CN103917629A - 用于润滑组合物的无灰摩擦改进剂 - Google Patents
用于润滑组合物的无灰摩擦改进剂 Download PDFInfo
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- CN103917629A CN103917629A CN201280053330.6A CN201280053330A CN103917629A CN 103917629 A CN103917629 A CN 103917629A CN 201280053330 A CN201280053330 A CN 201280053330A CN 103917629 A CN103917629 A CN 103917629A
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Classifications
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M129/00—Lubricating compositions characterised by the additive being an organic non-macromolecular compound containing oxygen
- C10M129/02—Lubricating compositions characterised by the additive being an organic non-macromolecular compound containing oxygen having a carbon chain of less than 30 atoms
- C10M129/24—Aldehydes; Ketones
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- C10M2203/00—Organic non-macromolecular hydrocarbon compounds and hydrocarbon fractions as ingredients in lubricant compositions
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- C10M2203/102—Aliphatic fractions
- C10M2203/1025—Aliphatic fractions used as base material
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- C10M2207/026—Hydroxy compounds having hydroxy groups bound to carbon atoms of six-membered aromatic rings with tertiary alkyl groups
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- C10M2207/023—Hydroxy compounds having hydroxy groups bound to carbon atoms of six-membered aromatic rings
- C10M2207/028—Overbased salts thereof
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- C10M2207/04—Ethers; Acetals; Ortho-esters; Ortho-carbonates
- C10M2207/042—Epoxides
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- C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
- C10M2207/08—Aldehydes; Ketones
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- C10M2207/289—Partial esters containing free hydroxy groups
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- C10M2215/04—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to acyclic or cycloaliphatic carbon atoms
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- C10M2215/064—Di- and triaryl amines
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- C10M2215/082—Amides containing hydroxyl groups; Alkoxylated derivatives
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- C10M2215/221—Six-membered rings containing nitrogen and carbon only
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- C10M2215/28—Amides; Imides
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- C10M2219/046—Overbasedsulfonic acid salts
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- C10M2219/082—Thiols; Sulfides; Polysulfides; Mercaptals containing sulfur atoms bound to acyclic or cycloaliphatic carbon atoms
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- C10M2219/089—Overbased salts
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- C10M2223/00—Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions
- C10M2223/02—Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions having no phosphorus-to-carbon bonds
- C10M2223/04—Phosphate esters
- C10M2223/043—Ammonium or amine salts thereof
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- C10M2223/045—Metal containing thio derivatives
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- C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/06—Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
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Abstract
本发明提供一种润滑组合物，所述组合物包含具有润滑粘度的油和无灰酮化合物，其中无灰酮化合物具有连接在与酮的羰基碳相邻的碳原子上的羟基和醚键中的至少一个，所述无灰酮化合物尤其是α-羟基酮。本发明进一步涉及通过将所述润滑组合物供入内燃机中而润滑内燃机的方法。本发明进一步涉及α-羟基酮化合物作为摩擦改进剂和抗磨剂的用途。
Description
发明领域
本发明提供包含α-羟基-酮和具有润滑粘度的油的润滑组合物。本发明进一步涉及润滑组合物在内燃机中的用途。本发明进一步涉及α-羟基-酮作为摩擦改进剂的用途。
发明背景
熟知润滑油含有大量用于保护内燃机以防腐蚀、磨损、烟灰沉积物和酸建立的表面活性添加剂(包括抗磨剂、分散剂或清净剂)。通常，这类表面活性添加剂可能对发动机组件磨损(在铁和铝基组件中)、轴承腐蚀或燃料经济性具有有害影响。用于发动机润滑油的常用抗磨添加剂为二烷基二硫代磷酸锌(ZDDP)。认为ZDDP抗磨添加剂通过在金属表面上形成保护膜而保护发动机。ZDDP还可能对燃料经济性和效率和铜腐蚀具有有害影响。因此，发动机润滑剂还可含有摩擦改进剂以避免ZDDP对燃料经济性的有害影响以及腐蚀抑制剂以避免ZDDP对铜腐蚀的有害影响。摩擦改进剂和其它添加剂也可提高铅腐蚀。
另外，含有磷化合物和硫化合物如ZDDP的发动机润滑剂显示出部分地贡献于颗粒物排放和其它污染物排放。另外，硫和磷倾向于毒害催化转化器中所用的催化剂，导致所述催化剂的性能降低。
存在排放降低(通常NOx形成、SOx形成的降低)和发动机油润滑剂中硫酸盐灰降低的商业倾向。因此，含磷抗磨剂如ZDDP、过碱性清净剂如钙或镁磺酸盐和酚盐的量降低。因此，对提供至少与上述非无灰添加剂一样好，或者甚至更好的摩擦、抗磨或抗氧化剂性能的无灰添加剂存在提高的兴趣。已知表面活性无灰化合物如无灰摩擦改进剂在一些情况下可提高金属，即铜或铅的腐蚀。铜和铅腐蚀可来自衍生自使用铜或铅的合金的轴承和其它金属发动机组件。因此，可能需要降低由无灰添加剂导致的腐蚀量。
美国专利3,250,710公开了制备过碱性多价金属磺酸盐的方法。在一列合适的分散助剂中，公开了3-羟基-2-丁酮。
美国专利申请2011/0143980公开了衍生自多种α-、β-和γ-羟基-羰基化合物(或其阴离子)，包括α-羟基-酮的油溶性钛配合物。然而，没有教导所公开的羰基化合物本身作为添加剂，而是仅作为添加剂的前体。
多个专利公开如CA1183125、U.S.5,387,351、U.S.2005/0198894、U.S.4,640,787、U.S.4,692,257、U.S.4,478,604、U.S.4,237,022、GB2105743、U.S.2,443,578、U.S.2,365,291、U.S.5,338,470、WO2005/087904、WO2008/147700、WO2008/147704和WO2008/144701公开了包含羟基羧酸酰胺、酰亚胺和酯作为无灰抗磨剂和/或摩擦改进剂的不同润滑组合物。这些参考文件都没有公开羟基取代的酮。
国际出版物WO2010/096167、WO2010/096168和WO2010/096169分别公开了降低磨损或摩擦和沉积物形成和氧化的方法。三个国际出版物中公开的组合物包括包含基油和至少一种添加剂的润滑组合物，所述添加剂选自抗氧化剂、分散剂、清净剂或抗磨剂。这些参考文件都没有公开α-羟基-酮。
发明概述
本发明提供能够提供摩擦改进(特别是增强燃料经济性)、抗磨性能、特压性能、抗氧化性能、铅、锡或铜(通常铅)腐蚀抑制、降低的对丙烯酸酯或含氟弹性体密封的腐蚀性、密封溶胀性能或其一些组合的润滑组合物。
本发明提供包含具有润滑粘度的油和添加剂的润滑组合物，所述添加剂包含具有连接在与羰基碳相邻的碳原子上(即在α位上)的羟基、醚键或其混合物中至少一个的酮化合物。这类化合物在本文中称为α-羟基酮。所述α-羟基酮还包括聚羟基酮，包括对称二羟基酮和包含连接在与羰基碳相邻的碳原子上(即在α位上)的羟基或醚键以及然后连接在下一相邻碳原子上(即在β位上)的羟基或醚键的二羟基酮。
本发明进一步提供制备上述α-羟基酮的方法。
本发明进一步提供润滑内燃机的方法，所述方法包括步骤：(I)向内燃机中供入本文所述润滑组合物。
本发明进一步提供所述α-羟基酮作为摩擦改进剂、抗磨性能添加剂、特压添加剂、抗氧化剂、铅、锡或铜腐蚀抑制剂、密封保护剂或密封溶胀添加剂的用途。
发明详述
下面通过非限定性阐述描述各个优选特征和实施方案。
除非另外指出，存在于本文所述润滑组合物中的添加剂的量基于无油，即活性物质的量报出。
α-羟基酮
本发明提供包含具有润滑粘度的油和添加剂的润滑组合物，所述添加剂包含具有连接在与羰基碳相邻的碳原子上(即在α位上)的羟基或醚键的酮化合物。
在一个实施方案中，酮包含式(1)表示的化合物：
其中R1为包含1-40个碳的线性或支化烃基；且R2、R3和R4各自独立地为氢或者包含1-30个碳原子的线性或支化烃基。烃基R1和R2一起可形成5元或6元饱和或不饱和烃基环。烃基R3和R4一起可独立地形成5元或6元饱和或不饱和烃基环。在一些实施方案中，R1包含一个或多个氧原子，但否则仅由碳和氢原子组成。在其它实施方案中，R1为不含氧原子和任何其它杂原子的烷基。在又其它实施方案中，R1可以为-C(R2)(R3)(OR4)；-C(＝O)-R2；-C(＝O)-C(R2)(R3)(OR4)；，其中在所有这些实施方案中，R2、R3和R4具有以上提供的相同定义。
在一个实施方案中，R1可以为包含1-40，或者4-30，或者8-20，或者10-16个碳原子的线性或支化烃基。
在一个实施方案中，R2、R3和R4为氢，且R1为包含8-20个碳原子的无氮烃基。在一个实施方案中，R1为包含8-20个碳原子的线性或支化烷基。
在一个实施方案中，R2、R3和R4可独立地为具有1-20，或者1-10，或者1-6个碳原子的无氮线性或支化烃基。
在一个实施方案中，α-羟基酮(通常式1化合物)不是含金属配合物的一部分。在一个实施方案中，α-羟基酮包含少于5％或少于3％或少于1％的金属、含金属化合物或贡献硫酸盐灰的材料。在一个实施方案中，α-羟基酮不含过渡金属、碱金属、碱土金属或其组合。在一个实施方案中，α-羟基酮不含钛。
在一个实施方案中，本发明酮化合物(通常式(1)化合物)可以以润滑组合物的0.01-5重量％，或者0.1-4重量％，或者0.2-3重量％，或者0.5-2重量％，或者0.05-0.5重量％存在于润滑组合物中。
α-羟基酮可以为1-羟基-2-十二烷酮、1-羟基-2-十四烷酮、1-羟基-2-十六烷酮、1-羟基-2-十八烷酮或其任何组合。
在一个实施方案中，α-羟基酮可衍生自线性或支化α-烯烃或者衍生自线性或支化烃基-1,2-二醇。合适的α-烯烃(也是1-烯烃)包括具有4-40，或者6-30，或者10-20个碳原子的那些。合适α-烯烃的实例包括1-癸烯、1-十二碳烯、1-十四碳烯、1-十六碳烯和1-十八碳烯。合适的1,2-二醇包括具有4-40，或者6-30，或者10-20个碳原子的那些。
在一些实施方案中，本发明α-羟基酮包含具有连接在与羰基碳相邻的碳原子上(即在α位上)的羟基或醚键以及然后连接在下一相邻碳原子上(即在β位上)的另一羟基或醚键的酮化合物。这类材料可称为二羟基酮，在一些实施方案中，可通过使含羰基醇如丙酮醇(也称为1-羟基丙-2-酮)与醛如丙醛、癸醛、1-甲基苯甲醛以及各种其它材料反应而制备。
合适的含羰基醇包括式HO-R5-C(＝O)-R6的那些，其中R5和R6各自独立地为烃基，R5为亚烃基或二价基团，且R6为单价烃基。在一些实施方案中，R6可以为以上关于R1定义的任何基团，同时R5通常为单碳原子，在所得二羟基酮化合物中变成与羰基相邻的碳。
合适的醛包括式H-C(＝O)-R7的那些，其中R7各自为烃基。在一些实施方案中，R6可以为以上关于R2或R3所定义的任何基团。醛可有效地变成以上式I中显示的R2，其中应当理解R2基团为具有位于该基团的第一碳原子上的羟基的含羟基烃基。在这类实施方案中，上式中的R3通常为氢。
在其中酮为二羟基酮化合物的这类实施方案中，化合物可由式(2)表示：
其中所有基团R1、R2、R3和R4各自可以为以上关于式(1)的各基团所定义的基团。在一些实施方案中，R1为小烷基，例如甲基；R2基团各自为氢；且R3基团为包含1-30个碳原子的线性或支化烃基，在一些实施方案中，为包含6-20、8-16或甚至约8-12，或者甚至10个碳原子的线性烃基，或者甚至烷基(不含杂原子)；R4基团各自为氢。
具有润滑粘度的油
本发明润滑组合物包含具有润滑粘度的油。合适的油包括天然和合成油，衍生自加氢裂化、氢化和加氢精制的油，未精炼、精炼、再精炼油或其混合物。
未精炼油为不经(或仅很少)进一步提纯处理，通常直接由天然或合成来源得到的那些。
精炼油类似于未精炼油，不同的是已将它们在一个或多个提纯步骤中进一步处理以改进一种或多种性能。提纯技术是本领域中已知的，包括溶剂萃取、二次蒸馏、酸或碱萃取、过滤、渗滤等。
再精炼油也称为再生或再加工油，并通过类似于用于得到精炼油的那些的方法得到且通常通过旨在除去废添加剂和油分解产物的技术另外加工。
用于制备本发明润滑剂的天然油包括动物油，植物油(例如蓖麻油)，矿物润滑油，例如液体石油以及烷烃、环烷烃和混合烷烃-环烷烃型的溶剂处理或酸处理矿物润滑油，和衍生自煤或页岩的油，或其混合物。
合成润滑油是有用的，包括烃油，例如聚合、低聚和共聚烯烃(例如聚丁烯、聚丙烯、丙烯异丁烯共聚物)；聚(1-己烯)、聚(1-辛烯)、1-癸烯的三聚物或低聚物如聚(1-癸烯)、通常称为聚α-烯烃的这类材料及其混合物；烷基苯(例如十二烷基苯、十四烷基苯、二壬基苯、二-(2-乙基己基)苯)；聚苯(例如联苯、三联苯、烷基化多酚)；二苯基链烷烃、烷基化二苯基链烷烃、烷基化二苯醚和烷基化二苯硫及其衍生物、类似物和同系物或混合物。
其它合成润滑油包括多元醇酯(例如3970)、二酯、含磷酸的液体酯(例如磷酸三甲苯酯、磷酸三辛基酯，和癸基膦酸的二乙基酯)，或聚四氢呋喃。合成油可通过费托反应制备，通常可以为加氢异构化费托烃或蜡。在一个实施方案中，油可通过费托天然气合成油合成程序制备以及为其它天然气合成油。
具有润滑粘度的油也可如“Appendix E-API Base OilInterchangeability Guidelines for Passenger Car Motor Oils and DieselEngine Oils”的2008年4月版本，第1.3部分，亚标题1.3“Base StockCategories”所述定义。在一个实施方案中，具有润滑粘度的油可以为API组II或组III油。在一个实施方案中，具有润滑粘度的油可以为API组I油。
存在的具有润滑粘度的油的量通常为从100重量％中减去本发明化合物和其它性能添加剂的量之和后的余量。
润滑组合物可以为浓缩物和/或完全配制润滑剂的形式。如果本发明润滑组合物(包含本文所公开的添加剂)为浓缩物的形式(其可以与其它油结合以完全或部分地形成最终润滑剂)，则这些添加剂与具有润滑粘度的油和/或与稀释油之比包括1:99-99:1重量计，或80:20-10:90重量计的范围。
其它性能添加剂
本发明组合物可任选包含一种或多种其它性能添加剂。这些其它性能添加剂可包括一种或多种金属减活剂、粘度改进剂、清净剂、摩擦改进剂(不同于本发明化合物)、抗磨剂(不同于本发明化合物)、腐蚀抑制剂(不同于本发明化合物)、分散剂、分散剂粘度改进剂、特压剂、抗氧化剂、抑泡剂、反乳化剂、倾点下降剂、密封溶胀剂及其任何组合或混合物。通常，完全配制润滑油包含这些性能添加剂中的一种或多种，通常多种性能添加剂的包。
在一个实施方案中，本发明提供润滑组合物，所述组合物进一步包含分散剂、抗磨剂(不同于本发明化合物)、分散剂粘度改进剂、摩擦改进剂、粘度改进剂、抗氧化剂、过碱性清净剂或其组合，其中所列添加剂各自可以为该类添加剂中两种或更多种的混合物。在一个实施方案中，本发明提供润滑组合物，所述组合物进一步包含聚异丁烯琥珀酰亚胺分散剂、抗磨剂、分散剂粘度改进剂、摩擦改进剂、粘度改进剂(通常烯烃共聚物如乙烯-丙烯共聚物)、抗氧化剂(包括酚类和胺类抗氧化剂)、过碱性清净剂(包括过碱性磺酸盐和酚盐)或其组合，其中所列添加剂各自可以为该类添加剂中两种或更多种的混合物。
在一个实施方案中，本发明润滑组合物进一步包含抗磨剂如金属二烃基二硫代磷酸盐(通常二烷基二硫代磷酸锌)，其中金属二烃基二硫代磷酸盐贡献至少100ppm，或者至少200ppm，或者200-1000ppm，或者300-800ppm，或者400-600ppm磷给润滑组合物。在一个实施方案中，润滑组合物不含或者基本不含二烷基二硫代磷酸锌(ZDDP)。
用于本发明组合物中的合适分散剂包括琥珀酰亚胺分散剂。在一个实施方案中，分散剂可作为单一分散剂存在。在一个实施方案中，分散剂可作为两种或三种不同分散剂的混合物存在，其中至少一种可以为琥珀酰亚胺分散剂。
琥珀酰亚胺分散剂可以为脂族多胺的衍生物或其混合物。脂族多胺可以为脂族多胺如亚乙基多胺、亚丙基多胺、亚丁基多胺或其混合物。在一个实施方案中，脂族多胺可以为亚乙基多胺。在一个实施方案中，脂族多胺可选自乙二胺、二亚乙基三胺、三亚乙基四胺、四亚乙基五胺、五亚乙基六胺、多胺釜残及其混合物。
分散剂可以为N-取代长链链烯基琥珀酰亚胺。N-取代长链链烯基琥珀酰亚胺的实例包括聚异丁烯琥珀酰亚胺。通常衍生出聚异丁烯琥珀酸酐的聚异丁烯具有350-5000，或者550-3000或750-2500的数均分子量。琥珀酰亚胺分散剂和它们的制备公开于例如美国专利3,172,892、3,219,666、3,316,177、3,340,281、3,351,552、3,381,022、3,433,744、3,444,170、3,467,668、3,501,405、3,542,680、3,576,743、3,632,511、4,234,435、Re26,433和6,165,235、7,238,650以及EP专利申请0355895A中。
也可将分散剂通过常规方法通过与多种试剂中的任一种反应而后处理。其中，这些为硼化合物、脲、硫脲、二巯基噻二唑、二硫化碳、醛、酮、羧酸、烃取代的琥珀酸酐、马来酸酐、腈、环氧化物和磷化合物。
分散剂可以以润滑组合物的0.01-20重量％，或者0.1-15重量％，或者0.1-10重量％，或者1-6重量％存在。
在一个实施方案中，本发明润滑组合物进一步包含分散剂粘度改进剂。分散剂粘度改进剂可以以润滑组合物的0-5重量％，或者0-4重量％，或者0.05-2重量％存在。
合适的分散剂粘度改进剂包括官能化聚烯烃，例如用酰化剂如马来酸酐和胺官能化的乙烯-丙烯共聚物；用胺官能化的聚甲基丙烯酸酯，或与胺反应的酯化苯乙烯-马来酸酐共聚物。分散剂粘度改进剂的更详细描述公开于国际公开WO2006/015130或美国专利4,863,623；6,107,257；6,107,258；和6,117,825中。在一个实施方案中，分散剂粘度改进剂可包括美国专利4,863,623(参见第2栏第15行至第3栏第52行)或国际公开WO2006/015130(参见第2页，第[0008]段，且制备实施例描述于第[0065]-[0073]段中)所述那些。
在一个实施方案中，本发明提供进一步包含含磷抗磨剂的润滑组合物。通常含磷抗磨剂可以为二烷基二硫代磷酸锌或其混合物。二烷基二硫代磷酸锌是本领域中已知的。抗磨剂可以以润滑组合物的0-3重量％，或者0.1-1.5重量％，或者0.5-0.9重量％存在。
在一个实施方案中，本发明提供进一步包含钼化合物的润滑组合物。钼化合物可选自二烷基二硫代磷酸钼、二硫代氨基甲酸钼、钼化合物的胺盐及其混合物。钼化合物可以提供给润滑组合物0-1000ppm，或者5-1000ppm，或者10-750ppm、5-300ppm，或者20-250ppm钼。
在一个实施方案中，本发明提供进一步包含过碱性清净剂的润滑组合物。过碱性清净剂可选自不含硫酚盐、含硫酚盐、磺酸盐、salixarate、水杨酸盐及其混合物。
过碱性清净剂还可包括用包含酚盐和/或磺酸盐组分的混合表面活性剂体系形成的“混杂”清净剂，例如酚盐/水杨酸盐、磺酸盐/酚盐、磺酸盐/水杨酸盐、磺酸盐/酚盐/水杨酸盐，如例如美国专利6,429,178；6,429,179；6,153,565；和6,281,179所述。如果例如使用混杂磺酸盐/酚盐清净剂，则认为混杂清净剂相当于分别引入相同量酚盐和磺酸盐皂的单独酚盐和磺酸盐的量。
通常过碱性清净剂可以为酚盐、含硫酚盐、磺酸盐、salixarate和水杨酸盐的钠盐、钙盐、镁盐或其混合物。过碱性酚盐和水杨酸盐通常具有180-450TBN的总碱值。过碱性磺酸盐通常具有250-600或300-500的总碱值。过碱性清净剂是本领域中已知的。在一个实施方案中，磺酸盐清净剂可以为具有至少8的金属比的主要线性烷基苯磺酸盐清净剂，如美国专利申请2005065045(授予US7,407,919)的第[0026]-[0037]段所述。线性烷基苯磺酸盐清净剂可特别用于帮助改进燃料经济性。线性烷基可沿着烷基的线性链的任何位置，但通常在线性链的2、3或4位上，在一些情况下主要在2位上连接在苯环上，产生线性烷基苯磺酸盐清净剂。过碱性清净剂是本领域中已知的。过碱性清净剂可以以0-15重量％，或者0.1-10重量％，或者0.2-8重量％，或者0.2-3重量％存在。例如在重型柴油机中，清净剂可以以润滑组合物的2重量％或2-3重量％存在。对于客车发动机，清净剂可以以润滑组合物的0.2-1重量％存在。
在一个实施方案中，润滑组合物包含抗氧化剂或其混合物。抗氧化剂可以以润滑组合物的0-15重量％，或者0.1-10重量％，或者0.5-5重量％存在。
抗氧化剂包括硫化烯烃、烷基化二芳基胺(通常烷基化苯基萘胺如作为L06由CIBA市购的那些，或者烷基化二苯胺如二壬基二苯胺、辛基二苯胺、二辛基二苯胺)、受阻酚、钼化合物(例如二硫代氨基甲酸钼)或其混合物。
受阻酚抗氧化剂通常含有仲丁基和/或叔丁基作为位阻基团。苯酚基可进一步被烃基(通常线性或支化烷基)和/或连接在第二芳族基团上的桥联基团取代。合适受阻酚抗氧化剂的实例包括2,6-二-叔丁基苯酚、4-甲基-2,6-二-叔丁基苯酚、4-乙基-2,6-二-叔丁基苯酚、4-丙基-2,6-二-叔丁基苯酚或4-丁基-2,6-二-叔丁基苯酚或4-十二烷基-2,6-二-叔丁基苯酚。在一个实施方案中，受阻酚抗氧化剂可以为酯，并可包括例如来自Ciba的IrganoxTML-135。合适的含酯受阻酚抗氧化剂化学的更详细描述在美国专利6,559,105中找到。
其它摩擦改进剂的实例包括胺、脂肪酯或环氧化物的脂肪酸衍生物；脂肪咪唑啉，例如羧酸与聚亚烷基多胺的缩合产物；烷基磷酸的胺盐；脂肪烷基酒石酸酯；脂肪烷基酒石酰亚胺；或脂肪烷基酒石酰胺。在一些实施方案中，如本文所用术语脂肪可意指C8-22线性烷基。
摩擦改进剂还可包括材料，例如硫化脂肪化合物和烯烃、二烷基二硫代磷酸钼、二硫代氨基甲酸钼、向日葵油，或多元醇和脂族羧酸的单酯。
在一个实施方案中，摩擦改进剂可选自胺、长链脂肪酯或长链脂肪环氧化物的长链脂肪酸衍生物；脂肪咪唑啉；烷基磷酸的胺盐；脂肪烷基酒石酸酯；脂肪烷基酒石酰亚胺；和脂肪烷基酒石酰胺。摩擦改进剂可以以润滑组合物的0-6重量％，或者0.05-4重量％，或者0.1-2重量％存在。
在一个实施方案中，摩擦改进剂可以为长链脂肪酸酯。在另一实施方案中，长链脂肪酸酯可以为单酯或二酯或其混合物，在另一实施方案中，长链脂肪酸酯可以为甘油三酯。
其它性能添加剂如腐蚀抑制剂包括作为WO2006/047486出版的美国申请US05/038319的第5-8段所述那些、辛基辛酰胺、十二碳烯基琥珀酸或酐和脂肪酸如油酸与多胺的缩合产物。在一个实施方案中，腐蚀抑制剂包括腐蚀抑制剂。腐蚀抑制剂可以为氧化丙烯的均聚物或共聚物。腐蚀抑制剂更详细地描述于Dow Chemical Company出版的Form No.118-01453-0702AMS产品小册子中。该产品小册子的标题为“SYNALOX Lubricants，High-Performance Polyglycols forDemanding Applications.”。
可使用金属减活剂，包括苯并三唑的衍生物(通常甲苯基三唑)、二巯基噻二唑衍生物、1,2,4-三唑、苯并咪唑、2-烷基二硫代苯并咪唑或2-烷基二硫代噻唑；抑泡剂，包括丙烯酸乙酯与丙烯酸2-乙基己酯的共聚物和乙基丙烯酸乙酯与丙烯酸2-乙基己酯和乙酸乙烯酯的共聚物；反乳化剂，包括三烷基磷酸酯、聚乙二醇、聚氧化乙烯、聚氧化丙烯和(氧化乙烯-氧化丙烯)聚合物；倾点下降剂，包括马来酸酐-苯乙烯的酯、聚甲基丙烯酸酯、聚丙烯酸酯或聚丙烯酰胺。
可用于本发明组合物中的倾点下降剂包括聚α烯烃、马来酸酐-苯乙烯的酯、聚(甲基)丙烯酸酯、聚丙烯酸酯或聚丙烯酰胺。
在不同的实施方案中，润滑组合物可具有如下表所述组成：
本发明α-羟基酮(通常具有式(1))可以在实施方案(D)中以润滑组合物的0.1-8重量％，或者在(E)中以1-7重量％，或者在(F)中以2-6重量％存在，且具有上表关于实施方案(A)-(C)所示量的分散剂粘度改进剂、过碱性清净剂、抗氧化剂、抗磨剂、摩擦改进剂、粘度改进剂、任何其它性能添加剂(除分散剂外)和所示量的具有润滑粘度的油。衍生自式(1)或式(4)的本发明化合物还可显示出分散剂性能。如果衍生自式(1)或式(4)的本发明化合物显示出分散剂性能，则实施方案(D)-(F)中报出的一部分或所有分散剂范围可以为润滑组合物的0-12重量％，或者0-8重量％或0-6重量％。
工业应用
在一个实施方案中，本发明提供润滑内燃机的方法，所述方法包括步骤：向内燃机中供入如本文所公开的润滑组合物。通常将润滑剂加入内燃机的润滑系统中，所述润滑系统然后在其操作期间将润滑组合物输送至需要润滑的发动机的关键部件。
在一个实施方案中，本发明提供本文所述α-羟基酮化合物作为如下至少一种的用途：摩擦改进剂、抗氧化剂、分散剂、抗磨剂、特压剂、铅、锡或铜(通常铅)腐蚀抑制剂、降低丙烯酸酯或含氟弹性体密封的腐蚀的密封添加剂或改进密封溶胀性能的密封添加剂。
上述润滑组合物可用于内燃机中。发动机组件可具有钢或铝表面(通常钢表面)，并可例如涂有金刚石如碳(DLC)涂层。
铝表面可由铝合金组成，其可以为共晶或过共晶铝合金(例如衍生自硅酸铝、铝氧化物或其它陶瓷材料的那些)。铝表面可存在于具有铝合金或铝复合物的气缸筒、气缸柱或活塞环上。
内燃机可具有或不具有废气循环系统。内燃机可安装有排放控制系统或涡轮增压器。排放控制系统的实例包括柴油颗粒过滤器(DPF)，或使用选择性催化还原(SCR)的系统。
在一个实施方案中，内燃机可以为柴油燃烧发动机(通常重型柴油机)、汽油燃烧发动机、天然气燃烧发动机或混合汽油/醇燃烧发动机。在一个实施方案中，内燃机可以为柴油燃烧发动机，在另一实施方案中为汽油燃烧发动机。
内燃机可以为2冲程或4冲程发动机。合适的内燃机包括船用柴油机、航空用活塞式发动机、低载荷柴油机以及汽车和筒塞发动机。
本发明内燃机不同于燃气轮机。在内燃机中，单独的燃烧事件通过杆和曲轴从线性往复力转化成转动扭矩。相反，在燃气轮机(也称为喷气式发动机)中，它是连续产生转动扭矩而不转化并且还可在排气口发展推力的连续燃烧方法。这些区别导致汽轮机和内燃机不同操作环境和应力的操作条件。
用于内燃机的润滑剂组合物可适于任何发动机润滑剂而不管硫、磷或硫酸盐灰(ASTM D-874)含量。发动机油润滑剂的硫含量可以为1重量％或更少，或者0.8重量％或更少，或者0.5重量％或更少，或者0.3重量％或更少。在一个实施方案中，硫含量可以为0.001-0.5重量％，或者0.01-0.3重量％。磷含量可以为0.2重量％或更少，或者0.12重量％或更少，或者0.1重量％或更少，或者0.085重量％或更少，或者0.08重量％或更少，或者甚至0.06重量％或更少、0.055重量％或更少，或者0.05重量％或更少。在一个实施方案中，磷含量可以为100-1000ppm，或者200-600ppm。总硫酸盐灰含量可以为2重量％或更少，或者1.5重量％或更少，或者1.1重量％或更少，或者1重量％或更少，或者0.8重量％或更少，或者0.5重量％或更少，或者0.4重量％或更少。在一个实施方案中，硫酸盐灰含量可以为0.05-0.9重量％，或者0.1至0.2重量％或至0.45重量％。
在一个实施方案中，润滑组合物可以为发动机油，其中润滑组合物的特征可以为具有如下的至少一项：(i)0.5重量％或更少的硫含量，(ii)0.1重量％或更少的磷含量，(iii)1.5重量％或更少的硫酸盐灰含量，或其组合。
实施例
通过以下实施例进一步阐述本发明，所述实施例描述特别有利的实施方案。尽管提供实施例阐述本发明，但它们不意欲限制它。
添加剂A
添加剂A(ADD A)为1-羟基-2-十二烷酮且如下制备。3L3颈圆底烧瓶装配有搅拌器、热电偶、氮气入口、冷凝器并置于适于冷却的浴内。向烧瓶中加入乙酸(500mL)，其后加入十二烷-1,2-二醇(120g)。搅拌混合物直至接近完全溶解。经约45分钟，将次氯酸钠溶液(600mL的15％水溶液)加入烧瓶中，在此期间烧瓶内部的温度从18℃提高至约27℃。然后将反应混合物搅拌约3小时。将反应用水(约2000ml)稀释，然后将反应物质(借助分液漏斗)用二氯甲烷(3×750ml)萃取3次，将结合的有机相结合并用饱和碳酸氢钠溶液(3×1000ml)洗涤3次，然后用水(1×1000ml)洗涤。将有机物用硫酸镁干燥，然后过滤。将滤液真空汽提以除去挥发性有机物，并分离蜡质灰白色固体产物(92g)。
添加剂B
添加剂B(ADD B)为1-羟基-2-十六烷酮并如下制备。将2L3颈烧瓶中装入乙酸(500ml)和VikinolTM16(来自Arkema的市售16碳1,2-二羟基链烷烃)(200g)。烧瓶装配有水冷冷凝器和氮气入口。次氯酸钠溶液(600ml的15％水溶液)借助均压滴液漏斗装入并在室温下经2.5小时逐滴加入反应中。在室温下搅拌另外3小时并保持静止14小时以后，反应混合物显现出淤浆。固体通过过滤分离并收集。将固体滤出物用二氯甲烷(3000ml)萃取，将其用水(1000ml)和碳酸氢钠溶液(2×750mL)洗涤，然后经硫酸镁干燥并过滤。将滤液真空汽提以分离产物固体蜡产物。
添加剂C
添加剂C(ADD C)为1-羟基-2-十八烷酮，并使用以上关于添加剂B所述相同的程序制备，不同之处在于将VikinolTM16用18碳原子等价物取代。
添加剂D
添加剂D(ADD D)为1-羟基-2-十八烷酮且如下制备。5L3颈圆底烧瓶装配有搅拌器、热电偶、氮气入口、冷凝器并置于适于冷却的浴内。向该烧瓶中加入丙酮(2500ml)、水(200mL)、乙酸(50ml)和1-十八碳烯(50.7g)。在约27分钟期间，将高锰酸钾(44.53g)加入烧瓶中，在此期间烧瓶内的温度从22.3℃提高至约26.8℃。然后将反应混合物搅拌约1-2小时，然后保持静止整夜。然后向反应中加入亚硝酸钠(20.56g)，其后经12分钟加入硫酸溶液(405ml)(8份水:1份酸)，并将反应搅拌至少1小时。在此期间，产物从溶液中沉淀出，其它锰基固体沉降到烧瓶底部，所以通过从反应物质中倾析而收集产物淤浆。然后借助过滤收集产物沉淀物。将收集的白色固体再溶于二氯甲烷(或二乙醚)(1000ml)中，然后用1000ml盐水洗涤(通过分液漏斗)，然后用1000ml饱和碳酸氢钠洗涤一次。将有机物用硫酸钠干燥，然后过滤。将滤液真空汽提以除去挥发性有机物并分离蜡质灰白色固体产物。然后将产物如下进一步提纯：在150ml己烷中浆化，然后借助过滤分离固体以得到6.6g产物。其它产物可如下分离：将4000ml水加入含水反应物质中(在收集初始产物沉淀物以后)，借助过滤收集产物，然后重复将其溶于3000ml二乙醚中，用盐水(1×1000ml)洗涤，用饱和碳酸氢钠(1×1000ml)洗涤，用硫酸钠干燥，将滤液过滤并真空汽提。最后将产物在约150ml己烷中浆化。这得到另外7.9g产物。分离的总产物为14.5g。
添加剂E
添加剂E(ADD E)为3,4-二羟基十四烷-2-酮并如下制备。500ml烧瓶安装有凸缘盖、PTFE密封垫和压盖、顶入式搅拌器、N2入口、热电偶和水冷冷凝器。然后将反应容器中装入十一醛(45g)、羟基丙酮(19.6g)和DBN(1,5-二氮杂二环[4.3.0]壬-5-烯)(1.6g)并在室温下搅拌。当搅拌时，反应放热至47℃，放热量通过将烧瓶用压缩空气吹扫而控制。将反应保持1小时直至反应混合物变成不能搅拌的浅黄色蜡质固体。将反应冷却，并保持静止整夜。将二氯甲烷(500ml)加入容器中并搅拌以完全溶解产物。然后将这转移至分液漏斗中，在那里将它用稀盐酸(1:9)洗涤4×250ml份。然后将二氯甲烷层经硫酸镁干燥，通过烧结漏斗过滤，将滤液真空汽提以除去挥发性有机物并分离蜡质灰白色固体产物(52.95g)。
润滑组合物
在具有润滑粘度的组III基油中制备包含上述添加剂以及常规添加剂，包括聚合物粘度改进剂、无灰琥珀酰亚胺分散剂、过碱性清净剂、抗氧化剂(苯酚酯与二芳基胺的组合)、二烷基二硫代磷酸锌(ZDDP)，以及如下其它性能添加剂(表1)的一系列0W-20发动机润滑剂。实施例各自的磷、硫和灰含量也显示于表中以部分地显示各实施例具有类似量的这些材料，所以提供对比例与本发明实施例之间的合适对比。
表1—润滑油组合物配制剂
1–除非另外指出，以上所示所有量为重量％，且基于无油。
2–油基酒石酰亚胺，目前用于许多润滑组合物中的优秀摩擦改进剂。
3–实施例中所用其它添加剂包括分散剂、清净剂和消泡剂，且包含一定量的稀释油。相同添加剂包用于各个实施例中。
α-羟基酮的摩擦和磨损性能
在程序升温高频往复试验机(HFRR)中评估汇总于表1中的润滑油组合物实施例的边界润滑摩擦性能和磨损。评估的HFRR条件为200g载荷、75分钟持续时间、1000μm冲程、20Hz频率，和在40℃下15分钟，然后以2℃/分钟的速率将温度升高至160℃的温度程序。接触电势通过将小电势施加在上部与下部试样之间而测量。试样为钢发动机部件。如果仪器测量施加的全部电势，则这是上部与下部试样之间的电绝缘层的表示，这通常解释为表面上化学保护膜的形成。如果没有形成保护膜，则上部与下部试样之间存在金属-金属接触且测量的电势降至0。中间值为部分或不完全保护膜的表现。接触电势通常表示为施加的电势与所谓百分数膜厚度的百分数。所得磨损和接触系数(COF)结果显示于下表中。该试验的结果汇总于表2中。
表2—摩擦和磨损试验
结果显示存在于本发明组合物中的α-羟基酮提供至少与油基酒石酰亚胺一样有效的摩擦性能，且每个本发明实施例产生比对比例更低的总磨痕。即使对比对比例中0.5重量％的摩擦改进剂处理率与0.25重量％的本发明α-羟基酮添加剂处理率，本发明实施例仍提供一致且明显改进的性能，如通过表2中的磨痕数据所证明。
已知一些上述材料在最终配制剂中可能相互作用，使得最终配制剂的组分可能与起初加入的那些不同。由此形成的产品，包括经以其意欲用途使用本发明润滑剂组合物而形成的产品可能不容易描述。然而，所有这类改进和反应产物均包括在本发明的范围内；本发明包括通过将上述组分混合而制备的润滑剂组合物。
将以上提及的各文件通过引用并入本发明，如如果有的话本申请要求其利益的优先权文件和所有相关申请。除实施例中，或另外明确说明外，在本说明书中描述材料的量、反应条件、分子量、碳原子数等的所有数量应当理解被措辞“约”修饰。除非另有说明，本文提及的各个化学品或组合物应当理解为可含有异构体、副产物、衍生物和通常应当理解存在于商品级中的其它这类材料的商品级材料。然而，除非另有说明，各个化学组分的量表示为排除了通常可存在于商业材料中的任何溶剂或稀释剂。应当理解本文所述量、范围和比的上限和下限可独立地组合。类似地，本发明各个元素的范围和量可以与任何其它元素的范围或量一起使用。
如本文所用，术语“烃基取代基”或“烃基”以其本领域技术人员熟知的常用意义使用。具体而言，它指具有直接连接在分子其余部分上的碳原子且主要具有烃性质的基团。烃基的实例包括：
(i)烃取代基，即脂族(例如烷基或链烯基)、脂环族(例如环烷基、环烯基)取代基，和芳族-、脂族-和脂环族取代的芳族取代基，以及其中环通过该分子的另一部分完成(例如两个取代基一起形成环)的环状取代基；
(ii)取代的烃取代基，即含有在本发明上下文中不改变取代基的主要烃性质的非烃基团(例如卤素(尤其是氯和氟)、羟基、烷氧基、巯基、烷基巯基、硝基、亚硝基和亚硫酰基(sulfoxy))的取代基；
(iii)杂取代基，即在本发明上下文中，在具有主要烃性质的同时在由碳原子组成的环或链中含有不同于碳的取代基。
杂原子包括硫、氧、氮，且包括取代基如吡啶基、呋喃基、噻吩基和咪唑基。一般而言，对于每10个碳原子，在烃基中存在不多于2，优选不多于1个非烃取代基；通常，烃基中不存在非烃取代基。
尽管已关于优选实施方案解释了本发明，应当理解经阅读本说明书，其各个改进会为本领域技术人员所了解。因此，应当理解此处公开的发明意欲涵盖属于所附权利要求范围的改进。
Claims (14)
1.一种润滑组合物，其包含具有润滑粘度的油和无灰酮化合物，其中无灰酮化合物具有连接在与无灰酮的羰基碳相邻的碳原子上的羟基、醚键或其混合物中至少一个。
2.根据权利要求1的润滑组合物，其中无灰酮化合物由下式表示：
其中：
R1为烃基；且
R2、R3和R4独立地为氢或烃基。
3.根据权利要求1的润滑组合物，其中R2、R3和R4为氢，且R1为无氮烷基。
4.根据前述权利要求中任一项的润滑组合物，其中R1为包含8-20个碳原子的无氮烷基。
5.根据前述权利要求中任一项的润滑组合物，其中R2、R3和R4为氢，且R1为包含10-16个碳原子的无氮烷基。
6.根据前述权利要求中任一项的润滑组合物，其中无灰酮化合物以0.05-0.5重量％存在于组合物中。
7.根据前述权利要求中任一项的润滑组合物，其进一步包含抗磨剂、分散剂粘度改进剂、其它摩擦改进剂、粘度改进剂、抗氧化剂、过碱性清净剂或其混合物。
8.根据前述权利要求中任一项的润滑组合物，其进一步包含其它摩擦改进剂。
9.根据权利要求7的润滑组合物，其中其它摩擦改进剂选自胺的长链脂肪酸衍生物、长链脂肪酯、长链脂肪环氧化物、脂肪咪唑啉、烷基磷酸的胺盐、脂肪烷基酒石酸酯、脂肪烷基酒石酰亚胺、脂肪烷基酒石酰胺及其组合。
10.根据前述权利要求中任一项的润滑组合物，其进一步包含过碱性清净剂。
11.根据权利要求9的润滑组合物，其中过碱性清净剂选自酚盐、含硫酚盐、磺酸盐、salixarate、水杨酸盐及其混合物。
12.根据前述权利要求中任一项的润滑组合物，其中组合物基本不含任何磷含量，基本不含任何硫含量，具有通过ASTM D874测量不大于1.0重量％的硫酸盐灰含量，基本不含二烷基二硫代磷酸锌，或其任何组合。
13.一种润滑机械装置的方法，其包括向机械装置中供入权利要求1的润滑组合物。
14.根据权利要求1的方法，其中机械装置为内燃机、液压设备、手动或自动变速器、工业齿轮、汽车齿轮(或轴)或农用拖拉机。
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- 2012-10-11 EP EP12778006.2A patent/EP2773730B1/en active Active
- 2012-10-11 CN CN201280053330.6A patent/CN103917629B/zh active Active
- 2012-10-11 WO PCT/US2012/059635 patent/WO2013066585A1/en active Application Filing
- 2012-10-11 KR KR1020147014590A patent/KR101994372B1/ko active IP Right Grant
- 2012-10-11 CA CA2853443A patent/CA2853443C/en active Active
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Also Published As
| Publication number | Publication date |
|---|---|
| EP2773730A1 (en) | 2014-09-10 |
| CA2853443C (en) | 2019-10-29 |
| CN103917629B (zh) | 2016-06-29 |
| US20140303054A1 (en) | 2014-10-09 |
| KR20140088190A (ko) | 2014-07-09 |
| KR101994372B1 (ko) | 2019-06-28 |
| WO2013066585A1 (en) | 2013-05-10 |
| EP2773730B1 (en) | 2019-02-13 |
| US10590363B2 (en) | 2020-03-17 |
| CA2853443A1 (en) | 2013-05-10 |
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