ETHER COMPOUNDS AND RELATED COMPOSITIONS
20180163150 ยท 2018-06-14
Inventors
- Gordon LAMB (Naperville, IL, US)
- Amit GOKHALE (Naperville, IL, US)
- John Philip DAVIES (Naperville, IL, US)
- John REDSHAW (Naperville, IL, US)
- Peter SEDEN (Naperville, IL, US)
- Kevin WEST (Naperville, IL, US)
Cpc classification
International classification
Abstract
In some embodiments, a compound has the formula (I) where: R.sub.1 and R.sub.2 are alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.3, R.sub.4 and R.sub.5 are H or alkyl (formula II); R.sub.6 is alkyl or where: R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; and p is 0, 1, 2 or 3; and m and n are 0, 1, 2 or 3 provided that m is 0 when R.sub.4 and R.sub.5 are H. The compound is suitable for use as a base stock which provides low volatility for a given viscosity profile. The compound may be used in a lubricant composition for an internal combustion engine.
##STR00001##
Claims
1-33. (canceled)
34. A compound of formula (1): ##STR00062## where: R.sub.1 and R.sub.2 are alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.3, R.sub.4 and R.sub.5 are H or alkyl; R.sub.6 is alkyl or ##STR00063## where: R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; and p is 0, 1, 2 or 3; and m and n are 0, 1, 2 or 3 provided that m is 0 when R.sub.4 and R.sub.5 are H.
35. The compound of claim 34, wherein R.sub.1 and R.sub.2 are C.sub.1-15 alkyl or, together with the carbon atom to which they are attached, C.sub.5-30 cycloalkyl, such as C.sub.2-12 alkyl or, together with the carbon atom to which they are attached, C.sub.5-25 cycloalkyl.
36. The compound of claim 34, wherein R.sub.3, R.sub.4 and R.sub.5 are H or C.sub.1-15 alkyl, such as H or C.sub.2-12 alkyl.
37. The compound of claim 36, wherein R.sub.5 is H.
38. The compound of claim 34, wherein R.sub.6 is C.sub.1-20 alkyl or ##STR00064## such as C.sub.1-16 alkyl or ##STR00065##
39. The compound of claim 34, wherein m and n are 0, 1 or 2, such as 0 or 1.
40. The compound of claim 34, wherein the compound has the formula (2): ##STR00066## where: R.sub.1 and R.sub.2 are alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.3 and R.sub.5 are H or alkyl; R.sub.4 is alkyl; R.sub.6 is alkyl or ##STR00067## where: R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; and p is 0, 1, 2 or 3; and n is 0, 1, 2 or 3.
41. The compound of claim 40, wherein the compound has the formula (3): ##STR00068## where: R.sub.1 is alkyl; R.sub.3 and R.sub.5 are H or alkyl; R.sub.4 is alkyl; R.sub.6 is alkyl or ##STR00069## where: R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; and p is 0, 1, 2 or 3; and n is 0, 1, 2 or 3.
42. The compound of claim 41, wherein the compound has the formula (4): ##STR00070## where: R.sub.1 and R.sub.4 are alkyl; R.sub.3 and R.sub.5 are H or alkyl.
43. The compound of claim 42, wherein: R.sub.1 is C.sub.4-12 alkyl, such as C.sub.6-10 alkyl; R.sub.3 is H; R.sub.4 is C.sub.1-10 alkyl, such as C.sub.2-8 alkyl; and R.sub.5 is H.
44. The compound of claim 34, wherein the compound has the formula (6): ##STR00071## where: R.sub.1 and R.sub.2 are alkyl or, together with the carbon to which they are attached, cycloalkyl; R.sub.3, R.sub.4 and R.sub.5 are H or alkyl; R.sub.6 is alkyl or ##STR00072## where: R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; and p is 0, 1, 2 or 3; and n is 0, 1, 2 or 3.
45. The compound of claim 44, wherein the compound has the formula (7): ##STR00073## where: R.sub.1 and R.sub.2 are alkyl or, together with the carbon to which they are attached, cycloalkyl; R.sub.3, R.sub.4 and R.sub.5 are H or alkyl; and R.sub.6 is alkyl.
46. The compound of claim 34, wherein the compound has the formula (10): ##STR00074## where: R.sub.1 and R.sub.4 are alkyl; R.sub.3 and R.sub.5 are H or alkyl; R.sub.6 is alkyl or ##STR00075## where: R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; and and p is 0, 1, 2 or 3.
47. The compound of claim 34, wherein the compound has the formula (11): ##STR00076## where: R.sub.1 and R.sub.2 are alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.3, R.sub.4 and R.sub.5 are H or alkyl; R.sub.7 and R.sub.8 are H, alkyl or, together with the carbon atom to which they are attached, cycloalkyl; R.sub.9 is H or alkyl; X is alkylene or is absent; p is 0, 1, 2 or 3; and m and n are 0, 1, 2 or 3.
48. The compound of claim 34, wherein the compound contains a total number of carbons atoms of from 20 to 50, such as from 25 to 45, such as from 28 to 40 or from 30 to 36.
49. The compound of claim 34, wherein the compound is prepared from bio-derived feedstock.
50. The compound of claim 34, wherein the compound contains greater than 50%, such as greater than 70%, or greater than 90% by weight of biobased carbon.
51. The compound of claim 34, wherein the compound has at least one of: a kinematic viscosity at 40? C. of less than 25 cSt, such as less than 20 cSt, or less than 17 cSt; a kinematic viscosity at 100? C. of less than 7 cSt, such as less than 5 cSt, or less than 4 cSt; a viscosity index of greater than 100, such as greater than 110, or greater than 120; a viscosity at 150? C. and a shear rate of 10.sup.6 s.sup.?1 of no greater than 1.7 cP, such as no greater than 1.5 cP; a Noack volatility of less than 26%, such as less than 20%, less than 16%, or less than 12% by weight; and a pour point of less than ?10? C., such as less than ?25? C., or less than ?35? C.
52. The compound of claim 34, wherein the compound has a kinematic viscosity at 100? C. of 3 to 4 cSt and a Noack volatility of less than 20%, such as less than 16% or less than 12%, by weight; or a kinematic viscosity at 100? C. of 2 to 3 cSt, and a Noack volatility of less than 40%, such as less than 30%, by weight.
53. A base oil comprising a compound as defined in claim 34.
54. The base oil of claim 53, wherein the base oil comprises greater than 10%, such as greater than 25%, or greater than 40% by weight of the compound.
55. The base oil of claim 53, wherein the base oil comprises a base stock selected from Group I, Group II, Group III, Group IV and Group V base stocks and mixtures thereof.
56. A method of preparing a base oil, said method comprising providing a compound as defined in claim 34, and preparing a base oil comprising said compound.
57. A lubricant composition comprising a base oil as defined in claim 34.
58. The lubricant composition of claim 57, wherein the lubricant composition comprises greater than 50%, such as greater than 65%, or greater than 80% by weight of the base oil.
59. The lubricant composition of claim 57, wherein the lubricant composition has at least one of: a kinematic viscosity at 40? C. of less than 60 cSt, such as less than 55 cSt, or less than 50 cSt; a kinematic viscosity at 100? C. of less than 12 cSt, such as less than 10 cSt, or less than 9.5 cSt; a viscosity index of greater than 100, such as greater than 110, or greater than 120; a viscosity at 150? C. and a shear rate of 10.sup.6 s.sup.?1 of no greater than 3 cP, such as no greater than 2.8 cP; and a Noack volatility of less than 25%, such as no more than 20%, less than 15%, or less than 10% by weight.
60. The lubricant composition of claim 57, wherein the lubricant composition has at least one of: an oxidative stability performance on a CEC-L-088-02 test indicated by an absolute viscosity increase at 40? C. of no more than 45 cSt, such as no more than 35 cSt or no more than 25 cSt; a fuel economy performance on a CEC-L-054-96 test of at least 2.5%, such as at least 3%; and a piston cleanliness performance on a CEC-L-088-02 test indicated by an overall piston merit of at least 8.5, such as 9.
61. A method of preparing a lubricant composition, said method comprising providing a base oil as defined in claim 53, and preparing a lubricant composition from said base oil, such as wherein the method comprises blending the base oil with one or more lubricant additives.
62. A method of lubricating a surface, said method comprising supplying a lubricant composition as defined in claim 57 to said surface, such as wherein the lubricant composition is supplied to a surface in an internal combustion engine.
63. A method of improving the oxidative stability performance, fuel economy performance, and/or piston cleanliness performance of a lubricating composition, comprising the step of providing to the lubricating composition a compound according to claim 34.
64. A method of improving the oxidative stability performance, fuel economy performance, and/or piston cleanliness performance of a lubricating composition, comprising the step of providing to the lubricating composition a base oil according claim 53.
65. A method of improving the fuel economy performance and/or piston cleanliness performance of an engine and/or a vehicle, such as an automotive vehicle associated with an internal combustion engine, comprising the step of providing to the engine and/or the vehicle a compound according to claim 34.
66. A method of improving the fuel economy performance and/or piston cleanliness performance of an engine and/or a vehicle, such as an automotive vehicle associated with an internal combustion engine, comprising the step of providing to the engine and/or the vehicle a base oil according to claim 53.
67. A method of improving the fuel economy performance and/or piston cleanliness performance of an engine and/or a vehicle, such as an automotive vehicle associated with an internal combustion engine, comprising the step of providing to the engine and/or the vehicle a lubricating composition according to claim 57.
Description
[0278] The invention will now be described with reference to the accompanying figures and examples, which are not limiting in nature, in which:
[0279]
[0280]
[0281]
[0282]
[0283]
[0284]
EXAMPLES
Example 1Properties of Ether Base Stocks
[0285] Guerbet-derived base stocks GE1-GE3, GE5 and GE7-GE9, secondary ether base stocks SE1 and SE2, and tertiary ether base stock TE1 of formula (1) were prepared. Two further Guerbet-derived base stocks, GE4 and GE6, and an experimental group V base stock of the type previously described in WO 2014/207235, i.e. a farnesene-derived ether base stock, were also prepared. The structure of these compounds is shown in Table 3.
TABLE-US-00003 TABLE 3 Molecular Chemical Weight Formula Structure GE1 466.87 C.sub.32H.sub.66O
[0286] The following properties of the base stocks were tested:
[0287] Kinematic viscosity at 100? C. (KV100) and kinematic viscosity at 40? C. (KV40) were tested according to ASTM D7279.
[0288] Viscosity index (VI) was calculated according to ASTM D2270.
[0289] Pour point was determined according to ASTM D7346.
[0290] Differential scanning calorimetry (DSC) oxidation onset temperature was tested using a method which was based on ASTM E2009 (method B). According to the method, the base stocks were heated from 50? C. to 300? C., at a rate of 50? C./minute, under a pressure of 500 psi in an aluminium SFI pan. The temperature at which an exotherm was observed was recorded.
[0291] Noack volatility was measured using a method which was based on IP 393 and was considered similar to CEC-L-40-A-93. According to the method, reference oils of known Noack volatility were heated from 40? C. to 550? C. to determine the temperature at which the Noack volatility weight loss of each of the reference oils was reached. The base stocks were subjected to the same process as the reference oils. The Noack weight of the base stocks could be determined based on the results obtained from the reference oils.
[0292] The results of the tests are summarized in Table 4, together with results obtained from conventional base stocks (Durasyn 162, a group IV base stock; Durasyn 164, a group IV base stock; Yubase 3, a group II base stock; Yubase 4, a group III base stock; Yubase 4 Plus, a group III base stock; Nexbase 3020, a group II base stock; Nexbase 3030, a group II base stock; Nexbase 3043, a group III base stock; and Chevron 100RLV, a group II base stock). Results obtained from the farnesene-derived ether base stock are also shown for reference.
TABLE-US-00004 TABLE 4 DSC Pour Oxidation Noack KV100 KV40 Point Onset T (% by (cSt) (cSt) VI (? C.) (? C.) weight) GE1 3.3 13.0 125 ?42 201.26 5.9 GE2 3.5 13.7 145 ?36 205.74 5.1 GE3 3.9 16.0 143 ?42 202.89 2.4 GE4 3.3 11.9 146 ?27 213.37 3.9 GE5 2.5 8.2 136 ?60 203.87 17.9 GE6 3.8 14.6 166 ?12 212.71 2.0 GE7 4.0 16.5 144 ?36 206.26 6.8 GE8 2.3 7.7 111 ?66 213.95 44.9 GE9 3.8 14.9 160 ?15 208.17 2.5 SE1 2.7 9.6 123 ?18 195.37 12.9 SE2 2.5 9.0 101 ?45 183.21 51.8 TE1 3.6 14.9 133 212.91 6.8 Durasyn 162 1.7 5.2 92 ?72 223.61 99.6 Durasyn 164 4.0 17.8 126 ?75 221.31 18.8 Yubase 3 3.0 14.1 105 ?36 220.74 38.6 Yubase 4 4.2 19.2 126 ?12 220.00 11.7 Yubase 4 4.2 18.4 138 ?18 220.32 11.6 Plus Nexbase 2.2 7.6 93 ?51 221.66 81.9 3020 Nexbase 3.0 12.0 101 ?39 221.05 36.8 3030 Nexbase 4.3 19.9 124 ?18 222.09 13.2 3043 Chevron 4.6 22.6 119 ?15 225.86 13.2 110RLV Farnesene- 3.2 11.6 152 ?36 222.26 14.1 derived ether
[0293] A graph of volatility against pour point for ether base stocks GE1-GE9, SE1, SE2 and TE1 and the conventional base stocks is shown in
[0294] A graph of volatility against kinematic viscosity at 100? C. for ether base stocks GE1-GE9, SE1, SE2 and TE1 and the conventional base stocks is shown in
[0295] Cold-cranking simulator (CCS) analysis of Guerbet-derived base stocks GE2 and GE3 was also carried out according to ASTM D5293. A graph of volatility against cold-cranking simulator viscosity is shown in
Example 2: Properties of Lubricant Compositions Containing Ether Base Stocks
[0296] Guerbet-derived ether base stocks GE2 and GE3 were blended with conventional base oil additives (additive A, a commercially available additive package; additive B, a cold-flow improver; additive C, an oxidation inhibitor; and additive D, a viscosity index improver) and conventional base oils (Yubase 4, a group III base oil; and Yubase 6, a group III base oil) to form lubricant blends. A Baseline blend and a farnesene-derived ether blend were also prepared. Yubase 4 was chosen as the main component of the Baseline blend, since it exhibits a similar KV100 to Guerbet-derived ether base stock, GE3. The Baseline blend was believed to be a stringent baseline for comparison, since it is a 5W-30 formulation which meets certain specifications (ACEA A5/B5, API-SN/GF-4). The details of the blended compositions are shown in Table 5 in % by weight.
TABLE-US-00005 TABLE 5 Baseline Farnesene- blend GE2 blend GE3 blend derived blend Additive A 16.4 16.4 16.4 16.4 Additive B 0.15 0.15 0.15 0.15 Additive C 0.1 0.1 0.1 0.1 Additive D 4 4 4 4 Yubase 4 67.45 30.47 17.45 17.45 Yubase 6 11.9 11.9 11.9 11.9 GE2 0 36.98 0 0 GE3 0 0 50 0 Farnesene-derived 0 0 0 50 ether
[0297] No problems with miscibility were encountered during preparation of the blended compositions.
[0298] The blended compositions were tested to see whether the advantageous properties of the base stocks would be reflected in a fully formulated lubricant composition. The following properties were tested:
[0299] Kinematic viscosity at 100? C. (KV100) and kinematic viscosity at 40? C. (KV40) were tested according to ASTM D445 (part of SAE J300).
[0300] Viscosity index (VI) was calculated according to ASTM D2270.
[0301] Cold-cranking simulator (CCS) analysis was carried out at ?30? C. according to ASTM D5293 (part of SAE J300).
[0302] High temperature high shear (HTHS) analysis was carried out according to CEC-L-36-A-90.
[0303] Total base number (TBN) was determined according to ASTM D2896.
[0304] Noack volatility was tested according to CEC-L-40-A-93.
[0305] Sulphated ash content was measured according to IP 163.
[0306] The results of the tests are summarized in Table 6.
TABLE-US-00006 TABLE 6 Baseline Farnesene- blend GE2 blend GE3 blend derived blend KV40 (cSt) 53.59 48.26 44.63 38.57 KV100 (cSt) 9.542 9.105 8.688 7.877 VI 164 173 177 181 CCS ?30? C. (cP) 4656 2608 2702 2010 HTHS (cP) 2.98 2.85 2.75 2.62 TBN (mg KOH/g) 11.66 11.29 11.44 10.88 NOACK 11.2 7.7 9.7 14.9 (% by weight) Sulphated ash (%) 1.22 1.26 1.27 1.20
[0307] It can be seen that the properties of the Guerbet-derived base stocks are also exhibited in the blended compositions. In particular, beneficial viscosity, volatility and cold-flow properties are observed. The Guerbet-derived base stocks also exhibited similar HTHS measurements, TBNs and sulphated ash contents to the Baseline blend.
Example 3: Engine Performance of Lubricant Compositions Containing Ether Base Stocks
[0308] The blended compositions from Example 2 were subjected to a TU-5 JP engine test run according to CEC-L-88-02 (part of ACEA A, B and C sequences) in order to determine the oxidative stability of the compositions by assessment of viscosity increases, as well as piston cleanliness and piston ring sticking. The temperature in the oil gallery was controlled to 150? C. for the duration of the test. The results of the TU-5 JP engine tests for the Baseline, GE2 and GE3 lubricant compositions are shown in Table 7.
[0309] The blended compositions from Example 2 were also subjected to MRV testing at ?35? C. according to ASTM D4684 in order to gauge low-temperature viscosity characteristics of the compositions before and after use in the TU-5 JP engine test. The results of the MRV testing are also shown in Table 7.
TABLE-US-00007 TABLE 7 Baseline GE2 GE3 Limits Absolute viscosity increase 47.3 27 13.1 ?57.3 at 40? C. (mm.sup.2/s) Viscosity at 40? C. 53.8 45.1 48.2 None 0 hours (mm.sup.2/s) Viscosity at 40? C. 101.1 72.1 61.3 None 72 hours (mm.sup.2/s) Overall piston merit (?/10) 8.2 9.2 9.0 >7.6 (5 elements, CRC rating) Ring sticking merit 1st ring 10 10 10 ?9 (worst) MRV pre-TU-5 (cP) 21500 7200 7500 Yield stress pre-TU-5 (Pa) <35 <35 <35 MRV post-TU-5 (cP) 56500 11700 18000 Yield stress post-TU-5 (Pa) <35 <35 <35
[0310] The lubricant compositions containing Guerbet-derived base stocks passed all aspects of the TU-5 JP engine test.
[0311] A graph of kinematic viscosity at 40? C. against time is shown in
[0312] A graph showing the overall piston merit is shown in
[0313] The MRV results further demonstrate the excellent low-temperature viscosity characteristics of lubricant compositions containing Guerbet-derived base stocks before and after their use.
Example 4: Engine Compatibility of Lubricant Compositions Containing Ether Base Stocks
[0314] The blended formulation of GE3 from Example 2 was subjected to Mercedes EAM and ACEA RE2 seal tests (test methods VDA 675301 and CEC-L-39-96, respectively) to determine the compatibility of the ether base stocks with typical seals that are found in engines. An ethylene acrylic rubber is used in the EAM test, whilst an acrylic-based rubber is used in the RE2 test. The results of the Mercedes EAM and ACEA RE2 seal tests are shown in Table 8.
TABLE-US-00008 TABLE 8 Baseline GE3 Pass Limits AEM Seal Tensile strength 9.5 3.4 >?35 Test (Mpa % variation) Elongation Rupture ?18.6 ?26.9 >?50 (% variation) Hardness 3 5 10 to ?5 (Variation, points) Relative volume change 2.5 0.3 15 to ?5 (%) ACEA Tensile Strength 2 2 18 to ?15 RE2 (% variation) Elongation Rupture ?32 ?35 10 to ?35 (% variation) Hardness 7 3 8 to ?5 (Variation, points) Relative volume change 0.6 0.6 5 to ?7 (%)
[0315] It can be seen that the lubricant composition containing a Guerbet-derived base stock passed both of the seal tests, indicating that the ether base stocks are suitable for use in engines.
Example 5: Engine Fuel Consumption Performance of Lubricant Compositions Containing Ether Base-Stocks
[0316] Another blended formulation of GE3 and the baseline blend were subjected to an M111 fuel economy test according to CEC-L-054-96 (part of the ACEA A and B sequences) in order to determine the fuel consumption performance of engines run on ether base-stocks. The results are given below in table 9 and are quoted as percentage improvement over the RL191 15W-40 baseline oil commonly used for such assessments. Accordingly, the results reported as Baseline below recite the percentage performance of the Baseline blend (5W-30 formulation mentioned above) over the RL 191 15W-40 standard.
TABLE-US-00009 TABLE 9 Baseline GE3 Pass Limits Fuel Economy 2.89% 3.19% >2.5% Improvement relative to RL191 15W-40
[0317] It can be seen that the lubricant containing a Guerbet-derived base stock passed the fuel economy test and showed an improvement over the baseline lubricant composition, indicating that the ether base stocks offer a fuel economy benefit.