TECHNICAL FIELD
[0001] The present invention relates to the use of a lubricant composition, and more particularly
to the use of a lubricant composition with a distinguished rust inhibition, particularly
even after having been subjected to heat hysteresis for lubrication of bearings in
automobile auxiliary equipment.
BACKGROUND ART
[0002] Lubricants such as grease, etc. are widely used in lubrication of various machines
including automobiles, construction machines, industrial machines, machine tools,
etc., and also various parts as members of the machines. The machines have a possibility
of water intrusion, depending on the locations where they are used, and thus requirements
for the rust inhibition thereof are more and more strict. Furthermore, recent trends
towards higher speed, much more size reduction, higher performance, lighter weight,
etc. have made service temperatures of these peripheral equipment higher and higher,
so the rust inhibition after having been subjected to such heat hysteresis has been
also an important requirement.
[0003] To improve the rust inhibition use of some of additives have been studied. A grease
composition for ball-and-roller bearings, which comprises a grease composition containing
silicone oil- or fluorocarbon oilbased lubricating oil as a base oil, and a rust inhibitor
comprising a magnesium compound and a volatile rust inhibitor as essential components
has been so far proposed, where triazole-based compound such as benzotriazole, methylbenzotriazole,
etc., or dicyclohexyl ammonium nitrite have been recommended as preferable volatile
rust inhibitors.
Patent Literature 1 : JP-A-9-59664
[0004] The proposed grease composition for ball-and-roller bearings is said to have a distinguished
rust inhibitive action in addition to a high durability at elevated temperatures,
but it contains a volatile rust inhibitor as one of rust inhibitor components, so
a long term rust inhibition at elevated temperatures is not satisfactory, and as to
the alkaline component such as magnesium oxide, etc., their influence on the environments
must be taken into consideration.
[0005] A heat-resistant grease composition, which comprises fluorosilicone oil, a fluororesin-based
thickener, and an additive such as calcium alkylsulfonate, etc., and which can also
contain other well known thickeners such as calcium stearate, etc. has been also proposed,
where it is shown by evaporation tests or engine tests that the heat resistance is
distinguished and also stable for a long time, but no mention is made of the rust
inhibition, particularly even after having been subjected to heat resistance tests.
Patent Literature 2 : JP-A-8-143883
[0006] The present applicant has previously proposed a lubricating grease composition, which
comprises perfluoropolyether base oil, and a metal salt of aliphatic dicarboxylic
acid as a thickener, where the applicant shows that the composition can further contain
a powdery fluororesin to attain improvements of abrasion resistance of mating material,
leakage resistance, detergency, etc.
Patent Literature 3 : JP-A-2001-354986
[0007] It is recommended that in the proposed lubricating grease composition a mixing proportion
of the metal salt of aliphatic dicarboxylic acid used as a thickener is about 1 to
about 50% by weight, preferably 3 to 35% by weight, on the basis of the composition.
In the disclosed Examples 1 to 14 relate to lubricating grease compositions consisting
of two components, i.e. the thickener and perfluoropolyether oil, the thickener is
used in such preferable mixing proportions.
[0008] As to the powdery fluororesin as an admixable component, it is recommended that the
admixing proportion is not more than about 50% by weight, preferably about 3 to about
35% by weight, on the basis of the composition. In the disclosed Examples 15 to 17
relate to lubricating grease composition consisting of these three components, it
is recommended that the admixing proportion of powdery fluororesin is 5% by weight,
whereas that of metal salt of aliphatic dicarboxylic acid as a thickener is 15-25%
by weight. As is known from such results, an increase in the admixing proportion of
metal salt of aliphatic dicarboxylic acid as a thickener will inhibit any increase
the admixing proportion of powdery fluororesin.
DISCLOSURE OF THE INVENTION
PROBLEM TO BE SOLVED BY THE INVENTION
[0009] An object of the present invention is to provide a lubricant composition with a distinguished
rust inhibition, particularly even after having been subjected to heat hysteresis,
which comprises a fluoro-oil and an appropriate admixing proportion of powdery fluororesin
as a thickener for lubrication of bearings in automobile auxiliary equipment:
MEANS FOR SOLVING THE PROBLEM
[0010] The object of the present invention can be attained by the use of a lubricant composition,
which comprises a perfluoropolyether oil, a powdery fluororesin thickener, and Ca
salt or Na salt of aromatic sulfonic acid or saturated aliphatic dicarboxylic acid
as a rust-inhibitive additive, where the thickener is in a proportion of 10-40% by
weight, and the rust-inhibitive additive is in a proportion of 0.3-10% by weight on
the basis of total weight of the composition, the balance being the perfluoropolyether
oil, wherein the perfluoropolyether oil is selected from perfluoropolyether oils having
the following formulae (1) to (4)
(1) RfO(CF
2CF
2O)
m(CF2O)
nRf
wherein in the formula (1) m+n=3-200, and m:n=10-90:90-10, and the CF
2CF
2O group and the CF
2O group are in random combination in the main chain,
(2) RfO[CF(CF
3)CF
2O]
p(CF
2CF
2O)
q(CF
2O)
rRf
wherein in the formula (2) p+q+r=3-200, q and r can be 0, respectively, and (q+r)/p=0-2,
and the CF(CF
3)CF
2O group, the CF
2CF
2O group, and the CF
2O group are in random combination in the main chain,
(3) RfO[CF(CF
3)CF
2O]
s(CF
2CF
2O)
t(Rf
wherein in the formula (3) s+t=2-200, t can be 0, and t/s=0-2, and the CF(CF
3)CF
2O group and the CF
2CF
2O group are in random combination in the main chain, and
(4) F(CF
2CF
2CF
2O)
2-100C
2F
5
for lubrication of bearings in automobile auxiliary equipment,
wherein Rf in formulae (1) to (3) is a perfluoroalkyl group having 1 to 5 carbon atoms.
EFFECT OF THE INVENTION
[0011] The present lubricant composition has a distinguished rust inhibition, particularly
even after having been subjected to heat hysteresis, and thus can be used widely in
lubrication of machines and their parts to be used particularly outdoors, and specifically
used in effective lubrication of bearings requiring substantial rust inhibition, heat
resistance, low-temperature characteristics, load-carrying capacity, etc. in automobile
auxiliary equipment such electric fan motors, fuel injector equipments, alternators,
etc. of automobiles. Furthermore, the present lubricant composition can be used for
lubrication of solid-solid contacts such as sliding parts of ball-and-roller bearings,
slide bearings, sintered bearings, gears, valve, cocks, oil seals, rolls, electric
contacts, etc.
BEST MODES FOR CARRYING OUT THE INVENTION
[0012] The perfluoropolyether oil used according to the present invention is represented
by the following formulae (1)-(4),
where Rf is a perfluoro lower alkyl groups having 1-5 carbon atoms, preferably 1-3
carbon atoms, such as a perfluoromethyl group, a perfluoroethyl group, perfluoropropyl
group, etc.
(1) RfO(CF
2CF
2O)
m(CF
2O)
nRf
[0013] In the formula (1), m+n=3-200, and m:n=10-90:90-10, and the CF
2CF
2O group and the CF
2O group are in random combination in the main chain. The perfluoropolyether (1) can
be obtained by complete fluorination of a precursor formed by photo-oxidation polymerization
of tetra-fluoroethylene.
(2) RfO[CF(CF
3)CF
2O]
p(CF
2CF
2O)
q(CF
2O)
rRf
[0014] In the formula (2), p+q+r=3-200, q and r can be 0, respectively, and (q+r)/p=0-2
, and the CF(CF
3)CF
2O group, the CF
2CF
2O group, and the CF
2O group are in random combination in the main chain. The perfluoropolyether (2) can
be obtained by complete fluorination of a precursor formed by photo-oxidation polymerization
of hexafluoropropene and tetra-fluoroethylene.
(3) RfO[CF(CF
3)CF
2O]
s(CF
2CF
2O)
tRf
[0015] In the formula (3), s+t=2-200, t can be 0, and t/s=0-2 , and the CF(CF
3)CF
2O group and the CF
2CF
2O group are in random combination in the main chain, and the perfluoropolyether (3)
can be obtained by complete fluorination of a precursor formed by photo-oxidation
polymerization of hexafluoropropene and tetrafluoroethylene, or by anionic polymerization
of hexafluoropropylene oxide or tetrafluoroethylene oxide in the presence of a cesium
fluoride catalyst, followed by successive treatment of the resulting acid fluoride
compound having a terminal-CF(CF
3)COF group with a fluorine gas.
(4) F(CF
2CF
2CF
2O)
2-100C
2F
5,
[0016] The perfluoropolyether (4) can be obtained by anionic polymerization of 2,2,3,3-tetrafluorooxetane
in the presence of a cesium fluoride catalyst, followed by treatment of the resulting
fluorine -containing polyether (CH
2CF
2CF
2O)
n under ultraviolet irradiation at about 160° to about 300°C with a fluorine gas.
[0017] These perfluoropolyether base oils can be used alone or in a mixture thereof, and
when used as a lubricating oil the viscosity (40°C) is desirably about 5 to about
2,000mm
2/sec, preferably about 10 to about 1,500mm
2/sec. When the viscosity is less than about 5mm
2/sec., the evaporation rate will be increased, and will fail to satisfy the requirements
for evaporation rate of 1.5% or less set forth in JIS ball-and-roller bearing grease,
class 3 as a heat-resistant grease, whereas when the viscosity is more than about
2, 000mm
2/sec, the pour point (JIS K-2283) will be more than 10 °C , and bearings, gears, chains,
etc. fail to start at low temperatures in the ordinary manner, resulting in necessary
heating for starting, that is, a failure to meet the admissible limit to use as the
ordinary grease.
[0018] Fluororesin for use herein as a thickener includes polytetrafluoroethylene [PTFE],
tetrafluoroethylene-hexafluoropropene copolymer [FEP], perfluoroalkylene resin, etc.,
so far used as a lubricant. Polytetrafluoroethylene obtained by subjecting tetrafluoroethylene
to such a process as emulsion polymerization, suspension polymerization, solution
polymerization, or the like, thereby preparing polytetrafluoroethylene, followed by
subjecting it to a treatment by such a process as heat decomposition, decomposition
using electron beam irradiation, physical pulverization, or the like, thereby reducing
the number average molecular weight Mn from about 1,000- 1,000,000 to about 1,000-
500,000, can be used. Tetrafluoroethylene-hexafluoropropene copolymer having a number
average molecular weight of about 1,000 to about 600,000, obtained by conducting copolymerization
reaction of tetrafluoroethylene and hexafluoropropene and treatment to reduce the
molecular weight, in the same manner as in the case of polytetrafluoroethylene can
be used. To obtain PTFE having a melting point of 300°C or higher, which is suitable
for use in the present invention, it is desirable that Mn is about 10,000 or more.
Control of molecular weight can be also carried out by using a chain transfer agent
during the copolymerization reaction. The resulting powdery fluororesin having, among
others, an average primary particle size of generally about 500 µm, preferably about
0.1 to about 30 µm, can be used.
[0019] The powdery fluororesin is used in a proportion of 10-40% by weight, preferably 15-35%
by weight, on the basis of total weight with base oil and rust-inhibitive additive.
When the fluororesin thickener is used in a proportion of above 40% by weight, the
composition will be too hard, whereas in a proportion below 10% by weight, no satisfactory
thickening capacity of fluororesin etc. can be obtained, resulting in deterioration
such as oil separation, and any increase in scattering prevention and leakage prevention
can be no more expected.
[0020] The powdery fluororesin can be used together with other thickeners, which include
metal soaps such as Li soap, etc., urea resin, minerals such as bentonite, silica,
clay, graphite, carbon, zinc oxide, etc., organic pigments, polyethylene, polypropylene,
and polyamide. From the viewpoints of heat resistance and lubricability, it is preferable
to use monoamide monocarboxylic acid metal salts, monoester carboxylic acid metal
salts, diurea, triurea, tetraurea, etc. These other thickeners having a melting point
of 300°C or higher can be preferably used.
[0021] Aromatic sulfonic acid salts for use herein as a rust-inhibitive additive include,
for example, Ca salts or Na salts of petroleum sulfonic acid, alkylbenzene sulfonic
acid, dialkylnaphtharene sulfonic acid, etc. The sulfonic acid salts having an aromatic
ring are distinguished in both heat resistance and rust inhibition.
[0022] Saturated aliphatic dicarboxylic acid salts, for use herein as a rust-inhibitive
additive include, for example, Ca salts or Na salts of oxalic acid, malonic acid,
succinic acid, methylsuccinic acid, glutaric acid, adipic acid, pimelic acid, suberic
acid, azelaic acid, sebacic acid, nonamethylenedicarboxylic acid, decamethylenedicarboxylic
acid, undecamethylenedicarboxylic acid, dodecamethylenedicarboxylic acid, tridecamethylnenedicarboxylic
acid, tetradecamethylenedicarboxylic acid, pentadecamethylenedicarboxylic acid, hexadecamethylenedicarboxylic
acid, heptadecamethylenedicarboxylic acid, octadecamethylenedicarboxylic acid, etc.
These with an aliphatic group having 6-12 carbon atoms are preferably used particularly
in respect to the distinguished rust inhibition.
[0023] These rust-inhibitive additives are used in a proportion of 0.3-10% by weight, preferably
0.3-5% by weight, on the basis of total weight with base oil and powdery fluororesin
thickener. In a proportion below 0.3% by weight no desired rust-inhibitive effect
can be obtained, whereas in a proportion above 10% by weight no desired proportion
of the thickener can be admixed, and no thickening effect can be expected.
[0024] Even among these aromatic sulfonic acid salts and saturated aliphatic dicarboxylic
acid salts, the amine salts have no satisfactory heat resistance, whereas the Ba salts
and Zn salts have satisfactory rust inhibition and heat resistance, but must be labeled
from the viewpoint of recent environmental problem.
[0025] The lubricant composition can further contain other additives so far used in the
conventional lubricant, such as an antioxidant, other rust-inhibitors, a corrosion
inhibitor, an extreme pressure additive, an oiliness agent, a solid lubricant, etc.,
when required. The antioxidant includes, for example phenol-based antioxidants such
as 2,6-di-t-butyl-4-methylphenol, 4,4' -methylenebis(2,6-di-t-butylphenol), etc. and
amine-based antioxidants such as alkyldiphenylamine, triphenylamine, phenyl- a -naphthylamine,
phenothiazine, alkylated phenyl- a -naphtylamine, alkylated phenothiazine, etc.
[0026] Other rust inhibitors include, for example, fatty acids, fatty acid amines, alkylsulfonic
acid metal salts, alkylsulfonic acid amine salts, oxidiged paraffin, polyoxyalkylethers,
etc. The corrosion inhibitors include, for example, benzotriazole, benzoimidazole,
thiadiazole, etc.
[0027] The extreme pressure agent includes, for example, phosphorus-based compounds such
as phosphoric acid esters, phosphorous acid esters, phosphoric acid ester amine salts,
etc., sulfur-based compounds such as sulfides, disulfides, etc., and sulfur-based
compound metal salts, such as dialkyldithiophosphoric acid metal salts, dialkyldithiocarbamic
acid metal salts, etc.
[0028] The oiliness agent includes, for example, fatty acids, or their esters, higher alcohols,
polyhydric alcohols, or their esters, aliphatic amines, fatty acid monoglycerides,
etc. The other solid lubricant includes, for example, molybdenum disulfide, graphite,
boron nitride, silane nitride, etc.
[0029] The composition can be prepared by adding predetermined amounts of a powdery fluororesin
thickener, a rust-inhibitive additive and other necessary additives to perfluoropolyether
base oil, followed by through stirring in a stirring kettle, etc. and then by homogenization
treatment through three-rolls, or in a high pressure homogenizer.
EXAMPLES
[0030] The present invention will be described below, referring to Examples.
[0031] EXAMPLES 1 TO 25 AND COMPARATIVE EXAMPLES 1 TO 7
[0032] The following base oils, thickeners, and rust-inhibitive additives could be easily
mixed together only by stirring, thereby preparing lubricant compositions.
[Base oil]
[0033]
| A-1 : RfO(CF2CF2O)m(CF2O)nRf |
Viscosity (40°C) 85mm2/sec: |
| A-2 : RfO(CF2CF2O)m(CF2O)nRf |
Viscosity (40°C) 150mm2/sec. |
| A-3 : RfO[CF(CF3)CF2O]pRf |
Viscosity (40°C)390mm2/sec. |
| A-4 : RfO[CF(CF3)CF2O]p(CF2O)rRf |
Viscosity (40°C)230mm2/sec. |
| A-5 : F(CF2CF2CF2O)2-100C2F5 |
Viscosity (40°C)200mm2/sec. |
[Thickener]
[0034]
B-1 : Emulsion-polymerized PTFE (molecular weight: 100-200 × 103; melting point:330°C; average primary particle size:0.2 µm)
B-2 : Suspension-polymerized PTFE (molecular weight:10-100 × 103; melting point:318°C; average primary particle size:5 µm)
B-3 : Solution polymerized FEP (molecular weight:50-150 × 103; melting point:256°C; average primary particle size:0.2 µm)
[Rust-inhibitive additive]
[0035]
C-1 : Ca dinonylnaphthalene sulfonate
C-2 : Na petroleum sulfonate
C-3 : Na sebacate
C-4 : RfO[CF(CF3)CF2O]nCF(CF3)COOH
C-5 : Benzotriazole
C-6 : Octylamine salt of dinonylnaphthalene sulfonic acid
[0036] The resulting lubricant compositions were subjected to MKO test (corrosion degree).
The test included, in addition to the test under the following ordinary conditions,
comparison of corrosion degrees after having been subjected to heat hysteresis at
180°C for 500 hours as to heating grease-sealed test bearings, followed by similar
test to the above.
<EKO test (corrosion degree) according to DIN 51802 >
[0037] 1306K bearings were sealed with grease, amounted on an EKO tester, and tested under
such cycle conditions as revolution rate : 80rpm ; revolution cycle : revolution for
8 hours→stoppage for 16 hours→revolution for 8 hours→stoppage for 16 hours→revolution
for 8 hours→stoppage for 108 hours (total 164 hours) to evaluate corrosion states
on the outer race track surface of the bearing according to the following basis.
[0038] In the test, distilled water was used.
Corrosion
[0039]
| degree |
Appearance |
Evaluation basis |
| 0 |
No corrosion |
No changes |
| 1 |
Traces of corrosion |
Up to 3 corrosion points in sizes of 1mm or less |
| 2 |
Weakly corroded |
Corroded portions at corrosion degree of 1 or more being within 1% of the surface |
| 3 |
Corroded |
Corrosion extended in a range of 1-5% of the surface |
| 4 |
Strongly corroded |
Corrosion extended in a range of 5-10% of the surface |
| 5 |
Much strongly corroded |
Corrosion extended in a range of 10% or more of the surface |
[0040] The results are shown in the following Table together with components of the lubricant
compositions.
Table
| |
|
|
|
|
|
|
|
EMK Test |
| Example No. |
Base oil |
Thickener |
Rust-inhibitive additive |
Normal corrosion degree |
After heating corrosion degree |
| Species |
wt.% |
Species |
wt.% |
Species |
wt.% |
| Example |
1 |
A-1 |
74.2 |
B-1 |
24 |
C-1 |
1.8 |
0 |
0 |
| " |
2 |
" |
74 |
" |
" |
C-2 |
2.0 |
0 |
1 |
| " |
3 |
" |
72.6 |
" |
" |
C-3 |
3.4 |
0 |
0 |
| " |
4 |
" |
67.2 |
B-2 |
31 |
C-1 |
1.8 |
0 |
0 |
| " |
5 |
" |
67 |
" |
" |
C-2 |
2.0 |
0 |
1 |
| " |
6 |
" |
65.6 |
" |
" |
C-3 |
3.4 |
0 |
0 |
| " |
7 |
" |
77.2 |
B-3 |
21 |
C-1 |
1.8 |
0 |
0 |
| " |
8 |
" |
77 |
" |
" |
C-2 |
2.0 |
0 |
1 |
| " |
9 |
" |
75.6 |
" |
" |
C-3 |
3.4 |
0 |
0 |
| " |
10 |
A-2 |
74.2 |
B-1 |
24 |
C-1 |
1.8 |
0 |
0 |
| " |
11 |
" |
74 |
" |
" |
C-2 |
2.0 |
0 |
1 |
| " |
12 |
" |
72.6 |
" |
|
C-3 |
3.4 |
0 |
0 |
| " |
13 |
" |
67.2 |
B-2 |
31 |
C-1 |
1.8 |
0 |
0 |
| " |
14 |
" |
67 |
" |
" |
C-2 |
2.0 |
0 |
1 |
| " |
15 |
" |
65.6 |
" |
" |
C-3 |
3.4 |
0 |
0 |
| " |
16 |
A-3 |
74.2 |
B-1 |
24 |
C-1 |
1.8 |
0 |
0 |
| " |
17 |
" |
74 |
" |
" |
C-2 |
2.0 |
0 |
0 |
| " |
18 |
" |
67.2 |
B-2 |
31 |
C-1 |
1.8 |
0 |
0 |
| " |
19 |
" |
67 |
" |
" |
C-2 |
2.0 |
0 |
0 |
| " |
20 |
A-4 |
74.2 |
B-1 |
24 |
C-1 |
1.8 |
0 |
0 |
| " |
21 |
" |
74 |
" |
" |
C-2 |
2.0 |
0 |
0 |
| " |
22 |
" |
72.6 |
" |
" |
C-3 |
3.4 |
0 |
0 |
| " |
23 |
A-5 |
74.2 |
" |
" |
C-1 |
1.8 |
0 |
0 |
| " |
24 |
" |
74 |
" |
" |
C-2 |
2.0 |
0 |
0 |
| " |
25 |
" |
72.6 |
" |
" |
C-3 |
3.4 |
0 |
0 |
| Comp.Ex. |
1 |
A-1 |
73 |
" |
" |
C-4 |
3.0 |
4 |
5 |
| " |
2 |
" |
75 |
" |
" |
C-5 |
1.0 |
2 |
5 |
| " |
3 |
" |
74 |
" |
" |
C-6 |
2.0 |
0 |
5 |
| " |
4 |
A-2 |
73 |
" |
" |
C-4 |
3.0 |
4 |
5 |
| " |
5 |
" |
75 |
" |
" |
C-5 |
1.0 |
2 |
5 |
| " |
6 |
" |
74 |
" |
" |
C-6 |
2.0 |
0 |
4 |
| " |
7 |
A-1 |
61 |
" |
" |
C-3 |
15 |
- |
- |
[0041] Lubricant composition of Comparative Example 7 had a consistency number (JIS K2220
7 ; corresponding to DIN ISO 2137) of No. 4 and therefore too hard impossible to test
and to use as a practical grease. The lubricating oil composition of all the Examples
had consistency numbers of Nos. 1-3, and could form greases successfully.