify mineral oils or the like in water.
SUMMARY OF THE INVENTION
[0004] It is, therefore, an object of the present invention to provide a lubricating oil
which can be used in any of an aqueous solution, oily solution, and water-oil emulsion
form.
[0005] The lubricating oil of the present invention comprises a copolymer of monomers comprising
as essential ingredients a compound represented by formula (1) and one of maleic anhydride,
maleic acid, a salt of maleic acid, and an ester of maleic acid

where Z represents a residue of a compound having from 2 to 8 hydroxyl groups; AO
represents one or more kinds of oxyalkylene groups each having from 2 to 18 carbon
atoms, provided that in the case of two or more kinds of oxyalkylene groups, the oxyalkylene
groups are linked to one another in either a block or a random arrangement; R represents
an alkenyl group having from 2 to 5 carbon atoms; R¹ represents a hydrocarbon or acyl
group having from 1 to 24 carbon atoms; and a≧0, b≧0, c≧0, ℓ is a positive integer,
and m and n independently are 0 or a positive integer, provided that ℓ + m + n = 2
to 8, n/(ℓ + m) ≦ 1/2, and aℓ + bm + cn = 1 to 1,000.
DETAILED DESCRIPTION OF THE INVENTION
[0006] Examples of the compound a residue of which is Z in formula (1) and which has from
2 to 8 hydroxyl groups include polyhydric phenols such as catechol, resorcin, hydroquinone,
and phloroglucin; polyhydric alcohols such as ethylene glycol, propylene glycol, butylene
glycol, dodecylene glycol, octadecylene glycol, neopentyl glycol, styrene glycol,
glycerol, diglycerol, polyglycerol, trimethylolethane, trimethylolpropane, 1,3,5-pentanetriol,
erythritol, pentaerythritol, dipentaerythritol, sorbitol, sorbitan, sorbide, a sorbitol-glycerol
condensate, adonitol, arabitol, xylitol, and mannitol; saccharides such as xylose,
arabinose, ribose, rhamnose, glucose, fructose, galactose, mannose, sorbose, cellobiose,
maltose, isomaltose, trehalose, sucrose, raffinose, gentianose, and melezitose; and
products of partial etherification or partial esterification of above compounds.
[0007] Examples of the oxyalkylene group having from 2 to 18 carbon atoms and represented
by AO include an oxyethylene group, an oxypropylene group, an oxybutylene group, an
oxytetramethylene group, an oxystyrene group, an oxydodecylene group, an oxytetradecylene
group, an oxyhexadecylene group, and an oxyoctadecylene group. Of these, oxyalkylene
groups having from 2 to 4 carbon atoms are particularly preferred.
[0008] Examples of the alkenyl group having from 2 to 5 carbon atoms and represented by
R include a vinyl group, an allyl group, a methallyl group, a 3-butenyl group, a 4-pentenyl
group, and a 3-methyl-3-butenyl group.
[0009] Examples of the hydrocarbon group having from 1 to 24 carbon atoms and represented
by R¹ include a methyl group, an ethyl group, a propyl group, an isopropyl group,
a butyl group, an isobutyl group, a tert-butyl group, a pentyl group, an isopentyl
group, a hexyl group, a heptyl group, a decyl group, an undecyl group, a dodecyl group,
an isotridecyl group, a tetradecyl group, a hexadecyl group, an isohexadecyl group,
an octadecyl group, an isooctadecyl group, an oleyl group, an octyldodecyl group,
a docosyl group, a decyltetradecyl group, a benzyl group, a cresyl group, a butylphenyl
group, a dibutylphenyl group, an octylphenyl group, a nonylphenyl group, a dodecylphenyl
group, a dioctylphenyl group, a dinonylphenyl group, a naphthyl group, and a styrenated
phenyl group. Examples of the acyl group represented by R¹ include those derived from
acetic acid, propionic acid, butyric acid, isobutyric acid, caprylic acid, pelargonic
acid, 2-ethylhexanoic acid, capric acid, undecylenic acid, lauric acid, myristic acid,
palmitic acid, margaric acid, stearic acid, arachic acid, behenic acid, palmitoleic
acid, oleic acid, linoleic acid, linolenic acid, erucic acid, isopalmitic acid, isostearic
acid, benzoic acid, hydroxybenzoic acid, cinnamic acid, and gallic acid.
[0010] Examples of the salt of maleic acid include alkali metal salts such as a lithium
salt, a sodium salt, a potassium salt; alkaline earth metal salts such as a magnesium
salt and calcium salt; an ammonium salt; and organic amine salts.
[0011] Examples of the organic amine salt include salts of aliphatic or aromatic monoamines
such as a methylamine salt, an ethylamine salt, a propylamine salt, a butylamine salt,
a pentylamine salt, a hexylamine salt, an octylamine salt, a 2-ethylhexylamine salt,
a decylamine salt, a dodecylamine salt, an isotridecylamine salt, a tetradecylamine
salt, a hexadecylamine salt, an isohexadecylamine salt, an octadecylamine salt, an
isooctadecylamine salt, an octyldodecylamine salt, a docosylamine salt, a decyltetradecylamine
salt, an oleylamine salt, a linolamine salt, a dimethylamine salt, a trimethylamine
salt, and an aniline salt; polyamine salts such as an ethylenediamine salt, a tetramethylenediamine
salt, a dodecylpropylenediamine salt, a tetradecylpropylenediamine salt, a hexadecylpropylenediamine
salt, an octadecylpropylenediamine salt, an oleylpropylenediamine salt, a diethylenetriamine
salt, a triethylenetetramine salt, a tetraethylenepentamine salt, and a pentaethylenehexamine
salt; alkanolamine salts such as a monoethanolamine salt, a diethanolamine salt, a
triethanolamine salt, a monoisopropanolamine salt, a diisopropanolamine salt, a triisopropanolamine
salt, salts of alkylene oxide adducts of these amines, and salts of alkylene oxide
adducts of mono- or diamines; and amino acid salts such as a lysine salt and an arginine
salt. Particularly preferred of these are alkali metal salts, an ammonium salt, and
alkanolamine salts.
[0012] Examples of the maleic acid ester include esters with alcohols such as methanol,
ethanol, allyl alcohol, methallyl alcohol, propanol, isopropanol, butanol, isobutanol,
tert-butanol, pentanol, isopentanol, hexanol, heptanol, 2-ethylhexanol, octanol,
nonanol, decanol, undecanol, dodecanol, isotridecanol, tetradecanol, hexadecanol,
isocetyl alcohol, octadecanol, isostearyl alcohol, oleyl alcohol, octyldodecanol,
docosanol, and decyltetradecanol, and with alkylene oxide adducts of these alcohols;
and maleic acid esters with alkylene oxide adducts of phenols such as phenol, cresol,
butylphenol, octylphenol, nonylphenol, dodecylphenol, catechol, resorcinol, hydroquinone,
and phloroglucinol. Examples of the maleic acid ester further include maleic acid
esters with: polyhydric alcohols such as ethylene glycol, propylene glycol, butylene
glycol, dodecylene glycol, octadecylene glycol, neopentyl glycol, styrene glycol,
glycerol, diglycerol, polyglycerol, trimethylolethane, trimethylol propane, 1,3,5-pentanetriol,
erythritol, pentaerythritol, dipentaerythritol, sorbitol, sorbitan, sorbide, a sorbitolglycerol
condensate, adonitol, arabitol, xylitol, and mannitol; saccharides such as xylose,
arabinose, ribose, rhamnose, glucose, fructose, galactose, mannose, sorbose, cellobiose,
maltose, isomaltose, trehalose, sucrose, raffinoise, gentianose, and melezitose; products
of partial etherification or partial esterification of the above polyhydric alcohols
and saccharides, or alkylene oxide adducts of the above polyhydric alcohols and saccarides;
alkylene oxide adducts of aliphatic or aromatic monoamines such as methylamine, ethylamine,
propylamine, butylamine, amylamine, hexylamine, octylamine, 2-ethylhexylamine, decylamine,
dodecylamine, isotridecylamine, tetradecylamine, hexadecylamine, isohexadecylamine,
octadecylamine, isooctadecylamine, octyldodecylamine, docosylamine, decyltetradecylamine,
oleylamine, linolamine, dimethylamine, trimethylamine, and aniline; alkylene oxide
adducts of polyamines such as ethylenediamine, tetramethylenediamine, dodecylpropylenediamine,
tetradecylpropylenediamine, hexadecylpropylenediamine, octadecylpropylenediamine,
oleylpropylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine,
and pentaethylenehexamine; and alkanolamines such as monoethanolamine, diethanolamine,
triethanolamine, mono isopropanolamine, diisopropanolamine, and triisopropanolamine,
and alkylene oxide adducts of these alkanolamines.
[0013] The copolymer employed in the present invention can be obtained by copolymerizing
the compound represented by formula (1) with maleic anhydride, maleic acid, a salt
of maleic acid, or an ester of maleic acid by use of a radical catalyst. However,
in the case of the copolymer with maleic acid or with a salt or an ester thereof,
it is convenient to obtain the copolymer through the hydrolysis, the hydrolysis and
subsequent neutralization or the esterification of a copolymer with maleic anhydride.
[0014] In the copolymerization of the compound represented by formula (1) with maleic anhydride,
maleic acid, a maleic acid salt, or a maleic acid ester, the ratio of the compound
of formula (1) to its comonomer is from 3:7 to 7:3 in terms of equivalent based on
polymerizable double bond, with the particularly preferred ratio being about 1:1.
In performing the copolymerization, other monomers may be added for copolymerization
with the above monomers, but the amount of such other monomers used is not more than
30 mole% based on the total amount of all the monomers.
[0015] Examples of such other monomers include acrylic acid, methacrylic acid, itaconic
acid, crotonic acid, salts of these acids with mono- or divalent metals, ammonium
salts of the above acids, organic amine salts of the above acids, and esters of the
above acids with alcohols having 1 to 24 carbon atoms, polyhydric alcohols, or with
polyoxyalkylene glycols. Examples of other monomers further include aromatic vinyl
compounds such as styrene and methylstyrene, halogenatd vinyl compounds such as vinyl
chloride and vinylidene chloride, olefins such as isobutylene and diisobutylene, vinyl
acetate, acrylonitrile, and acrylamide.
[0016] The weight-average molecular weight of the copolymer is generally from 1,000 to 2,000,000,
preferably from 3,000 to 500,000.
[0017] The number of carbon atoms in R is from 2 to 5, which is the proper range since the
carbon atom number affects the polymerizability of the compound of formula (1), with
too long R resulting in poor polymerizability.
[0018] When the number of R, which is shown by ℓ, is 1, a linear copolymer is formed, while
if the number is 2 or larger, a crosslinked copolymer is formed.
[0019] Symbol n may be in the range of from 0 to 2. If n is too large, an ester with an
acid is prone to be formed during the copolymerization reaction, so that the resulting
copolymer has a high molecular weight to show too high a viscosity and to be less
soluble in water and oils. For the above reason, n is preferably an integer that is
not so large. Therefore, with regard to the relationship among ℓ, m, and n, they should
satisfy the equation n/(ℓ + m) ≦ 1/2.
[0020] Symbols a, b, and c are a≧0, b≧0, and c≧0, and (aℓ + bm + cn) are from 1 to 1,000,
preferably from I to 300, more preferably from 1 to 100.
[0021] The copolymer employed in this invention can be made either hydrophilic or lipophilic
by varying the number of carbon atoms contained in AO in the compound of general formula
(1), the molar amount of AO in the compound, combination of AO with R¹, and combination
of the compound of formula (1) with maleic anhydride, maleic acid, a maleic acid salt,
or a maleic acid ester.
[0022] The copolymer for use in the lubricating oil of this invention include those with
various properties, such as a copolymer soluble in water but not in oils, a copolymer
soluble in oils but insoluble in water, and a copolymer is soluble in both water and
oils and emulsifying the both. Therefore, the lubricating oil of the present invention
can be used in many applications.
[0023] Although the copolymer employed in this invention can be used alone as a lubricant,
it may be used in combination with a mineral oil, an animal or vegetable fats and
oils, a synthetic ester oil, a silicone oil, water, ethylene glycol, propylene glycol,
glycerin, etc. In this case, the concentration of the copolymer is from 0.01 to 80%,
preferably from 0.1 to 50%, by weight. In the case where the copolymer is for use
in a refrigerating machine oil, the oil is required to be soluble in refrigerants
such as Freon R-11 (trichloromonofluoromethane), Freon R-12 (dichlorodifluoromethane),
Freon R-22 (monochlorodifluoromethane), Freon R-134a (1,1,1,2-tetrafluoroethane),
and Freon R-152a (1,1-difluoroethane). Hence, it is preferred to use the copolymer
in combination with a polyoxyalkylene glycol derivative having an average molecular
weight of 1,000 or less so as to be soluble in refrigerants. Examples of such polyoxyalkylene
glycol derivative include polypropylene glycol, mono- or dialkyl ethers thereof, polyoxypropylene
glycerol ether, a polyoxyethylenepolyoxypropylene glycol (having an oxyethylene group
content of 50 mole% or less), mono- or dialkyl ethers thereof, and a polyoxyethylenepolyoxypropylene
glycerol ether. If the polyoxyalkylene glycol derivative is an adduct of two or more
kinds of alkylene oxides, it may be either a block adduct or a random adduct.
[0024] The lubricating oil of this invention, which comprises a copolymer of monomers comprising
as essential ingredients the compound of formula (1) and one of maleic anhydride,
maleic acid, a maleic acid salt, and a maleic acid ester, shows an excellent lubricating
effect in any of an aqueous solution, emulsion, and oily solution form.
[0025] Therefore, the lubricating oil of this invention can be used in various lubricating
applications as a hydraulic fluid, gear oil, cutting oil, grinding oil, pressing oil,
rolling oil, drawing oil, sliding oil, etc.
[0026] The present invention is described below in further detail by way of Examples.
[0027] The following Table 1 shows the compositions (monomer proportions) and weight-average
molecular weights of the copolymers used in Examples 1 to 4 below.

EXAMPLE 1
[0028] Copolymers Nos. 1 to 5 shown in Table 1 were used as a base oil to prepare water-based
lubricants according to the following formulation. The thus-obtained lubricants were
evaluated for properties. For the purpose of comparison, lubricants prepared using
conventional polyoxyalkylene glycols as a base oil in place of the copolymers were
likewise subjected to a performance test.
Formulation |
Base oil |
18.00 wt% |
Propylene glycol |
37.00 wt% |
Ion-exchanged water |
40.00 wt% |
Oleic acid |
3.45 wt% |
Morpholine |
0.60 wt% |
Benzotriazole |
0.10 wt% |
Potassium hydroxide |
0.85 wt% |
Dimethylpolysiloxane (viscosity 350 cSt) |
100 ppm based on the sum of the above. |
[0029] The results of the performance test are shown in Table 2. Table 2 shows that the
lubricating oils of this invention employing the specific copolymers as base oils
have excellent performances.
Table 2
|
Copolymer |
Kinematic viscosity 40°C |
Viscosity index |
Pour point |
Foaming test JIS K-2518 24°C (mm) |
Soda 4-ball test JIS K-2519 220 rpm |
Timken wear test JIS K-2519 |
|
|
(cSt) |
VIE |
(°C) |
0 min. |
After 10 min. |
(kg/cm²) |
Maximum load (lbs) |
File strength (psi) |
Present Invention |
No. 1 |
47.2 |
189 |
-50.0 |
35 |
0 |
9.5 |
42 |
32,000 |
" |
No. 2 |
46.5 |
193 |
-50.0 |
25 |
0 |
10.5 |
47 |
33,000 |
" |
No. 3 |
46.3 |
192 |
-50.0 |
35 |
0 |
10.0 |
45 |
31,500 |
" |
No. 4 |
46.8 |
190 |
-50.0 |
30 |
0 |
10.0 |
45 |
30,000 |
" |
No. 5 |
45.9 |
188 |
-45.0 |
50 |
0 |
9.0 |
40 |
26,000 |
Comparative Example |
Polyoxyethylenepropylene glycol1) |
46.3 |
185 |
-45.0 |
80 |
0 |
8.5 |
36 |
18,400 |
" |
Polyethylene glycol2) |
44.8 |
187 |
-37.5 |
165 |
10 |
7.5 |
34 |
15,100 |
1) Weight-average molecular weight 11,000; a random adduct in whch oxyethylene group:
oxypropylene group = 75:25 (by weight). |
2) Weight-average molecular weight 20,000. |
EXAMPLE 2
[0030] Copolymers Nos. 3, 4, 6, 7, 8, and 9 shown in Table 1 were used to prepare cutting
oils according to the following formulation. The cutting oils thus obtained were subjected
to a cutting and working test (JIS B-4012) under the following conditions. The results
obtained are shown in Table 3.
Formulation |
Machine oil |
80.0 wt% |
Copolymer |
20.0 wt% |
Conditions for Cutting and Working Test |
Test specimen |
Free-machining stainless steel (SAE 51-416F) 40 ø x 300 (mm) |
Cutting tool |
SKH-4B (JIS G-4403) |
Cutting speed |
70 m/min. |
Working speed |
8 µ/min. |
Flow of cutting oil |
1 ℓ/min. |
[0031] For the purpose of comparison, polyoxyethylene (7 mole) monooleate was used in place
of the copolymers to perform the same test. The results obtained are shown in Table
3, in which the performance of each cutting oil is expressed in terms of the number
of test specimens that were able to be cut with one cutting tool. Table 3 shows that
the cutting oils of this invention employing the specific copolymers are highly effective.
Table 3
|
|
Number of specimens cut |
|
Copolymer |
Cutting tool 1 |
Cutting tool 2 |
Cutting tool 3 |
Present Invention |
No. 3 |
1385 |
1402 |
1377 |
" |
No. 4 |
1364 |
1388 |
1395 |
" |
No. 6 |
1433 |
1405 |
1414 |
" |
No. 7 |
1424 |
1413 |
1409 |
" |
No. 8 |
1410 |
1412 |
1396 |
" |
No. 9 |
1407 |
1400 |
1388 |
Comparative |
Polyoxyethylene (7 mole) monooleate |
820 |
831 |
819 |
EXAMPLE 3
[0032] Each of the cutting oils formulated in Example 2 was used to prepare an emulsion
consisting of 2% by weight of the cutting oil and 98% by weight of ion-exchanged water.
The emulsions thus obtained were subjected to a cutting test under the same conditions
as in Example 2. The results obtained are shown in Table 4. Table 4 shows that the
lubricants of this invention are excellent even in the form of a cutting oil of the
emulsion type.
Table 4
|
|
Number of specimens cut |
|
Copolymer |
Cutting tool 1 |
Cutting tool 2 |
Cutting tool 3 |
Present Invention |
No. 3 |
1291 |
1300 |
1284 |
" |
No. 4 |
1195 |
1253 |
1203 |
" |
No. 6 |
1312 |
1314 |
1336 |
" |
No. 7 |
1325 |
1306 |
1341 |
" |
No. 8 |
1342 |
1322 |
1318 |
" |
No. 9 |
1224 |
1275 |
1236 |
Comparative |
Polyoxyethylene (7 mole) monooleate |
706 |
698 |
721 |
EXAMPLE 4
[0033] With respect to the compositions shown in Table 5, a test for evaluating solubility
in Freon R-12 and Freon R-134a and a Timken wear test were conducted. The results
are shown in Table 6. In the solubility test, a composition shown in Table 5 and a
Freon were placed in a pressure vessel made of glass and visually examined as to whether
the mixture in the vessel became whitely turbid or not over a temperature range of
from -5 to 60°C. Compositions that resulted in white turbidity were judged to be insoluble.
[0034] Table 6 shows that the lubricating oils of this invention are excellent not only
in the solubility in refrigerants, Freons, but also in lubricating performance.
Table 6
|
No. |
Solubility test |
Timken wear test |
|
|
Freon R-12 |
Freon R-134a |
Maximum load (lbs) |
Film strength (psi) |
Present Invention |
10 |
soluble |
soluble |
56 |
36,000 |
" |
11 |
" |
" |
52 |
32,000 |
" |
12 |
" |
" |
50 |
30,000 |
" |
13 |
" |
" |
51 |
31,000 |
" |
14 |
" |
" |
52 |
32,000 |
" |
15 |
" |
" |
56 |
35,000 |
" |
16 |
" |
" |
53 |
32,000 |
" |
17 |
" |
" |
57 |
36,000 |
Comparative |
18 |
" |
" |
35 |
17,000 |
" |
19 |
" |
" |
35 |
17,000 |
" |
20 |
insoluble |
insoluble |
36 |
18,000 |
" |
21 |
" |
" |
37 |
19,000 |
[0035] While the invention has been described in detail and with reference to specific embodiments
thereof, it will be apparent to one skilled in the art that various changes and modifications
can be made therein without departing from the spirit and scope thereof.
1. A lubricating oil comprising a copolymer of monomers comprising as essential ingredients
a compound represented by formula (1) and one of maleic anhydride, maleic acid, a
salt of maleic acid, and an ester of maleic acid

where Z represents a residue of a compound having from 2 to 8 hydroxyl groups; AO
represents one or more kinds of oxyalkylene groups each having from 2 to 18 carbon
atoms, provided that in the case of two or more kinds of oxyalkylene groups, the oxyalkylene
groups are linked to one another in either a block or a random arrangement; R represents
an alkenyl group having from 2 to 5 carbon atoms; R¹ represents a hydrocarbon or acyl
group having from 1 to 24 carbon atoms; and a≧0, b≧0, c≧0, ℓ is a positive integer,
and m and n independently are 0 or a positive integer, provided that ℓ + m + n = 2
to 8, n/(ℓ + m) ≦ 1/2, and aℓ + bm + cn = 1 to 1,000.
2. A lubricating oil composition comprising: (a) a copolymer of a compound represented
by formula (1) with maleic anhydride, maleic acid, or a salt or ester of maleic acid

where Z represents a residue of a compound having from 2 to 8 hydroxyl groups; AO
represents one or more kinds of oxyalkylene groups each having from 2 to 18 carbon
atoms, provided that in the case of two or more kinds of oxyalkylene groups, the oxyalkylene
groups are linked to one another in either a block or a random arrangement; R represents
an alkenyl group having from 2 to 5 carbon atoms; R¹ represents a hydrocarbon or acyl
group having from 1 to 24 carbon atoms; and a≧0, b≧0, c≧0, ℓ is a positive integer,
and m and n independently are 0 or a positive integer, provided that ℓ + m + n = 2
to 8, n/(ℓ + m) ≦ 1/2, and aℓ + bm + cn = 1 to 1,000, and (b) a liquid medium.
3. A lubricating oil composition as claimed in claim 2, wherein said liquid medium
is selected from the group consisting of a mineral oil, an animal or vegetable fats
and oils, a synthetic ester oil, a silicone oil, water, ethylene glycol, propylene
glycol, glycerin, and a polyoxyalkylene glycol derivative.
4. A lubricating oil composition as claimed in claim 2, wherein said liquid medium
is an aqueous medium, an oily medium, or an emulsion consisting of an aqueous medium
and an oily medium.
5. A lubricating oil composition as claimed in claim 2 which is selected from the
group consisting of a hydraulic fluid, a gear oil, a cutting oil, a grinding oil,
a pressing oil, a rolling oil, a drawing oil, a sliding oil, and a refrigerating machine
oil.
6. A lubricating oil composition as claimed in claim 2, wherein the content of said
copolymer in the composition is from 0.01 to 80% by weight.