BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] This invention relates to a lubricating oil composition, and more specifically to
a lubricating oil composition with a novel metal salt of an organic acid added therein,
said metal salt having a chain-hydrocarbon-group-substituted aromatic structure and
high friction characteristics improving effects.
DESCRIPTION OF THE PRIOR ART
[0002] It is the fundamental theme of lubrication to reduce friction and wear which occur
at sliding surfaces of moving parts in machineries, devices, equipments and the like.
Technical developments have been continued for many years. In recent years, still
further improvements are required in lubrication technology for the reduction of friction
and wear in the field of lubrication especially from the viewpoint of resource and
energy saving, and in attempts to achieve low friction and low wear by improvements
in the quality of lubricating oils, investigations are now under way from a variety
of viewpoints. For the production of a lubricating oil excellent in friction characteristics
with such technical developments as a basis, it has already become indispensable to
incorporate additives in base stocks for lubricating oils so that the base stocks
can be provided with desired friction characteristics. Accordingly a number of various
friction modifiers have been proposed, resulting in the use of fatty acids and their
metal salts, alcohols, esters, amines and the like - all of which are of the oiliness
improver type - and phosphate esters, phosphite esters, zinc dithiophosphate and the
like - all of which are of the extreme pressure agent type - in automatic transmission
fluids, wet brake oils, sliding surface oils, plastic working oils and the like; and
also in the use of phosphate esters, phosphite esters, acidic phosphite ester amine
salts, molybdenum dithiophosphate, molybdenum dithiocarbamate and the like - all of
which are of the extreme pressure agent type - in engine oils, gear oils, cutting
oils and the like.
[0003] Meanwhile, an automatic transmission fluid has been proposed, which contains magnesium
sulfonate, especially over-based magnesium sulfonate having a base number of 300 mg-KOH/g
or greater and added to improve its friction characteristics (see JP Kokai 62-84190).
Further, it has also been proposed to use calcium salicylate, which has been used
as a metallic detergent, as a friction coefficient modifier for automatic transmission
fluids (see JP Kokai 5-163496).
[0004] No matter whether these conventionally-proposed friction modifiers are of the organic
type or of the metallic type, their friction reducing effects are however not sufficient.
Especially, magnesium sulfonate, calcium salicylate and the like are still insufficient
in assuring stable reducing effects for friction characteristic as their effects vary
significantly depending on the kind and use conditions of a lubricating base stock,
although they provide friction reducing effects to some extents. Therefore they merely
exhibit advantageous effects as friction-reducing adjuvants which show their effects
when employed in combination with other friction modifiers. If an organic acid metal
salt is discovered with long-lasting stable friction reducing effects, it will find
utility in a much wider range of fields and hence to have a significantly-increased
industrial value. Its development has therefore been desired strongly.
[0005] In view of the technical developments on friction reducing technology in lubrication
field and the circumstances of development of conventional friction modifiers as described
above, the present invention has as an object thereof the provision of a lubricating
oil composition which contains a novel metal salt of an organic acid, said metal salt
having friction characteristics improving ability.
PRESENT INVENTION
[0006] It has been found that it is important for an organic acid metal salt to have a specific
chain-hydrocarbon-group-substituted aromatic structure and also that an organic acid
metal salt, said metal salt being a metal salt of an aromatic organic acid having
a chain hydrocarbon group with the aromatic group thereof being bonded to the chain
hydrocarbon group at a particular position of the chain hydrocarbon group, is excellent
in friction characteristics improving effects. Based on these findings, the present
inventors have come to the completion of the present invention.
[0007] Namely, the present invention relates to a lubricating oil composition characterized
in that said composition comprises:
a lubricating base stock; and
a mixture of metal salts of chain-hydrocarbon-group-substituted aromatic organic acids,
each of said aromatic groups having been substituted by at least one chain hydrocarbon
group, and the number of chain hydrocarbon groups each carrying at C-2 or C-3 thereof
the associated aromatic group being in a range of from 30% to 90% of the total number
of said chain hydrocarbon groups.
[0008] The present invention will hereinafter be described in detail.
[0009] No particular limitation is imposed on the lubricating base stock which is used as
a component of the lubricating oil composition according to the present invention.
The base stock can be any one of those conventionally used as base stocks for lubricating
oils, for example, any one of mineral base stocks, synthetic base stocks and vegetable
base stocks, or can be a blended base stock of two or more of these base stocks.
[0010] As a mineral base stock, it is possible to use, for example, a mineral oil obtained
by the treatment of a lubricating oil fraction, which is in turn available by vacuum
distillation of an atmosphere distillation residue of paraffin-base, neutral or naphthene-base
crude oil, through a refining step such as solvent refining, hydrocracking, hydrotreatment,
hydro-refining, catalytic dewaxing, solvent dewaxing or clay treatment; a mineral
oil obtained by subjecting a vacuum distillation residue to solvent deasphalting and
then treating the resulting deasphalted oil through the above-described refining step;
a mineral oil obtained by isomerizing wax components; or a blended oil thereof. In
the above solvent refining, an aromatic extraction solvent such as phenol, furfural
or N-methylpyrrolidone can be used, whereas as a solvent for the solvent dewaxing,
liquefied propane, MEK/toluene, MEK/MIBK, or the like can be used. Further, shape-selective
zeolites can also be used in catalytic dewaxing.
[0011] Examples of synthetic base stocks, on the other hand, can include poly(a-olefin)
oligomers; polybutene; alkylbenzenes; polyol esters such as trimethylolpropane esters
and pentaerythritol esters; polyoxyalkylene glycols; polyoxyalkylene glycol esters;
polyoxyalkylene glycol ethers; dibasic acid esters; phosphate esters; and silicone
oils.
[0012] Further, usable examples of vegetable base stocks can include castor oil, rape seed
oil, palm oil, coconut oil, olive oil and sunflower oil.
[0013] As various lubricating base stock such as those described above, it is possible to
use a blended base stock obtained by suitably blending plural base stocks so that
the blended base stock has a viscosity and other properties desired for the intended
application of the lubricating oil composition. For example, it is preferred to control
the kinematic viscosity at 100°C in a range of from 2 mm
2/s to 30 mm
2/s, especially from 3 mm
2/s to 10 mm
2/s for a lubricating oil for internal combustion engines, and the kinematic viscosity
at 100°C in a range of from 2 mm
2/s to 30 mm
2/s, especially from 3 mm
2/s to 15 mm
2/s for an automatic transmission fluid.
[0014] The organic acid metal salt added in the lubricating oil composition according to
the present invention is composed of an organic acid portion, which has a chain-hydrocarbon-group-substituted
aromatic structure, and a metal component portion. Specific examples can include metal
sulfonates, metal phenates, metal phenate sulfides, metal salicylates, metal salicylate
sulfides, metal phosphonates, and the like.
[0015] The metal component of the organic acid metal salt according to the present invention
can be an alkali metal or an alkaline earth metal. Generally, a metal of an atomic
number in a range of from 3 to 56 can also be mentioned. Specific examples can include
sodium, potassium, lithium, calcium, magnesium and barium. In addition, aluminum,
zinc, tin, chromium, copper, cobalt and the like are also usable. In particular, calcium,
magnesium, barium and the like are preferred.
[0016] Accordingly, preferred examples of the organic acid metal salt according to the present
invention include the sulfonates, phenates, salicylates and the like of alkaline earth
metals such as calcium, magnesium and barium.
[0018] No particular limitation is imposed on the chain hydrocarbon group of the chain-hydrocarbon-group-substituted
aromatic structure, but alkyl and alkenyl groups and the like with 4-32 carbon atoms
are preferred. Specific examples can include alkyl groups such as butyl, pentyl, hexyl,
octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl,
heptadecyl, octadecyl, nonadecyl, eicosyl, tetracosyl, pentacosyl, hexacosyl, heptacosyl,
octacosyl, nonacosyl and triacontyl and their corresponding alkenyl groups. Further,
these alkyl and alkenyl groups may contain one or more groups such as allyl, ester,
ketone, ether, amine, amide, imide and/or like groups.
[0019] Specific examples of the chain-hydrocarbon-group-substituted aromatic structure of
the organic acid metal salt according to the present invention can include alkylbenzenes,
alkenylbenzenes, alkylnaphthalenes, alkenylnaphthalenes, alkylanthracenes, alkenylanthracenes,
and the like. In the organic acid metal salt of the present invention, alkylbenzenes,
alkenylbenzenes, alkylnaphthalenes, alkenylnaphthalenes and the like are particularly
preferred. The number of substituted alkyl groups in the chain-hydrocarbon-group-substituted
aromatic structure, for example, an alkylbenzene may range from 1 to 4, and the particularly-preferred
chain-hydrocarbon-group-substituted aromatic structure is one containing at least
25% of a chain-hydrocarbon-group-substituted aromatic structure which contains one
substituted alkyl group.
[0020] In the chain-hydrocarbon-group-substituted aromatic structure of each organic acid
metal salt according to the present invention, the chain hydrocarbon group may be
one carrying an associated aromatic group at C-2, C-3, C-4 or another carbon of the
chain hydrocarbon group. According to an investigation by the present inventors, however,
it has become evident that a mixture of chain-hydrocarbon-group-substituted aromatic
structures of organic acid metal salts, in which the sum of the number of chain hydrocarbon
groups each carrying at C-2 thereof an associated aromatic group bonded thereto and
the number of chain hydrocarbon groups each carrying at C-3 thereof an associated
aromatic group bonded thereto falls within a range of from at least 30%, preferably
30% to 90%, especially from 35% to 70% of the total number of the chain hydrocarbon
groups, is particularly good in friction reducing effects. If the number of the chain
hydrocarbon groups each carrying at C-2 or C-3 thereof the associated aromatic group
bonded thereto does not reach 30%, no sufficient friction coefficient reducing effects
can be brought about. Even if this number exceeds 90%, the friction coefficient reducing
effects cannot be obtained to such an extent as corresponding to the increased proportion.
[0021] Further, if the number of chain hydrocarbon groups each carrying at C-2 thereof the
associated aromatic group bonded thereto accounts for 10% or more of the total number
of the chain hydrocarbon groups, the friction coefficient improving effects are improved
further. A chain-hydrocarbon-group-substituted aromatic structure, in which the ratio
of the number of chain hydrocarbon group(s) each carrying at C-2 thereof an associated
aromatic group bonded thereto to the number of chain hydrocarbon group(s) each carrying
at C-3 thereof an associated aromatic group bonded thereto falls within a range of
from 10:90 to 90:10, notably from 30:70 to 70:30, brings about still higher friction
reducing effects and moreover, has better rubber compatibility improving effects.
[0022] Certain representative compounds of the organic acid metal salt which can be added
in the lubricating base stock in the present invention will be exemplified below.

[0024] The above formulas (II) to (V) exemplify metal salicylates and metal salicylate sulfides,
and in the respective formulas,

are chain-hydrocarbon-group-substituted aromatic structures. In the formulas (II)
to (V), R
1s to R
4s are alkyl groups having 4 to 32 carbon atoms, and in each formula, these alkyl groups
may be the same or different. Preferred alkyl groups are those containing 12 to 30
carbon atoms, respectively. M represents an alkaline earth metal, and n indicates
the number of alkyl group(s) substituted on the associated aromatic group. Further,
in the formulas (IV) and (V), x stands for a number of 1 to 5.
[0025] In these chain-hydrocarbon-group-substituted aromatic structures, the sum of the
numbers of chain hydrocarbon groups each carrying at C-2 or C-3 thereof the associated
aromatic group bonded thereto is 30% to 90% of the total number of the chain hydrocarbon
groups.

[0026] The above formulas (VI) and (VII) exemplify metal phenates and metal phenate sulfides
having chain-hydrocarbon-group-substituted aromatic structures. In the respective
formulas, the chain-hydrocarbon-group-substituted aromatic structures are:

[0027] In the formulas (VI) and (VII), R
5 and R
6 are alkyl groups having 4 to 32 carbon atoms, which may be the same or different.
Preferred alkyl groups are those having 12 to 30 carbon atoms. M represents an alkaline
earth metal, and n indicates the number of alkyl group(s) substituted on the associated
aromatic group. In the formula (VII), x stands for a number of 1 to 5.
[0028] In these chain-hydrocarbon-group-substituted aromatic structures, the sum of the
numbers of chain hydrocarbon groups each carrying at C-2 or C-3 thereof the associated
aromatic group substituted thereon is 30% to 90% of the total number of the chain
hydrocarbon groups.
[0029] The organic acid metal salt according to the present invention can provide friction
coefficient reducing effects no matter whether it is a neutral salt or an over-based
salt. An over-based salt is in the form of a colloidal system in which a metal hydroxide
or metal carbonate is primarily dispersed in the form of fine particles in an organic
acid metal salt. As an over-basing method, a method known well to date can be adopted,
for example, an acidic substance is reacted with a reaction mixture of an organic
acid or a salt thereof and a metal compound. As the acidic substance, a gas such as
carbon dioxide or sulfur dioxide can be used. For example, an over-based alkaline
earth metal salicylate can also be produced by treating its neutral salt with carbon
dioxide (see, for example, U.S. Patent No. 3,057,896).
[0030] Concerning the proportion of the organic acid metal salt to be added in the lubricating
oil composition according to the present invention, sufficient friction reducing effects
can be exhibited provided that the organic acid metal salt is added in a proportion
of from 0.01 wt% to 10 wt%, preferably from 0.05 to 5 wt% based on the whole weight
of the lubricating oil composition or in a proportion of from 1 ppm to 10,000 ppm,
preferably from 50 ppm to 5,000 ppm in terms of the content of the metal although
the proportion varies depending on the application purpose of the lubricating.
[0031] To the lubricating oil composition according to the present invention, it is also
possible to add selected ones of viscosity index improvers, ashless dispersants, anti-oxidants,
extreme pressure agents, wear inhibitors, metal deactivators, pour-point depressants,
rust inhibitors, other friction modifiers and other additives as desired.
[0032] Illustrative usable examples of the viscosity index improvers can include polymethacrylates,
polyisobutylenes, ethylene-propylene copolymers, and hydrogenated styrene-butadiene
copolymers. These viscosity index improvers are used generally in a proportion of
from 3 wt% to 35 wt%.
[0033] Illustrative of the ashless dispersants can be polybutenylsuccinimides, polybutenylsuccinamides,
benzylamines, and succinate esters. They can be used generally in a proportion of
from 0.05 wt% to 7 wt%.
[0034] Illustrative examples of the anti-oxidants can include amine-type anti-oxidants such
as alkylated diphenylamines, phenyl-α-naphthylamine and alkylated phenyl-α-naphthylamines;
phenol-type anti-oxidants such as 2,6-di-t-butylphenol and 4,4'-methylene-bis(2,6-di-t-butylphenol);
and zinc dithiophosphate. They can be used generally in a proportion of from 0.05
wt% to 5 wt%.
[0035] Illustrative of the extreme pressure agents can be dibenzyl sulfide and dibutyl disulfide.
They can be used generally in a proportion of from 0.05 wt% to 3 wt%.
[0036] Illustrative examples of the metal deactivators can include benzotriazole, benzotriazole
derivatives, and thiadiazole. They can be used generally in a proportion of from 0.01
wt% to 3 wt%.
[0037] Illustrative of the pour-point depressants can be ethylene-vinyl acetate copolymers,
chlorinated paraffin-naphthalene condensation products, chlorinated paraffin-phenol
condensation products, polymethacrylates, and polyalkylstyrenes. They can be used
generally in a proportion of from 0.1 wt% to 10 wt%.
[0038] Illustrative of the wear inhibitors can be phosphate esters, acidic phosphate esters,
phosphite esters, acidic phosphite esters, zinc dialkyldithiophosphates, and sulfur
compounds. They can be used generally in a proportion of from 0.01 wt% to 5 wt%.
[0039] Other additives can also be selectively used as described provided that they do not
inhibit the action of the organic metal salt according to the present invention.
[0040] The organic acid metal salt according to the present invention can be used in a form
dissolved in a solvent such as a mineral oil. It can also be used as a component of
an additive package.
[0041] As preferred embodiments of the present invention, it is possible to provide:
(i) A lubricating oil composition comprising:
a lubricating base stock; and
a mixture of metal salts of chain-hydrocarbon-group-substituted aromatic organic acids,
each of said aromatic groups having been substituted by at least one chain hydrocarbon
group, and the sum of the number of chain hydrocarbon groups each carrying at C-2
or C-3 thereof the associated aromatic group bonded thereto being in a range of from
35% to 70% of the total number of the chain hydrocarbon groups.
(ii) A lubricating oil composition comprising:
a lubricating base stock; and
a mixture of metal salts of chain-hydrocarbon-group-substituted aromatic organic acids,
each of said aromatic groups having been substituted by at least one chain hydrocarbon
group, the number of chain hydrocarbon groups each carrying at C-2 thereof the associated
aromatic group bonded thereto is at least 10% of the total number of the chain hydrocarbon
groups, and the ratio of the number of the chain hydrocarbon groups each carrying
at C-2 thereof the associated aromatic group bonded thereto to that of chain hydrocarbon
groups each carrying at C-3 thereof an associated aromatic group bonded thereto is
in a range of from 10:90 to 90:10.
(iii) A lubricating oil composition comprising:
a lubricating base stock; and
a mixture of metal salts of chain-hydrocarbon-group-substituted aromatic organic acids,
each of said aromatic groups having been substituted by at least one chain hydrocarbon
group, the number of chain hydrocarbon groups each carrying at C-2 thereof the associated
aromatic group bonded thereto is greater than 10% of the total number of the chain
hydrocarbon groups, and the ratio of the number of the chain hydrocarbon groups each
carrying at C-2 thereof the associated aromatic group bonded thereto to that of chain
hydrocarbon groups each carrying at C-3 thereof an associated aromatic group bonded
thereto is in a range of from 10:90 to 65:35.
(iv) A lubricating oil composition comprising:
a lubricating base stock;
a mixture of metal salts of chain-hydrocarbon-group-substituted aromatic organic acids
each substituted by at least one chain hydrocarbon group, the number of chain hydrocarbon
groups each carrying at C-2 or C-3 thereof the associated aromatic group bonded thereto
being in a range of from 30% to 90% of the total number of the chain hydrocarbon groups;
and
at least one additive selected from the group consisting of viscosity index improvers,
ashless dispersants, anti-oxidants, wear inhibitors and metal deactivators.
EXAMPLES
[0042] The present invention will next be described specifically by Examples and Comparative
Examples.
[0043] For the structure analysis of each chain-hydrocarbon-group-substituted aromatic structure
in each organic acid metal salt and also for the evaluation of performance (coefficient
of friction) of each lubricating oil composition, the following measuring methods
were adopted.
[0044] Structure analysis of chain-hydrocarbon-group-substituted aromatic structure in organic
acid metal salt analyzed by a
13C-NMR measurement.
Measuring method of friction coefficient:
[0045] By a testing method similar to JASO M348-95 entitled "ATF (Automatic Transmission
Fluid) Friction Characteristics Testing Method", a static friction coefficient after
10 c/c was measured by using an SAE No. 2 friction machine. As a friction material,
SD1777 was used.
Example 1
[0046] Refined mineral oil 100SN (kinematic viscosity: 4.1 mm
2/s at 100°C) was used as a lubricating base stock. To the refined mineral oil, 1.0
wt% (1,000 ppm in terms of Ca content) of an over-based alkylbenzene calcium sulfonate
- in which, as shown in Table 1, the average carbon number of alkyl groups was 23,
the number of alkyl groups each carrying at C-2 thereof an associated phenyl group
bonded thereto was 27% of the total number of the alkyl groups, and the sum of the
number of alkyl groups each carrying at C-2 or C-3 thereof an associated phenyl group
bonded thereto was 53% of the total number of the [phenyl] alkyl groups - was added
as an organic acid metal salt, whereby a lubricating oil composition was formulated.
The friction coefficient of the thus-obtained lubricating oil composition was measured
by the above-described method. It was found to be 0.133.
Example 2
[0047] To the refined mineral oil 100SN (kinematic viscosity: 4.1 mm
2/s at 100°C), 1.0 wt% (100 ppm in terms of Ca content) of a neutral alkylbenzene calcium
sulfonate - in which the average carbon number of alkyl groups was 22, the number
of alkyl groups each carrying at C-2 thereof an associated phenyl group bonded thereto
was 28% of the total number of the alkyl groups, and the sum of the number of alkyl
groups each carrying at C-2 or C-3 thereof an associated phenyl group bonded thereto
was 45% of the total number of the alkyl groups - was added, whereby a lubricating
oil composition was formulated. As a result of a measurement of the friction coefficient
of the thus-obtained lubricating oil composition, it was found to be 0.134.
Example 3
[0048] To the refined mineral oil 100SN (kinematic viscosity: 4.1 mm
2/s at 100°C), 1.0 wt% (1,000 ppm in terms of Ca content) of an over-based alkylbenzene
calcium sulfonate - in which the number of alkyl groups each carrying at C-2 thereof
an associated phenyl group bonded thereto was 14% of the total number of the alkyl
groups, and the number of alkyl groups each carrying at C-2 or C-3 thereof an associated
phenyl group bonded thereto was 37% of the total number of the alkyl groups - was
added, whereby a lubricating oil composition was formulated. The friction coefficient
of the thus-obtained lubricating oil composition was found to be 0.140.
Comparative Example 1
[0049] The refined mineral oil 100SN (kinematic viscosity: 4.1 mm
2/s at 100°C) was used as a lubricating base stock. The friction coefficient of the
lubricating base stock alone was measured without addition of an organic acid metal
salt. It was found to be 0.168.
Comparative Example 2
[0050] To the refined mineral oil 100SN (kinematic viscosity: 4.1 mm
2/s at 100°C), 1.0 wt% (1,000 ppm in terms of Ca content) of an over-based alkylbenzene
calcium sulfonate - in which the average carbon number of alkyl groups was 25.5, the
number of alkyl groups each carrying at C-2 thereof an associated phenyl group bonded
thereto was 6% of the total number of the alkyl groups, and the sum of the number
of alkyl groups each carrying at C-2 or C-3 thereof an associated phenyl group bonded
thereto was 9% of the total number of the alkyl groups - was added, whereby a lubricating
oil composition was formulated. As a result of a measurement of the friction coefficient
of the thus-obtained lubricating oil composition, it was found to be 0.164.
[0051] The structures of the organic acid metal salts used in the Examples and the Comparative
Examples and the performance evaluation results (SAE No. 2 friction coefficient measurement
results) of the lubricating oil compositions are shown in Table 1.

[0052] From the above Examples and Comparative Examples, the friction coefficient reducing
effects by the control of the total percentage of chain hydrocarbon group(s) each
carrying at C-2 thereof an associated aromatic group bonded thereto and chain hydrocarbon
group(s) each carrying at C-3 thereof an associated aromatic group bonded thereto
has been clarified although there is no correlation between the individual percentages
of the hydrocarbon groups each carrying at C-3 thereof the associated aromatic group
bonded thereto and the chain hydrocarbon groups each carrying at C-4 thereof an associated
aromatic group bonded thereto and a friction coefficient. Namely, it has been demonstrated
that the friction coefficient is significantly lowered when the percentage of the
number of chain hydrocarbon groups each carrying C-2 or C-3 thereof an associated
aromatic group bonded thereto based on the number of all the chain hydrocarbon groups
is 30% or higher.
[0053] Thus it is seen that a lubricating oil composition containing a mixture of organic
acid metal salts having chain-hydrocarbon-group-substituted aromatic structures in
which the sum of the number of chain hydrocarbon groups each carrying at C-2 or C-3
thereof an associated aromatic group bonded thereto is 30% to 90% of the total number
of the chain hydrocarbon groups. For example, a calcium sulfonate with aromatic group(s)
bonded concentrating on a specific position of C-2 or C-3 of an associated chain hydrocarbon
group(s) exhibits extremely high friction coefficient improving effects. Use of the
enumerated metal salts makes it possible to provide a lubricating oil composition
of improved in friction characteristics.