WO2018057830A1 - Lubricant composition comprising polyalkylene oxides - Google Patents
Lubricant composition comprising polyalkylene oxides Download PDFInfo
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- WO2018057830A1 WO2018057830A1 PCT/US2017/052858 US2017052858W WO2018057830A1 WO 2018057830 A1 WO2018057830 A1 WO 2018057830A1 US 2017052858 W US2017052858 W US 2017052858W WO 2018057830 A1 WO2018057830 A1 WO 2018057830A1
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- polyalkylene oxide
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- 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
- C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
- C10M107/20—Lubricating compositions characterised by the base-material being a macromolecular compound containing oxygen
- C10M107/30—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M107/32—Condensation polymers of aldehydes or ketones; Polyesters; Polyethers
- C10M107/34—Polyoxyalkylenes
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- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
-
- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
- C10M2209/1033—Polyethers, i.e. containing di- or higher polyoxyalkylene groups used as base material
-
- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
- C10M2209/104—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of alkylene oxides containing two carbon atoms only
- C10M2209/1045—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of alkylene oxides containing two carbon atoms only used as base material
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- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
- C10M2209/105—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of alkylene oxides containing three carbon atoms only
- C10M2209/1055—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of alkylene oxides containing three carbon atoms only used as base material
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- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
- C10M2209/106—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of alkylene oxides containing four carbon atoms only
- C10M2209/1065—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of alkylene oxides containing four carbon atoms only used as base material
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- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
- C10M2209/107—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of two or more specified different alkylene oxides covered by groups C10M2209/104 - C10M2209/106
- C10M2209/1075—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of two or more specified different alkylene oxides covered by groups C10M2209/104 - C10M2209/106 used as base material
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- 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
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- 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
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- 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
- C10N2030/06—Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
-
- 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
Definitions
- the present invention is related to a lubricant composition; and more specifically, to a polyalkylene oxide-based lubricant composition that exhibits improved properties when used in applications such as for gear lubricants.
- mineral oil-based lubricants Groups I, II and III base oils
- PAO polyalphaolefin-based lubricants
- the known fluids are characterized as "fill for life” meaning that once the lubricant has been incorporated into a vehicle no oil change is required over the useful life of the vehicle.
- the 2025 CAFE (Corporate Average Fuel Economy) regulations related to the requirement that automobiles perform at 54.5 miles per gallon (mpg) are prompting original manufacturers (OEMs) to look at different compositions of lubricants as a possible option that can further enhance fuel economy without compromising durability.
- One approach to improve the fuel economy of an automobile is to improve the lubricant fluid used as gear lubricants for axles, transfer cases and the like of an automobile. For example, reducing the kinematic viscosity of the lubricant from about 11-12 centistokes (cSt) to about 5-6 cSt will, in turn, reduce spinning losses by about 50 percent (%) to about 60 %; and will reduce power losses by about 30 % to about 40 %, thereby achieving an improvement in fuel economy of from about 1 % to about 2%.
- the challenge with the above approach is that reducing the viscosity of a lubricant can result in thin films which will cause metal to metal contact which will ultimately cause higher friction and wear that can result in premature failures, for example, of a gear system.
- V.I. viscosity index
- a V.I. viscosity modifiers
- cP centipoise
- °C degrees Centigrade
- the above known lubricants can also use compounds known as "friction modifiers" such as glycerol oleates for friction reduction of the lubricant to achieve energy efficiency.
- Group IV base oils such as polyalphaolefin base fluids have been used in place of Groups I to III base oils because Group IV base oils inherently have, for example: (1) a good low temperature property, (2) a better V.I.
- Group III base oils compared to Group III base oils, and (3) a lower traction coefficient compared to Group III oils.
- Group IV base oils in combination with V.I. improvers and friction modifiers provide a better alternative compared to Group III base oils in achieving fuel economy.
- Fluids (lubricants) with a V.I. of up to 190 have been used in the industry with the help of V.I. improvers and friction modifiers to achieve energy efficiency.
- Group V base oils such as polyalkylene oxide based oils made from 50/50 ethylene oxide (EO)/propylene oxide (PO) with butanol as the initiator, have inherently a higher V.I. compared to Group III and Group IV base oils (e.g., from about 30 % to about 40 % higher); and the Group V base oils also have a significantly lower (e.g., from about 30 % to about 50 % lower) traction coefficients and hence are ideally suited for applications where energy efficiency is required.
- One of the challenges with the Group V base oils is that these fluids have a 15 % - 20 % higher density compared to Group III base oils and Group IV base oils.
- the higher density of the Group V base oils increases the dynamic viscosity at low temperatures (e.g., from about 20 °C to about 60 °C).
- the churning losses are directly proportional to the dynamic viscosity; and hence, when the performance of formulated alcohol initiated 50/50 EO/PO fluids without the use of V.I. improvers is compared with formulated Group III and Group IV base oil with V.I. improvers, the churning losses at low temperatures (e.g., from about 20 °C to about 60 °C) are similar.
- a formulated alcohol initiated 50/50 EO/PO fluid e.g., UCONTM 50-HB fluid; a trademark of The Dow Chemical Company
- UCONTM 50-HB fluid a trademark of The Dow Chemical Company
- Drag forces are energy losses due to a mechanical element (gear) spinning in a liquid (oil). The drag forces are calculated using the following equation:
- Cd is the drag coefficient and is a function of the Reynolds number
- V is velocity of the spinning element
- p is the density of the liquid
- A is a characteristic wetted cross sectional area.
- the known polyalkylene oxides are further defined generally as including diether, monol, diol, CI- C20 alcohol initiated, any and all combination of EO/PO/BO and higher oxides in any ratio, and polymer blends thereof.
- the prior art does not disclose specific blends of butanol initiated EO/PO copolymers and dodecanol initiated PO/BO copolymers at ratios required to maintain the miscibility of such copolymer components.
- Not all blends of polyalkylene glycols are miscible, such immiscible blends are impractical for use as a lubricant base stock.
- a required additive or combination of additives is added to the lubricant formulation to make the formulation useful.
- the present invention in one embodiment, is directed to a lubricant composition including: (a) a first low viscosity polyalkylene oxide based fluid with a first alcohol as an initiator; wherein the first low viscosity polyalkylene oxide based fluid has a number average molecular weight of less than about 600 Da; and (b) a second high viscosity polyalkylene oxide based fluid with a second alcohol as an initiator; wherein the second high viscosity polyalkylene oxide based fluid has a number average molecular weight greater than about 600 Da; and wherein the first low viscosity polyalkylene oxide based fluid is different from the second high viscosity polyalkylene oxide based fluid.
- the problems of known lubricant compositions of the prior art are addressed by the present invention lubricant composition.
- the present invention lubricant composition provides important and beneficial properties including for example: (i) a low temperature viscosity (e.g., -40 °C dynamic viscosity of less than 40,000 cP for an 11-12 cSt fluid at 100 °C), (ii) a high viscosity index (e.g., a viscosity index of greater than (> 215), and (iii) a low traction coefficient inter alia.
- the present invention is directed to the use of the above lubricant composition in a driveline fluid.
- viscosity index is an arbitrary number used to characterize the variation of the kinematic viscosity of a petroleum product with temperature.
- V.I. the higher the V.I. the smaller the effect of temperature on its kinematic viscosity.
- the V.I. number is a widely used and accepted measure of the variation in kinematic viscosity due to changes in the temperature of a petroleum product between 40 °C and 100 °C.
- a higher V.I. indicates a smaller decrease in kinematic viscosity with increasing temperature of the lubricant.
- the V.I. is used in practice as a single number indicating temperature dependence of kinematic viscosity.
- V.I. is sometimes used to characterize base oils for purposes of establishing engine testing requirements for engine oil performance categories.
- Dynamic viscosity with reference to a lubricant composition, herein means a viscosity as measured by a Stabinger viscometer in units of mPa s. See ASTM D 7042, "Standard Test Method for Dynamic Viscosity and Density of Liquids by Stabinger Viscometer (and the Calculation of Kinematic Viscosity)".
- Traction is a force transmitted through a lubricant film between to surfaces in relative motion.
- a “traction coefficient” is the measured traction force/normal applied force.
- Group I, II, III, IV and/or V base oils are those as defined by the American Petroleum Institute (Annex E— API Base Oil Interchangeability Guidelines for Passenger Car Motor Oils and Diesel Engine Oils, March 2015 Version).
- the present invention includes a lubricant composition including: (a) a first low viscosity polyalkylene oxide based fluid with a first alcohol as an initiator; wherein the first low viscosity polyalkylene oxide based fluid has a number average molecular weight of less than about 600 Da; and (b) a second high viscosity polyalkylene oxide based fluid with a second alcohol as an initiator; wherein the second high viscosity polyalkylene oxide based fluid has an average molecular weight greater than about 600 Da; and wherein the first low viscosity polyalkylene oxide based fluid is different from the second high viscosity polyalkylene oxide based fluid.
- the number average molecular weights provided herein are as reported by manufacturer.
- the viscosity of the first low viscosity polyalkylene oxide based fluid in general, can be from about 2 cSt to about 8 cSt in one embodiment, from about 2 cSt to about 6 cSt in another embodiment, and from about 2 cSt to about 4 cSt in still another embodiment.
- the kinematic viscosity is calculated according to ASTM D 7042.
- the first low viscosity polyalkylene oxide based fluid with a first alcohol as an initiator in general, has a number average molecular weight of less than about 600 Da in one embodiment, less than about 550 Da in another embodiment, and less than about 400 Da in still another embodiment.
- the polyalkylene oxide of the first low viscosity polyalkylene oxide based fluid can include for example, a polyethylene oxide, a polypropylene oxide, a polybutylene oxide, polyalkylene oxide copolymers derived from EO/PO/BO and polymer mixtures thereof.
- the first low viscosity polyalkylene oxide based fluid is a combination of a propylene oxide and a butylene oxide.
- the combination of a propylene oxide and a butylene oxide to arrive at a first low viscosity polyalkylene oxide based fluid can include a 50/50 propylene oxide/butylene oxide based fluid (wt. % basis).
- the first low viscosity polyalkylene oxide based fluid may include a lower molecular weight capped oil soluble polyalkylene oxides (e.g., a capped UCONTM OSP, an oil soluble polyalkylene oxide having less than about 600 Da average molecular weight, where UCONTM is a trademark of The Dow Chemical Company).
- capped indicates that the terminal hydroxyl groups of the polyalkylene oxide(s) are substituted with a hydrocarbyl group of CI to C12 or a C8 alkyl phenyl group (i.e., a benzyl group).
- capped oil soluble polyalkylene oxides are substituted with a CI to C4 hydrocarbyl group.
- the first low viscosity polyalkylene oxide based fluid used as component (a) of the lubricant composition, includes for example UCONTM OSP-12 (a C12 alcohol initiated 50/50 PO/BO UCONTM OSP fluid with 3 cSt viscosity at 100 °C, commercially available from The Dow Chemical Company), UCONTM OSP-18 (a C12 alcohol initiated 50/50 PO/BO UCONTM OSP fluid with 4 cSt viscosity at 100 °C and 550 Da), and mixtures thereof.
- the first low viscosity polyalkylene oxide based fluid may also be formed using a C4-C18 alcohol initiator, where different ratios of PO/BO can be used.
- the low viscosity fluid useful in the lubricant composition of the present invention may include for example, UCONTM OSP-12 (a C12 alcohol initiated 50/50 PO/BO UCONTM OSP fluid with 3 cSt viscosity at 100 °C).
- UCONTM OSP-12 a C12 alcohol initiated 50/50 PO/BO UCONTM OSP fluid with 3 cSt viscosity at 100 °C.
- the concentration of the low viscosity fluid used in the lubricant composition of the present invention may range generally from about 30 weight percent (wt %) to about 90 wt % in one embodiment, from about 40 wt % to about 80 wt % in another embodiment, and from about 50 wt % to about 70 wt % in still another embodiment, based on the total weight of the components in the lubricant composition.
- concentration of the low viscosity fluid is greater than 80 wt % concentration, it is difficult to achieve a target viscosity of 11-12 cSt at 100 °C; and even if it were possible to achieve the target viscosity, the V.I. of the resulting fluid is lower.
- the first alcohol initiator useful for the first low viscosity polyalkylene oxide based fluid can include for example, an alcohol selected from ethanol, methanol, propanol, butanol, dodecanol, and mixtures thereof.
- the viscosity of the second high viscosity polyalkylene oxide based fluid in general, can be from about 16 cSt at 100 °C to about 250 cSt at 100 °C in one embodiment, from about 25 cSt at 100 °C to about 164 cSt at 100 °C in another embodiment, and from about 25 cSt at 100 °C to about 70 cSt at 100 °C in still another embodiment.
- the second high viscosity polyalkylene oxide based fluid with a second alcohol as an initiator in general, has a number average molecular weight of greater than about 600 in one embodiment, greater than about 2,000 in another embodiment, and greater than about 2,660 in still another embodiment.
- the second high viscosity polyalkylene oxide based fluid (the "high viscosity fluid") used as component (b) of the lubricant composition includes for example a 50/50 EO/PO copolymer blend having a molecular weight in the range of from about 1,590 Da (e.g., UCONTM 50-HB-660, commercially available from The Dow
- the second high viscosity polyalkylene oxide based fluid also includes for example a 45/55 EO/PO copolymer blend with molecular weight in the range of from about 1,590 Da to about 3,930 Da.
- the high viscosity fluid useful in the lubricant composition of the present invention may include for example, UCONTM 50-HB-2000 (a 50/50 EO/PO copolymer commercially available from The Dow Chemical Company) with butanol as initiator and molecular weight of 2,660 Da; SYNALOXTM 55-150B (a 45/55 EO/PO copolymer blend, commercially available from The Dow Chemical Company) with butanol as the initiator and molecular weight of 2,200 Da; and mixtures thereof.
- UCONTM 50-HB-2000 a 50/50 EO/PO copolymer commercially available from The Dow Chemical Company
- SYNALOXTM 55-150B a 45/55 EO/PO copolymer blend, commercially available from The Dow Chemical Company
- the concentration of the high viscosity fluid used in the lubricant composition of the present invention may range generally from about 10 wt % to about 70 wt % in one embodiment, from about 20 wt % to about 60 wt % in another embodiment, and from about 30 wt % to about 50 wt % in still another embodiment, based on the total weight of the components in the lubricant composition.
- concentration of the high viscosity fluid is greater than 50 wt % concentration, the resulting fluid will have a viscosity of greater than about 11-12 cSt target viscosity at 100 °C
- the ratio of component (a) such as UCONTM OSP-12, UCONTM OSP-18 to component (b) such as UCONTM 50-HB-2000, UCONTM 50-HB-3520, UCONTM 50-HB- 5100 or SYNALOXTM 55-150B can be generally from about 90 to about 10 in one embodiment; from about 70 to about 30 in another embodiment; and from about 50 to about 50 in still another embodiment.
- the second alcohol useful as an initiator for the second high viscosity polyalkylene oxide based fluid can include for example, an alcohol selected from ethanol, methanol, propanol, butanol, dodecanol, alcohols up to a carbon chain length of 18 (CI 8), and mixtures thereof.
- the second alcohol can also be alcohols with mixed chain lengths.
- the second initiator alcohol, when used, is different than the first initiator alcohol.
- the lubricant composition of the present invention may also include any number of optional components such as for example one or more of antioxidants; antiwear compounds; extreme pressure, rust and corrosion inhibitors; sulfur scavengers; detergents; dispersants; antifoaming additives; and mixtures thereof.
- optional components such as for example one or more of antioxidants; antiwear compounds; extreme pressure, rust and corrosion inhibitors; sulfur scavengers; detergents; dispersants; antifoaming additives; and mixtures thereof.
- the concentration of the optional additives for the lubricant composition of the present invention may range generally from 0 wt % to about 20 wt % in one
- the process and type of equipment used to prepare the lubricant composition of the present invention includes blending or mixing of the above components in conventional mixing equipment or vessels known in the art.
- the preparation of the lubricant composition of the present invention is achieved by blending, in known mixing equipment, (a) the low viscosity fluid, and (b) the high viscosity fluid, and (c) optionally any other desirable additive.
- All the above compounds of the lubricant composition are typically mixed and dispersed in a vessel at a temperature enabling the preparation of an effective working lubricant fluid.
- the temperature during the mixing of the above components may be generally from about 25 °C to about 75 °C in one embodiment, and from about 25 °C to about 55 °C in another embodiment.
- Components (a) - (c) of the present invention are miscible at room temperature (about 25 °C) and at low temperatures, (e.g., down to about -5 °C).
- the preparation of the lubricant composition of the present invention, and/or any of the steps thereof, may be a batch or a continuous process.
- a preferred method of preparing the lubricant composition of the present invention may be a batch or a continuous process.
- the mixing process of the components for preparing the lubricant composition; and the mixing equipment used in the process may be any vessel and ancillary equipment well known to those skilled in the art.
- the present invention includes a combination or blend of at least two components including, for example: (a) a first low viscosity (e.g., less than about 4 cSt) polyalkylene oxide based fluid made from a combination of at least two different polyalkylene oxide fluids with a first alcohol such as dodecanol as the initiator and a average molecular weight of less than about 600 Da ; and (b) a high viscosity (e.g., greater than about 4 cSt) polyalkylene oxide based fluid made from a combination of at least two different polyalkylene oxide fluids with a second alcohol such as butanol as the initiator and a number average molecular weight of greater than about 600 Da.
- a first low viscosity e.g., less than about 4 cSt
- a first alcohol such as dodecanol as the initiator and a average molecular weight of less than about 600 Da
- a high viscosity e.g.,
- This unique combination or mixture of two different polyalkylene oxide based fluids of the present invention provides several benefits including based fluids having a low density, a high V.I. index, a low traction coefficient, and good low temperature properties.
- One of the surprising results of the fluid mixture of the present invention is that the low temperature property at -40 °C of the combination of a low and a high viscosity or molecular weight polyalkylene oxide base fluids as previously defined is better than the baseline or control polyalkylene oxide fluid.
- the present invention includes a blend of at least two components including (a) a first low viscosity 50/50 PO/BO based fluid with a first alcohol such as dodecanol as the initiator and the fluid having a number average molecular weight of less than about 580 Da; and (b) a second high viscosity 50/50 EO/PO or 45/55 EO/PO based fluid with a second alcohol such as butanol as the initiator and the fluid having a number average molecular weight greater than about 2,660 Da.
- SYNALOXTM 55-150B which can be one embodiment of the second high viscosity 50/50 EO/PO or 45/55 EO/PO based fluid, has a molecular weight of about 2,200 Da.
- the composition has: (1) a higher V.I. for the same 100 °C viscosity base oil compared to a dodecanol initiated 50/50 PO/BO base fluid and butanol initiated 50/50 EO/PO base fluid; (2) a lower traction coefficient compared to dodecanol initiated 50/50 PO/BO base fluid and similar traction coefficients compared to butanol initiated 50/50 EO/PO base fluid; (3) a higher V.I.
- One of the surprising results of the lubricant composition of the present invention is that the properties of the composition at sub-zero temperature, e.g., at a temperature of about -40 °C, are better (e.g., less than about 40,000 cP at -40 °C for a 11-12 cSt fluid at 100 °C) than the baseline 50/50 EO/PO based fluid.
- the properties of the composition at sub-zero temperature e.g., at a temperature of about -40 °C
- are better e.g., less than about 40,000 cP at -40 °C for a 11-12 cSt fluid at 100 °C
- a lower dynamic viscosity e.g., from about 10 % to about 20 % lower dynamic viscosity
- a lower traction coefficient for base fluids e.g., a lower traction coefficient for base fluids, and extremely good low temperature properties, without the need to use pour point depressants or V.I. improvers.
- the present invention is directed to a lubricant composition with a target 11-12 cSt viscosity at 100 °C including: (a) a low viscosity (e.g., a viscosity of from about 2 cSt to about 4 cSt at 100 °C) 50/50 PO/BO based fluid with dodecanol as the initiator and molecular weight of less than about 580Da; and (b) a high viscosity (e.g., a viscosity of greater than about 25 cSt at 100 °C) 50/50 EO/PO based fluid with butanol as the initiator and a molecular weight greater than about 1,500 Da; wherein the lubricant composition has a viscosity index of greater than about 215; a dynamic viscosity of lower than about 40,000 cP at a temperature of -40 °C; and a lower traction coefficient for the base fluid in the absence of a pour point de
- Examples of the low viscosity 50/50 PO/BO based fluid include the UCONTM OSPs and their capped analogs, as both discussed herein, and examples of the high viscosity 50/50 EO/PO based fluids include UCONTM 50-HB fluids and their capped analogs, also as both discussed herein.
- the lubricant composition of the present invention relates to compositions of a polyalkylene oxides based base oil wherein a PO/BO co-polymer with a dodecanol initiator and with a molecular weight of less than or equal to about 550 Da is mixed with a EO/PO co-polymer with a butanol initiator and with a molecular weight of greater than about 2,000.
- the mixing ratios can vary, for example, a 67/33 (UCONTM OSP-18/ UCONTM 50-HB-2000) ratio can be used to achieve a lubricant composition's target viscosity of about 11-12 cSt at 100 °C for applications such as gear oils.
- an 87/13 (UCONTM OSP-128/ UCONTM 50-HB-2000) ratio can be used to achieve a lubricant composition's target viscosity of about 6 cSt at 100 °C to target applications such as gear oils, ATF oils, or engine oils in transportation applications.
- the lubricant composition prepared by the above process of the present invention exhibits several unexpected and unique properties.
- the dynamic viscosity of the lubricant composition of the present invention is such that the composition can be easily handled and processed.
- the lubricant composition with a 11-12 cSt kinematic viscosity at 100 °C may have a dynamic viscosity in the range of from about 45 millipascals second (mPa-s) to about 60 mPa-s at 40 °C in one embodiment, from about 47 mPa-s to about 55 mPa-s at 40 °C in another embodiment, and from about 47 mPa-s to about 52 mPa- s at 40 °C in still another embodiment. Greater than 60 mPa-s at 40 °C does not provide any improvement in fuel economy.
- V.I. property can be between 209 and 229 in one embodiment, between about 215 and 229 in another embodiment, and between about 220 and 229 in still another embodiment.
- V.I. of 209 for the combination mixture the 40 °C dynamic viscosities are similar to compounds similar to the UCONTM 50-HB series of copolymers and lower spinning losses cannot be achieved.
- the V.I. of the composition may be further increased by using a low viscosity base oil as defined above which is a C12 alcohol initiated PO/BO polyalkylene oxide diether or capped base oil.
- a low viscosity base oil as defined above which is a C12 alcohol initiated PO/BO polyalkylene oxide diether or capped base oil.
- capped base oils as the lower molecular weight component can impact the solubility of the overall composition. Since homogenous mixtures are desirable, the solubility of the C12 alcohol initiated PO/BO polyalkylene oxide diether component can be further improved in the higher molecular weight base oil, if necessary.
- modification of the higher molecular base oil include, but are not limited to, using a longer initiator such as a C12 alcohol initiator or by using a combination of longer initiator and capping the EO/PO polymer.
- the capped 50/50 EO/PO polymer may further enhance the V.I.
- Another way of improving the solubility of C12 alcohol initiated PO/BO diether is by changing the EO/PO ratio in the higher molecular weight base oil, for example, from 50/50 to 40/60 or 30/70. There may be a limitation on how much the ratio can be altered as adding more PO will increase the traction coefficients and will also adversely affect the -40 °C viscosity.
- the lubricant composition can also exhibit a low traction coefficient.
- the traction coefficient (e.g., at 80 °C and 500 millimeters per second (mm/s) speed with 150 % slide to roll ratio) can be between about 0.025 and about 0.04 in one embodiment, between about 0.025 and about 0.035 in another embodiment, and between about 0.025 and about 0.03 in still another embodiment.
- the traction coefficients under the same conditions may be between about 0.045 and about 0.05 for a Group III base oil; and between about 0.035 and about 0.04 for a Group IV base oil.
- the fluids of the present invention have a traction coefficient which is from about 25 % to about 30 % lower than a Group IV base oil (polyalpha olefin or PAO). Fluids having lower traction coefficients are desired as these fluids may provide benefit in terms of fuel economy. A fluid having a traction coefficient close to 0.035 under these conditions may not provide a fuel economy benefit over a Group IV base oil.
- the lubricant composition of the present invention exhibits is an excellent viscosity at a lower temperature, such as -40 °C.
- the -40 °C dynamic viscosity property can be between about 20,000 cP and about 50,000 cP in one embodiment, between about 20,000 cP and about 40,000 cP in another embodiment, and between about 20,000 cP and about 30,000 cP in still another embodiment without the use of pour point depressants.
- the lubricant composition can be used in various driveline fluids.
- the lubricant composition can be used for driveline fluids for applications such as engine oil, axle oils, transmissions fluids, worm gear oils, industrial gear oils, and the like.
- the gears are submerged in the lubricant to a certain depth (e.g., a depth of from about 25 % to about 50 %) for lubrication.
- a certain depth e.g., a depth of from about 25 % to about 50 %) for lubrication.
- churning or spinning losses can be significant especially at low temperatures and during start up and such losses can have a negative impact on fuel economy and energy efficiency of an automobile.
- These churning losses are directly dependent on the dynamic viscosity of the fluid at that temperature and hence reducing the dynamic viscosity can reduce the churning losses.
- OEM's are contemplating lowering viscosity grade oils for these types of applications to minimize these spinning losses and improve fuel economy.
- the challenge with going to lower viscosity grades is thinner films and faster transition to boundary and mixed lubrication regime which can cause higher wear and affect the durability and life of the gears.
- One way to achieve lower viscosity at lower temperatures is by using V.
- UCONTM OSPs e.g., UCONTM OSP-12 and/or UCONTM OSP-18
- UCONTM 50-HB fluids unique combinations of fluids can be developed that provide lower dynamic viscosity at low temperatures, significantly improved cold temperature viscosity, and traction coefficients similar to the UCONTM 50-HB fluids.
- UCONTM OSPs have a 7-8 % lower density compared to the UCONTM 50-HB fluids whereas for the same viscosity grades, UCONTM 50-HB fluids have 30 % higher VI compared to UCONTM OSP's.
- EO ethylene oxide
- PO propylene oxide
- BO butylene oxide
- UCONTM OSP stands for oil soluble polyalkylene glycols.
- Traction coefficients as reported herein are derived from Stribeck curves formed from data measured on a PCS Mini-Traction Machine using 3 ⁇ 4 inch ball on a disc 5 both made of AISI 52100 steel. Both ball and disc had surface finishes of Ra (arithmetical mean deviation) better than 0.01 micron.
- the measurements were done at 80 °C and 120 °C, a load of 50 Newton, a slide to roll ratio (SRR) of 150 % and from speeds of 2000 mm/s to 100 mm/s. The test measurements were conducted 12 times in succession at each temperature. The traction coefficient at 500 mm/s +/- 2 mms of the 12 th repeat was 10 reported.
- a viscometer Stabinger ViscometerTM SVM 3000, measures the dynamic viscosity and density of oils and fuels according to ASTM D7042. From the above measurements, the viscometer automatically calculates the kinematic viscosity and delivers measurement results which are equivalent to ASTM D445.
- the Stabinger ViscometerTM 10 SVM 3000 is a rotational viscometer with a cylinder geometry which works according to the modified Couette principle with a rapidly rotating outer tube and an inner measuring bob which rotates more slowly. A 2.5 milliliter (mL) sample is placed in the viscometer and the dynamic viscosity and density are measured as a function of temperature of from about 20 °C to about 100 °C.
- Cold temperature viscosity measurements are obtained using a Brookfield viscometer.
- the principle of operation of the viscometer is to rotate a spindle (which is immersed in a test sample fluid) through a calibrated spring.
- the viscous drag of the fluid against the spindle is measured by spring deflection.
- Spring deflection is measured with a 20 rotary transducer which provides a torque signal.
- Approximately 7 mL of sample are placed in a cup, containing a number 31 spindle, and placed in a small sample adapter that connects to a Brookfield programmable rheometer. (The software accounts for the specific geometry of this setup).
- the temperature of the sample is controlled by an external bath that cools the sample to the desired temperature.
- Viscosity measurements are made starting at 0 °C and continuing down to -30 °C.
- Table II describes the composition or formulation of various base fluids.
- Table III describes the results of evaluating the various formulations with the components listed in Table II. Table III highlights the kinematic and dynamic viscosities, viscosity index, low temperature dynamic viscosity, solubility, and traction coefficients of different combinations of base fluids making up the formulations. All of the fluids have a target viscosity of 1 1.7 cSt at 100 °C.
- Comparative Example A shows the viscometrics and traction coefficients of standard UCONTM 50-HB-260 with UCONTM 50-HB-400 and compares these properties to an UCONTM OSP-68 base fluid highlighted in Comparative Example E (C. Ex. E). These comparisons are made for similar viscosity grades (75W85) which is dictated, in part, by kinematic viscosity at 100 °C.
- UCONTM OSPs in general, have about 15 % to about 20 % higher dynamic viscosity at 40 °C compared to a UCONTM 50-HB fluid when the kinematic viscosities are matched at 100 °C.
- UCONTM OSPs also have about 75% to about 80 % higher dynamic viscosity at -40 °C and about 60 % higher traction coefficients when compared to UCONTM 50-HB fluids.
- the resulting fluid has a VI of 217 which is similar to that of the UCONTM 50- HB-260 + UCONTM 50-HB-400 (221) fluid. Also this combination provides 11 % lower dynamic viscosity at 40 °C and 40 % lower dynamic viscosity at -40 °C. These properties are further enhanced when UCONTM OSP-18 is mixed with even a higher molecular weight UCONTM 50-HB- 5100 as highlighted in Ex. 2.
- Comparative Example G Comparative Example G
- Comparative Example I Comparative Example I
- a combination of lower molecular weight butanol initiated BO homopolymer (SYNALOXTM OA-25) and higher molecular weight butanol initiated EO/PO copolymer (UCONTM 50-HB-2000) were used as shown in C. Ex. I. This combination was found to be miscible but the composition of C. Ex. I did not provide as good of a low temperature viscometrics compared to the 5 Examples of the present invention.
- Table IV describes the composition of various base fluids.
- Table V describes the results of evaluating the several formulations with the components listed in Table IV.
- Table IV highlights the kinematic and dynamic viscosities, viscosity index, low temperature dynamic 0 viscosity, solubility and traction coefficients of different combinations of base fluids. All of the fluids have a target viscosity of 11.7 cSt at 100 °C.
- Comparative Example L C. Ex. L
- This blend was insoluble with UCONTM OSP suggesting that5 the EO/PO ratio cannot be increased beyond 50/50 unless changes are made in the initiators.
- a blend of SYNALOXTM 55-150B was made with UCONTM OSP-18 (Comparative Example K) and UCONTM OSP-12 (Example 4). It was found that similar to the UCONTM OSP-18 and UCONTM 50-HB-660 blends (C. Ex. J) a blend of SYNALOXTM 55-150B and UCONTM OSP-180 had a V.I.
- a combination of multiple blends of base oils including those that include UCONTM OSP-12 and/or UCONTM OSP-18 with UCONTM 50-HB-2000, UCONTM 50-HB-5100 and/or SYNALOXTM 55-150B provided V.I. of above 217, 40 °C dynamic viscosities that were 10- 15 % lower than individual UCONTM 50-HB fluids, similar traction coefficients as 50/50 EO/PO fluids and 10-50 % lower dynamic viscosity compared to a baseline 50/50 EO/PO copolymer of similar kinematic viscosity at 100 °C.
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Abstract
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Priority Applications (4)
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CN201780057276.5A CN109715769B (en) | 2016-09-23 | 2017-09-22 | Lubricant compositions comprising polyalkylene oxide |
EP17778129.1A EP3516023B1 (en) | 2016-09-23 | 2017-09-22 | Lubricant composition comprising polyalkylene oxides |
US16/333,068 US20190225907A1 (en) | 2016-09-23 | 2017-09-22 | Lubricant composition |
BR112019005088-4A BR112019005088B1 (en) | 2016-09-23 | 2017-09-22 | LUBRICANT COMPOSITION, AND, PROCESS FOR MANUFACTURING A LUBRICANT COMPOSITION. |
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US201662398791P | 2016-09-23 | 2016-09-23 | |
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EP (1) | EP3516023B1 (en) |
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Citations (4)
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US20080312113A1 (en) * | 2004-07-16 | 2008-12-18 | Beatty Daryl L | Food Grade Lubricant Compositions |
US20130157909A1 (en) * | 2010-08-31 | 2013-06-20 | Dow Global Technologies Llc | Corrosion Inhibiting Polyalkylene Glycol-Based Lubricant Compositions |
WO2015139209A1 (en) * | 2014-03-18 | 2015-09-24 | Dow Global Technologies Llc | Corrosion resistant lubricant |
US20160251592A1 (en) * | 2013-11-07 | 2016-09-01 | Dow Global Technologies Llc | Demulsifiers for oil soluble polyalkylene glycol lubricants |
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US20080182770A1 (en) * | 2007-01-26 | 2008-07-31 | The Lubrizol Corporation | Antiwear Agent and Lubricating Compositions Thereof |
US20100210487A1 (en) * | 2009-02-16 | 2010-08-19 | Chemtura Coproration | Fatty sorbitan ester based friction modifiers |
US9920277B2 (en) * | 2012-12-12 | 2018-03-20 | Dow Global Technologies Llc | Concentrated metalworking fluid and metalworking process |
-
2017
- 2017-09-22 EP EP17778129.1A patent/EP3516023B1/en active Active
- 2017-09-22 US US16/333,068 patent/US20190225907A1/en not_active Abandoned
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Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080312113A1 (en) * | 2004-07-16 | 2008-12-18 | Beatty Daryl L | Food Grade Lubricant Compositions |
US20130157909A1 (en) * | 2010-08-31 | 2013-06-20 | Dow Global Technologies Llc | Corrosion Inhibiting Polyalkylene Glycol-Based Lubricant Compositions |
US20160251592A1 (en) * | 2013-11-07 | 2016-09-01 | Dow Global Technologies Llc | Demulsifiers for oil soluble polyalkylene glycol lubricants |
WO2015139209A1 (en) * | 2014-03-18 | 2015-09-24 | Dow Global Technologies Llc | Corrosion resistant lubricant |
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BR112019005088A2 (en) | 2019-06-04 |
CN109715769B (en) | 2022-05-06 |
CN109715769A (en) | 2019-05-03 |
EP3516023A1 (en) | 2019-07-31 |
EP3516023B1 (en) | 2023-02-22 |
US20190225907A1 (en) | 2019-07-25 |
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