Solid anti-friction devices – materials therefor – lubricant or se – Lubricants or separants for moving solid surfaces and... – Nitrogen and heavy metal – or nitrogen and aluminum – in the...
Reexamination Certificate
2002-02-08
2003-11-11
McAvoy, Ellen M. (Department: 1764)
Solid anti-friction devices, materials therefor, lubricant or se
Lubricants or separants for moving solid surfaces and...
Nitrogen and heavy metal, or nitrogen and aluminum, in the...
C508S367000, C554S038000, C556S057000
Reexamination Certificate
active
06645921
ABSTRACT:
TECHNICAL FIELD
The present invention relates to organomolybdenum compositions having high molybdenum content, which are useful as lubricant additives. The organomolybdenum compositions of the present invention are the reaction products of a fatty oil reacted with a diamine, followed by further reaction of the resulting intermediate with a molybdenum source to form the organomolybdenum product compositions, in which the process does not require a volatile organic solvent to promote and achieve high molybdenum incorporation in the additive product, nor does it require sulfur-containing or phosphorus-containing reactants nor post-reaction filtration removal for unreacted molybdenum source reactant.
BACKGROUND OF THE INVENTION
Lubricating oils used in the internal combustion engines of automobiles or trucks are subjected to a demanding environment during use. Among other adverse effects, this environment can lead to oxidative degradation of the oil. This oxidation of the oil is catalyzed by the presence of certain impurities in the oil, such as iron compounds. This oxidation also is promoted by the elevated temperatures to which the oil is subjected during use. The oxidation of lubrication oils during use is usually controlled in part by the use of antioxidant additives, which may extend the useful life of the oil, particularly by reducing or inhibiting unacceptable increases in the viscosity of the oil.
Various molybdenum compounds have been used and proposed as performance-enhancing additives for lubricant compositions. For instance, there are numerous examples in the patent literature which describe the use of molybdenum additives variously as antioxidants, deposit control additives, anti-wear additives and friction modifiers, in lubricant compositions. A partial list of such patent references includes, for example, U.S. Pat. Nos. 4,164,473, 5,840,672, 6,103,674, 6,174,842, and U.S. Reissued Pat. No. RE37,363 E, among others.
The preparation of organomolybdenum additives generally requires complicated reaction steps that add considerable cost to the manufacturing of these additives. Examples of some costly processing steps in this respect are as follows:
1. The use of volatile organic compound (“VOC”) solvents, such as toluene, xylenes, 2-propanol, and dimethylformamide add considerable cost to the production of organomolybdenum compounds.
2. Low levels of molybdenum incorporation into the lubricant additive itself are achieved, which increases cost because higher concentrations of the resulting organomolybdenum product/additive must be used in the oil to deliver the required level of molybdenum to the crankcase package or finished oil. Ideally, it would be desirable to produce these organomolybdenum products/additives having molybdenum contents above 8 percent by weight, and preferably above 10 percent by weight.
3. Filtration is generally required to remove unreacted inorganic molybdenum. Unreacted molybdenum adds considerable cost to the production of organomolybdenum compounds because inorganic molybdenum is an expensive raw material.
4. Other costly processing steps associated with prior schemes for producing organomolybdenum components or lubricant additives include the need for acid or base neutralizations, the use of expensive catalysts or promoters, and water washes.
Examples of such prior processes for making organomolybdenum components or lubricant additives are reported, for example, in the patent literature as follows:
EP 1 136 496 discloses a product derived from methylaminopropylamine (R contains 1 carbon), which shows limited solubility in oil, while products containing 6 or more carbons in the R group have low molybdenum content (less than or equal to 8% undiluted).
EP 1 136 497 discloses molybdenum compounds derived from carboxylic acids and glycerides, which are relatively expensive.
U.S. Pat. No. 4,889,647 discloses molybdenum products that have relatively low molybdenum contents, for example 6 percent by weight, or lower.
U.S. Pat. No. 6,103,674 discloses molybdenum products that have low molybdenum contents, for example, 8 percent by weight or lower, and which contain sulfur.
Sulfur can be an undesirable component in engine oils. At high temperatures and under severe conditions, even the less aggressive forms of sulfur can cause corrosion, and in some cases elastomeric seal incompatibility (e.g., rubber hardening). Ideally, therefore, molybdenum compounds intended for use in lubricant engine oils should have minimal sulfur content.
U.S. Pat. No. 4,692,256 discloses a process for making an organomolybdenum compound that requires neutralization steps and water separations in order to isolate the organomolybdenum compound. When water is used as a promoter, as in U.S. Pat. No. 4,692,256, a filtration is required to remove unreacted molybdenum.
U.S. Pat. No. 5,137,647 discloses a sulfur and phosphorous-free organomolybdenum complex of organic amide, such as molybdenum containing compounds prepared from the reaction of fatty derivatives of 2-(2-aminoethyl)aminoethanol with a molybdenum source, in which the reaction temperature can be as high as 160° C. The sole example provided therein has a reaction temperature ranging from 130° C. to 140° C., and a filtration is carried out. Also, the reaction product is filtered, which adds an additional processing step.
U.S. Pat. No. 4,765,918 discloses molybdenum-containing compositions derived from fatty oils, amines, and a sulfur source.
U.S. Pat. No. 5,412,130 discloses molybdenum products derived from specially pre-treated fatty oils, e.g., treated by epoxidation followed by alkylation, that are reacted with molybdenum using a very specific fatty oil-derived catalyst. This special pre-treatment of the fatty oil adds considerable cost to the resulting product, making it impractical for use in lubricants.
The above problems suggest a previously unfulfilled need in the lubricant additive and composition industry and related technologies for oil soluble, sulfur-free molybdenum additives having high molybdenum content and low tendency to discolor finished oils without the need to use volatile solvents and without the need to remove non-reacted molybdenum. It has unexpectedly been found that the molybdenum additives of the present invention provide the above benefits to lubricating compositions without the attendant problems.
SUMMARY OF THE INVENTION
The present invention is directed to unique organomolybdenum compositions, which are especially useful as lubricant additives. To form the organomolybdenum compositions of this invention, a fatty oil, a diamine and a molybdenum source are combined in the absence of a volatile organic solvent yet effective to form a high organo molybdenum content reaction product. This reaction product obtained also does not have to be filtered to remove unreacted molybdenum source material.
In a more particular aspect, the present invention is directed to an organomolybdenum composition comprising the reaction product of a fatty oil reacted with an aliphatic diamine, followed by further reaction of the resulting intermediate reaction product with a molybdenum source in the absence of volatile organic solvent and without need for post-reaction filtering. In one preferred aspect, the first process step is performed neat, while in the second process step a small amount of water, but no volatile organic solvent is introduced or present during the molybdenum incorporation reaction, sufficient for the molybdenum source ingredient to go into solution such that reaction still proceeds well.
In one further aspect, the diamine reactant used is a monsubstituted amine having high hydrocarbon character, such as represented by the following general structure:
where x is 1 or 2, and R is a hydrocarbon-containing group containing at least about 6 carbon atoms. In one preferred aspect, the R group also contains oxygen, such as where R represents an alkyloxyalkylene group.
In another aspect, this invention provides a low cost process for producing sulfur- and phosphorus-free organomolybdenum compositions with h
Ethyl Corporation
McAvoy Ellen M.
Rainear Dennis H.
Robinson Leah O.
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