LUBRICTING OIL COMPOSITIONS AND USES

A non-aqueous lubricating oil composition comprises a major amount of a base oil and a minor amount of an additive which is present in solution in the base oil and is a non-halide, non-aromatic ionic liquid which is a salt of general formula C+A−, with the cation, C+, being a quaternary phosphonium or quaternary ammonium ion having four hydrocarbyl groups, optionally containing heteroatoms, which hydrocarbyl groups do not all have the same number of carbon atoms, there being at least one long chain hydrocarbyl group having greater than 4 carbon atoms and at least one short chain hydrocarbyl group having fewer carbon atoms than each of the long chain hydrocarbyl groups, and the anion, A−, comprising at least one oxygen atom and having an ionic head group attached to at least one alkyl or alicyclic hydrocarbyl group which has at least four carbon atoms and optionally at least one heteroatom. The ionic liquid may be used as an anti-wear component in a lubricating oil composition. The ionic liquid may be used as a friction modifier in the lubricating oil composition. The lubricating oil composition may be used in an ignition engine.

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Description

The present invention relates to a composition, in particular, to a non-aqueous lubricating oil composition and to an additive concentrate. The present invention also relates to the use of an additive to reduce wear and/or to modify friction properties.

Lubricating oil compositions, in general, comprise a major amount of a base oil and a minor amount of at least one additive. Additives frequently used in lubricating oil compositions include detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam additives, friction modifiers and anti-wear additives.

Anti-wear additives are used in lubricating oil compositions to reduce the wear of components that are lubricated by the lubricating oil composition. The anti-wear additives most commonly used in lubricating oil compositions for engines are ZDDPs (zinc dialkyldithiophosphates). However, ZDDPs are a source of sulphated ash, sulfur and phosphorus which may poison catalysts in catalytic converters, which could result in a reduction in performance of the catalyst.

Ionic liquids have recently been shown to be potentially suitable for some lubricant applications.

An ionic liquid is an ionic material which, at atmospheric pressure, is in a liquid state at temperatures below 150° C., particularly at temperatures below 100° C. Since they are comprised entirely of ionic material, ionic liquids possess virtually no vapour pressure. Therefore, in use, they generally present a low risk of atmospheric contamination, have no odour, and are likely to have a low impact on human health. Further, ionic liquids are generally non-flammable, thermally stable and liquid over a wide range of temperatures. However, due to their ionic nature, miscibility of ionic liquids in non-polar organic solvents, for example non-aqueous lubricant base oils, tends to be limited.

Some ionic liquids have been shown to be capable of use as lubricant base oils, as neat lubricants and as solvents in the synthesis of polyalphaolefin base oils.

Jiménez et. al., in Wear 260 2006 766-782, and Wear 261 2006 347-359 have shown 1-n-alkyl-3-methylimidazolium ionic liquids to be potentially useful as neat lubricants and lubricant additives in the lubrication of steel-aluminium contacts. However, the Applicant has found that, at temperatures between room temperature and 100° C., such ionic liquids are insoluble in Group I to IV base oils, as well as in some Group V base oils. Such insolubility is undesirable, for example for engine lubricants, which are desirably clear. Furthermore, the ionic liquids described in these two papers comprise fluorine-containing anions. The presence of fluorine in lubricants is undesirable, particularly for engine lubricants, since high temperatures may lead to the production of toxic compounds, for example, hydrofluoric acid. Fluorine compounds, such as salts of [PF6]−, are also expected to be corrosive.

Liu et al in Wear 261 (2006) 1174-1179 describe a series of asymmetrical tetraalkylphosphonium ionic liquids and their evaluation as lubricants for steel/aluminium contacts where BF4− anions were used.

International Patent Publication WO 2006/120145 relates to liquid for compressing a gaseous medium and use of the same. According to this document certain molecular liquids with a low vapour pressure of the order of 10−4 to 10−10 mbar are said to include perfluoropolyether, polyphenyl-ether or polyphenyl-thioether, silicon oil, mineral oil, synthetic oil or a mixture of at least two of these and it states that liquids that are mixtures of at least one ionic compound and at least one molecular compound can be employed. According to this document, in accordance with a preferred embodiment, the liquid is an emulsion and in accordance with an additional preferred embodiment, the liquid can be a liquid crystalline or a mixture of a micro- to nanocrystalline solid with at least one ionic and/or at least one molecular liquid. It is stated that such liquids behave in some respects more like solids and this makes them especially well suited for use in the compression of gaseous substances. Also, according to this document, liquids that can be use can also be mixtures from at least one ionic compound with at least one molecular liquid. It is stated that in this context, the liquid can be an emulsion or liquid crystalline or a mixture of a micro to nanocrystalline solid with at least one ionic and/or at least one molecular liquid.

There remains a need for a lubricating oil composition which avoids or at least mitigates these disadvantages.

According to a first aspect of the present invention, there is provided a non-aqueous lubricating oil composition comprising a minor amount of an additive and a major amount of a base oil characterised in that the additive is present in solution in the base oil and is a non-halide, non-aromatic ionic liquid which is a salt of general formula C+A− having an atmospheric melting point in the range of −50° C. to 250° C., preferably, in the range of −50° C. to 150° C., with the cation, C+, being a quaternary phosphonium or quaternary ammonium ion having four hydrocarbyl groups, optionally containing heteroatoms, which hydrocarbyl groups do not all have the same number of carbon atoms, there being at least one long chain hydrocarbyl group having greater than 4 carbon atoms and at least one short chain hydrocarbyl group having fewer carbon atoms than each of the long chain hydrocarbyl groups, and the anion, A−, comprising at least one oxygen atom and having an ionic head group attached to at least one alkyl or alicyclic hydrocarbyl group which has at least four carbon atoms and optionally at least one heteroatom.

The cation and the anion of the ionic liquid according to the present invention do not contain any halide atoms. The ionic liquid is halide-free.

The ionic liquid defined herein may be used as an additive in a lubricating oil composition to reduce wear.

Thus, according to a further aspect of the present invention, there is provided the use of a base oil-soluble ionic liquid as an additive in a non-aqueous lubricating oil composition comprising a major amount of a base oil and a minor amount of the ionic liquid in solution in the base oil, to reduce wear of components lubricated by the lubricating oil composition, in which use, the ionic liquid is a non-halide, non-aromatic ionic liquid which is a salt of general formula C+A− having an atmospheric melting point in the range of −50° C. to 250° C., preferably in the range of −50° C. to 150° C., with the cation, C+, being a quaternary phosphonium or quaternary ammonium ion having four hydrocarbyl groups, optionally containing heteroatoms, which hydrocarbyl groups do not all have the same number of carbon atoms, there being at least one long chain hydrocarbyl group having greater than 4 carbon atoms and at least one short chain hydrocarbyl group having fewer carbon atoms than each of the long chain hydrocarbyl groups, and the anion, A−, comprising at least one oxygen atom and having an ionic head group attached to at least one alkyl or alicyclic hydrocarbyl group which has at least four carbon atoms and optionally at least one heteroatom.

The ionic liquid defined herein may be used as an additive in a lubricating oil composition to modify friction properties.

Thus, according to yet a further aspect of the present invention, there is provided the use of a base oil-soluble ionic liquid as an additive in a non-aqueous lubricating oil composition comprising a major amount of a base oil and a minor amount of the ionic liquid in solution in the base oil, to modify the friction properties of the lubricating oil composition, in which use, the ionic liquid is a non-halide, non-aromatic ionic liquid which is a salt of general formula C+A− having an atmospheric melting point in the range of −50° C. to 250° C., preferably in the range of −50° C. to 150° C., with the cation, C+, being a quaternary phosphonium or quaternary ammonium ion having four hydrocarbyl groups, optionally containing heteroatoms, which hydrocarbyl groups do not all have the same number of carbon atoms, there being at least one long chain hydrocarbyl group having greater than 4 carbon atoms and at least one short chain hydrocarbyl group having fewer carbon atoms than each of the long chain hydrocarbyl groups, and the anion, A−, comprising at least one oxygen atom and having an ionic head group attached to at least one alkyl or alicyclic hydrocarbyl group which has at least four carbon atoms and optionally at least one heteroatom.

The present invention solves the technical problem defined above by providing an ionic liquid having a defined structure which imparts solubility in the base oil. The defined non-halide, non-aromatic ionic liquid additive of the present invention is present in solution in the base oil in the non-aqueous lubricating oil composition of the present invention.

The ionic liquid of the present invention may be used as an anti-wear additive and/or a friction modifier in a lubricating oil composition. It is believed that the ionic liquids of the present invention do not produce (or produce less) undesirable decomposition products, for example, like those produced by ZDDPs (e.g. sulphated ash). Also, it is believed that the ionic liquids of the present invention will not produce toxic or corrosive compounds, unlike halide-containing ionic liquids.

The cation, C+, is a quaternary phosphonium or quaternary ammonium ion having four hydrocarbyl groups, optionally containing heteroatoms, which hydrocarbyl groups do not all have the same number of carbon atoms, there being at least one long chain hydrocarbyl group having greater than 4 carbon atoms and at least one short chain hydrocarbyl group having fewer carbon atoms than each of the long chain hydrocarbyl groups.

Preferably, the at least one short chain hydrocarbyl group of the cation has more than two fewer carbon atoms than each of the long chain hydrocarbyl groups. The hydrocarbyl groups of the cation are preferably straight chain hydrocarbyl groups. The hydrocarbyl groups of the cation may each have independently, up to and including 18 carbon atoms, more preferably, up to and including 16 carbon atoms. Suitable long chain hydrocarbyl groups of the cation may each have independently, 6 to 18 carbon atoms, preferably, 6 to 16 carbon atoms. Suitable short chain hydrocarbyl groups of the cation may each have independently, 1 to 8 carbon atoms.

The hydrocarbyl groups of the cation may each have independently, at least one heteroatom, for example oxygen and/or sulfur.

Examples of cations of ionic liquids according to the present invention are set out in Table 1 below.

TABLE 1 Short chain hydrocarbyl Long chain hydrocarbyl group(s) group(s) n-octyl, n-octyl, n-octyl Methyl n-tetradecyl n-hexyl, n-hexyl, n-hexyl n-dodecyl, n-dodecyl, n-dodecyl n-butyl n-dodecyl, n-dodecyl, n-dodecyl 2-n-butoxyethyl

These examples show that the cation may have three long chain hydrocarbyl groups and one short chain hydrocarbyl group, or may have one long chain hydrocarbyl group and three short chain hydrocarbyl groups. Alternatively, the cation may have two long chain hydrocarbyl groups and two short chain hydrocarbyl groups.

The cation may be selected from the group consisting of tri-n-octyl(methyl) phosphonium, tri-n-octyl(methyl) ammonium, tri-n-hexyl(n-tetradecyl) phosphonium, tri n-hexyl(n-tetradecyl) ammonium, tri-n-dodecyl(n-butyl) ammonium, tri-n-dodecyl(n-butyl) phosphonium, tri-n-dodecyl(n-butoxyethyl) phosphonium, tri-n-dodecyl(n-butoxyethyl) ammonium.

Examples of quaternary phosphonium cations include tri-n-hexyl(n-tetradecyl) phosphonium; tri-n-dodecyl(n-butyl) phosphonium; and tri-n-dodecyl(2-n-butoxyethyl) phosphonium cations. Examples of quaternary ammonium cations include tri-n-octyl(methyl)ammonium cation.

The anion may contain one or more heteroatoms, for example, sulfur and/or phosphorus. The anion has at least one alkyl or alicyclic hydrocarbyl group which has at least four carbon atoms, but no aromatic groups. The anion may have more than one alkyl or alicyclic hydrocarbyl group each independently having at least four carbon atoms. The alkyl and/or alicyclic hydrocarbyl group or groups of the anion may be independently, branched- or straight-chain.

Suitably, the anion, A− is selected from the group consisting of anions (a) to (c) defined herein.


Anions of the general formula: [R1R2P(O)O]−  (a)

wherein R1 and R2 are independently, alkyl or alicyclic hydrocarbyl groups each having at least four carbon atoms and optionally containing at least one heteroatom. The hydrocarbyl groups may be branched or straight chain. Preferred alkyl hydrocarbyl groups include alkyl groups each independently, having 4 to 1.8 carbon atoms, preferably, 4 to 16 carbon atoms, more preferably 4 to 8 carbons atoms. Particularly preferred alkyl groups include 2,4,4-trimethylpentyl. Preferred alicyclic hydrocarbyl groups include alicyclic groups having 6 carbon atoms. Particularly preferred alicyclic groups include cyclohexyl. The hydrocarbyl groups may be branched or straight chain. Preferred hydrocarbyl groups include alkyl groups each having independently, 4 to 18 carbon atoms, preferably 4 to 16 carbon atoms, more preferably 4 to 8 carbons atoms. Examples of anions of this group include phosphinate anions, for example, bis(2,4,4-trimethylpentyl)phosphinate and dicyclohexylphosphinate.

The optional at least one heteroatom may be at least one heteroatom selected from the group consisting of oxygen, sulfur, phosphorus and combinations thereof. Thus, suitable anions can include those of general formula [(R3O)(R4O)P(O)O]− wherein R3 and R4 are independently, alkyl or alicyclic hydrocarbyl groups each independently, having at least four carbon atoms, preferably 4 to 18 carbon atoms, more preferably 4 to 16 carbon atoms, for example, 4 to 6 carbon atoms. R3 and R4 may each contain independently, at least one heteroatom, for example oxygen. Thus, R3 and R4 may each independently be ether groups having 4 to 18 carbon atoms, preferably 4 to 16 carbon atoms, for example, 4 to 6 carbon atoms. Specific examples of anions of this group include phosphate, anions, for example di n-butylphosphate and bis(2-butoxyethyl)phosphate.

Preferred anions of group (a) are those of general formula [(R3O)(R4O)P(O)O]− wherein R3 and R4 are independently, alkyl hydrocarbyl groups each independently, having at least four carbon atoms, preferably 4 to 18 carbon atoms, more preferably 4 to 16 carbon atoms, for example, 4 to 6 carbon atoms and wherein R3 and R4 may each contain independently, at least one heteroatom, for example oxygen. Specific examples of anions of this group include phosphate anions, for example di n-butylphosphate and bis(2-butoxyethyl)phosphate.


Sulfosuccinate esters of general formula: R1OOCCH2CH(SO3−)COOR2  (b)

wherein R1 and R2 are straight chain or branched chain C4 to C8 alkyl groups. Examples of sulfosuccinate esters include dioctylsulfosuccinate and dihexylsulfosuccinate.


Carboxylate anions of general formula: RC(O)O−  (c)

wherein R is a straight chain or branched chain C9 to C17 alkyl or alkenyl group. A suitable example of this group of anions is decanoate.

Aromatic hydrocarbyl groups are preferably not present in the anion.

Preferably, the minor amount of ionic liquid is present in the lubricating oil composition at a concentration in the range of 0.1 to 10% by weight.

The base oil may comprise one or more base stocks each of which is any one of Groups I to V according to API standard 1509, “ENGINE OIL LICENSING AND CERTIFICATION SYSTEM”, November 2004 version 15th edition Appendix E, which defines base stocks for base oils as belonging to one of five Groups as set out in Table 2 below.

TABLE 2 Base stocks Saturated hydrocarbon Sulfur content content Group (wt %) (wt %) Viscosity Index I <90 and/or >0.03 and ≧80 and <120 II ≧90 and ≦0.03 and ≧80 and <120 III ≧90 and ≦0.03 and ≧120 IV polyalpha olefins V all base stocks not in Groups I, II, III or IV

Preferably, phosphorus atoms are present in both the cation and the anion of the ionic liquid. Preferably, phosphorus atoms are present in the ionic liquid and the minor amount of the ionic liquid is present in the lubricating oil composition in an amount corresponding to no more than 0.05% by weight phosphorus based upon the lubricating oil composition.

Sulfur atoms may be present in the ionic liquid. If sulfur atoms are present in the ionic liquid, preferably the minor amount of the ionic liquid is present in the lubricating oil composition in an amount corresponding to no more than 0.2% by weight sulfur based upon the lubricating oil composition.

The lubricating oil composition may comprise at least one further additive component selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives.

The ionic liquid defined herein may be used as a friction modifier in a lubricating oil composition, in which case the lubricating oil composition will usually comprise one or more other friction modifiers. Such friction modifiers may be present in lesser amounts than might be required to achieve a predetermined performance of the lubricating oil composition and/or such friction modifiers may be present in conventional amounts such that the lubricating oil has improved friction properties. Suitable other friction modifiers may comprise oxygen-containing organic compounds, for example those selected from the group consisting of alcohols, esters and carboxylic acid derivatives. Other friction modifiers may comprise organic molybdenum compounds for example molybdenum dialkyldithiophosphates or molybdenum dialkyldithiocarbamates.

The other friction modifiers may be present in the lubricating oil composition at a concentration in the range from greater than 0 to 10%, by weight, preferably in the range 0.1 to 10% by weight.

Preferably, the low shear rate kinematic viscosity of the lubricant composition is in the range 3.8 to 100 cSt at 100° C., preferably 3.8 to 41.0 cSt at 100° C., most preferably 3.8 to 26.1 cSt at 100° C.

The lubricating oil composition of the present invention may be prepared by mixing the ionic liquid into the base oil and heating the mixture to 70° C. The ionic liquid may be mixed with the base oil as an additive concentrate.

Thus, according to yet a further embodiment of the present invention, there is provided an additive concentrate comprising a base oil-soluble ionic liquid as herein defined and at least one further additive selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives and optionally a solvent. Preferably, the additive concentrate comprises a base oil-soluble ionic liquid as herein defined, at least one other function modifier and at least one further additive selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives and optionally a solvent.

The lubricating oil composition of the present invention is suitable for use as a lubricant in an ignition engine. The lubricating oil composition of the present invention is suitable for use as a lubricant in transmissions and/or gears.

According to a further aspect of the present invention, there is provided a method of operating a spark ignition engine or a compression ignition engine which method comprises lubricating said engine with a lubricating oil composition according to any one of the embodiments described herein.

The present invention will now be illustrated with reference to the following non-limiting examples and FIGS. 1 to 3. FIGS. 1 to 3 are graphs showing the friction properties of lubricating oil compositions according to the present invention, in particular, FIG. 1 shows Stribeck curves, FIG. 2 shows friction coefficients using a Cameron-Plint apparatus, and FIG. 3 shows friction coefficients according to high frequency reciprocating rig (HFRR) and a high temperature high frequency reciprocating rig (HTHFRR) tests.

Ionic Liquid Preparation

The following ionic liquids (ILs) were prepared:

Trioctyl(methyl)ammonium dioctylsulfosuccinate (IL 1)

This ionic liquid, also called trioctyl(methyl)ammonium docusate, may be represented by the general formula I.

IL 1 was prepared by stirring a solution of trioctyl(methyl)ammonium chloride (404 g, 1.00 mol) and sodium dioctylsulfosuccinate salt (454 g, 1.02 mol) in deionised water (1.5 L) in a round-bottomed flask using an overhead stirrer set at 450 rpm for 16 hours at 60° C. The product, a pale yellow liquid, formed an upper phase in the reaction mixture, which was separated and washed a number of times with water (7×750 mL). The product was dissolved in a minimum amount of dichloromethane and dried over anhydrous magnesium sulfate. It was then dried in a rotary evaporator and then further dried by heating at 80° C., under vacuum at 1 mbar, to yield a pale yellow viscous liquid.

Trihexyl(tetradecyl)phosphonium dicyclohexylphosphinate (IL 2)

This ionic liquid may be represented by the general formula II.

IL 2 was prepared by the following two step method adapted from that described in WO 02/079212 and Bradaric et al Green Chem. 2003, 5, 143.

Step 1: Dicyclohexylphosphinic acid (461 g, 2.0 mol) was dissolved in a minimum amount of methanol (100 mL) in a round-bottomed flask. An excess of sodium hydroxide (120 g, 3.0 mol) was dissolved in methanol (1.0 L) and was added slowly to the solution in small portions with stirring over a 30 minute period. After this time, a colour change of light yellow to dark yellow occurs. The product was then dried on a rotary evaporator giving a white solid of sodium salt of dicyclohexylphosphinic acid.

Step 2: Trihexyl(tetradecyl)phosphonium chloride (520 g, 1.0 mol) was dissolved in propanone (1 L) in a round-bottomed flask. The sodium salt of dicyclohexylphosphinic acid (2.0 mol) prepared in step 1 was dissolved in deionised water (1 L) and was added slowly to the solution in small portions with stirring over a 10 minute period. The solution was stirred using an overhead stirrer set at 450 rpm, for 36 hours at 25° C. The product, a pale yellow liquid, formed an upper phase in the reaction mixture, which was separated and washed a number of times with water (7×750 mL). The product was dissolved in a minimum amount of ethyl ethanoate and dried over anhydrous magnesium sulfate then dried on a rotary evaporator and then further dried by heating at 80° C., under vacuum at 1 mbar, to yield a pale yellow viscous liquid.

Trihexyl(tetradecyl)phosphonium bis(2,4,4-trimethylpentyl)phosphinate (IL 3)

This ionic liquid may be presented by the general formula III.

IL 3 was prepared by the following two step method adapted from that described in WO 02/079212 and Bradaric et al Green Chem. 2003, 5, 143.

Step 1: Bis(2,4,4-trimethylpentyl)phosphinic acid (290 g, 2.0 mol) was dissolved in a minimum amount of methanol (100 mL) in a round-bottomed flask. An excess amount of sodium hydroxide (120 g; 3.0 mol) was dissolved in methanol (1.0 L) and was added slowly to the solution in small portions with stirring over a 30 minute period. After this time a colour change of light yellow, to dark yellow occurs. The product was then dried on a rotary evaporator giving a white solid of the sodium salt of bis(2,4,4-trimethylpentyl)phosphinic acid.

Step 2: Trihexyl(tetradecyl)phosphonium chloride (520 g, 1.0 mol) was dissolved in propanone (1 L) in a round-bottomed flask. The sodium salt of bis(2,4,4-trimethylpentyl)phosphinic acid (2.0 mol) prepared in step 1 was dissolved in deionised water (1 L) and was added slowly to the solution in small portions with stirring over a 10 minute period. The solution was stirred using an overhead stirrer set at 450 rpm, for 36 hours at 25° C. The product, a pale yellow liquid, formed an upper phase in the reaction mixture, which was separated and washed a number of times with water (7×750 mL). The product was dissolved in a minimum amount of ethyl ethanoate and dried under anhydrous magnesium sulfate, then dried on a rotary evaporator and then further dried by heating at 80° C., under vacuum at 1 mbar, to yield a pale yellow viscous liquid.

Trihexyl(tetradecyl)phosphonium decanoate (IL 4)

This ionic liquid may be represented by the general formula IV.

IL 4 was prepared according to the following method.

Trihexyl(tetradecyl)phosphonium chloride (520 g, 1.0 mol) was dissolved in propanone (500 mL) in a round-bottomed flask. An excess of sodium decanoate (388 g, 2.0 mol) was dissolved in deionised water (500 mL) and was added slowly to the solution in small portions with stirring over a 20 minute period. The solution was stirred using an overhead stirrer set at 450 rpm, for 16 hours at 25° C. The product, a pale yellow liquid, formed an upper phase in the reaction mixture, which was separated and washed a number of times with water (7×750 mL). The product was dissolved in a minimum amount of propanone and dried under anhydrous magnesium sulfate, then dried on a rotary evaporator and then further dried by heating at 80° C., under vacuum at 1 mbar, to yield a pale yellow viscous liquid.

Tridodecyl(butyl)phosphonium dibutylphosphate (IL 5)

This ionic liquid may be represented by the general formula V.

IL 5 was prepared according to the following method.

Tridodecylphosphine (270 g, 0.5 mol) was placed in a two-necked round-bottomed flask and was stirred under dinitrogen at 100° C. Then, using a dropping funnel, an excess of tributylphosphate (160 g, 0.6 mol) was added slowly to the tridodecylphosphine over one hour. The reaction mixture was stirred for 20 hours under reflux conditions (210° C.). The product formed was a pale yellow liquid, which was dried on a rotary evaporator and heated at 80° C. under vacuum at 1 mbar, to yield a pale yellow viscous liquid.

Tridodecyl(2-butoxyethyl)phosphonium bis(2-butoxyethyl)phosphate (IL 6)

This ionic liquid may be represented by the general formula VI.

IL 6 was prepared according to the following method.

Tridodecylphosphine (270 g, 0.5 mol) was placed in a two-necked round-bottomed flask and stirred under dinitrogen at 100° C. Then, using a dropping funnel, an excess of tris(2-butoxyethyl)phosphate (239 g, 0.6 mol) was added slowly to the tridodecylphosphine over one hour. The reaction mixture was stirred for 20 hours under reflux conditions (210° C.). The product formed was a pale yellow liquid, which was dried on a rotary evaporator and heated at 80° C., under vacuum at 1 mbar, to yield a pale yellow viscous liquid.

Preparation of Lubricating Oil Compositions

Lubricating oil compositions according to the present invention were prepared by dissolving each of the above ionic liquids in Yubase 4 base oil, using ionic liquid concentrations of 5% by weight (for ILs 1 to 4) and 1% by weight (for ILs 1 to 6) based upon the lubricating oil composition. A lubricating oil formulation using ZDDP was prepared using a secondary zinc dialkyl dithiophosphate available from Lubrizol Corporation under the trade designation LZ 1371.

Wear Testing

The wear properties of the lubricating oil compositions were tested using equipment designed to mimic the contact between engine components. The reciprocating component was held on the static wear surface and reciprocated at a frequency of 24 Hz. for 12 hours at 250° C. The reciprocating component was able to articulate to a small degree around its centre point and carried a load of 300 N. There was a 15 mm sweep stroke. The lubricating oil composition under test was drip fed onto the wear surface at a rate of 3 ml/h. At the end of each test, the samples were cleaned with a nickel spatula and the wear volume loss determined to 2 significant figures using a Form Tallysurf apparatus.

The wear data obtained using lubricating oil compositions according to the present invention was compared with wear data obtained using the base oil alone, and a lubricating oil composition having a secondary ZDDP in place of ionic liquid. The compositions used and wear data obtained are shown in Table 3.

TABLE 3 Amount Wear of Base oil Wear (vol. additive amount test loss) Experiment Additive (wt. %) Base oil % ref. mm3 Experiment A No 0 Yubase 4 100 006A 0.86 anti-wear additive Experiment B ZDDP 1 Yubase 4 99 005A 0.06 Example 1 IL 1 5 Yubase 4 95 001A 0.58 Example 2 IL 1 1 Yubase 4 99 001B 0.47 Example 3 IL 2 5 Yubase 4 95 002A 0.05 Example 4 IL 2 1 Yubase 4 99 002B 0.04 Example 5 IL 3 5 Yubase 4 95 003A 0.06 Example 6 IL 3 1 Yubase 4 99 003B 0.06 Example 7 IL 4 5 Yubase 4 95 004A 0.03 Example 8 IL 4 1 Yubase 4 99 004B 0.05 Example 9 IL 5 1 Yubase 4 99 008A 0.09 Example 10 IL 6 1 Yubase 4 99 009A 0.04

The wear data in Table 3 show that the lubricating oil compositions according to the present invention reduced wear of the components lubricated by the lubricating oil composition. In particular, the lubricating oils of the present invention reduced wear compared to the base oil alone and, in most cases; the wear rates are comparable to that obtained using 1% by weight ZDDP as the anti-wear additive in the lubricating oil composition.

Friction Properties.

The friction properties of lubricating oil compositions prepared above were tested using an MTM ball on disc test, operated at 150° C., with a ball load of 71 N. The friction data obtained using lubricating oil compositions according to the present invention was compared with friction data obtained using conventional engine base oils alone and a lubricating oil composition having a secondary ZDDP in place of ionic liquid. The compositions tested are shown in Table 4 and the Stribeck curves obtained from the tests are shown in FIG. 1.

TABLE 4 Amount of Amount of additive Base Oil Experiment Additive (wt. %) Base Oil (wt. %) Experiment C No additive 0 Yubase 6 100 Experiment D No additive 0 PAO 4 100 Experiment E ZDDP 1 Polyalpha 99 olefin PAO4 Experiment F Molybdenum 1 Esso 150SN 99 dialkyl dithiocarbamate Example 11 2 5 Yubase 4 95 Example 12 1 5 Yubase 4 95 Example 13 1 1 Yubase 4 99

The Stribeck curves shown in FIG. 1 show that lubricating oil compositions according to the present invention have friction coefficients which are greater than the base oil, but lower than the formulation with ZDDP. Thus, not only are additives according to the present invention useful for wear, they also provide lower frictional properties than conventional ZDDP.

The friction properties of lubricating oil compositions prepared above were further tested using a Cameron-Plint apparatus at 250° C., 300 N and 24 Hz. The friction data obtained using lubricant oil compositions according to the present invention were compared with friction data obtained using base oil alone and a lubricant oil composition having a secondary ZDDP in place of ionic liquid. The compositions tested are shown in Table 5 and the friction coefficients measured are shown in FIG. 2.

TABLE 5 Amount of Base Oil Additive Amount Experiment Additive (wt. %) Base Oil (wt. %) Experiment G No additive 0 Yubase 4 100 Experiment H ZDDP 1 Yubase 4 99 Example 14 IL 1 5 Yubase 4 95 Example 15 IL 1 1 Yubase 4 99 Example 16 IL 2 5 Yubase 4 95 Example 17 IL 2 1 Yubase 4 99 Example 18 IL 3 5 Yubase 4 95 Example 19 IL 3 1 Yubase 4 99 Example 20 IL 4 5 Yubase 4 95 Example 21 IL 4 1 Yubase 4 99 Example 22 IL 5 1 Yubase 4 99 Example 23 IL 6 1 Yubase 4 99

The friction coefficients shown in FIG. 2 show that lubricating oil compositions according to the present invention generally exhibit a lower friction coefficient than secondary ZDDP. Thus, ILs 1 to 6 are suitable for use as additives to modify the friction properties of the lubricating oil composition. This will enable a lubricating oil composition according to the present invention to be formulated, using such ionic liquids, in which other friction modifiers may be present in lesser amounts than might be required to achieve a predetermined performance of the lubricating oil composition and/or such other friction modifiers may be present in conventional amounts such that the lubricating oil has improved friction properties.

The friction properties of lubricating oil compositions prepared above were further tested using a HFRR and HTHFRR apparatus. The friction data obtained using lubricant oil compositions according to the present invention were compared with friction data obtained using base oil alone and a lubricant oil composition having a secondary ZDDP in place of ionic liquid. The test conditions used are shown in Table 6, the compositions tested are shown in Table 7 and the friction coefficients measured are shown in FIG. 3.

TABLE 6 HFRR Test HTHFRR Test Conditions Conditions Stroke Length (mm) 1 1 Load (g) 400 400 Oil Temperatures (° C.) 40, 60, 80, 150, 180, 210, 100, 120, 140 240, 270, 300 Oscillation Frequency 40 40 (Hz)

TABLE 7 Amount of Base Oil Additive Amount Experiment Additive (wt. %) Base Oil (wt. %) Experiment I No additive 0 Yubase 4 100 Experiment J ZDDP 1 Yubase 4 99 Example 24 IL 1 5 Yubase 4 95 Example 25 IL 1 1 Yubase 4 99 Example 26 IL 2 5 Yubase 4 95 Example 27 IL 2 1 Yubase 4 99 Example 28 IL 3 5 Yubase 4 95 Example 29 IL 3 1 Yubase 4 99 Example 30 IL 4 5 Yubase 4 95 Example 31 IL 4 1 Yubase 4 99 Example 32 IL 5 1 Yubase 4 99 Example 33 IL 6 1 Yubase 4 99

The friction coefficients shown in FIG. 3 demonstrate that as the test temperature is increased from 40° C., the tested lubricant oil compositions of the present invention initially have a friction coefficient which is higher than that of the lubricant oil composition comprising ZDDP. However, at 80° C. ZDDP begins to decompose and the friction coefficient of the ZDDP-containing lubricant oil composition increases. Between 120 and 210° C. all of the lubricant oil compositions containing ionic liquids exhibit lower friction properties than the ZDDP-containing lubricant oil composition.

Engine Testing.

Lubricating oils according to the present invention were used as lubricants in an ignition engine in engine tests. A base oil with additives was prepared by mixing a mixed Group I base oil with additive components to give a base oil with additives composition containing Group I base oil (93.37 wt. %), detergents (2.1 wt. %), dispersant (4 wt. %), antioxidant (0.5 wt. %) and anti-foam (0.003 wt. %).

Lubricating oil compositions were prepared by mixing ionic liquids or ZDDP into the base oil with additives as previously prepared and the resultant lubricating oil compositions were used to lubricate the ignition engine in engine tests. The engine was a Nissan KA24E four-cylinder, 2.4-litre engine with three valves per cylinder operated via a single overhead camshaft and rockers. The engine was operated in each engine test for 100 hours according to a two-stage cycle under low-speed, light-duty engine conditions. The results are shown in Table 8.

The data show that the phosphate ionic liquids performed well as additives in lubricating oil compositions to reduce wear. Thus, IL5 gave the best cam wear performance reducing the wear from about 45 μm (no anti-wear additive) to 15.56 μm. IL 6 also performed well reducing the wear to 18.55 μm. The lubricating oil composition with IL 5 gave iron content of the oil at the end of the test which was less than that obtained for the lubricating oil composition with ZDDP. The lubricating oil composition with IL 6 gave iron content of the oil at the end of the test which was comparable with that obtained for the lubricating oil composition with ZDDP.

TABLE 8 Experiment K Example 34 Example 35 Example 36 Example 37 Example 38 Experiment L Lubricating oil composition Base oil with additives, 99.5 99 99 99 99 99 100 % by weight Additive % by weight 0.5 1 1 1 1 1 — Additive ZDDP (LZ1371) IL1 IL3 IL6 IL5 IL4 none Used Oil data Kv40 decrease (cSt) 11.57 10.17 18.71 8.95 9.32 10.38 10.94 Kv100 decrease (cSt) 0.82 0.67 1.2 0.61 0.53 0.66 0.73 TBN depletion 1.64 2.66 2.18 6.29 1.65 3.31 2.24 End of test iron content 6 139 81 6 4 102 32 in oil ppm Camshaft Wear Average Cam Lobe Wear μm 24.60 149.37 129.81 15.56 18.55 148.23 45.03 Average Cam Nose wear μm 3.60 22.14 21.87 2.47 3.14 28.51 9.30 Camshaft Rating Average Follower Scuffing % 0.42 77.50 67.08 4.67 3.17 54.58 35.17

Claims

1-17. (canceled)

18. A non-aqueous lubricating oil composition comprising a minor amount of an additive and a major amount of a base oil characterised in that the additive is present in solution in the base oil and is a non-halide, non-aromatic ionic liquid which is a salt of general formula C+A− having an atmospheric melting point in the range of −50° C. to 250° C., preferably in the range of −50° C. to 150° C., with the cation, C+, being a quaternary phosphonium or quaternary ammonium ion having four hydrocarbyl groups, optionally containing heteroatoms, which hydrocarbyl groups do not all have the same number of carbon atoms, there being at least one long chain hydrocarbyl group having greater than 4 carbon atoms and at least one short chain hydrocarbyl group having fewer carbon atoms than each of the long chain hydrocarbyl groups, and the anion, A−, comprising at least one oxygen atom and having an ionic head group attached to at least one alkyl or alicyclic hydrocarbyl group which has at least four carbon atoms and optionally at least one heteroatom.

19. A composition as claimed in claim 18 in which the cation has three long chain hydrocarbyl groups and one short chain hydrocarbyl group, or has one long chain hydrocarbyl groups and three short chain hydrocarbyl groups.

20. A composition as claimed in claim 18 in which the at least one short chain hydrocarbyl group of the cation has more than 2 fewer carbon atoms than each of the long chain hydrocarbyl groups.

21. A composition as claimed in claim 19 in which the at least one short chain hydrocarbyl group of the cation has more than 2 fewer carbon atoms than each of the long chain hydrocarbyl groups.

22. A composition as claimed in claim 18 in which the hydrocarbyl groups of the cation are straight chain hydrocarbyl groups.

23. A composition as claimed in claim 18 in which the hydrocarbyl groups of the cation each have independently up to and including 18 carbon atoms.

24. A composition as claimed in claim 23 in which the long chain hydrocarbyl groups each have independently 6 to 18 carbon atoms.

25. A composition as claimed in claim 19 in which the long chain hydrocarbyl groups each have independently 6 to 18 carbon atoms.

26. A composition as claimed in claim 18 in which the short chain hydrocarbyl groups of the cation each have independently 1 to 8 carbon atoms.

27. A composition as claimed in claim 19 in which the short chain hydrocarbyl groups of the cation each have independently 1 to 8 carbon atoms.

28. A composition as claimed in claim 18 in which the hydrocarbyl groups of the cation each have independently, at least one heteroatom.

29. A composition as claimed in claim 28 in which the at least one heteroatom, is oxygen and/or sulfur.

30. A composition as claimed in claim 18 in which the anion, K is selected from the group consisting of anions (a) to (c) wherein

(a) are anions of the general formula: [R1R2P(O)O]− wherein R1 and R2 are independently, alkyl or alicyclic hydrocarbyl groups having at least four carbon atoms and optionally containing at least one heteroatom;
(b) are sulfosuccinate esters of general formula: R1OOCCH2CH(SO3−)COOR2 wherein R1 and R2 are straight chain or branched chain C4 to C8 alkyl groups; and (c) are carboxylate anions of general formula: RC(O)O− wherein R is a straight chain or branched chain C9 to C17 alkyl or alkenyl group.

31. A composition as claimed in claim 19 in which the anion, A− is selected from the group consisting of anions (a) to (c) wherein

(a) are anions of the general formula: [R1R2P(O)O]− wherein R1 and R2 are independently, alkyl or alicyclic hydrocarbyl groups having at least four carbon atoms and optionally containing at least one heteroatom;
(b) are sulfosuccinate esters of general formula: R1OOCCH2CH(SO3−)COOR2 wherein R1 and R2 are straight chain or branched chain C4 to C8 alkyl groups; and (c) are carboxylate anions of general formula: RC(O)O− wherein R is a straight chain or branched chain C9 to C17 alkyl or alkenyl group.

32. A composition as claimed in claim 21 in which the anion, K is selected from the group consisting of anions (a) to (c) wherein

(a) are anions of the general formula: [R1R2P(O)O]− wherein R1 and R2 are independently, alkyl or alicyclic hydrocarbyl groups having at least four carbon atoms and optionally containing at least one heteroatom;
(b) are sulfosuccinate esters of general formula: R1OOCCH2CH(SO3−)COOR2 wherein R1 and R2 are straight chain or branched chain C4 to C8 alkyl groups; and (c) are carboxylate anions of general formula: RC(O)O− wherein R is a straight chain or branched chain C9 to C17 alkyl or alkenyl group.

33. A composition as claimed in claim 25 in which the anion, A− is selected from the group consisting of anions (a) to (c) wherein

(a) are anions of the general formula: [R1R2P(O)O]− wherein R1 and R2 are independently, alkyl or alicyclic hydrocarbyl groups having at least four carbon atoms and optionally containing at least one heteroatom;
(b) are sulfosuccinate esters of general formula: R1OOCCH2CH(SO3−)COOR2 wherein R1 and R2 are straight chain or branched chain C4 to C8 alkyl groups; and
(c) are carboxylate anions of general formula: RC(O)O− wherein R is a straight chain or branched chain C9 to C17 alkyl or alkenyl group.

34. A composition as claimed in claim 27 in which the anion, A− is selected from the group consisting of anions (a) to (c) wherein

(a) are anions of the general formula: [R1R2P(O)O]− wherein R1 and R2 are independently, alkyl or alicyclic hydrocarbyl groups having at least four carbon atoms and optionally containing at least one heteroatom;
(b) are sulfosuccinate esters of general formula: R1OOCCH2CH(SO3−)COOR2 wherein R1 and R2 are straight chain or branched chain C4 to C8 alkyl groups; and
(c) are carboxylate anions of general formula: RC(O)O− wherein R is a straight chain or branched chain C9 to C17 alkyl or alkenyl group.

35. A composition as claimed in claim 30 wherein the anion A− is selected from the group of anions of general formula [(R3O)(R4O)P(O)O]− wherein R3 and R4 are independently, alkyl hydrocarbyl groups each independently, having at least four carbon atoms and wherein R3 and R4 may each contain independently, at least one heteroatom.

36. A composition as claimed in claim 35 wherein R3 and R4 are independently, alkyl hydrocarbyl groups each independently, having 4 to 18 carbon atoms.

37. A composition as claimed in claim 35 wherein R3 and R4 are independently, alkyl hydrocarbyl groups each independently, having 4 to 16 carbon atoms.

38. A composition as claimed in claim 35 wherein R3 and R4 are independently, alkyl hydrocarbyl groups each independently, having 4 to 6 carbon atoms.

39. A composition as claimed in claim 30 wherein the anions are selected from di n-butylphosphate and bis(2-butoxyethyl)phosphate.

40. A composition as claimed in claim 18 in which aromatic hydrocarbyl groups are not present in the anion.

41. A composition as claimed in claim 18 in which the ionic liquid is present in the lubricating oil composition at a concentration in the range of 0.1 to 10% by weight.

42. A composition as claimed in claim 18 which comprises at least one further additive component selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives.

43. A method of operating a spark ignition engine or a compression ignition engine which method comprises lubricating said engine with a lubricating oil composition as claimed in claim 18.

44. A method of operating a spark ignition engine or a compression ignition engine which method comprises lubricating said engine with a lubricating oil composition as claimed in claim 19.

45. A method of operating a spark ignition engine or a compression ignition engine which method comprises lubricating said engine with a lubricating oil composition as claimed in claim 20.

46. A method of operating a spark ignition engine or a compression ignition engine which method comprises lubricating said engine with a lubricating oil composition as claimed in claim 21.

47. The use of a base oil-soluble ionic liquid in a non-aqueous lubricating oil composition comprising a major amount of a base oil and a minor amount of the ionic liquid in solution in the base oil, to modify the friction properties of the lubricating oil composition and/or to reduce wear of components lubricated by the lubricating oil composition, in which use, the ionic liquid is an ionic liquid as defined in claim 18.

48. The use of a base oil-soluble ionic liquid in a non-aqueous lubricating oil composition comprising a major amount of a base oil and a minor amount of the ionic liquid in solution in the base oil, to modify the friction properties of the lubricating oil composition and/or to reduce wear of components lubricated by the lubricating oil composition, in which use, the ionic liquid is an ionic liquid as defined in claim 19.

49. The use of a base oil-soluble ionic liquid in a non-aqueous lubricating oil composition comprising a major amount of a base oil and a minor amount of the ionic liquid in solution in the base oil, to modify the friction properties of the lubricating oil composition and/or to reduce wear of components lubricated by the lubricating oil composition, in which use, the ionic liquid is an ionic liquid as defined in claim 20.

50. The use of a base oil-soluble ionic liquid in a non-aqueous lubricating oil composition comprising a major amount of a base oil and a minor amount of the ionic liquid in solution in the base oil, to modify the friction properties of the lubricating oil composition and/or to reduce wear of components lubricated by the lubricating oil composition, in which use, the ionic liquid is an ionic liquid as defined in claim 21.

51. An additive concentrate comprising a base oil-soluble ionic liquid as defined in claim 18 and at least one further additive selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives and optionally a solvent.

52. An additive concentrate comprising a base oil-soluble ionic liquid as defined in claim 19 and at least one further additive selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives and optionally a solvent.

53. An additive concentrate comprising a base oil-soluble ionic liquid as defined in claim 20 and at least one further additive selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives and optionally a solvent.

54. An additive concentrate comprising a base oil-soluble ionic liquid as defined in claim 21 and at least one further additive selected from the group consisting of detergents, viscosity improvers, anti-oxidants, dispersants, anti-foam and anti-wear additives and optionally a solvent.

Patent History
Publication number: 20100093577
Type: Application
Filed: Dec 17, 2007
Publication Date: Apr 15, 2010
Inventors: Craig Ritchie (West Berkshire), Kenneth Richard Seddon (Northern Ireland)
Application Number: 12/448,423