Solid anti-friction devices – materials therefor – lubricant or se – Lubricants or separants for moving solid surfaces and... – Heavy metal or aluminum bonded directly to carbon
Reexamination Certificate
2001-08-10
2003-06-03
Johnson, Jerry D. (Department: 1764)
Solid anti-friction devices, materials therefor, lubricant or se
Lubricants or separants for moving solid surfaces and...
Heavy metal or aluminum bonded directly to carbon
C508S118000, C508S175000, C508S468000, C508S485000, C508S496000
Reexamination Certificate
active
06573224
ABSTRACT:
TECHNICAL FIELD
This invention relates generally to lubricant compositions and fuel-lubricant mixtures useful in internal combustion engines. It is particularly useful in two-cycle engines, four-cycle engines, grease lubricants, fuels (diesel and gasoline), and gears, and to methods of treating two-cycle engines, four-cycle engines, and gears to improve their cleanliness and operating efficiency.
BACKGROUND OF THE INVENTION
The use of lubricants in two-cycle and four-cycle engine operation is common place. Such lubricants serve to allow facile movement between adjoining moving parts of the engine. However, the use of lubricants, as well as the fuels used to power the engine, often cause undesirable side-effects. Such side-effects include deposition of partially oxidized organic materials along pistons and other moving parts. These deposits interfere with the efficient operation of both two-cycle and four-cycle engines and gears.
Over the past several decades, the use of spark-ignited two-cycle (2-stroke) internal combustion engines has steadily increased. They are presently found in power lawn mowers and other power-operated garden equipment, power chain saws, pumps, electrical generators, marine outboard engines, snowmobiles, motorcycles and the like. The increasing use of two-cycle engines coupled with increasing severity of the conditions in which they have operated has led to an increased demand for oils to adequately lubricate such engines and which provide enhanced performance. Among the problems associated with two-cycle engines are piston ring sticking, piston scuffing, rusting, lubrication-related failure of connecting rod and main bearings and the general formation on the engine's interior surfaces of carbon and varnish deposits. Piston ring sticking is a particularly serious problem. Ring sticking leads to failure of the sealing function of piston rings. Such sealing failure causes loss of cylinder compression which is particularly damaging in two-cycle engines because these engines depend on suction to draw the new fuel charge into the exhausted cylinder. Thus, ring sticking can lead to deterioration in engine performance and unnecessary consumption of fuel and/or lubricant. Other concerns associated with two-cycle engines include piston lubricity, scuffing and scoring.
Four cycle engines, commonly found in automobiles, have been use for over 60 years. However, their operation is still attended by problems such as the production of organic and to some extend inorganic deposits on the internal surfaces of the engine. Where these surfaces are moving parts (e.g., pistons), a severe decrease in engine operating efficiency attends such deposits.
Gears are used in industry, transportation, and many other areas. Gears transmit power and alter the direction of movement. The load on gear teeth (the load-bearing surface) is intermittent and higher than on most other bearing or loaded surfaces. The lateral sliding action of gear teeth imposes severe lubrication requirements. While gear lubricants must have superior anti-wear and extreme pressure protection they must also be non-corrosive to “yellow metal” (copper alloy) components. Gear lubricants, particularly ones used in mining, milling, and similar operations need to be composed of high viscosity index oils and extreme pressure/anti-wear agents.
Grease lubrication of bearings, gears, and other components is used when seals or other devices can not be used to prevent migration of the lubricant away from lubricated surfaces. Grease consists of thickeners, typically 6 to 10 percent by weight of the mixture, lubricating oil, and additives to enhance the performance of the grease. The thickener in grease acts as a “sponge” to keep the oil and additives on the bearing, gear, or other component being lubricated. The additives used in grease blending are similar to the ones used in the production of gear, engine oil, and other petroleum based lubricants.
The lubrication of fuel system components such as diesel pumps, diesel injectors, gasoline engine valves, the upper cylinder, and ring area of four cycle and two cycle engines has become an important area of research as fuel composition changes to meet new environmental regulations. Upper cylinder lubricants act to lubricate and clean the ring and upper cylinder area of spark and compression ignition engines. This action can benefit fuel economy, emissions, as well as ring and cylinder wear. The introduction of low sulfur diesel fuels has increased wear in pumps and diesel fuel injectors. Lubricants that will operate successfully at high temperatures and not contribute to damage of emission control devices are difficult to develop.
All of the aforementioned problems associated with two-cycle and four-cycle engines must be adequately addressed. Improved performance is continually being sought. The unique problems and techniques associated with the lubrication of two-cycle and four-cycle engines has led researches to develop a wide variety of products. However, further improvements in terms of combustion efficiency, lubrication efficiency and the like are still needed. The present invention fulfills these needs and provides further advantages in the context of in engine lubrication.
SUMMARY OF THE INVENTION
In brief, the present invention is directed to lubricant and anti-wear compositions for two-cycle and four-cycle engines. Suitable compositions for two-cycle engines comprise a copolymer of an alpha olefin and diester selected from a dialkyl fumarate and a dialkyl maleate, an aliphatic diester having exactly two ester groups and about 20-40 carbon atoms, preferably in the presence of an octane booster, such as methylcyclopentadienyl manganese tricarbonyl.
Suitable anti-wear compositions for four-cycle engines comprise a copolymer of an alpha olefin and diester selected from a dialkyl fumarate and a dialkyl maleate, a molybdenum or bismuth compound, an anti-corrosion additive such as dimercapto 1,3,4 thiadiazole and a extreme pressure additive such as sulfur-phosphorous EP or chlorinated paraffin. A fullerene compound (optionally dissolved in mineral oil) is a preferred optional ingredient for the anti-wear composition.
Another suitable gear lubricant composition is made with a copolymer of an alpha olefin and diester selected from a dialkyl fumarate and a dialkyl maleate, a molybdenum or bismuth compound, an anti-corrosion additive such as dimercapto 1.3.4 thiadiazole. A fullerene compound (optionally dissolved in mineral oil) is a preferred optional ingredient for the anti-wear composition. This blend may also be used as an anti-wear and extreme pressure additive in grease and fuels.
Another suitable composition for four-cycle engines is termed herein a synthetic lubricant composition (SLC) and comprises one or both of a copolymer of an alpha olefin and diester selected from a dialkyl fumarate and a dialkyl maleate, and an aliphatic diester having exactly two ester groups and about 20-40 carbon atoms. The SLC further comprises a molybdenum or bismuth compound, an anti-corrosion additive such as dimercapto 1,3,4 thiadiazole, and extreme pressure additive such as sulfur-phosphorous EP or chlorinated paraffin (optionally in an oil (e.g., vegetable oil) base), and fullerene (optionally in an oil (e.g., naphthalenic oil) base).
In another aspect, the invention is directed to operation of two-cycle and four-cycle engines using the compositions of the invention, as well as gear oil and grease lubricants.
These and other aspects of this invention will become apparent upon reference to the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
As briefly explained above, the invention is directed to compositions that may be added to internal combustion engines, particularly two-cycle and four-cycle engines, in order to improve the performance thereof. In addition, the invention is directed to methods of operating internal combustion engines under conditions of high efficiency and cleanliness of operation. The various compositions of the invention will now be describ
Eskridge Mark
Kiehn Arthur J.
McNeil Hugh A.
Bardahl Manufacturing Corporation
Johnson Jerry D.
Seed Intellectual Property Law Group PLLC
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