Dispersion-stabilizing agent for inorganic powder in oily material

Abstract: A dispersion stabilizing agent for inorganic powder in an oily material, comprising a copolymer of (i) a poly­ oxyalkylene derivative represented by the general formula [I] below with (ii) one or more of maleic acid and the derivatives thereof selected from the group of maleic anhydride, maleic acid, maleic acid salts, maleic acid amides, and maleic acid esters, where Z is a residue of a compound having 2 - 8 hydroxyl groups, AO is an oxyalkylene group having 2 - 18 carbon atoms, R¹ is an unsaturated hydrocarbon group having 2 - 5 carbon atoms, R² is a hydrocarbon group having 1 - 40 carbon atoms, a = 0 to 1000, b = 0 to 1000, c = 0 to 1000, ℓ = 1 to 8, m = 0 to 2, n = 0 to 7, (ℓ + m + n) = 2 to 8, (aℓ + bm + cn) = 1 to 1000, m/(ℓ + n) ≦ 1/2.

Description: The present invention relates to the use of a dispersion-stabilizing agent for inorganic powder in an oily material whereby an inorganic powder can be dispersed in an oily material within a short period of time and the dispersion can be stabilized over a long period of time. Dispersion of inorganic powder in an oily material are used in various industrial fields. Recently, dispersions of inorganic powder in hydrocarbon oils have come to be used for abrasives and fuel tank cleaning liquids. In such a dispersion in oil, a dispersion-stabilizing agent is generally employed for dispersing an inorganic powder into the oil. USP 4,354,872 discloses use of an alkanolamide, a fatty acid and magnesium lauryl sulfate for dispersing magnesium oxide in hydrocarbon oil. The dispersion-stabilizing agents are required to be capable of dispersing the inorganic powder rapidly in an oily material within a short period of time, and are required simultaneously to be capable of stabilizing the inorganic powder without precipitating the inorganic powder over a long period of time, and to be capable of easily re-dispersing the inorganic powder even when it has precipitated. Various dispersion-stabilizing agents have been reported to meet the requirements. However, none has satisfied simultaneously the above-mentioned two requirements. EP 315167 and 361203 which are documents under Article 54(3) EPC disclose co-polymers of maleic anhydride, maleic acid or a salt or ester thereof with a polyoxyalkylene derivative as a synthetic resin compatibilizer and synthetic resin compositions, respectively. EP 56627 relates to co-polymers which are used as pigment dispersers in water and polar solvents. The object of the present invention is to provide a dispersion-stabilizing agent for inorganic powder in an oily material, which satisfies the above-mentioned two requirements: namely, capability of dispersing inorganic powder rapidly in an oily material within a short period of time, and capability of stabilizing the inorganic powder over a long period of time. The invention is directed to the use of a copolymer of (i) a polyoxyalkylene derivative represented by general formula (I) below with (ii) one or more of maleic acid and the derivatives thereof selected from the group of maleic anhydride, maleic acid, maleic acid salts, maleic acid amides, and maleic acid esters, where Z is a residue of a comound having 2 - 8 hydroxyl groups, AO is an oxyalkylene group having 2 - 18 carbon atoms, R¹ is an unsaturated hydrocarbon group having 2 - 5 carbon atoms, R² is a hydrocarbon group having 1 - 40 carbon atoms, a = 0 to 1000, b = 0 to 1000, c = 0 to 1000, ℓ = 1 to 8, m = 0 to 2, n = 0 to 7, (ℓ + m + n) = 2 to 8 , (aℓ + bm + cn) = 1 to 1000 , m/(ℓ + n) ≦ 1/2 as a dispersion stabilizing agent for inorganic powder in an oily material selected from fuel oil selected from kerosene, gas oil, and heavy oil; an aliphatic hydrocarbon selected from hexane, cyclohexane and isooctane; an aromatic hydrocarbon selected from benzene, toluene and xylene; an ester oil selected from ethyl acetate, dioctyl phthalate, soybean oil and linseed oil; a halogenated hyrocarbon selected from 1,1,1-trichloroethane, trichloroethylene and chlorodifluoromethane; and a liquid parrafin. The dispersion-stabilizing agent as used in the present invention is a copolymer of (i) a polyoxyalkylene derivative represented by the general formula [I] shown above with (ii) one or more of maleic acid and its derivatives selected from the group of maleic anhydride, maleic acid, maleic acid salts, maleic acid amides, and maleic acid esters, where the polyoxyalkylene derivative unit and the maleic unit may respectively be composed of one kind of units or a mixture of two or more kinds of units. The ratio of the polyoxyalkylene derivative units to the maleic units used is preferably be from 7:3 to 3:7, more preferably approximately 1:1 based on polymerizable double bond equivalence, but is not limited thereto. The average molecular weight of the copolymer is preferably from 1,000 to 2,000,000 in terms of weight average molecular weight, but is not limited thereto. In the general formula [1], the compounds having 2 - 8 hydroxyl groups and containing Z as a residue include polyhydric alcohols such as ethylene glycol, propylene glycol, butylene glycol, dodecylene glycol, octadecylene glycol, neopentyl glycol, styrene glycol, glycerol, diglycerol, polyglycerol, trimethylolethane, trimethylolpropane, 1,3,5-pentanetriol, erythritol, pentaerythritol, dipentaerythritol, sorbitol, sorbitan, sorbide, a sorbitol-glycerol condensate, adonitol, arabitol, xylitol, and mannitol; polyhydric phenols such as catechol, resorcin, hydroquinone, and phloroglucin; saccharides such as xylose, arabinose, ribose, rhamnose, glucose, fructose, galactose, mannose, sorbose, cellobiose, maltose, isomaltose, trehalose, sucrose, raffinose, gentianose, and melezitose; and partially etherfied compounds or partially esterified compounds thereof. The oxyalkylene groups denoted by AO having 2 - 18 carbons include an oxyethyelne group, an oxypropylene group, an oxybutylene group, an oxytetramethylene group, an oxystyrene group, an oxydodecylene group, an oxytetradecylene group, an oxyhexadecylene group, and an oxyoctadecylene group, the oxyalkylene group may be composed of one kind of units or a mixed adduct of two or more kinds of units, and the mixed adduct may be a random adduct or a block adduct. The unsaturated hydrocarbon groups denoted by R¹ having 2 - 5 carbons include those having a polymerizable unsaturated bond such as a vinyl group, an allyl group, a methallyl group, a 3-butenyl group, a 4-pentenyl group, and a 3-methyl-3-butenyl group. The hydrocarbon groups denoted by R² include those having 1 - 40 carbons, of which particularly those having 1 - 24 carbons are preferable, including methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, amyl, isoamyl, hexyl, heptyl, 2-ethylhexyl, octyl, nonyl, decyl, undecyl, dodecyl, isotridecyl, tetradecyl, hexadecyl, isohexadecyl, octadecyl, isooctadecyl, oleyl, octyldodecyl, docosyl, decyltetradecyl, benzyl, cresyl, butylphenyl, dibutylphenyl, octylphenyl, nonylphenyl, dodecylphenyl, dioctylphenyl, dinonylphenyl, styrenated phenyl, and naphthyl. The polyoxyalkylene derivative represented by the general formula [I] have at least one R¹. The carbon number of R¹ affects to the polymerization reactivity: excessively long carbon chain of R¹ lowers the reactivity of the derivative, the above-mentioned range of the carbon number therefore being suitable. The derivative in which ℓ, namely, the number of R¹, is 1 will give a linear copolymer, while the derivative in which ℓ is 2 or more will give a cross-linked copolymer. The crosslinking degree can be adjusted by selecting the value of ℓ to prepare a desired copolymer. The value of ( aℓ + bm + cn ) is limited to be not more than 1000, because the value exceeding 1000 is not easily attainable practically. Regarding the relationship among ℓ, m, and n, while m is defined to be in the range of from 0 to 2, an excessively high value of m relative to (ℓ + n) is undesirable, because it causes gellation during the reaction to give a crosslinked ester which cannot be adjusted. Hence ℓ, m, and n should be in the relationship of m/(ℓ+n)≦1/2 . The carbon number of AO may be selected arbitrarily from the range of from 2 to 18. By combination of AO with R², the ratio of the hydrophilic group to the lipophilic group may be adjusted. Of the maleic acid group copolymerizing with the polyoxyalkylene derivative of the general formula [I] the maleic acid salts include the salts of ammonia; salts of monoamines such as methylamine, ethylamine, propylamine, butylamine, hexylamine, octylamine, 2-ethylhexylamine, nonylamine, decylamine, dodecylamine, isotridecylamine, tetradecylamine, hexadecylamine, isohexadecylamine, stearylamine, isostearylamine, oleylamine, linolamine, octyldodecylamine, docosylamine, decyltetradecylamine, and aniline; salts of polyamines such as ethylenediamine, tetramethylenediamine, dodecylpropylenediamine, octadecylpropylenediamine, oleylpropylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, and pentaethylenehexamine; salts of alkanolamines such as monoethanolamine, diethanolamine, triethanolamine, monoisopropanolamine, diisopropanolamine, triisopropanolamine, adducts of alkylene oxide to the aforementioned monoamines and polyamines; salts of amino acids such as lysine, arginine, and histidine; salts of alkali metals such as lithium, sodium, and potassium; and salts of alkaline earth metals such as magnesium, and calcium. The maleic acid amides include reaction products of amidation of maleic anhydride with the aforementioned salt-forming amines. The maleic acid esters include reaction products of esterification of maleic anhydride or maleic acid with aliphatic, aromatic or alicyclic alcohols having 1 - 22 carbon atoms. Specific examples of the alcohols are butanol, hexanol, decanol, tridecanol, octadecanol, benzyl alcohol, and cyclohexanol. The polymer is easily prepared by copolymerizing a polyoxyalkylene derivative of the general formula [I] with a maleic acid or its derivative in the presence of a radical initiator such as a peroxide. In the case where the maleic unit is other than maleic anhydride, a polyoxyalkylene derivative of the general formula [I] is preferably copolymerized with maleic anhydride in the presence of a radical initiator, and the maleic anhydride moiety is then hydrolyzed to a maleic acid moiety, neutralized to form a salt, reacted with an amine to form an amide, or reacted with alcohol to form an ester, because such procedures will produce easily a high molecular product in a simpler manner. In the copolymerization, another copolymerizable component such as styrene, α-olefin, or vinyl acetate may be incorporated. The copolymer thus prepared may vary properties thereof over a broad range by changing suitably Z, AO, R¹, R², ℓ, m, n, and the maleic unit. The copolymers soluble in an oily material in a certain limited degree will be adsorbed better by an inorganic powder, giving favorable results, in comparison with the copolymers freely soluble or completely insoluble in the oily material. By a certain kind of inorganic powder, a copolymer having remaining carboxylic group is adsorbed better. In case where the maleic unit is a maleic acid salt, a maleic acid amide, or a maleic acid ester, the copolymer with the carboxyl group having been partially reacted, preferably 50% equivalent or less is in many cases preferred in comparison with the one with the carboxyl group having totally reacted. The inorganic powder to be dispersed in the present invention is not limited, and the examples thereof are silicates such as kaoline, aluminum silicate, clay, talc, mica, asbestos powder, calcium silicate, sericite, and bentonite; carbonates such as calcium carbonate, magnesium carbonate, barium carbonate, and dolomite; sulfates such as calcium sulfate, and barium sulfate; metal oxides such as magnesium oxide, alumina, antimony oxide, titanium oxide, white carbon, diatomaceous earth, and iron oxide; metal hydroxides such as aluminum hydroxide, magnesium hydroxide, calcium hydroxide, iron hydroxide, and metatitanic acid; metal powders such as aluminum powder, copper powder, and nickel powder; and other various inorganic powders such as silicon carbide, silicon nitride, boron nitride, zirconium oxide, barium titanate, satin white, carbon black, and graphite. Average particle sizes of the inorganic powder vary significantly depending on the kind of the inorganic powder, but generally not more than 100 µm, and normally and preferably in the range approximately from 0.1 to 50 µm. The oils as the dispersion medium for dispersing the above-mentioned inorganic powder include fuel oils such as kerosene, gas oil, and heavy oil; aliphatic hydrocarbons such as hexane, cyclohexane, and isooctane; aromatic hydrocarbons such as benzene, toluene, and xylene; ester oils such as ethyl acetate, dioctyl phthalate, soybean oil, and linseed oil; halogenated hydrocarbons such as 1,1,1-trichloroethane, trichloroethylene, and chlorodifluoromethane; and liquid paraffin. The amount of the dispersion-stabilizing agent for an oily material to be used in the present invention is from 0.05 to 10 parts by weight, preferably from 0.1 to 7 parts by weight based on 100 parts by weight of the inorganic powder. The amount of 0.05 part by weight or less is ineffective, while the use of 10 parts by weight or more does not significantly enhance the effect, and is economically disadvantageous. By employing the dispersion-stabilizing agent of the present invention, a dispersion of inorganic powder in oily material can be prepared in a conventional manner: for example, an inorganic powder is added to an oil containing the dissolved dispersion-stabilizing agent mentioned above, and the mixture is agitated. In the present invention, the use of the specified copolymer of polyoxyalkylene derivative with a maleic unit as the effective ingredient makes it possible to disperse inorganic powder rapidly in an oily material within a short period of time and to prepare a dispersion of inorganic powder in an oily material which is stable over a long period of time. The examples below illustrate specifically the present invention. The compounds shown in Table 1 were used for the dispersion-stabilizing agents in the examples of the present invention and the comparative examples. In the Examples, all percents are by weight. Example 1 200 g of precipitated calcium carbonate powder having an average particle diameter of 0.5 µm was placed as an inorganic powder in a 2-liter beaker. Thereto, 400 g of toluene was added which contains the dissolved dispersion-stabilizing agent in the indicated amount. The mixture was agitated with a 4-blade impeller at 120 rpm for 3 minutes, and then left to stand for 1 minute. The wettability, in the presence of the dispersion-stabilizing agent, of the precipitated calcium carbonate by toluene was evaluated from the state of the calcium carbonate powder remaining in the bottom of the beaker based on the four grades below. 1: The powder is entirely dispersed in the oil, and no powder remains at the bottom. 2: The powder is almost entirely dispersed in the oil, but only a slight portion of the powder remains undispersed at the bottom. 3: Approximately half of the powder remain undispersed at the bottom. 4: Most of the powder remain at the bottom. The dispersions rated as 1, 2, and 3, excluding those rated as 4 respectively were violently agitated at 4,000 rpm for 5 minutes with an Autohomomixer (Type M, made by Tokushu Kika Kogyo K.K.), and the dispersion was transferred into a 500-ml measuring cylinder and left to stand for two days. Then a glass rod of 5 mm in diameter and 50 g in weight was allowed to fall through a guide provided on the upper portion of the measuring cylinder. The falling state was observed, and the dispersion stability was rated on two grades below: 1: The glass rod reaches the bottom of the cylinder. 2: The glass rod stops falling before reaching the bottom of the cylinder, a hard packed layer being formed. The test results are shown in Table 2, which shows that the samples employing the dispersion-stabilizing agent of the present invention are superior in wettability and dispersion stability. Dispersion Stabilizing Agent Remarks Test No. Sample Number Amount Used (%) Wettability Dispersion Stability Invention 1 1 3.5 1 1 " 2 2 3.5 1 1 " 3 3 3.5 1 1 " 4 4 3.5 1 1 " 5 5 3.5 2 1 " 6 6 3.5 2 1 " 7 7 3.5 2 1 " 8 8 3.5 2 1 " 9 9 3.5 2 1 " 10 10 3.5 2 1 " 11 11 3.5 2 1 Comparison 12 12 3.5 2 2 " 13 13 3.5 3 2 " 14 14 3.5 3 2 " 15 none 0 4 _ Example 2 A mixture of 100 g of alumina powder having an average particle diameter of 0.5 µm and 100 g of titanium oxide powder having a particle diameter of 0.8 µm was used as the inorganic powder. The tests were conducted by employing a 500 g of gas oil containing the dissolved dispersion-stabilizing agent in the indicated amount relative to the weight of the inorganic powder in the same manner as in Example 1. The time period of standing for testing the dispersion stability was one week. The test results are shown in Table 3, which clearly shows that the samples employing the dispersion-stabilizing agent of the present invention are superior in wettability and dispersion stability. Dispersion Stabilizing Agent Remarks Test No. Sample Number Amount Used (%) Wettability Dispersion Stability Invention 16 1 4 2 1 " 17 3 4 1 1 " 18 5 4 1 1 " 19 7 4 2 1 " 20 9 4 2 1 " 21 11 4 2 1 Comparison 22 12 4 2 2 " 23 13 4 3 2 " 24 14 4 3 2 " 25 none 0 4 _ Example 3 100 g of flaky graphite having an average particle diameter of 0.1 µm was used as the inorganic powder . The tests were conducted by employing 900 g of petroleum lubricant containing the dissolved dispersion-stabilizing agent in the indicated amount relative to the weight of the graphite, in the same manner as in Example 1. The time period of standing for testing the dispersion stability was one month. The test results are shown in Table 4, which shows that the samples employing the dispersion-stabilizing agent of the present invention are superior in wettability and dispersion stability. Dispersion Stabilizing Agent Remarks Test No. Sample Number Amount Used (%) Wettability Dispersion Stability Invention 26 2 4 1 1 " 27 4 4 1 1 " 28 6 4 1 1 " 29 8 4 2 1 " 30 10 4 2 1 Comparison 31 12 4 3 2 " 32 13 4 3 2 " 33 14 4 3 2 " 34 none 0 3 2

Claims: Use of a copolymer of (i) a polyoxyalkylene derivative represented by general formula (I) below with (ii) one or more of maleic acid and the derivatives thereof selected from the group of maleic anhydride, maleic acid, maleic acid salts, maleic acid amides, and maleic acid esters, where Z is a residue of a compound having 2 - 8 hydroxyl groups, AO is an oxyalkylene group having 2 - 18 carbon atoms, R¹ is an unsaturated hydrocarbon group having 2 - 5 carbon atoms, R² is a hydrocarbon group having 1 - 40 carbon atoms, a = 0 to 1000, b = 0 to 1000, c = 0 to 1000, ℓ = 1 to 8, m = 0 to 2, n = 0 to 7, (ℓ + m + n) = 2 to 8 , (aℓ + bm + cn) = 1 to 1000, m/(ℓ + n) ≦ 1/2 as a dispersion stabilizing agent for inorganic powder in an oily material selected from fuel oil selected from kerosene, gas oil, and heavy oil; an aliphatic hydrocarbon selected from hexane, cyclohexane and isooctane; an aromatic hydrocarbon selected from benzene, toluene and xylene; an ester oil selected from ethyl acetate, dioctyl phthalate, soybean oil and linseed oil; a halogenated hyrocarbon selected from 1,1,1-trichloroethane, trichloroethylene and chlorodifluoromethane; and a liquid parrafin. A composition comprising an inorganic powder, an oily material as defined in claim 1 and as a dispersion stablilizing agent a copolymer (i) as defined in claim 1. Use or composition, respectively, as in claims 1 or 2, wherein the inorganic powder is a silicate selected from kaoline, aluminum silicate, clay, talc, mica, asbestos powder, calcium silicate and bentonite; a carbonate selected from calcium carbonate, magnesium carbonate, barium carnbonate, and dolomite; a sulfate selected from calcium sulfate and barium sufate; a metal oxide selected frog magnesium oxide, alumina, antimony oxide, titanium oxide, white carbon, diatomaceous earth, and iron oxide; a metal hdyroxide selected from aluminum hydroxide, magnesium hydroxide, calcium hydroxide, iron hydroxide, and metatitanic acid; a metal powder selected from aluminum powder, cooper powder, and nickel powder; silicon carbide, silicon nitride, boron nitride, zirconium oxide, barium titanate, satin white, carbon black or graphite. Use or composition, respectively, as in claims 1 or 2, wherein the amount of the copolymer is from 0.05 to 10 parts by weight based on 100 parts by weight of the inorganic powder.

Inventors: HONDA SUSUMU, IGARASHI TAIZO, ONODERA SHOW, YASUKOHCHI TOHRU, HONDA, SUSUMU, IGARASHI, TAIZO, ONODERA, SHOW, YASUKOHCHI, TOHRU
Applicants: NIPPON OILS & FATS CO LTD, NIPPON OIL AND FATS COMPANY, LIMITED
Application year: 1989
Main classification: C08F216
IPC codes: C08F299, C09D17, B01F17, C09D155, C08F290, C08F216