WO2023125235A1 - Composition de graisse à base de complexe polyurée/sulfonate de calcium destinée à être utilisée dans des joints homocinétiques - Google Patents

Composition de graisse à base de complexe polyurée/sulfonate de calcium destinée à être utilisée dans des joints homocinétiques Download PDF

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Publication number
WO2023125235A1
WO2023125235A1 PCT/CN2022/141050 CN2022141050W WO2023125235A1 WO 2023125235 A1 WO2023125235 A1 WO 2023125235A1 CN 2022141050 W CN2022141050 W CN 2022141050W WO 2023125235 A1 WO2023125235 A1 WO 2023125235A1
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grease
calcium
polyurea
calcium sulfonate
acid
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PCT/CN2022/141050
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English (en)
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Dabo LIU
Xiaolong Li
Yan Wang
Lianhui Zhang
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Lanxess Specialty Chemicals Co., Ltd.
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Publication of WO2023125235A1 publication Critical patent/WO2023125235A1/fr

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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
    • C10M169/00—Lubricating compositions characterised by containing as components a mixture of at least two types of ingredient selected from base-materials, thickeners or additives, covered by the preceding groups, each of these compounds being essential
    • C10M169/06—Mixtures of thickeners and additives
    • C—CHEMISTRY; METALLURGY
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    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M119/00—Lubricating compositions characterised by the thickener being a macromolecular compound
    • C10M119/24—Lubricating compositions characterised by the thickener being a macromolecular compound containing nitrogen
    • C—CHEMISTRY; METALLURGY
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    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
    • C10M2201/06—Metal compounds
    • C10M2201/062—Oxides; Hydroxides; Carbonates or bicarbonates
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    • C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
    • C10M2201/087—Boron oxides, acids or salts
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    • C10M2203/00—Organic non-macromolecular hydrocarbon compounds and hydrocarbon fractions as ingredients in lubricant compositions
    • C10M2203/10—Petroleum or coal fractions, e.g. tars, solvents, bitumen
    • C10M2203/102—Aliphatic fractions
    • C10M2203/1025—Aliphatic fractions used as base material
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    • 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
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    • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/10—Carboxylix acids; Neutral salts thereof
    • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
    • C10M2207/121—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of seven or less carbon atoms
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    • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/10—Carboxylix acids; Neutral salts thereof
    • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
    • C10M2207/125—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids
    • C10M2207/126—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids monocarboxylic
    • C10M2207/1265—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids monocarboxylic used as thickening agent
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    • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/10—Carboxylix acids; Neutral salts thereof
    • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
    • C10M2207/125—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids
    • C10M2207/128—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids containing hydroxy groups; Ethers thereof
    • C10M2207/1285—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids containing hydroxy groups; Ethers thereof used as thickening agents
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    • C10M2215/00—Organic non-macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2215/02—Amines, e.g. polyalkylene polyamines; Quaternary amines
    • C10M2215/04—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to acyclic or cycloaliphatic carbon atoms
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    • C10M2215/00—Organic non-macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2215/02—Amines, e.g. polyalkylene polyamines; Quaternary amines
    • C10M2215/06—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to carbon atoms of six-membered aromatic rings
    • C10M2215/064—Di- and triaryl amines
    • C10M2215/065—Phenyl-Naphthyl amines
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10M2215/00—Organic non-macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2215/10—Amides of carbonic or haloformic acids
    • C10M2215/102—Ureas; Semicarbazides; Allophanates
    • C10M2215/1026—Ureas; Semicarbazides; Allophanates used as thickening 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
    • C10M2217/00—Organic macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2217/04—Macromolecular compounds from nitrogen-containing monomers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/045—Polyureas; Polyurethanes
    • C10M2217/0456—Polyureas; Polyurethanes used as thickening agents
    • 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
    • C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
    • C10M2219/04—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions containing sulfur-to-oxygen bonds, i.e. sulfones, sulfoxides
    • C10M2219/044—Sulfonic acids, Derivatives thereof, e.g. neutral salts
    • 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
    • C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
    • C10M2219/04—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions containing sulfur-to-oxygen bonds, i.e. sulfones, sulfoxides
    • C10M2219/044—Sulfonic acids, Derivatives thereof, e.g. neutral salts
    • C10M2219/0445—Sulfonic acids, Derivatives thereof, e.g. neutral salts used as thickening agents
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
    • C10M2219/04—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions containing sulfur-to-oxygen bonds, i.e. sulfones, sulfoxides
    • C10M2219/046—Overbasedsulfonic acid salts
    • C10M2219/0466—Overbasedsulfonic acid salts used as thickening agents
    • C—CHEMISTRY; METALLURGY
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    • C10M2223/00—Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions
    • C10M2223/02—Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions having no phosphorus-to-carbon bonds
    • C10M2223/04—Phosphate esters
    • C10M2223/045—Metal containing thio derivatives
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    • 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
    • C10N2010/00—Metal present as such or in compounds
    • C10N2010/12—Groups 6 or 16
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    • 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
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    • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/08—Resistance to extreme temperature
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    • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/12—Inhibition of corrosion, e.g. anti-rust agents or anti-corrosives
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    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/10—Semi-solids; greasy

Definitions

  • the present application generally relates to polyurea/calcium sulfonate complex grease composition for use in constant velocity joints.
  • High performance, thixotropic polyurea/overbased calcium sulfonate complex hybrid greases comprising solid particles of colloidally dispersed calcium carbonate essentially in the form of calcite, calcium soap of a fatty acid of 12 to 24 carbon atoms, calcium borate or calcium borate complex, an organic molybdenum compound, and oleaginous medium are provided, which have lower concentrations of overbased calcium sulfonate for each thickness grade than available overbased calcium sulfonate complex greases, for example, greases of the invention are provided comprising less than 22 wt%overbased calcium sulfonate complex that have a worked cone penetration rating of 295 or less.
  • Corrosion-inhibiting, thixotropic greases or grease-like overbased calcium sulfonate compositions are well known, as is their use in a variety of demanding applications. Such greases or grease-like compositions can be used alone, or in combination with other components, and in general exhibit good extreme pressure and antiwear properties, high dropping points, mechanical stability, salt spray and water-corrosion resistance, thermal stability at high temperatures, and other desirable properties.
  • Greases are rated or graded on the basis of their worked cone penetration range.
  • cone penetration is measured by the ASTM cone penetration test (D217) .
  • Penetration is the depth, in tenths of millimeters, to which a standard cone sinks into the grease under prescribed conditions. Higher penetration numbers indicate softer greases with a higher base oil content, since the cone has sunk deeper into the sample.
  • grade zero has a cone penetration number from 355 to 385
  • those having a cone penetration range of 310 to 340 are designated grade one and the most widely sold greases have a cone penetration range of 265 to 295 and are designated grade two.
  • U.S. Pat. No. 6,919,301 discloses a grease composition with a thickener of a calcium sulfonate complex and a second thickener component in a base oil.
  • a grease composition of a second thickener is a thickener component of polyurea and a complex metallic soap.
  • a calcium sulfate complex used as a thickener in the invention comprises calcium sulfonate as an essential component, and also comprises a calcium salt (acalcium soap) selected from a group of (a) calcium carbonate, (b) a higher fatty acid calcium salt such as calcium dibehenate, calcium distearate and calcium dihydroxystearate, (c) a lower fatty acid calcium salt such as calcium acetate, and (d) calcium borate.
  • the polyurea used as a second thickener is a diurea.
  • a calcium sulfonate complex in U.S. Pat. No. 6,919,301 was synthesized in a base oil as follows. Overbased calcium sulfonate, having a high base number, was added to dialkyl diphenyl ether, and then the mixture was fully stirred at 50°C. Boric acid, acetic acid, behenic acid, stearic acid, water and calcium hydroxide were added thereto, and water was evaporated and removed by heating the mixture up to 80 to 95°C. Carbon dioxide was then introduced into this mixture to generate calcium carbonate.
  • the obtained mixture was analyzed with an infrared spectrometer, and when the stabilization of calcium carbonate was confirmed at a peak of 882 to 886 cm -1 , the introduction of carbon dioxide was terminated. Further, diurea was synthesized in a base oil.
  • the mixture, obtained by the above operations, was cooled to 60°C, and 4, 4 ‘-diphenylmethane diisocyanate was added to the mixture and completely dissolved. Thereafter, cyclohexylamine and dialkyl diphenyl ether were added thereto and stirred. After, the mixture was retained at 100°C for 60 minutes, then the mixture was heated up to 150°C and the generation reaction of diurea was terminated. Thereafter, amine antioxidant and sulfonate anticorrosive were added to the mixture, and milling and degassing processes were carried out to obtain a grease composition.
  • the invention disclosed in U.S. Pat. No. 6,919,301 relates to a grease composition having excellent heat resistance, water resistance, lubricating life, oxidation stability, and biodegradability.
  • the invention relates to a rolling apparatus which is preferably used in cars, rolling stocks, electric motors, iron manufacturing machines and others.
  • the thickener comprises 25 to 75%by mass of polyurea and 75 to 25%by mass of the complex metallic soap.
  • High polyurea content in this invention is hard to ensure excellent load carrying capacity, high temperature performance, and excellent mechanical stability of the prepared grease without the addition of proper additives.
  • U.S. Pat. No. 4,560,489 discloses a calcium borate modified overbased calcium sulfonate complex grease broadly defined as a combination of (1) an overbased calcium sulfonate in an oil, particularly a mineral oil, containing finely divided particles of calcium carbonate in the form of calcite; (2) a product formed by the reaction of boric acid with a calcium compound (e.g., calcium hydroxide or calcium carbonate) , presumably calcium borate or calcium borate intermingled or in some kind of complex in the grease or grease composition as a whole; and (3) a product formed from calcium hydroxide/calcium carbonate and a soap-forming aliphatic monocarboxylic or fatty acid, preferably a soap-forming hydroxy-fatty acid, such as 12-hydroxystearic acid.
  • a calcium compound e.g., calcium hydroxide or calcium carbonate
  • a soap-forming aliphatic monocarboxylic or fatty acid preferably a soap-forming hydroxy-fatty acid,
  • the greases of U.S. Pat. No. 4,560,489 have excellent properties, but the grease must contain about 40 to 45%by weight overbased calcium sulfonate to obtain a worked cone penetration of 265 to 295. If the content of overbased calcium sulfonate is 38%by weight or less, a relatively soft, generally undesired grease is obtained.
  • U.S. Pat. No. 5,308,514 discloses high performance overbased calcium sulfonate complex greases comprising overbased calcium sulfonate, solid particles of colloidally dispersed calcium carbonate in the form of calcite, calcium borate, and a calcium soap of a fatty acid of 12 to 24 carbon atoms, dispersed in an oleaginous medium, similar to the grease components of U.S. Pat. No. 4,560,489, but the concentrations of overbased calcium sulfonate for each grade of the grease are lower.
  • U.S. Pat. No. 6,037,314 discloses a polyurea grease composition for constant velocity joints comprising (a) a base oil and (b) a urea thickener, and certain additives needed to improve performance, i.e., (c) at least one organic molybdenum compound, (d) at least one calcium salt selected from the group consisting of calcium salts of petroleum sulfonates, calcium salts of alkyl aryl sulfonates, calcium salts of salicylate, calcium salts of phenates, calcium salts of oxidized waxes, overbasic calcium salts of petroleum sulfonates, overbasic calcium salts of alkyl aryl sulfonates, overbasic calcium salts of salicylate, overbasic calcium salts of phenates, and overbasic calcium salts of oxidized waxes; and (e) a thiophosphate.
  • These polyurea greases need additional additives to meet the lubricating application for
  • U.S. Pat. No. 4,902,435 discloses greases with a hybrid thickener system, which uses both polyurea and calcium soap thickeners, and an additive package containing tricalcium phosphate and calcium carbonate to improve performance.
  • the calcium soap thickeners used therein are simple calcium soaps or calcium complex soaps, but these are not the calcium sulfonate complex soaps of U.S. Pat. Nos. 5,308,514 and 4,560,489 that are prepared from overbased calcium sulfonate wherein the amorphous calcium carbonate is converted into calcite form.
  • Overbased calcium sulfonate is mentioned in U.S. Pat. No. 4,902,435 as a possible source of the calcium carbonate portion of the additive package. Similar greases are disclosed in U.S. Pat. No. 5,084,193.
  • Overbased calcium sulfate complex greases have excellent properties, but the ash content due to the amount of calcium sulfonate, calcium soaps and other materials required is too high for many applications. Polyurea greases having a much lower ash content and many good performance characteristics are known, but tend to show poor mechanical stability.
  • the high performance, thixotropic polyurea/overbased calcium sulfonate complex hybrid greases of the invention comprise the following components (a) to (d) : (a) a base oil, (b) a thickener, (c) an organic molybdenum compound, and (d) an antioxidant.
  • the high performance, thixotropic polyurea/overbased calcium sulfonate complex hybrid greases of the invention comprise, in addition to the polyurea/overbased calcium sulfonate complex thickener, solid, finely divided particles of colloidally dispersed calcium carbonate in the form of calcite, calcium borate or complex of calcium borate, and a calcium soap of a fatty acid of 12 to 24 carbon atoms, preferably a soap of a hydroxy fatty acid, evenly dispersed in an oleaginous medium, e.g., one or more non-volatile oils, such as a mixture of mineral and synthetic oils, a mineral oil, a synthetic oil, or other lubricating oil, wherein the greases contain less than 22%by weight, typically 20%by weight or less, of overbased calcium sulfonate.
  • a non-volatile oils such as a mixture of mineral and synthetic oils, a mineral oil, a synthetic oil, or other lubricating oil
  • the grease has a worked cone penetration rating of 295 or less.
  • the present greases contain less borate salts and calcium soaps than overbased calcium sulfonate complex hybrid greases in the art, due to replacing a portion of the overbased calcium sulfonate with the polyurea thickener, thus further lowering the ash content.
  • the present greases also have outstanding wear resistance, load bearing capacity, low/high temperature properties, and excellent grease leakage preventing performance.
  • the invention provides a grade 2 grease, i.e., a grease having a worked cone penetration rating 265-295, comprising less than 22 wt%overbased calcium sulfonate and at least 70%by weight oil, and typically at least 75%or 80%by weight, of a non-volatile oil.
  • a grade 2 grease i.e., a grease having a worked cone penetration rating 265-295, comprising less than 22 wt%overbased calcium sulfonate and at least 70%by weight oil, and typically at least 75%or 80%by weight, of a non-volatile oil.
  • one process comprises a step wherein a mixture of overbased calcium sulfonate comprising amorphous calcium carbonate, water, a converting agent at least a portion of which comprises a fatty acid, preferably a hydroxy fatty acid, of 12 to 24 carbon atoms capable of forming a calcium soap, alkylbenzene sulfonic acid and boric acid in an oleaginous medium is heated to convert the amorphous calcium carbonate to calcite in a manner similar to that of U.S. Pat. No.
  • the high performance, thixotropic, polyurea/overbased calcium sulfonate complex hybrid greases of the invention comprise:
  • 70 wt%or more e.g., 70 to 90 wt%or 70 to 85 wt%, oleaginous medium in which there is homogeneously dispersed:
  • overbased calcium sulfonate complex thickener comprising fine particles of calcium carbonate in calcite form
  • the grease of the invention comprises:
  • overbased calcium sulfonate complex thickener comprising fine particles of calcium carbonate in calcite form
  • At least a portion of the calcium soap of C 12-24 aliphatic fatty acids is formed in situ during conversion of the calcium carbonate to calcite, and preferably all of the calcium soap of C 12-24 aliphatic fatty acids are formed in situ during the processing of the overbased calcium sulfonate during preparation of the grease. More than one type of calcium soap may be present, i.e., calcium soaps of different fatty acids may be present.
  • the calcium soaps of C 12-24 aliphatic fatty acids comprise calcium soaps of hydroxy C 12 -C 24 fatty acids, in particular 12-hydroxystearic acid. It is also more preferred that the calcium borate species is formed in situ during the processing of the overbased calcium sulfonate during preparation of the grease.
  • the grease may also comprise calcium salts of short chain organic acids having from one to seven carbon atoms.
  • Various common supplemental ingredients e.g., antioxidants phenyl alpha naphthylamine and other additives, are often incorporated into the greases of the invention at commonly used levels.
  • the grease is prepared according to a general process wherein 1) an overbased calcium sulfonate comprising amorphous calcium carbonate starting material in an oleaginous medium, e.g., base oil, is heated in the presence of water, a conversion agent comprising a C 12-24 fatty acid such as 12-hydroxylstearic acid and typically other compounds useful in converting amorphous calcium carbonate to calcite calcium carbonate, such as alcohols, lower aliphatic carboxylic acids, ketones, etc., to convert the calcium carbonate crystal form; 2) calcium salts of boric acid and C 12-24 fatty acids are formed; and 3) an isocyanate compound and one or more amine containing compounds are converted into a polyurea.
  • all of the calcium borates and the calcium soap of C 12-24 aliphatic fatty acids are formed in situ during preparation of the grease starting from an overbased calcium sulfonate starting material.
  • the mixture heated during calcite formation also comprises mono-and/or di-alkyl benzene sulfonic acid in which the alkyl groups contain 12 to 40 carbon atoms, and often the mixture of also comprises boric acid.
  • additional C 12-24 fatty acids are added, optionally with boric acid and water, after the calcite has been formed, in which case the resulting mixture is heated to effect conversion of the added materials to calcium salts of boric acid and calcium soaps of C 12-24 fatty acids.
  • the boric acid and/or C 12-24 fatty acids used in the process it is often convenient to introduce all of the boric acid and/or C 12-24 fatty acids used in the process to the mixture subjected to calcite formation. Where all the boric acid and C 12-24 fatty acids are present during calcite formation step, there is no need for an additional step to prepare the calcium borate and calcium salts, and the product of 1) and 2) above are formed during a single procedure.
  • the polyurea is formed after the formation of the products of 1) and 2) . Additional components, e.g., additional base oil or additives, may be added and other process steps, e.g., kneading or milling the final grease, may be used.
  • the overbased calcium sulfonates useful in the preparation of the grease of the invention can be prepared by any technique employed in the art. Typically, these materials can be prepared by heating neutral calcium sulfonate or sulfonic acid, oleaginous medium, i.e., a base oil often comprising a mineral oil, hydrated lime and a carbonation promoter, such as methanol, to the carbonation temperature, and adding sufficient carbon dioxide to produce an overbased sulfonate having the desired TBN as described in U.S. Pat. No. 4,560,489. A molar ratio of 0.55-0.6 CO 2 /Ca (OH) 2 produces an excellent starting material for the production of the greases of the present invention.
  • oleaginous medium i.e., a base oil often comprising a mineral oil, hydrated lime and a carbonation promoter, such as methanol
  • the overbased calcium sulfonate can have a metal ratio of about 6 to 40, e.g., 10 to 36.
  • the base oils are, generally speaking, oils obtained by well-known refining procedures from mineral oils or can be derived from mineral oils.
  • the mineral base oils can be of natural or synthetic character, the proportions of calcium sulfonates in the mineral oil can be variable, e.g., 15 to 45 %.
  • a semi-crude, unfiltered mineral oil composition containing about 10 to 20%naphtha and varying proportions of mineral oil and neutral calcium sulfonate is readily usable as a charge stock.
  • Suitable sulfonic acids useful in the production of the calcium sulfonates are oil-soluble and can be produced by sulfonating a linear or branched chain alkyl benzene, such as a mixture of mono-and di-alkyl benzenes in which the alkyl group contains largely from 12 to 40 carbon atoms, generally mixtures of such alkyl groups.
  • the sulfonic acids are conventionally converted to calcium sulfonates by reaction with calcium hydroxide.
  • the oleaginous medium content of the finished grease includes the total amount of all non-volatile oil present, that is, the oil introduced as part of the original overbased calcium sulfonate composition plus the base oil.
  • Any base oil useful in the art may be used and more than one lubricating oil may be used.
  • useful base oils include mineral oil, naphthenic oil, paraffinic oil, aromatic oil, or a synthetic oil such as a polyalphaolefin (PAO) , silicon oils, a fluoronated or polyfluoronated derivative of any of these preceding fluids, or combinations thereof.
  • the base oil may be a mixture of mineral oil and synthetic oil.
  • refined solvent-extracted hydrogenated dewaxed base oil and combinations of such base oils are often used.
  • the viscosity of the base oil can range from 50 to 10,000 SUS at 100°F, e.g., 200 to 2,000 SUS or 300 to 1500 SUS at 100°F.
  • the polyurea thickeners of the present invention include diureas and higher oligomeric ureas. Diurea thickeners are preferred. Diurea compounds include those obtained through a reaction of one or more monoamine with a diisocyanate compound or one or more diamine with a mono-isocyanate compound, generally diureas prepared from a diisocyanate are preferred.
  • diisocyanates include phenylene diisocyanate, diphenyl diisocyanate, tolylenediisocyanate, diphenylmethane diisocyanate, octadecane diisocyanate, decane diisocyanate, and hexane diisocyanate.
  • mono-isocyanates include hexylisocyanate, decylisocyanate, dodecylisocyante, tetradecylisocyanate, hexadecylisocyanate, phenylisocyanate, cyclohexylisocyanate and xyleneisocyanate.
  • monoamines include pentylamine, hexylamine, cyclohexylamine, heptylamine, octylamine, decylamine, dodecylamine, tetradecylamine, hexadecylamine, octadecylamine, eicosylamine, dodecenylamine, hexadecenylamine, octadecenylamine, octadeccadienylamine, isomers thereof, aniline, substituted anilines, toluidine, naphthylamine, substituted naphthylamines, benzylamine and substituted benzylamines.
  • Higher oligomeric urea compounds include those obtained through a reaction of a diamine or triamine with a polyisocyante, typically a diisocyanate compound.
  • diamines include ethylenediamine, propanediamine, butanediamine, hexanediamine, octanediamine, dodecanediamine, hexadecanediamine, cyclohexanediamine, cyclooctanediamine, phenylenediamine, tolylenediamine, xylylenediamine, dianiline methane, and ditoluidinemethane;
  • representative triamines include aminoethyl piperazine, diethylene triamine, dipropylene triamine and N-methyldiethylene triamine.
  • urea thickeners examples include those obtained through a reaction of aliphatic amine such as octylamine, stearylamine, cyclohexyl amine, and often a mixture thereof, with a diisocyanate, such as diphenylmethane diisocyanate.
  • Calcium-soap-forming fatty acids of 12 to 24 carbon atoms useful in the invention include dodecanoic acid, palmitic acid, stearic acid, oleic acid, ricinoleic acid, 12-hydroxystearic acid.
  • the hydroxy fatty acids, particularly hydroxystearic acid, are preferred since they provide greater thickening to the greases than the unsubstituted fatty acids.
  • Conversion agents in addition to the calcium-soap-forming C12-24 fatty acids and boric acid, useful in the formation of calcite include (among many others) : water; alcohols, lower aliphatic carboxylic acids, ketones; aldehydes; amines; phosphorus acids; alkyl and aromatic amines; certain imidazoilines; alkanolamines; other boron acids including tetraboric acid; metaboric acid; and esters of such boron acids; and, also, carbon dioxide as such or in combination with water.
  • Suitable salt-forming acids may also be used in preparation of the greases of the present invention, including inorganic acids, such as sulfonic acid, hydrochloric acid, orthophosphoric acids, pyrophosphoric acid, sulfurous acid, boric acid; and organic acids of 1 to 7 carbon atoms, such as formic acid, acetic acid, propionic acid, valeric acid, oxalic acid, malonic acid, succinic acid and benzene sulfonic acid.
  • inorganic acids such as sulfonic acid, hydrochloric acid, orthophosphoric acids, pyrophosphoric acid, sulfurous acid, boric acid
  • organic acids of 1 to 7 carbon atoms such as formic acid, acetic acid, propionic acid, valeric acid, oxalic acid, malonic acid, succinic acid and benzene sulfonic acid.
  • Boric acid and boric acid formers are preferred since they provide the best grease properties.
  • a polyurea/overbased calcium sulfonate complex grease is prepared according to a procedure comprising 1) mixing an overbased calcium sulfonate, a base oil, a C 12-24 fatty acid such as 12-hydroxylstearic acid, water, detergent dodecylbenzene sulfonic acid, boric acid and a carboxylic acid having from 1 to 7 carbon atoms, such as acetic acid in a sealed high pressure reactor while heating, e.g., at temperatures of above 250 °F, e.g., between 270 and 300°F, and elevated pressures, e.g., 20-25 psi; 2) venting the reactor with heating to remove water and volatiles; 3) adding additional base oil, diisocyanate and one or more amines, heating to effect reaction and removal of volatiles; and 4) adjusting the final properties of the grease by adding additional base oil and/or additives, followed by any additional processing steps.
  • a procedure comprising 1) mixing an overbased calcium sulfon
  • a grade 2 grease comprising less than 22 wt%overbased calcium sulfonate can be formed by the following procedure:
  • overbased calcium sulfonate 400TBN
  • overbased calcium sulfonate 400TBN
  • detergent dodecylbenzene sulfonic acid 0.5 to 5 parts, e.g., 1 to 3.5 parts 12-hydroxy stearic acid
  • 1 to 7 parts e.g., 2.5 to 5 parts water
  • 0.05 to 3.5 parts e.g., 0.1 to 3 parts, boric acid.
  • calcite is monitored by the appearance of calcite peaks in the IR at 880 and 705 cm -1 .
  • additional mixed oil is generally added.
  • the mixed oil is base oil that is a mixture of mineral oil and synthetic oil.
  • the grease of the present invention may be prepared by a process similar to the above process except that after calcite formation and before addition of the polyurea forming components, additional hydroxy stearic acid and optionally lime are added and mixed at temperatures of about 280°F. Additional boric acid and/or water may also be added during this alternative step. In a less preferred process, the conversion to calcite is run without boric acid and all the boric acid used in the grease is added during this alternative step.
  • lime or Ca (OH) 2 may be added to the reaction mixture at any stage prior to polyurea formation, but in many cases this is not done. Often after carbonation of the starting overbased calcium sulfonate, or after the conversion of amorphous calcium carbonate to calcite, free dispersed lime or calcium hydroxide may be present.
  • the greases of the invention are characterized by good extreme pressure and anti-wear properties, high dropping points, good mechanical stability, salt spray and water resistance, thermal stability at high temperature and other desirable properties, even without additives.
  • the greases of the present invention have much lower ash content, making them useful in a wider range of applications, than available calcium sulfonate greases, including high speed applications in automobile and other industries, where lower ash content grease products are desired.
  • the greases of the present invention are well suited for general use as a lubricant between contacting metals and/or elastomeric plastics. They are multi-purpose greases which equal and, in many cases, outperform other high temperature greases such as polyurea greases and are especially effective in environments with high load situations. A limited selection of possible uses includes CV joints, front-wheel drive joints, universal joints and bearings which are subjected to heavy shock loads, fretting, and oscillating motions and high temperatures such as in steel mills.
  • the greases of the present invention have outstanding wear resistance, load bearing capacity, low/high temperature properties, and excellent grease leakage preventing performance. Furthermore, the greases of the present invention are conveniently prepared from non-toxic and low-cost materials.
  • Example A1 The procedure of Example A1 was repeated except that the amount of 4, 4-diphenylmethane diisocyanate, cyclohexanamine and octodecylamine added was increased 1.2 times respectively and additional oil was added to adjust the final grease thickness, yielding a grade 2 grease thickness containing 17.5%starting overbased calcium sulfonate.
  • Example A1 The procedure of Example A1 was repeated except that the base oil was completely mineral oil instead of semi-synthetic oil (for example, a mixture of mineral oil and synthetic oil) , yielding a grade 2 grease containing 19.7%starting overbased calcium sulfonate.
  • semi-synthetic oil for example, a mixture of mineral oil and synthetic oil
  • Example A1 The procedure of Example A1 was repeated except that the base oil was completely mineral oil, the amount of 4, 4-diphenylmethane diisocyanate, cyclohexanamine and octodecylamine added was increased 1.2 times respectively, and additional oil was added to adjust the final grease thickness, yielding a grade 2 grease thickness containing 17.1%starting overbased calcium sulfonate.
  • a commercial polyurea grease for the application of CVJ was used to a comparative example.
  • a commercial molybdenum disulfide lithium grease for the lubrication of CVJ was also used to another comparative example.
  • Examples A1 and A2 have similar performance. Both Examples A1 and A2 include a base oil that is a semi-synthetic oil, which is a mixture of mineral oil and synthetic oil.
  • Example A2 was prepared in higher yield of grease and had lower concentrations of overbased calcium sulfonate (and lower ash content) to improve mobility when compared to the concentrations of overbased calcium sulfonate in Example A1. The same trend also appeared in Examples A3 and A4.
  • Example A4 was prepared in higher yield of grease and had lower concentrations of overbased calcium sulfonate (and lower ash content) to improve mobility when compared to the concentrations of overbased calcium sulfonate in Example A3.
  • the trend is lower concentration of overbased calcium sulfonate when increased the polyurea content as showed in Examples A1, A2 and Examples A3, A4.
  • Examples A1 and A2 which included a mixture of mineral oil and synthetic oil as the base oil, have more excellent low temperature property than Examples A3 and A4, which included mineral oil as the base oil.
  • Examples A1 to A4 Compared with the pure calcium sulfonate grease of Comparative Example B1, Examples A1 to A4 have lower calcium sulfonate thickener content, lower wheel bearing leakage and higher weld load.
  • the greases of Examples A1 to A4 are more suitable for the application of constant velocity joints in automobiles.
  • the greases of Examples A1 to A4 show better mechanical stability, friction and wear performance, low temperature and extreme pressure properties than the polyurea grease of Comparative Example B2.
  • the greases of Examples A1 to A4 are shown to have better mechanical stability, friction and wear performance, extreme pressure and high temperature properties.
  • the prepared polyurea/calcium sulfonate complex grease decreased the thickener content compared with pure calcium sulfonate grease.
  • the prepared polyurea/calcium sulfonate complex grease shows more excellent properties than main CVJ greases available on the market and provides a suitable option for the lubrication of CVJ in automobiles.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Lubricants (AREA)

Abstract

La présente demande concerne une composition de graisse à base de complexe polyurée/sulfonate de calcium destinée à être utilisée dans des joints homocinétiques. L'invention concerne une graisse lubrifiante ayant une thixotropie et son procédé de préparation. La graisse lubrifiante comprend un épaississant composite de sulfonate de calcium à indice de base élevé/polyurée, des particules solides de carbonate de calcium dispersées de manière colloïdale sous la forme de calcite, un borate de calcium ou un composite de borate de calcium et un savon de calcium d'acide gras ayant de 12 à 24 atomes de carbone, un composé organique de molybdène et un antioxydant. Les composants ci-dessus sont dispersés uniformément dans un milieu en phase huileuse. La teneur en sulfonate de calcium à indice de base élevé dans la graisse lubrifiante est inférieure à 22 % en poids.
PCT/CN2022/141050 2021-12-31 2022-12-22 Composition de graisse à base de complexe polyurée/sulfonate de calcium destinée à être utilisée dans des joints homocinétiques WO2023125235A1 (fr)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1168916A (zh) * 1996-06-05 1997-12-31 协同油脂株式会社 用于等速万向节的润滑脂组合物
JPH11131086A (ja) * 1997-10-28 1999-05-18 Nippon Koyu:Kk 潤滑グリ−ス組成物
JPH11172276A (ja) * 1997-12-10 1999-06-29 Kyodo Yushi Co Ltd 等速ジョイント用グリース組成物
JP2010090243A (ja) * 2008-10-07 2010-04-22 Kyodo Yushi Co Ltd 等速ジョイント用グリース組成物及び等速ジョイント
CN103965996A (zh) * 2014-04-18 2014-08-06 杭州新港石油化工有限公司 一种强吸附脲基润滑脂及其制备方法
US20200109345A1 (en) * 2017-04-19 2020-04-09 Chemtura Chemicals (Nanjing) Company Limited Lubricating grease of polyurea/high base number calcium sulfonate composite

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1168916A (zh) * 1996-06-05 1997-12-31 协同油脂株式会社 用于等速万向节的润滑脂组合物
JPH11131086A (ja) * 1997-10-28 1999-05-18 Nippon Koyu:Kk 潤滑グリ−ス組成物
JPH11172276A (ja) * 1997-12-10 1999-06-29 Kyodo Yushi Co Ltd 等速ジョイント用グリース組成物
JP2010090243A (ja) * 2008-10-07 2010-04-22 Kyodo Yushi Co Ltd 等速ジョイント用グリース組成物及び等速ジョイント
CN103965996A (zh) * 2014-04-18 2014-08-06 杭州新港石油化工有限公司 一种强吸附脲基润滑脂及其制备方法
US20200109345A1 (en) * 2017-04-19 2020-04-09 Chemtura Chemicals (Nanjing) Company Limited Lubricating grease of polyurea/high base number calcium sulfonate composite

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