CN111511884A

CN111511884A - Production of fluids

Info

Publication number: CN111511884A
Application number: CN201880079195.XA
Authority: CN
Inventors: 梁铭堂
Original assignee: Hai Jun International Trade Co ltd
Current assignee: Hai Jun International Trade Co ltd
Priority date: 2017-10-10
Filing date: 2018-10-08
Publication date: 2020-08-07
Also published as: JP7414722B2; CA3078786A1; TWI793193B; EP3694961A4; WO2019074814A1; EP3694961A1; TW201923055A; US20200318030A1; JP2020537033A; KR20200096757A

Abstract

A manufacturing fluid composition, such as a metal cutting fluid concentrate, includes water, a first surfactant that is an anionic surfactant, a second surfactant that is an amphoteric surfactant, a third surfactant selected from the group consisting of anionic surfactants and amphoteric surfactants, the third surfactant being different from the first surfactant and the second surfactant, and at least one of water and a rust inhibitor, a colorant, and an antifoaming agent. The concentrate may be combined with water to provide a manufacturing fluid, such as a metal cutting fluid composition, that may be applied to a sheet of cut metal for a time and in an amount effective to dissipate heat from the cut metal.

Description

Production of fluids

Reference to related applications

This application claims the benefit of U.S. provisional patent application No. 62/570,617 filed 2017, 10/c. § 119(e), which is incorporated herein by reference in its entirety.

Technical Field

The present invention generally relates to compositions for making materials in which heat is generated (e.g., cutting of metal or stone), concentrates thereof, and methods of making and using the same.

Background

In the manufacture (e.g., cutting) of solid materials such as stone or metal (e.g., drilling holes in the metal or cutting pieces of metal into smaller pieces), cutting or forming devices are often lubricated with a fluid in order to reduce wear and tear on the devices involved in the manufacture. A fluid (e.g., a metal cutting fluid) is applied at a location where a material (e.g., metal) is cut by a cutting device (e.g., a blade). The fluid provides various functions including helping to dissipate heat generated during the manufacturing process (e.g., cutting action). Without dissipation, the heat may cause warping and/or other damage to one or both of the cutting device and the material being cut (e.g., metal). Other advantages of manufacturing fluids include enhanced tool life, improved surface finish, and flushing debris from the cutting zone. In fact, all cutting fluids currently in use fall into one of four types: 1) straight run oil, 2) soluble oil, 3) semi-synthetic fluid, and 4) synthetic fluid.

Straight run oils are non-emulsifiable and used in undiluted form for mechanical processing operations. They are composed of base mineral or petroleum oils and usually contain polar lubricants such as fats, vegetable oils and esters and extreme pressure additives such as chlorine, sulfur and phosphorus. Straight run oils provide the best lubrication and worst cooling characteristics in the cutting fluid.

When mixed with water, the soluble oil fluid forms an emulsion. The concentrate is composed of a base mineral oil and an emulsifier to help create a stable emulsion. They are used in diluted form (typically at concentrations of 3% to 10%) and provide good lubricating and heat transfer properties. They are widely used in industry and are the least expensive of all cutting fluids.

Semi-synthetic fluids are essentially a combination of synthetic and soluble oil fluids and have properties common to both types. The cost and heat transfer performance of semi-synthetic fluids is intermediate between that of synthetic oil fluids and soluble oil fluids.

Synthetic fluids do not contain petroleum or mineral oil substrates, but are formulated from basic inorganic and organic compounds with additives for corrosion inhibition. They are usually used in diluted form (usually at a concentration of 3% to 10%). Synthetic fluids generally provide the best cooling performance in all cutting fluids and the worst lubrication characteristics in the cutting fluids.

There is a need for improved manufacturing fluids, such as improved metal cutting fluids. The present disclosure is directed to meeting this need.

SUMMARY

Briefly, the present disclosure provides for the manufacture of fluid concentrates, e.g., metal cutting, the manufacture of fluid compositions, e.g., metal cutting fluids, which are dilute forms of the concentrates, methods of making the concentrates and compositions, and methods of using the concentrates and compositions in material manufacturing processes, e.g., for cutting metal, stone, plastic, and the like.

In one embodiment, the present disclosure provides a composition comprising water and nonvolatile components (also referred to herein as solids, even though some of the nonvolatile components may be liquids in a pure state). The solids include one or more surfactants, with exemplary surfactants being anionic and amphoteric surfactants. For example, the solid may comprise a first surfactant selected from amphoteric surfactants, a second surfactant selected from anionic surfactants, and a third surfactant selected from amphoteric surfactants and anionic surfactants, the third surfactant being different from the first and second surfactants. The solids also include one or more agents selected from the group consisting of rust inhibitors and preservatives, which are collectively referred to herein as rust inhibitors.

Optional non-volatile components present in the composition include one or more thickeners, also known as thickeners, suitable for increasing the viscosity or body of the composition; inorganic salts that are water soluble at the concentrations used in the composition; an organic solvent that is miscible with water at the concentrations used in the composition; a defoamer, the term including a defoamer, used in an amount effective to reduce foaming of the composition during use; and a colorant, also referred to herein as a colorant, that imparts coloration to the composition.

As previously mentioned, the compositions of the present disclosure comprise water in addition to the non-volatile, non-aqueous ingredients. In one embodiment, the composition contains relatively little water, such that the composition has a high concentration of non-volatile components. Such compositions may be referred to herein as concentrate (or concentrated) compositions, or metal cutting concentrates. The concentrate may be provided to equipment that cuts metal or otherwise manufactures materials, where an operator in those equipment may dilute the concentrate with an amount of water that provides a fluid having suitable characteristics for a particular manufacturing situation (e.g., cutting metal or other material). For example, cutting bronze may benefit from different dilutions of concentrates used to cut different metals, such as stainless steel. In one embodiment, the concentrate is 5% to 50% by weight water. In another embodiment, the concentrate composition is 40 to 50 weight percent water and 50 to 60 weight percent non-water components, including surfactants, rust inhibitors, and at least one of thickeners and inorganic salts suitable for aqueous compositions. In another embodiment, the present disclosure provides a metal cutting fluid ready for use in a metal cutting operation. In such ready-to-use compositions, the water content is typically from 75 wt% to 99 wt%, or from 75.0 wt% to 99.9 wt%, or from 90 wt% to 99 wt% of water, or from 90.0 wt% to 99.9 wt% of water, or from 97.0 wt% to 99.9 wt% of water, or from 98.0 wt% to 99.9 wt% of water, or from 99.0 wt% to 99.9 wt% of water.

In one embodiment, the composition comprises water, a first surfactant selected from amphoteric surfactants, a second surfactant selected from anionic surfactants, a third surfactant selected from amphoteric and anionic surfactants, an inorganic salt, an organic solvent, a thickener, a rust inhibitor, and a defoamer, the third surfactant being different from the first and second surfactants.

The following numbered embodiments are further exemplary embodiments of the compositions of the present disclosure:

1) a fluid composition is made comprising water, a first surfactant, a thickener, and a rust inhibitor.

2) A fluid composition is made comprising water, a first surfactant, an inorganic salt, and a rust inhibitor.

3) The composition of embodiment 1 or 2, wherein the first surfactant is an anionic surfactant.

4) The composition of embodiment 3, wherein the first surfactant is a sulfonate-containing or sulfate-containing anionic surfactant.

5) The composition of embodiment 3, wherein the first surfactant is sodium dodecyl benzene sulfonate.

6) The composition of embodiment 3, wherein the first surfactant is sodium laureth sulfate.

7) The composition of embodiment 1 or 2, wherein the first surfactant is an amphoteric surfactant.

8) The composition of embodiment 7, wherein the amphoteric surfactant comprises a betaine group.

9) The composition of embodiment 7, wherein the first surfactant is cocamidopropyl betaine.

10) The composition of embodiment 1 or 2, comprising two surfactants, each of which is an anionic surfactant.

11) The composition of embodiment 10, wherein the two surfactants are a sulfate-containing surfactant and a sulfonate-containing surfactant.

12) The composition of embodiment 10, wherein the two surfactants are sodium laureth sulfate and sodium dodecylbenzenesulfonate.

13) A composition according to embodiment 1 or 2 comprising two surfactants, one being an anionic surfactant and the other being an amphoteric surfactant.

14) The composition of embodiment 13, wherein the two surfactants are a sulfate-containing anionic surfactant and a betaine-containing amphoteric surfactant.

15) The composition of embodiment 14, wherein the sulfate-containing anionic surfactant is sodium laureth sulfate and the betaine-containing amphoteric surfactant is cocamidopropyl betaine.

16) The composition of embodiment 13, wherein the two surfactants are a sulfonate-containing anionic surfactant and a betaine-containing amphoteric surfactant.

17) The composition of embodiment 16, wherein the sulfonate-containing anionic surfactant is sodium dodecyl benzene sulfonate and the betaine-containing amphoteric surfactant is cocamidopropyl betaine.

18) The composition of embodiment 1 or 2 comprising three surfactants, two of the three surfactants being different anionic surfactants and one of the three surfactants being an amphoteric surfactant.

19) The composition of embodiment 18, wherein the three surfactants are a sulfate-containing surfactant, a sulfonate-containing surfactant, and a betaine-containing surfactant.

20) The composition of embodiment 19, wherein the three surfactants are sodium dodecyl benzene sulfonate, sodium lauryl ether sulfate, and cocamidopropyl betaine.

21) The composition of embodiment 1 or 2 wherein the rust inhibitor is sodium nitrite.

22) The composition of embodiment 20 wherein the rust inhibitor is sodium nitrite.

23) The composition of embodiment 1 or 2, comprising a thickener which is a cellulosic thickener.

24) The composition of embodiment 23, wherein the cellulosic thickener is hydroxyethyl cellulose.

25) The composition of embodiment 20, comprising a thickener that is a cellulosic thickener.

26) The composition of embodiment 25, wherein the cellulosic thickener is hydroxyethyl cellulose.

27) The composition of embodiment 1 or 2, comprising an inorganic salt, which is calcium chloride.

28) The composition of embodiment 20, comprising an inorganic salt.

29) The composition of embodiment 28, wherein the inorganic salt is calcium chloride.

30) The composition of embodiment 1 or 2, comprising an antifoaming agent.

31) The composition of embodiment 30, wherein the anti-foaming agent is a silicone polymer.

32) The composition of embodiment 20, comprising an antifoaming agent.

33) The composition of embodiment 32, wherein the anti-foaming agent is a silicone polymer.

34) The composition of embodiment 20, comprising one or more of a cellulosic thickener, an inorganic salt, and a defoamer.

35) The composition of embodiment 20 comprising a cellulosic thickener, an inorganic salt, and an antifoaming agent.

36) The composition of embodiment 1, comprising water, sodium dodecylbenzene sulfonate, sodium laureth sulfate, cocamidopropyl betaine, a thickener such as a cellulosic thickener, and a rust inhibitor.

37) The composition of embodiment 2, comprising water, sodium dodecylbenzene sulfonate, sodium lauryl ether sulfate, cocamidopropyl betaine, an inorganic salt such as calcium chloride, and a rust inhibitor.

The compositions may be used in metal making and may alternatively be referred to as metal making compositions, or metal working compositions, or metal cooling compositions, or metal cutting compositions. The composition can also be used to make parts made of stone, plastic or glass, or other solid materials, which can be made by processing in a heat generating process.

In one embodiment, the present disclosure provides a method of making a concentrate composition (e.g., a metal cutting fluid concentrate) by combining ingredients as discussed herein. Optionally, the ingredients may be combined in a batch process. In such embodiments, the composition, e.g., a metal cutting fluid concentrate composition, is prepared by a method comprising: adding to the vessel hot water, one or more surfactants such as anionic surfactants, amphoteric surfactants, and optionally a third surfactant selected from the group consisting of anionic surfactants and amphoteric surfactants, wherein the third surfactant is different from the anionic surfactant and amphoteric surfactant that have been added. Other optional ingredients include inorganic salts, organic solvents, thickeners, rust or corrosion inhibitors, colorants, and defoamers; wherein after addition of a component to the vessel, the resulting mixture is stirred until it reaches a complete or nearly homogeneous state, for example about 30 minutes, before addition of the next component, with a minimum amount of foaming occurring. In one embodiment, an inorganic salt, an organic solvent, a thickener, a rust inhibitor or preservative, and a defoamer are added to the container.

For example, the present invention provides a method for preparing a fluid composition (e.g., a composition suitable for metal cutting) comprising:

a) heating water to about 70-80 ℃ to provide hot water;

b) adding an anionic surfactant to the hot water;

c) adding an amphoteric surfactant to the mixture of step b);

d) adding hot water to the mixture of step c);

e) optionally, adding to the mixture of step d) a third surfactant selected from anionic and amphoteric surfactants, said third surfactant being different from the anionic and amphoteric surfactants already present in the mixture;

f) adding an inorganic salt to the mixture of step e);

g) cooling the mixture of step f) to ambient temperature; and

h) adding a thickener to the mixture of step f);

wherein after addition of the components, the resulting mixture is stirred for a time effective to obtain a homogeneous or nearly homogeneous mixture, typically about 30 minutes, before addition of the next component, wherein minimal foaming occurs. Exemplary optional ingredients that may be used in the method include inorganic salts, organic solvents, thickeners, rust or corrosion inhibitors, colorants, and defoamers. In one embodiment, an inorganic salt, an organic solvent, a thickener, a rust inhibitor or preservative, and a defoamer are added to the mixture.

In one embodiment, the present disclosure provides a method of making a composition (e.g., a metal cutting fluid concentrate) by a continuous process. In such embodiments, the composition (e.g., metal cutting fluid concentrate) is prepared by: providing a continuous reactor, injecting water into the continuous reactor, adding to the water in the continuous reactor a) an anionic surfactant, b) an amphoteric surfactant, and optionally c) a third surfactant selected from the group consisting of anionic surfactants and cationic surfactants, the third surfactant being different from the anionic surfactant and amphoteric surfactant that have been injected into the reactor; and mixing components a), b) and optionally c) to provide a homogeneous mixture. Optionally, the water in the continuous reactor is maintained at a temperature in excess of 50 ℃. Optionally, other ingredients are added to the formulation, such as organic solvents, inorganic salts, thickeners, rust or corrosion inhibitors, colorants, and defoamers. In one embodiment, each of an organic solvent, an inorganic salt, a thickener, a rust inhibitor or preservative, and a defoaming agent is added to the mixture. Optionally, a mixer selected from an inline mixer (inline mixer) and a static mixer is present in the continuous reactor.

In one embodiment, the present disclosure provides a method for forming a manufacturing fluid from a precursor concentrate, such as forming a metal cutting fluid composition from a metal cutting fluid concentrate. According to such embodiments, water and concentrate are combined at a suitable water to concentrate ratio, and the two components are mixed together to form the metal cutting fluid composition. In various optional embodiments, the concentrate is diluted 5-fold, or 10-fold, or 15-fold. For the sake of clarity, a 5-fold dilution means that 100 parts of the concentrate are combined with 500 parts of water, wherein the parts may be in liquid or solid measuring form, e.g. g, kg, l.

In one embodiment, the present disclosure provides a method for cutting metal, wherein the method comprises applying an effective amount of the metal cutting fluid composition of the present disclosure to the metal being cut. The metal cutting fluids of the present disclosure may be applied to metal during a process in which the metal is cut. One exemplary method for applying the compositions of the present disclosure is an overflow application, wherein an overflow cutting fluid is applied to the workpiece being cut. Another exemplary method for applying the compositions of the present disclosure is spray application, wherein a sprayed cutting fluid is applied to a workpiece for cutting a region. Another exemplary method for applying the compositions of the present disclosure is an atomizing application, wherein the cutting fluid is atomized by ejecting air and a mist is applied to the cutting area of the workpiece.

With reference to the foregoing composition embodiments, the following numbered embodiments are additional exemplary embodiments of the machining feed of the present disclosure:

38) a method of machining a material selected from the group consisting of metal, stone, glass, and plastic, comprising applying a composition comprising the composition of any one of embodiments 1 to 37 to a sheet of machined material in an amount and for a time effective to dissipate heat from the machined material.

39) The method of embodiment 38, wherein the machined material is a metal selected from the group consisting of aluminum alloys, brass, cast iron, bronze, mild steel, stainless steel, alloy steels, and titanium alloys.

40) The method of embodiment 38, wherein the machined material is stone.

41) The method of embodiment 38, wherein the machined material is glass.

42) The method of embodiment 38, wherein the machined material is plastic.

43) The method of embodiment 38, wherein the piece of machined material is subjected to a process selected from the group consisting of broaching, tapping, hobbing, cutting, drilling, milling, turning, sawing, honing, and grinding.

The following description sets forth details of one or more embodiments. Features illustrated or described in connection with one exemplary embodiment may be combined with features of other embodiments. Other features, objects, and advantages will be apparent from the description and from the claims. Furthermore, the disclosures of all patents and patent applications referenced herein are incorporated by reference in their entirety.

Detailed Description

In one aspect, the present disclosure provides a material making composition, such as a metal cutting fluid composition, in a concentrated and diluted (ready to use) form. In another aspect, the present disclosure provides a method of forming a manufacturing fluid in a concentrated form and then diluting the concentrated composition to a diluted form. In another aspect, the present disclosure provides methods of using the compositions in methods of making materials therein (e.g., metal cutting operations). Thus, in another aspect, the present disclosure provides a method of forming a manufacturing fluid composition (e.g., a metal cutting fluid composition) in a concentrated form, and then diluting the concentrated composition to a diluted form. In another aspect, the present disclosure provides methods of using the compositions in material cutting or forming processes (e.g., metal cutting operations). While the present disclosure relates to metal cutting fluids or metal coolants, it is understood that these fluid compositions may be used in materials manufacturing in general, such as glass manufacturing, stone manufacturing, and plastic manufacturing, and are not limited to use in metal manufacturing. Thus, the metal cutting or metal cooling composition may be used for metal cutting or fabrication, but may also be used for fabricating other materials, such as stone or plastic or glass, where the fabrication generates heat that is desirably dissipated during the fabrication process.

Optional non-volatile components present in the composition include one or more thickeners, also known as thickeners, suitable for increasing the viscosity or body of the composition; inorganic salts that are water soluble at the concentrations used in the composition; an organic solvent that is miscible with water at the concentrations used in the composition and has a boiling point above that of water, e.g., a boiling point of at least 125 ℃, or at least 150 ℃, or at least 170 ℃; a defoamer, the term including a defoamer, used in an amount effective to reduce foaming of the composition during use; and a colorant, also referred to herein as a colorant, that imparts coloration to the composition.

In one aspect, the fluid composition is free of carbon-halogen bonds and is therefore more environmentally friendly than alternative fluid compositions containing one or more components having such bonds.

The fluids of the present disclosure provide the following effects during material manufacturing, particularly during metal machining. The main effects include lubrication of the cutting process, mainly at low cutting speeds, cooling of the workpiece, mainly at high cutting speeds, and flushing of chips from the cutting area. A second effect includes corrosion protection of the machined surface and component treatment by cooling the hot surface. The process effects of using the cutting fluids of the present disclosure in machining include: longer tool life, reduced thermal distortion of the workpiece, better surface finish, and ease of chip and chip handling.

The compositions of the present disclosure provide good heat transfer performance, good lubrication performance, good debris flushing performance, good fluid mist generation, good fluid carry-over of debris, and good corrosion inhibition. The compositions in emulsion form exhibit good fluid stability.

Note that as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "an amphoteric surfactant" includes a single amphoteric surfactant as well as one or more of the same or different amphoteric surfactants.

Components

The compositions of the present disclosure include at least one surfactant. In one embodiment, the composition contains an amphoteric surfactant. In another embodiment, the composition contains an anionic surfactant. In one embodiment, the composition contains two different amphoteric surfactants, optionally in combination with an anionic surfactant. In one embodiment, the composition contains two different anionic surfactants, optionally in combination with an amphoteric surfactant.

Amphoteric surfactant

In one embodiment, the compositions of the present disclosure comprise at least one amphoteric surfactant, and optionally a plurality of amphoteric surfactants. As used herein, an amphoteric surfactant is a molecule that contains both positively and negatively charged atoms. The surfactant molecule may comprise a polymeric component and may also include a counter ion such as sodium and ammonium, but the counter ion is not considered to be one of the positively or negatively charged atoms that makes the molecule an amphoteric surfactant.

The positively charged atom may be, for example, a nitrogen atom providing an ammonium group, or may be a sulfur atom providing a sulfonium group. The presence of a positive charge on a particular atom may vary with the pH to which the molecule is exposed. In other words, the amphoteric surfactants of the present disclosure need not contain positively and negatively charged atoms at each pH of the surrounding solution, but may contain these charged atoms only within the pH range. For example, when a molecule contains a positively charged nitrogen atom, the charge may only be present when the pH of the surrounding solution (aqueous solution) is sufficiently low (the nitrogen atom becomes protonated). This occurs, for example, when the nitrogen atom is part of a primary, secondary or tertiary amine. Alternatively, the nitrogen atom may be part of a quaternary ammonium ion that maintains its positive charge regardless of the pH of the surrounding solution.

The negatively charged atom can be, for example, an oxygen atom that can be part of a recognized functional group (e.g., carboxylate, sulfate, sulfonate, or phosphate). As with positive charges, the presence of a negative charge on a particular atom can vary with the pH to which the molecule is exposed. In other words, the amphoteric surfactants of the present disclosure need not contain negatively charged atoms and positively charged atoms at each pH of the surrounding solution, but may contain these charged atoms only within the pH range. For example, when a molecule contains a negatively charged oxygen atom, the charge may only be present when the pH of the surrounding solution (aqueous solution) is sufficiently high (the oxygen atom becomes deprotonated). This can occur, for example, when the oxygen atom is part of, for example, a carboxylic acid group, wherein only the carboxylate form of the carboxylic acid group contains a negatively charged oxygen atom, while the corresponding carboxylic acid form contains a neutral oxygen atom.

In summary, amphoteric surfactants need not contain both positively charged atoms and negatively charged atoms over all possible pH ranges of the surrounding solution, but will contain both charged atoms in some pH ranges, sometimes referred to in the art as the isoelectric point pH range. When an amphoteric surfactant contains both positively and negatively charged atoms, it can be said that the surfactant is in its zwitterionic form. When the chemical structure of the amphoteric surfactant is provided herein, the term X can be used to refer to a counterion that may be associated with an atom that is positively or negatively charged in the isoelectric pH range. Exemplary cationic counterions are sodium and ammonium. Exemplary anionic counterions are chloride and phosphate. Notably, the positive or negative charges can be delocalized within multiple atoms. For example, when the negative charge is on an oxygen atom and the oxygen atom is part of a carboxylate, the negative charge is delocalized within both oxygen atoms of the carboxylate.

In addition, and as with all surfactants, amphoteric surfactants will contain lipophilic (also called hydrophobic) regions and lipophobic (also called hydrophilic) regions. The lipophilic region may be referred to as the fat region. The fatty region may be composed of hydrocarbon moieties that are present in naturally occurring fatty acids, fatty alcohols, fatty amines, and the like, although it may alternatively be synthetically formed, i.e., it may be a synthetically produced fragment such as polyethylene, polypropylene, poly (propylene oxide), and the like. As used herein, and when describing a class of amphoteric surfactants, the term "R" will be used to refer to the fatty region of the molecule. In various embodiments, R represents a medium or long chain aliphatic group, such as: c₆-C₂₄Fragments, i.e., molecular fragments containing at least 6 and up to 24 carbon atoms and optionally any other atoms (e.g., hydrogen, halogen (e.g., F, Cl, Br), nitrogen, and oxygen); c₆-C₂₄Hydrocarbons, i.e., molecular fragments containing 6 to 24 carbon atoms and sufficient hydrogen atoms to complete the valency of the carbon atoms; c₈-C₂₂A fragment; c₈-C₂₂A hydrocarbon; c₁₀-C₂₀A fragment; c₁₀-C₂₀A hydrocarbon; c₁₂-C₁₈A fragment; and C₁₂-C₁₈A hydrocarbon. In various embodiments, R contains at least 6, or at least 8, or at least 10, or at least 12, or at least 14, or at least 16 carbon atoms. In various embodiments, R contains no more than 30, or no more than 26, or no more than 24, or no more than 22, or no more than 20, or no more than 18 carbon atoms. The term R may represent an alkyl group, wherein the term alkyl refers to a straight, branched, or cyclic saturated hydrocarbon group, typically containing any number of carbon atoms in the range of carbon atoms specified above (e.g., C6-C24 refers to an alkyl group containing 6 to 24 carbon atoms). Examples of the alkyl group include a 3-methylhexyl group, a 2, 2-dimethylpentyl group, a 2, 3-dimethylpentyl group, an octanoic acid group, a decanoic acid group, a lauric acid group, a myristic acid group, a palmitic acid group, a stearic acid group, an oleic acid group, an linoleic acid group, a linolenic acid group and a behenic acid group.

The following paragraphs provide examples of exemplary specific surfactant classifications and specific amphoteric surfactants that can be incorporated into the fluid compositions of the present disclosure. It should be noted that the classifications are not mutually exclusive, as a particular amphoteric surfactant may fall into multiple classifications, i.e., the two classifications may overlap in the surfactant covered by the classification. The surfactant art uses different nomenclature to classify and identify, inter alia, amphoteric surfactants and, in general, the class of surfactants, wherein the nomenclature does not generally provide for the classification of surfactants that are mutually exclusive. However, the following provides amphoteric surfactants for use in the present disclosure. For convenience, surfactants may be identified by reference to only the charged portion thereof. For example, the amphoteric surfactant may be referred to as a betaine or betaine surfactant to indicate that the amphoteric surfactant contains a betaine group. As another example, when amphoteric surfactants contain a hydroxysultaine group, such surfactants may be referred to as hydroxysultaine surfactants, or even more simply as hydroxysultaines when the context permits. Alternatively, it can be said that the amphoteric surfactants contain well-identified charged groups, such as betaine or betaine groups, hydroxysulfobetaine groups, amine oxide groups, and the like.

In some of the chemical structures described below, the term "L" is used to refer to a linking group, which is a short chain of atoms that links together two significant functional groups present in an amphoteric surfactant, in one embodiment, L is methylene, i.e., -CH₂In one embodiment L is ethylene, i.e., -CH₂CH₂In one embodiment L is propylene, i.e., -CH₂CH₂CH₂-. The linking group may comprise a substituent on the alkylene chain, wherein the substituent may be, for example, halogen, hydroxy or short chain (about C)₁-C₄) In one embodiment L is a hydroxy-substituted propylene group, such as-CH₂CH(OH)CH₂In another embodiment L is a methyl-substituted methylene group, for example, -CH (CH)₃) In one embodiment L is methylene, ethylene or propylene, each optionally substituted with hydroxyl in one embodiment L is dimethyl ether, i.e., -CH₂-O-CH₂In one embodiment L is a chain of 1 to 5 atoms selected from carbon and oxygen, wherein the chain is optionally substituted with hydroxyl or halide.

Any of the following terms may be used to expressly state "amphoteric surfactant" to thereby provide a selection of amphoteric surfactants for use in embodiments of the present disclosure: alkyl amidopropyl betaines, alkyl amine oxides, alkyl amphoacetates, alkyl betaines, alkyl carboxyglycinates, alkyl glycinates, alkyl sulfobetaines, alkyl amphopropionates, alkyl amphoglycinates, alkyl amidopropyl hydroxysultaines, acyl taurates, and acyl glutamates. Each of these terms is known in the art, and many of these terms are described below.

In one embodiment, the amphoteric surfactant is a betaine surfactant, which means that the surfactant comprises a betaine group. The betaine surfactant may be an alkylamidopropyl betaine, which when the alkyl group is a straight chain alkyl group may be represented by the chemical structure CH₃-(CH₂)_n-CONH-CH₂CH₂CH₂-N(CH₃)₂-CH₂-COOX. More generally, the amidopropyl betaine may be represented by the chemical structure R-CONH-CH₂CH₂CH₂-N(CH₃)₂-CH₂-COOX. These are all examples of alkyl amido betaines.

In one embodiment, the amphoteric surfactant is an alkylamidothiobetaine, which may be represented by the chemical structure R-CONH-L-N (CH)₃)₂-(CH₂)_m-SO₂A subset of this class is ammonium alkylbenzyldimethyl ammonium propanesulfonate obtained by quaternizing an alkylxylylenediamine with propane sultone (propansultone) furthermore, the propylene linking group L may be substituted, for example, with a hydroxyl group which provides a 2-hydroxy-1-propanesulfonate derivative, to provide another amphoteric surfactant suitable for use in the compositions of the present invention.

In one embodiment, the amphoteric surfactant is an alkyl amino acid type amphoteric surfactant, which may be represented by the chemical structure R-NH-L-COOX, where R and L are as defined above.

In one embodiment, the amphoteric surfactant is an alkyl betaine amphoteric surfactant, which may be represented by the chemical structure R-N (CH)₃)₂-L-COOX, wherein R is an alkyl group and L is a linking group like the other amphoteric surfactants disclosed herein, the R group can be an aliphatic group and is not limited toAs previously mentioned, however, the alkyl betaines also include α - (N, N, N-trialkylammonium) alkanoates having the structure R¹-N(R²)(R³)-C(R⁴) Alkyl betaines are named using various alternative and sometimes more specific names, such as N-alkyl-N, N-dimethylglycine, N-alkyl-N, N-dimethyl-N-carboxymethylammonium betaine, alkyl-dimethylammonium acetate or alkyl-dimethylammonium acetate.

In one embodiment, the amphoteric surfactant is an alkyl imidazoline derived amphoteric surfactant, which may be represented by the chemical structure R-CONH-L-N (CH)₂CH₂OH)CH₂COONa is as shown. In another embodiment, the alkyl imidazoline derived amphoteric surfactant is a diacid, which may be formed from the chemical structure R-CON (CH)₂CH₂OH)-L-N(CH2COONa)₂In any of these embodiments, linker L is optionally an ethylene group.

In one embodiment, the amphoteric surfactant is an alkyliminodiacid amphoteric surfactant, which may be represented by the chemical structure R-N (CH)₂CH₂COONa)₂And (4) showing. In an alternative embodiment, the alkyl imidodiacid amphoteric surfactant consists of the chemical structure R-N (CH)₂CH₂CH₂COONa)₂Or R-N (CH)₂COONa)₂And (4) showing.

In one embodiment, the amphoteric surfactant is an alkyl thiobetaine amphoteric surfactant. The chemical structure of alkylthiobetaines may be represented as R-N (CH)₃)₂-L-SO₂OX (sometimes also denoted as-L-SO)₃X) where R is alkyl and L is methylene the following are examples of specific alkylthiobetaines that may be used in the practice of the present invention, octanoylthiobetaine, hexadecylthiobetaine, lauryl thiobetaine, myristylthiobetaineBetaine, n-octyl thiobetaine, palmityl thiobetaine, tetradecyl thiobetaine.

In one embodiment, the amphoteric surfactant is an alkyl sultaine, which is a preferred term for CTFA. the alkyl sultaine is a thiobetaine amphoteric surfactant that includes a propanesulfonate group, i.e., L-SO₃X, wherein L is propylene, the alkylsulfobetaine has the chemical structure R-N (CH)₃)₂-CH₂CH₂CH₂-SO₂OX。

In one embodiment, the amphoteric surfactant is an amidopropyl betaine, which may be represented by the chemical structure R (C ═ O) -NH- (CH)₂)₃-N(CH₃)₂-CH₂COOX represents. Such amidopropyl betaines may also be referred to as alkyl amidopropyl betaines, as R may be an alkyl group. Alkyl amidopropyl betaine surfactants are typically synthesized by: fatty acids (e.g., from natural oils such as coconut oil) are reacted with 3, 3-dimethylaminopropylamine to provide an amidopropyl dimethylamine intermediate, which is in turn reacted with sodium monochloroacetate to provide the corresponding betaine. Betaine surfactants are often named after the source of fatty acid used for their preparation, e.g., coconut oil provides cocoamidopropyl betaine and isostearic acid provides isostearamidopropyl betaine. Many alkyl amidopropyl betaine surfactants suitable for use in the present invention are commercially available in both solid and solution form and may be purchased from different suppliers.

The following are specific exemplary amidopropyl betaines that may be used in the practice of the present invention: almond oil amidopropyl betaine, wild apricot amidopropyl betaine (apricotamidopropyl betaine), avocado amidopropyl betaine, babassu amidopropyl betaine, behenamidopropyl betaine, canola amidopropyl betaine, capryl/capramidopropyl betaine (formed from a mixture of caprylic acid and capric acid), coco/oleamidopropyl betaine, coco/sunflower amidopropyl betaine (formed from a mixture of coconut oil and sunflower seed oil), arachis lipoamidopropyl betaine (formed from pulp of arachis hypoglauca), isostearoylaminopropyl betaine, lauramidopropyl betaine, meadowfoam amidopropyl betaine (formed from meadowfoam seed oil), cow amidopropyl betaine, mink amidopropyl betaine (formed from mink oil), Myristyl amidopropyl betaine, oat oil amidopropyl betaine (formed from oat (Avena Sativa) (oal) kernel oil), oleoyl amidopropyl betaine, olive oil amidopropyl betaine, palm oil amidopropyl betaine (formed from palm oil), palm amidopropyl betaine, palm kernel oil amidopropyl betaine (formed from palm kernel oil), ricinoleic acid amidopropyl betaine, sesame amidopropyl betaine, shea butter amidopropyl betaine (formed from shea butter), soybean oil amidopropyl betaine, stearyl amidopropyl betaine, tallow amidopropyl betaine, undecylenic amidopropyl betaine, and wheat germ oleoyl amidopropyl betaine (formed from oils in wheat germs).

In one embodiment, the amphoteric surfactant is an amine oxide amphoteric surfactant, which may be represented by the chemical structure R-N (CH)₃)₂-O-represents, wherein R is a lipophilic group. An exemplary R group is a lipophilic alkyl group, where amine oxide surfactants containing R as an alkyl group are commonly referred to as alkyl amino oxides. Exemplary alkyl groups are caprylic acid groups, capric acid groups, lauric acid groups, myristic acid groups, palmitic acid groups, stearic acid groups, oleic acid groups, linoleic acid groups, linolenic acid groups, and behenic acid groups. Exemplary amine oxide amphoteric surfactants include cocamidopropyl amine oxide and lauryl dimethyl amine oxide (also known as dodecyl dimethyl amine oxide, N-dimethyldodecylamine N-oxide, and DDAO), soya oil amidopropyl amine oxide, and myristyl amine oxide. The nitrogen atom of the amine group may be bonded to two methyl groups as shown above, however, alternatively, the nitrogen atom may be bonded to two hydroxyethyl groups to provide the structure R-N (CH)₂CH₂OH)₂-O-。

In one embodiment, the amphoteric surfactant is an amino acid type amphoteric surfactant. Amphoteric surfactants of this type exhibit a zwitterionic structure in certain pH ranges, which depend on the structure of the surfactant. A common example of this type of amphoteric surfactant is the structure R-NH-CH₂CH₂-amino acids of COOH, wherein R is an aliphatic group. These are sometimes referred to as aliphatic amino acids, or more precisely aliphatic aminopropionates when in the form of the corresponding carboxylates. This structural variant contains two carboxylic acid groups, i.e. has the structure R-N (CH)₂CH₂COOH)₂When in the corresponding carboxylate salt form, it is designated as the fatty imino dipropionate. Any of these classes of amphoteric surfactants can be used in the compositions of the present disclosure.

In one embodiment, the amphoteric surfactant is an amphoacetate amphoteric surfactant comprising the chemical structure-CH in addition to an aliphatic group and a chemical group that will become positively charged at a suitable pH₂-CO₂And (4) X. These surfactants are sometimes referred to as amphoglycinates. In one embodiment, the amphoacetate ampholytic surfactant may be represented by the chemical structure R (CO) NH-CH₂CH₂-N(CH₂CH₂OH)(CH₂CO₂X) wherein R may be alkyl or R (co) may be a fatty acyl derived from a fatty acid such as found in coconut oil to provide, for example, cocoamphoacetate. May be prepared by reacting a compound of the formula R (CO) NH-CH as disclosed in U.S. Pat. No. 6232496₂CH₂-NHCH₂CH₂OH compounds are reacted with formaldehyde and cyanide to prepare such amphoacetate surfactants. Under appropriate conditions, such amphoacetates can interconvert into the corresponding amphoacetates containing imidazolium groups providing positively charged chemical groups, such as lauroamphoacetates (sodium salts).

The amphoacetate ampholytic surfactant may comprise two acetate species rather than one,to provide a compound having the chemical structure R (CO) NH-CH₂CH₂-N(CH₂CH₂OCH₂CO₂X)(CH₂CO₂X) amphoteric surfactants. Exemplary amphoacetate ampholytic surfactants include disodium cocoamphodiacetate, sodium cocoamphoacetate, disodium lauroamphoacetate, and sodium lauroamphoacetate.

In one embodiment, the amphoteric surfactant is an amphopropionate amphoteric surfactant comprising the chemical structure-CH in addition to an aliphatic group and a chemical group that will become positively charged at a suitable pH₂CH₂-CO₂And (4) X. Such amphoteric surfactants can be prepared from acrylic acid as described in us patent 6030938. Exemplary amphopropionate amphoteric surfactants are sodium caprylocamphopropionate, sodium lauriminodipropionate, sodium isostearyl amphopropionate, and sodium cocoamphopropionate. The amphopropionate amphoteric surfactant may comprise two, but not one, propionate groups to provide a surfactant having the chemical structure R (CO) NH-CH₂CH₂-N(CH₂CH₂OCH₂CH₂CO₂X)(CH₂CH₂CO₂Amphoteric propionate amphoteric surfactants of this class are known as amphoteric dipropionate amphoteric surfactants, with exemplary amphoteric dipropionate amphoteric surfactants being the disodium salt of cocoyl amphoteric dipropionate (also known as N- (2-cocoamidoethyl) -N- (2- (2-carboxyethyl) oxyethyl) - β -aminopropionic acid, disodium salt) and disodium caprylyl amphoteric dipropionate.

In one embodiment, the amphoteric surfactant is a betaine surfactant. Betaine refers to a surfactant molecule that incorporates both positively charged (cationic) functional groups (e.g., phosphonium or quaternary ammonium groups without hydrogen atoms) and negatively charged (anionic) functional groups (e.g., carboxylate or oxygen ions). In betaines, the cationic and anionic groups are not adjacent to each other. Betaine surfactants as referred to herein will meet the aforementioned definition and will furthermore contain a lipophilic surfactantAnd (4) partial. In one embodiment, the cation is a quaternary amine. In one embodiment, the anion is a carboxylate. In another embodiment, the anion is an oxyanion. In another embodiment, the anion is sulfate. In another embodiment, the anion is a sulfonate. In another embodiment, the anion is phosphate. Many commercially available betaines contain a dialkyl-substituted dimethylammonium group. While such groups are common in commercial amphoteric surfactants, the amphoteric surfactants useful in the present disclosure do not necessarily (although they may) contain a dimethylammonium group. More generally, they contain a dialkylammonium group, in order to provide, for example, a chemical structure R¹-N(R²)(R³)-CH₂Trialkylammonium alkanoates of COOX. In other words, R²And R³Not necessarily methyl. Some exemplary betaines are of the chemical structure R-N (CH)₃)₂-CH₂Alkyl dimethyl betaine of-COO H and structure R-CONH-CH₂CH₂CH₂-N(CH₃)₂-CH₂-alkyl amidopropyl dimethyl betaine of-COOH.

In one embodiment, the amphoteric surfactant is a surfactant having the chemical structure R-N (CH)₃)₂-CH₂CH(OH)-SO₃A hydroxysulfobetaine of X, wherein R is an aliphatic group, e.g., a long chain alkyl group. Hydroxysultaines are often named after the source of the R group, so for example hydroxysultaines from coconut oil may be named cocamidopropyl hydroxysultaine (however, they are also known as cocohydroxysultam (sulfoline) and CAHS). Other exemplary hydroxysulfobetaine amphoteric surfactants include laurylamidopropyl hydroxysultaine, oleoylamidopropyl hydroxysultaine, tallow amidopropyl hydroxysultaine, erucamidopropyl hydroxysultaine, and laurylhydroxysultaine.

In one embodiment, the amphoteric surfactant is an imidazoline derivative amphoteric surfactant, which is sometimes referred to as an imidazolinium salt derivative. The chemical structure of amphoteric surfactants, which represent imidazoline derivatives, becomes complex due to the fact that imidazolines are characteristically hydrolyzed when exposed to water. The aliphatic imidazolines slowly hydrolyze upon exposure to humid air to produce alkylamidoamines. Thus, the alkylamidoamine amphoteric surfactants that have been described elsewhere herein are examples of imidazolinium salt derivative amphoteric surfactants. In general, imidazolinium salt derivative amphoteric surfactants, sometimes referred to as imidazoline amphoteric surfactants, are well known in the art as a class of surfactants. In one embodiment, the amphoteric surfactant is an imidazoline derivative, optionally an aliphatic alkyl imidazoline. Amphoteric surfactants of this type form cations in acidic solutions, anions in basic solutions, and "zwitterions" in solutions in the neutral pH range. The neutral pH range, also known as the isoelectric point range, within which the imidazoline surfactant carries a neutral charge, is compound specific and, depending on the precise structure of the compound, will affect the basicity of the nitrogen atom and the acidity of the carboxylic acid group. Exemplary suitable imidazoline-type amphoteric surfactants include, but are not limited to, 2-cocoyl-2-imidazolinium hydroxide-1-carboxyethoxy disodium (2-cocoyl-2-imidazolium hydroxide-1-carboxyethoxy disodium).

The imidazolinium salt derivative amphoteric surfactant can be prepared by the reaction of sodium chloroacetate with the corresponding 2-alkyl-1- (2-hydroxyethanethiol-) -2-imidazoline. Such reaction products are generally designated to have the following chemical structure:

wherein R is a hydrophobic group. The reactions that produce these cyclic imidazolinium salt derivatives can be readily extended to provide the corresponding open-chain molecules having the following structures: RCO-NH-CH₂CH₂-N(CH₂CH₂OH)CH₂COO- (sodium chloroacetate with one equivalent) and RCO-NH-CH₂CH₂-N(CH₂CH₂OH)(CH₂COO-)₂(with two equivalents of sodium chloroacetate). Such open chain structures are commonly referred to as imidazoline derivatives, or alkyl (when R is alkyl) amido amino acids (when a single equivalent of sodium chloroacetate is used for their preparation).

Commercially available amphoteric imidazolinium salts can be one or more of the foregoing structures, which are suitable for use in the present disclosure. Imidazolinium salt derivatives should be chosen with some care, as the same term is used somewhat confusingly to refer to cationic (as opposed to amphoteric) surfactants that are incorporated into or prepared from imidazolines, for example, cationic surfactants having the following structure:

thus, the skilled person will sometimes specify amphoteric imidazolinium surfactants to distinguish them from the so-called cationic imidazolinium surfactants.

Examples of suitable amphoteric imidazolinium salt derivatives have an R group selected from C6-C22 alkyl groups, for example, octanoic acid groups, decanoic acid groups, lauric acid groups, myristic acid groups, palmitic acid groups, stearic acid groups, oleic acid groups, linoleic acid groups, linolenic acid groups and behenic acid groups.

In one embodiment, the amphoteric surfactant is a phosphinate betaine amphoteric surfactant. Phosphinate betaines are similar to alkyl betaines and thiobetaines in which the carboxyl or sulfonic acid group has been replaced by a phosphine group. The phosphinate betaine may be represented by the chemical structure R-N (CH)₃)₂-L-P (═ O) (R) OX denotes L may be, for example, propylene.

In one embodiment, the amphoteric surfactant is a phosphonate betaine amphoteric surfactant. Phosphonate betaines are similar to alkyl betaines and thiobetaines in that the carboxyl or sulfonic acid group has been replaced with a phosphonate. The phosphonate betaine may be of the chemical structure R-N (CH)₃)₂-L-P (═ O) (OR) OX denotes L may be, for example, propylene.

In one embodiment, amphotericity tableThe surfactant is pyridinium alkanoate amphoteric surfactant, which can be composed of chemical structure

Wherein R is an aliphatic group, e.g., a medium or long chain alkyl group. At a suitable pH, however, the pyridinium alkanoate, shown as a carboxylic acid, will have its carboxylic acid (-COOH) group converted to a Carboxylate (COOX) group.

In one embodiment, the amphoteric surfactant is an amphoteric surfactant comprising sulfate ions. Sulfate ion groups can be readily added to aliphatic unsaturated amines such as oleylamine (1-amino-9, 10-octadecene) to provide the corresponding sulfate ion containing amphoteric surfactant named 9- (10) -hydroxyoctadecylamine.

In one embodiment, the amphoteric surfactant is a sulfate betaine, also known as alkyl dimethyl ammonium alkyl sulfate, which may be represented by the chemical structure R-N (CH)₃)₂-L-OSO₃X represents. Sulfate betaines are examples of amphoteric surfactants that contain sulfate ions and also contain a betaine group.

In one embodiment, the amphoteric surfactant is a thiobetaine amphoteric surfactant. The chemical structure of the base compound may be represented as R-N (CH)₃)₂-L-SO₂OX (sometimes also denoted as-L-SO)₃X) because of the commercial availability, many thio betaines have L which is propylene, and such amphoteric surfactants can be used in embodiments of the present disclosureWhen there are 12 carbon atoms, i.e. lauryl, the corresponding thiobetaine is called lauryl thiobetaine.

For example, the propylene group designated "L" may be substituted with different functional groups, e.g., halogen, hydroxyl, and methoxy. the R group need not be straight chain alkyl, but may be branched chain hydrocarbons or even alicyclic or aromatic hydrocarbons indeed, the R group need not even be a hydrocarbon.

In one embodiment, the amphoteric surfactant is an amphoteric surfactant comprising a sulfonic acid. For example, the amphoteric surfactant may be of the formula RNH-CH₂CH₂-SO₃N-alkyl taurines of H, wherein R is alkyl. In a related embodiment, R is an aliphatic group. Another sulfonic acid containing amphoteric surfactant may be prepared by: sulfonating a linear amidoamine precursor of a 1-hydroxyethyl 2-alkylimidazoline to provide R-CONH-CH₂CH₂-N(CH₂CH₂OH)CH₂CH₂SO₃H, wherein R may be an aliphatic group, e.g., an alkyl group.

Specific examples of amphoteric surfactants and classes thereof that may be used in the compositions of the present invention include, but are not limited to, cocamidopropyl amine oxide, cocamidopropyl betaine, cocamidopropyl hydroxysultaine, cocadimethyl sulfopropyl betaine, disodium cocoamphodipropionate, lauryl amine oxide, lauryl amidopropyl betaine; lauryl betaine, lauryl hydroxy thiobetaine, myristyl amine oxide, sodium cocoamphoacetate, and stearyl betaine. As previously mentioned, these terms do not necessarily define mutually exclusive sets of surfactants, i.e., a particular amphoteric surfactant can fall within two or more sets of amphoteric surfactants each defining one of the selected terms.

Anionic surfactants

Suitable exemplary anionic surfactants include, but are not limited to, alkyl sulfates, alkyl ether sulfates, alkyl sulfonates, alkylaryl sulfonates, alkyl succinates, alkyl sulfosuccinates, N-alkanoyl sarcosinates, acyl taurates, acyl isethionates, alkyl phosphates, alkyl ether carboxylates, α -olefin sulfonates, and alkali and alkaline earth metal and ammonium and triethanolamine salts thereof.

In one embodiment, the anionic surfactant is a carboxylic acid or carboxylate salt that contains an anionic group-C (O) -O-in addition to an aliphatic group. The aliphatic group, denoted herein as R, may be an alkyl group, in which case the carboxylate may be referred to as an alkyl carboxylate. Exemplary alkyl carboxylates are sodium or potassium or ammonium salts of fatty acids such as stearic acid and oleic acid. Potassium oleate is an exemplary alkyl carboxylate. Alternatively, the aliphatic group may be a water-insoluble polyalkylene oxide group. Some carboxylate anionic surfactants are prepared from alkyl alcohols, such as octanol, which are then reacted with ethylene oxide to provide a polyoxyethylene extended octanol known as polyoxyethylene (8) octyl ether carboxylic acid when the average number of ethylene oxide units per molecule is 8.

In one embodiment, the anionic surfactant is diphenyl oxide. Diphenyl oxide can be considered as a subclass of sulfonate anionic surfactants because the aromatic ring of the diphenyl precursor is sulfonated to provide a diphenyl ether anionic surfactant. The diphenol (diphenol) precursor is typically a diphenyl ether, i.e., Ar-O-Ar, in which one or both of the aromatic rings (Ar) may be substituted with an alkyl group. The anionic diphenyl oxide surfactant may be represented by the formula XSO₃-Ar(R)-O-Ar(R)-SO₃X represents, wherein R is hydrogen or alkyl at each site of the aromatic ring that is not sulfonated or bonded to an ether oxygen. Exemplary anionic diphenyl oxide surfactants include alkyl substituted disulfonated diphenyl oxides such as linear decyl substituted disulfonated diphenyl oxide, linear dodecyl substituted disulfonated diphenyl oxide, branched decyl substituted disulfonated diphenyl oxide, any of which can be neutralized with sodium, potassium, or ammonium.

In one embodiment, the anionic surfactant is a phosphate ester, i.e., it may be of the chemical structure R-O-P (O) (OH)₂Or a phosphoric acid diester of the chemical structure R-O-P (O) (OH) O-R, wherein the two Rs in the diester may be the same or different. The R group is an aliphatic group, i.e., a water insoluble group. The R group may be an alkyl group, and the phosphate ester with R ═ alkyl group is typically prepared from the corresponding alkyl alcohol. In one embodiment, the R group is a polyalkylene oxide group to provide a compound of the formula R- (OCH)₂CH₂)_n-O-P(O)(OH)₂The polyether phosphate of (1). The general nomenclature for polyether phosphates provides for the number of polyoxyethylene groups in the surfactant, for example, polyoxyethylene (10). The R group in the polyether phosphate may be an alkyl group (when the polyether phosphate is derived from an alkyl alcohol), an aryl group (when the polyether phosphate is derived from an aromatic alcohol, for example phenol), or an alkylaryl group, for exampleSuch as alkyl substituted phenols, such as nonyl-phenol. Exemplary phosphate esters include polyoxyethylene (10) nonylphenol phosphate, polyoxyethylene (4) phenol phosphate and C₈H₁₇A phosphate ester. Commercial preparation of phosphate esters typically provides a mixture of phosphoric monoesters and phosphoric diesters, which can be used in the compositions of the present disclosure.

In one embodiment, the anionic surfactant is a sarcosinate, i.e., having the chemical structure R-c (o) -N (CH)₃)-CH₂-CO₂A compound of X, wherein R is an aliphatic group. Sarcosinate surfactants comprise an N-acyl group, wherein the fatty acid from which the acyl group is derived is commonly used to designate the sarcosinate. Exemplary sarcosinates include sodium lauroyl sarcosinate, sodium cocoyl sarcosinate, sodium myristoyl sarcosinate, and ammonium ion equivalents.

In one embodiment, the anionic surfactant is a sulfate, i.e., contains an anion-O-SO in addition to an aliphatic group₃Compounds of the group X. The aliphatic group may be a long chain alkyl group, wherein the alkyl group in the surfactant may be branched or straight chain. The aliphatic group need not be an alkyl group, however alkyl groups are routinely available from many vegetable and animal oils and are therefore a convenient source of aliphatic groups for surfactants. Exemplary sulfate anionic surfactants include sodium lauryl Ether sulfate, sodium lauryl sulfate, sodium decyl sulfate, sodium octyl sulfate, ammonium lauryl sulfate, sodium trideceth (rrideceth) sulfate, C₁₂–₁₄Sodium tert-alkyl-ethoxylate sulphate and poly (oxy-1, 2-ethanediyl), α -thio-omega- (nonylphenoxy) ammonium salts.

In one embodiment, the anionic surfactant is a sulfoacetate, i.e., contains an anion-CH in addition to an aliphatic group₂-SO₃Compounds of the group X. Common aliphatic groups have the structure R-O-C (O) -where R is alkyl, e.g., C₈-C₁₈A linear alkyl group. Exemplary anionic sulfoacetate surfactants are sodium lauryl sulfoacetate and ammonium cetyl sulfoacetate. Can exemplifySulfoacetate salts were prepared as described in U.S. patent No. 5616782.

In one embodiment, the anionic surfactant is a sulfonate, i.e., contains an anion-SO in addition to an aliphatic group₃Compounds of the group X. The aliphatic group may be, for example, a long chain alkyl group. The sulfonate may be considered to have the chemical structure R-SO₃And (4) X. In one embodiment, the R group is derived from a fatty acid and is a long linear alkyl group, such as stearyl and oleyl. Long chain olefins are often used as precursors to sulfonates because the double bond can be treated to convert it to a sulfonate. Such sulfonates are generally named after the precursors used to form the sulfonate, e.g., C₁₄-C₁₆Olefin sulfonates of formula (I) wherein₁₄-C₁₆Indicating that the mixture of olefins having 14 and 16 carbons is a sulfonate providing an anionic surfactant. In one embodiment, the R group is an alkyl benzene group, such as a dodecyl benzene group. Alkyl (e.g., dodecyl) groups can be straight chain alkyl or branched chain alkyl groups. Exemplary sulfonate anionic surfactants are linear dodecylbenzene sulfonate and branched dodecylbenzene sulfonate. The anionic groups may be neutralized conventionally with any suitable cation, such as sodium, potassium, ammonium, and the like.

In one embodiment, the anionic surfactant is a sulfosuccinate, i.e., a compound having a chemical structure based on sulfonated succinic acid, i.e., an aliphatic group-O-c (O) -CH2-CH (sulfate) -c (O) -O-R (which may be an aliphatic group or hydrogen). The sulfosuccinates are typically the sodium salts of alkyl esters of sulfosuccinic acid, the sodium salt being the condensation of maleic anhydride with a fatty alcohol, followed by sodium bisulfite (NaHSO)₃) As a result of sulfonation. As shown in the foregoing chemical structure, the sulfosuccinate will have at least one aliphatic group, and may have two aliphatic groups. However, when the sulfosuccinate has one aliphatic group, it may also have an anionic carboxylate rather than a second aliphatic group. Exemplary sulfosuccinate anionic surfactants include sodium dioctyl sulfosuccinate (having two aliphatic groups) and disodium laureth sulfosuccinate (having two aliphatic groups)One aliphatic group, one sulfate group and one carboxylate group, and is referred to as D L S).

Other specific examples of anionic surfactants include, but are not limited to, ammonium lauryl sulfosuccinate, sodium lauryl sulfate, sodium lauryl ether sulfate, ammonium lauryl ether sulfate, triethanolamine dodecylbenzene sulfonate, sodium lauryl sarcosinate, ammonium lauryl sulfate, sodium oleyl succinate, sodium lauryl sulfate, and sodium dodecylbenzene sulfonate.

In one embodiment, the fluid concentrates and compositions of the present disclosure comprise a third surfactant selected from amphoteric surfactants and anionic surfactants. The third surfactant is different from the first (amphoteric) or second (anionic) surfactant, i.e. different from the first or second surfactant. Any amphoteric surfactant and anionic surfactant previously disclosed are optionally used as the third surfactant in the formulation of the present invention, as long as it (the third surfactant) is different from the first or second surfactant. In one embodiment, the third surfactant is of a different species than either the first or second surfactant, i.e., the third surfactant has a functional group that: which is different from the functional groups that provide the charged functionality present in the first and second amphoteric or anionic surfactants. For example, if the second surfactant is a sulphate anionic surfactant, then the third surfactant is not a sulphate but, for example, a sulphonate anionic surfactant.

Amphoteric and/or anionic surfactants suitable for use in the present invention may be obtained from one or more of the following exemplary manufacturers and/or suppliers, Aceto Corp. (Allendale, NJ); Air Products (Allentown, PA); Akzo Nobel Chemicals Co. (Chicago, I L); azo International (Sayreville, NJ); BASF Corp. (Florham Park, NJ); Clariant Corp. (Frankfurt, Germany); Croda, Edison, NJ); Dow Chemical (Midland MI); E.I.du Pod Nemours & Co.; WilmingtDE, Harrisos, Inc. (Kazeas, Hunthane, Inc.), and Harrison, Inc., Sankyo, Inc., Tokyo, Inc., and/or supplier, and Harrison, Inc., Tokyo, Inc., and Tokyo, Inc., and company, Inc., and S.56, Inc., Tokyo, Inc., and S..

Optional Components

The following ingredients are optionally present in the compositions of the present disclosure, however, the present disclosure also provides: the following ingredients may be expressly excluded from the presence in the compositions of the present disclosure.

The compositions of the present disclosure may include a rust inhibitor, which may also be referred to herein as a preservative. An exemplary rust inhibitor is sodium nitrite. Other exemplary rust inhibitors are sodium benzoate, organoboron compounds, amines, aminophosphate compounds, zinc dialkyldithiophosphates, and tall oil fatty acids. The rust inhibitor may be present in the composition in an amount of less than 10% by weight of the composition, which is used directly as a material making fluid, for example as a metal cutting fluid. In optional embodiments, the amount is less than 9 wt%, or less than 8 wt%, or less than 7 wt%, or less than 6 wt%, or less than 5 wt%, or less than 4 wt%, or less than 3 wt%, or less than 2 wt%, or less than 1 wt%, or less than 0.5 wt%, or less than 0.1 wt%. The amount may also be expressed in terms of a minimum amount, such as at least 500ppm, or at least 1000ppm, or at least 1500ppm, or at least 2000ppm, or at least 2500ppm, 0.5 wt%, or at least 1 wt%, or at least 1.5 wt%, or at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, or at least 3.5 wt%, or at least 4 wt%, or at least 4.5 wt%, or at least 5 wt%. Rust inhibitors are well known commercial materials.

The compositions of the present disclosure may include a colorant, such as a dye or pigment. The colorant should be used in a small amount just sufficient to impart a visible color to the eye when the composition is applied to a material (e.g., metal) to be cut or otherwise shaped. Colorants are well known commercial materials.

The compositions of the present disclosure may include a defoamer, which may also be referred to as a defoamer. Suitable anti-foaming agents are silicone polymers. Silicone defoamers are well known commercial materials. This defoamer is sold by Dow Corning (Michigan, USA). Another suitable anti-foaming agent is tributyl phosphate.

The compositions of the present disclosure may comprise a thickening agent. As used herein, a thickener increases the viscosity of a fluid composition when added to or contained in an aqueous solution of the composition or a concentrate thereof. Among other things, the inclusion of a thickener provides improved adhesion of the composition to a surface. This is particularly advantageous when the surface is non-horizontal and thus the material making composition will tend to fall off the surface under gravity in the absence of the thickener. The thickener may be water soluble. Thickeners for aqueous compositions are well known in the art and may be referred to as aqueous thickeners, and any such thickener may be used in the compositions of the present invention.

The amount of thickener included in the composition will depend on the exact nature of the thickener and the desired viscosity of the material in concentrated form to make the fluid composition. For thickeners selected from cellulosic materials or polyamide thickeners, and to achieve a viscosity similar to that of whole milk or orange juice, when the composition is a concentrate having about 5 to 25% total solids, the thickener will typically be present in the composition in a weight percent of 0.1 weight percent based on the total weight of the composition. The viscosity of the concentrate can be varied primarily by incorporating more or less thickener. If a more viscous concentrate is desired, adding more thickener will provide a more viscous composition. Alternatively, a more effective thickener may be used, i.e., a thickener that achieves the same viscosity increase at a lower concentration.

In one aspect, the thickener can be a polyhydroxy polymer, for example a polysaccharide such as a cellulosic material or a functionalized cellulosic material. When the thickener is a polysaccharide, the polysaccharide may have at least 50, or at least 100, or at least 150, or at least 200 saccharide units per polymer chain. The number average molecular weight of the polysaccharide may be at least 13,000, alternatively at least 17,000, alternatively at least 21,000 or at least 25,000.

In one aspect, the thickener is a small polyhydroxy molecule, such as glycerol. The small polyhydroxyl molecules have a molecular weight of less than 500g/mol and have at least three hydroxyl groups.

In one aspect, the thickener is a cellulosic material comprising a derivative of a cellulosic resin. A suitable cellulosic material is hydroxyethyl cellulose (HEC). HEC is-CH₂Conversion of OH groups to-CH₂OCH₂CH₂OCH₂CH₂OH group and conversion of-OH group to-OCH₂CH₂Derivatives of cellulose with OH groups. Many grades of HEC are commercially available, varying with molecular weight and degree of derivatization, which in turn leads to different solution viscosities (typically measured at 2% solids aqueous solution). A suitable HEC is Cellosize from Dow Chemical (Midland, MI)^TMAnd Aqualon from Ashland Chemical (Covington, KY)^TM。

Other suitable cellulosic thickeners include methylcellulose, ethylcellulose, methylhydroxyethylcellulose, methylhydroxypropylcellulose, hydroxypropylcellulose, and anionic (salt) forms (such as sodium carboxymethylcellulose), dihydroxypropyl ethers of cellulose (see, e.g., U.S. patent No. 4,096,326).

In addition to cellulosic materials, suitable polyhydroxy polymers include corn starch or modified corn starch, potato starch or modified potato starch, and pectin or modified pectin.

The thickener may be polyacrylamide. Suitable polyacrylamide thickeners may be selected from copolymers of acrylamide and ammonium acrylate; copolymers of acrylamide or methacrylamide and methacryloyloxyethyltrimethylammonium halide (e.g., chloride); and copolymers of acrylamide and 2-acrylamido-2-methylpropanesulfonic acid. These copolymers may be prepared in the presence of a crosslinking agent, with exemplary crosslinking agents including divinylbenzene, tetraallyloxyethane, methylenebisacrylamide, diallyl ether, polyallylglycerol ethers, or allyl ethers of alcohols of the sugar series, such as erythritol, pentaerythritol, arabitol, mannitol, sorbitol, and glucose. See, for example, U.S. Pat. Nos. 2,798,053 and 2,923,692. The polyacrylamide may be ionic and neutralized with a neutralizing agent such as sodium hydroxide, potassium hydroxide, ammonia or an amine (e.g., triethanolamine or monoethanolamine). The ionic polyacrylamide may be prepared by: acrylamide is copolymerized with sodium 2-acrylamido-2-methylpropanesulfonate via a free radical route using an initiator of the azobisisobutyronitrile type and precipitated from an alcohol, for example tert-butanol. The crosslinked copolymer of acrylamide and methacryloyloxyethyltrimethylammonium chloride can be obtained by: the copolymerization of acrylamide with dimethylaminoethyl methacrylate quaternized with methyl chloride followed by crosslinking with a compound containing ethylenic unsaturation (e.g., methylene bisacrylamide).

Suitable polyacrylic acid thickeners are commercially available, for example, L ubizol (Wickliffe, Ohio) sells Carbopol, which is made from polyacrylic acid^TMAnd (4) synthesizing a thickening agent. Polyacrylic acid may be neutralized in order to adjust its thickening properties. For example, polyacrylic acid may be neutralized with ammonium ions using, for example, ammonium hydroxide. The Carbomer is sold by Ashland chemical^TMA series of crosslinked polyacrylic acids. Again, these polymers need to be neutralized to provide effective thickening properties.

The thickening agent may be a gum or a derivative thereof. Examples include locust bean gum and derivatives, guar gum and derivatives, and xanthan gum and derivatives. Exemplary gum derivatives include sulfonated gums (e.g., sulfonated guar), hydroxypropyl derived gums (e.g., hydroxypropyl guar), cationic derivatives (e.g., cationic guar).

The thickener may be a hydrophobically modified thickener. In one aspect, the thickener comprises hydrophobic groups such as hydrophobic alkyl chains, wherein suitable examples of such thickeners include hydrophobically modified ethylene oxide urethane (HEUR) polymers, hydrophobically modified alkali soluble emulsion (HASE) polymers, hydrophobically modified hydroxyethyl cellulose (HMHEC), and Hydrophobically Modified Polyacrylamides (HMPA). HEUR polymers are linear reaction products of diisocyanates with polyoxyethylene capped with hydrophobic hydrocarbyl groups. HASE polymers are homopolymers of (meth) acrylic acid, or copolymers of (meth) acrylic acid, (meth) acrylate esters, or maleic acid modified with hydrophobic vinyl monomers. HMHEC refers to hydroxyethyl cellulose modified with hydrophobic alkyl chains. HMPA refers to a copolymer of acrylamide and acrylamide modified with a hydrophobic alkyl chain (N-alkylacrylamide).

In one aspect, the fluid compositions of the present disclosure include an inorganic salt of an organic or inorganic acid. Suitable inorganic salts of organic acids include ammonium citrate, calcium acetate, copper citrate, magnesium citrate, melamine phosphate, nickel acetate, potassium citrate, sodium acetate, sodium hydrogen tartrate, strontium acetate, urea phosphate, and zinc acetate.

The amount of inorganic components present in the composition may vary within wide ranges. The inorganic component can comprise from 1% to about 15% of the weight based on the total weight of solids present in the composition. In various embodiments, the inorganic component is at least 2%, or at least 3%, or at least 4%, or at least 5%, or at least 6%, or at least 7%, or at least 8%, or at least 9%, or at least 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%, or at least 15% of the total weight of the solid components of the composition. In various embodiments, the inorganic component comprises no more than 30%, or 25%, or 20%, or 15%, or no more than 10% of the total weight of solids present in the composition. As previously mentioned, in one embodiment, the inorganic component is an inorganic salt.

As used herein, a nonvolatile material or solvent that is a liquid has a boiling point greater than water, i.e., greater than 100 ℃. an exemplary organic solvent is ethylene glycol monobutyl ether, also known as BUTY L CE LL OSO L VE^TM。

As previously described, the present disclosure provides a concentrate composition comprising water and solids, the solids comprising a first surfactant selected from amphoteric surfactants, a second surfactant selected from anionic surfactants, and a third surfactant selected from amphoteric surfactants and anionic surfactants, the third surfactant being different from the first and second surfactants. Optionally, the third surfactant (other than the first or second surfactant) is a fluorosurfactant. The third surfactant may be a fluorinated or perfluorinated anionic fluorosurfactant and the second (anionic) surfactant of the concentrate is non-fluorinated. Alternatively, the third surfactant may be a fluorinated or perfluorinated amphoteric surfactant, while the first (amphoteric) surfactant of the concentrate is non-fluorinated. The fluorinated surfactant will contain some C-F bonds and may contain only C-F bonds (in which case it is perfluorinated) and may contain some C-H bonds (in which case it is a molecule containing a hydrofluorocarbon).

In addition to the amphoteric surfactants and fluorinated forms of anionic surfactants identified herein, other exemplary fluorosurfactants that can be included in the concentrates or compositions of the present disclosure include Captstone^TMFluorosurfactants and Forafac^TMFluorosurfactants, both from DuPont (Wilmington, DE). Other exemplary fluorosurfactants are those described in U.S. patent publication nos. US 20130112908; US 20120255651; US 20110232924; US 20110091408; US 20100168318 and US patent numbers US 8,287,752; US 8,039,677; any of those disclosed in US 7,977,426 and US 7,989,568.

However, in another embodiment, the third surfactant is not a fluorosurfactant. Fluorine-containing compounds should be used with caution because they may have undesirable biopersistence characteristics and/or they may decompose into hazardous materials. In one embodiment, the concentrates and compositions of the present invention do not comprise any fluorocarbon, while in another embodiment, the concentrates and compositions of the present invention do not comprise any halocarbon.

Preparation

The present disclosure provides material manufacturing fluids, such as metal cutting fluids, in concentrated form as well as in diluted (ready-to-use) form. The concentrated form can be described in terms of the amounts of the various components, where these amounts are relative to the total amount of surfactant present in the concentrate.

For example, the concentrate may contain 1 to 10 parts by weight of the rust inhibitor per part by weight of surfactant (e.g., per 1g, or per 1kg, etc., of surfactant). Thus, if the concentrate contains 10 grams of surfactant, the concentrate may also contain 10 grams to 100 grams of rust inhibitor. Optionally, the concentrate contains at least 1 part by weight, or at least 2 parts by weight, or at least 3 parts by weight, or at least 4 parts by weight, or at least 5 parts by weight of rust inhibitor (relative to 1 part by weight of surfactant) and may contain less than 10 parts by weight, or less than 9 parts by weight, or less than 8 parts by weight, or less than 7 parts by weight, or less than 6 parts by weight, or less than 5 parts by weight of rust inhibitor. In exemplary embodiments, the concentrate contains 1 to 10, or 2 to 8, or 3 to 7, or 4 to 6 parts by weight of a rust inhibitor, such as sodium nitrite, per 1 gram of total surfactant present in the concentrate.

The concentrate may contain 0.1 to 0.5 parts by weight of the thickener per part by weight of the surfactant. Thus, if the concentrate contains 10 grams of surfactant, the concentrate may also contain 1 gram to 5 grams of thickener. Optionally, the concentrate contains at least 0.1 parts by weight, or at least 0.2 parts by weight, or at least 0.3 parts by weight, or at least 0.4 parts by weight thickener (relative to 1 part by weight surfactant) and may contain less than 0.5 parts by weight, or less than 0.4 parts by weight, or less than 0.3 parts by weight thickener. In exemplary embodiments, the concentrate contains 0.1 to 0.5, or 0.2 to 0.4 parts by weight of a thickener, such as hydroxyethyl cellulose, per 1 gram of total surfactant present in the concentrate.

The concentrate may contain 0.05 to 0.25 parts by weight of the inorganic salt per part by weight of the surfactant. Thus, if the concentrate contains 10 grams total surfactant, the concentrate may also contain 0.5 grams to 2.5 grams of inorganic salt. Optionally, the concentrate contains at least 0.05 parts by weight, or at least 0.1 parts by weight, or at least 0.15 parts by weight, or at least 0.2 parts by weight of inorganic salt (relative to 1 part by weight of surfactant present in the concentrate), and may contain less than 0.25 parts by weight, or less than 0.2 parts by weight, or less than 0.15 parts by weight, or less than 0.1 parts by weight of inorganic salt. In exemplary embodiments, the concentrate contains 0.05 to 0.25 parts by weight, or 0.1 to 0.2 parts by weight of an inorganic salt, such as calcium chloride.

The concentrate may contain 0.01 to 0.1 parts by weight of a nonvolatile, water-soluble organic solvent per part by weight of the surfactant. Thus, if the concentrate contains 10 grams of total surfactant, the concentrate may also contain 0.1 grams to 1 gram of organic solvent. Optionally, the concentrate contains at least 0.01 parts by weight, or at least 0.02 parts by weight, or at least 0.03 parts by weight, or at least 0.04 parts by weight, or at least 0.05 parts by weight, or at least 0.06 parts by weight, or at least 0.07 parts by weight of organic solvent (relative to 1 part by weight of surfactant present in the concentrate), and may contain less than 0.1 parts by weight, or less than 0.09 parts by weight, or less than 0.08 parts by weight, or less than 0.07 parts by weight, or less than 0.06 parts by weight, or less than 0.05 parts by weight of organic solvent. In exemplary embodiments, the concentrate contains 0.01 to 0.1, or 0.02 to 0.9, or 0.03 to 0.8 parts by weight of an organic solvent, such as ethylene glycol butyl ether.

The concentrate may contain 0.2 to 1.0 parts by weight of a defoamer per part by weight of surfactant. Thus, if the concentrate contains 10 grams total surfactant, the concentrate may also contain 2 grams to 10 grams of defoamer. Optionally, the concentrate contains at least 0.2 parts by weight, or at least 0.3 parts by weight, or at least 0.4 parts by weight, or at least 0.5 parts by weight of a defoamer (relative to 1 part by weight of surfactant present in the concentrate) and may contain less than 1.0 parts by weight, or less than 0.9 parts by weight, or less than 0.8 parts by weight, or less than 0.7 parts by weight, or less than 0.6 parts by weight of a defoamer. In exemplary embodiments, the concentrate contains 0.2 to 1.0 parts by weight, or 0.3 to 0.8 parts by weight, or 0.4 to 0.6 parts by weight of a defoamer, such as a silicone defoamer.

The concentrate will also have water. The amount of water can vary, but is typically from 5 to 50% by weight of the concentrate. In other words, 100 grams of concentrate will include 5 to 50 grams of water. In optional embodiments, the concentrate is at least 5 wt.%, or at least 10 wt.%, or at least 15 wt.%, or at least 20 wt.%, or at least 25 wt.% water, while in other optional embodiments, the concentrate is less than 50 wt.%, or less than 45 wt.%, or less than 40 wt.%, or less than 35 wt.%, or less than 30 wt.% water.

The present disclosure also provides a concentrate in diluted form ready for use in a material manufacturing process, such as a metal cutting operation. In an optional embodiment, the diluted forms of the concentrates have been sufficiently diluted so that their water content is from 75% to 99%. Diluted forms of the concentrate may be prepared by combining the concentrate with an equal volume of water (1-fold dilution) for dilution, or by 2-fold, or 3-fold, or 4-fold, or 5-fold, or 6-fold, or 7-fold, or 8-fold, or 9-fold, or 10-fold, or 11-fold, or 12-fold, or 13-fold, or 14-fold, or 15-fold, or 16-fold, or 17-fold, or 18-fold, or 19-fold, or 20-fold dilution, and by selecting the ranges provided by any two of these values. For example, a diluted form may be prepared by 5-fold to 15-fold dilution, i.e., adding 5 volumes to 15 volumes of water per volume of concentrate, or adding 5 weights to 15 weights of water per weight of concentrate.

In one embodiment, the present disclosure provides a composition comprising water and solids, the solids comprising at least one surfactant, such as an amphoteric first surfactant, an anionic second surfactant, and a third surfactant selected from an amphoteric surfactant and an anionic surfactant, the third surfactant being different from the first and second surfactants. In an optional embodiment: water comprises 75 wt% to 95 wt% of the composition; for example, water comprises 75 wt% to 80 wt% of the composition, or water comprises 80 wt% to 85 wt% of the composition, or water comprises 85 wt% to 90 wt% of the composition, or water comprises 95 wt% to 95 wt% of the composition. In an optional embodiment: the amphoteric surfactant comprises 10 wt% to 30 wt% of the solids, or 15 wt% to 25 wt% of the solids; for example, the amphoteric surfactant comprises 10 wt% to 15 wt% of the solids, or the amphoteric surfactant comprises 15 wt% to 20 wt% of the solids, or the amphoteric surfactant comprises 20 wt% to 25 wt% of the solids, or the amphoteric surfactant comprises 25 wt% to 30 wt% of the solids. In an optional embodiment, the amphoteric surfactant comprises from 1 wt% to 5 wt% of the composition. In an optional embodiment, the anionic surfactant comprises 45 wt% to 85 wt% of the solids; for example, the anionic surfactant may comprise 45 wt% to 55 wt% of the solids, or the anionic surfactant may comprise 55 wt% to 65 wt% of the solids, or the anionic surfactant may comprise 65 wt% to 75 wt% of the solids, or the anionic surfactant may comprise 75 wt% to 85 wt% of the solids. In an optional embodiment, the anionic surfactant comprises from 5 wt% to 25 wt% of the composition.

In other optional embodiments, the amphoteric surfactant is one or more betaines selected from the group consisting of coco dimethyl sulfopropyl betaine, lauryl betaine, and coco amidopropyl betaine; the anionic surfactant is one or more surfactants selected from the group consisting of: ammonium lauryl sulfosuccinate, sodium lauryl sulfate, sodium laureth sulfate, sodium lauryl ether sulfate, ammonium lauryl ether sulfate, triethanolamine dodecylbenzene sulfonate, sodium lauryl sarcosinate, ammonium lauryl sulfate, sodium oleylsuccinate, sodium lauryl sulfate, sodium decyl sulfate, sodium octyl sulfate, and sodium dodecylbenzene sulfonate; the composition further comprises an inorganic salt, wherein optionally the inorganic salt comprises from 2 wt% to 20 wt% of the solids; the composition further comprises a thickener, wherein optionally the thickener comprises from 0.1 wt% to 5 wt% of the solids.

As previously described, the compositions of the present disclosure comprise both amphoteric surfactants (and optionally amphoteric surfactants) and anionic surfactants (and optionally anionic surfactants). In one aspect, the one or more amphoteric surfactants are present in the composition in an amount by weight approximately equal to the one or more anionic surfactants. In other aspects, and again measured on a weight basis, the amphoteric surfactant comprises less weight of the total weight of the composition than the anionic surfactant, wherein in various embodiments, the amphoteric surfactant comprises from 1% to 50%, alternatively from 5% to 40%, alternatively from 10% to 30%, alternatively from 15% to 25%, of the total weight of the anionic surfactant and the amphoteric surfactant.

When the composition comprises two amphoteric surfactants or two anionic surfactants, the two surfactants need not be present in equal amounts by weight. In various embodiments, the composition comprises first and second anionic surfactants, wherein the first surfactant provides from 1% to 50% of the total weight of the first and second surfactants. In other embodiments, the first surfactant provides 1-40%, alternatively 1% -30%, alternatively 1% -20%, alternatively 1% to 10%, alternatively 1% to 5% of the total weight of the first and second anionic surfactants. Likewise, in various embodiments, the composition comprises first and second amphoteric surfactants, wherein the first amphoteric surfactant provides from 1% to 50% of the total weight of the first and second surfactants, and in other embodiments, the first amphoteric surfactant provides from 1% to 40%, alternatively from 1% to 30%, alternatively from 1% to 20%, alternatively from 1% to 10%, alternatively from 1% to 5%, of the total weight of the first and second amphoteric surfactants.

In one embodiment, a mixture of two amphoteric surfactants is included in a material making fluid (e.g., a metal cutting fluid composition) of the present disclosure. For example, mixtures of any of the previously described amphoteric surfactants may be used. When two amphoteric surfactants are present in the composition, the two surfactants will be present in relative amounts based on the weight of each surfactant in the composition. For example, if the composition comprises equal amounts by weight of two amphoteric surfactants, the two surfactants are present in a 1:1 weight ratio. If the composition comprises twice as much first surfactant as second surfactant, the two surfactants are present in a 1:2 weight ratio. If the second surfactant is present in an allowable weight range relative to the weight of the first surfactant, and the range is "equal to the weight of the first surfactant" to "twice the weight of the first surfactant", the two surfactants are present in a weight ratio of 1 (1-2).

As noted above, in one embodiment, the present disclosure provides for the presence of two amphoteric surfactants in the composition. In various embodiments, the two amphoteric surfactants can be present in any of the following relative amounts: 1: 1; 1 (1-5); 1 (1-10); 1 (1-15); 1, (1-20); 1, (1-25); 1, (1-30); 1, (5-10); 1, (5-15); 1, (5-20); 1, (5-25); 1, (5-30); 1, (10-15); 1, (10-20); 1 (10-25); 1 (10-30); 1, (15-20); 1, (15-25); 1, (15-30); 1 (20-25) and 1 (25-30).

In one embodiment, a mixture of two anionic surfactants is included in a material making fluid (e.g., a metal cutting fluid composition) of the present disclosure. For example, mixtures of any of the previously described anionic surfactants may be used. When two anionic surfactants are present in the composition, the two surfactants will be present in relative amounts based on the weight of each surfactant in the composition. For example, if the composition comprises equal amounts by weight of two anionic surfactants, the two surfactants are present in a 1:1 weight ratio. If the composition comprises twice as much first surfactant as second surfactant, the two surfactants are present in a 1:2 weight ratio. If the second surfactant is present in an allowable weight range relative to the weight of the first surfactant, and the range is "equal to the weight of the first surfactant" to "twice the weight of the first surfactant", the two surfactants are present in a weight ratio of 1 (1-2).

As noted above, in one embodiment, the present disclosure provides for the presence of two anionic surfactants in the composition. In various embodiments, the two anionic surfactants can be present in any of the following relative amounts: 1: 1; 1 (1-5); 1 (1-10); 1 (1-15); 1, (1-20); 1, (1-25); 1, (1-30); 1, (5-10); 1, (5-15); 1, (5-20); 1, (5-25); 1, (5-30); 1, (10-15); 1, (10-20); 1 (10-25); 1 (10-30); 1, (15-20); 1, (15-25); 1, (15-30); 1 (20-25) and 1 (25-30).

In one embodiment, the present disclosure provides a materials making fluid (e.g., a metal cutting fluid concentrate composition) comprising 10 wt% to 25 wt% of a first anionic surfactant, optionally a sulfonate surfactant such as sodium dodecyl benzene sulfonate, optionally 12 wt% to 23 wt% or optionally 15 wt% to 20 wt% of the first anionic surfactant; from 5 wt% to 15 wt% of an amphoteric surfactant, optionally a betaine surfactant such as cocamidopropyl betaine, optionally from 7 wt% to 13 wt% or optionally from 7 wt% to 11 wt% of a betaine surfactant; 1 to 10 wt% of a second anionic surfactant, optionally a sulfate surfactant such as sodium laureth sulfate or sodium lauryl sulfate, optionally 2 to 8 wt% or 3 to 7 wt% of a second anionic surfactant; up to about 5 wt% of an organic solvent, optionally a glycol ether such as ethylene glycol butyl ether, optionally 1 wt% to 4 wt% or 2 wt% to 3 wt% of a glycol ether; 2 to 15 wt% of a thickener such as a cellulosic thickener, for example hydroxyethyl cellulose, optionally 4 to 12 wt% or 6 to 10 wt% of a thickener; up to about 10 wt% calcium chloride, optionally 2 wt% to 7 wt% or 3 wt% to 6 wt% calcium chloride. Optionally, the concentrate may contain a third anionic surfactant, such as sodium octyl sulfate, in an amount up to about 5 wt%. Water will also be present in the concentrate. The total non-water content of the concentrate is about 25 wt% to 75 wt%, or about 30 wt% to 70 wt%, or about 35 wt% to 55 wt%, or about 40 wt% to 50 wt% (in the last case, the water content is 50 wt% to 40 wt%).

In one embodiment, the present disclosure provides a composition comprising a first anionic surfactant at a concentration of 0.1 wt% to 0.3 wt% (i.e., 0.1g to 0.3g of the first anionic surfactant, i.e., 1000ppm to 3000ppm of the first anionic surfactant, in 100g of the composition), a second anionic surfactant different from the first anionic surfactant at a concentration of 0.01 wt% to 0.10 wt% (i.e., 100ppm to 1000ppm of the second anionic surfactant), an amphoteric surfactant at a concentration of 0.05 to 0.15 (i.e., 500ppm to 1500ppm of the amphoteric surfactant), and a rust inhibitor at a concentration of 0.1 wt% to 0.3 wt% (i.e., 1000ppm to 3000ppm of the rust inhibitor). The composition optionally further comprises a thickener in a concentration of 0.05 wt% to 0.15 wt% (500ppm to 1500ppm thickener), and/or an inorganic salt in a concentration of 0.01 wt% to 0.1 wt% (100ppm to 1000ppm inorganic salt), and/or a non-volatile organic solvent in a concentration of 0.01 wt% to 0.1 wt% (100ppm to 1000ppm non-volatile organic solvent), and/or a defoamer in a concentration of 0.05 wt% to 0.2 wt% (i.e., 500ppm to 2000ppm defoamer). In one embodiment, the composition contains each of these components, i.e., each of the first anionic surfactant, the second anionic surfactant, the amphoteric surfactant, the rust inhibitor, the thickener, the inorganic salt, the non-volatile organic solvent, and the defoamer. In one embodiment, the composition contains each of these components, i.e., each of a first anionic surfactant (which is a sulfonate-containing surfactant), a second anionic surfactant (which is a sulfate-containing surfactant), an amphoteric surfactant (which is a betaine-containing surfactant), a rust inhibitor, a thickener (which is a cellulose thickener), an inorganic salt, a non-volatile organic solvent, and an antifoaming agent. In one embodiment, the composition contains each of these components, i.e., each of a first anionic surfactant (which is a sulfonate-containing surfactant), a second anionic surfactant (which is a sulfate-containing surfactant), an amphoteric surfactant (which is a betaine-containing surfactant), a rust inhibitor (which is sodium nitrite), a thickener (which is hydroxyethyl cellulose), an inorganic salt (which is calcium chloride), a non-volatile organic solvent (which is ethylene glycol butyl ether), and a defoamer (which is a silicone defoamer).

In one embodiment, the present disclosure provides a composition comprising a first anionic surfactant at a concentration of about 0.2 wt.% (i.e., about 0.2g of the first anionic surfactant, i.e., about 2000ppm of the first anionic surfactant, in 100g of the composition), a second anionic surfactant different from the first anionic surfactant at a concentration of about 0.05 wt.% (i.e., about 500ppm of the second anionic surfactant), an amphoteric surfactant at a concentration of about 0.09 wt.% (i.e., about 900ppm of the amphoteric surfactant), and a rust inhibitor at a concentration of about 0.2 wt.% (i.e., about 2000ppm of the rust inhibitor). The composition optionally further comprises a thickener in a concentration of 0.05 wt% to 0.15 wt% (500 plus 1500ppm thickener) or about 800ppm thickener, and/or an inorganic salt in a concentration of 0.01 wt% to 0.1 wt% (100ppm to 1000ppm inorganic salt) or about 400ppm inorganic salt, and/or a non-volatile organic solvent in a concentration of 0.01 wt% to 0.1 wt% (100ppm to 1000ppm non-volatile organic solvent) or about 200ppm non-volatile organic solvent, and/or an antifoaming agent in a concentration of 0.05 wt% to 0.2 wt% (i.e., 500ppm to 2000ppm antifoaming agent) or about 1000ppm antifoaming agent. In one embodiment, the composition contains each of these components, i.e., each of the first anionic surfactant, the second anionic surfactant, the amphoteric surfactant, the rust inhibitor, the thickener, the inorganic salt, the non-volatile organic solvent, and the defoamer. In one embodiment, the composition contains each of these components, i.e., each of a first anionic surfactant (which is a sulfonate-containing surfactant), a second anionic surfactant (which is a sulfate-containing surfactant), an amphoteric surfactant (which is a betaine-containing surfactant), a rust inhibitor, a thickener (which is a cellulose thickener), an inorganic salt, a non-volatile organic solvent, and an antifoaming agent. In one embodiment, the composition contains each of these components, i.e., each of a first anionic surfactant (which is a sulfonate-containing surfactant), a second anionic surfactant (which is a sulfate-containing surfactant), an amphoteric surfactant (which is a betaine-containing surfactant), a rust inhibitor (which is sodium nitrite), a thickener (which is hydroxyethyl cellulose), an inorganic salt (which is calcium chloride), a non-volatile organic solvent (which is ethylene glycol butyl ether), and a defoamer (which is a silicone defoamer).

The following are some additional exemplary embodiments of the compositions of the present disclosure, wherein the metal cutting composition and the metal cooling composition are used interchangeably:

1) a metal cutting composition includes water, a first surfactant, a thickener such as a cellulosic thickener, and a rust inhibitor.

2) A metal cutting composition includes water, a first surfactant, an inorganic salt such as calcium chloride, and a rust inhibitor.

3) The metal cooling composition of any one of embodiments 1-2, wherein the first surfactant is an anionic surfactant.

4) The composition of any one of embodiments 1-3, wherein the first surfactant is a sulfonate-containing anionic surfactant.

5) The composition of any of embodiments 1-4, wherein the first surfactant is sodium dodecyl benzene sulfonate.

6) The composition of any of embodiments 1-5, comprising a third surfactant, wherein the second surfactant is an amphoteric surfactant.

7) The composition of any of embodiments 1-6, comprising a second surfactant, wherein the second surfactant is an amphoteric surfactant comprising a betaine group.

8) The composition of any one of embodiments 1 to 7, comprising a second surfactant, wherein the second surfactant is cocamidopropyl betaine.

9) The composition of any one of embodiments 1 to 8, comprising a third surfactant, wherein the third surfactant is an anionic surfactant.

10) The composition of any one of embodiments 1 to 9, comprising a third surfactant, wherein the third surfactant is an anionic surfactant comprising a sulfate.

11) The composition of any of embodiments 1-10, comprising a third surfactant, wherein the third surfactant is sodium laureth sulfate.

12) The composition of any of embodiments 1-11, wherein the rust inhibitor is sodium nitrite.

13) The composition of any one of claims 1 to 12, comprising a thickener that is a cellulosic thickener, wherein the cellulosic thickener is hydroxyethyl cellulose.

14) The composition of any one of embodiments 1 to 13, comprising an antifoaming agent.

15) The composition of any one of embodiments 1 to 14, comprising an antifoaming agent, wherein the antifoaming agent is a silicone polymer.

16) The composition of any of embodiments 1-15, comprising a first surfactant comprising a sulfonate and a second surfactant comprising a sulfate.

As discussed below, the present disclosure also provides a method of machining a metal comprising applying a composition comprising the composition of any one of embodiments 1 to 16 to a sheet of machined metal in an amount and for a time effective to dissipate heat from the machined metal. The machining process can effect cutting of metal and is therefore referred to as a cutting process. The machining process may be any of broaching, tapping, hobbing, cutting, drilling, milling, turning, sawing, honing or grinding, which are examples of machining processes that may be used in the methods of the present disclosure.

The following are some additional exemplary embodiments of the compositions of the present disclosure. The composition includes water, a first surfactant, a thickener, and a rust inhibitor. The first surfactant may be an anionic surfactant, such as a sulfonate or sulfate containing surfactant. Optionally, the first surfactant is sodium dodecylbenzenesulfonate. Optionally, the first surfactant is sodium laureth sulfate. Instead of an anionic surfactant, the first surfactant may be an amphoteric surfactant, for example a betaine-containing surfactant, for example cocamidopropyl betaine. Optionally, the composition may comprise two surfactants, each of which is an anionic surfactant, for example, where the two surfactants are a sulfate-containing surfactant and a sulfonate-containing surfactant, such as sodium laureth sulfate and sodium dodecylbenzenesulfonate. Optionally, the composition may comprise two surfactants, one of which is an anionic surfactant and the other of which is an amphoteric surfactant, such as a sulfate-containing anionic surfactant which may be sodium laureth sulfate and a betaine-containing amphoteric surfactant which may be cocamidopropyl betaine. Optionally, the composition may comprise two surfactants, one of which is an anionic surfactant and the other of which is an amphoteric surfactant, such as a sulfonate-containing anionic surfactant, which may be sodium dodecylbenzene sulfonate, and a betaine-containing amphoteric surfactant, which may be cocamidopropyl betaine. Optionally, the composition may comprise three surfactants, two of the three surfactants being different anionic surfactants, one of the three surfactants being an amphoteric surfactant, wherein the three surfactants may optionally be sulfate-containing surfactants, sulfonate-containing surfactants, and betaine-containing surfactants, such as sodium dodecylbenzene sulfonate, sodium laureth sulfate, and cocamidopropyl betaine. When present, the sulfonate-containing surfactant may be present at a concentration of about 1800ppm, for example, 1000ppm to 3000 ppm. When present, the sulfate-containing surfactant may be present at a concentration of about 500ppm, for example 100ppm to 1000 ppm. When present, the amphoteric surfactant may be present at a concentration of about 900ppm, for example 500ppm to 1500 ppm. The composition will contain an effective amount of a rust inhibitor as described herein, where the rust inhibitor may be, for example, sodium nitrite. The concentration of the rust inhibitor may be about 100ppm to 5000ppm, or about 1000ppm to 3000ppm, or about 2000 ppm. Thickeners are described herein, and may be, for example, a cellulosic thickener, such as hydroxyethyl cellulose. The concentration of the thickener in the composition may be from about 100ppm to 2000ppm, or from about 500ppm to 1500ppm, or about 800 ppm. The composition may optionally, and in one embodiment does, contain an antifoaming agent as described herein. An exemplary anti-foaming agent is a silicone polymer. When present, the defoamer can be present in a concentration of about 100ppm to 5000ppm, or about 500ppm to 2000ppm, or about 1000 ppm.

The following are some additional exemplary embodiments of the compositions of the present disclosure. The composition includes water, a first surfactant, an inorganic salt, and a rust inhibitor. The first surfactant may be an anionic surfactant, such as a sulfonate or sulfate containing surfactant. Optionally, the first surfactant is sodium dodecylbenzenesulfonate. Optionally, the first surfactant is sodium laureth sulfate. Instead of an anionic surfactant, the first surfactant may be an amphoteric surfactant, for example a betaine-containing surfactant, for example cocamidopropyl betaine. Optionally, the composition may comprise two surfactants, each of which is an anionic surfactant, for example, where the two surfactants are a sulfate-containing surfactant and a sulfonate-containing surfactant, such as sodium laureth sulfate and sodium dodecylbenzenesulfonate. Optionally, the composition may comprise two surfactants, one of which is an anionic surfactant and the other of which is an amphoteric surfactant, such as a sulfate-containing anionic surfactant which may be sodium laureth sulfate and a betaine-containing amphoteric surfactant which may be cocamidopropyl betaine. Optionally, the composition may comprise two surfactants, one of which is an anionic surfactant and the other of which is an amphoteric surfactant, such as a sulfonate-containing anionic surfactant, which may be sodium dodecylbenzene sulfonate, and a betaine-containing amphoteric surfactant, which may be cocamidopropyl betaine. Optionally, the composition may comprise three surfactants, two of the three surfactants being different anionic surfactants, one of the three surfactants being an amphoteric surfactant, wherein the three surfactants may optionally be sulfate-containing surfactants, sulfonate-containing surfactants, and betaine-containing surfactants, such as sodium dodecylbenzene sulfonate, sodium laureth sulfate, and cocamidopropyl betaine. When present, the sulfonate-containing surfactant may be present at a concentration of about 1800ppm, for example, 1000ppm to 3000 ppm. When present, the sulfate-containing surfactant may be present at a concentration of about 500ppm, for example 100ppm to 1000 ppm. When present, the amphoteric surfactant may be present at a concentration of about 900ppm, for example 500ppm to 1500 ppm. The composition will contain an effective amount of a rust inhibitor as described herein, where the rust inhibitor may be, for example, sodium nitrite. The concentration of the rust inhibitor may be about 100ppm to 5000ppm, or about 1000ppm to 3000ppm, or about 2000 ppm. Inorganic salts are described herein, and may be, for example, calcium chloride. The concentration of the inorganic salt in the composition may be from about 50ppm to 2000ppm, or from about 100ppm to 1000ppm, or about 400 ppm. The composition may optionally, and in one embodiment does, contain an antifoaming agent as described herein. An exemplary anti-foaming agent is a silicone polymer. When present, the defoamer can be present in a concentration of about 100ppm to 5000ppm, or about 500ppm to 2000ppm, or about 1000 ppm.

Manufacturing method

In one aspect, the present disclosure provides methods of making materials to make fluids, such as metal cutting fluid concentrate compositions and corresponding metal cutting fluid compositions as identified herein. Typically, the concentrate is prepared by combining water with one or more surfactants selected from anionic and amphoteric surfactants, and optional ingredients. The composition is prepared by diluting the concentrate with water or an aqueous solution.

In one embodiment, the concentrate is prepared by combining a first surfactant that is an amphoteric surfactant, a second surfactant that is an anionic surfactant, and a third surfactant selected from the group consisting of amphoteric surfactants and anionic surfactants, wherein the third surfactant is different from the first or second surfactant. The concentrate may optionally include other surfactants, i.e., a fourth, fifth, etc. surfactant. In addition, or alternatively, the concentrate may contain active ingredients, such as inorganic components, organic solvents, and thickeners, in addition to the surfactant. The compositions are water-based, in other words they are aqueous compositions, since the carrier is mainly water. The composition may be prepared by any of the methods described below.

In one embodiment, a container is provided for holding water. This container holds about 5Kg to 20Kg of water. The method may be scaled up or down to provide a desired amount of fluid concentrate. The initial amount of water is about 5-40%, or about 10-30% of the total amount of water in the concentrate. The water may be at ambient temperature or it may be at an elevated temperature. Elevated temperatures below the boiling point of water, i.e., below 100 ℃, or below 90 ℃, or below 80 ℃, or below 70 ℃ may be used. Elevated temperatures above ambient temperature may be used, for example, above 25 ℃, or above 30 ℃, or above 40 ℃, or above 50 ℃, or above 60 ℃, or above 70 ℃.

One or more surfactants are then added to the water. In one embodiment, the amphoteric surfactant is added to water, followed by the sequential addition of the first and second anionic surfactants. In an alternative embodiment, the anionic surfactant is added to the water first, then the amphoteric surfactant is added, followed by the addition of the second anionic surfactant or the second amphoteric surfactant. In another embodiment, the first and second anionic surfactants are added sequentially, followed by the amphoteric surfactant.

After the surfactant is added to the water, the resulting mixture is stirred to provide a homogeneous or near homogeneous state. Stirring can be carried out slowly or vigorously, but in either case, it is preferred not to generate excessive foaming. The foam is typically caused by air being trapped in the mixture, wherein the air tends to be trapped when significant turbulence is created during the mixing process and/or when the stirring device is repeatedly moved in and out of the mixture. Foam retention also tends to be stronger when the viscosity of the mixture is greater. These are preferably avoided to minimize foam generation. To ensure good mixing, a stirring time of about 15-60 minutes may be employed after addition of each surfactant.

Depending on the presence or absence of insulation around the container in which the concentrate is prepared, the temperature of the mixture may drop during the surfactant addition and agitation steps. Alternatively, the temperature of the mixture may be maintained at or near the original temperature of the water by, for example, maintaining a slight heating of the sides and/or bottom of the container holding the concentrate. Alternatively or additionally, heating coils may be placed within the container to add or recover heat from the concentrate as needed.

The viscosity of the mixture will tend to increase as a result of the addition of the surfactant to the water. All other factors being equal, a solution of increased viscosity will tend to trap air more readily than a solution of lower viscosity. To reduce the viscosity of the mixture, additional water may be added to the mixture after the addition of any of the first, second or third surfactants. For example, an amount of water of about 5-40% or about 10-30% of the total amount of water in the concentrate can be added to the mixture after the first addition of surfactant. Additionally or alternatively, an amount of water of about 5-40% or about 10-30% of the total amount of water in the concentrate can be added to the mixture after the second addition of surfactant.

After all additives have been added and mixed completely into the water, optional ingredients may be added to the resulting mixture. For example, an inorganic component such as an inorganic salt may be added to the mixture, and then stirred to completely dissolve the inorganic component. The optional ingredients may be added to the warm or hot mixture or added to the mixture after it has cooled to room temperature. Since concentrates are typically stored and used at room temperature, any optional ingredients that significantly affect the viscosity or flow characteristics of the mixture are typically added to the mixture at room temperature.

The surfactant and optional ingredients may be added to the water in pure form (i.e., not contacted with a solvent) or in diluted form (i.e., contacted with a solvent) to provide a solution, paste, dispersion, or the like of the ingredients. In one embodiment, the surfactants are added to the water in order of their solids content in the water, with the more concentrated ingredients being added first. In other words, if a surfactant is 50% solids and another surfactant is 25% solids, then the 50% solids surfactant is added to the water before the 25% solids surfactant is added to the mixture.

The concentrate can be prepared in a batch, continuous or semi-continuous mode. In batch mode, the ingredients are added sequentially to a container containing water until all the ingredients have been added, in which case a batch of concentrate has been prepared. In continuous mode, water is driven through a tube or other conduit and ingredients are added to the water at different points along the conduit. For example, the conduit may be fitted with a T-valve, wherein the ingredients may be fed into the water or aqueous mixture through the T-valve. The conduit may also contain a mixer (static mixer or in-line mixer) within the conduit to facilitate the creation of a homogeneous mixture after the ingredients are added to the water or aqueous mixture. For example, water and the first surfactant may be fed into a tube and passed through a mixer. Generally, if the surfactant is pre-dissolved in water, a static mixer is sufficient. Otherwise, in-line mixers are generally preferred. Thereafter, a second surfactant is added to the conduit downstream of the mixer, which again undergoes the mixing process. Finally, a third surfactant is added to the aqueous mixture, and then mixed as necessary to provide an aqueous mixture comprising the three surfactants. Thereafter, other optional ingredients may be added to the conduit, for example, through a T-valve, and then appropriately agitated to form the final concentrate.

To facilitate mixing of the different components and to minimize vortex formation and thus foam formation, baffles may be installed in either the batch reactor or the continuous reactor. Suitable mixing equipment (e.g., stirrers, impellers, static mixers, colloid mills, and homogenizers) are prepared and sold, for example, by Chemineer (Dayton, Ohio) and Sulzer (Winterthur, Switzerland).

In an alternative embodiment of the continuous process, three T-valves are located at the beginning of the conduit at a location after water is added to the conduit. The first, second and third surfactants are each delivered into the catheter through one of three T-valves. In this manner, the three surfactants are all combined substantially simultaneously, and the resulting mixture is then passed through an in-line mixer or static mixer within the conduit to provide a homogeneous aqueous mixture. Optional ingredients are then added to the homogeneous aqueous mixture as needed to provide the final concentrate.

In a continuous or batch process, the water and/or aqueous mixture may be heated to a temperature above ambient temperature, for example, a temperature of 50 ℃ to 90 ℃. Heating may be accomplished by conventional methods known in the art. Elevated temperatures may be maintained as needed to promote rapid mixing of the ingredients to form a homogeneous mixture.

Accordingly, in one embodiment, the present disclosure provides a continuous process for preparing a material-making fluid (e.g., a metal cutting fluid concentrate composition). The method comprises the following steps: providing a continuous reactor, injecting water into the continuous reactor, adding to the water in the continuous reactor a desired surfactant or surfactants, such as a) a first anionic surfactant, b) a second amphoteric surfactant, and c) a third surfactant selected from the group consisting of anionic surfactants and cationic surfactants, the third surfactant being different from the first surfactant and the second surfactant; and mixing components a), b) and c) to provide a homogeneous mixture. Optionally, the continuous reactor is maintained at a temperature in excess of 50 ℃. Also optionally present in the continuous reactor is a mixer selected from the group consisting of an in-line mixer and a static mixer.

Application method

The present invention provides manufacturing fluids useful in materials manufacturing (e.g., metal cutting) processes, such as fluids useful in metal cutting. In one embodiment, the fluid concentrate of the present disclosure is diluted with water to provide a composition that can be applied to tools involved in material manufacturing, such as a metal cutting fluid composition applied directly to metal. The concentrate will have a solids level or content measured as the total weight of the non-aqueous components in the concentrate divided by the total weight of the concentrate. When water is combined with the concentrate to form a metal cutting fluid composition, the metal cutting fluid composition will likewise have a solids level or content that will be lower than the solids level or content of the concentrate. In various embodiments, the composition is formed by combining sufficient water with the concentrate to provide a metal cutting fluid composition having the following weight percent solids, based on the total weight of the composition: 0.1%, or 0.5%, or 1%, or 1.5%, or 2%, or 2.5%, or 3%, or 3.5%, or 4%, or 4.5%, or 5%, or 5.5%, or 6, 5%, or 7%, or 7.5%, or 8%, or 8.5%, or 9%, or 9.5%, or 10%, or 10.5%, or 11%, or 11.5%, or 12%, or 12.5%, or 13%, or 13.5%, or 14%, or 14.5%, or 15%, or 15.5%, or 16%, or 16.5%, or 17%, or 17.5%, or 18%, or 18.5%, or 19%, or 20%, or a concentration within the range provided by any two of the aforementioned percentage solids values, e.g., 0.5% to 4%.

In one aspect, a prepared person would provide a metal cutting fluid concentrate in storage, readily available when metal cutting is desired, and a method of combining the concentrate with water to form a metal cutting fluid composition. Optionally, the metal cutting fluid concentrations as disclosed herein may be diluted with water to produce a metal cutting fluid composition.

Cutting fluid maintenance includes checking the concentration of the soluble oil emulsion (using a refractometer), pH (using a pH meter), amount of miscellaneous oil (hydraulic oil leaks into the cutting fluid system), and amount of particulates in the fluid. The actions taken to maintain the fluid include adding supplemental concentrate or water, skimming miscellaneous oils, adding biocides to prevent bacterial growth, and filtering the particles by centrifugation.

The cutting fluid within the coolant system degrades over time due to bacterial growth and is contaminated with miscellaneous oils and fine metal chips from the machining operation. When it becomes uneconomical to keep the fluid through conventional makeup operations, it is discarded. The fluid should be treated prior to flowing into the sewer system to bring the fluid composition to a safe level for disposal.

Some metals are more difficult to process than others. Stainless steel, exotic alloys, and very hard metals require a very high level of performance from the cutting fluid. Other metals (e.g., brass and aluminum) are readily processed with common oils. In the case of tough, low-workability metals, it is advantageous to use highly added cutting oils having excellent Extreme Pressure (EP) and anti-welding capabilities. Most commonly, these oils contain active sulfur and chlorine to protect the tool and ensure a good part finish. In one embodiment, the cutting fluid of the present invention comprises active sulfur and/or chlorine.

For brass, aluminum, many carbon steels and low alloy steels, cutting oils with lubricant additives, friction modifiers and mild EP/weld resistance properties are sufficient. These oils are typically formulated with sulfurized fats (non-reactive) and/or chlorinated paraffins. Reactive cutting oils (containing reactive sulfur) are not used for brass and aluminum because they can color or darken the finished part. Oils formulated for brass and aluminum are commonly referred to as "non-staining" oils. In one embodiment, the cutting fluid of the present invention comprises one or more of a lubricity additive, a friction modifier, a sulfurized fat (non-reactive), and a chlorinated paraffin.

Easy machining operations (turning, forming, drilling, milling, etc.) can be performed at higher speeds and only modest EP capabilities require a high level of cooling. Milder operations can be performed with lower viscosity, slightly added fluids. Difficult machining operations must be run at slower speeds and require a significant amount of protection against welding. Oils designed specifically for the most difficult operations (e.g., wire cutting or broaching) are generally relatively high in viscosity and are loaded with EP additives (e.g., activated sulfur and chlorine).

The type of machine will also determine some cutting oil properties. For example, screw machines experience severe cross-contamination between lubricating and cutting oils. For this reason, these machines often run on dual or three-purpose oil, which can be used for lubrication tanks, hydraulic systems, and cutting oil tanks.

Grinders, gun drills, and deep hole drilling machines require lower viscosity oils for high cooling rates, good chip and chip flushing, transport through the tool, and high pressure applications without foaming. CNC OEMs may impose restrictions on cutting oil due to potential incompatibilities between the cutting fluid and machine components (e.g., seals). Centerless grinders may require tougher fluids than surface grinders.

In general, the compositions of the present disclosure can be applied during the material manufacturing process in a ready-to-use form. As used herein, material fabrication (which may also be referred to as machining) is the process by which a tool is brought into contact with a material by any suitable method and used to change the shape or surface of the material and generate heat at the point of contact between the material and the tool. Examples include cutting into the material with a blade, drilling a hole in the material with a drill, and removing a surface layer of the material with a lathe. Another example of material fabrication is stamping. The composition may be applied to the material being manufactured and/or to a tool in contact with the material being manufactured. Examples of application processes include flooding, spraying, dripping, atomizing, and brushing the composition onto the part being manufactured and/or associated tools that come into contact with the part being manufactured. The material being manufactured may be, for example, metal, stone, or plastic. After application, the composition will maintain the tool/material interface at a relatively cold temperature so that damage, such as warping, is avoided for each material manufactured and the tool being manufactured. The composition may also provide lubricating properties.

For example, when the manufacturing fluid is a metal cutting fluid, the fluid provides coolant and lubricant properties as required by the metal working process (e.g., machining and stamping). Metal cutting generates heat due to friction, which can deform the material. The coolant acts to remove heat from the machine and material so it can speed up the cutting process making the machine more efficient. In addition to cooling, the cutting fluid also assists the cutting process by lubricating the interface between the cutting edge of the tool and the chip. By preventing friction at this interface, some heat generation is prevented. This lubrication also helps to prevent chips that would interfere with subsequent cutting from being welded to the tool. Depending on the workpiece material, most metalworking and machining processes may benefit from the use of cutting fluids.

The compositions of the present disclosure provide one or more of the following benefits in the manufacture of materials: maintaining the workpiece at a stable temperature (which is critical when machining to close tolerances); maximizing the life of the cutting tip by lubricating the machined edges and reducing the top weld; ensuring the safety of the person handling it (toxic, bacterial and fungal) and of the environment after the treatment; and rust prevention of the machine and the tool.

A portion of the manufacturing equipment will be in contact with the workpiece being manufactured. For example, a manufacturing apparatus may have blades that cut material during manufacturing. The blade may be metal, such as stainless steel, or it may be diamond jacketed. Alternatively, the manufacturing equipment may be a turning tool, such as a pin or drill, or a polishing or sanding device.

Accordingly, the present disclosure provides a method of delivering a manufacturing fluid (e.g., a metal cooling composition) as described herein. In one embodiment, the present disclosure provides a method comprising: providing a manufacturing composition of the present disclosure, applying the composition to one or both of a material being manufactured and a tool used to make the material, and manufacturing the material with the tool in the presence of the composition of the present disclosure. The method provides cooling and temperature control at the interface where the tool contacts the build material, and/or lubrication at the interface.

For example, the present disclosure provides a method for manufacturing a solid material (e.g., metal, stone, plastic) comprising providing a composition of the present disclosure, e.g., a composition comprising water, a first surfactant, a thickener, and a rust inhibitor; applying the composition to the material being manufactured, for example by brushing, spraying or pouring the composition onto the material and/or onto a tool in which the manufacturing is taking place, wherein the composition will be transferred to the tool/material interface during the manufacturing process; and manufacturing the material with a tool in the presence of the composition.

As another example, the present disclosure provides a method for manufacturing a solid material (e.g., metal, stone, plastic) comprising providing a composition of the present disclosure, e.g., a composition comprising water, a first surfactant, an inorganic salt, and a rust inhibitor; applying the composition to the material being manufactured, for example by brushing, spraying or pouring the composition onto the material and/or onto a tool in which the manufacturing is taking place, wherein the composition will be transferred to the tool/material interface during the manufacturing process; and manufacturing the material with the tool in the presence of the composition.

The stone material may be, for example, any one of granite, limestone, marble, sandstone, slate, basalt, travertine or quartzite. Other stone materials can also be made using the compositions of the present disclosure.

The plastic may be, for example, a pure polymer (e.g., polypropylene and polyethylene), or a plastic composite (e.g., a composite of a polymer and stone, such as CORIAN^TM). The plastic may be a silicon chip or other silicon product, such as a silicon wafer or other silicon material used in the semiconductor industry.

The compositions and methods of use thereof according to the present disclosure achieve one or both of the following: a) reducing the amount of heat generated on the cutting surface to improve the quality of the product (e.g., less burr, smoother cut, less deformation (in the case of plastic); and b) increasing the lifetime of the manufacturing apparatus. In one embodiment, the compositions of the present disclosure contain little or no oil, and thus their use eliminates the disposal problems of toxic oil-based waste associated with alternative manufacturing fluids.

The following examples are provided to illustrate embodiments of the present disclosure and should not be construed as limiting the embodiments of the present disclosure.

Examples

In the following examples, commercial products as shown may not have the solids content or neutralization as shown as used in the examples. In this case, the commercial product may be diluted with water to the indicated solids content and/or neutralized with an acid or base as needed to provide the indicated neutralized form. The thickener is added to provide a final viscosity that approximates the viscosity of whole milk or orange juice.

Example 1

To about 10kg of hot water (about 75 c) were added sequentially the ingredients which, after addition, were stirred for a period of about 30 minutes in a manner to minimize FOAM formation, a first anionic surfactant solution (about 9kg of branched sodium dodecylbenzene sulfonate (about 60% solids) in water after neutralization with sodium hydroxide, such as SU L fonc 100 from Stepan Company), an amphoteric surfactant solution (about 4.5kg of cocamidopropyl betaine (about 35% solids) in water, such as AMPHOSO L CA from Stepan Company), hot water (about 9kg), a second anionic surfactant solution (about 11kg of sodium lauryl ether sulfate in water (about 3% solids), such as CA L FOAM-703 from piont Chemical co., and an inorganic salt solution (about 2kg of calcium chloride in water (about 30% solids), wherein the calcium chloride in both solid and solution form can be obtained from, for example, oxyton chem, =t &chemical co &) and the final defoamer fluid (about 35 g.5 g.u) was added and the resulting mixture was allowed to further cool the final defoamer, and the defoamer was added to the environment, such as about 35 g.5 g.l.

Example 2

To about 10kg of hot water (about 75 c) are added sequentially the ingredients that are stirred for a period of about 30 minutes after addition in a manner that minimizes foam formation, a first anionic surfactant solution (about 9kg of triethanolamine dodecylbenzene sulfonate (about 53% solids) in water, CA L SOFT T60(Pilot Chemical)), an amphoteric surfactant solution (about 4.5kg of sodium cocoamphoacetate (about 35% solids) in water, AMPHITO L Y-b (kao chemicals)), hot water (about 6.5kg), a second anionic surfactant solution (about 14kg of ammonium lauryl sulfate (about 7% solids) in water), EMA L AD-25r (kao chemicals)), and an inorganic salt solution (about 2kg of calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution form can be obtained from, for example, OxyChem, &ttransform &l &) and the final defoamer mixture is added as a thickening fluid to about 82 g.5 g.r.g.r.2 kg of sodium carbonate and optionally the defoamer is added to the final defoamer mixture and the final defoamer (23 g.g.g.2 g.g.g.r) and the resulting viscosity is then added to the final defoamer, the slurry is added to the slurry.

Example 3

To about 8kg of hot water (about 75 ℃), the following ingredients were added sequentially, each of which was stirred for a period of about 30 minutes after addition in a manner to minimize foam formation, a first anionic surfactant solution (about 8.5kg of sodium lauryl sulfoacetate (about 53% solids) in water, L atono L L a L shake (Stepan Co.), an amphoteric surfactant solution (about 6.3kg of lauryl hydroxysulfobetaine (about 30% solids) in water, AMPHITO L HD, Kao Chemicals), hot water (about 6.5kg), a second anionic surfactant solution (about 14kg of sodium octylphenol ethoxylate sulfate (about 7% solids) in water), POE-3, PO L Y-STEP C-OP3S (ttpanco.) and an inorganic salt solution (about 2kg of calcium chloride (about 30% solids) in water, wherein the aqueous solution and the aqueous solution were either obtained as a single component from a calcium chloride solution, (ttk) and optionally the additional additives were added to the final defoamer solution in a temperature range of about 25 kg, and the defoamer was added to the environment as a defoamer, and the final defoamer was added to the defoamer, the defoamer was added as a final defoamer, and the defoamer was added as a defoamer, the final defoamer was added to the environment.

Example 4

To about 8.5kg hot water (about 75 c) were added sequentially the ingredients, after addition, stirred for a period of about 30 minutes in a manner to minimize foam formation, a first anionic surfactant solution (about 9kg polyoxyethylene (10) nonylphenol phosphate (about 53% solids), fosfofet 9Q/22(Kao Chemicals)), an amphoteric surfactant solution (about 5.3kg disodium cocoamphodipropionate (about 35% solids) in water), CRODATERIC CADP 38(Croda)), hot water (about 6kg), a second anionic surfactant solution (about 14kg dioctyl sodium sulfosuccinate (about 7% solids) in water, steppet DOS-70 (stepman Co.)) and an inorganic salt solution (about 3.3kg calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution form can be obtained from, for example, OxyChem, =t &l & &l) and the final thickening agent is added to about 5 g of a final defoamer mixture of sodium carbonate, optionally the additives are added at a temperature of about 5 g.3 g.l in water, and the final defoamer is then added to a final defoamer mixture of sodium carbonate solution (about 5 g.3 r.3 r.r.r.3 r.3 r.r.r.r.r.s.s.3 r.s.s.s.3 r.s.r.s.s.s.s.r.s.s.s.s.r.s.s..

Example 5

To about 15kg of hot water (about 75 c) were added sequentially the ingredients which, after addition, were stirred for a period of about 30 minutes in a manner to minimize foam formation, a first anionic surfactant solution (about 5kg of polyoxyethylene (8) octyl ether carboxylic acid (about 53% solids) in water, AKYPO L F2(Kao Chemical)), an amphoteric surfactant solution (about 8.3kg of cocamidopropyl amine oxide (about 30% solids) in water, CA L oxamix CPO (Pilot Chemical)), hot water (about 14kg), a second anionic surfactant solution (about 7.5kg of sodium lauroyl sarcosinate (about 20% solids) in water, MAPROSY L-B (Stepan Co 30), and an inorganic salt solution (about 3.3kg of calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution form can be obtained from, for example, oxytton transform &l &) and the final viscosity of a colorant mixture was added to about 5 g.5 g.k.2 and optionally further concentrated in a defoamer, and allowing the resulting mixture to be added to a final viscosity of sodium carbonate solution (environmental defoamer) and a final viscosity of about 5 g.5.

Example 6

To about 14kg of hot water (about 75C) were added sequentially the following ingredients, after addition, stirred for a period of about 30 minutes in a manner to minimize foam formation, a first anionic surfactant solution (about 5.6kg of potassium oleate (about 50% solids) in water, icto L K-50(Kao Chemicals)), an amphoteric surfactant solution (about 8.3kg of cocamidopropyl betaine (about 30% solids) in water, CA L TAINE C-35(Pilot Chemical)), hot water (about 15kg), a second anionic surfactant solution (about 6kg of linear decyl-substituted bissulfonated diphenyl oxide (about 20% solids) in water), DOWFAX C10L, (Dow Chemical)) and an inorganic salt solution (about 3.3kg of calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution form can be obtained from, for example, oxym, &ttransfer & &l &2) in a final mix of sodium carbonate, optionally providing a further thickening fluid (about 36% defoamer) in a final mix of water, and allowing the addition of the one of the defoamer, and the defoamer to be added as a final defoamer mixture, and then the final defoamer (about 36 g.5 kg of the defoamer).

Example 7

To about 15kg of hot water (about 75 ℃), the following ingredients were added sequentially, each followed by stirring for a period of about 30 minutes in a manner to minimize foam formation, a first anionic surfactant solution (about 5kg of isopropylamine dodecylbenzene sulfonate (about 50% solids) in water, NINATE 411(Stepan Co.), an amphoteric surfactant solution (about 10kg of cocamidopropyl hydroxysultaine (about 30% solids) in water, AMPHOSO L CS-50(Stepan)), hot water (about 15kg), a second anionic surfactant solution (about 5kg of sodium dodecylbenzene sulfonate (about 30% solids) in water), ME L IOSO L x (kao chemical)), and an inorganic salt solution (about 3.3kg of calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution form can be obtained from, for example, OxyChem, &transfer = L "&gtton L &l & &l &) solutions, and the resulting mixture of the two optional additives was added to the final defoamer fluid (about 35 kg) and the final defoamer was added to the environment, and the final defoamer was added as a further processed, and the defoamer was added to the next fed into a defoamer.

Example 8

To about 20kg of hot water (about 75C) were added sequentially the ingredients which, after addition, were stirred for a period of about 30 minutes in a manner to minimize foam formation, a first anionic surfactant solution (about 8.4kg of alkyl substituted bis-sulfonated diphenyl oxide (about 50% solids) in water, DOWFAX C10L (Dow Chemical)), an amphoteric surfactant solution (about 6.7kg of laurylamidopropyl betaine (about 30% solids) in water), AMPHITO L ab (Kao chemicals), hot water (about 12kg), a second anionic surfactant solution (about 4kgC14-C16 sodium olefin sulfonate (about 20% solids) in water, a L FANOX 46(Kao Chemical)) and an inorganic salt solution (about 1.7kg of calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution form can be obtained from, for example, oxym, &ttransfer &ll & &l & &.5) in a final mix of two colorants, and the additives, which were added as a further thickening agent, and the final viscosity WAs allowed to be added to the environment as a defoamer (about 25 g.5).

Example 9

To about 10kg of hot water (about 75 ℃), the following ingredients were added sequentially, each followed by stirring for a period of about 30 minutes in a manner to minimize FOAM formation, a first anionic surfactant solution (about 9kg of sodium linear dodecylbenzene sulfonate (about 60% solids) in water, such as CA L SOFT F90(Pilot Chemical)), an amphoteric surfactant solution (about 4.5kg of cocamidopropyl betaine (about 35% solids) in water, such as AMPHOSO L CA from Stepan Company), hot water (about 9kg), a second anionic surfactant solution (about 11kg of sodium lauryl ether sulfate (about 3% solids) in water, such as CA L FOAM ES-703 from pilott Chemical co.), and an inorganic salt solution (about 2kg of calcium chloride (about 30% solids) in water), wherein the calcium chloride in both solid and solution forms are available from, for example, OxyChem, &ttransform =tl &l & &2 &) in a final mix of water, and the two optional additives are added as a thickening fluid, and the defoamer, the final viscosity of the two optional additives, such as about 5kg of sodium carbonate, 5% defoamer, and 5kg of sodium carbonate, and 5% defoamer, and the final viscosity is provided in the environment.

Example 10

To about 10kg of hot water (about 75 c) were added sequentially the ingredients which, after addition, were stirred for a period of about 30 minutes in a manner to minimize FOAM formation, a first anionic surfactant solution (about 9kg of sodium linear dodecyl benzene sulfonate (about 60% solids) in water, such as CA L SOFT F90(Pilot Chemical)), an amphoteric surfactant solution (about 4.5kg of cocamidopropyl betaine (about 35% solids) in water, such as AMPHOSO L CA from Stepan Company), hot water containing dissolved ethylene glycol butyl ether (about 9kg of water and about 1kg of ether), a second anionic surfactant solution (about 11kg of sodium lauryl sulfate in water (about 3% solids), such as CA L FOAM ES-703 from pilott co., and inorganic salt solution (about 2kg of calcium chloride in water (about 30% solids), wherein the calcium chloride in both solid and solution form can be obtained from, for example, oxyton t Chemical co &chemical) and the inorganic salt solution can be added to a final thickening fluid (about 5 g) of sodium carbonate solution, and the optional defoamer, which is added to the environment as a further thickening fluid (about 5% defoamer) and the final viscosity of the defoamer.

Example 11

The present disclosure provides a high solids (also referred to as high solids concentration) cutting fluid, which is referred to as a concentrate (or cutting fluid concentrate), and which may be diluted with water prior to use in a machining or manufacturing operation. Table 1 identifies various machining operations characterized by the metal being machined and the processes applied to the metal. The process is an exemplary process used in metal working, such as broaching, tapping, hobbing, cutting, drilling, milling, turning, sawing, honing, and grinding. Each of these methods benefits from applying a cutting fluid to the metal during a metalworking or machining process, where the desired amount of cutting fluid depends not only on the particular process, but also on the characteristics of the metal undergoing that process. In addition to identifying the various processes, table 1 identifies 8 common metals, namely aluminum (Al) alloys, brass, cast iron (also known as cast iron), bronze, mild steel, stainless steel, alloy steel, and titanium (Ti) alloys. For each process and metal selected, table 1 represents the portion of water that can be added to 1 part of the cutting fluid concentrate of the present disclosure to produce an effective cutting fluid. For example, bronze may be broached using a cutting fluid prepared from 10 parts water and 1 part of the cutting fluid concentrate of the present disclosure. As another example, a cutting fluid turning titanium alloy prepared by combining 5 to 10 parts water per 1 part of the cutting fluid concentrate of the present disclosure may be used.

TABLE 1

Table 1 is based on diluting the concentrate of the present disclosure with water. For example, when the desired operation is broaching with bronze, it is recommended to dilute the concentrate of the present disclosure with 10 parts to 15 parts water.

For example, using a concentrate having 18 wt% sodium dodecylbenzenesulfonate, 9 wt% cocamidopropyl betaine, 8 wt% hydroxyethyl cellulose, 5 wt% sodium laureth sulfate, 4 wt% calcium chloride, 2 wt% ethylene glycol butyl ether, and 54 wt% water, it is diluted 10-fold with water. The rust inhibitor was added at 1.5 times the concentrate/10000 ppm based on a 1:150 ratio mixture. Antifoam was added at 0.15 times concentrate/1000 ppm based on a 1:150 ratio mixture. The colorant was added at a ratio of 1:150 of 0.0000095 times concentrate (liters) per 10ppm in the mixture. The rust inhibitor was based on 1% of the fully diluted concentrate (1:150 ratio mixture). Antifoam was 0.01% based on the fully diluted concentrate (1:150 ratio mixture). An antimicrobial agent may optionally be added.

The metal cutting fluid concentration and efficacy of the compositions of the present disclosure may be evaluated by one or more test methods that indicate the effectiveness of the composition during a metal cutting operation.

For example, a vibration test was conducted to compare the cutting fluid composition described in example 11 with a commercially available emulsified oil. The cutting was performed with an insert movement of 3,000 revolutions per minute and 250mm/min during the milling operation. Along the x-axis, the vibration was measured to be 0.08179268 for the commercially available emulsified oil, and 0.056828924 for the metal cutting fluid of example 11, which was a 30.5% reduction in vibration amplitude. Along the y-axis, the vibration was measured to be 0.07328386 for the same commercial emulsified oil, whereas 0.044023185 for the metal cutting fluid of example 11 was measured, which was a 39.9% reduction in vibration amplitude. Along the z-axis, the vibration was measured to be 0.077851914 for the same commercial emulsified oil, and 0.059323387 for the metal cutting fluid of example 11, with a 23.8% reduction in vibration amplitude.

When tested for roughness using a milling operation on medium carbon steel, the commercial cream provided a roughness of 4.972 as the average R_max(. mu.m), whereas the metal cutting fluid of example 11 provided 3.913R_maxRoughness (μm). Thus, the metal cutting fluids of the present disclosure provide a 21.3% reduction in roughness of the cut portion compared to commercial emulsified oil based.

Example 12

As shown in table 1, the materials of the present disclosure make 5-fold to 15-fold dilutions of concentrates suitable for use in a variety of metal and other machining operations. In one embodiment, the present disclosure provides compositions resulting from 5-fold to 15-fold dilutions of the concentrates of the present disclosure. In one embodiment, the present disclosure provides compositions resulting from a 5-fold dilution of the concentrate of the present disclosure. In another embodiment, the present disclosure provides compositions derived from 15-fold dilutions of the concentrates of the present disclosure.

In one embodiment, the present disclosure provides a composition resulting from a 10-fold dilution of the concentrate of the present disclosure. This composition had 0.2 wt% sodium dodecylbenzene sulfonate, 0.05 wt% sodium lauryl ether sulfate, 0.09 wt% cocamidopropyl betaine, 0.08 wt% hydroxyethyl cellulose, 0.04 wt% calcium chloride, 0.02 wt% ethylene glycol butyl ether. To this diluted solution, a rust inhibitor was added in an amount of 0.2 wt% and a defoaming agent was added in an amount of 0.1 wt%.

Such a composition may be used in each of the mechanical operations shown in table 1, namely broaching, tapping, hobbing, cutting, drilling, milling, turning, sawing, honing or grinding of any of aluminum (Al) alloys, brass, cast iron (also known as pig iron), bronze, mild steel, stainless steel, alloy steel and titanium (Ti) alloys.

Any of the various embodiments described above can be combined to provide further embodiments. All U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the application data sheet, are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary, to employ concepts of the various patents, applications and publications to provide yet further embodiments. These and other changes can be made to the embodiments in light of the above detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

1. A fluid composition is made comprising water, a first surfactant, a thickener, and a rust inhibitor.

2. A fluid composition is made comprising water, a first surfactant, an inorganic salt, and a rust inhibitor.

3. The composition of claim 1 or 2, wherein the first surfactant is an anionic surfactant.

4. The composition of claim 3, wherein the first surfactant is a sulfonate-containing or sulfate-containing anionic surfactant.

5. The composition of claim 3, wherein the first surfactant is sodium dodecylbenzenesulfonate.

6. The composition of claim 3, wherein the first surfactant is sodium laureth sulfate.

7. The composition of claim 1 or 2, wherein the first surfactant is an amphoteric surfactant.

8. The composition of claim 7, wherein the amphoteric surfactant comprises a betaine group.

9. The composition of claim 7, wherein the first surfactant is cocamidopropyl betaine.

10. A composition according to claim 1 or 2, comprising two surfactants, each of which is an anionic surfactant.

11. The composition of claim 10, wherein the two surfactants are a sulfate-containing surfactant and a sulfonate-containing surfactant.

12. The composition of claim 10, wherein the two surfactants are sodium laureth sulfate and sodium dodecylbenzenesulfonate.

13. A composition as claimed in claim 1 or 2 comprising two surfactants, one being an anionic surfactant and the other being an amphoteric surfactant.

14. The composition of claim 13, wherein the two surfactants are a sulfate-containing anionic surfactant and a betaine-containing amphoteric surfactant.

15. The composition of claim 14, wherein the sulfate-containing anionic surfactant is sodium laureth sulfate and the betaine-containing amphoteric surfactant is cocamidopropyl betaine.

16. The composition of claim 13, wherein the two surfactants are a sulfonate-containing anionic surfactant and a betaine-containing amphoteric surfactant.

17. A composition according to claim 16, wherein the sulfonate-containing anionic surfactant is sodium dodecylbenzene sulfonate and the betaine-containing amphoteric surfactant is cocamidopropyl betaine.

18. A composition according to claim 1 or 2 comprising three surfactants, two of the three surfactants being different anionic surfactants and one of the three surfactants being an amphoteric surfactant.

19. The composition of claim 18, wherein the three surfactants are a sulfate-containing surfactant, a sulfonate-containing surfactant, and a betaine-containing surfactant.

20. The composition of claim 19, wherein the three surfactants are sodium dodecyl benzene sulfonate, sodium lauryl ether sulfate, and cocamidopropyl betaine.

21. The composition of claim 1 or 2, wherein the rust inhibitor is sodium nitrite.

22. The composition of claim 20 wherein the rust inhibitor is sodium nitrite.

23. A composition according to claim 1 or 2, comprising a thickener which is a cellulosic thickener.

24. The composition of claim 23 wherein the cellulosic thickener is hydroxyethyl cellulose.

25. The composition of claim 20 comprising a thickener which is a cellulosic thickener.

26. The composition of claim 25 wherein the cellulosic thickener is hydroxyethyl cellulose.

27. The composition of claim 1 or 2, comprising an inorganic salt, which is calcium chloride.

28. The composition of claim 20, comprising an inorganic salt.

29. The composition of claim 28, wherein the inorganic salt is calcium chloride.

30. A composition as claimed in claim 1 or 2, comprising an anti-foaming agent.

31. The composition of claim 30, wherein the anti-foaming agent is a silicone polymer.

32. The composition of claim 20, comprising an anti-foaming agent.

33. The composition of claim 32, wherein the anti-foaming agent is a silicone polymer.

34. The composition of claim 20, comprising one or more of a cellulosic thickener, an inorganic salt, and a defoamer.

35. The composition of claim 20 comprising a cellulosic thickener, an inorganic salt, and an antifoaming agent.

36. The composition of claim 1, comprising water, sodium dodecylbenzene sulfonate, sodium laureth sulfate, cocamidopropyl betaine, a thickener such as a cellulosic thickener, and a rust inhibitor.

37. The composition of claim 2, comprising water, sodium dodecylbenzene sulfonate, sodium laureth sulfate, cocamidopropyl betaine, an inorganic salt such as calcium chloride, and a rust inhibitor.

38. A method of machining a material selected from the group consisting of metal, stone, glass and plastic, comprising applying a composition comprising the composition of any one of claims 1 to 37 to a sheet of machined material in an amount and for a time effective to dissipate heat from the machined material.

39. The method of claim 38, wherein the machined material is a metal selected from the group consisting of aluminum alloys, brass, cast iron, bronze, low carbon steel, stainless steel, alloy steels, and titanium alloys.

40. The method of claim 38, wherein the machined material is stone.

41. The material of claim 38, wherein the machined material is plastic.

42. The material of claim 38, wherein the material is glass.

43. The method of claim 38, wherein the piece of machined material is subjected to a process selected from the group consisting of broaching, tapping, hobbing, cutting, drilling, milling, turning, sawing, honing, and grinding.