EP0225580A2 — Metal-containing lubricant compositions

Claim 1

Independent Claim 109 words

A lubricating oil composition comprising: a) a major amount of a lubricating oil; b) from 1 to 10 (wt)% of an ashless dispersant compound; or c) from 0.3 to 10 (wt)% of a nitrogen or ester containing polymeric viscosity index improver dispersant; or d) mixtures of (b) and (c); e) from 0.01 to 10.0 parts by weight per 100 parts of said lubricating oil composition of zinc dialkyldithiophosphate and characterized in that the lubricant oil composition further contains from 0.1 to 5.0 (wt)% of a dispersant/detergent, antioxidant, and corrosion inhibitor comprising an overbased copper metal sulfonate, phenate and/or salicylate, wherein the metal is selected from magnesium, calcium or sodium.

Claim 2

Dependent Claim 109 words

A lubricating oil composition comprising: a) a major amount of a lubricating oil; b) from 1 to 10 (wt)% of an ashless dispersant compound; or c) from 0.3 to 10 (wt)% of a nitrogen or ester containing polymeric viscosity index improver dispersant; or d) mixtures of (b) and (c); e) from 0.01 to 10.0 parts by weight per 100 parts of said lubricating oil composition of zinc dialkyldithiophosphate and characterized in that the lubricant oil composition further contains from 0.1 to 5.0 (wt)% of a dispersant/detergent, antioxidant, and corrosion inhibitor comprising an overbased copper metal sulfonate, phenate and/or salicylate, wherein the metal is selected from magnesium, calcium or sodium.

Claim 3

Dependent Claim 259 words

The composition of Claim 1 wherein said ashless dispersant is a nitrogen or ester containing dispersant compound selected from the group consisting of: (i) oil soluble salts, amides, imides, oxazolines and esters, or mixtures thereof, of long chain hydrocarbon substituted mono- and di-carboxylic acids or their anhydrides; (ii) long chain aliphatic hydrocarbon having a polyamine attached directly thereto; and (iii) Mannich condensation products formed by condensing about a molar proportion of long chain hydrocarbon-substituted phenol with about 1 to 2.5 moles of formaldehyde and about 0.5 to 2 moles of polyalkylene polyamine; wherein said long chain hydrocarbon group is: A) a polymer of a C 2 to C 5 mono- olefin, said polymer having a molecular weight of about 700 to about 5000; or B) from 0.3 to 10 (wt)% of a nitrogen or ester-containing polymeric viscosity index improver dispersant which includes: (1) polymers comprised of C 4 to C 24 unsaturated esters of vinyl alcohol or C 3 to C 10 unsaturated mono- or di-carboxylic acid with unsaturated nitrogen-containing monomers having 4 to 20 carbons; 2) polymers of C 2 to C 20 olefin with unsaturated C3 to C 10 mono- or di-carboxylic acid neutralized with amine, hydroxy amine, or alcohols; and 3) polymers of ethylene with a C 3 to C 20 olefin further reacted either by grafting C 4 to C 20 unsaturated nitrogen-containing monomers thereon, or by grafting an unsaturated acid onto the polymer backbone and then reacting said carboxylic acid groups with amine, hydroxy amine, or alcohol; or (C) mixtures of (A) and (B).

Claim 4

Dependent Claim 34 words

The composition of Claim 1 wherein said ashless dispersant is an alkenyl succinic acid or anhydride of an ester of alkenyl succinic acid or anhydride derived from monohydric or polyhydric alcohols, phenols, or naphthols.

Claim 5

Dependent Claim 28 words

The composition of Claim 1 wherein said ashless dispersant comprises the reaction product of polyisobutenyl succinic anhydride with an amine selected from the group consisting of polyethylene amines.

Claim 6

Dependent Claim 22 words

The composition of Claim 4 wherein said reaction product of polyisobutenyl succinic anhydride with an amine is borated with a boron compound.

Claim 7

Dependent Claim 35 words

The composition of Claims 1 to 4 wherein said composition contains an overbased alkyl phenate or overbased sulfurized alkyl phenate selected from the group of magnesium phenates, calcium phenates, and sodium phenates or mixtures thereof.

Claim 8

Dependent Claim 28 words

The composition of Claims 1 to 6 wherein said composition contains an overbased salicylate selected from the group of magnesium'salicylate, calcium salicylate, and sodium salicylate or mixtures thereof.

Claim 9

Dependent Claim 30 words

The composition of Claims 1 to 7 wherein said composition contains an overbased sulfonate selected from the group consisting of magnesium sulfonates, calcium sulfonates, and sodium sulfonates or mixtures thereof.

Claim 10

Dependent Claim 40 words

The composition of Claims 1 to 8 wherein said zinc dialkyldithiophosphate is selected from the group consisting of compounds prepared from secondary alcohols, primary alcohols, phenols, alkylphenols, mixtures of alkylphenols, and mixtures of secondary alcohols, primary alcohols, phenols, and alkylphenols.

Claim 11

Dependent Claim 58 words

The composition of Claims 1 to 9 wherein said composition contains supplemental antioxidants selected from the group consisting of hindered phenols, aryl amines, sulfurized unsaturated esters, sulfurized carboxylate salts, and oil-soluble-metal compounds selected from the group of oil-soluble salts of carboxylic acids of from 3 to 20 carbon atoms wherein said metal is copper, molybdenum, cobalt, or nickel.

Claim 12

Dependent Claim 31 words

The composition of Claims 1 to 10 wherein said copper-containing material is present as a copper magnesium sulfonate in Said composition within the range of from 0.1 (wt)% to 2.5 (wt)%.

Claim 13

Dependent Claim 31 words

The composition of Claims 1 to 10 wherein said copper-containing material is present as a copper calcium sulfonate in said composition within tne range of from 0.3 (wt)% to 2.5 (wt)%.

Claim 14

Dependent Claim 31 words

The composition of Claims 1 to 10 wherein said copper-containing material is present as a copper calcium phenate in said composition within the range of from 0.1 (wt)% to 2.5 (wt)%.

Claim 15

Dependent Claim 31 words

The composition of Claims 1 to 10 wherein said copper-containing material is present as a copper sodium sulfonate in said composition within the range of from 0.3 (wt)% to 2.5 (wt)%.

Claim 16

Dependent Claim 78 words

A concentrate of a lubricating oil composition wherein said concentrate comprises a) from 5 to 65 (wt)% of an ashless dispersant; or b) from 2 to 20 (wt)% of a nitrogen- or ester-containing polymeric viscosity index improver dispersant; c) or mixtures of a) and b); d) from 2 to 25 parts by weight of a zinc dialkyldithiophosphate and from 5 to 25 (wt)% of a dispersant/detergent, antioxidant, and corrosion inhibitor comprising an overbased copper phenate, sulfonate, or salicylate.

Claim 17

Dependent Claim 78 words

A concentrate of a lubricating oil composition wherein said concentrate comprises a) from 5 to 65 (wt)% of an ashless dispersant; or b) from 2 to 20 (wt)% of a nitrogen- or ester-containing polymeric viscosity index improver dispersant; c) or mixtures of a) and b); d) from 2 to 25 parts by weight of a zinc dialkyldithiophosphate and from 5 to 25 (wt)% of a dispersant/detergent, antioxidant, and corrosion inhibitor comprising an overbased copper phenate, sulfonate, or salicylate.

Claim 18

Dependent Claim 253 words

The concentrate of Claim 15 wherein said ashless dispersant is a nitrogen- or ester-containing dispersant compound selected from the group consisting of: (i) oil-soluble salts, amides, and esters, or mixtures thereof, of long chain hydrocarbon-substituted mono- and di-carboxylic acids or their anhydrides; (ii) long chain aliphatic hydrocarbon having a polyamine attached directly thereto; and (iii) Mannich condensation products formed by condensing about a molar proportion of long chain hydrocarbon-substituted phenol with about 1 to 2.5 moles of formaldehyde and about 0.5 to 2 moles of polyalkylene polyamine; wherein said long chain hydrocarbon group is: A) a polymer of a C 2 to C 5 monoolefin, said polymer having a molecular weight of about 700 to about 5000; or B). from 0.3 to 10 (wt)% of a nitrogen- or ester-containing polymeric viscosity index improver dispersant which includes: (1) polymers comprised of C 4 to C 24 unsaturated esters of vinyl alcohol or C 3 to C 10 unsaturated mono- or di-carboxylic acid with unsaturated nitrogen-containing monomers having 4 to 20 carbons; 2) polymers of C 2 to C 20 olefin with unsaturated C 3 to C 10 mono- or di-carboxylic acid neutralized with amine, hydroxy amine, or alcohols; 3) polymers of ethylene with a C 3 to C 20 olefin further reacted either by grafting C 4 to C 20 unsaturated nitrogen-containing monomers thereon or by grafting an unsaturated acid onto the polymer backbone and then reacting said carboxylic acid groups with amine, hydroxy amine or alcohol; or C) mixtures of A) and B).

Claim 19

Dependent Claim 34 words

The concentrate of Claim 15 wherein said ashless dispersant is an alkenyl succinic acid or anhydride or an ester of alkenyl succinic acid or anhydride derived from monohydric or polyhydric alcohols, phenols, or naphthols.

Claim 20

Dependent Claim 27 words

The concentrate of Claim 15 wherein said ashless dispersant comprises the reaction product of polyisobutenyl succinic anhydride with an amine selected from the group consisting of polyethyleneamines.

Claim 21

Dependent Claim 22 words

The concentrate of Claim 18 wherein said reaction product of polyisobutenyl succinic anhydride with an amine is borated with a boron compound.

Claim 22

Dependent Claim 34 words

The concentrate of Claims 15 to 19 wherein said concentrate contains an overbased phenate or overbased alkylphenol sulfide selected from the group consisting of magnesium phenates, calcium phenates, and sodium phenates or mixtures thereof.

Claim 23

Dependent Claim 28 words

The concentrate of Claims 15 to 20 wherein said con centrate contains an overbased salicylate selected from the group consisting of magnesium salicylates, calcium salicylates, or sodium salicylates.

Claim 24

Dependent Claim 28 words

The concentrate of Claims 15 to 20 wherein said con centrate contains an overbased sulfonate selected from the group consisting of magnesium sulfonates, calcium sulfonates, and sodium sulfonates.

Claim 25

Dependent Claim 40 words

The concentrate of Claims 15 to 22 wherein said zin dialkyldithiophosphate is selected from the group consisting of compounds prepared from secondary alcohols, primary alcohols, phenols, alkylphenols, mixtures of alkylphenols, and mixtures of secondary alcohols, primary alcohols, phenols, and alkylphenols.

Claim 26

Dependent Claim 60 words

The concentrate of Claims 15 to 23 wherein said cor centrate contains supplemental antioxidants selected from the group consisting of hindered phenols, aryl amines, sulfurized unsaturated esters, sulfurized carboxylate salts, and oil-soluble metal compounds selected from the group of oil-soluble salts of carboxylic acids of from three to 20 carbon atoms wherein said metal is copper, molybdenum, cobalt, or nickel.

Claim 27

Dependent Claim 28 words

The concentrate of Claims 15 to 24 wherein said co F overbased sulfonate is present in said composition within the range of from 5 (wt)% to 25 (wt)%.

Claim 28

Dependent Claim 27 words

The concentrate of Claims 15 to 24 wherein said cop overbased phenate is present in said composition within the range of from 5 (wt)% to 25 (wt)%.

Claim 29

Dependent Claim 30 words

27 . The concentrate of Claims 15 to 24 wherein said cO f overbased salicylate is present in said composition within the range of from 5 (wt)% to 25 (wt)%.

Claim 30

Dependent Claim 177 words

A process for preparing a copper overbased metal-containing composition which comprises: a) mixing at ambient temperature to about reflux temperature of said mixture a mixture of (1) from about 0.1 to about 15 parts by weight of an oil-insoluble neutral acid copper salt, (2) from 25 to 200 parts by weight of an overbased metal-containing compound selected from the group consisting of alkali metal and alkaline earth metal sulfonates, phenates, and salicylates, (3) from 25 to 200 parts by weight of an alcohol of from 1 to 10 carbon atoms, and (4) from 25 to 200 parts by weight of a hydrocarbon solvent of from 6 to 18 carbon atoms; b) mixing and heating said mixture at a temperature of from about 25°C to about reflux temperature of said mixture for a period of up to 4 hours; c) removing said alcohol and said solvent from said mixture by distillation at a temperature of up to said reflux temperature under conditions of ambient pressure or of vacuum; d) clarifying the bottom product by filtration or by centrifugation.

Claim 31

Dependent Claim 177 words

A process for preparing a copper overbased metal-containing composition which comprises: a) mixing at ambient temperature to about reflux temperature of said mixture a mixture of (1) from about 0.1 to about 15 parts by weight of an oil-insoluble neutral acid copper salt, (2) from 25 to 200 parts by weight of an overbased metal-containing compound selected from the group consisting of alkali metal and alkaline earth metal sulfonates, phenates, and salicylates, (3) from 25 to 200 parts by weight of an alcohol of from 1 to 10 carbon atoms, and (4) from 25 to 200 parts by weight of a hydrocarbon solvent of from 6 to 18 carbon atoms; b) mixing and heating said mixture at a temperature of from about 25°C to about reflux temperature of said mixture for a period of up to 4 hours; c) removing said alcohol and said solvent from said mixture by distillation at a temperature of up to said reflux temperature under conditions of ambient pressure or of vacuum; d) clarifying the bottom product by filtration or by centrifugation.

Claim 32

Dependent Claim 32 words

The process of Claim 28 wherein said oil-insoluble neutral copper salt is selected from the group consisting of copper carboxylates of from 1 to 6 carbon atoms, copper chloride, and copper sulfate.

Claim 33

Dependent Claim 25 words

The process of Claim 28 or 29 wherein said alkali metal and alkaline earth metal is selected from the group of calcium, magnesium and sodium.

Claim 34

Dependent Claim 18 words

3 1 . The process of Claims 28 to 30 wherein said overbased metal-containing compound is magnesium sulfonate.

Claim 35

Dependent Claim 15 words

The process of Claims 28 to 30 wherein said overbased metal-containing compound is calcium sulfonate.

Claim 36

Dependent Claim 15 words

The process of Claims 28 to 30 wherein said overbased metal-containing compound is sodium sulfonate.

Claim 37

Dependent Claim 26 words

The process of Claims 28 to 30 wherein said overbased metal-containing compound is selected from the group consisting of magnesium,_calcium, or sodium sulfonates, phenates or salicylates.

Claim 38

Dependent Claim 225 words

A process for preparing an overbased magnesium sulfonate which comprises: a) addition to a suitable vessel a charge mixture of (1) about 30 to about 90 parts by weight of ammonium sulfonate, (2) about 50 to about 120 parts by weight of No. 100 neutral petroleum oil, (3) about 100 to about 400 parts by weight of xylene, and (4) about 25 to about 60 parts of magnesium oxide wherein said magnesium oxide was added during mixing at ambient temperature to about reflux temperature of said charge mixture; b) heating said charge mixture to about 100°F wherein from about 10 to about 35 parts by weight of methanol is added and heating is continued up to about 140°F wherein from about 30 to about 60 parts by weight of water is added and the resulting mixture is refluxed for up to 4 hours; c) distilling said mixture to remove methanol, water, and xylene at a temperature of up to about 225°F at ambient pressure; d) cooling said mixture to about 100°F and thereupon carbonating said mixture with about 35 to about 90 parts by weight of carbon dioxide at a temperature of from about 60°F to about 200°F until said mixture is saturated; e) removing magnesium oxide impurities by centrifuge or filtration; f) removing remaining xylene, methanol, and water by distillation at a reflux temperature.

Claim 39

Dependent Claim 225 words

A process for preparing an overbased magnesium sulfonate which comprises: a) addition to a suitable vessel a charge mixture of (1) about 30 to about 90 parts by weight of ammonium sulfonate, (2) about 50 to about 120 parts by weight of No. 100 neutral petroleum oil, (3) about 100 to about 400 parts by weight of xylene, and (4) about 25 to about 60 parts of magnesium oxide wherein said magnesium oxide was added during mixing at ambient temperature to about reflux temperature of said charge mixture; b) heating said charge mixture to about 100°F wherein from about 10 to about 35 parts by weight of methanol is added and heating is continued up to about 140°F wherein from about 30 to about 60 parts by weight of water is added and the resulting mixture is refluxed for up to 4 hours; c) distilling said mixture to remove methanol, water, and xylene at a temperature of up to about 225°F at ambient pressure; d) cooling said mixture to about 100°F and thereupon carbonating said mixture with about 35 to about 90 parts by weight of carbon dioxide at a temperature of from about 60°F to about 200°F until said mixture is saturated; e) removing magnesium oxide impurities by centrifuge or filtration; f) removing remaining xylene, methanol, and water by distillation at a reflux temperature.

Claim 40

Dependent Claim 19 words

The composition of Claims 1 to 14 wherein the overbased copper metal sulfonate is an overbased copper magnesium sulfonate.

Claim 41

Dependent Claim 63 words

A process for preparing the lubricating oil compositions as defined in Claims 1 to 14 by adding of an overbased copper metal sulfonate, phenate and/or salicylate, wherein the metal is selected from magnesium, calcium or sodium to components a), b) or c) or d) and e) as a dispersant/detergent, antioxidant and corrosion inhibitor in the amounts as defined in Claims 1 to 14.

Claim 42

Dependent Claim 48 words

A process for preparing the concentrates as defined in Claims 15 to 27 by adding an overbased copper phenate, sulfonate or salicylate to components a) or b) or c) and d) as a dispersant/detergent, antioxidant, and corrosion inhibitor in the amounts as defined in Claims 15 to 27.

Claim 43

Dependent Claim 30 words

Use of the compounds as prepared in accordance with Claims 28 to 34 and 35 as a dispersant/detergent and oxidation and corrosion inhibitors in lubricating oil compositions or concentrates thereof.

Metal-containing lubricant compositions

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