MOTOR OIL BLENDS VOID OF ZPPD AND METHODS FOR REDUCING ENGINE WEAR VIA MOTOR OIL BLENDS VOID OF ZPPD

Abstract

An environmentally-improved motor oil blend and related methods for properly lubricating components of an engine and favorably modifying a plastic response of components of the engine, the blend being free of zinc di-alkyl-di-thiophosphates (ZDDP) and free of zinc di-thiophosphate (ZDTP), comprising: a motor oil selected from the motor oil group consisting of Group I, Group II, Group III, Group IV, and Group V motor oils; a motor oil additive comprising alpha-olefins and hydroisomerized hydro-treated severe hydrocracked base oil; ZDDP omitted from the chemical constituents of the motor oil; and ZDTP omitted from the chemical constituents of the motor oil.

Claims

1. A method of producing a motor oil blend, the method comprising: obtaining a motor oil that is configured to lubricate engines that include loaded steel-on-steel sliding mechanisms and/or non-babbitt bearings, and is void of zinc di-alkyl-di-thiophosphates (ZDDP) and void of zinc di-thiophosphate (ZDTP) as chemical constituents thereof; obtaining a motor oil additive comprising alpha-olefins and hydroisomerized hydro-treated severe hydrocracked base oil; omitting ZDDP from the chemical constituents of said motor oil additive such that the motor oil additive is void of ZDDP; omitting ZDTP from the chemical constituents of said motor oil additive such that the motor oil additive is void of ZDTP; combining said motor oil additive and said motor oil to form a motor oil blend that contains no ZDDP and no ZDDP yet provides lubrication of at least the sliding mechanisms and bearings of such engines and modifies a plastic response of at least a portion of the sliding mechanisms and bearings of such engines sufficient to achieve tribologically-measurable antiwear performance at least as good as that of the motor oil blend for such engines comprising at least one of ZDDP and ZDTP.

2. The method of claim 1, further comprising combining from 5% to 15% by volume of said motor oil additive with from 85% to 95% by volume of said motor oil.

3. The method of claim 1, said motor oil additive further comprising synthetic sulfonates.

4. The method of claim 3, said synthetic sulfonates comprising thixotropic calcium sulfonates.

5. The method of claim 1, said alpha-olefins comprising polymerized alpha-olefins.

6. The method of claim 5, said polymerized alpha-olefins comprising metallocene polymerized alpha-olefins.

7. The method of claim 1, said motor oil additive further comprising vacuum distilled non-aromatic solvent.

8. The method of claim 1, said motor oil additive further comprising liquefied polytetrafluoroethylene (PTFE).

9. The method of claim 1, further comprising: blending said alpha-olefins with said base oil to produce a first blend; blending non-aromatic solvent with synthetic sulfonates to produce a second blend; and blending said first and second blends with liquefied polytetrafluoroethylene (PTFE).

10. The method of claim 9, further comprising combining from 5% to 15% by volume of said motor oil additive with from 85% to 95% by volume of said motor oil.

11. The method of claim 1, further comprising: blending said alpha-olefins with said base oils to produce a first blend; blending non-aromatic solvent with synthetic sulfonates to produce a second blend; blending said first and second blends with additional low-aromatic aliphatic solvents to produce a third blend; and blending said first, second and third blends with liquefied polytetrafluoroethylene (PTFE).

12. A method for lubricating an engine that includes loaded steel-on-steel sliding mechanisms and/or non-babbitt bearings, the method comprising: combining a motor oil configured for the engine and a motor oil additive to form a motor oil blend, said motor oil being void of ZDDP from its chemical constituents, said motor oil being void of ZDTP from its chemical constituents, said motor oil additive comprising polymerized alpha-olefins and hydroisomerized hydro-treated severe hydrocracked base oil, said motor oil additive being void of ZDDP from its chemical constituents, and said motor oil additive being void of ZDTP from its chemical constituents; introducing said motor oil blend that is void of ZDDP and ZDTP into the engine to lubricate at least one of the sliding mechanisms and bearings of the engine and modify a plastic response of at least a portion of the sliding mechanisms and bearings of the engine sufficient to achieve tribologically-measurable antiwear performance at least as good as that of the motor oil blend for such engines comprising at least one of ZDDP and ZDTP, and wherein introducing said motor oil blend into the engine, comprises lubricating the engine to a tribologically-measurable antiwear performance that is at least as good as that of the motor oil blend comprising at least one of ZDDP and ZDTP while preventing the release of environmentally-harmful ZDDP or ZDTP into the environment from the engine.

13. The method of claim 12, wherein said motor oil blend comprises 5% to 15% by volume of said motor oil additive and from 85% to 95% by volume of said motor oil.

14. The method of claim 12, said motor oil additive further comprising synthetic sulfonates.

15. The method of claim 14, said synthetic sulfonates comprising thixotropic calcium sulfonates.

16. The method of claim 12, said alpha-olefins comprising polymerized alpha-olefins.

17. The method of claim 16, said polymerized alpha-olefins comprising metallocene polymerized alpha-olefins.

18. The motor oil blend of claim 12, said motor oil additive further comprising vacuum distilled non-aromatic solvent.

19. The motor oil blend of claim 12, motor oil additive further comprising liquefied polytetrafluoroethylene (PTFE).

20. A method of producing a motor oil blend configured to lubricate an engine, comprising: configuring a motor oil to lubricate steel-to-steel contacting components and/or or between bearing and steel surfaces of the engine, said configuring comprising: obtaining a Group I, Group II, Group III, Group IV, or Group V motor oil; preventing ZDDP from being a chemical constituent of the motor oil such that the motor oil additive is void of ZDDP; preventing ZDTP from being a chemical constituent of the motor oil such that the motor oil is void of ZDTP; obtaining a motor oil additive comprising alpha-olefins and a hydroisomerized hydro-treated severe hydrocracked base oil; preventing ZDDP from being a chemical constituent of the motor oil additive such that the motor oil additive is void of ZDDP; preventing ZDTP from being a chemical constituent of the motor oil additive such that the motor oil additive is void of ZDTP; and combining an amount of said motor oil and an amount of said motor oil additive to form a motor oil blend that is void of ZDDP and ZDDP and is configured to provide lubrication of the engine and favorably modify a plastic response and to influence a chemical reactivity of the surfaces of the steel-to-steel contacting components and/or the bearing and steel surfaces of the engine that inhibits wear between said steel-to-steel contacting components and/or the bearing and steel surfaces to at least the same level than motor oil compositions for such an engine that comprises at least one of ZDDP and ZDTP while preventing the release of ZDDP or ZDTP from the engine during use thereof.

Description

DETAILED DESCRIPTION

[0021] The preferred blending ratios for each of the components of this additive are shown below. It is important to maintain a blend of components falling within the following percentages:

[0022] Polymerized alpha-olefins (PAO): It is preferred that these comprise from 20% to 60% by volume. It is most preferred that these comprise approximately 55% by volume. One may also use alpha-olefins (AO) which have not been polymerized, though PAOs are preferred. One may also use the modern metallocene poly-alpha-olefins (mPAO) which have higher viscosity indexes than conventional PAOs.

[0023] Hydroisomerized high viscosity index (VI) hydro-treated (HT) severe hydro-cracked base oils: It is preferred that these comprise from 5% to 55% by volume. It is more preferred that these comprise from 7% to 25% by volume. It is most preferred that these comprise approximately 21% by volume. It is preferred, but not required, that these base oils have a viscosity grade 32. One may also use can also saturated hydrocarbons, process oil and hydraulic oil for this base oil.

[0024] Synthetic sulfonates: These are preferred, albeit optional ingredients. It is preferred that when used these comprise from 0.05% to 10% by volume. It is most preferred that these comprise approximately 3% by volume. It is preferred that these synthetic sulfonates comprise a total base number (TBN) from 200 to 600. It is most preferred that these comprise a 300 TBN. One may also use thixotropic calcium sulfonates.

[0025] Vacuum Distilled Low-Viscosity and Low-Aromatic Solvents: Often referred to as aliphatic or mineral spirits, these are optional ingredients. It is preferred that when used, these comprise from 10% to 40% by volume. It is most preferred that these comprise approximately 21.5% by volume. The low-aromatic range is preferred to be less than 0.5% aromatic. It is preferred that these solvents have a VOC Exemption, defined by the California Air Resources Board as including those compounds “not expected to meaningfully contribute to ozone formation due to their low reactivity in the atmosphere.” The envisioned low viscosity is in the approximate range of 40 C mm2/s (ASTM D 445) and viscosity at 25 C cSt 2.60 and at 40 C cSt 1.98 (ASTM D 445).

[0026] Liquefied Polytetrafluoroethylene (PTFE): This is an optional ingredient. When used, it is preferred that these comprise from 0.001% to 10% by volume. It is most preferred that these comprise approximately 0.45% by volume. The PTFE should be liquefied to avoid agglomeration, and preferably comprise a stable aqueous dispersion of PTFE particles in water or oil. If oil is used, it is preferred to use 150 solvent neutral petroleum oil or an approximate equivalent.

[0027] The following describes the preferred method for blending these components to produce this motor oil additive.

[0028] Initially, the alpha olefins, and the base oils are blended until the liquid is a consistent amalgamation without any appearance of separation, to yield a first blend. Blending is based on speed of the agitator, and temperature will dictate the amount of time for the blend to complete. The blending time range may vary from 4 to 6 hours. The ideal temperature for each component is between 22 to 30 degrees centigrade for optimum blending.

[0029] Further, the vacuum distilled non-aromatic solvent and synthetic sulfonates are blended together to yield a second blend. This second blend may be prepared in a much smaller, high-speed, enclosed blender. This second blend is then added to the first blend.

[0030] PTFE is used, then the first and second blends are finally blended together with the PTFE.

[0031] If low-aromatic aliphatic solvent is used, then the first and second blends are blended with additional low-aromatic aliphatic solvents to produce a third blend. Then, if PTFE is used, all of the foregoing is blended together with the PTFE.

[0032] It is preferred that there is an approximate 25%/75% ratio of calcium sulfonates to aliphatic or mineral spirits, when these are used.

[0033] This third blend, or the mineral spirits alone absent the synthetic sulfonates, together with the balance of the ingredients, added to the first blend and the agitator is run until the components appear to have thoroughly blended into a consistent liquid. Following the blending, the product is sheered by a high speed sheering pump until the product is consistent. The sheering provides a stable flow viscosity exhibiting Newtonian behavior and greatly enhances the shelf life when there are substantial differences in specific gravity of each component.

[0034] The preferred blending equipment used in this process is as follows: This process involves several blending and holding tanks in which the product can be weighed and then pumped through control valves to maintain consistent flow and pressure. The blending should be performed in an enclosed tank to reduce product evaporation loss and prevent exposure to open spark. Blending equipment can be by a combination of high- or low-speed blending apparatus. The size or volume of the tank is not critical to the blend. Sheering equipment should have a range of 60 to 5200 cycles per second with a typical speed of 3600 cycle per second and be capable of making stable emulsions of products with oil ingredients providing liquid suspensions and dispersions without aeration.

[0035] This motor additive is then combined with a motor oil selected from the motor oil group consisting of Group I, Group II, Group III, Group IV, and Group V motor oils, without the use of ZDDP of ZDTP, to provide an environmentally-improved motor oil blend for properly lubricating components of an engine and favorably modifying a plastic response of components of the engine. The preferred blend ratio is from 85% to 95% by volume of motor oil, and from 5% to 15% by volume of the motor oil additive.

[0036] To create the motor-oil blend, the motor oil and the additive are combined together, and this combination is then simply mixed with a high-speed blender before being packaged. Given the chemical characteristics of motor oil and of the additive, there should be minimal or no separation thereafter while the packaged blend is maintained on a shelf, i.e., the blend should remain homogeneous for whatever shelf-life the motor oil blend may have before it is poured by a user into an engine.

[0037] While not the preferred mode of usage, one could take a motor oil with no ZDDP and no ZDTP and introduce that into an engine separately from introducing the lubricant. However, in this circumstance the user would need to take care to maintain an optimum mix of 85% to 95% by volume of motor oil and 5% to 15% by volume of the motor oil additive. Using a blend that is already combined in the desired ratios is preferred because the user need not then be concerned with maintaining the ratio of motor oil to additive within the desired ranges, and the possibility of user mistake is eliminated.

[0038] Referring to the API properties laid out earlier in the background of the invention, the overall combination of the motor oil with the lubricant, depending upon the viscosity of the host motor oil without ZDDP or ZDTP, will have the following characteristics: 1) For some selected temperatures: 100° C., kinematic viscosity 1.7 to 102.0; 40° C., kinematic viscosity 5.4 to 1350; −40° C.; kinematic viscosity 2,704 to 35,509. 2) Viscosity index: 90 to 200. 3) NOACK Volatility 0.6 to 99.5. 4) Pour point up to −20 to −61 C. Again, these ranges are dependent on the viscosity of the host oil. Finally, 5) the POA (or AO or mPAO) base should have a PAO Unsaturates viscosity grade from PAO-2 to PAO-100.

[0039] Generally, for motor oil blends, the range from PAO-2 to PAO-10 is sufficient. However, for other lubricating applications in which it is desirable to remove environmentally-undesirable chemicals such as ZDDP and ZDTP replace them with the alpha-olefin and base oil additive of this disclosure, given the understanding disclosed in U.S. 62/109,172 regarding how this additive favorably modifies plastic response and influences chemical reactivity, one may find it desirable to use alpha-olefins in the higher range up to and including PAO-100 for other lubricating applications, as outlined further below.

[0040] Specifically, it is also understood and disclosed here that the base combination of alpha-olefins and hydroisomerized hydro-treated severe hydrocracked base oil can serve as a replacement for environmentally-undesirable chemicals not only in motor oils, but in other lubricating/anti-wear agents and applications including, but not limited to: Gear Oils; Automatic Transmission Fluids; Hydraulic Fluids; Greases; Turbine Oils and Fluids; Metal Working Oils;

[0041] Chain Lubes; Compressor Lubricants; Conveyor Lubricants; Paper Machine Oil; Form Oils; Way Oils; Drill Oils; Drawing and Stamping Oil; Bar Oils; 2 Cycle Oil; Steam Oil.

[0042] The ability to omit environmentally-undesirable chemicals in this broad range of circumstances, which chemicals are widely thought to be essential to providing proper lubrication and protecting against wear, emanates from the disclosure in U.S. 62/109,172 that this base combination of alpha-olefins and hydroisomerized hydro-treated severe hydrocracked base oil modifies the plastic response of steel and changes the chemical reactivity of the surfaces subjected to being worn down due to friction whereby these environmentally-undesirable chemicals were not detected under spectroscopic analysis of the wear tracks. So while a very important application of this disclosure is to motor oils because of the widespread usage of these oils and the consequent substantial environmental impact of these oils, it is also understood that the same favorable plastic response modifications and chemical reactivity changes will also transpire in many other applications, which enables this disclosure to be fruitfully applied to those other applications as well, and particularly, to the removal from fluids, lubricants and oils generally of environmentally-undesirable chemicals widely regarded to be essential for proper lubrication and anti-wear protection.

[0043] The knowledge possessed by someone of ordinary skill in the art at the time of this disclosure, including but not limited to the prior art disclosed with this application, is understood to be part and parcel of this disclosure and is implicitly incorporated by reference herein, even if in the interest of economy express statements about the specific knowledge understood to be possessed by someone of ordinary skill are omitted from this disclosure. While reference may be made in this disclosure to the invention comprising a combination of a plurality of elements, it is also understood that this invention is regarded to comprise combinations which omit or exclude one or more of such elements, even if this omission or exclusion of an element or elements is not expressly stated herein, unless it is expressly stated herein that an element is essential to applicant's combination and cannot be omitted. It is further understood that the related prior art may include elements from which this invention may be distinguished by negative claim limitations, even without any express statement of such negative limitations herein. It is to be understood, between the positive statements of applicant's invention expressly stated herein, and the prior art and knowledge of the prior art by those of ordinary skill which is incorporated herein even if not expressly reproduced here for reasons of economy, that any and all such negative claim limitations supported by the prior art are also considered to be within the scope of this disclosure and its associated claims, even absent any express statement herein about any particular negative claim limitations.

[0044] Finally, while only certain preferred features of the invention have been illustrated and described, many modifications, changes and substitutions will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.