Solid anti-friction devices – materials therefor – lubricant or se – Lubricants or separants for moving solid surfaces and... – Organic phosphorus compound – wherein the phosphorus is...
Reexamination Certificate
1999-02-24
2001-03-20
Medley, Margaret (Department: 1714)
Solid anti-friction devices, materials therefor, lubricant or se
Lubricants or separants for moving solid surfaces and...
Organic phosphorus compound, wherein the phosphorus is...
C508S577000, C072S042000
Reexamination Certificate
active
06204227
ABSTRACT:
TECHNICAL FIELD
This invention relates to concentrated lubricant compositions that, upon dilution with water, produce emulsions that are useful as lubricants in metal working processes.
BACKGROUND
Metal working processes of many kinds are used in the fabrication of metal goods. Typically metal is removed from the workpiece during metal working. Examples of metal working processes include machining, cutting, drilling, grinding, turning, milling, tapping and broaching. Metal working differs from metal forming. In metal forming typically no metal is removed. Examples of metal forming processes include rolling, forging, molding, stamping, casting, ironing, drawing, and extruding. In metal forming operations, the metal is typically preheated to at least about 800° C. so that the metal can be more easily formed into the desired shape. In metal working operations, the metal is typically not preheated; the only heat incident to the operation is that caused by the metal working operation itself.
In all metal working operations it is necessary to lubricate the interface between the workpiece and the tool to decrease the force required to work the metal; to cool the workpiece; to remove chips from the cutting zone; to impart a good surface finish; and to extend the life of the tool. The formulation of lubricant compositions is complex, because a wide variety of compounds may be used, as, for example, antifriction agents, anticorrosion agents, surfactants, and biocides.
Triaryl phosphate esters have been proposed for use in metal working lubricant compositions. Berens, U.S. Pat. No. 4,362,634, discloses metal working lubricant compositions that comprise a polyol ester, such as a pentaerythritol/fatty ester, as the major ingredient together with a triaryl phosphate ester and a carboxylic ester non-ionic surfactant of the anhydrosorbitol or glycerol ester type, such as sorbitan monotallate. The phosphate ester comprises 1 to 10 weight % of the concentrated lubricant composition. About 2 to 30 weight % of concentrated composition can be dispersed with water to form a diluted lubricant composition as an emulsion that was reported to be phase stable for at least one hour under quiescent conditions.
Metal working lubricant compositions are preferably produced as concentrates, which are diluted prior to use. Concentrated lubricant compositions are prepared by the manufacturer and shipped in drums to the user, who may store the drums of concentrated lubricant composition for several weeks to months prior to use. Because the lubricant properties of the metal working lubricant composition are typically lost if the lubricant composition deemulisifies, the concentrated lubricant composition should have a shelf life (stability, i.e., time before deemulsification occurs) at room temperature (about 25° C.) of at least one month, and preferably at least six months. The high temperature (about 75° C.) stability and the low temperature stability (about −15° C.) should each be at least 5 days. Following dilution of the concentrated lubricant composition, the resulting diluted lubricant composition should have a shelf life at room temperature of at least one month, preferably at least six months, a high temperature stability of at least one day and a low temperature stability of at least one day.
Thus, there is a need in the art for both concentrated and diluted metal working lubricant emulsions that are stable for longer periods so that they can be produced and stored for longer periods of time prior use.
SUMMARY OF THE INVENTION
In one aspect the invention is a concentrated lubricant composition useful upon dilution with water as a lubricant in metal working operations. The concentrated lubricant composition comprises:
a substantially neutral phosphate ester; optionally, an extreme pressure additive;
a surfactant;
a non-ionic alcohol; and
water;
in which:
the phosphate ester and the extreme pressure additive together comprise 5 to 30% by weight of the composition;
the surfactant and the non-ionic alcohol together comprise 10 to 60% by weight of the composition;
the ratio of the total weight of the surfactant and the non-ionic alcohol to the total weight of the phosphate ester and the extreme pressure additive is 2:1 to 12:1; and
the composition is an emulsion.
In another aspect, the invention is concentrated lubricant composition for use in metal working operations.
The composition comprises:
a substantially neutral phosphate ester;
optionally, an extreme pressure additive;
a high HLB surfactant; and
water;
in which:
the phosphate ester and the extreme pressure additive together comprise 5% to 20% by weight of the composition;
the surfactant comprises 2.5% to 20% by weight of the composition;
the ratio of the weight of the surfactant to the total weight of the phosphate ester and the extreme pressure additive is 0.5:1 to 2:1, and
the composition is a macroemulsion.
In yet another aspect, the invention is a process for using these compositions in metal working operations.
The concentrated lubricant composition emulsions typically are stable on storage at room temperature for up to about six months. When diluted, the diluted lubricant composition emulsions are stable on storage at room temperature for at least ten days, typically at least one month, and offer improved lubricity when used in metal working operations.
REFERENCES:
patent: 3483122 (1969-12-01), MacPhail
patent: 3978908 (1976-09-01), Klaus et al.
patent: 4362634 (1982-12-01), Berens et al.
patent: 4654155 (1987-03-01), Kipp et al.
patent: 4765917 (1988-08-01), Otaki et al.
patent: 4822507 (1989-04-01), Kanamori
patent: 5206404 (1993-04-01), Gunkel et al.
patent: 5495737 (1996-03-01), Graham
patent: 5584201 (1996-12-01), Graham et al.
patent: WO 9302164 (1993-02-01), None
Placek Douglas G.
Rao Arvind M. N.
Medley Margaret
PABU Services, Inc.
Toomer Cephia D.
Woodard Emhardt Naughton Moriarty & McNett
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