Compound comprising pol y amine, acidic and boron functionalities and its use as a lubricant additive

Abstract

A product resulting from the reaction of at least: a hydroxybenzoic acid, optionally substituted by a hydrocarbyl group, a boron compound, an amine component selected from compounds including two or three amine functions, wherein at least one amine function is substituted by at least one hydrocarbyl group. A lubricant composition including this product. Use of this product as a lubricant for two-stroke marine engines and four-stroke marine engines, more preferably two-stroke marine engines.

Claims

1. A product resulting from the reaction of at least: a hydroxybenzoic acid, optionally substituted by a hydrocarbyl group, a boron compound, an amine component selected from the group consisting of: di- amines of formula (IV): R.sub.1NX—Ra—NZ.sub.1Z.sub.2 (IV) tri-amines of formula (V): R.sub.1NX—Ra-NY-Rb—NZ.sub.1Z.sub.2 (V) wherein X represents a group selected from the group consisting of: a hydrogen, an alkyl group and an alkenyl group R.sub.2, Y represents a group selected from the group consisting of: a hydrogen, an alkyl group and an alkenyl group R.sub.4, Z.sub.1 and Z.sub.2 are independently selected from the group consisting of: a hydrogen, an alkyl group and an alkenyl group R.sub.3, R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are independently selected from the group consisting of alkyl and alkenyl groups having from 8 to 22 atoms of carbon, Ra and Rb are independently selected from the group consisting of alkyl and alkenyl groups having from 1 to 20 atoms of carbon, when Z.sub.1 and Z.sub.2 both represent an alkyl group or an alkenyl group R.sub.3, they can be different.

2. The product according to claim 1, wherein the hydroxybenzoic acid, optionally substituted by a hydrocarbyl group, is selected from the group consisting of mono-alk(en)yl substituted salicylic acids, di-alk(en)yl substituted salicylic acids, acid functionalized calixarenes, and mixtures thereof.

3. The product according to claim 1, wherein the hydroxybenzoic acid compound, optionally substituted by a hydrocarbyl group, corresponds to formula (I): ##STR00010## Wherein: R represents a hydrocarbyl with 1 to 50 carbon atoms, and R can have one or more heteroatoms, a is an integer, a represents 0, 1 or 2.

4. The product according to claim 3, wherein R has from 12 to 40 carbon atoms.

5. The product according to claim 3, wherein the hydroxybenzoic acid compound, optionally substituted by a hydrocarbyl group, corresponds to formula (IA): ##STR00011##

6. The product according to claim 5, wherein the hydroxybenzoic acid compound is salicylic acid.

7. The product according to claim 1, wherein the boron compound is selected from the group consisting of: boric acid, boric acid complexes, boric oxide, a trialkyl borate in which the alkyl groups comprise independently from 1 to 4 carbon atoms, a C.sub.1-C.sub.12 alkyl boronic acid, a C.sub.1-C.sub.12 dialkyl boric acid, a C.sub.6-C.sub.12 aryl boric acid, a C.sub.6-C.sub.12 diaryl boric acid, a C.sub.7-C.sub.12 aralkyl boric acid, a C.sub.7-C.sub.12 diaralkyl boric acid, and products deriving from these by substitution of an alkyl group by one or more alkoxy unit.

8. The product according to claim 7, wherein the boron compound is boric acid.

9. The product according to claim 1, wherein the amine component is selected from compounds corresponding to formula (IVA): ##STR00012## with x=2, 3, 4.

10. The product according to claim 1, wherein the amine component is selected from compounds corresponding to formula (VB): ##STR00013## With: x=2, 3, 4, y=2, 3, 4.

11. The product according to claim 1, wherein R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are, independently, selected from the group consisting of linear alkyl groups and alkenyl groups with 14 to 22 carbon atoms.

12. The product according to claim 11, wherein R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are, independently, selected from the group consisting of linear alkyl groups and alkenyl groups with 14 to 18 carbon atoms.

13. The product according to claim 12, wherein R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are, independently, selected from the group consisting of linear alkyl groups and alkenyl groups with 16 to 18 carbon atoms.

14. The product according to claim 11, wherein R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are derived from animal and vegetal oils and fats.

15. The product according to claim 14, wherein R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are derived from tallow oil.

16. The product according to claim 1, wherein Ra and Rb are independently selected from linear alkyl groups having from 2 to 4 carbon atoms.

17. The product according to claim 16, wherein Ra and Rb are selected from the group consisting of: —CH.sub.2—CH.sub.2—, and —CH.sub.2—CH.sub.2—CH.sub.2—.

18. A lubricant composition comprising a product according to claim 1 and a base oil.

19. A lubricant composition according to claim 18 comprising: from 60 to 99.9% of at least one base oil, from 0.1 to 20% of at least one product the percentage being defined by weight of component as compared to the total weight of the composition.

20. Method for lubricating two-stroke marine engines and four-stroke marine engines comprising application to said marine engines of a product according claim 1 or a lubricant composition comprising the product and a base oil.

Description

DETAILED DESCRIPTION

(1) The term “consists essentially of” followed by one or more characteristics, means that may be included in the process or the material of the invention, besides explicitly listed components or steps, components or steps that do not materially affect the properties and characteristics of the invention.

(2) The expression “comprised between X and Y” includes boundaries, unless explicitly stated otherwise. This expression means that the target range includes the X and Y values, and all values from X to Y.

(3) “Alkyl” means a saturated hydrocarbon chain, that can be linear, branched or cyclic.

(4) “Alkenyl” means a hydrocarbon chain, that can be linear, branched or cyclic and comprises at least one unsaturation, preferably a carbon-carbon double bond.

(5) “Aryl” means an aromatic hydrocarbon functional group. This functional group can be monocyclic or polycyclic. As examples of an aryl group one can mention: phenyl, naphtalen, anthracen, phenanthren and tetracen.

(6) “Aralkyl” means an aromatic hydrocarbon functional group, preferably monocyclic, that comprises an alkyl chain substituent.

(7) “Hydrocarbyl” means a compound or fragment of a compound selected from: an alkyl, an alkenyl, an aryl, an aralkyl. Where indicated, some hydrocarbyl groups include heteroatoms.

(8) The Hydroxybenzoic Acid

(9) The hydroxybenzoic acid compounds, optionally substituted by a hydrocarbyl group, are molecules that comprise at least one benzoic acid fragment, and the aromatic ring bears at least one hydroxyl function and possibly one alkyl, alkenyl, aryl or aralkyl substituent. When present, the hydrocarbyl substituent and the hydroxy function can be in ortho, meta or para position with regards to the acidic function and with regards to each other. The hydrocarbyl substituent can comprise from 1 to 50 carbon atoms.

(10) The hydroxybenzoic acid compounds include salicylic acid (hydroxy-2-benzoic acid), hydroxy-3-benzoic acid, hydroxy-4-benzoic acid, preferably salicylic acid.

(11) The hydrocarbyl-substituted hydroxybenzoic acid compounds include, non limitatively, mono-alk(en)yl substituted salicylic acids, di-alk(en)yl substituted salicylic acids, acid functionalized calixarenes, notably salicylic acid calixarenes, and mixtures thereof.

(12) A calixarene is a macrocycle consisting of several phenolic units which can be parasubstituted and connected by a methylene bridge. This cyclic oligomer comprises a sequence of 4 to 16 phenols forming a ring and connected by methylene bridges —(CH.sub.2)— or similar bridges.

(13) The hydroxybenzoic acid compounds, optionally substituted by a hydrocarbyl group, can, according to a first variant, respond to formula (I) below:

(14) ##STR00003##

(15) Wherein:

(16) R represents a hydrocarbyl with 1 to 50 carbon atoms, and R can comprise one or more heteroatoms,

(17) a is an integer, a represents 0, 1 or 2.

(18) According to a first variant a=0.

(19) According to another variant a=1 or 2.

(20) When a=2, the two hydrocarbyl groups can be identical or different.

(21) Advantageously a=1.

(22) Hydrocarbyl groups in formula (I) means alkyl, alkenyl, aryl and aralkyl groups, possibly comprising one or more heteroatoms.

(23) Hydrocarbyl groups in formula (I) may be linear, branched or cyclic.

(24) Heteroatoms in R can be selected from O, N, S. For example, they can be present as one or more of: an —OH, —NH.sub.2, or —SH substituent, or an —O—, —NH—, —N═ or —S— bridge.

(25) Preferably, R does not comprise heteroatoms.

(26) Preferably, R is selected from alkyl and alkenyl groups.

(27) Advantageously, R represents an alkyl or an alkenyl with 1 to 50 carbon atoms.

(28) Preferably, R is selected from linear and branched alkyl and alkenyl groups.

(29) Even more advantageously, R represents a linear alkyl with 1 to 50 carbon atoms.

(30) Preferably R comprises from 12 to 40 carbon atoms, even more preferably R comprises from 18 to 30 carbon atoms.

(31) Salicylic acid is commercially available.

(32) Hydrocarbyl substituted hydroxybenzoic acids can be prepared according to the method disclosed in EP1 783 134.

(33) Advantageously, in formula (I), —OH and —COOH are in the ortho position on the phenyl ring, and the molecule of formula (I) is salicylic acid or a salicylic acid derivative of formula (IA):

(34) ##STR00004##

(35) Wherein R and a have the same definition as in formula (I) and the favourite variants of these parameters are the same as in formula (I).

(36) Hydrocarbyl substituted salicylic acids are commercially available from Chemtura under trade name RD-225 and S-220 or from Oronite under trade name OLOA 16300, OLOA 16301 and OLOA 16305 or from Infineum under trade name M7101, M7102, M7121 and M7125.

(37) According to a second variant, the hydroxybenzoic acid compounds, optionally substituted by a hydrocarbyl group, can be selected from calixarene structures. Calixarene structures according to the invention include cyclic structures comprising m units of a hydrocarbyl-substituted hydroxybenzoic acid of formula (II) and n units of a phenol of formula (III) which are joined together to form a ring:

(38) ##STR00005##

(39) wherein

(40) G.sub.1 represents a hydrocarbyl with 1 to 50 carbon atoms, and G.sub.1 can comprise one or more heteroatoms,

(41) b is an integer, b represents 0, 1 or 2,

(42) Q represents independently a divalent bridging group,

(43) G.sub.2, G.sub.3, G.sub.4 and G.sub.5, are selected from: OH, H, or a hydrocarbyl group with 1 to 50 carbon atoms that can comprise one or more heteroatoms, with the condition that one or two of G.sub.2, G.sub.3, G.sub.4 and G.sub.5 is OH,

(44) m and n are integers that verify:

(45) m is from 1 to 8,

(46) n is at least 3,

(47) m+n is from 4 to 20.

(48) According to a variant, b represents 0.

(49) According to another variant, b represents 1 or 2.

(50) Advantageously, m+n is from 5 to 12.

(51) When b=2, the two hydrocarbyl groups G.sub.1 can be identical or different.

(52) Hydrocarbyl groups in formula (II) and (III) means alkyl, alkenyl, aryl and aralkyl groups, possibly comprising one or more heteroatoms.

(53) Hydrocarbyl groups in formula (II) and (III) may be linear, branched or cyclic.

(54) Heteroatoms in G.sub.1, G.sub.2, G.sub.3, G.sub.4 and G.sub.5 can be selected from O, N, S. For example, they can be present as one or more of: an —OH, —NH.sub.2, or —SH substituent, or an —O—, —NH—, —N═ or —S— bridge.

(55) Preferably, G.sub.1 is selected from alkyl and alkenyl groups.

(56) Advantageously, G.sub.1 represents an alkyl or an alkenyl with 1 to 50 carbon atoms. Even more advantageously, G.sub.1 represents a linear alkyl with 1 to 50 carbon atoms.

(57) Preferably G.sub.1 comprises from 12 to 40 carbon atoms, even more preferably G.sub.1 comprises from 18 to 30 carbon atoms.

(58) Preferably, the units (II) are selected from those that respond to formula (IIA) here-under:

(59) ##STR00006##

(60) wherein G.sub.1, Q and b have the same definition as in formula (II) and the favourite variants of these parameters are the same as in formula (II).

(61) Advantageously in formula (III), G.sub.5 is hydroxyl.

(62) Advantageously, G.sub.2, G.sub.3, G.sub.4 independently represent H or an alkyl or an alkenyl with 1 to 50 carbon atoms. Even more advantageously, G.sub.2, G.sub.3, G.sub.4 independently represent H or a linear alkyl with 1 to 40 carbon atoms.

(63) Preferably G.sub.2, G.sub.3, G.sub.4 are independently selected from H and linear alkyl groups comprising from 1 to 30 carbon atoms, even more preferably they are selected from H and linear alkyl groups comprising from 4 to 25 carbon atoms.

(64) When more than one unit (II) is present, the units (II) can be identical or different.

(65) The units (III) can be identical or different in a calixarene molecule.

(66) When more than one unit (II) is present in the ring (m>1), the units (II) and (III) are distributed randomly.

(67) Each Q may independently be selected from —S— and groups represented by the formula —(CHG.sub.6).sub.c- in which G.sub.6 is selected from: hydrogen or hydrocarbyl group with 1 to 10 carbon atoms and c is an integer from 1 to 4. Advantageously, each G.sub.6 is H or a hydrocarbyl group that contains 1 to 6 carbon atoms, and even more preferably each G.sub.6 is H.

(68) Preferably, at least 50% of the bridging groups Q are independently represented by the formula —(CHG.sub.6).sub.c-. Preferably, c is an integer from 1 to 4, wherein each G.sub.6 is H or a hydrocarbyl group that contains 1 to 6 carbon atoms, and even more preferably each G.sub.6 is H.

(69) Advantageously, all Q groups are selected from —(CHG.sub.6).sub.c- and c is 1, wherein each G.sub.6 is H or a hydrocarbyl group that contains 1 to 6 carbon atoms, and even more preferably each G.sub.6 is H.

(70) The Boron Compound

(71) The boron compound is selected from boric acid, hydrocarbyl boronic acids, boric esters and hydrocarbyl boronic esters, boric oxide, boric acid complexes.

(72) The boron compound can, for example, be selected from: boric acid, boric oxide, boric acid complexes, a trialkyl borate in which the alkyl groups comprise independently from 1 to 4 carbon atoms, a C.sub.1-C.sub.12 alkyl boronic acid, a C.sub.1-C.sub.12 dialkyl boric acid, a C.sub.6-C.sub.12 aryl boric acid, a C.sub.6-C.sub.12 diaryl boric acid, a C.sub.7-C.sub.12 aralkyl boric acid, a C.sub.7-C.sub.12 diaralkyl boric acid, or products deriving from these by substitution of an alkyl group by one or more alkoxy unit.

(73) Alkyl groups and alkoxy groups can be linear, branched or cyclic.

(74) Boric acid complexes are complexes with a molecule comprising one or more alcohol functionality.

(75) Advantageously, the boron compound is boric acid.

(76) The Amine Component

(77) The amine component is selected from compounds comprising two or three amine functions (diamines and triamines) and at least one amine function is substituted by at least one hydrocarbyl group.

(78) Preferably, the amine component is selected from compounds comprising two or three amine functions (diamines and triamines) and at least one amine function is substituted by at least one C.sub.1-C.sub.40 alkyl or alkenyl group.

(79) According to a first variant, the amine component is selected from diamines. According to this variant, the amine component is advantageously selected from mono-hydrocarbyl and di-hydrocarbyl amino hydrocarbyl amines (IV):
R.sub.1NX—Ra—NZ.sub.1Z.sub.2  (IV)

(80) wherein

(81) X represents a group selected from: a hydrogen, an alkyl group or an alkenyl group R.sub.2,

(82) Z.sub.1 and Z.sub.2 are independently selected from: a hydrogen, an alkyl group or an alkenyl group R.sub.3,

(83) R.sub.1, R.sub.2 and R.sub.3 are independently selected from alkyl and alkenyl groups comprising from 1 to 40 atoms of carbon,

(84) Ra is selected from alkyl and alkenyl groups comprising from 1 to 20 atoms of carbon,

(85) when Z.sub.1 and Z.sub.2 both represent an alkyl group or an alkenyl group R.sub.3, they can be different.

(86) According to a second variant, the amine component is selected from triamines. According to this variant, the amine component is advantageously selected from mono-hydrocarbyl and di-hydrocarbyl amino hydrocarbyl amino hydrocarbyl amines (V):
R.sub.1NX—Ra—NY—Rb—NZ.sub.1Z.sub.2  (V)

(87) wherein

(88) X represents a group selected from: a hydrogen, an alkyl group or an alkenyl group R.sub.2,

(89) Y represents a group selected from: a hydrogen, an alkyl group or an alkenyl group R.sub.4,

(90) Z.sub.1 and Z.sub.2 are independently selected from: a hydrogen, an alkyl group or an alkenyl group R.sub.3,

(91) R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are independently selected from alkyl and alkenyl groups comprising from 1 to 40 atoms of carbon,

(92) Ra and Rb are independently selected from alkyl and alkenyl groups comprising from 1 to 20 atoms of carbon,

(93) when Z.sub.1 and Z.sub.2 both represent an alkyl group or an alkenyl group R.sub.3, they can be different.

(94) The explanation and favourite embodiments detailed here-under are relevant to both formula (IV) and formula (V).

(95) “hydrocarbyl groups” in formula (IV) and (V) preferably means alkyl groups and alkenyl groups, that may be linear, branched or cyclic.

(96) R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are preferably selected from linear and branched alkyl groups and alkenyl groups. Even more preferably R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are selected from linear alkyl groups and alkenyl groups.

(97) R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are preferably selected from alkyl groups and alkenyl groups comprising from 4 to 30 atoms of carbon, even more preferably from 8 to 22 carbon atoms.

(98) According to a favourite variant, R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are, independently, selected from linear alkyl groups and alkenyl groups with 14 to 22 carbon atoms, preferably with 14 to 18 carbon atoms, more preferably with 16 to 18 carbon atoms.

(99) Although the groups R.sub.1, R.sub.2, R.sub.3 and R.sub.4 can be different, they are, in one embodiment, the same, since such materials are more economically produced. Irrespective of whether they are the same or not, R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are, independently, preferably derived from chemical feedstock or from a natural source, such as from natural oils and fats. Particularly if a natural source is used, it means that each of R.sub.1, R.sub.2, R.sub.3 and R.sub.4 may be a mixture of alkyl and alkenyl radicals with varied chain lengths. Suitably R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are derived from animal and vegetal oils and fats, such as from tallow oil, colza oil, sunflower oil, soya oil, flax oil, olive oil, palm oil, castor oil, wood oil, corn oil, squash oil, grapeseed oil, jojoba oil, sesame oil, walnut oil, hazelnut oil, almond oil, shea oil, macadamia oil, cotton oil, alfalfa oil, rye oil, safflower oil, peanut oil, coconut oil and copra oil, and mixtures thereof

(100) Preferably R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are derived from tallow oil, coconut oil and palm oil. Preferably the R.sub.1, R.sub.2, R.sub.3 and R.sub.4 groups represent an aliphatic group obtained from tallow oil, and the corresponding mixture of fatty-alkyl(ene) polyamines are formed.

(101) R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are derived from animal and vegetal oils and fats means that R.sub.1, R.sub.2, R.sub.3 and R.sub.4 correspond to the mixture of aliphatic chains obtained by reduction of the fatty acids obtained from animal and vegetal oils and fats.

(102) According to some variant, it may be beneficial to use hydrogenated groups R.sub.1, R.sub.2, R.sub.3 and R.sub.4. However, for certain feedstocks, even after hydrogenization, an appreciable amount of unsaturated bonds may remain. Alternatively, the R.sub.1, R.sub.2, R.sub.3 and R.sub.4 groups of the raw material are unsaturated. Also, compounds of formula (IV) and (V) wherein one of R.sub.1, R.sub.2, R.sub.3 and R.sub.4 is fully saturated and one is unsaturated are amine products that can be used according to the invention.

(103) Ra and Rb are preferably selected from linear alkyl and alkenyl groups. Advantageously, Ra and Rb are preferably selected from alkyl groups, even more preferably from linear alkyl groups. Even more preferably, Ra and Rb are selected from linear alkyl groups comprising 2 to 4 atoms of carbon. Even more advantageously, Ra and Rb are selected from:

(104) —CH.sub.2—CH.sub.2—, —CH(CH.sub.3)—CH.sub.2— and —CH.sub.2—CH.sub.2—CH.sub.2—.

(105) According to a favourite variant, Ra and Rb are selected from:

(106) —CH.sub.2—CH.sub.2—, and —CH.sub.2—CH.sub.2—CH.sub.2—.

(107) According to a favourite embodiment of formula (IV) variant, the amine component is selected from compounds responding to formula (IVA):

(108) ##STR00007##

(109) With:

(110) R.sub.1, X have the same definition and favourite embodiments as in formula (IV) and

(111) x=2, 3, 4.

(112) According to a favourite embodiment of formula (V) variant, the amine component is selected from compounds responding to formula (VB):

(113) ##STR00008##

(114) With:

(115) R.sub.1, X have the same definition and favourite embodiments as in formula (V) and

(116) x=2, 3, 4,

(117) y=2, 3, 4.

(118) Reaction Product

(119) The reaction of the hydroxybenzoic acid, optionally substituted by a hydrocarbyl, the boron compound, and the amine component can be effected in any suitable manner.

(120) For example, the reaction can be conducted by first combining hydroxybenzoic acid (optionally hydrocarbyl substituted) and the boron compound in the desired ratio and in the presence of a suitable solvent.

(121) Suitable solvents are for example naphtha and polar solvents such as water and an alcohol, like for example: methanol, ethanol, propanol, butanol.

(122) After a sufficient time, the boron compound dissolves. Then, the amine component is added slowly to the mixture to effect neutralization and formation of the desired reaction product.

(123) The reaction can advantageously be conducted by maintaining the reaction medium at a temperature of from about 20° C. to about 100° C., for example from about 50° C. to about 75° C., generally for a time period ranging from about 0.5 to 5 hours, more preferably from 1 to 4 hours.

(124) After the reaction is completed, the solvent may be evaporated from the reaction medium, preferably, it is evaporated by distillation under vacuum. Alternately, the solvent may remain in mixture with the reaction products which are used as such.

(125) A diluting oil can be added as needed to control viscosity, particularly during removal of solvents by distillation.

(126) The product resulting from this reaction will contain a complex mixture of compounds. The reaction product mixture need not be separated to isolate one or more specific components. Accordingly, the reaction product mixture can be employed as is in the lubrication oil composition of the present invention.

(127) The reaction can be achieved with other reactants in addition to the hydroxybenzoic acid (optionally hydrocarbyl substituted), the boron compound, and the amine component.

(128) However, according to the invention, preferably the reaction product results from the reaction of a mixture of reactants (not including the solvent(s)) that consists essentially of at least one hydroxybenzoic acid (optionally hydrocarbyl substituted), at least one boron compound, and at least one amine component.

(129) Even more preferably, the reaction product results from the reaction of a mixture of reactants (not including the solvent(s)) that consists of at least one hydroxybenzoic acid (optionally hydrocarbyl substituted), at least one boron compound, and at least one amine component.

(130) Lubricant Composition

(131) The invention is also directed to the use of the reaction products that have been above disclosed as additives in lubricating oil (or lubricant) compositions. It is also directed to the lubricant compositions comprising such additives.

(132) Advantageously, the lubricant composition comprises: from 60 to 99.9% of at least one base oil, from 0.1 to 20% of at least one reaction product of at least a hydroxybenzoic acid (optionally hydrocarbyl substituted), a boron compound, and an amine component as above defined

(133) the percentages being defined by weight of component as compared to the total weight of the composition.

(134) Even more advantageously, the lubricant composition comprises: from 60 to 99.9% of at least one base oil from 0.1 to 15% of at least one reaction product of at least a hydroxybenzoic acid (optionally hydrocarbyl substituted), a boron compound, and an amine component as above defined,

(135) the percentages being defined by weight of component as compared to the total weight of the composition.

(136) Base Oils

(137) Generally, the lubricating oil compositions according to the invention comprise as a first component an oil of lubricating viscosity, also called “base oils”. The base oil for use herein can be any presently known or later-discovered oil of lubricating viscosity used in formulating lubricating oil compositions for any of the following applications, e.g., engine oils, marine cylinder oils, functional fluids such as hydraulic oils, gear oils, transmission fluids, like for example automatic transmission fluids, turbine lubricants, trunk piston engine oils, compressor lubricants, metal-working lubricants, and other lubricating oil and grease compositions.

(138) Advantageously, the lubricant compositions according to the invention are marine engine lubricating oil compositions, preferably they are 2-stroke marine engine lubricating oil compositions.

(139) Generally, the oils also called “base oils” used for formulating lubricant compositions according to the present invention may be oils of mineral, synthetic or plant origin as well as their mixtures. The mineral or synthetic oils generally used in the application belong to one of the classes defined in the API classification as summarized below:

(140) TABLE-US-00002 Saturated substance content Sulfur content Viscosity (weight percent) (weight percent) Index Group 1  <90% >0.03% 80 ≤ VI < Mineral oils 120 Group 2 ≥90% ≤0.03% 80 ≤ VI < Hydrocracked oils 120 Group 3 ≥90% ≤0.03% ≥120 Hydroisomerized oils Group 4 PAOs Group 5 Other bases not included in the base Groups 1 to 4

(141) These mineral oils of Group 1 may be obtained by distillation of selected naphthenic or paraffinic crude oils followed by purification of these distillates by methods such as solvent extraction, solvent or catalytic dewaxing, hydrotreating or hydrogenation.

(142) The oils of Groups 2 and 3 are obtained by more severe purification methods, for example a combination of hydrotreating, hydrocracking, hydrogenation and catalytic dewaxing. Examples of synthetic bases of Groups 4 and 5 include poly-alpha olefins, polybutenes, polyisobutenes, alkylbenzenes.

(143) These base oils may be used alone or as a mixture. A mineral oil may be combined with a synthetic oil.

(144) The lubricant compositions of the invention have a viscosity grade of SAE-20, SAE-30, SAE-40, SAE-50 or SAE-60 according to the SAEJ300 classification.

(145) Grade 20 oils have a kinematic viscosity at 100° C. of between 5.6 and 9.3 mm.sup.2/s.

(146) Grade 30 oils have a kinematic viscosity at 100° C. of between 9.3 and 12.5 mm.sup.2/s.

(147) Grade 40 oils have a kinematic viscosity at 100° C. of between 12.5 and 16.3 mm.sup.2/s.

(148) Grade 50 oils have a kinematic viscosity at 100° C. of between 16.3 and 21.9 mm.sup.2/s.

(149) Grade 60 oils have a kinematic viscosity at 100° C. of between 21.9 and 26.1 mm.sup.2/s.

(150) Preferably, the lubricant composition according to the first aspect and the second aspect is a cylinder lubricant.

(151) The cylinder oils for two-stroke diesel marine engines have a viscosimetric grade SAE-40 to SAE-60, generally preferentially SAE-50 equivalent to a kinematic viscosity at 100° C. comprised between 16.3 and 21.9 mm.sup.2/s. Typically, a conventional formulation of cylinder lubricant for two-stroke marine diesel engines is of grade SAE 40 to SAE 60, preferentially SAE 50 (according to the SAE J300 classification) and comprises at least 50% by weight of a lubricating base oil of mineral and/or synthetic origin, adapted to the use in a marine engine, for example of the API Group 1 class. Their viscosity index (VI) is comprised between 80 and 120; their sulfur content is greater than 0.03% and their saturated substance content is less than 90%.

(152) The system oils for two-stroke diesel marine engines have a viscosimetric grade SAE-20 to SAE-40, generally preferentially SAE-30 equivalent to a kinematic viscosity at 100° C. comprised between 9.3 and 12.5 mm.sup.2/s.

(153) These viscosities may be obtained by mixing additives and base oils for example containing mineral bases of Group 1 such as Neutral Solvent (for example 150 NS, 500 NS or 600 NS) bases and brightstock. Any other combination of mineral, synthetic bases or bases of plant origin, having, as a mixture with the additives, a viscosity compatible with the chosen SAE grade, may be used.

(154) The quantity of base oil in the lubricant composition of the invention is from 30% to 90% by weight relative to the total weight of the lubricant composition, preferably from 40% to 90%, more preferably from 50% to 90%.

(155) In one embodiment of the invention, the lubricant composition has a Base Number (BN) determined according to the standard ASTM D-2896 of at most 50, preferably at most 40, advantageously at most 30 milligrams of potassium hydroxide per gram of the lubricating composition, in particular ranging from 10 to 40, preferably 15 to 40 milligrams of potassium hydroxide per gram of the lubricant composition.

(156) In another embodiment of the invention, the lubricant composition has a BN determined according to the standard ASTM D-2896 of at least 50, preferably at least 60, more preferably at least 70, advantageously 70 to 100.

(157) Additives:

(158) It is optionally possible to substitute the above-described base oils in full or in part by one or more thickening additives whose role is to increase both the hot and cold viscosity of the composition, or by additives improving the viscosity index (VI).

(159) The lubricant composition of the invention may comprise at least one optional additive, chosen in particular from among those frequently used by persons skilled in the art.

(160) In one embodiment, the lubricant composition further comprises an optional additive chosen amongst a neutral detergent, an overbased detergent, an anti-wear additive, an oil soluble fatty amine, a polymer, a dispersing additive, an anti-foaming additive or a mixture thereof.

(161) Detergents are typically anionic compounds containing a long lipophilic hydrocarbon chain and a hydrophilic head, wherein the associated cation is typically a metal cation of an alkali metal or alkaline earth metal. The detergents are preferably selected from alkali metal salts or alkaline earth metal (particularly preferably calcium, magnesium, sodium or barium) salts of carboxylic acids, sulphonates, salicylates, naphthenates, as well as the salts of phenates. These metal salts may contain the metal in an approximately stoichiometric amount relative to the anion group(s) of the detergent. In this case, one refers to non-overbased or “neutral” detergents, although they also contribute to a certain basicity. These “neutral” detergents typically have a BN measured according to ASTM D2896, of less than 150 mg KOH/g, or less than 100 mg KOH/g, or less than 80 mg KOH/g of detergent. This type of so-called neutral detergent may contribute in part to the BN of lubricating compositions. For example, neutral detergents are used such as carboxylates, sulphonates, salicylates, phenates, naphthenates of the alkali and alkaline earth metals, for example calcium, sodium, magnesium, barium. When the metal is in excess (amount greater than the stoichiometric amount relative to the anion groups(s) of the detergent), then these are so-called overbased detergents. Their BN is high, higher than 150 mg KOH/g of detergent, typically from 200 to 700 mg KOH/g of detergent, preferably from 250 to 450 mg KOH/g of detergent. The metal in excess providing the character of an overbased detergent is in the form of insoluble metal salts in oil, for example carbonate, hydroxide, oxalate, acetate, glutamate, preferably carbonate. In one overbased detergent, the metals of these insoluble salts may be the same as, or different from, those of the oil soluble detergents. They are preferably selected from calcium, magnesium, sodium or barium. The overbased detergents are thus in the form of micelles composed of insoluble metal salts that are maintained in suspension in the lubricating composition by the detergents in the form of soluble metal salts in the oil. These micelles may contain one or more types of insoluble metal salts, stabilised by one or more types of detergent. The overbased detergents comprising a single type of detergent-soluble metal salt are generally named according to the nature of the hydrophobic chain of the latter detergent. Thus, they will be called a phenate, salicylate, sulphonate, naphthenate type when the detergent is respectively a phenate, salicylate, sulphonate or naphthenate. The overbased detergents are called mixed type if the micelles comprise several types of detergents, which are different from one another by the nature of their hydrophobic chain. The overbased detergent and the neutral detergent may be selected from carboxylates, sulphonates, salicylates, naphthenates, phenates and mixed detergents combining at least two of these types of detergents. The overbased detergent and the neutral detergent include compounds based on metals selected from calcium, magnesium, sodium or barium, preferably calcium or magnesium. The overbased detergent may be overbased by metal insoluble salts selected from the group of carbonates of alkali and alkaline earth metals, preferably calcium carbonate. The lubricating composition may comprise at least one overbased detergent and at least a neutral detergent as defined above.

(162) Polymers are typically polymers having a low molecular weight of from 2000 to 50 000 dalton (Mn). The polymers are selected amongst PIB (of from 2000 Dalton), polyacrylates or polymetacrylates (of from 30 000 Dalton), olefin copolymers, olefin and alpha-olefin copolymers, EPDM, polybutenes, poly alpha-olefin having a high molecular weight (viscosity 100° C.>150), hydrogenated or non-hydrogenated styrene-olefin copolymers.

(163) Anti-wear additives protect the surfaces from friction by forming a protective film adsorbed on these surfaces. The most commonly used is zinc dithiophosphate or DTPZn. Also in this category, there are various phosphorus, sulphur, nitrogen, chlorine and boron compounds. There are a wide variety of anti-wear additives, but the most widely used category is that of the sulphur phospho additives such as metal alkylthiophosphates, especially zinc alkylthiophosphates, more specifically, zinc dialkyl dithiophosphates or DTPZn. The preferred compounds are those of the formula Zn((SP(S)(OR.sub.1)(OR.sub.2)).sub.2, wherein R.sub.1 and R.sub.2 are alkyl groups, preferably having 1 to 18 carbon atoms. The DTPZn is typically present at levels of about 0.1 to 2% by weight relative to the total weight of the lubricating composition. The amine phosphates, polysulphides, including sulphurised olefins, are also widely used anti-wear additives. One also optionally finds nitrogen and sulphur type anti-wear and extreme pressure additives in lubricating compositions, such as, for example, metal dithiocarbamates, particularly molybdenum dithiocarbamate. Glycerol esters are also anti-wear additives. Mention may be made of mono-, di- and trioleates, monopalmitates and monomyristates. In one embodiment, the content of anti-wear additives ranges from 0.01 to 6%, preferably from 0.1 to 4% by weight relative to the total weight of the lubricating composition.

(164) Dispersants are well known additives used in the formulation of lubricating compositions, in particular for application in the marine field. Their primary role is to maintain in suspension the particles that are initially present or appear in the lubricant during its use in the engine. They prevent their agglomeration by playing on steric hindrance. They may also have a synergistic effect on neutralisation. Dispersants used as lubricant additives typically contain a polar group, associated with a relatively long hydrocarbon chain, generally containing 50 to 400 carbon atoms. The polar group typically contains at least one nitrogen, oxygen, or phosphorus element. Compounds derived from succinic acid are particularly useful as dispersants in lubricating additives. Also used are, in particular, succinimides obtained by condensation of succinic anhydrides and amines, succinic esters obtained by condensation of succinic anhydrides and alcohols or polyols. These compounds can then be treated with various compounds including sulphur, oxygen, formaldehyde, carboxylic acids and boron-containing compounds or zinc in order to produce, for example, borated succinimides or zinc-blocked succinimides. Mannich bases, obtained by polycondensation of phenols substituted with alkyl groups, formaldehyde and primary or secondary amines, are also compounds that are used as dispersants in lubricants. In one embodiment of the invention, the dispersant content may be greater than or equal to 0.1%, preferably 0.5 to 2%, advantageously from 1 to 1.5% by weight relative to the total weight of the lubricating composition. It is possible to use a dispersant from the PIB succinimide family, e.g. boronated or zinc-blocked.

(165) Other optional additives may be chosen from defoamers, for example, polar polymers such as polydimethylsiloxanes, polyacrylates. They may also be chosen from antioxidant and/or anti-rust additives, for example organometallic detergents or thiadiazoles. These additives are known to persons skilled in the art. These additives are generally present in a weight content of 0.1 to 5% based on the total weight of the lubricating composition.

(166) In one embodiment, the lubricant composition according to the invention may further comprise an oil soluble fatty amine.

(167) The fatty amine is of a general formula (VI):
R′.sub.1—[(NR′.sub.2)—R′.sub.3].sub.n—NR′.sub.4R′.sub.5,  (VI)

(168) wherein, R′.sub.1 represents a saturated or unsaturated, linear or branched, hydrocarbon group comprising at least 12 carbon atoms, and optionally at least one heteroatom chosen amongst nitrogen, sulfur or oxygen, R′.sub.2, R′.sub.4 and R′.sub.5 represent independently a hydrogen atom or a saturated or unsaturated, linear or branched, hydrocarbon group comprising optionally at least one heteroatom chosen amongst nitrogen, sulfur or oxygen, R′.sub.3 represents a saturated or unsaturated, linear or branched, hydrocarbon group comprising at least 1 carbon atom, and optionally at least one heteroatom chosen amongst nitrogen, sulfur or oxygen, preferably oxygen, n is an integer, n is superior or equal to 1, preferably comprised between 1 and 10, more preferably between 1 and 6, notably chosen amongst 1, 2 or 3.

(169) Preferably, the fatty amine is of a general formula (VI), wherein: R′.sub.1 represents a saturated or unsaturated, linear or branched, hydrocarbon group comprising between 12 and 22 carbon atoms, preferably between 14 and 22 carbon atoms, and optionally at least one heteroatom chosen amongst nitrogen, sulfur or oxygen, and/or R′.sub.2, R′.sub.4 and R′.sub.5 represent independently a hydrogen atom; a saturated or unsaturated, linear or branched, hydrocarbon group comprising between 12 and 22 carbon atoms, preferably between 14 and 22 carbon atoms, more preferably between 16 and 22 carbon atoms; a (R′.sub.6—O).sub.p—H group wherein R′.sub.6 represents a saturated, linear or branched, hydrocarbon group comprising at least 2 carbon atoms, preferably between 2 and 6 carbon atoms, more preferably between 2 and 4 carbon atoms, and p is superior or equal to 1, preferably comprised between 1 and 6, more preferably comprised between 1 and 4; a (R′.sub.7—N).sub.p—H.sub.2 group wherein R′.sub.7 represents a saturated, linear or branched, hydrocarbon group comprising at least 2 carbon atoms, preferably between 2 and 6 carbon atoms, more preferably between 2 and 4 carbon atoms, and p is superior or equal to 1, preferably comprised between 1 and 6, more preferably comprised between 1 and 4, and/or R′.sub.3 represents a saturated or unsaturated, linear or branched, alkyl group comprising between 2 and 6 carbon atoms, preferably between 2 and 4 carbon atoms.

(170) In one embodiment, the fatty amine of general formula (VI) represents of from 0.5 to 10%, preferably of from 0.5 to 8% by weight with respect to the total weight of the lubricant composition.

(171) The optional additives such as defined above contained in the lubricant compositions of the present invention can be incorporated in the lubricant composition as separate additives, in particular through separate addition thereof in the base oils. However, they may also be integrated in a concentrate of additives for marine lubricant compositions.

(172) Method for Producing a Marine Lubricant

(173) The present disclosure provides a method for producing a marine lubricant as above disclosed comprising the step of mixing the base oil with the reaction product of at least a hydroxybenzoic acid (optionally hydrocarbyl substituted), a boron compound, and an amine component as above defined as above defined.

(174) Use for Lubricating Engines

(175) The application also relates to the use of a reaction product of at least a hydroxybenzoic acid (optionally hydrocarbyl substituted), a boron compound, and an amine component as above defined for lubricating engines, preferably marine engines. Specifically, the invention is directed to the use of a reaction product of at least a hydroxybenzoic acid (optionally hydrocarbyl substituted), a boron compound, and an amine component as above defined for lubricating two-stroke marine engines and four-stroke marine engines, more preferably two-stroke marine engine.

(176) In particular, the reaction product of at least a hydroxybenzoic acid (optionally hydrocarbyl substituted), a boron compound, and an amine component as above defined is suitable for use in a lubricant composition, as cylinder oil or system oil, for lubricating 2-stroke engines and four-stroke marine engines, more preferably 2-stroke engines.

(177) The application also relates to a method for lubricating a two-stroke marine engines and four-stroke marine engines, more preferably two-stroke marine engine said method comprising application to said marine engine of the marine lubricant as above disclosed. In particular, the lubricant is applied to the cylinder wall, typically by a pulse lubricating system or by spraying the lubricant onto the piston's rings pack through an injector for lubricating 2-stroke engines. It has been observed that applying to the cylinder wall the lubricant composition according to the invention provides increased protection against corrosion, improved engine cleanliness.

EXPERIMENTAL

(178) I—Material and Methods: salicylic acid was bought from Sigma Aldrich boric acid was bought from Sigma Aldrich diamine was bought from Akzo Nobel base oil 1: Mineral oils Group I or brightstock of density between 895 and 915 kg/m.sup.3, base oil 2: Group I mineral oils, in particular called 600NS viscosity at 40° C. of 120 cSt measured according to ASTM D7279, detergent package comprising an anti-foaming agent C.sub.18H.sub.37 salicylic acid was prepared by the following protocol: Salicylic acid (50.0 g) was combined with 1-octadecene with a catalytic amount of methanesulfonic acid (0.3 equivalent) and heated to 130° C. over 8 hours.

(179) II—Preparation of the Lubricant Composition C1:

(180) A mixture of 13.8 g of salicylic acid and 3.1 g of boric acid was suspended in 50 mL of heptane/water/methanol (20/15/15) at ambient temperature and under stirring. Said mixture was heated to 70° C. To this mixture was added 31.4 g of a diamine of the following formula:

(181) ##STR00009##
with R=linear C.sub.18H.sub.37

(182) to provide a solution which was heated to 70° C. over 4 hours. Then, the solvent was removed under vacuum and the resulting product A1 was a homogeneous, light amber, viscous fluid.

(183) The composition C.sub.1 is disclosed in Table I. The percentages disclosed in Table I correspond to weight percent.

(184) TABLE-US-00003 TABLE I C.sub.1 Composition (invention) Base oil 1 29.8 Base oil 2 55.0 Detergent package 9.0 A1 6.2 TBN (Total base number in 25 mgKOH/g of composition)