[0001] The subject of the present invention relates to a grafted polyolefin - polysuccinic
anhydride based ashless detergent dispersant (DD) additive that increases both viscosity
and viscosity index and which can be used advantageously for improving the properties
of lubricating oils and to the manufacturing process thereof.
The ashless, imide and ester type additives synthesised from alkenyl-succinic acid
derivatives have been used for more than thirty years for the improvement of the detergent
- dispersant properties of motor oils. Due to their polar and often basic character
these additives restrict the formation and surface deposition of the insoluble acidic
contaminations developed during the operation of the engine. Thus the life span of
the engine and the duration of applicability of oils are thereby significantly increased.
The various, so called, modified derivatives containing sulfur, boron, halogens, molybdenum,
copper atoms etc. exhibit good anticorrosion and antiwear properties beside their
DD effect, whereas those containing large molecular weight (
n > 2000) polymer side chains impart viscosity and viscosity index improving properties.
The alkenyl-succinic acid derivatives are generally mixed into the lubricating oils
together with other metal containing DD additives, with VI improvers, antioxidants,
anticorrosion and antiwear components, friction modifiers and foam inhibitors making
use of advantageous interactions.
In the last ten years, the manufacturers of oil additives directed their research
to improve the DD efficiency and the advantageous by-effects. According to results
of engine tests this can be achieved either by increasing the molecular weight of
the intermediates and the end product, or by the formation of polysuccinimides, polyesters,
polyester-amides etc. coupled through their polar groups (e.g. U.S. Patent No.4.234,435).
The synthesis of such additives is based on the recognition that in the first step
of the succinimide synthesis when the polyolefins and the maleic anhydride (MAH) are
reacted under specific conditions more than one MAH is coupled to the polyolefin molecule
or alternatively the so called olefin - MAH copolymers are formed. When the so formed
intermediates having more than two carboxylic groups are reacted with amines, polyamines,
alcohols, polyalcohols, alkanolamines or their mixtures of various compositions then
higher molecular weight polyimide, polyamide, polyester, polyester-amide type end
products are obtained (e.g. U.S. Patent No. 4.234,435).
Despite of their high DD effect, these ashless additives have only a low base number
due to the blocking of their basic amino and imino groups and compared to the traditional
succinimides they cause less damage to the fluor containing elastomer sealings of
the engines.
Owing to the higher DD effect and significant viscosity and viscosity index increasing
effect of these ashless additives they increase the performance level of the engine
oils and proved also to be useful in replacing a part of the traditional additives
used for improving flow properties reducing thereby the costs of motor oil production.
In the published procedures various methods are recommended for the synthesis of the
alkenyl-succinic anhydride type intermediates.
According to the US 4.234.435 and EP 0.208.560 patents the succinic anhydride (SA)
: polyisobutylene (PIB
n = 1300 - 5000) molar ratio can be increased over 1.05 by a one or multi step addition
of the chlorine catalyst and by raising the temperature up to 160 - 220 °C. A serious
disadvantage of this procedure is that hazardous chlorine is built in the polyolefin
molecule during the addition reaction, and referred to the additive, it remains in
the end product in a 0.001 - 0.5 weight percent.
Processes have also been reported where the polyisobutylene -MAH addition is achieved
at high temperature (over 190 °C) without the use of a catalyst. SA/PIB molar coupling
ratios higher than one have been achieved by using highly reactive (more than 70 percent
alpha olefin content) polyisobutylene raw material and a large excess of MAH. The
disadvantages of this method are the need for a more expensive raw material, the high
reaction temperature and the long reaction time (e.g. European Patent No.0.271.937.).
A low temperature procedure has been reported in the PCT.No. WO 90/03359 where the
polyisobutylene - maleic anhydride copolymer was prepared by using a radical initiator
and an aromatic or chlorinated hydrocarbon solvent. In the PIB-MAH copolymer of alternating
structure the average number of the PIB-MAH units varies from 1.1 to 20. When these
type of intermediates are used for the acylation reaction then the end products might
have a wide range of molar weight (
n = 10 000 - 150 000).
According to the EP 0400866 and EP 0002286 European Patents maleic anhydride and other
unsaturated comonomer or comonomers are grafted on the traditional viscosity index
improving ethylene-propylene copolymers of a number average molecular weight higher
than 10 000, preferably 100 000 - 200 000 by viscosity average molecular weight using
chlorinated hydrocarbons or other solvents in the presence of a radical initiator.
The copolymer so prepared was then reacted with amines, polyamines etc. whereby a
viscosity index improving additive with dispersant effect was obtained. For this purpose
the use of polymers of number average molecular weight below 30 000 as well as viscosity
average molecular weight below 100 000 is considered to be disadvantageous by the
above patents. According to the argument of these patents the hydrocarbon polymers
of number average molecular weight below 30 000 were difficult to handle due to their
unfavourable low temperature flow properties.
The methods published so far for the advantageous synthesis of the high molecular
weight polyfunctional succinimides have both technological and structural limitations.
According to the advantageous examples patented for the synthesis of the polyisobutylene
based succinimides the use of polyisobuthylens of average molecular weight
n = 1300 - 2500 can be considered as typical and beneficial. As it is well known, the
increasing of the average molecular weight of the polyisobutylene raw material above
the limit of
n = 2500 leads to considerable difficulties in the traditional technologies due to
the high viscosity of the raw material. In addition to this, experience shows that
due to the application of these raw materials a significant disadvantageous increase
of the cold viscosity and a decrease of the polar nitrogen containing groups per unit
mass of the additive and a concomitant decrease in the DD effect can be expected.
Succinimide derivatives obtained by grafting of ethylene - propylene copolymers have
been produced and applied to achieve an additional DD effect beside their main viscosity
and viscosity index increasing functions (EP 400866, EP 002286). For these kind of
additives the optimal viscosity and viscosity index increasing effect occurs in the
molecular weight range of
n = 15000 - 200 000. Successful application of olefin copolymers of a number average
molecular weight lower than 15 000 have not been reported probably due to a loss in
their flow property improving effect.
Surprisingly, however, it has been recognised that by making use of our invention
polyisobutylene based succinimide additives with significant DD, viscosity and viscosity
index increasing properties can be synthesised even in the molecular weight range
deemed unfavourable for both the polyisobutylene and the ethylene - propylene copolymers.
Our invention is based on the recognition that the mentioned drawbacks of the synthesis
based on grafting the hydrocarbon polymers limiting the average molecular weight of
the applicable raw material can be eliminated by the appropriate control of the grafting
reaction. The recommended procedure makes feasible the synthesis of such intermediates
from polyolefins of lower average molecular weight and in addition to this the intermediates
obtained from polyisobutylenes or especially from their high alpha-olefin containing
so called high reactivity homologous are suitable for the preparation of additives
of new molecular structure showing higher viscosity and viscosity index improving
effect, more advantageous antifriction effect and at the same time exhibit a better
compatibility with the sealing materials as compared to the other well known ashless
dispersants of molecular weight lower than 15 000.
The invention is related to an additive in a given case in an oil solution and the
preparation thereof used in lubricating oils of internal combustion engines containing
the imide - and/or ester and/or ester-amide derivative of the reaction product of
a polyolefin, preferably polyisobutylene and some unsaturated reactive dicarboxylic
acid and/or its anhydride, which comprises the reaction product of a polyolefin of
a number average molecular weight 800 - 30 000, preferably 800 - 15 000 and an unsaturated
reactive dicarboxylic acid and/or its anhydride, preferably maleic anhydride containing,
on average, 1.6 - 6.0 SA-derivative per polyolefin chain and the concentration of
molecules containing more than one SA - derivative is more than 25 weight percent
in the additive, and the polyolefin is grafted or reacted with a more reactive, low
molecular weight SA containing copolymer of low degree of polymerisation formed from
a comonomer suitable for copolymerization containing olefinic double bond or from
their mixture and from unsaturated reactive dicarboxylic acid and/or their anhydride,
preferably maleic anhydride using the molar ratio 1.2 - 5.5 : 0.1 - 3.5 : 1 = MAH
: comonomer : polyolefin, and the widening of the molecular weight distribution is
less than 70 percent, referred to the starting polyolefin, while the SA groups of
the grafted copolymer are reacted, in a 0.7 - 5.5 molar ratio, with compounds containing
at least bifunctional amine and/or hydroxyl groups.
Further on, the invention is related to the preparation of an additive applicable
to the above lubricating oil where the polyolefin, preferably polyisobutylene of an
average molecular weight higher than 800 is reacted with unsaturated dicarboxylic
acid and/or its anhydride, preferably maleic anhydride and with a more reactive, lower
molecular weight comonomer with olefinic double bond susceptible to copolymerization
or the mixtures of comonomers and/or with a copolymer of a low degree of polymerisation
prepared previously consisting of unsaturated dicarboxylic acid and/or its anhydride
and the comonomer and/or comonomers using the molar ratio 1.2 - 5.5 : 0.1 - 3.5 :
1 = maleic anhydride : comonomer : polyolefin, in a solvent or without a solvent preferably
at a solvent concentration of 15 - 75 weight percent with respect to the reaction
mixture, ensuring homogeneous phase, carried out in the presence of a radical initiator
in 5 - 25 weight percent referred to the unsaturated dicarboxylic acid or its anhydride,
at a pressure of 1 - 15*10² kPa and in an inert and/or hydrocarbon atmosphere, at
80 - 180 °C, in 1 - 16 hours while the concentration of the unreacted dicarboxylic
acid and/or anhydride and the comonomer and/or comonomers are kept below 5 weight
percent; the obtained intermediate in which the increase of the number average molecular
weight of the components measured by GPC is lower than 2.5 times of the molar weight
of the starting polyolefin, the widening of the molar weight distribution is less
than 70 percent referred to the starting polyolefin, is diluted with a base oil if
desired and in the presence of a filtering aid is treated and filtered, and is reacted
with compounds containing one or more at least bifunctional amine and/or hydroxyl
groups, while the molar ratio of the compounds carrying the succinic anhydride groups
and the amine and/or hydroxyl groups is 0.7 - 5.5 and the acylation is carried out
in the presence or absence of a catalyst in 0.01 - 2 weight percent, at a pressure
of 0.05 - 600 kPa, at 120 - 235 °C temperature, in 2 - 15 hours and the product, if
desired, is modified in a usual way, diluted and filtered.
Further on, the scope of the invention covers also the intermediate used for the production
of the additive and the preparation thereof. As polyolefins mostly homo and/or copolymers
of alpha olefins such as ethylene, propylene, butene-1, isobutylene or other olefins
and diolefins such as 1,3-butadiene are used with a number average molecular weight
between 800 and 30 000, preferably in the range of 800 and 15000. Polyisobutylenes
of a number average molecular weight between 1300 and 8000 were found to be the most
advantageous.
Today, these kind of polyisobutylenes, especially of average molecular weight above
5000, have some limited applications as viscosity and viscosity index improving additives.
Despite of their good thermal oxidation and shear stability their widespread application
is limited because they increase the low temperature viscosity of the oils more than
other type of viscosity index improving polymers. For this reason they cannot be applied
alone in the production of modern multi-grade motor oils. The method applied in our
invention dramatically decreases and in preferable cases eliminate these disadvantages
of the PIB based viscosity index improving additives. Grafting the polar side chain
into the PIB main chain results in a combined polymer structure having good thermal
and chemical stability as well as viscosity increasing effect characteristic of polyisobutylenes,
and at the same time the cold viscosity increasing effect is decreased significantly
due to a decrease in the solubility of the polymer.
As comonomers reactive, polar and apolar monomers of low molecular weight such as
ethylene, propylene, butene-1, 1,3-butadiene, isobutylene, C₅₋₂₀ alpha olefins, styrene,
acrylic acid, methacrylic acid, acrylates and methacrylates prepared from alcohols
of C₁₋₂₀, acrylonitrile or their mixtures have been applied.
The polyolefin - polysuccinic acid derivatives prepared from polyolefin, preferably
from polyisobutylene unsaturated dicarboxylic acid and/or its anhydride and from comonomer
or from comonomer mixture having the general formula I. General formula (I).

where:
- R
- is a polyolefin group, preferably polyisobutylene (

= 800 to 30 000, preferably 800 - 15 000),
- n
- is an integer from 1 to 4, preferably 1,
- m
- is an integer from 0 to 5, preferably 1,
- p
- is an integer from 1 to 15, preferably from 2 to 6.
- Y
- means:

and/or a group containing less than 30 carbon atoms, formed from an other olefin or
diolefin or a mixture thereof,
X stands for hydrogen or a saturated or unsaturated group formed from Y group, and
R₁ and R₂ stand for hydrogen or C₁₋₂₀ alkyl group.
[0002] Those derivatives are the most suitable where the number of the succinic anhydride
(SA) groups linked to one polyolefin molecule is between 1.6 and 6 on average, preferably
between 1.8 and 4 on average, and the concentration of the molecules containing more
than one SA group is at least 25 weight percent, the concentration of the free maleic
acid is less than 0.3 weight percent and the increase of the number average molecular
weight of the components determined by GPC is smaller than 2.5 times the molar weight
of the starting polyolefin. The intermediate consisting of the above long apolar polyolefin
chain and a shorter, strongly polar, random or alternating copolymer chain is especially
suitable for the preparation of the imide and/or ester and/or amide and/or ester-amide
derivatives of great dispersing effect, where the derivatives occurring in one polyolefin
chain could be identical or different.
It is also ensured by the multifunctional usually polar chain terminating groups that
by using appropriate at least bifunctional basic reagents in the acylation reaction
additives of chain like polymers are formed under advantageous conditions beside the
usual crosslinked polymers.
The additive prepared according to this invention could contain components of various
average molecular weight in which the average number of molecules linked by the carboxyl
groups is between 2 and 100.
The additive prepared according to this invention exists advantageously in an oil
solution. In this oil solution the concentration of the oil is at least 10 weight
percent, preferably between 30 and 80 weight percent. For this purpose any type of
refined oil, lubricating oil or base oil may be used.
In the actual preparation procedure maleic anhydride and comonomer or comonomers containing
olefinic double bond or their copolymers are grafted to the starting polyolefins.
During the reaction the double bonds of the maleic anhydride and the comonomer or
the comonomers are activated by a radical initiator and due to the consecutive coupling
to the polyolefins and /or due to the coupling of the random or alternating copolymers
formed from the maleic anhydride and a comonomer a polymer chain is developed containing
several SA groups (general formula I.).
The first step of the synthesis of the additive i.e. the reaction of the polyolefin
and the unsaturated dicarboxylic acid and/or its anhydride, preferably maleic anhydride
and comonomer or comonomers is performed in a homogeneous solution at an energetically
favourable low temperature, with the suitable choice of the weight ratio corresponding
to the molar ratio of the reactants of various reactivity, under circumstances unfavourable
for the multiple coupling of the polyolefin, occasionally in the presence of compounds
controlling the structure of side chain containing polar groups.
The reaction of the polyolefin and the unsaturated dicarboxylic acid and/or its anhydride
preferably maleic anhydride and the comonomer or the comonomers was carried out in
a solvent containing components also within the boiling range of 110 - 250 °C and
in which the reactants and the intermediates were readily dissolved at a concentration
of 20 - 75 weight percent, preferably 35 - 60 weight percent with respect to the reaction
mixture, in the temperature range 80 - 180 °C, preferably between 120 - 160 °C, within
a reaction period of 1 - 16 hours, using 1.2 - 5.5 : 0.1 - 3.5 : 1 maleic anhydride
: comonomer : polyolefin molar ratio, and applying 5 - 25 weight percent peroxide,
with respect to the amount of maleic anhydride, or other type of initiator such as
azobisisobutyronitrile or cumene hydroperoxide or if desired, compounds or their mixtures
controlling the incorporation ratios of the monomers in 0.01 - 5 weight percent, with
respect to the amount of the maleic anhydride, at a pressure of 1 - 15x10² kPa, preferably
at 1 - 5x10² kPa, in an inert atmosphere such as nitrogen and/or hydrocarbon gas.
It has been found that high SA/polyolefin average molar ratio can be achieved, while
the formation of the oil insoluble by-product is kept at a minimum level, if such
a solvent or the mixture of solvents is used wherein the fraction of components having
a boiling point below 250 °C is at least 3 weight percent. In order to decrease the
concentration of by-products insoluble in oil the concentration of the comonomer or
the comonomers should be less than 5 weight percent in the reaction mixture during
the addition. These conditions can be met if the rates of addition of the MAH, the
comonomer or the comonomers and the radical initiator decomposing in the temperature
range 80 - 180 °C are set to appropriate values. For this purpose the radical initiator,
the MAH as well as the comonomer or the comonomers are added in two or more portions
or in a continuous way.
As initiator, organic peroxides, hydroperoxides or azo- compounds such as dibenzoyl
peroxide, di-tert-butyl peroxide, azobis-isobutyro dinitrile, azodicarboxylic amide,
or their mixture can be used.
Compounds used for inhibiting undesirable side reactions, such as e.g. decarboxylation,
resin formation, or for controlling the MAH : comonomer incorporation ratio could
be carboxylic acids with 1 - 20 carbon number, dicarboxylic acids or anhydrides, hydroxycarboxylic
acids, ketones, ethers, esters, alcohols, water or the mixtures of these and their
derivatives. Isobutyl alcohol, isopropyl alcohol, succinic monobutyl ester can be
applied advantageously. If desired, such additives are applied in a concentration
of 0.01 - 5 weight percent with respect to the amount of the maleic anhydride. During
the decomposition of these compounds or the radical initiators highly reactive species
may be formed that may participate in the addition and polymerisation reactions occurring
in the reaction mixture.
The reaction products have been identified by their ¹³C and ¹H NMR spectra using deuterated
chloroform as solvent. It has been pointed out that under the experimental circumstances
applied in this invention the monomers added to the reaction mixture are mostly coupled
to the α-double bond of the polyisobutylenes. This has been proved by the disappearance
of the ¹³C peaks at 114.5 and 143.6 ppm characteristic of the terminal double bonds
of the polyisobutylenes, as well as the peaks of the ¹H spectra at 4.3 ppm and of
the ¹³C peaks at 136.6 ppm typical of the maleic anhydride and of the peaks characteristic
of the double bonds of the comonomers. Experiments with maleic anhydride enriched
in ¹³C isotope proved the existence of bonds characteristic of the built in comonomer
groups forming the grafted copolymer chains.
From the colourless - light brown intermediate prepared according to this invention
the solvent can be recovered by stripping out the components of a boiling point below
250 °C and the remaining heavier part, if desired, can be diluted in 20 - 60 weight
percent by refined oil, preferably by a refined oil having viscosity of 2 - 15 mm²/s,
at 100 °C.
The solution of the intermediate can be filtered without or with the addition of a
filtration aid or filtration improving material in a 0.5 - 5 weight percent concentration.
If the intermediate prepared according to this invention is reacted in the second
so called acylation step with polyamines, polyalcohols, alcanol amines containing
at least two reactive groups and/or their mixtures and/or their derivatives by using
hydrocarbon and/or refined oil as solvent at 120 - 235 °C, in inert e.g. nitrogen
gas atmosphere at a pressure of 0.05 - 6x10² kPa, in the presence of a catalyst in
a 0.01 - 2 weight percent concentration then a polysuccinimide and/or polyamide and/or
polyester and/or polyester-amide based mixture of the additive is obtained (such as
the polysuccinimide, general formula II.) where one or more components can be formed
with significantly different molecular weights depending on the reagents and molar
ratios used. General formula II.

where:
R is a polyolefin, preferably polyisobutylene group (molar weight = 800 to 30 000,
preferably 800 - 15 000),
U stands for an at least bifunctional group derived from polyalkylene - polyamines
and/or polyalcohols and/or polyalkanolamines or other usual compounds containing basic
nitrogen and/or hydroxyl group,
Y' means a:

group, or an other bifunctional group formed from an olefin or diolefin or a mixture
thereof, or a monofunctional group obtained by transformation of the groups defined
above,
Z means hydrogen or -NH-(CH₂CH₂NH)-H or -OR₁ group,
R₁ and R₂ stands for C₁₋₂₀ alkyl group each,
a,b,c,d,e and f are integers from 0 to 5, preferably 1,
q,m,n are 0, 1 or an integer greater than 1, with the proviso that:
the sum of m and n is an integer greater than 1, the proportion of molecules containing
groups (II.b) and/or (II.c) in the product is higher than 25 % by weight and the compounds
of structures (II.a), (II.b) and (II.c) can be interconnected in an optional sequence.
[0003] The important feature of the additive prepared according to this invention is due
to the new structure of the intermediate. In this intermediate the presumably reactive
SA and other groups are closely located at the end of the long polyolefin chain. Consequently,
the growing of the macromolecule by multiple or chain like coupling is not hindered
sterically, as in the case of other intermediates where the SA groups are randomly
located either at the end or in between the polyolefin chains.
As a multifunctional polyamine component e.g. ethylene- diamine, diethylenetriamine,
triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, cyclic polyamine
e.g. piperazine, diethyleneamino piperazine or the mixtures of these; as polyalcohol
e.g. ethylene glycol, diethylene glycol, triethylene glycol, glycerol, trimethylolpropane
or pentaerythritol; as amino-alcohol e.g. ethanolamine, diethanolamine, triethanolamine,
or the mixtures and derivatives of these can be used.
Since in the additive the mole fraction of the various polymers of different molar
weights can be altered in a wide range the need to prepare different motor oils is
met easily by a slight modification of the preparation procedure.
According to our experience, especially those additive compositions proved to be advantageous
where, in terms of weight percentage, the higher molar weight / lower molar weight
ratio was in the 0.01 - 5 range.
The average molecular weight of the lower average molecular weight polymer is less
than six times the number average molar weight of the polyolefin used as raw material.
The experimental circumstances of the acylation have to be chosen in such a way that
promote the formation of multiple couplings in the amide, imide and ester formation
condensation reactions, i.e. that result in compounds characterised by polyamide,
polyimide and polyester structure or by their combination. This can be achieved by
keeping the molar ratio of the succinic anhydride group of the intermediate and the
component to be acylated in the 0.7 - 5.5 : 1 range, preferably in the 1.7 - 4.5 :
1 range.
In order to ensure the required level of conversion in the acylation a 2 - 15 hour
reaction period and, if desired, the usual acidic or basic catalysts were used in
a 0.1 - 2 weight percent concentration range.
As a catalyst, acidic or basic compounds such as petroleum sulfonic acid, p-toluenesulfonic
acid, sulfuric acid, potassium hydroxide, triethanolamine, ethanolamine or ion exchange
resin, preferably in hydrogen ion form can be used in the acylation reaction.
In the polyester formation, which is one possible version of the acylation, the petroleum
sulfonic acid can be used especially advantageously which so far has been suggested
as a catalyst only in the preparation of low molecular weight (
n < 3500) alkenyl succinic esters (Hungarian Patent No. 205.778).
After the acylation reaction the non-reacted acid can be removed, if this is needed.
In order to promote other preferential by-effects such as the anticorrosion or anti-wear,
antioxidant effect a structure modifying step can be applied as a finishing one. In
this process a modifying compound is added in a 0.1 - 8 weight percent concentration
referred to the reaction mixture, which is then stirred for 0.5 - 10 hours, at 80
- 230 °C temperature, in inert atmosphere.
For modification the usual modifying chemicals can be applied, such as sulfur, active
sulfur containing compounds, phosphorus pentasulfide, boric acid or its derivative,
zinc containing compounds like zinc dialkyldithiophosphate, copper compounds including
organic copper salts or complexes, molybdenum dioxide, organic acids e.g. fatty acids,
glycolic acids, malic acid, fumaric acid, amides, alkenyl succinimide, their mixture
or their derivatives.
After the completion of the acylation and the optional modifying reactions the volatile
components can be stripped off from the reaction mixture in vacuum, at 160 - 210 °C,
the reaction product is then diluted by refined oil, and if desired, it can be filtered
without or with the use of filtration aids.
The various components of different average molecular weight of the end product exhibit
characteristic differences, the additives containing the lower molecular weight components
in a higher concentration have a higher acid neutralising capacity and deposition
removing effect, whereas the products containing the higher molecular weight components
in a higher concentration have a significant dispersion stabilising, viscosity and
viscosity index increasing as well as an anti-wear effect.
In the products described herein the components are characterised by their number
average molecular weight calculated as follows:

where
n is the number average molecular weight,
n
i is the mole number of the i-th polymer molecule,
M
i is the molar weight of the i-th polymer molecule,
i is 1,2,... positive integer.
The degree of polydispersity characterising the molecular weight distribution is the
ratio of the weight average and number average molecular weights. The weight average
molecular weight is calculated by the following equation:

where
w is the weight average molecular weight, the other symbols have the same meaning as
above. Polydispersity is calculated by the following equation:

The widening of the molecular weight distribution (Δα) is:

where α
PIB is the polydispersity of the polyolefin raw material and α is the polydispersity
of the reaction product.
The invention is illustrated by the following non-limiting examples.
Example "A"
[0004] In a 3 dm³ pressure proof, stirred tank reactor equipped with thermometer, inert
gas supply and a cooler on the top connected to a condensate collecting vessel 1125
g (0.5 mole) polyisobutylene (
n = 2250) and 1450 g xylene is weighed, the mixture is heated to 76 ± 4 °C in inert
atmosphere and under stirring, 98.6 g (1 mole) maleic anhydride, and at a rate of
0.7 g/h 2.8 g dibenzoyl peroxide are added and altogether 28 g isobutylene in four
portions, 7 g each. After the completion of additions the reaction mixture is stirred
for an hour under the above conditions. The xylene and other unreacted lighter components
can be removed by distillation carried out at 140 °C, at 15 kPa pressure, for 1.5
hours. 1200 g refined lubricating oil (viscosity 3.5 mm²/s at 100 °C, viscosity index
95, pour point -22 °C) is added to the intermediate. After homogenization at 135 -
150°C and clarification the mixture is filtered in the presence of 3.5 weight percent
filtration aid. The acid number of the yellow - brown, viscous, oily intermediate
is 43.0 mg KOH/g, its maleic anhydride content is 1.5 mg/g and it contains 1.7 succinic
anhydride group on the average referred to a PIB molecule. The SA/PIB succination
ratio was calculated by the following equation:

where
SR = SA/PIB succination ratio,
E = acid number of the intermediate (mg KOH/g),
nPIB = number average molar weight of the PIB.
Example "B"
[0005] The reaction vessel described in Example "A" is charged with 1125 g (0.5 mole) polyisobutylene
of a number average molar weight
n = 2250, 950 g SAE-30 base oil (viscosity 9.5 mm²/s at 100 °C) and 110 g of MOL Rt.
solvent of high aromatic content (having the trade name AROMATOL) and mixed. The mixture
is stirred at atmospheric pressure in inert atmosphere, at 135 ± 6 °C and in 8 equal
portions 118.3 g MAH, 76 g octylmethacrylate and 9.6 g di-tert-butyl peroxide are
added to it in 4 hours. The reaction mixture is then stirred for further 6 hours and
the AROMATOL and the other lighter components are boiled off at 155 °C, and 12 kPa
pressure. To the intermediate 250 g SN-150/A (MOL Rt.) refined oil is added at 120
°C. The so obtained intermediate is first clarified with 2 weight percent filtration
aid and in the presence of 1 weight percent of a filtration improving material it
is filtered at 110 °C. The acid number of the diluted and filtered intermediate is
39.7 mg KOH/g, its maleic anhydride content is 2.8 mg/g and it contains 1.6 succinic
anhydride group on average referred to a PIB molecule. The increase in the average
molecular weight is less than 60 percent and the fraction of the compounds containing
more than one succinic anhydride group per molecule is more than 55 percent.
Example "C"
[0006] Into the reaction vessel described in Example "A" 1200 g (0.15 mole) polyisobutylene
(
n = 8000), and 500 g xylene were weighted and mixed. The mixture was then heated to
115 °C and in six equal portions, in 3 hours 59.2 g (0.6 mole) maleic anhydride, 12.0
g azobisisobutyronitrile and 24.0 g styrene were added. Following the additions the
reaction mixture was heated up to 180 °C and was stirred for a further 6 hours. The
unreacted maleic anhydride was removed at 195 °C and 10 kPa pressure, the product
was then mixed with 1150 g refined lubricating oil mentioned in Example "A" and the
obtained mixture was filtered in the presence of 3 weight percent filtration aid.
The acid number of the filtered and diluted intermediate is 23.9 mg KOH/g, its maleic
anhydride content is 1.3 mg/g and it contains 3.3 succinic anhydride group, on average,
referred to a PIB molecule. The increase in the average molecular weight and the widening
of the molar weight distribution is less than 20 percent and the fraction of the compounds
containing more than one SA group per molecule is 42 weight percent.
Example "D"
[0007] Into the reaction vessel described in Example "A" 1200 g (0.5 mole) polypropylene
and a 9 : 1 weight ratio mixture of an SN 150/A base oil (commercial product of the
MOL Rt.) and kerosine were added. The mixture was heated to 80 ± 4 °C and under stirring
98.6 g (1 mole) maleic anhydride and 4.2 g di-benzoyl peroxide were added, the mixture
was stirred for 2 hours and the temperature was raised to 160 °C and the following
components were added to it: 33 g isobutylene; as initiator 11.4 g di-tert-butyl peroxide;
in 2 - 2 equal fractions per hour 43.3 g maleic anhydride, 6.5 g succinic monobutyl
ester; 33 g styrene and within 6 hours in 5 equal fractions 88.7 g maleic anhydride.
The unreacted, lighter components were removed at 200 °C and at 10 kPa pressure during
one and half hour. The product was then diluted with 1060 g of the base oil mentioned
in Example "B" and the obtained mixture was filtered in the presence of 4 weight percent
filtration aid, the acid number of the filtered and diluted intermediate was 60.1mg
KOH/g, its maleic anhydride content was 2.1 mg/g, its average SA : PIB succination
ratio was 2.4, the fraction of the components containing more than one SA group per
molecule was 64 percent, the increase in the average molecular weight was less than
60 percent, and the measured widening of the molar weight distribution was 68 percent.
Example "E"
[0008] Into the reaction vessel described in Example "A" 0.08 mole polyisobutylene (
n = 15000) 600 g xylene, 0.4 g cumene hydroperoxide and a 1 : 1 weight ratio mixture
of fumaric acid : maleic anhydride mixture were added, the mixture was stirred and
heated to 180 ± 5 °C, in inert atmosphere at 6 bar for 2.5 hours. The reaction mixture
was then cooled down to 150 ± 4 °C and under stirring 9 g acrylic acid and 1.8 g di-tert-butyl
peroxide as well as 12.8 g of the above acid mixture were added in 6 equal fractions
in 6 hours in such a way that before each addition of the acrylic acid 0.5 - 0.5 g
isobutyl alcohol was also added to the mixture.
After the distillation carried out for two hours at 165 °C and 15 kPa pressure, 1000
g oil characterised in Example "A", 2 - 2 percent filtration aid and filtration improving
material were added and was filtered. The acid number of the filtered and diluted
intermediate was 9.3 mg KOH/g, its maleic anhydride content was 1.7 percentage, its
average dicarboxylic acid - polyisobutylene coupling ratio was 2.3, the fraction of
the compounds containing more than one group originating from the dicarboxylic acid
was 47 percent, the increase in the average molecular weight and in the widening of
the molar weight distribution were less than 10 percent.
Example "F"
[0009] Into the reaction vessel described in Example "A" 500 g xylene saturated with water
and 28.5 g isobutylene were weighed and under stirring the mixture was heated to 130
± 5 °C in 2 hours, 0.75 mole (73.95 g) maleic anhydride and under continuous feed
14 g di-tert-butyl peroxide initiator was added, at 130 °C, to this reaction mixture
3 g succinic monobutyl ester were added in drops in half an hour, after about 0.25
hours 98.6 g maleic anhydride, 60 g styrene and 27 g di-tert-butyl peroxide initiator
were added in 4-4, and the latter in 6 equal fractions. Before the addition of the
last two fractions of the initiator 0.5 mole poly-isobutylene (
n = 2250) and 0.5 mole (43.3 g) maleic anhydride were added to the reaction mixture
which was then heated to 140 ± 5 °C and stirred for 1 hour. The unreacted, lighter
components of the mixture were removed by boiling for 1.5 hours at 175 °C and at 15
kPa pressure. The product so obtained was then diluted with 1200 g of the base oil
mentioned in Example "B" and was filtered in the presence of 2 weight percent filtration
improving material. The saponification number of the filtered and diluted intermediate
was 78.8 mg KOH/g, its maleic anhydride content was 1.9 mg KOH/g, its average SA :
PIB succination ratio was 3.1, the increase of the average molecular weight was less
than 30 percent, the widening of the molar weight distribution was 40 percent, the
fraction of the components containing more than one succinic anhydride group per molecule
was 65 percent.
Example " G "
[0010] Into the reaction vessel described in Example "A" 800 g SN 150/A base oil and 200
g xylene saturated with water were weighed and through this mixture 10 g " C₄ - fraction"
(product of naphtha pyrolysis, commercial product of the TVK Rt.) was bubbled through
and under stirring the mixture was heated to 90 ± 3 °C with a rate of 50°C/hour and
in 2 hours, 0.5 mole (49.3 g) maleic anhydride and 12 g dibenzoyl peroxide were added
in 3 - 3 equal portions, the temperature of the reaction mixture was then raised to
140 ± 5°C and in 4 hours 70 g styrene, 147.9 g (15 mole) maleic anhydride and 14 g
di-tert-butyl peroxide were added in a continuous way. To the oily xylene solution
of the low molecular weight copolymer 1125 g (0.5 mole) poly-isobutylene was added
and the reaction mixture was then heated to 140 ± 5 °C and under continuous stirring
for 1 hour 10 g di-tert-butyl peroxide was added, the mixture was then stirred for
a further 1.5 hours.
The unreacted, lighter components of the mixture were removed by boiling as in Example
"A" and the obtained intermediate diluted further by 300g SN 150/A oil was suitable
for further use without filtering and further processing. Its acid number was 72.4
mg KOH/g, maleic anhydride content was 1.8, its average SA : PIB succination ratio
was 3.3, the increase of the average molecular weight was less than 35 percent, the
widening of the molar weight distribution was 45 percent, the fraction of the components
containing more than one succinic anhydride group per molecule was 73 percent.
Example " H " (Reference)
[0011] Into the reaction vessel described in Example "A" 1125 g (0.5 mole) polyisobutylene
and 500 g xylene were weighed. The mixture was heated to 135 ± 5 °C , and in inert
atmosphere, under stirring, in 5 equal fractions 111.0 g (1.1 mole) maleic anhydride
and in 7 equal fractions 9 g di-tert-butyl peroxide initiator were added.
The lighter components of the mixture were removed as in Example " A " and the obtained
intermediate was diluted by 1300 g of the oil mentioned in Example " B " , its acid
number after clarification and filtration was 31.6 mg KOH/g, its free maleic anhydride
content was 3.2 mg/g, the increase of its average molecular weight was less than 15
percent, the widening of the molar weight distribution was 45 percent, the average
SA : PIB molar ratio was 1.3 the fraction of the components containing more than one
succinic anhydride group per molecule was 35 percent.
Example " I "
[0012] Into the reaction vessel described in Example "A" 950 g (1 mole) polyisobutylene
and under stirring in inert atmosphere at 180 ± 10 °C, 270 g of an isobutylene - styrene
mixture (weight ratio 4 : 5), in 5 hours, in 5 equal fractions 246.5 g (2.5 mole)
maleic anhydride and in 7 hours 28 g di-tert-butyl peroxide were added. After the
first hour of the reaction but before all the maleic anhydride has been added 1 -
1 g of isopropyl alcohol was also added in drops to the reaction mixture. The lighter
unreacted components of the mixture were removed as in Example " B " and the obtained
intermediate was diluted by 1300 g of the base oil mentioned in Example " B ". Its
acid number after clarification and filtration again according to Example " B " was
87.6 mg /g, its free maleic anhydride content was 3.0 mg/g, the average SA : PIB succination
ratio was 1.5; the increase of its average molecular weight was 60 percent, the widening
of the molar weight distribution was less than 68 percent, the fraction of the components
containing more than one succinic anhydride group per molecule was 47 percent.
Example " J " (Reference)
[0013] Into the reaction vessel described in Example "A" 1300 g (1 mole) polyisobutylene
and 350 g xylene were weighed and under stirring the mixture in inert atmosphere at
atmospheric pressure it was heated to 145 °C and in 6 hours, 197.2 g (2 mole) maleic
anhydride as well as 11.9 g cumene hydroperoxide and 6.8 g di-tert-butyl peroxide
were added in 4 and 7 fractions. The unreacted, lighter components of the mixture
were removed by boiling for 1 hour at 150 °C and at 15 kPa pressure. The mixture of
the intermediate so obtained was then diluted with 1150 g of the oil mentioned in
Example "A" and was filtered in the presence of 3 weight percent filtration improving
material. The saponification number of the filtered and diluted intermediate was 70.3
mg KOH/g, its maleic anhydride content was 2.5 mg/g, its average number of the succinic
anhydride groups linked to one PIB molecule was 1.6. The fraction of the components
containing more than 3 succinic anhydride groups per molecule was 34 percent, the
increase of the average molecular weight was 550 percent, the widening of the molar
weight distribution was 85 percent referred to the polyisobutylene used as raw material.
Example " 1. "
[0014] In a stirred tank reactor equipped with reagent supply, condenser, sampling facility,
nitrogen discharge vent, thermometer and pressure gauge 783.3 g of the acylation reagent
described in example " A " is weighed at 65 °C and to this 14.2 g tetraethylenepentamine
as well as 0.1 weight percent triethanolamine as catalyst were added. The reaction
mixture was then heated to 175 - 180 °C, under stirring in inert atmosphere and the
acylation reaction was then continued under such circumstances for 5 hours. This was
followed by the addition of 3.1 g diethylenetriamine to the reaction mixture and at
190 °C, at 50, 30 and 10 kPa pressures the mixture was stirred for 1 - 1 hour. The
nitrogen content of the end product was 0.8 percent, the ratio of the higher and lower
molecular weight polymers was 0.6.
Example " 2. "
[0015] Into the stirred tank reactor described in Example " 1 " 84.7 g acylation reagent
characterised in Example " B " and 5 g triethylenetetramine, 22.4 g triethanolamine
were weighed at 60 °C . The reaction mixture was then heated to 175 - 180 °C, under
stirring in inert atmosphere and the acylation reaction was then continued under such
circumstances for 6 hours.
In the last four hours of the acylation reaction 300 kPa pressure was applied for
3 hours then for a further hour 10 kPa pressure. After filtration in the presence
of 1 weight percent filtration aid the nitrogen content of the obtained product was
0.40 weight percent, the ratio of the higher and lower molecular weight polymers was
0.5.
Example " 3. "
[0016] Into the stirred tank reactor described in Example " 1 " 938.9 g of the intermediate
according to Example " C " was weighed at room temperature then at 140 °C, 10.3 g
diethylenetriamine was added to it. The acylation reaction was carried out under stirring
in inert atmosphere at 50 kPa pressure for 4 hours while the temperature was raised
to 190 °C at the rate of 20 °C/hour. After filtration at 120 °C in the presence of
1 weight percent filtration aid the nitrogen content of the obtained product was 0.4
weight percent, the ratio of the higher and lower molecular weight components was
2.3.
Example " 4. "
[0017] Into the stirred tank reactor described in Example " 1 " 746.8 g of the intermediate
according to Example " D " , 0.2 weight percent malic acid catalyst and 12.3 g glycerol
were added in two parts, at room and at 130 °C temperatures, then the acylation was
carried out in inert atmosphere at 210 °C, at 400 kPa pressure for 4 hours, and at
10 kPa for 3.5 hours. The reaction mixture was then cooled down to 120 °C, and 3.1
g diethylenetriamine was added to it, then it was stirred at 155 °C, at 65 kPa pressure
for 1 hour, then at 185 °C at 10 kPa pressure for 2 hours. After filtration in the
presence of 1 weight percent filtration aid the nitrogen content of the obtained product
was 0.11 weight percent, the ratio of the higher and lower molecular weight components
was 0.2.
Example " 5. "
[0018] Into the stirred tank reactor described in Example " 1 " 844.5 g of the intermediate
according to Example " E " was weighed. Under stirring in inert atmosphere, 1.24 g
diethylenetriamine was added at room temperature then at 70 °C 2.27 g tetraethylenepentamine
was added and the reaction was carried out for 2 hours at 130 °C. Then a further 0.6
g diethylenetriamine and 1.1 g of tetraethylenepentamine were added in drops to the
reaction mixture. The reaction was carried out under atmospheric pressure for 4 hours
at 190 °C, and was filtered at 120 °C in the presence of 1 weight percent filtration
aid. The nitrogen content of the obtained product was 0.2 weight percent, the ratio
of the higher and lower molecular weight components was 0.1.
Example " 6. "
[0019] Into the stirred tank reactor described in Example " 1 " 711.9 g of the intermediate
according to Example " F " was weighed and in the presence of 0.2 weight percent petroleum-sulfonic
acid catalyst, 6.0 g ethylenediamine was added to this mixture at room temperature
and at atmospheric pressure, then the temperature was raised to 190 °C, and the pressure
to 15x10² kPa and the acylation reaction was carried out for 6 hours. To the reaction
mixture 11.3 g tetraethylene- pentamine was added and at 215 °C, and 10³ kPa pressure
the reactants were mixed for 2 hours. After filtration at 120 °C in the presence of
1 weight percent filtration aid the nitrogen content of the obtained product was 0.9
weight percent, the ratio of the higher and lower molecular weight components was
1.25.
Example " 7. "
[0020] Into the stirred tank reactor described in Example " 1 " 774.9 g of the acylation
reagent used in Example " G " was weighed, in inert atmosphere, at atmospheric pressure
8.76 g triethylenetetramine and under continuous stirring 9.49 g diethanolamine were
weighed.
After the acylation reaction carried out at 175 °C under 50 kPa pressure for 4 hours
25 g monosuccinimide derivative (KOMAD-303, MOL Rt.) was added in drops at 120 °C,
in 10 minutes. The reaction was continued for 3 hours at 170 °C and 2x10² kPa and
for a further 1.5 hour at 15 kPa pressure. The nitrogen content of the obtained product
was 0.54 weight percent, the ratio of the higher and lower molecular weight polymers
was 0.7.
Example " 8. " (Reference)
[0021] Into the stirred tank reactor described in Example " 1 " 711.3 g of the intermediate
prepared according to Example "H" was weighed then in nitrogen atmosphere 10.3 g diethylenetriamine
was added at room temperature and at 120°C, 37.8 g tetraethylenepentamine was added
and the acylation reaction carried out for 2 hours at 250 °C was followed by the addition
of 13.6 g pentaerythritol and 2.4 g of petroleum sulfonic acid as catalyst. After
a 3 hours final reaction period at 15 kPa pressure the product was filtered in the
presence of 3 weight percent filtration aid. The difficult-to-filtrate product was
only partially soluble in base oil due to its 2.2 percent nitrogen content.
Example " 9. "
[0022] Into the stirred tank reactor described in Example " 1 " 768.5 g of the acylation
reagent used in Example " I " was weighed, in inert atmosphere, at atmospheric pressure.
Under continuous stirring at 80 °C, first 21.2 g diethylene glycol was added in 0.5
hours using a 80 °C/hour heating rate, then 18.9 g tetraethylenepentamine was added
in drops to the reaction mixture and the acylation reaction was carried out at 180
°C, under atmospheric pressure for 6 hours. The nitrogen content of the filtered end
product was 0.82 weight percent, the ratio of the higher and lower molecular weight
components was 0.4.
[0023] For the sake of easier handling and comparison - the oil content of all the end products
was adjusted to 50 percent before further use. When the oil content of the end product
prepared in the various examples was lower than 50 percent then it was adjusted to
this value by dilution with the oil component used in the synthesis. For the dilutions
refined lubricating oils characterised in Examples " A " and " B " were used.
By comparing the characteristics of the intermediates prepared in Examples " A " to
" G " and " I " it turned out that under the circumstances applied in this invention
the reaction between the comonomer(s), the polyolefin and the MAH leads to the linkage
of copolymer chains containing 1.6 - 6, preferably 1.8 - 4 succinic anhydride groups
on the average to the polyolefin molecule.
The efficiency of the detergent - dispersant effect of the additives mentioned in
the above examples was evaluated according to the method described by L.Bartha et
al.: Method of determination of optimum composition of detergent - dispersant engine
oil additives, Hung. J. Ind. Chem.,1979
7, 359-366. The potential detergent - dispersant effect (PDDE) values are given in
terms of percentage as the 225th part of the sum of the dispersion stabilising effect
of the additive (detergent index, DI, %) and its washing effect (M, mm). The deposition
reducing effect was evaluated by identical methods given in the above quoted publication
on the basis of results obtained by the so called panel coking method. In addition
to the above characteristics the dispersant effect of the additive has also been evaluated
by the so called spot dispersancy test method. According to this method the oil mixture
containing the additive or additives to be investigated is mixed in a high speed mixer
with 2 percent carbon black of a specific quality and the suspension obtained is treated
in six different ways (keeping them at various temperatures, in the presence or absence
of water) and from the six suspensions samples are dropped on filter paper and the
ratio of the diameters of the carbon black and the oil spots is evaluated after 48
hours. The theoretical maximum of the sum of the six results is 600 percent, the higher
the dispersant effect the higher this value.
The detergent - dispersant effect of the products prepared in Examples 1 through 9
were evaluated in lubricating oils and are shown in Table 1.
Table 1
DD efficiency of additive compositions (3 weight percent in an SN-150 oil) |
Example No |
PDDE, % * (100 max.) |
Base oil |
1 |
1. |
96 |
2. |
87 |
3. |
76 |
4. |
69 |
5. |
74 |
6. |
85 |
7. |
87 |
8. |
Cannot be evaluated |
9. |
86 |
* PDDE: potential detergent - dispersant effect |
For these studies the products prepared according to the mentioned examples were mixed
in 3 percent concentration into the base oil characterised by the following parameters:
Kinematic viscosity (100 °C): 5.2 mm²/s
Viscosity index, VI
E : 101
The results of the detergent - dispersant effect studies of the oil compositions obtained
using the products prepared in Examples 1.,2.,3.,7. and 8. as well as that of the
reference are shown in Tables 2. and 3, while those on viscosity and VI improving
are presented in Table 4.
Table 5
Data for the oil compositions obtained by the VW 3344 method |
Oil composition |
Breaking load, mPa |
Breaking elongation % |
Storage at 100 % elongation |
Additive according to: |
|
|
|
Example No.1 |
9.8 |
225 |
Crack free |
Example No.7. |
9.9 |
215 |
Crack free |
Example No.2. |
11.1 |
271 |
Crack free |
Example No.3. |
11.4 |
269 |
Crack free |
KOMAD-302 |
7.3 |
136 |
Broken |
Minimum level |
8.0 |
160 |
Crack free |
Dispersants were studied in the oil compositions shown in Table 3.
[0024] The structure and properties of the intermediates prepared according to Examples
"A" through "G" and "I" and of the end products synthesised from these according to
Examples 1. through 7. and 9. are similar to others prepared according to this invention
and were also obtained under the advantageous experimental conditions and parameter
combinations of the present invention.
The structure and properties of the intermediates and end products according to Examples
"H" and "J" as well as 8., and also their preparation are different in some way from
the advantageous structures and procedures of this invention.
The results concerning the detergent-dispersant, viscosity modifying, sealing compatibility
studies of the end products obtained under advantageous acylation and modifying conditions
according to the invention from the intermediates of advantageous structure and composition
prepared according to the advantageous conditions of the invention are shown in Tables
1. through 5. and indicate that the efficiency of these products is either identical
or superior as compared to the reference additives, i.e. their detergent - dispersant
effect in the base oil either in themselves or in oil compositions is really advantageous.
Their viscosity index improving effect and their compatibility with sealing materials
are significantly superior as compared to commercially available reference additives.
The use of additives prepared according to this invention further improves the properties
of lubricants or fuels.
Due to their less significant cold viscosity increasing effect the applicable concentration
can be further increased especially in the case of motor oils. Their preferential
viscosity and viscosity index improving effect makes possible ta more extensive substitution
of the traditional high molecular weight polymers. The feasibility of higher dosage
level, of additives prepared according to the present invention starting from low
molecular weight polyolefins, especially polyisobutylenes used so far for the preparation
of ashless dispersants offers a more economic formulation of lubricants.