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  • C10L1/00—Liquid carbonaceous fuels
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  • C10L1/1625—Hydrocarbons macromolecular compounds
  • C10L1/1633—Hydrocarbons macromolecular compounds homo- or copolymers obtained by reactions only involving carbon-to carbon unsaturated bonds
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  • C07C2/02—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons
  • C07C2/04—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons by oligomerisation of well-defined unsaturated hydrocarbons without ring formation
  • C07C2/06—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons by oligomerisation of well-defined unsaturated hydrocarbons without ring formation of alkenes, i.e. acyclic hydrocarbons having only one carbon-to-carbon double bond
  • C07C2/08—Catalytic processes
  • C07C2/26—Catalytic processes with hydrides or organic compounds
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  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
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  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
  • C10M107/02—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation
  • C10M107/10—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation containing aliphatic monomer having more than 4 carbon atoms
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  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M143/00—Lubricating compositions characterised by the additive being a macromolecular hydrocarbon or such hydrocarbon modified by oxidation
  • C10M143/08—Lubricating compositions characterised by the additive being a macromolecular hydrocarbon or such hydrocarbon modified by oxidation containing aliphatic monomer having more than 4 carbon atoms
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  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2531/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • C07C2531/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
  • C07C2531/12—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides
  • C07C2531/14—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides of aluminium or boron
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  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2531/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • C07C2531/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
  • C07C2531/22—Organic complexes
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound
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  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
  • C10M2205/02—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers
  • C10M2205/028—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers containing aliphatic monomers having more than four carbon atoms
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
  • C10M2205/02—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers
  • C10M2205/028—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers containing aliphatic monomers having more than four carbon atoms
  • C10M2205/0285—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers containing aliphatic monomers having more than four carbon atoms used as base material
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
  • C10N2020/01—Physico-chemical properties
  • C10N2020/02—Viscosity; Viscosity index
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
  • C10N2020/01—Physico-chemical properties
  • C10N2020/04—Molecular weight; Molecular weight distribution
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
  • C10N2020/01—Physico-chemical properties
  • C10N2020/081—Biodegradable compounds
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
  • C10N2030/02—Pour-point; Viscosity index
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
  • C10N2030/10—Inhibition of oxidation, e.g. anti-oxidants
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/04—Oil-bath; Gear-boxes; Automatic transmissions; Traction drives
  • C10N2040/042—Oil-bath; Gear-boxes; Automatic transmissions; Traction drives for automatic transmissions
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/04—Oil-bath; Gear-boxes; Automatic transmissions; Traction drives
  • C10N2040/044—Oil-bath; Gear-boxes; Automatic transmissions; Traction drives for manual transmissions
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/08—Hydraulic fluids, e.g. brake-fluids
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/25—Internal-combustion engines
  • C10N2040/255—Gasoline engines
  • C10N2040/26—Two-strokes or two-cycle engines
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
  • Y10S526/943—Polymerization with metallocene catalysts

Definitions

• This invention relates to poly-alpha olefin oligomers and methods of making such oligomers. More particularly, the invention relates to a composition for a lubricant and methods of making the composition.
• Synthetic hydrocarbons have been used as lubricant components for automotive, aviation, and industrial applications.
• lubricant oils include engine oils, brake fluids, and lubricating greases.
• Engine oils for an automobile include 2-stroke oils, 4-stroke oils, and gear oils.
• lubricant oils include turbine oils, piston engine oils, hydraulic fluids, and lubricating greases.
• lubricant oils are used as gas-turbine oils, gear oils, bearing and circulation oils, compressor oils, hydraulic oils, metal-working fluids, heat-transfer and insulation oils, and lubricating greases.
• Poly- ⁇ -olefins PAOs; polyalphaolefms
• PAOs polyalphaolefms
• PAOs have good flow properties at low temperatures, relatively high thermal and oxidative stability, low evaporation losses at high temperatures, higher viscosity index, good friction behavior, good hydrolytical stability, and good erosion resistance. PAOs are not toxic and are miscible with mineral oils and esters. Consequently, PAOs are suited for use in engine oils, compressor oils, hydraulic oils, gear oils, and greases. However, PAOs that have been characterized to date, have limited oxidative stability, limited biodegradability and limited additive miscibility.
• PAOs often include tertiary hydrogen which is prone to oxidation. Therefore, it would be desirable to minimize the presence of tertiary hydrogen so as to improve oxidation resistance of synthetic hydrocarbons.
• PAOs are synthesized by a two-step reaction sequence from linear - olefins, which are derived from ethylene.
• the first step is the synthesis of a mixture of oligomers, which are polymers of relatively low molecular weight.
• This first step is catalyzed using a boron trifluoride catalyst in conjunction with a protic catalyst such as water, alcohol, or a weak carboxylic acid.
• boron trifluoride catalysis causes excess skeletal branching during the oligomerization process.
• the second step in the manufacturing process entails hydrogenation of the unsaturated oligomer.
• PAO made in a process in which no substantially additional tertiary hydrogens are introduced during oligomerization, would be less prone to oxidation, and would possess greater stability than the branched PAOs currently known in the art.
• This type of PAO is hereafter referred to as a non-isomerized oligomer.
• non-isomerized oligomers which comprise repeating units of olefin monomers organized in a substantially head to tail molecular structure, wherein the oligomer has a molecular weight of about 10,000 or less, and is prepared in the presence of a single site catalyst.
• the olefin monomer is selected from a group consisting of aliphatic olefins, aromatic olefins, and cyclic olefins.
• the aliphatic olefin of the present invention may be an ⁇ -olefin.
• the oligomer is substantially free of tertiary hydrogen formed due to isomerization, i.e., a hydrogen which is attached to a carbon that is directly attached to three carbons.
• the oligomer displays improved oxidative stability and biodegradibility.
• the oligomer is hydrogenated by reaction with hydrogen gas in the presence of a catalytic amount (0.1 to 5 wt. %) of a hydrogenation catalyst.
• the oligomer may be a dimer, a trimer, a tetramer, a pentamer, a higher oligomer, or a mixture thereof.
• the unsaturation, such as the double bonds of the oligomer may be f ⁇ inctionalized by the addition of a moiety containing polar groups, ester groups, polyether groups, detergents, and the like.
• polyalphaolefins obtained in accordance with embodiments of the invention may be hydrogenated to formulate lubricant oils in amounts from about 0.1 wt% to about
• the lubricant oils may also contain a number of conventional additives in amounts required to provide various functions.
• Figure 1 shows a high temperature simulated distillation chromatogram for the reaction product described in Example 8.
• Figure 2 shows a high temperature simulated distillation chromatogram for fraction E8-1 described in Example 8 containing 89% dimer, 7% trimer, and 4% higher oligomers.
• Figure 3 shows a high temperature simulated distillation chromatogram for a commercial polyalphaolefin (Durasyn 162).
• R L R L +k*(R u -R L ), wherein k is a variable ranging from 1% to 100% with a 1% increment, i.e., k is 1%, 2%, 3%, 4%, 5%, ....,50%,
• Embodiments of the invention provide non-isomerized oligomers comprising repeating units of olefin monomers organized in a substantially head to tail molecular structure, wherein the oligomer has a molecular weight of about 10,000 or less, and is prepared in the presence of a single site catalyst.
• the molecular weight of the oligomer may range from a molecular weight of about 3,000 or less to about 10,000 or less.
• the molecular weight of the oligomer may preferably be about 9,000 or less, about 7,000 or less, or about 5,000 or less.
• regio-regular refers to an oligomer comprising repeating units of olefin monomers organized in a head to tail molecular structure.
• the oligomers described herein are substantially regio-regular, i.e., substantially free of head- to-head and tail-to-tail configurations.
• the oligomers display > 60% regio-regularity.
• the oligomers display > 70% regio-regularity.
• Certain embodiments of the invention display > 80% regio-regularity.
• Preferred embodiments of the invention display > 90% regio- regularity.
• the oligomers are characterized by a regio-regularity of about 95-100%.
• the regio-regularity of the oligomers can be measured by nuclear magnetic resonance spectroscopy.
• the term "poly- ⁇ -olefin" used herein refers to hydrocarbons manufactured by the oligomerization of ⁇ -olefins. Generally, suitable ⁇ -olefins are represented by the following formula:
• R can be any hydrocarbyl group, such as alkyl, aryl, or aralkyl.
• R can be any hydrocarbyl group, such as alkyl, aryl, or aralkyl.
• preferred ⁇ -olefins include, but are not limited to, 1-propene (propylene), 1- butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1- dodecene, 1-tridecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 4-methyl- 1-pentene, 5-methyl- 1-nonene, 3-methyl- 1-pentene, 3, 5, 5-trimethyl- 1-hexene and vinylcyclohexene.
• Styrene and p-methylstyrene are preferred styrenic olefins.
• Another preferred class of ⁇ -olefins is linear ⁇ -olefins.
• monomers of the same type are used in oligomerization reactions, although a mixture of two or more kinds of monomers may also be used, if desired.
• single site catalyst used herein refers to those catalysts which have only one catalytic site for each catalyst molecule. This is in contrast to the traditional Ziegler-Natta catalyst which has multiple catalytic sites per catalyst molecule for olefin polymerization.
• One class of single site catalysts is metallocene catalysts.
• Another class of single site catalysts is constrained geometry catalysts. Constrained geometry catalysts are disclosed in U.S. Patents No. 5,064,802, No. 5,132,380, No. 5,703,187, No.
• constrained geometry catalysts may be considered as metallocene catalysts, and both are sometimes referred to in the art as single-site catalysts.
• Such catalyst systems comprise preferably the combination of (a) metallocene compounds which are compounds of a transition metal of Group IVb of the Periodic Table and (b) an aluminoxane.
• Other single site catalysts are disclosed, for example, in U.S. Patents No. 5, 866,663; 5,880,241; 5,886,224; 5,891,963; 5,892,101; 6,034,259; 6,140,439; and 6,015,767. The disclosures of all of the preceding patents are incorporated by reference herein in their entirety.
• the olefin monomer may be selected from aliphatic olefins, aromatic olefins, or cyclic olefins.
• the aliphatic olefin may be an ⁇ - olefin.
• Suitable ⁇ -olefins may include, but are not limited to, propylene, 1-butene, 1- pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1- tridecene, 1-tetradecene, 1-hexadecene, 1-octadecene or 1-eicosene.
• the oligomer is synthesized using a single species of olefin monomer.
• the oligomer is synthesized using one or more different species of olefin monomer.
• the oligomer is substantially free of tertiary hydrogen formed due to isomerization, i.e., a hydrogen which is attached to a carbon that is directly attached to three carbons.
• An oligomer substantially free of tertiary hydrogens added as a result of the oligomerization process is referred to as a non-isomerized oligomer herein.
• the oligomer is completely free of tertiary hydrogen resulting from isomerization.
• non-isomerized oligomer does not preclude oligomers made in a process in which isomerization occurs to some limited extent. Preferably, no isomerization occurs during oligomerization. As such, the
• PAO preferably is characterized by a uniform, head-to-tail structure, improved biodegradability, higher viscosity index and/or better oxidative stability.
• the number of tertiary hydrogens not including those due to isomerization is calculated using the following formulae. Isomerization during the oligomerization reaction would render the number of the total tertiary hydrogen higher than that calculated by the formulae. Therefore, the term "substantially free of tertiary hydrogen due to isomerization" means that the number of tertiary hydrogen is equal to or substantially equal to that calculated by the following formulae.
• the monomer is decene (C ⁇ o ⁇ 0 )
• A 0; TH in a dimer is 1; in a trimer is 2; in a tetramer is 3, and so on.
• Cp ZrCl 2 /MAO Bis(cyclopentadienyl)zirconium dichloride/methylaluminoxane
• MAO reacts with Cp 2 ZrCl 2 to form the Cp 2 Zr + CH 3 active species.
• Cp 2 Zr + CH 3 initiates insertion of decene monomer in between Zr + and CH leading to the formation of the following species:
• the CH 3 stays at the end of the chain regardless of the insertions of more monomers. After a second insertion of decene monomer, it becomes
• decene dimer will have the following structure (before hydrogenation):
• the dimer has one t-H.
• a decene trimer has a structure like:
• the trimer has two t-H's.
• TH should be the sum of A*N (contribution of t-H's in the side chain of the oligomer) and N-1.
• a dimer formed under this condition has the following structure:
• the dimer has two t-H's.
• the trimer has a structure like:
• the trimer has three t-H's.
• the oligomer displays improved oxidative stability and biodegradibility.
• the oligomer is hydrogenated by reaction with hydrogen gas in the presence of a catalytic amount (0.1 to 5 wt. %) of a hydrogenation catalyst.
• a catalytic amount 0.1 to 5 wt. %
• suitable hydrogenation catalysts are metals of Group VIII of the Periodic Table such as iron, cobalt, nickel, rhodium, palladium and platinum. These catalysts may be deposited on alumina, on silica gel, or on activated carbon in preferred embodiments.
• the synthesized oligomer has some unsaturation. The unsaturation is primarily in the form of vinylidene groups. In another embodiment of the invention the synthesized oligomer is saturated. In an aspect of the invention, the oligomer is synthesized as an unsaturated oligomer, and it is subsequently hydrogenated to produce a saturated oligomer.
• the oligomer may be a dimer, a trimer, a tetramer, a pentamer, a higher oligomer, or a mixture thereof.
• the unsaturation such as the double bonds of the oligomer
• the unsaturation may be functionalized by the addition of a moiety containing polar groups, ester groups, polyether groups, detergents, and the like.
• preferred functional compounds include vinyl fluoride, vinyl chloride, vinyl bromide, vinyl iodide, vinyl acetate, acrylate esters of C ⁇ -C 20 alcohols, vinyl ketones, vinyl amines, vinyl amides, acrylonitrile, acrylamide, vinyl oxazoles, vinyl thiazoles, and vinyl ethers.
• More preferred monomers include vinyl chloride, vinylidene chloride, vinyl bromide, vinyl iodide, vinyl acetate, methyl acrylate methyl vinyl ether and isobutyl vinyl ether.
• compounds containing one or more functional groups such as hydroxy, carboxylic acid, amine, carboxylic ester, phenolic ester, carboxylic amide, phosphate, sulfonamide, and thiophosphate may also be used. Any known or unknown chemistry capable of functionalizing an unsaturated moiety may be employed to functionalize an unsaturated oligomer.
• Embodiments of the invention also provide a poly-alpha-olefin composition
• a poly-alpha-olefin composition comprising one or more oligomers of an alpha-olefin, the .oligomers having a molecular weight of about 10,000 or less and characterized by being substantially free of tertiary hydrogen resulting from isomerization.
• the PAOs obtained in accordance with embodiments of the invention may be hydrogenated to formulate lubricant oils in amounts from about 0.1 wt% to about 99 wt%.
• the lubricant oils may also contain a number of conventional additives in amounts required to provide various functions.
• additives include, but are not limited to, ashless dispersants, metal or overbased metal detergent additives, anti-wear additives, viscosity index improvers, antioxidants, rust inhibitors, pour point depressants, friction reducing additives, and the like.
• Suitable ashless dispersants may include, but are not limited to, polyalkenyl or borated polyalkenyl succinimide where the alkenyl group is derived from a C -C 4 olefin, especially polyisobutenyl having a number average molecular weight of about 5,000 to 7,090.
• Other well known dispersants include the oil soluble polyol esters of hydrocarbon substituted succinic anhydride, e.g. polyisobutenyl succinic anhydride, and the oil soluble oxazoline and lactone oxazoline dispersants derived from hydrocarbon substituted succinic anhydride and di-substituted amino alcohols.
• Lubricating oils typically contain about 0.5 to about 5 wt% of ashless dispersant.
• Suitable metal detergent additives are known in the art and may include one or more of overbased oil-soluble calcium, magnesium and barium phenates, sulfiirized phenates, and sulfonates (especially the sulfonates of C ⁇ 6 -C 50 alkyl substituted benzene or toluene sulfonic acids which have a total base number of about 80 to 300). These overbased materials may be used as the sole metal detergent additive or in combination with the same additives in the neutral form; but the overall metal detergent additive should have a basicity as represented by the foregoing total base number.
• Suitable anti-wear additives include, but are not limited to, oil-soluble zinc dihydrocarbyldithiophosphates with a total of at least 5 carbon atoms and are typically used in amounts of about 1-6% by weight.
• Suitable viscosity index improvers, or viscosity modifiers include, but are not limited to olefin polymers, such as polybutene, hydrogenated polymers and copolymers and terpolymers of styrene with isoprene and/or butadiene, polymers of alkyl acrylates or alkyl methacrylates, copolymers of alkyl methacrylates with N-vinyl pyrrolidone or dimethylaminoalkyl methacrylate, post-grafted polymers of ethylene and propylene with an active monomer such as maleic anhydride which may be further reacted with alcohol or an alkylene polyamine, styrene-maleic anhydride polymers post-reacted with alcohols and amines and the like. These are used as required to provide the viscosity range desired in the finished oil in accordance with known formulating techniques.
• olefin polymers such as polybutene, hydrogenated polymers and copoly
• Suitable oxidation inhibitors include, but are not limited to hindered phenols, such as 2,6-di-tertiary-butyl-paracresol, amines sulfiirized phenols and alkyl phenothiazones.
• a lubricating oil may contain about 0.01 to 3 wt% of oxidation inhibitor, depending on its effectiveness. For improved oxidation resistance and odor control, it has been observed that up to about 5 wt. % of an antioxidant should be included in the aforementioned formula.
• BHT butylated hydroxytoluene
• di-t-butyl-p-cresol is sold by many suppliers including Rhein Chemie and PMC Specialties.
• Another suitable example is Irganox L-64 from Ciba Gigy Corp.
• Rust inhibitors may be employed in very small proportions such as about 0.1 to 1 weight percent with suitable rust inhibitors being exemplified by Co. -C 30 aliphatic succinic acids or anhydrides such as dodecenyl succinic anhydride.
• Antifoam agents are typically include, but are not limited to polysiloxane silicone polymers present in amounts of about 0.01 to 1 wt%.
• pour point depressants are used generally in amounts of from about 0.01 to about 10.0 wt%, more typically from about 0.1 to about 1 wt%, for most mineral oil basestocks of lubricating viscosity.
• Illustrative of pour point depressants which are normally used in lubricating oil compositions include, but are not limited to, polymers and copolymers of n-alkyl methacrylate and n-alkyl acrylates, copolymers of di-n-alkyl fumarate and vinyl acetate, alpha-olefin copolymers, alkylated naphthalenes, copolymers or terpolymers of alpha-olefins and styrene and/or alkyl styrene, styrene dialkyl maleic copolymers and the like.
• additives may be used to improve oxidation stability and serviceability of lubricants used in automotive, aviation, and industrial applications.
• additives include calcium phenate, magnesium sulfonate and alkenyl succinimide to agglomerate solid impurities, a combination of an ashless dispersant, metallic detergent and the like, an oxidation inhibitor of sulfur-containing phenol derivative or the like, an oxidation inhibitor or the like, or mixtures thereof.
• another embodiment of the invention provides a method of making a non-isomerized oligomer which comprises: contacting repeating units of an olefin monomer in the presence of a single site catalyst; and effecting oligomerization of the olefin monomer to produce a non-isomerized oligomer organized in a substantially head to tail molecular structure, with a molecular weight of about 10,000 or less.
• the molecular weight of the oligomer may range from a molecular weight of about 3,000 or less to about 10,000 or less.
• the molecular weight of the oligomer may preferably be about 9,000 or less, about 7,000 or less, or about 5,000 or less.
• the method involves the oligomerization of olefin monomers which involves relatively low to no isomerization, thereby resulting in relatively fewer branches (i.e. tertiary hydrogens) in the product molecule.
• the molecular weight of the oligomer may be controlled by modulating the temperature of the synthesis, the concentration of the catalyst, or through the use of hydrogen in the synthesis.
• Any catalyst which is capable of effecting oligomerization of the olefin monomer may be used in embodiments of the invention.
• a selected catalyst is capable of minimizing the occurrence of isomerization of an olefin monomer (e.g. an ⁇ -olefin) during the reaction.
• Suitable catalysts include, but are not limited to, single-site catalysts (both metallocene catalysts and constrained geometry catalysts), and variations therefrom. They include any known and presently unknown catalysts for olefin polymerization. It should be understood that the term "catalyst” as used herein refers to a metal-containing compound which is used, along with an activating cocatalyst, to form a catalyst system.
• the catalyst, as used herein is usually catalytically inactive in the absence of a cocatalyst or other activating technique. However, not all suitable catalyst are catalytically inactive without a cocatalyst and thus requires activation.
• suitable catalyst systems may comprise preferably the combination of (a) metallocene compounds which are compounds of a transition metal of Group IVb of the Periodic Table and (b) an aluminoxane.
• metallocene compounds are preferably tri- and tetravalent metals having one or two hapto ⁇ 5 -ligands selected from the group comprising cyclopentadienyl, indenyl, fluorenyl with the maximum number of hydrogen substituted with alkyl, alkenyl, aryl, allylaryl, arylalkyl or benzo radicals to none.
• ⁇ 5 -ligands When there are two ⁇ 5 -ligands, they may be the same or different which are either connected by bridging groups, selected from the group comprising, C ⁇ -C alkylene, R 2 Si, R 4 Si 2 , R 2 Si-O-Si-R 2 , R 2 Ge, R 2 P, R 2 N with R being hydrogen, alkyl or aryl radicals, or the two ⁇ 5 -ligands are not connected.
• the non-hapto ligands are either halogen or R, there are two or one such ligands for the tetravalency or trivalency transition metal, respectively.
• hapto ⁇ igands it can be selected from the group comprising cyclopentadienyl, indenyl, fluorenyl with from the maximum number of hydrogen substituted with R or benzo radicals or to none.
• the transition metal will have three or two non-hapto ligands in the +4 and +3 oxidation state, respectively.
• One hydrogen of the hapto ligand may be substituted with a heteratom moiety selected from the group NR, NR 2 , PR, PR 2 which are connected by C ⁇ -C alklene, R 2 Si, R Si 2 to the raring.
• the appropriate number of non-hapto ligands is three for tetravalent metal in the case of coordinate bonding NR 2 or PR 2 moiety and one less non-hapto ligands for the trivalent metal. These numbers are decreased by one in the case of covalent bonding NR or PR moieties.
• titanium compounds comprise bis(cyclopentadienyl) dimethyltitanium, bis(cyclopentadienyl) diisopropyltitanium, bis(cyclopentadienyl) methyltitanium monochloride, bis(cyclopentadienyl) ethyltitanium monochloride, bis(cyclopentadienyl) isopropyltitanium monochloride, bis(cyclopentadienyl) titanium dichloride, dimethylsilylene (l- ⁇ 5 -2,3,4,5- tetramethylpentadienyl) (t-butylamido) titanium dichloride, 2-dimethyl aminoethyl- ⁇ 5 - cyclopentadienyl titanium dichloride.
• zirconium compounds comprise as bis(isopropylcyclopentadienyl) zirconium dichloride, bis(cyclopentadienyl) dimethyl- zirconium, bis(cyclopentadienyl) diethylzirconium, bis(methylcyclopentadienyl) diisopropylzirconium, bis(cyclopentadienyl) methylzirconium monochloride, bis- (cyclopentadienyl) ethylzirconium monochloride, bis(cyclopentadienyl) dimethyl zirconium, rac-ethylene bis(l- ⁇ 5 -indenyl) zirconium dichloride, rac-ethylene bis(l- ⁇ 5 - indenyl) dimethyl zirconium, rac-ethylene bis(l- ⁇ 5 -4,5,6,7 tetrahydroindenyl) zirconium dichloride and iso
• hafnium compounds comprise bis(cyclopentadienyl) dimethylhafnium, bis(cyclopentadienyl) methylhafnium monochloride, bis(cyclopentadienyl) hafnium dichloride, and rac-ethylene bis(l- ⁇ 5 - indenyl) hafnium dichloride.
• the aluminoxane co-catalyst useful in the catalysts of the present invention are polymeric aluminum compounds which can be represented by the general formulae (R ⁇ Al— O) n which is a cyclic compound and R(R— A1--O— ) n AlR 2 , which is a linear compound.
• R is a Cj-C 5 alkyl group such as, for example, methyl, ethyl, propyl, butyl and pentyl and n is an integer from 1 to about 20. Most preferably, R is methyl and n is about 4.
• aluminoxanes from, for example, aluminum trimethyl and water, a mixture of the linear and cyclic compounds is obtained.
• the proportion of the catalyst comprising a compound of a transition metal of Group IVb of the Periodic Table may be, for example, 10 " to 1 mole/liter, preferably 10 to 10 "2 mole/liter, as the concentration of the catalyst comprising a compound of a transition metal in the oligomerization reaction.
• the proportion of the aluminoxane used may be, for example, 10 "4 to 10 mole/liter, preferably 10 '3 to 5x10 " ' mole/liter, as the concentration of the aluminum atom in the oligomerization reaction.
• the ratio of the aluminum atom to the transition metal in the oligomerization reaction system may be, for example, in the range of 25 to 10 6 , preferably 50 to 10 4 .
• the molecular weight of the oligomer may be controlled by using hydrogen, and/or by adjusting the oligomerization temperature, or by changing the monomer and catalyst concentrations.
• the oligomerization reaction in an embodiment of the invention may be carried out in absence of a solvent or in a hydrocarbon solvent.
• a hydrocarbon solvent suitable for this purpose are aliphatic hydrocarbons such as butane, isobutane, pentane, hexane, octane, decane, dodecane, hexadecene and octadecane; alicyclic hydrocarbons such as cyclopentane, methylcyclopentane, cyclohexane and cyclooctane; aromatic hydrocarbons such as benzene, toluene and xylene; and petroleum fractions such a gasoline, kerosene, lubricant base stocks and light oils.
• the starting olefins or PAOs may themselves serve as the hydrocarbon medium. Among these hydrocarbon media, the aromatic hydrocarbons and the starting olefins may be preferably used in the process of this invention.
• the oligomerization temperature in this first step of the process of the invention may range, for example, from about 0 °C to about 200 °C, preferably from about 20 °C to about 120 °C.
• the single-site catalyst used is a metallocene-based catalyst comprising bis(cyclopentadienyl) zirconium dichloride.
• oligomers according to embodiments of the invention may have some level of unsaturation, such as the presence of double bonds.
• the unsaturated bonds may be hydrogenated in a hydrogenation reaction.
• the hydrogenation reaction can be carried out in the presence or absence of solvents.
• Solvents are necessary only to increase the volume. Examples of suitable solvents are hydrocarbons such as pentane, hexane, heptane, octane, decane, cyclohexane, methycyclohexane and cyclooctane aromatic hydrocarbons such as toluene, xylene or benzene.
• the temperature of the hydrogenation reaction may range, for example, from about 150°C to about 500°C, preferably from about 250°C to about 350°C.
• the hydrogenation reaction pressure may be, for example, in the range of 250-1000 psig hydrogen.
• the hydrogenated oligomeric product is then recovered by conventional procedures. In the hydrogenated product, the double bonds formed in the oligomerization step have been hydrogenated so that the oligomer is a separate type of product.
• the hydrogenated oligomer may be used in the same manner as the unhydrogenated oligomer.
• EXAMPLE 1 A 120 ml pressure reaction bottle with a magnetic stir bar was thoroughly evacuated followed by purging with argon. Then the bottle was charged with 10 ml of dried toluene (distilled over potassium) and 10 ml of 1-tetradecene (dried over 5 A molecular sieves). At 40 °C, 4 ml of 3.3 M methylaluminoxane in toluene solution was added to the reaction bottle and stirred for 15 minutes. Then 4 ml of 6.2 x 10 "3 M bis(cyclopentadienyl)zirconium dichloride in toluene solution was injected into the bottle to start the reaction.
• the procedure was essentially the same as Example 1 , except the reaction was run at 60 °C.
• the oligomers yield was 86%.
• the oligomers contained about 60% dimer, 23% trimer, 8% tetramer, 4% pentamer and 5% higher oligomers.
• EXAMPLE 3 The procedure was essentially the same as Example 1 , except the reaction was run at 60 °C and 2 ml of 3.3 M methylaluminoxane in toluene solution was used. The oligomers yield was 87%. The oligomers contained about 68% dimer, 20% trimer, 7% tetramer, 3% pentamer and 2% higher oligomers. EXAMPLE 4
• Example 5 The procedure was essentially the same as Example 1 , except the reaction was run at 70 °C and 2 ml of 3.3 M methylaluminoxane in toluene solution was used. The oligomers yield was 89%. The oligomers contained about 71% dimer, 19% trimer, 7% tetramer, 1% pentamer and 2% higher oligomers. EXAMPLE 5
• Example 6 The procedure was essentially the same as Example 1, except the reaction was run at 70 °C and 1 ml of 3.3 M methylaluminoxane in toluene solution was used. The oligomers yield was 88%. The oligomers contained about 78% dimer, 15% trimer, 5% tetramer, 1% pentamer and 1% higher oligomers. EXAMPLE 6
• Example 2 The procedure was essentially the same as Example 1, except the starting monomer was 1 -decene instead of 1-tetradecene, and the reaction was run at 60 °C with 2 ml of 3.3 M methylaluminoxane in toluene solution was used.
• the oligomers yield was
• the oligomers contained about 60% dimer, 23% trimer, 9% tetramer, 3% pentamer and 5% higher oligomers.
• Example 2 The procedure was essentially the same as Example 1, except the starting monomer was 1 -decene instead of 1-tetradecene, and the reaction was run at 60 °C with 1 ml of 3.3 M methylaluminoxane in toluene solution was used.
• the oligomers yield was 95%.
• EXAMPLE 8 A 500 ml pressure reaction bottle with a magnetic stir bar was thoroughly vacuumed followed by purging with argon. Then the bottle was charged with 50 ml of dried toluene (distilled over potassium) and 100 ml of 1 -decene (dried over 5 A molecular sieves). At 50 °C, 20 ml of 3.3 M methylaluminoxane in toluene solution was added to the reaction bottle and stirred for 20 minutes. Then 4 ml of 0.049 M bis(isopropylcyclopentadienyl)zirconium dichloride in toluene solution was injected into the bottle to start the reaction.
• the oligomer mixture was hydrogenated and then fractionated by vacuum distillation.
• a fraction (Fraction E8-I) containing 89% dimer, 7% trimer, and 4% higher oligomers was collected and further characterized ( Figure 2).
• the viscosity properties of this fraction were determined to be kinematic viscosity at 100 °C (KV100) of 1.8 cSt, kinematic viscosity at 40 °C (KV40) of 5.3 cSt and viscosity index (VI) of 138.9.
• the PDSC induction time was recorded to be 44.2 minutes.
• Fraction E8-II Another fraction (Fraction E8-II) of the oligomer mixture synthesized in Example 8 contains 86% trimer, 10% tetramer, and 4% higher oligomers. It was measured to have KV100 of 3.6 cSt, KV40 of 14.8 cSt, VI of 129.7 and PDSC induction time of 31.4 minutes.
• another commercial poly-alpha olefin obtained from BP under the trade name of Durasyn 164 with KV100 of 4.0 cSt, KV40 of 17.6 cSt and VI of 126 was measured to have a PDSC induction time of 27.4 minutes.
• a 1000 ml pressure reaction bottle with a magnetic stir bar was thoroughly vacuumed followed by purging with argon. Then the bottle was charged with 100 ml of dried toluene (distilled over potassium) and 150 ml of 1-tetradecene (dried over 5 A molecular sieves). At 70 °C, 15 ml of 3.3 M methylaluminoxane in toluene solution was added to the reaction bottle and stirred for 20 minutes. Then 8 ml of 0.051 M bis(cyclopentadienyl)zirconium dichloride in toluene solution was injected into the bottle to start the reaction. Temperature of the reaction system was controlled by a constant temperature bath within ⁇ 1 °C range.
• oligomers yield was 86%.
• the oligomer mixture contained about 85% dimer, 10% trimer, 3% tetramer, and 1% higher oligomers.
• the oligomer mixture was hydrogenated and then fractionated by vacuum distillation. A fraction (Fraction E10-I) containing 45% dimer, 42% trimer, 10% tetramer and 3% higher oligomers was collected and further characterized. The viscosity properties of this fraction were determined to be KV100 of 5.1 cSt, KV40 of 21.8 cSt and
• EXAMPLE 11 Another fraction (Fraction E 10-11) of the oligomer mixture synthesized in Example 10 contains mostly dimer and is a wax at ambient temperature. It was measured to have PDSC induction time of 48.4 minutes.
• EXAMPLE 12 A third fraction (Fraction E10-III) of the oligomer mixture synthesized in Example 10 contains 16% dimer, 55% trimer, 13% tetramer and 16% higher oligomer. It was measured to have KV100 of 6.4 cSt, KV40 of 30.3 cSt, VI of 169 and PDSC induction time of 46.2 minutes.
• EXAMPLE 13 Another fraction (Fraction E 10-11) of the oligomer mixture synthesized in Example 10 contains mostly dimer and is a wax at ambient temperature. It was measured to have PDSC induction time of 48.4 minutes.
• EXAMPLE 12 A third fraction (Fraction E10-III) of the oligomer mixture synthesized in Example 10 contains 1
• Example 10 The procedure was essentially the same as Example 10, except the reaction was run at 50 °C and 8 ml of 0.034 M bis(isopropylcyclopentadienyl)zirconium dichloride in toluene solution was used.
• the oligomers yield was 88%.
• the oligomer mixture was hydrogenated and then fractionated by vacuum distillation. A fraction (Fraction El 3-1) containing 2% dimer, 40% trimer, 22% tetramer and 36% higher oligomers was collected and further characterized.
• PAOs made in accordance with an embodiment of the invention may have one or more of the following characteristics: 1) substantial absence of tertiary hydrogen resulting from isomerization; 2) greater oxidative stability; 3) greater biodegradability; and 4) cost effectiveness. Therefore, lubricants made in accordance with an embodiment of the invention can be produced for relatively lower cost, have greater oxidation stability, and are environmentally safe. Other characteristics and advantages provided by embodiments of the invention are apparent to those skilled in the art.
• the products of the invention are also useful in applications such as air care, skin care, hair care, cosmetics, household products, cleaners, polishes, fabric care, textile coatings and textile lubricants, automotive products, car cleaners and polishes, fuel additives, oil additives, candles, pharmaceuticals, suspending agents, sun care, insecticides, gels, hydraulic fluids, transmission fluids, modifier for polymers, biodegradable applications and 2-cycle oils.

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