FIELD OF THE INVENTION
[0001] The present invention relates to automotive engine lubricating oils, which exhibit
improved friction reduction and fuel consumption reduction, especially at lower operating
temperatures, in particular at engine operating temperatures below 80 °C.
BACKGROUND OF THE INVENTION
[0002] It is well known that molybdenum containing additives can be used in automotive engine
lubricants to improve friction reduction performance. However, it has generally been
found that the efficacy of such additives is not realized until the engine temperature
reaches around 80 °C. Thus, when an engine is operating at temperatures below 80 °C
the excellent friction reducing properties of molybdenum-containing additives is not
exhibited.
WO2011/161982 discloses fuel-saving engine oils comprising an organic molybdenum compound.
[0003] Benzotriazole compounds have been used for many years in lubricating oil compositions
as corrosion inhibitors to reduce copper corrosion.
[0004] It is the object of the present invention to further improve the friction and fuel
economy performance of automotive engine lubricating oils.
SUMMARY OF THE INVENTION
[0005] According to a first aspect the present invention provides an automotive engine lubricating
oil composition comprising
- (A) a base oil of lubricating viscosity,
- (B) at least one benzotriazole derivative represented by Formula (I):

wherein R5 is a hydrocarbyl group having 1-3 carbon atoms and R6 is a tertiary amine group represented by

wherein R7 and R8 are independently, linear or branched, hydrocarbyl groups having 3 to 10 carbon atoms,
- (C) at least one molybdenum dithiocarbamate compound represented by either Formula
(II) or Formula (III):

wherein R1 through R4 independently denote a straight chain, branched chain or aromatic hydrocarbyl group
having 1 to 24 carbon atoms; and X1 through X4 independently denote an oxygen atom or a sulfur atom,
Formula (III) Mo3SkLnQz
wherein L are independently selected ligands having organo groups with a sufficient
number of carbon atoms to render the compound soluble or dispersible in the oil, n
is from 1 to 4, k is from 4 to 7, Q is selected from the group of neutral electron
donating compounds such as water, amines, alcohols, phosphines, and ethers, and z
ranges from 0 to 5 and includes non-stoichiometric values, and
- (D) one or more additional additives chosen from metal containing or ashless detergents,
ashless antioxidants, antiwear additives, corrosion inhibitors, rust inhibitors, viscosity
index improvers, and dispersants,
wherein the lubricating oil composition comprises a total amount of from 450 to 2000
ppm molybdenum from components (C) and wherein the benzotriazole derivative (B) is
present in the lubricating oil in an amount from 0.01 to 0.04 mass%.
[0006] Preferably, the base oil of lubricating viscosity (A) is present in a major amount.
[0007] Preferably, the automotive engine lubricating oil composition of the present invention
is used to lubricate the crankcase of the engine (i.e. an automotive engine crankcase
lubricant).
[0008] Suitably, the automotive engine lubricating oil composition is used to lubricate
an automotive spark-ignited or automotive compression-ignited internal combustion
engine, preferably an automotive spark-ignited internal combustion engine.
[0009] Unexpectedly, it has been found that the use of the benzotriazole compound as an
additive in a lubricating oil composition which includes a molybdenum containing additive,
especially a molybdenum dithiocarbamate compound, permits improved friction reduction
performance, particularly boundary regime friction reduction performance, of the molybdenum
containing additive when the lubricating oil composition is used to lubricate an automotive
engine. Furthermore, the improved friction reduction performance of the molybdenum
containing compound is realized at lower engine operating temperatures i.e. when the
engine is operating at temperatures below 80 °C. Accordingly, the automotive engine
lubricating oil composition of the present inventions provides benefits in terms of
improved friction reduction and/or improved fuel consumption reduction.
[0010] In accordance with a second aspect, the present invention provides a method of lubricating
an automotive engine comprising lubricating the engine with a lubricating oil composition
as defined in accordance with the first aspect of the present invention. Suitably,
the method comprises lubricating the crankcase of the engine.
[0011] In accordance with a third aspect, the present invention provides the use, in the
lubrication of an automotive engine, of at least one benzotriazole derivative (B),
as defined in the first aspect of the invention, as an additive in an effective minor
amount, in a lubricating oil composition comprising a base oil of lubricating viscosity
(A) and at least one molybdenum dithiocarbamate compound (C), as defined in the first
aspect of the invention, to improve the friction reducing performance properties of
the molybdenum dithiocarbamate compound(s) (C) during operation of the automotive
engine, wherein
said molybdenum dithiocarbamate compound(s) (C) provide the lubricating oil composition
with from 450 to 2000 ppm of molybdenum.
[0012] In accordance with a fourth aspect, the present invention provides the use, in the
lubrication of an automotive engine, of the combination of at least one benzotriazole
derivative (B), as defined in the first aspect of the invention, and at least one
molybdenum dithiocarbamate compound (C), as defined in the first aspect of the invention,
as a combination of additives in an effective minor amount, in a lubricating oil composition
comprising a base oil of lubricating viscosity (A), to improve friction reduction
of the lubricating oil composition during operation of the automotive engine, wherein
said molybdenum dithiocarbamate compound(s) (C) provide the lubricating oil composition
with from 450 to 2000 ppm of molybdenum.
[0013] In accordance with a fifth aspect, the present invention provides the use, in the
lubrication of an automotive engine, of the combination of at least one benzotriazole
derivative (B), as defined in the first aspect of the invention, and at least one
molybdenum dithiocarbamate compound (C), as defined in the first aspect of the invention,
as a combination of additives in an effective minor amount, in a lubricating oil composition
comprising a base oil of lubricating viscosity (A), to reduce fuel consumption of
the automotive engine during operation of the engine, wherein said molybdenum dithiocarbamate
compound(s) (C) provide the lubricating oil composition with from 450 to 2000 ppm
of molybdenum.
[0014] Preferably, the automotive engine in the second to fifth aspects of the invention
operates at temperatures below 80 °C.
[0015] Preferably, the lubricating oil composition as defined in the third, fourth and fifth
aspects of the present invention further includes (D) one or more additional additives
chosen from metal containing or ashless detergents, ashless antioxidants, antiwear
additives, corrosion inhibitors, rust inhibitors, viscosity index improvers, and dispersants.
[0016] Suitably, the engine as defined in the second, third, fourth and fifth aspects of
the present invention is a spark-ignited or compression-ignited internal combustion
engine, preferably a spark-ignited internal combustion engine.
[0017] The at least one benzotriazole derivative (B) is present, in the lubricating oil
composition in an amount of 0.01 to 0.04 mass % on an active matter basis.
[0018] The at least one molybdenum dithiocarbamate compound (C) provides the lubricating
oil composition of the first aspect of the invention, and the lubricating oil composition
as defined in the second to fifth aspects of the invention, with a total amount of
450 to 2000, more preferably 450 to 1200, even more preferably 450 to 900, most preferably
600 to 900, ppm molybdenum (ASTM D5185).
[0019] Suitably, the lubricating oil composition of the present invention has a sulphated
ash content of less than or equal to 1.2, preferably less than or equal to 1.1, more
preferably less than or equal to 1.0, mass % (ASTM D874) based on the total mass of
the composition.
[0020] Preferably, the lubricating oil composition of the present invention contains low
levels of phosphorus. Suitably, the lubricating oil composition contains phosphorus
in an amount of less than or equal to 0.12, preferably up to 0.11, more preferably
less than or equal to 0.10, even more preferably less than or equal to 0.09, even
more preferably less than or equal to 0.08, most preferably less than or equal to
0.06, mass % of phosphorus (ASTM D5185) based on the total mass of the composition.
Suitably, the lubricating oil composition contains phosphorus in an amount of greater
than or equal to 0.01, preferably greater than or equal to 0.02, more preferably greater
than or equal to 0.03, even more preferably greater than or equal to 0.05, mass %
of phosphorus (ASTM D5185) based on the total mass of the composition.
[0021] Typically, the lubricating oil composition may contain low levels of sulphur. Preferably,
the lubricating oil composition contains sulphur in an amount of up to 0.4, more preferably
up to 0.3, even more preferably up to 0.2, mass % sulphur (ASTM D2622) based on the
total mass of the composition.
[0022] Typically, a lubricating oil composition according to the present invention contains
up to 0.30, more preferably up to 0.20, most preferably up to 0.15, mass % nitrogen,
based on the total mass of the composition and as measured according to ASTM method
D5291.
[0023] Suitably, the lubricating oil composition may have a total base number (TBN), as
measured in accordance with ASTM D2896, of from 4 to 15, preferably from 5 to 12 mg
KOH/g.
[0024] In this specification, the following words and expressions, if and when used, have
the meanings given below:
"active ingredients" or "(a.i.)" refers to additive material that is not diluent or
solvent;
"comprising" or any cognate word specifies the presence of stated features, steps,
or integers or components, but does not preclude the presence or addition of one or
more other features, steps, integers, components or groups thereof. The expressions
"consists of', or "consists essentially of' or cognates may be embraced within "comprises"
or cognates, wherein "consists essentially of' permits inclusion of substances not
materially affecting the characteristics of the composition to which it applies;
"hydrocarbyl" means a chemical group of a compound that contains hydrogen and carbon
atoms and that is bonded to the remainder of the compound directly via a carbon atom.
The group may contain one or more atoms other than carbon and hydrogen provided they
do not affect the essentially hydrocarbyl nature of the group. Those skilled in the
art will be aware of suitable groups (e.g., halo, especially chloro and fluoro, amino,
alkoxyl, mercapto, alkylmercapto, nitro, nitroso, sulfoxy, etc.). Preferably, the
group consists essentially of hydrogen and carbon atoms, unless specified otherwise.
Preferably, the hydrocarbyl group comprises an aliphatic hydrocarbyl group. The term
"hydrocarbyl" includes "alkyl", "alkenyl", "allyl" and "aryl" as defined herein;
"alkyl" means a C1 to C30 alkyl group which is bonded to the remainder of the compound directly via a single
carbon atom. Unless otherwise specified, alkyl groups may, when there are a sufficient
number of carbon atoms, be linear (i.e. unbranched) or branched, be cyclic, acyclic
or part cyclic/acyclic. Preferably, the alkyl group comprises a linear or branched
acyclic alkyl group. Representative examples of alkyl groups include, but are not
limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl,
n-pentyl, iso-pentyl, neo-pentyl, hexyl, heptyl, octyl, dimethyl hexyl, nonyl, decyl,
undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl,
nonadecyl, icosyl and triacontyl;
"aryl" means a C6 to C18, preferably C6 to C10, aromatic group, optionally substituted by one or more alkyl groups, halo, hydroxyl,
alkoxy and amino groups, which is bonded to the remainder of the compound directly
via a single carbon atom. Preferred aryl groups include phenyl and naphthyl groups
and substituted derivatives thereof, especially phenyl and alkyl substituted derivatives
thereof; "alkenyl" means a C2 to C30, preferably a C2 to C12, group which includes at least one carbon to carbon double bond and is bonded to
the remainder of the compound directly via a single carbon atom, and is otherwise
defined as "alkyl"; "alkylene" means a C2 to C20, preferably a C2 to C10, more preferably a C2 to C6 bivalent saturated acyclic aliphatic radical which may be linear or branched. Representative
examples of alkylene include ethylene, propylene, butylene, isobutylene, pentylene,
hexylene, heptylene, octylene, nonylene, decylene, 1-methyl ethylene, 1-ethyl ethylene,
1-ethyl-2-methyl ethylene, 1,1-dimethyl ethylene and 1-ethyl propylene;
"polyol" means an alcohol which includes two or more hydroxyl functional groups (i.e.
a polyhydric alcohol) but excludes a "polyalkylene glycol" (component B(ii)) which
is used to form the oil-soluble or oil-dispersible polymeric friction modifier. More
specifically, the term "polyol" embraces a diol, triol, tetrol, and/or related dimers
or chain extended polymers of such compounds. Even more specifically, the term "polyol"
embraces glycerol, neopentyl glycol, trimethylolethane, trimethylolpropane, trimethylolbutane,
pentaerythritol, dipentaerythritol, tripentaerythritol and sorbitol;
"polycarboxylic acid" means an organic acid, preferably a hydrocarbyl acid, which
includes 2 or more carboxylic acid functional groups. The term "polycarboxylic acid"
embraces di-, tri- and tetra- carboxylic acids;
"halo" or "halogen" includes fluoro, chloro, bromo and iodo;
"oil-soluble" or "oil-dispersible", or cognate terms, used herein do not necessarily
indicate that the compounds or additives are soluble, dissolvable, miscible, or are
capable of being suspended in the oil in all proportions. These do mean, however,
that they are, for example, soluble or stably dispersible in oil to an extent sufficient
to exert their intended effect in the environment in which the oil is employed. Moreover,
the additional incorporation of other additives may also permit incorporation of higher
levels of a particular additive, if desired;
"ashless" in relation to an additive means the additive does not include a metal;
"ash-containing" in relation to an additive means the additive includes a metal;
"major amount" means in excess of 50 mass % of a composition expressed in respect
of the stated component and in respect of the total mass of the composition, reckoned
as active ingredient of the component;
"minor amount" means less than 50 mass % of a composition, expressed in respect of
the stated additive and in respect of the total mass of the composition, reckoned
as active ingredient of the additive;
"effective minor amount" in respect of an additive means an amount of such an additive
in a lubricating oil composition so that the additive provides the desired technical
effect;
"ppm" means parts per million by mass, based on the total mass of the lubricating
oil composition;
"metal content" of the lubricating oil composition or of an additive component, for
example detergent metal, molybdenum or boron content or total metal content of the
lubricating oil composition (i.e. the sum of all individual metal contents), is measured
by ASTM D5185;
"TBN" in relation to an additive component or of a lubricating oil composition of
the present invention, means total base number (mg KOH/g) as measured by ASTM D2896;
"KVioo" means kinematic viscosity at 100°C as measured by ASTM D445;
"phosphorus content" is measured by ASTM D5185;
"sulfur content" is measured by ASTM D2622; and,
"sulfated ash content" is measured by ASTM D874.
[0025] All percentages reported are mass % on an active ingredient basis, i.e. without regard
to carrier or diluent oil, unless otherwise stated.
[0026] Also, it will be understood that various components used, essential as well as optimal
and customary, may react under conditions of formulation, storage or use and that
the invention also provides the product obtainable or obtained as a result of any
such reaction.
[0027] Further, it is understood that any upper and lower quantity, range and ratio limits
set forth herein may be independently combined.
[0028] Also, it will be understood that the preferred features of each aspect of the present
invention are regarded as preferred features of every other aspect of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
OIL OF LUBRICATING VISCOSITY
[0029] The oil of lubricating viscosity (sometimes referred to as "base stock" or "base
oil") is the primary liquid constituent of a lubricant, into which additives and possibly
other oils are blended, for example to produce a final lubricant (or lubricant composition).
A base oil is useful for making concentrates as well as for making lubricating oil
compositions therefrom, and may be selected from natural (vegetable, animal or mineral)
and synthetic lubricating oils and mixtures thereof.
[0031] Definitions for the base stocks and base oils in this invention are the same as those
found in the American Petroleum Institute (API) publication "
Engine Oil Licensing and Certification System", Industry Services Department, Fourteenth
Edition, December 1996, Addendum 1, December 1998. Said publication categorizes base stocks as follows:
- a) Group I base stocks contain less than 90 percent saturates and/or greater than
0.03 percent sulphur and have a viscosity index greater than or equal to 80 and less
than 120 using the test methods specified in Table E-1.
- b) Group II base stocks contain greater than or equal to 90 percent saturates and
less than or equal to 0.03 percent sulphur and have a viscosity index greater than
or equal to 80 and less than 120 using the test methods specified in Table E-1.
- c) Group III base stocks contain greater than or equal to 90 percent saturates and
less than or equal to 0.03 percent sulphur and have a viscosity index greater than
or equal to 120 using the test methods specified in Table E-1.
- d) Group IV base stocks are polyalphaolefins (PAO).
- e) Group V base stocks include all other base stocks not included in Group I, II,
III, or IV.
Table E-1: Analytical Methods for Base Stock
Property |
Test Method |
Saturates |
ASTM D 2007 |
Viscosity Index |
ASTM D 2270 |
Sulphur |
ASTM D 2622 |
|
ASTM D 4294 |
|
ASTM D 4927 |
|
ASTM D 3120 |
[0032] Other oils of lubricating viscosity which may be included in the lubricating oil
composition are detailed as follows.
[0033] Natural oils include animal and vegetable oils (e.g. castor and lard oil), liquid
petroleum oils and hydrorefined, solvent-treated mineral lubricating oils of the paraffinic,
naphthenic and mixed paraffinic-naphthenic types. Oils of lubricating viscosity derived
from coal or shale are also useful base oils.
[0034] Synthetic lubricating oils include hydrocarbon oils such as polymerized and interpolymerized
olefins (e.g. polybutylenes, polypropylenes, propylene-isobutylene copolymers, chlorinated
polybutylenes, poly(1-hexenes), poly(1-octenes), poly(1-decenes)); alkylbenzenes (e.g.
dodecylbenzenes, tetradecylbenzenes, dinonylbenzenes, di(2-ethylhexyl)benzenes); polyphenols
(e.g. biphenyls, terphenyls, alkylated polyphenols); and alkylated diphenyl ethers
and alkylated diphenyl sulfides and the derivatives, analogues and homologues thereof.
[0035] Another suitable class of synthetic lubricating oils comprises the esters of dicarboxylic
acids (e.g. phthalic acid, succinic acid, alkyl succinic acids and alkenyl succinic
acids, maleic acid, azelaic acid, suberic acid, sebasic acid, fumaric acid, adipic
acid, linoleic acid dimer, malonic acid, alkylmalonic acids, alkenyl malonic acids)
with a variety of alcohols (e.g. butyl alcohol, hexyl alcohol, dodecyl alcohol, 2-ethylhexyl
alcohol, ethylene glycol, diethylene glycol monoether, propylene glycol). Specific
examples of these esters include dibutyl adipate, di(2-ethylhexyl) sebacate, di-n-hexyl
fumarate, dioctyl sebacate, diisooctyl azelate, diisodecyl azelate, dioctyl phthalate,
didecyl phthalate, dieicosyl sebacate, the 2-ethylhexyl diester of linoleic acid dimer,
and the complex ester formed by reacting one mole of sebacic acid with two moles of
tetraethylene glycol and two moles of 2-ethylhexanoic acid.
[0036] Esters useful as synthetic oils also include those made from C
5 to C
12 monocarboxylic acids and polyols, and polyol ethers such as neopentyl glycol, trimethylolpropane,
pentaerythritol, dipentaerythritol and tripentaerythritol.
[0037] Unrefined, refined and re-refined oils can be used in the compositions of the present
invention. Unrefined oils are those obtained directly from a natural or synthetic
source without further purification treatment. For example, a shale oil obtained directly
from retorting operations, a petroleum oil obtained directly from distillation or
ester oil obtained directly from an esterification process and used without further
treatment would be unrefined oil. Refined oils are similar to the unrefined oils except
they have been further treated in one or more purification steps to improve one or
more properties. Many such purification techniques, such as distillation, solvent
extraction, acid or base extraction, filtration and percolation are known to those
skilled in the art. Re-refined oils are obtained by processes similar to those used
to obtain refined oils applied to refined oils which have been already used in service.
Such re-refined oils are also known as reclaimed or reprocessed oils and often are
additionally processed by techniques for approval of spent additive and oil breakdown
products.
[0038] Other examples of base oil are gas-to-liquid ("GTL") base oils, i.e. the base oil
may be an oil derived from Fischer-Tropsch synthesised hydrocarbons made from synthesis
gas containing H
2 and CO using a Fischer-Tropsch catalyst. These hydrocarbons typically require further
processing in order to be useful as a base oil. For example, they may, by methods
known in the art, be hydroisomerized; hydrocracked and hydroisomerized; dewaxed; or
hydroisomerized and dewaxed.
[0039] Preferably, the oil of lubricating viscosity is present in an amount of greater than
55 mass %, more preferably greater than 60 mass %, even more preferably greater than
70 mass %, based on the total mass of the lubricating oil composition. Preferably,
the oil of lubricating viscosity is present in an amount of less than 98 mass %, more
preferably less than 95 mass %, even more preferably less than 90 mass %, based on
the total mass of the lubricating oil composition.
[0040] The lubricating oil composition of each aspect of the present invention may be a
multigrade oil identified by the viscometric descriptor SAE 20W-X, SAE 15W-X, SAE
10W-X, SAE 5W-X or SAE 0W-X, where X represents any one of 8, 12, 16, 20, 30, 40 and
50; the characteristics of the different viscometric grades can be found in the SAE
J300 classification. In an embodiment of each aspect of the invention, independently
of the other embodiments, the lubricating oil composition is in the form of an SAE
10W-X, SAE 5W-X or SAE 0W-X, preferably in the form of a SAE 0W-X or SAE 5W-X viscosity
grade, wherein X represents any one of 8, 12, 16, 20 or 30. Preferably X is 8, 12,
16 or 20.
BENZOTRIAZOLE DERIVATIVE (B)
[0041] The lubricating oil composition of the present invention comprises at least one benzotriazole
derivative represented by Formula (I):

wherein R
5 is a hydrocarbyl group having 1-3 carbon atoms and R
6 is a tertiary amine group represented by

wherein R
7 and R
8 are independently, linear or branched, hydrocarbyl groups having 3 to 10 carbon atoms.
[0042] In a preferred embodiment R
5 is a methyl group. Preferably, R
7 and R
8 are both the same. In a preferred embodiment, R
7 and R
8 are hydrocarbyl groups having 6 to 8 carbon atoms.
[0043] In a preferred embodiment, the benzotriazole derivative has the following structure:

[0044] The benzotriazole derivative is present in the lubricating oil composition of the
present invention in an amount from 0.01 to 0.04 wt% on an active matter basis.
OIL-SOLUBLE MOLYBDENUM COMPOUND (C)
[0045] Suitable dinuclear or dimeric molybdenum dialkyldithiocarbamate compounds are represented
by the Formula (II):

wherein R
1 through R
4 independently denote a straight chain, branched chain or aromatic hydrocarbyl group
having 1 to 24 carbon atoms; and X
1 through X
4 independently denote an oxygen atom or a sulfur atom. The four hydrocarbyl groups,
R
1 through R
4, may be identical or different from one another.
[0046] Suitable tri-nuclear organo-molybdenum compounds include those of the formula Mo
3S
kL
nQ
z and mixtures thereof wherein L are independently selected ligands having organo groups
with a sufficient number of carbon atoms to render the compound soluble or dispersible
in the oil, n is from 1 to 4, k varies from 4 through 7, Q is selected from the group
of neutral electron donating compounds such as water, amines, alcohols, phosphines,
and ethers, and z ranges from 0 to 5 and includes non-stoichiometric values. At least
21 total carbon atoms should be present among all the ligands' organo groups, such
as at least 25, at least 30, or at least 35 carbon atoms.
[0047] The ligands are independently selected from the group of:
-X-R 1,

and mixtures thereof, wherein X, X
1, X
2, and Y are independently selected from the group of oxygen and sulfur, and wherein
R
1, R
2, and R are independently selected from hydrogen and organo groups that may be the
same or different. Preferably, the organo groups are hydrocarbyl groups such as alkyl
(e.g., in which the carbon atom attached to the remainder of the ligand is primary
or secondary), aryl, substituted aryl and ether groups. More preferably, each ligand
has the same hydrocarbyl group.
[0048] Importantly, the organo groups of the ligands have a sufficient number of carbon
atoms to render the compound soluble or dispersible in the oil. For example, the number
of carbon atoms in each group will generally range between about 1 to about 100, preferably
from about 1 to about 30, and more preferably between about 4 to about 20. Preferred
ligands include dialkyldithiophosphate, alkylxanthate, and dialkyldithiocarbamate,
and of these dialkyldithiocarbamate is more preferred. Organic ligands containing
two or more of the above functionalities are also capable of serving as ligands and
binding to one or more of the cores. Those skilled in the art will realize that formation
of the compounds of the present invention requires selection of ligands having the
appropriate charge to balance the core's charge.
[0049] Compounds having the formula Mo
3S
kL
nQ
z have cationic cores surrounded by anionic ligands and are represented by structures
such as

and

and have net charges of +4. Consequently, in order to solubilize these cores the total
charge among all the ligands must be -4. Four mono-anionic ligands are preferred.
Without wishing to be bound by any theory, it is believed that two or more tri-nuclear
cores may be bound or interconnected by means of one or more ligands and the ligands
may be multidentate. This includes the case of a multidentate ligand having multiple
connections to a single core. It is believed that oxygen and/or selenium may be substituted
for sulfur in the core(s).
[0050] Oil-soluble or oil-dispersible tri-nuclear molybdenum compounds can be prepared by
reacting in the appropriate liquid(s)/solvent(s) a molybdenum source such as (NH
4)
2Mo
3S
13.n(H
2O), where n varies between 0 and 2 and includes non-stoichiometric values, with a
suitable ligand source such as a tetralkylthiuram disulfide. Other oil-soluble or
dispersible tri-nuclear molybdenum compounds can be formed during a reaction in the
appropriate solvent(s) of a molybdenum source such as of (NH
4)
2Mo
3S
13.n(H
2O), a ligand source such as tetralkylthiuram disulfide, dialkyldithiocarbamate, or
dialkyldithiophosphate, and a sulfur abstracting agent such as cyanide ions, sulfite
ions, or substituted phosphines. Alternatively, a tri-nuclear molybdenum-sulfur halide
salt such as [M']
2[Mo
3S
7A
6], where M' is a counter ion, and A is a halogen such as Cl, Br, or I, may be reacted
with a ligand source such as a dialkyldithiocarbamate or dialkyldithiophosphate in
the appropriate liquid(s)/solvent(s) to form an oil-soluble or dispersible trinuclear
molybdenum compound. The appropriate liquid/solvent may be, for example, aqueous or
organic.
[0051] A compound's oil solubility or dispersibility may be influenced by the number of
carbon atoms in the ligand's organo groups. Preferably, at least 21 total carbon atoms
should be present among all the ligands' organo groups. Preferably, the ligand source
chosen has a sufficient number of carbon atoms in its organo groups to render the
compound soluble or dispersible in the lubricating composition.
[0052] The lubricating oil composition of the present invention may comprise either a dimeric
or trimeric molybdenum compound or both.
[0053] The total amount of oil-soluble molybdenum dithiocarbamate compounds will depend
upon the particular performance requirements of the lubricating oil composition. The
lubricating oil composition of the present invention contains a total amount of molybdenum
dithiocarbamate compounds in an amount providing the composition with at least 450ppm
of molybdenum (as measured according to ASTM D5185). The lubricating oil composition
of all aspects of the present invention may contain the molybdenum compound in an
amount providing the composition with up to 2000 ppm, or up to 1500ppm or up to 1200ppm,
or up to 800 ppm of molybdenum (as measured according to ASTM D5185). In a preferred
embodiment the molybdenum dithiocarbamate compound (C) provides the lubricating oil
composition with from 600 to 900 ppm molybdenum.
[0054] Preferably, the dimeric molybdenum dithiocarbamate and/or the trimeric molybdenum
dithiocarbamate are the sole sources of molybdenum atoms in the lubricating oil composition.
[0055] In a preferred embodiment the lubricating oil composition comprises both dimeric
and trimeric oil soluble molybdenum dithiocarbamate.
ADDITIONAL ADDITIVES (D)
[0056] The lubricating oil of all aspects of the present invention may also comprise one
or more additional conventional additives, including, but not limited to metal containing
or ashless detergent, ashless antioxidant, antiwear additives, corrosion inhibitors,
rust inhibitors, viscosity index improvers and dispersants.
[0057] In a preferred embodiment the lubricating oil compositions of the present invention
include an
aminic friction modifier having a structure according to Formula (IV) below:

[0058] Typically, the total amount of aminic friction modifier of Formula (IV) in the lubricating
oil composition of all aspects of the present invention does not exceed 5 mass %,
based on the total mass of the lubricating oil composition and preferably does not
exceed 2 mass % and more preferably does not exceed 0.5 mass %. Preferably, the aminic
friction modifier of Formula (IV) is present, in the lubricating oil composition of
all aspects of the present invention, in an amount of from 0.1 to 1.0, more preferably
0.1 to 0.5, even more preferably 0.1 to 0.3, mass %.
[0059] Dispersants are additives whose primary function is to hold solid and liquid contaminations in
suspension, thereby passivating them and reducing engine deposits at the same time
as reducing sludge depositions. For example, a dispersant maintains in suspension
oil-insoluble substances that result from oxidation during use of the lubricant, thus
preventing sludge flocculation and precipitation or deposition on metal parts of the
engine.
[0060] Dispersants are usually "ashless", being non-metallic organic materials that form
substantially no ash on combustion, in contrast to metal-containing, and hence ash-forming
materials. They comprise a long hydrocarbon chain with a polar head, the polarity
being derived from inclusion of e.g. an O, P, or N atom. The hydrocarbon is an oleophilic
group that confers oil-solubility, having, for example 40 to 500 carbon atoms. Thus,
ashless dispersants may comprise an oil-soluble polymeric backbone.
[0061] The ashless dispersant suitable for all aspects of the present invention is preferably
an ashless, nitrogen-containing dispersant.
[0062] Suitable ashless dispersant may be made from polyalkenes that have been functionalised
exclusively by the thermal "ene" reaction, a known reaction. Such polyalkenes are
mixtures having predominantly terminal vinylidene groups, such at least 65, e.g. 70,
more preferably at least 85, %. As an example, there may be mentioned a polyalkene
known as highly reactive polyisobutene (HR-PIB), which is commercially available under
the tradename Glissopal
™ (ex BASF).
US-A-4 152 499 describes the preparations of such polymers.
[0063] Alternatively, the ashless dispersant may be made from polyalkenes that have been
functionalised by the so-called chlorination method, which results in a product where
minor percentage of its polymer chains (e.g. less than 20%) have terminal vinylidene
groups.
[0064] Preferred monounsaturated reactants that may be used to functionalize the polyalkene
comprise mono- and dicarboxylic acid material, i.e., acid, anhydride, or acid ester
material, including (i) monounsaturated C
4 to C
10 dicarboxylic acid wherein (a) the carboxyl groups are vicinyl, (i.e., located on
adjacent carbon atoms) and (b) at least one, preferably both, of said adjacent carbon
atoms are part of said mono unsaturation; (ii) derivatives of (i) such as anhydrides
or C
1 to C
5 alcohol derived mono- or diesters of (i); (iii) monounsaturated C
3 to C
10 monocarboxylic acid wherein the carbon-carbon double bond is conjugated with the
carboxy group, i.e., of the structure -C=C-CO-; and (iv) derivatives of (iii) such
as C
1 to C
5 alcohol derived mono- or diesters of (iii). Mixtures of monounsaturated carboxylic
materials (i) - (iv) also may be used. Upon reaction with the polyalkene, the monounsaturation
of the monounsaturated carboxylic reactant becomes saturated. Thus, for example, maleic
anhydride becomes polyalkene-substituted succinic anhydride, and acrylic acid becomes
polyalkene-substituted propionic acid. Exemplary of such monounsaturated carboxylic
reactants are fumaric acid, itaconic acid, maleic acid, maleic anhydride, acrylic
acid, methacrylic acid, crotonic acid, cinnamic acid, and lower alkyl (e.g., C
1 to C
4 alkyl) acid esters of the foregoing, e.g., methyl maleate, ethyl fumarate, and methyl
fumarate.
[0065] To provide the required functionality, monounsaturated carboxylic reactants, preferably
maleic anhydride, typically will be used in an amount ranging from equimolar to 100,
preferably 5 to 50, wt. % excess, based on the moles of polyalkene. Unreacted excess
monounsaturated carboxylic reactant can be removed from the final dispersant product
by, for example, stripping, usually under vacuum, if required.
[0066] The functionalised oil-soluble polyalkene is then derivatized with a nucleophilic
reactant, such as an amine, amino-alcohol, alcohol, or mixture thereof, to form a
corresponding derivative containing the dispersant. Useful amine compounds for derivatizing
functionalized polymers comprise at least one amine and can comprise one or more additional
amine or other reactive or polar groups. These amines may be hydrocarbyl amines or
may be predominantly hydrocarbyl amines in which the hydrocarbyl group includes other
groups, e.g., hydroxy groups, alkoxy groups, amide groups, nitriles and imidazoline
groups. Particularly useful amine compounds include mono- and polyamines, e.g., polyalkene
and polyoxyalkylene polyamines of 2 to 60, such as 2 to 40 (e.g., 3 to 20), total
carbon atoms having 1 to 12, such as 3 to 12, preferably 3 to 9, most preferably 6
to 7, nitrogen atoms per molecule. Mixtures of amine compounds may advantageously
be used. Preferred amines are aliphatic saturated amines, including, for example,
1,2-diaminoethane; 1,3-diaminopropane; 1,4-diaminobutane; 1,6-diaminohexane; polyethylene
amines such as diethylene triamine; triethylene tetramine; tetraethylene pentamine;
and polypropyleneamines such as 1,2-propylene diamine; and di-(1,2-propylene)triamine.
Such polyamine mixtures, known as PAM, are commercially available. Particularly preferred
polyamine mixtures are mixtures derived by distilling the light ends from PAM products.
The resulting mixtures, known as "heavy" PAM, or HPAM, are also commercially available.
The properties and attributes of both PAM and/or HPAM are described, for example,
in
U.S. Patent Nos. 4,938,881;
4,927,551;
5,230,714;
5,241,003;
5,565,128;
5,756,431;
5,792,730; and
5,854,186.
[0067] Other useful amine compounds include: alicyclic diamines such as 1,4-di(aminomethyl)
cyclohexane and heterocyclic nitrogen compounds such as imidazolines. Another useful
class of amines is the polyamido and related amido-amines as disclosed in
U.S. Patent Nos. 4,857,217;
4,956,107;
4,963,275; and
5,229,022. Also usable is tris(hydroxymethyl)amino methane (TAM) as described in
U.S. Patent Nos. 4,102,798;
4,113,639;
4,116,876; and
UK 989,409. Dendrimers, star-like amines, and comb-structured amines may also be used. Similarly,
condensed amines, as described in
U.S. Patent No. 5,053,152 may be used. The functionalized polymer is reacted with the amine compound using
conventional techniques as described, for example, in
U.S. Patent Nos. 4,234,435 and
5,229,022, as well as in
EP-A-208,560.
[0068] A dispersant of the present invention preferably comprises at least one dispersant
that is derived from polyalkenyl-substituted mono- or dicarboxylic acid, anhydride
or ester, which has from greater than 1.3 to 1.7, preferably from greater than 1.3
to 1.6, most preferably from greater than 1.3 to 1.5, functional groups (mono- or
dicarboxylic acid producing moieties) per polyalkenyl moiety (a medium functionality
dispersant). Functionality (F) can be determined according to the following formula:

wherein SAP is the saponification number (i.e., the number of milligrams of KOH consumed
in the complete neutralization of the acid groups in one gram of the succinic-containing
reaction product, as determined according to ASTM D94); M
n is the number average molecular weight of the starting olefin polymer; A.I. is the
percent active ingredient of the succinic-containing reaction product (the remainder
being unreacted olefin polymer, succinic anhydride and diluent); and MW is the molecular
weight of the mono- or dicarboxylic acid producing moieties (e.g., 98 for maleic anhydride).
[0069] Generally, each mono- or dicarboxylic acid-producing moiety will react with a nucleophilic
group (amine, alcohol, amide or ester polar moieties) and the number of functional
groups in the polyalkenyl-substituted carboxylic acylating agent will determine the
number of nucleophilic groups in the finished dispersant.
[0070] The polyalkenyl moiety of the dispersant of the present invention may have a number
average molecular weight of at least 900, suitably at least 1500, preferably between
1800 and 3000, such as between 2000 and 2800, more preferably from about 2100 to 2500,
and most preferably from about 2200 to about 2400. The molecular weight of a dispersant
is generally expressed in terms of the molecular weight of the polyalkenyl moiety;
this is because the precise molecular weight range of the dispersant depends on numerous
parameters including the type of polymer used to derive the dispersant, the number
of functional groups, and the type of nucleophilic group employed.
[0071] Polymer molecular weight, specifically M̅
n, can be determined by various known techniques. One convenient method is gel permeation
chromatography (GPC), which additionally provides molecular weight distribution information
(see
W. W. Yau, J. J. Kirkland and D. D. Bly, "Modern Size Exclusion Liquid Chromatography",
John Wiley and Sons, New York, 1979). Another useful method for determining molecular weight, particularly for lower
molecular weight polymers, is vapor pressure osmometry (see, e.g., ASTM D3592).
[0072] The polyalkenyl moiety in a dispersant of the present invention preferably has a
narrow molecular weight distribution (MWD), also referred to as polydispersity, as
determined by the ratio of weight average molecular weight (M
w) to number average molecular weight (M
n). Polymers having a M
w/M
n of less than 2.2, preferably less than 2.0, are most desirable. Suitable polymers
have a polydispersity of from about 1.5 to 2.1, preferably from about 1.6 to about
1.8.
[0073] Suitable polyalkenes employed in the formation of the dispersants of the present
invention include homopolymers, interpolymers or lower molecular weight hydrocarbons.
One family of such polymers comprise polymers of ethylene and/or at least one C
3 to C
28 alpha-olefin having the formula H
2C=CHR
1 wherein R
1 is a straight or branched chain alkyl radical comprising 1 to 26 carbon atoms and
wherein the polymer contains carbon-to-carbon unsaturation, and a high degree of terminal
ethenylidene unsaturation. Preferably, such polymers comprise interpolymers of ethylene
and at least one alpha-olefin of the above formula, wherein R
1 is alkyl of from 1 to 18 carbon atoms, and more preferably is alkyl of from 1 to
8 carbon atoms, and more preferably still of from 1 to 2 carbon atoms
[0074] Another useful class of polymers is polymers prepared by cationic polymerization
of monomers such as isobutene and styrene. Common polymers from this class include
polyisobutenes obtained by polymerization of a C
4 refinery stream having a butene content of 35 to 75% by wt., and an isobutene content
of 30 to 60% by wt., by the thermal "ene" reaction. A preferred source of monomer
for making poly-n-butenes is petroleum feedstreams such as Raffinate II. These feedstocks
are disclosed in the art such as in
U.S. Patent No. 4,952,739. A preferred embodiment utilizes polyisobutylene prepared from a pure isobutylene
stream or a Raffinate I stream to prepare reactive isobutylene polymers with terminal
vinylidene olefins as described above.
[0075] The dispersant(s) of the invention are preferably mono- or bis-succinimides.
[0076] The dispersant(s) of the present invention can be borated by conventional means,
as generally taught in
U.S. Patent Nos. 3,087,936,
3,254,025 and
5,430,105. Boration of the dispersant is readily accomplished by treating an acyl nitrogen-containing
dispersant with a boron compound such as boron oxide, boron halide boron acids, and
esters of boron acids, in an amount sufficient to provide from 0.1 to 20 atomic proportions
of boron for each mole of acylated nitrogen composition.
[0077] The boron, which appears in the product as dehydrated boric acid polymers (primarily
(HBO
2)
3), is believed to attach, for example, to dispersant imides and diimides as amine
salts, e.g., the metaborate salt of the diimide. Boration can be carried out by adding
a sufficient quantity of a boron compound, preferably boric acid, usually as a slurry,
to the acyl nitrogen compound and heating with stirring at from 135C to 190, e.g.,
140 to 170, °C, for from 1 to 5 hours, followed by nitrogen stripping. Alternatively,
the boron treatment can be conducted by adding boric acid to a hot reaction mixture
of the dicarboxylic acid material and amine, while removing water. Other post-reaction
processes known in the art can also be applied.
[0078] Typically, the lubricating oil composition may contain from 1 to 20, such as 1 to
15, preferably 1 to 10, mass %, more preferably from 2 to 5 mass% dispersant.
[0079] In a preferred embodiment the lubricating oil composition of the present invention
comprises from 200-500 ppm boron from a borated dispersant.
[0080] Metal-containing detergents function both as detergents to reduce or remove deposits and as acid neutralizers
or rust inhibitors, thereby reducing wear and corrosion and extending engine life.
Detergents generally comprise a polar head with a long hydrophobic tail, with the
polar head comprising a metal salt of an acidic organic compound. The salts may contain
a substantially stoichiometric amount of the metal in which case they are usually
described as normal or neutral salts, and would typically have a total base number
or TBN (as can be measured by ASTM D2896) of from 0 to 80 mg KOH/g. A large amount
of a metal base may be incorporated by reacting excess metal compound (e.g., an oxide
or hydroxide) with an acidic gas (e.g., carbon dioxide). The resulting overbased detergent
comprises neutralized detergent as the outer layer of a metal base (e.g. carbonate)
micelle. Such overbased detergents may have a TBN of 150 mg KOH/g or greater, and
typically will have a TBN of from 250 to 450 mg KOH/g or more. In the presence of
the compounds of Formula I, the amount of overbased detergent can be reduced, or detergents
having reduced levels of overbasing (e.g., detergents having a TBN of 100 to 200 mg
KOH/g), or neutral detergents can be employed, resulting in a corresponding reduction
in the SASH content of the lubricating oil composition without a reduction in the
performance thereof.
[0081] Suitably the lubricating oil composition of the present invention further comprises
at least one metal-containing detergent additive.
[0082] Detergents that may be used include oil-soluble neutral and overbased sulfonates,
phenates, sulfurized phenates, thiophosphonates, salicylates, and naphthenates and
other oil-soluble carboxylates of a metal, particularly the alkali or alkaline earth
metals, e.g., sodium, potassium, lithium, calcium, and magnesium. The most commonly
used metals are calcium and magnesium, which may both be present in detergents used
in a lubricating oil composition according to any aspect of the present invention.
Combinations of detergents, whether overbased or neutral or both, may be used.
[0083] Sulfonates may be prepared from sulfonic acids which are typically obtained by the
sulfonation of alkyl substituted aromatic hydrocarbons such as those obtained from
the fractionation of petroleum or by the alkylation of aromatic hydrocarbons. Examples
included those obtained by alkylating benzene, toluene, xylene, naphthalene, diphenyl
or their halogen derivatives such as chlorobenzene, chlorotoluene and chloronaphthalene.
The alkylation may be carried out in the presence of a catalyst with alkylating agents
having from about 3 to more than 70 carbon atoms. The alkaryl sulfonates usually contain
from about 9 to about 80 or more carbon atoms, preferably from about 16 to about 60
carbon atoms per alkyl substituted aromatic moiety. The oil soluble sulfonates or
alkaryl sulfonic acids may be neutralized with oxides, hydroxides, alkoxides, carbonates,
carboxylate, sulfides, hydrosulfides, nitrates, borates and ethers of the metal. The
amount of metal compound is chosen having regard to the desired TBN of the final product
but typically ranges from about 100 to 220 mass % (preferably at least 125 mass %)
of that stoichiometrically required.
[0084] Metal salts of phenols and sulfurized phenols are prepared by reaction with an appropriate
metal compound such as an oxide or hydroxide and neutral or overbased products may
be obtained by methods well known in the art. Sulfurized phenols may be prepared by
reacting a phenol with sulfur or a sulfur containing compound such as hydrogen sulfide,
sulfur monohalide or sulfur dihalide, to form products which are generally mixtures
of compounds in which 2 or more phenols are bridged by sulfur containing bridges.
[0085] Carboxylate detergents, e.g., salicylates, can be prepared by reacting an aromatic
carboxylic acid with an appropriate metal compound such as an oxide or hydroxide and
neutral or overbased products may be obtained by methods well known in the art. The
aromatic moiety of the aromatic carboxylic acid can contain heteroatoms, such as nitrogen
and oxygen. Preferably, the moiety contains only carbon atoms; more preferably the
moiety contains six or more carbon atoms; for example benzene is a preferred moiety.
The aromatic carboxylic acid may contain one or more aromatic moieties, such as one
or more benzene rings, either fused or connected via alkylene bridges.
[0086] Preferred substituents in oil-soluble salicylic acids are alkyl substituents. In
alkyl - substituted salicylic acids, the alkyl groups advantageously contain 5 to
100, preferably 9 to 30, especially 14 to 20, carbon atoms. Where there is more than
one alkyl group, the average number of carbon atoms in all of the alkyl groups is
preferably at least 9 to ensure adequate oil solubility.
[0087] Lubricating oil compositions of the present invention preferably comprise one or
more metal detergents that are neutral or overbased alkali or alkaline earth metal
salicylates. Highly preferred salicylate detergents include alkaline earth metal salicylates,
particularly magnesium and calcium, especially, calcium salicylates. The metal salicylate
may be the sole metal-containing detergent present in the lubricating oil composition
of all aspects of the present invention. Alternatively, other metal-containing detergents,
such as metal sulfonates or phenates, may be present in the lubricating composition.
Preferably, the salicylate detergent provides the majority of the detergent additive
in the lubricating oil composition.
[0088] The total amount of metal-containing detergent additive present in the lubricating
oil composition according to any aspect of the present invention is suitably in the
range of 0.1-10 mass%, preferably from 0.5 to 5 mass% on an active matter basis.
[0089] Anti-wear additives reduce friction and excessive wear and are usually based on compounds containing
sulfur or phosphorous or both, for example that are capable of depositing polysulfide
films on the surfaces involved. Noteworthy are dihydrocarbyl dithiophosphate metal
salts wherein the metal may be an alkali or alkaline earth metal, or aluminium, lead,
tin, molybdenum, manganese, nickel, copper, or preferably, zinc.
[0090] Dihydrocarbyl dithiophosphate metal salts may be prepared in accordance with known
techniques by first forming a dihydrocarbyl dithiophosphoric acid (DDPA), usually
by reaction of one or more alcohols or a phenol with P
2S
5 and then neutralizing the formed DDPA with a metal compound. For example, a dithiophosphoric
acid may be made by reacting mixtures of primary and secondary alcohols. Alternatively,
dithiophosphoric acids can be prepared where the hydrocarbyl groups are entirely secondary
in character or the hydrocarbyl groups on are entirely primary in character. To make
the metal salt, any basic or neutral metal compound could be used but the oxides,
hydroxides and carbonates are most generally employed. Commercial additives frequently
contain an excess of metal due to the use of an excess of the basic metal compound
in the neutralization reaction.
[0091] The preferred zinc dihydrocarbyl dithiophosphates (ZDDP) are oil-soluble salts of
dihydrocarbyl dithiophosphoric acids and may be represented by the following formula:

wherein R and R' may be the same or different hydrocarbyl radicals containing from
1 to 18, preferably 2 to 12, carbon atoms and including radicals such as alkyl, alkenyl,
aryl, arylalkyl, alkaryl and cycloaliphatic radicals. Particularly preferred as R
and R' groups are alkyl groups of 2 to 8 carbon atoms. Thus, the radicals may, for
example, be ethyl, n-propyl, i-propyl, n-butyl, i-butyl, sec-butyl, amyl, n-hexyl,
i-hexyl, n-octyl, decyl, dodecyl, octadecyl, 2-ethylhexyl, phenyl, butylphenyl, cyclohexyl,
methylcyclopentyl, propenyl, butenyl. In order to obtain oil solubility, the total
number of carbon atoms (i.e. R and R') in the dithiophosphoric acid will generally
be about 5 or greater. The zinc dihydrocarbyl dithiophosphate can therefore comprise
zinc dialkyl dithiophosphates.
[0092] The ZDDP is added to the lubricating oil compositions in amounts sufficient to provide
at least 500 ppm such as at least 600ppm or at least 800ppm by mass of phosphorous
to the lubricating oil, based upon the total mass of the lubricating oil composition,
and as measured in accordance with ASTM D5185.
[0093] The ZDDP is suitably added to the lubricating oil compositions in amounts sufficient
to provide no more than 1200 ppm or, preferably no more than 1000ppm, by mass of phosphorous
to the lubricating oil, based upon the total mass of the lubricating oil composition,
and as measured in accordance with ASTM D5185.
[0094] Viscosity modifiers (VM) function to impart high and low temperature operability to a lubricating oil.
The VM used may have that sole function, or may be multifunctional. Multifunctional
viscosity modifiers that also function as dispersants are also known. Suitable viscosity
modifiers are polyisobutylene, copolymers of ethylene and propylene and higher alpha-olefins,
polymethacrylates, polyalkylmethacrylates, methacrylate copolymers, copolymers of
an unsaturated dicarboxylic acid and a vinyl compound, inter polymers of styrene and
acrylic esters, and partially hydrogenated copolymers of styrene/ isoprene, styrene/butadiene,
and isoprene/butadiene, as well as the partially hydrogenated homopolymers of butadiene
and isoprene and isoprene/divinylbenzene. Suitable viscosity modifiers for all aspects
of the present invention are copolymers of an unsaturated dicarboxylic acid and a
vinyl compound, inter polymers of styrene and acrylic esters, and, most preferably,
partially hydrogenated copolymers of styrene/ isoprene, styrene/butadiene, and isoprene/butadiene,
as well as the partially hydrogenated homopolymers of butadiene and isoprene and isoprene/divinylbenzene.
The preferred partially hydrogenated copolymers of styrene/ isoprene, styrene/butadiene,
and isoprene/butadiene, may be random copolymers but are preferably block copolymers.
The preferred, partially hydrogenated copolymers of styrene/isoprene, styrene/butadiene,
and isoprene/butadiene, and partially hydrogenated homopolymers of butadiene and isoprene
and isoprene/divinylbenzene viscosity modifiers may be linear polymers or star (radial)
polymers.
[0095] Linear block copolymers useful in the practice of the present invention may be represented
by the following general formula:
A
z-(B-A)
y-B
x
wherein:
A is a polymeric block comprising predominantly monoalkenyl aromatic hydrocarbon monomer
units;
B is a polymeric block comprising predominantly conjugated diolefin monomer units;
x and z are, independently, a number equal to 0 or 1; and
y is a whole number ranging from 1 to about 15.
[0096] Useful tapered linear block copolymers may be represented by the following general
formula:
A-A/B-B
wherein:
A is a polymeric block comprising predominantly monoalkenyl aromatic hydrocarbon monomer
units;
B is a polymeric block comprising predominantly conjugated diolefin monomer units;
and
A/B is a tapered segment containing both monoalkenyl aromatic hydrocarbon and conjugated
diolefin units.
[0097] Star or radial homopolymers or random copolymers of diene(s) (e.g., isoprene and/or
butadiene) may be represented, generally, by the following general formula:
(B)
n-C
wherein:
B and C are as previously defined; and
n is a number from 3 to 30;
C is the core of the radial polymer formed with a polyfunctional coupling agent;
B' is a polymeric block comprising predominantly conjugated diolefin units, which
B' may be the same or different from B; and
n' and n" are integers representing the number of each type of arm and the sum of
n' and n" will be a number from 3 to 30.
[0098] Star or radial block copolymers may be represented, generally, by the following general
formula:
(B
x-(A-B)
y-A
z)
n-C;
and
(B'
x-(A-B)
y-A
z)
n'-C(B')
n"
wherein:
A, B, x, y and z are as previously defined;
n is a number from 3 to 30;
C is the core of the radial polymer formed with a polyfunctional coupling agent;
B' is a polymeric block comprising predominantly conjugated diolefin units, which
B' may be the same or different from B; and
n' and n" are integers representing the number of each type of arm and the sum of
n' and n" will be a number from 3 to 30.
[0099] As used herein in connection with polymer block composition, the term "predominantly"
means that the specified monomer or monomer type which is the principle component
in that polymer block is present in an amount of at least 85% by weight of the block.
[0100] The lubricating oil composition according to all aspects of the present invention
may comprise one or more star polymer viscosity modifier one or more linear polymer
viscosity modifier or a mixture of linear and star polymer viscosity modifiers.
[0101] Oil-soluble viscosity modifying polymers generally have weight average molecular
weights of from 10,000 to 1,000,000, preferably 20,000 to 500,000, which may be determined
by gel permeation chromatography or by light scattering.
[0102] In an embodiment of the present invention, the viscosity modifier comprises a polymethacrylate,
polyalkylmethacrylate or methacrylate copolymer viscosity modifier. In a preferred
embodiment, the polymethacrylate, polyalkylmethacrylate or methacrylate copolymer
viscosity modifier is the only viscosity modifier in the lubricating oil composition.
[0103] Anti-oxidants, sometimes referred to as oxidation inhibitors, increase the resistance of the composition
to oxidation and may work by combining with and modifying peroxides to render them
harmless, by decomposing peroxides, or by rendering oxidation catalysts inert. Oxidative
deterioration can be evidenced by sludge in the lubricant, varnish-like deposits on
the metal surfaces, and by viscosity increase.
[0104] Examples of suitable antioxidants are selected from copper-containing antioxidants,
sulfur-containing antioxidants, aromatic amine-containing antioxidants, hindered phenolic
antioxidants and dithiophosphates derivative. Preferred anti-oxidants are ashless
antioxidants. Preferred ashless antioxidants are ashless aromatic amine-containing
antioxidants, ashless hindered phenolic antioxidants and mixtures thereof. Preferably,
one or more antioxidant is present in a lubricating oil composition of all aspects
of the present invention. In a preferred embodiment, a lubricating oil composition
of the present invention comprises a combination of aromatic amine antioxidants and
hindered phenolic antioxidant and optionally also a sulfurized olefin antioxidant.
[0105] Rust inhibitors selected from the group consisting of nonionic polyoxyalkylene polyols and esters
thereof, polyoxyalkylene phenols, and anionic alkyl sulfonic acids may be used.
[0106] In a preferred embodiment of the present invention, no copper-containing additives
are present in the lubricating oil composition.
[0107] A small amount of a
demulsifying component may be used. A preferred demulsifying component is described in
EP 330522. It is obtained by reacting an alkylene oxide with an adduct obtained by reacting
a bis-epoxide with a polyhydric alcohol. The demulsifier should be used at a level
not exceeding 0.1 mass % active ingredient. A treat rate of 0.001 to 0.05 mass % active
ingredient is convenient.
[0108] Pour point depressants, otherwise known as lube oil flow improvers, lower the minimum temperature at which
the fluid will flow or can be poured. Such additives are well known. Typical of those
additives which improve the low temperature fluidity of the fluid are C
8 to C
18 dialkyl fumarate/vinyl acetate copolymers, polyalkylmethacrylates and the like.
[0109] Foam control can be provided by many compounds including an
antifoamant of the polysiloxane type, for example, silicone oil or polydimethyl siloxane.
[0110] Suitable additional additives and their common treat rates are discussed below. All
the values listed are stated as mass percent active ingredient in a fully formulated
lubricant.
Additive |
Mass % |
Mass % |
|
(Broad) |
(Preferred) |
Corrosion Inhibitor |
0 - 5 |
0 - 1.0 |
Metal Dihydrocarbyl Dithiophosphate |
0 - 10 |
0 - 4 |
Anti-Oxidants |
0 - 5 |
0.01 - 3 |
Pour Point Depressant |
0.01 - 5 |
0.01 - 1.5 |
Anti-Foaming Agent |
0 - 5 |
0.001 - 0.15 |
Viscosity Modifier (1) |
0 - 10 |
0.01 - 4 |
Mineral or Synthetic Base Oil |
Balance |
Balance |
(1) Viscosity modifiers are used only in multi-graded oils. |
[0111] The final lubricating oil composition, typically made by blending the or each additive
into the base oil, may contain from 5 to 25, preferably 5 to 18, typically 7 to 15,
mass % of the additives; the remainder being oil of lubricating viscosity.
[0112] As is known in the art, some additives can provide a multiplicity of effects, for
example, a single additive may act as a dispersant and as an oxidation inhibitor.
[0113] The individual additives may be incorporated into a base stock in any convenient
way. Thus, each of the components can be added directly to the base stock or base
oil blend by dispersing or dissolving it in the base stock or base oil blend at the
desired level of concentration. Such blending may occur at ambient or elevated temperatures.
[0114] Preferably, all the additives except for the viscosity modifier and the pour point
depressant are blended into a concentrate or additive package described herein as
the additive package that is subsequently blended into base stock to make the finished
lubricant. The concentrate will typically be formulated to contain the additive(s)
in proper amounts to provide the desired concentration in the final formulation when
the concentrate is combined with a predetermined amount of a base lubricant.
[0115] The concentrate is preferably made in accordance with the method described in
US 4,938,880. That patent describes making a pre-mix of ashless dispersant and metal detergents
that is pre-blended at a temperature of at least about 100°C. Thereafter, the pre-mix
is cooled to at least 85°C and the additional components are added.
[0116] The final crankcase lubricating oil formulation may employ from 2 to 20, preferably
4 to 18, and most preferably 5 to 17, mass % of the concentrate or additive package
with the remainder being base stock.
[0117] The lubricating oil composition of the present invention may have a sulphated ash
content of less than or equal to 1.2, preferably less than or equal to 1.1, more preferably
less than or equal to 1.0, mass % (ASTM D874) based on the total mass of the composition.
The lubricating oil composition of the present invention suitably has a sulphated
ash content of at least 0.4, preferably at least 0.5, such as at least 0.6 mass %
(ASTM D874) based on the total mass of the composition. Suitably the sulphated ash
content of the lubricating oil composition is in the range of 0.4-1.2 mass%, preferably
in the range of 0.6 to 1.0 mass% (ASTM D874).
[0118] The amount of sulfur in the lubricating oil composition will depend upon the particular
application of the lubricating oil composition. The lubricating oil composition may
contain sulphur in an amount of up to 0.4, such as, up to 0.35 mass % sulphur (ASTM
D2622) based on the total mass of the composition. Generally the lubricating oil composition
will contain at least 0.1, or even at least 0.2 mass% sulphur (ASTM D2622) based on
the total mass of the composition.
[0119] Suitably, the lubricating oil composition of all aspects and embodiments of the present
invention may have a total base number (TBN), as measured in accordance with ASTM
D2896, of 4 to 15, preferably 4 to 10 mg KOH/g.
EXAMPLES
[0120] The invention will now be described in the following examples which are not intended
to limit the scope of the claims hereof.
Example 1
[0121] The Schwingung Reibung Verschleiss "SRV", supplied by Optimol, is used to evaluate
friction and wear properties of liquid lubricants across a broad range of applications.
The test oil forms a film in between a ball and disk, the ball is engaged in a sliding
or reciprocating stroke across the disk and friction between the metal-metal contact
is measured. This is used to evaluate the boundary regime friction characteristics
of the oils. There are different specimens and configurations that can be used in
SRV. In these examples the average friction was recorded at a frequency of 20 Hz and
a temperature of 80 C°.
[0122] Two oils having the formulations set out in Table 1 below were tested and the average
friction coefficient was recorded at each of the loads shown in Table 2 below.
Table 1
Additive |
Oil 1 |
Oil 2 |
Oil 3 |
Oil 4 |
Additive Package1 |
10.29 |
10.29 |
|
|
Additive Package8 |
|
|
9.95 |
9.95 |
Dimeric Molybdenum Dithiocarbamate2 |
0.70 |
0.70 |
0.80 |
0.80 |
Trimeric Molybdenum Dithiocarbamate3 |
0.20 |
0.20 |
|
|
Sulfurised ester antioxidant4 |
0.90 |
|
|
|
Irgamet395 |
|
0.01 |
|
0.01 |
Viscosity modifier |
6.90 |
6.90 |
6.60 |
6.60 |
Group III base oil |
Balance |
Balance |
Balance |
Balance |
Mo, ppm (ASTM D5185) |
865 |
865 |
800 |
800 |
1 The additive package had the same composition for Oils 1 and 2 and comprised a dispersant combination comprising non-borated and borated polyisobutenyl
succinimide dispersant, a calcium salicylate detergent, a magnesium salicylate detergent,
a combination of hindered phenol and diphenylamine antioxidants and zinc dialkyldithiophosphate.
2 Dimeric molybdenum dithiocarbamate, Sakuralube 525.
3Trimeric molybdenum dithiocarbamate from Infineum UK Ltd.
4 Available from Infineum UK Ltd
5 1H-benzotriazole-1-methanamine, N, N-bis(2-ethylhexyl)-ar-methyl, available from
BASF
8 The additive package had the same composition for Oils 3 and 4 and comprised a dispersant
combination comprising non-borated and borated polyisobutenyl succinimide dispersant,
a calcium salicylate detergent, a magnesium salicylate detergent, a combination of
hindered phenol and diphenylamine antioxidants, antifoam and zinc dialkyldithiophosphate. |
Table 2
Average Friction Coefficient |
Oil 1 |
Oil 2 |
Oil 3 |
Oil 4 |
20N |
0.154 |
0.125 |
0.133 |
0.119 |
30N |
0.124 |
0.105 |
0.115 |
0.107 |
40N |
0.107 |
0.096 |
0.103 |
0.099 |
50N |
0.095 |
0.089 |
0.096 |
0.093 |
[0123] It can be seen from this data that Oils 2 and 4 containing a combination of molybdenum
compound with Irgamet 39 exhibits significantly lower coefficient of friction than
the corresponding oil without the Irgamet 39.
Example 2
[0124] Four more oils having the formulations set out in Table 3 below were tested and the
average friction coefficient was recorded at each of the loads shown in Table 4 below.
Table 3
Additive |
Oil 5 |
Oil 6 |
Oil 7 |
Oil 8 |
Additive Package6 |
9.95 |
9.95 |
9.95 |
9.95 |
Dimeric Molybdenum Dithiocarbamate2 |
0.80 |
0.80 |
0.80 |
0.80 |
Irgamet395 |
0.01 |
0.01 |
0.01 |
0.01 |
Viscosity Modifier |
6.60 |
6.60 |
6.60 |
6.60 |
Ethoxylated amine friction modifier7 |
0 |
0.10 |
0.20 |
0.30 |
Group III base oil |
Balance |
Balance |
Balance |
Balance |
Mo, ppm (ASTM D5185) |
800 |
800 |
800 |
800 |
6 The additive package had the same composition for all oils in Table 3 and comprised
a dispersant combination comprising non-borated and borated polyisobutenyl succinimide
dispersant, a calcium salicylate detergent, a magnesium salicylate detergent, a combination
of hindered phenol and diphenylamine antioxidants and zinc dialkyldithiophosphate.
2 Dimeric molybdenum dithiocarbamate, Sakuralube 525.
5 1H-benzotriazole-1-methanamine, N, N-bis(2-ethylhexyl)-ar-methyl, available from
BASF 7Available from Infineum UK Ltd. |
Table 4
Average Friction Coefficient |
Oil 5 |
Oil 6 |
Oil 7 |
Oil 8 |
20N |
0.142 |
0.126 |
0.127 |
0.126 |
30N |
0.120 |
0.109 |
0.108 |
0.105 |
40N |
0.107 |
0.099 |
0.096 |
0.094 |
50N |
0.099 |
0.092 |
0.088 |
0.089 |
[0125] The data in Table 4 illustrates that addition of an ethoxylated amine friction modifier
to a lubricant containing a combination of molybdenum dithiocarbamate and a benzotriazole
derivative further reduced the coefficient of friction.