Solid anti-friction devices – materials therefor – lubricant or se – Lubricants or separants for moving solid surfaces and... – Inorganic compound
Reexamination Certificate
2001-02-28
2002-10-29
Toomer, Cephia D. (Department: 1714)
Solid anti-friction devices, materials therefor, lubricant or se
Lubricants or separants for moving solid surfaces and...
Inorganic compound
C508S156000, C508S158000, C508S160000, C508S185000, C508S539000, C508S579000
Reexamination Certificate
active
06472352
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to aqueous liquid lubricant compositions suitable for forming a coating containing an organic binder material on metal surfaces that are coated with a layer of the liquid composition and then dried without rinsing, so that the solids content of the aqueous composition forms on the metal surface a solid layer that lubricates the surface during subsequent cold working operations. The solid film thus deposited is protective against mechanical damage during cold working of the underlying metal. The metal surface processed as described above may or may not have other surface layers, such as phosphate or chromate conversion coatings, coatings formed by anodization, complex oxide layers such as those that can be formed with a commercially available product named BONDERITE® 770X from the Henkel Surface Technologies Div. of Henkel Corp., Madison Heights, Mich., or the like, underlying the coating produced on the surface by using this invention. This invention is generally applicable to cold working most metals, especially steel and aluminum alloys.
Many aqueous liquid compositions that form coatings on metal surfaces that protect the metal surface while it is being cold worked are known. The previously most effective ones have generally been zinc, calcium, and/or sodium soaps applied over a preceding heavy phosphate conversion coating on steel substrates or over a complex calcium aluminate conversion coating on aluminum substrates. (Normally, a sodium stearate or other sodium soap salt is applied over a zinc phosphate coating or a calcium aluminate coating. Reaction between the sodium soap and the zinc or calcium in the previous conversion coating is believed to result in both zinc or calcium soap and sodium soap layers.) However, this combination is environmentally disadvantageous, especially when used over phosphate coatings, because the liquid compositions used to form phosphate coatings generally contain some types of metal ions, such as those of zinc, nickel, manganese, and/or the like, that are regarded as polluting, and the phosphate ions themselves, which are required in phosphate conversion coating forming liquid compositions, are environmentally undesirable in waste waters because of their promotion of eutrophication of natural bodies of water. Zinc and calcium soaps are substantially insoluble in water, but cause workplace nuisances at best and hazards at worst because they tend to form fine dust particles in the air around sites of cold working processes when used as cold working lubricants.
Various polymer based lubricants have been taught in the art as replacements for the combination of stearates over zinc phosphate conversion coatings, but heretofore none of the polymer based lubricants have proved to be commercially acceptable in all applications. A frequently objectionable feature of commercial use of prior polymeric lubricants is the presence of scratches on the surface of the cold worked article
A major object of this invention is to provide lubricants and processes that will eliminate or at least reduce the environmental disutilities noted above while still achieving cold working performance that is adequate when compared with the prior art use of phosphate conversion coatings followed by zinc soap application. Other alternative or concurrent objects are to reduce total energy and/or other costs of cold forming operations, particularly by reducing process related waste of objects being cold worked, more particularly because of rejection for scratched surfaces, and/or by achieving higher production rates per unit time. Still another alternative or concurrent object is to provide a lubricant satisfactory for extruding under the more severe conditions in current commercial practice.
Except in the claims and the operating examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about” in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, throughout this description, unless expressly stated to the contrary: percent, “parts of”, and ratio values are by weight; the term “polymer” includes “oligomer”, “copolymer”, “terpolymer”, and the like; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description or of generation in situ by chemical reactions specified in the description, and does not necessarily preclude other chemical interactions among the constituents of a mixture once mixed; specification of materials in ionic form additionally implies the presence of sufficient counterions to produce electrical neutrality for the composition as a whole (any counterions thus implicitly specified should preferably be selected from among other constituents explicitly specified in ionic form, to the extent possible; otherwise such counterions may be freely selected, except for avoiding counterions that act adversely to the objects of the invention); and the term “mole” and its grammatical variations may be applied to elemental, ionic, and any other chemical species defined by number and type of atoms present, as well as to compounds with well defined molecules.
BRIEF SUMMARY OF THE INVENTION
It has been found that a lubricant composition comprising, preferably consisting essentially of, or more preferably consisting of, a combination of;
(A) a component selected from the group consisting of ethoxylated straight chain aliphatic alcohol molecules, wherein the initial alcohol molecules have a single—OH moiety and at least 18 carbon atoms; and
(B) a component selected from the group consisting of lithium salts, sodium salts, and calcium salts of fatty organic acids; and, optionally but preferably,
(C) a component selected from the group consisting of inorganic boron containing acids and salts thereof; and, optionally, one or more of the following components:
(D) a component selected from the group consisting of condensation products of ethylene oxide and/or propylene oxide with triglycerides of fatty acids that include moieties condensable with ethylene oxide and/or propylene oxide;
(E) a component of at least partially neutralized copolymers of (i) an alkene that contains no carboxyl or carboxylate group and (ii) a comonomer that is an organic acid including the moiety C═C—COOH, such at least partially neutralized copolymers of organic acids often being denoted in the art generally and hereinbelow as “ionomers”;
(F) a component of organic corrosion inhibitors that are not part of any of immediately previously recited components (A) through (E);
(G) a component of surfactant molecules that are not part of any of immediately previously recited components (A) through (F); and
(H) a component of antifoam agent molecules that are not part of any of previously immediately recited components (A) through (G) effectively achieves at least one of the objects of the invention as stated above.
It has also been found that a liquid composition comprising water and the following dissolved, dispersed, or both dissolved and dispersed components: (A) a component of ethoxylated straight chain aliphatic alcohol molecules, wherein the ethoxylated straight chain aliphatic alcohol molecules are produced by condensing ethylene oxide with aliphatic mono alcohols that have a single —OH moiety and at least 18 carbon atoms per molecule; and
(B) a component selected from the group consisting of lithium salts, sodium salts, and calcium salts, all of said salts being salts of fatty organic acids, wherein:
component (A) is selected from ethoxylated straight chain aliphatic alcohol molecules in which:
oxyethylene moieties con
Brooks & Kushman P.C.
Henkel Corporation
Toomer Cephia D.
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