Lubricant additive comprising mixed non-aryl diol/phosphorodithioate-derived borates

Abstract: Reaction products of dialkyl or diaryl phosphorodithioate acids and hydrocarbyl diols, hydroxyester or related polydiols and borating agent.

Description: This invention is concerned with the borate compounds of mixed non-aryl diol/phosphorodithioates and lubricant compositions containing these materials. U.S. Patent 3654155 discloses an organic composition comprising a major proportion of a lubricating oil or liquid fuel and an antioxidant amount of a product of the formula wherein R is selected from the group consisting of alkyl, aralkyl, aryl and alkaryl, each containing from 1 to 30 carbon atoms, R'' and R' are selected from the group consisting of hydrogen and R. Y is selected from the group consisting of oxygen, sulfur, alkyl, aryl, alkoxy, the latter groups from 1 to about 30 carbon atoms, cycloalkylene, alkenylenedioxy and arylenedioxy, n is from 1 to 3 and m is from 0 to v-n, v being the valence of B. This invention relates to the reaction product resulting from the reaction of phosphorodithioate-derived alcohols which are co-borated with hydrocarbyl diols, hydroxyesters, or related polydiols and lubricant compositions made from the reaction product and a liquid hydrocarbon liquid. The first step in the preparation of the reaction products of this invention is to obtain the 0 , 0 -dialkyl or 0 , 0 -diaryl phosphorodithioic acid by reacting an alcohol or hydrocarbyl phenol with phosphorus pentasulfide, according to the following schematic formulas: ROH + P₂S₅ → 2(RO)₂PSSH + H₂S I where R is C₃ to C₃₀ hydrocarbyl or oxyhydrocarbylene radical, or mixtures thereof and optionally contains sulfur, oxygen, and nitrogen atoms. By "oxyhydrocarbylene radical" is meant herein either the divalent radical -OCxHy- wherein both x and y represent integers or the monovalent olefinically unsaturated radical Cx'Hy' - wherein both x' and y' represent integers. The O , O , dialkyl or 0 , 0 diaryl phosphordithioic acid and an epoxide, hydroxyester or diol are then reacted as follows: wherein "a" ranges between 1 and 10 and where R¹, R², R³, and R⁴ are hydrogens or C₁ to C₃₀ hydrocarbyl groups, and optionally contain sulfur, nitrogen, oxygen, or phosphorus. Although ethylene oxide, butylene oxide, and cyclohexene oxide in particular can be used, preferred are propylene oxide and butylene oxide. The resulting product is then reacted with a non-aryl C₁ to C₃₀ hydrocarbyl diol and a borate such as boric acid. where R⁵ is a non-aryl C₁ - C₃₀ hydrocarbyl group and optionally contains ester, amide or oxygen, nitrogen and/or sulfur groups, y and z are integers and y + z = 3 . The non-aryl C₁ to C₃₀ hydrocarbyl diol compound can be 1,2-dodecanediol, 1,2-hexadecanediol, 1,2-octadecandiol, glycerol monooleate, glycerol monostearate, glycerol monomyristate, and similar species and mixtures thereof. It is preferred to react the materials in the stochiometric ratios indicated in the previous equation although less than molar quantities or greater than molar quantities of a boronating agent can be use. Boric acid is the boronating agent of choice, although other boron compounds such as metaborates, trialkylborates or other suitable boronating agents can be employed. An excess of boronating agent can be used and is often preferred. The reactions are all conducted at a temperature between -10°C and 250°C for a period of between 1 and 48 hours. Preferably the reaction designated II above is conducted at a temperature of between -10°C and 60°C and the reaction designated III at 50°C to 250°C. The desired reaction product separates as a liquid that can be then decanted from the remaining reaction mixture. In preparing the lubricant composition of this invention it is desirable to use the additive in a concentration of between 0.001% and 10% by weight of the total composition, although it is preferred to use between 0.1% to 3%. Greater concentrations can, of course, be used if such is desirable. Of particular significance is the ability of the additives of this invention to improve a variety of properties of a lubricant composition. They include the improved wear resistance or friction qualities of lubricated parts and improved resistance to oxidation and corrosion of oleaginous materials in lubricating media. These media preferably comprise liquid oils, in the form of either a mineral oil or a synthetic oil or mixtures thereof, but also may be a grease in which any of the aforementioned oils are employed as a vehicle. In general, mineral oils, both paraffinic, naphthenic and mixtures thereof, employed as the lubricant, or grease vehicle, may be of any suitable lubricating viscosity range, as for example, from 5.9cs (centistokes) (45 SUS (Saybolt Universal Seconds)) at 38°C (100°F) to 1300cs (6000 SUS) at 38°C, and preferably, from 7.4 to 53cs (50 to 250 SUS) at 99°C (210°F). These oils may have viscosity indexes ranging to about 100 or higher preferably from 70 to 95. The average molecular weights of these oils may range from 250 to 800. Where the lubricant is to be employed in the form of a grease, the lubricating oil is generally employed in an amount sufficient to balance the total grease composition, after accounting for the desired quantity of the thickening agent, and other additive components to be included in the grease formulation. A wide variety of thickening agents can be used in the greases of this invention. Included among the thickening agents are alkali and alkaline earth metal soaps of fatty acids and fatty materials having from 12 to 30 carbon atoms per molecule. The metals are typified by sodium, lithium, calcium and barium. Fatty materials are illustrated by stearic acid, hydroxystearic acid, stearin, cottonseed oil acids, oleic acid, palmitic acid, myristic acid and hydrogenated fish oils. Other thickening agents include salt and salt-soap complexes as calcium stearate-acetate (U.S. Patent No. 2,197,263); barium stearate acetate (U.S. Patent No. 2,564,561); calcium stearate-caprylate-acetate complexes (U.S. Patent No. 2,999,065); calcium caprylate-acetate (U.S. Patent No. 2,999,066); and calcium salts and soaps of low-, intermediate- and high-molecular weight acids and of nut oil acids. In general, grease thickeners may be employed which do not melt and dissolve when used at the required temperature within a particular environment; however, in all other respects, any material which is normally employed for thickening or gelling hydrocarbon fluids for forming grease can be used in preparing the aforementioned improved grease in accordance with the present invention. In instances where synthetic oils, or synthetic oils employed as the vehicle for the grease, are desired in preference to mineral oils, or in combination therewith, various compounds of this type may be successfully utilized. Typical synthetic vehicles include polyisobutylene, polybutenes, hydrogenated polydecenes, polypropylene glycol, polyethylene glycol, trimethylol propane esters, neopentyl and pentaerythritol esters, di(2-ethylhexyl) sebacate, di(2-ethylhexyl) adipate, dibutyl phthalate, fluorocarbons, silicate esters, silanes, esters of phosphorus-containing acids, liquid ureas, ferrocene derivatives, hydrogenated synthetic oils, chain-type polyphenyls, siloxanes and silicones (polysiloxanes), alkyl-substituted diphenyl ethers typified by a butyl-substituted bis(p-phenoxy phenyl) ether, phenoxy phenylethers. The compositions contemplated herein can also contain other materials. For example, other corrosion inhibitors, extreme pressure agents, antiwear agents, defoamants, detergents, dispersants, can be used. EXAMPLES Example 1 Propoxylated Di-2-Ethylhexylphosphorodithioic Acid Approximately 708.6 grams of di-2-ethylhexylphosphorodithioic acid (Stauffer Chemical Company) were charged into a one-liter flask and 116.5 grams (2.0 mole) propylene oxide were slowly added over a course of two hours. The reaction temperature was controlled at about or below 40°C. At the end of the addition, the color of the mixture changed from dark-green to light-yellow. The mixture weighed approximately 825 grams. Example 2 Borated Mixed Glycerol Monooleate/S-2 Hydroxypropyl 0,0-di-2-Ethylhexylphosphorodithioate Approximately 178.1 grams of commercial glycerol monooleate (Stepan Company), 31 grams boric acid, 206 grams of the product from Example 1 and 200 milliliters toluene were mixed in a one-liter, four-neck reactor equipped with thermometer, nitrogen gas sparger, Dean-Stark trap condenser, and agitator. The mixture was refluxed (113 ± 2°C) over a period of three hours. A total volume of 22.8 milliliters of water was collected in the Dean-Stark trap. An additional hour of heating produced no more water of reaction. The toluene was removed by distillation leaving about 392 grams of low-viscosity brown liquid product. Example 3 Borated Mixed Glycerol Monooleate/Propoxylated 0,0-di-2-Ethylhexylphosphorodithioate (Using Higher Boric Acid Charge) Approximately 178 grams glycerol monooleate, 93 grams boric acid, 206 grams of the product from Example 1 and 200 milliliters of toluene were mixed in a one-liter reactor with a nitrogen blanket. The mixture was heated and refluxed at 115 ± 2°C over 10 hours. A volume of 41.5 milliliters of water was collected in the Dean-Stark trap. Refluxing was continued for two more hours until H₂O evolution ceased. The mixture was diluted with 300 milliliter extra toluene when it had cooled to below 50°C. The unreacted solids were then removed by filtration. The yellow-brown filtrate was returned to a reactor and toluene was removed under reduced pressure at 110-115°C. A yield of 370 grams of brown liquid was obtained. The non-aryl C₁ to C₃₀ hydrocarbyl diol phosphorodithioate-derived alcohol borates from the examples were blended into fully formulated oils and evaluated for oxidative stability. Basically, in the test the lubricant is subjected to a stream of air which is bubbled through at a rate of 5 liters per hour at 165°C (325 °F) for 40 hours (Table 1), 127°C (260 °F) for 80 hours (Table 2), and 191°C (375 °F) for 24 hours (Table 3). Present in the composition are samples of metals commonly used in engine construction, namely, iron, copper, aluminum and lead. See U.S. Patent 3,682,980 further details of the test. Reductions in viscosity increase or limiting of neutralization number (or both) show effective control. CATALYTIC OXIDATION TEST Item Additive Conc. (Wt. %) Percent Change in Kinematic Viscosity Sludge Base Oil 32 cs(150 second), fully formulated, solvent refined paraffinic bright oil containing defoamant/demulsifier/antiwear/anticorrosion/EP/antirust performance package 0 30.61 Nil Example 2 1.0 26.67 Nil CATALYTIC OXIDATION TEST Item Additive Conc. (Wt. %) Percent Change in Acid Number Percent Change in Kinematic Viscosity Sludge Base Oil 32 cs(150 second), fully formulated, solvent refined paraffinic bright oil containing defoamant/demulsifier/antiwear/anticorrosion/EP/antirust performance package 0 0.01 6.48 Nil Example 2 1.0 0.11 6.46 Nil Example 3 1.0 -0.41 6.42 Nil CATALYTIC OXIDATION TEST Item Additive Conc. (Wt. %) Percent Change in Acid Number Percent Change in Kinematic Viscosity Sludge Base Oil 32 cs(150 second), fully formulated, solvent refined paraffinic bright oil containing defoamant/demulsifier/antiwear/anticorrosion/EP/antirust performance package - 6.53 177.9 Medium Example 2 1.0 4.29 125.6 Light Example 3 1.0 4.08 101.2 Medium Table 4 below shows the improved wear resistance of these additives when tested in a Shell 4-ball wear tester. Four-Ball Test Item Wear Scar Diameter in MM, 30 Minute Test 60 kg Load 1000RPM 200°F 2000RPM 200°F 1000RPM 300°F 2000RPM 300°F Base Oil (80% Solvent Paraffinic Bright, 20% Solvent Paraffinic Neutral Mineral Oils) No additive from the Examples 1.91 2.63 1.95 2.50 1% Example 2 in above Base Oil 0.77 1.13 0.86 1.15 1% Example 3 in above Base Oil 0.75 1.43 0.81 1.38 As an be seen from the above wear test results, the products described exhibit considerable antiwear activity.

Claims: A reaction product produced by : (a) reacting a phosphorodithioic acid and an epoxide, hydroxyester, or diol resulting in an intermediate product; and (b) reacting the intermediate product with a borating compound and a non-aryl C₁ to C₃₀ hydrocarbyl diol to produce the desired reaction product. A reaction product according to claim 1 wherein each reaction is conducted at a temperature from -10°C to 250°C for 1 to 48 hours in a proportion of reactants of 1 mole of each. A reaction product according to claim 1 or 2 wherein (a) is carried out from -10°C to 60°C and reaction (b) is carried out from 50°C to 250°C. A reaction product according to any preceding claim wherein the phosphorodithioic acid has a formula: (RO)₂PSSH where R comprises a C₃ to C₃₀ hydrocarbyl or oxyhydrocarbylene group, or mixtures thereof; the epoxide has the formula: wherein R¹, R², R³, or R⁴ which may be the same or different, comprises a hydrogen or a C₁ to C₃₀ hydrocarbyl group optionally containing sulfur, nitrogen, or oxygen atoms; wherein the non-aryl C₁ to C₃₀ hydrocarbyl diol compound has the formula: (HO)₂R⁵ where R⁵ comprises the non-aryl C₁ to C₃₀ hydrocarbyl group and optionally contains ester, amide, oxygen, nitrogen and/or sulfur groups; and wherein the borating agent is selected from boric acid, metaborates and trialkylborates. A reaction product according to any preceding claim wherein the intermediate product of (a) comprises the reaction product of di-2-ethylhexyl- phosphorodithioic acid with propylene oxide; and the non-aryl C₁ to C₃₀ hydrocarbyl diol compound of (b) comprising glycerol monooleate. A reaction product of the formula : where R, R₁, R₂, R₃, R₄ and R₅ are defined in claim 4; a is from 1 to 10; y and z are integers; and y + z = 3 . The reaction product of claim 4 wherein the mole ratio of borating agent to the other reactants is greater than 1. A lubricant composition comprising a lubricant and between 0.001% and 10% by weight of the composition of claim 1. A lubricant composition according to claim 8 formulated as a grease. A lubricant composition according to claim 9 wherein the grease comprises an alkali or alkaline earth metal soap of a fatty acid or fatty material having from 12 to 30 carbon atoms per molecule.

Inventors: FARNG LIEHPAO OSCAR, HORODYSKY ANDREW GENE, FARNG, LIEHPAO OSCAR, HORODYSKY, ANDREW GENE
Applicants: MOBIL OIL CORP, MOBIL OIL CORPORATION
Application year: 1988
Main classification: C07F9
IPC codes: C10M139, C07F9, C10M159, C10N30