LUBRICATING OIL COMPOSITIONS CONTAINING BIS-MANNICH BASE DEPOSIT INHIBITORS

Abstract: Bis-Mannich bases of the general formula: wherein R₁ is independently alkylene of from 1 to 4 carbon atoms; R₂ is alkylene of from 2 to 6 carbon atoms; R₃ and R₄ are independently hydrocarbyl of from 1 to 30 carbon atoms with the proviso that the sum of all R₃ and R₄ hydrocarbyl carbon atoms is sufficient to render the com­ pound of formula I oil-soluble; R₅ is independently selected from hydrogen, alkyl of from 1 to 6 carbon atoms, phenyl and phenyl substituted by 1 or 2 substituents selected from hydroxy and alkyl of from 1 to 6 carbon atoms and salts thereof have been found to be effective as deposit inhibitors in internal combustion engines when incorporated in lubricating oils used in such engines.

Description: This invention relates to lubricating oil composi­ tions containing Bis-Mannich base inhibitors. Oils suitable for lubricating internal combus­ tion engines are generally either mineral oils or syn­ thetic oils of lubricating viscosity. In either case, during engine operation, these oils are subject to degradation resulting in harmful deposits and varnish formation in the engine. In order to prevent deposit and varnish formation, it is customary to incorporate deposit inhibitors in such lubricating oils. U.S. Patent No. 2,967,196 discloses certain ethylene diamine diacetic acids containing phenolic groups useful for chelating polyvalent metal ions in neutral and alkaline aqueous solutions. U.S. Patents Nos. 3,632,637 and 3,758,540 dis­ close iron chelates of N-(2-hydroxybenzyl)-substituted amino polycarboxylic acids. These compounds are disclosed as a source of iron for plants growing in alkaline soils. U.S. Patents Nos. 2,624,757 and 2,794,818 dis­ close halo substituted aralkyl alkylene diamine diacetic acids and salts thereof useful as bactericidal and fungi­ cidal agents. However, none of these references discloses lubricating oil compositions containing the Bis-Mannich bases employed in this invention nor does any of these references suggest that these Bis-Mannich bases would possess deposit inhibiting properties. In accordance with the invention, there is provided a lubricating oil composition comprising an oil of lubricating viscosity and, as a deposit inhibitor, a Bis-Mannich base compound of the general formula: wherein R₁ is independently alkylene of from 1 to 4 carbon atoms; R₂ is alkylene of from 2 to 6 carbon atoms; R₃ and R₄ are independently hydrocarbyl of from 1 to 30 carbon atoms with the proviso that the sum of all R₃ and R₄ hydrocarbyl carbon atoms is sufficient to render the com­ pound of formula I oil-soluble; R₅ is independently selected from hydrogen, alkyl of from 1 to 6 carbon atoms, phenyl and phenyl substituted by 1 or 2 substituents selected from hydroxy and alkyl of from 1 to 6 carbon atoms; or a salt thereof. Suitable salts include salts such as the potassium, sodium, magnesium, barium, calcium and zinc salts. In preferred embodiments, R₁ is a straight-chain alkylene group of from 1 to 4 carbon atoms; - preferably - a straight-chain alkylene group of from 1 to 2 carbon atoms; and more preferably R₁ is methylene, i.e., -CH₂-. R₂ is preferably a straight-chain alkylene group of from 2 to 6 carbon atoms; more preferably a straight-chain alkylene group of from 2 to 3 carbon atoms; and most preferably R₂ is ethylene, i.e., -CH₂CH₂-. If the sum of all R₃ and R₄ hydrocarbyl carbon atoms is at least 10 carbon atoms and preferably at least 18 carbon atoms, the compounds are generally believed to be oil soluble. R₃ and R₄ can be the same or different alkyl groups of from 1 to 30 carbon atoms. R₃ and/or R₄ alkyl groups can be a single alkyl group or a mixture of alkyl groups. For instance, a C₁₅ to C₂₀ alkyl R₃ group can be prepared by employing a C₁₅ to C₂₀ olefin mixture and alkylating the appropriate phenol. R₅ is preferably hydrogen or alkyl of from 1 to 6 carbon atoms and most preferably is hydrogen. The Bis-Mannich base compounds of formula I may be prepared by a process which comprises the steps of (1) combining in a suitable inert diluent from about 2 equivalents to about 6 equivalents of a substituted phenol of the general formula: wherein R₃ and R₄ are as defined above; with substantially one equivalent of a diamine diacid of the formula: wherein R₁ and R₂ are as defined above, or a salt thereof; (2) adjusting the pH of the resulting mixture produced in (1) above to between about pH 7 to about pH 9; and (3) combining with the mixture formed in (2) above at a tem­ perature sufficient to cause reaction from about 2 equiva­ lents to about six equivalents of formaldehyde per equivalent of diamine diacid while maintaining the pH from about 7 to 9. It has been found that by adding the formaldehyde to a mixture of the phenol and diamine diacid in an inert diluent maintained at a pH of between 7 and 9, sub­ stantially theoretical yields of the Bis-Mannich base are obtained. In a preferred embodiment, approximately two-fold excess of formaldehyde and phenol to the diamine diacid results in the best yield. Preferably, the pH is maintained at a pH of from 7.5 to 8.5 and most preferably the pH is main­ tained at or near pH 8. The Bis-Mannich bases produced by the process described above are excellent metal ion chelators, especially for iron. Accordingly, these Bis-Mannich bases are useful for forming iron chelates which in turn are useful as a source of iron for plants growing in an alkaline soil environment. See, for instance, U.S. Patents Nos. 3,632,637 and 3,758,540.- It is also contemplated that the Bis-Mannich bases are useful in treating iron overload diseases in a patient in need of such treatment. Alkylene, as used in describing the R₁ and R₂ groups, denotes both straight- and branched-chain saturated alkylene groups, e.g. 1,3-propylene (-CH₂CH₂CH₂-); and Hydrocarbyl, as used in describing the R₃ and R₄ groups denotes an organic radical composed of carbon and hydrogen which may be aliphatic, alicyclic, aromatic or combinations thereof, e.g., aralkyl. Preferably, the hydrocarbyl group will be relatively free of aliphatic unsaturation, i.e., ethylenic and acetylenic, particularly acetylenic unsaturation. Formaldehyde, as used herein, includes both formaldehyde and paraformaldehyde and substituted formal­ dehyde, i.e. The process for producing the Bis-Mannich bases of formula I is generally conducted by combining into an inert diluent, a diamine diacid, II, and a substituted phenol, III. Pre­ ferably, the diluent is maintained at a pH of 8 and higher in order to solubilize the diamine diacid. Most prefer­ ably, the diluent is maintained at approximately pH 8. In any event, after combining the diamine diacid, II and the substituted phenol, III, in the inert diluent, it is critical that the pH of this system be adjusted to between pH 7 to 9. Generally, this is accomplished by adding a metal hydroxide to the system, i.e., M(OH) m wherein M is a metal selected from sodium, potassium, magnesium, calcium barium, zinc and the like and m is equal to the valence of M. Under such conditions, the salt of the diacid is generated. This salt is represented by the general formula: wherein R₁, R₂, M and m are as defined above. To this mixture is added formaldehyde (IV) as shown in reaction (1) below: wherein R₁, R, R₃, R₄, R₅, M, and m are as defined above. In regard to reaction (1) above, the order of reactants II, III, and IV is critical. In particular, if the formaldehyde is added to the diamine diacid prior to addition of the substituted phenol, a substantial amount of impurity is formed as shown is reaction (2) below: The impurity formed in reaction (2) is minimized in reac­ tion (1) by adding the formaldehyde at a temperature sufficient to cause reaction after combining both the diamine diacid and the phenol. Reaction (1) is conducted in an inert diluent which is generally any inert solvent in which the reac­ tants are soluble. Preferred diluents are water, alkanol and a water/alkanol mixture. It is critical that the diluent employed is maintained between pH 7.0 and 9.0 which is generally accomplished by titrating the diluent with the necessary acid or base until the desired pH is reached. This pH range is critical because at pH's lower than 7.0 the diamine diacid, II, becomes insoluble and at pH's higher than 9.0, the impurity of reaction (2) increases. Preferably, reaction (1) is conducted at between pH 7.5 and 8.5 and most preferably at or near pH 8.0. Reaction (1) is conducted at a temperature sufficient to cause reaction. In general, reaction (1) is conducted at from 30°C to 200°C although preferably at from 50°C to 130°C. The reaction is generally complete from within 1 to 24 hours. The salts of the Bis-Mannich base product can be isolated by conventional techniques, e.g. filtration, chromatography (on silica gel or alumina), etc. The salts of the Bis-Mannich base products are further purified from the reaction mixture by titrat­ ing the diluent with an appropriate metal hydroxide, i.e., sodium hydroxide, potassium hydroxide, etc. to a pH of approximately 9-10. The Bis Mannich base diacid is prepared by titrating the diluent with an acid to approximately pH 5. In titrating with an acid, it is critical that the pH be maintained above 4 because below pH 4 product decompo­ sition may occur. Alternatively, the product of reaction (1) may be employed in a lubricating oil composition without fur­ ther purification and/or isolation. Dialkyl phenols, III, are known in the art and may be prepared by alkylating phenol or an alkyl substi­ tuted phenol, i.e., ortho or para cresol, 4-ethylphenol, etc., via methods known per se. If R₃ and R₄ are iden­ tical, the alkylation reaction is accomplished by employ­ ing two equivalents of the same olefin. If R₃ and R₄ are different, alkylation can be conducted in a substituted phenol such as cresol or can proceed in a two-step process wherein first one equivalent of an olefin is employed to alkylate phenol to form a monoalkyl olefin which is then alkylated with a second equivalent of a different olefin to form a dialkyl phenol. Addition of the first equiva­ lent of olefin occurs generally at the para position of phenol although some amount of ortho substitution occurs. The second equivalent of olefin will generally add to the ortho position. Alternatively, the alkylation reaction can employ a mixture of the two olefins. The alkylation reaction is conducted in the presence of an alkylating catalyst such as Amberlyst 15® available from Rohm and Haas, Philadelphia, Pennsylvania. The reaction is conducted at a temperature of from about 60°C to about 200°C, and preferably 125°C to 180°C in an essentially inert solvent at atmospheric pressure. The reaction is generally complete in about 1 to 10 hours. Diamine diacids, II, are known in the art, some of which are commercially available. These compounds are readily prepared by reacting a diamine, VI, with a halo­ alkyl carboxylic acid, VII, as shown in reaction (3) below: wherein R₁ and R₂ are as defined above and X is a halogen selected from chloro and bromo. This reaction is known in the art. Formaldehyde, paraformaldehyde and are known in the art and are generally commercially avail­ able. The Bis-Mannich base inhibitors employed in this inven­ tion are useful as deposit inhibitors when employed in lubricating oils. When employed in this manner, the addi­ tive is usually present in from 0.01 to 15 percent by weight to the total composition and preferably at about 0.5 to 10 percent by weight and most preferably 1-5 per­ cent by weight. The lubricating oil used with the addi­ tive compositions of this invention may be mineral oil or synthetic oils of lubricating viscosity and preferably suitable for use in the crankcase of an internal combus­ tion engine. Crankcase lubricating oils ordinarily have a viscosity of about 1300 CSt 0°F to 22.7 CSt at 210°F (99°C). The lubricating oils may be derived from syn­ thetic or natural sources. Mineral oil for use as the base oil in this invention includes paraffinic, naphthenic and other oils that are ordinarily used in lubricating oil compositions. Synthetic oils include both hydrocarbon synthetic oils and synthetic esters. Useful synthetic hydrocarbon oils include liquid polymers of alpha olefins having the proper viscosity. Especially useful are the hydrogenated liquid oligomers of C₆ to C₁₂ alpha olefins such as 1-decene trimer. Likewise, alkyl benzenes of proper viscosity such as didodecyl benzene, can be used. Useful synthetic esters include the esters of both mono­ carboxylic acid and polycarboxylic acids as well as mono­ hydroxy alkanols and polyols. Typical examples are didodecyl adipate, pentaerthritol tetracapoate, di-2-­ ethylhexyl adipate, dilaurylsebacate and the like. Com­ plex esters prepared from mixtures of mono and dicar­ boxylic acid and mono and dihydroxy alkanols can also be used. Blends of hydrocarbon oils with synthetic oils are also useful. For example, blends of 10 to 25 weight percent hydrogenated 1-decene trimer with 75 to 90 weight percent 150 SUS (38°C) mineral oil gives an excellent lubricating oil base. Additive concentrates are also included within the scope of this invention. The concentrates of this invention usually include from about 85 to 50 weight percent of a diluent, preferably an oil of lubricating viscosity, and from about 15 to 50 weight percent of the inhibitor employed in this invention. Typically, the concentrates contain sufficient diluent to make then easy to handle during shipping and storage. Suitable diluents for the concentrates include any inert diluent, preferably an oil of lubricating viscosity, so that the concentrate may be readily mixed with lubricating oils to prepare lubricating oil compositions. Suitable lubricating oils which can be used as diluents typically have viscosities in the range from about 35 to about 500 Saybolt Universal Seconds (SUS) at 100°F (38°C). Other additives which may be present in the formulation include rust inhibitors, foam inhibitors, corrosion inhibitors, pour point depressants, antioxi­ dants, and a variety of other well-known additives. The following examples are offered to speci­ fically illustrate this invention. Examples 1 to 6 illustrate the preparation of Bis-Mannich bases, whilst Example 7 illustrates the preparation of lubricating oil compositions. Example 1 Preparation of Disodium Salt of N,N′-di(3,5-dimethyl-2-­ hydroxybenzyl)ethylene-diamine-N,N′-diacetic acid To a three-neck, 100-ml flask, equipped with a nitrogen source, thermometer, magnetic stirrer, heating mantle, SCM electrode + reference electrode, and dropping funnel was added 7 ml, 30% NaOH solution and 15 ml methanol. To this was added 4.4 g (0.025 mol) ethylene-diamine-N,N′-diacetic acid and 12.2 g of 2,4-dimethylphenol (0.10 mol) dissolved in 12 ml methanol. The pH initially at 10.9 was adjusted by the addition of 10% HCl to pH 8.2. The reaction was heated to reflux and to this was added dropwise with stirring 8.2 g 37% formaldehyde solution (0.10 mol) in 24 ml methanol. The pH of the mixture was controlled at pH 8.0. This was heated at reflux for a total of 5 hours, then the mixture was cooled to room temperature. The pH was adjusted in an NaOH solution to 9.0 and a product precipitated. This was filtered and dried in a vacuum oven at 70° overnight. A total of 8.08 g of product 7a as disodium salt was recovered; mp 181-183°C; 62% yield; Anal. Calcd. for C₂₄H₃₀N₂O₆Na2H₂O: C, 54.96; H, 6.54; N, 5.34; Na, 8.77. Found: C, 54.54; H, 6.26; N, 5.35; Na, 8.45; ¹H NMR δ (CD₃OD) 6.8 (brs, 2H, ArH), 6.5 (brs, 2H, ArH), 3.6 (S, 4H, HO₂CCH₂N), 3.1 (s, 4H, ArCH₂N), 2.6 (s, 4H, NCH₂CH₂), 2.20 (s, 6H, ArCH₃), 2.15 (s, 6H, ArCH₃). In a manner similar to the procedure outlined in Example 1 above, the following compounds were prepared: Example 7 The lubricating oil compositions of this inven­ tion were demonstrated as deposit inhibitors by a panel coker bench test. See U.S. Patent No. 3,966,807- - for its teaching of the panel coker bench test. The panel coker test is a controlled test for measuring deposit formation in formulated oils. The appa­ ratus consists of an oil container or sump with a multi­ pronged spinner controlled by a motor for splashing sample oil onto a hot plate. The plates used in the panel coker test are panels of aluminum pre-cleaned and weighed. The test consists of adding the test oil to the sump and plac­ ing the plate into the plate holder. The plate is heated and the test oil at 180°C to 300°C is splashed against the heated plate intermittently. After test completion, the plate is removed, washed with hexane and then dried. The dried plate is weighed and the difference between its after test weight and before test weight is taken as the deposit weight. The lubricating oil employed in this test is Cit-Con 350N which contains 4% of a monosuccinimide, 36 millimoles of a calcium overbased phenate, 18 millimoles of a zinc dithiophosphate; and 1% of the product of the example indicated in Table I. To a lubricating oil composi­ tion is added 0.2 ml of an oxidation catalyst per 200 g of lubricating oil composition. Said oxidation catalyst is prepared by adding 62.12 g of copper naphthenate solution (7.88% copper) to 48.04 g iron naphthenate (6.12% iron) and diluting to 200 ml with pearl oil. The results of the panel coker test are given in Table I below. These results indicate that lubricating oil additives of Examples 3-6 are effective in inhibiting deposits.

Claims: 1. A lubricating oil composition comprising an oil of lubricating viscosity and, as a deposit inhibitor, a Bis-Mannich base compound of the general formula: wherein R₁ is independently alkylene of from 1 to 4 carbon atoms; R₂ is alkylene of from 2 to 6 carbon atoms; R₃ and R₄ are independently hydrocarbyl of from 1 to 30 carbon atoms with the proviso that the sum of all R₃ and R₄ hydrocarbyl carbon atoms is sufficient to render the com­ pound of formula I oil-soluble; R₅ is independently selected from hydrogen, alkyl of from 1 to 6 carbon atoms, phenyl and phenyl substituted by 1 or 2 substituents selected from hydroxy and alkyl of from 1 to 6 carbon atoms; or a salt thereof. 2. A lubricating oil composition as claimed in Claim 1, wherein R₁ is a straight-chain alkylene group of from 1 to 4 carbon atoms. 3. A lubricating oil composition as claimed in Claim 2, wherein R₁ is methylene. 4. A lubricating oil composition as claimed in Claim 1, 2 or 3, wherein R₂ is a straight-chain alkylene group of from 2 to 6 carbon atoms. 5. A lubricating oil composition as claimed in Claim 4, wherein R₂ is ethylene. 6. A lubricating oil composition as claimed in any preceding claim, wherein R₅ is hydrogen. 7. A lubricating oil composition as claimed in any preceding claim, wherein R₃ and R₄ contain a total of at least 10 carbon atoms. 8. A lubricating oil composition as claimed in Claim 1, wherein R₁ is methylene, R₂ is ethylene, R₅ is hydrogen, R₃ is methyl and R₄ is lauryl. 9. A lubricating oil composition as claimed in any preceding claim, wherein the Bis-Mannich base inhibitor is present in an amount of from 0.01 to 15 percent by weight of the total composition. 10. A lubricating oil additive concentrate comprising from 85 to 50 weight percent of a diluent and from 15 to 50 weight percent of a Bis-Mannich base inhibitor as defined in any one of Claims 1 to 8. 11. A concentrate as claimed in Claim 10, wherein the diluent is an oil of lubricating viscosity.

Inventors: HARRISON, JAMES J.
Applicants: CHEVRON RESEARCH AND TECHNOLOGY COMPANY
Application year: 1987
Main classification: C10M133
IPC codes: C10N10, C10M159, C10M133, C10N30, C10N40