Multifunctional viscosity index improver, containing units from unsaturated chlorides and aromatic amines

Abstract: A substantially linear graft polymer containing a carbon-carbon backbone which comprises a substantially linear carbon-carbon backbone polymer and graft polymerized thereon, under graft polymerization reaction conditions in the presence of free radical initiator graft functional monomer derived from unsaturated chloride and hindered aromatic amine.

Description: This invention relates to a multi-functional lubricant additive which is a dispersant, antioxidant and antiwear VI improver additive when employed in a lubricating oil composition. It is well known to those skilled in the art that hydrocarbon lubricating oils must be formulated by addition of various additives to improve their properties. In the case of lubricating oils, typified by those employed in railway, automotive, aircraft and marine service, it is found that they become degraded during use due inter alia to formation of sludge which may be generated by deterioration of the oil or by introduction of undesirable components from other sources including the fuel or the combustion air. In order to maintain and improve the properties of the lubricating oil, various additives have heretofore been provided; and these have been intended to improve the viscosity index, dispersancy, oxidative stability, antiwear properties. It is, therefore, an object of this invention to provide an additive system which imparts to lubricating oils these improved properties of viscosity index, dispersancy, antiwear properties and oxidative stability. Other objects will be apparent to those skilled in the art. The art contains many teachings on the use of polymer additives in lubricating oil compositions. Ethylene-propylene copolymers and ethylene-propylene-diene terpolymers which have been further derivatized to provide multifunctional properties in lubricating oil compositions illustrate this polymer type of oil additive. U.S. 4,089,794 discloses ethylene copolymers derived from ethylene and one or more (C₃ to C₂₈) alpha-olefin solution grafted with an ethylenically-unsaturated carboxylic acid material followed by a reaction with a polyfunctional material reactive with carboxyl groups, such as a polyamine, a polyol, or a hydroxylamine, which reaction product is useful as a sludge and varnish control additive in lubricating oils. U.S. 4,146,489 discloses a graft copolymer where the backbone polymer is an oil-soluble ethylene-propylene copolymer or an ethylene-propylene-diene modified terpolymer with a graft monomer of C-vinylpyridine or N-vinylpyrrolidone to provide a dispersant VI improver for lubricating oils. U.S. 4,320,019 discloses a multipurpose lubricating additive prepared by the reaction of an interpolymer of ethylene and a (C₃-C₈) alpha-monoolefin with an olefinic carboxylic acid acylating agent to form an acylating reaction intermediate which is then reacted with an amine. U.S. 4,764,304 discloses a lubricating oil dispersant VI improver composition containing an additive prepared by the reaction of an olefin copolymer and an unsaturated isocyanate to form reactive intermediate which is then reacted with heterocyclic amines. U.S. 4,340,689 discloses a process for grafting a functional organic group onto an ethylene copolymer or an ethylene-propylene-diene terpolymer. U.S. 4,382,007 discloses a dispersant - VI improver prepared by reacting a polyamine-derived dispersant with an oxidized ethylene-propylene polymer or an ethylene-propylene diene terpolymer. U.S. 4,144,181 discloses polymer additives for fuels and lubricants comprising a grafted ethylene copolymer reacted with a polyamine, polyol or hydroxylanine and finally reacted with an alkaryl sulfonic acid. An object of this invention is to provide a derivatized polymer composition which imparts viscosity index improving, dispersant, antiwear and antioxidant activity to lubricating oil compositions. Another object is to provide a process for preparing a copolymer derivatized with an unsaturated chloride to form a reactive intermediate which is then reacted with an antioxidant aromatic hindered amine. Still another object is to provide a process for preparing a copolymer derivatized with graft monomers formed from a reactive unsaturated chloride and aromatic hindered amine to yield a modified copolymer which performs as a viscosity index improver, dispersant, antiwear agent and antioxidant in lubricating oil. Also, another object of this invention is to provide a multi-functional lubricant additive effective for imparting viscosity index, dispersant, antiwear and antioxidant properties to a lubricating oil composition. The present invention is directed to multi-functional VI improvers based on a polymer prepared in one step by free-radical grafting of monomer derived from unsaturated chloride and aromatic hindered amine onto an olefin copolymer. Also, the present invention is directed to multifunctional VI improvers based on a polymer prepared in a two-step process which comprises using olefin copolymers as a polymer base derived with unsaturated chlorides and hindered aromatic amines. First, unsaturated chloride is grafted under elevated temperatures with the addition of a free radical initiator. The grafting reaction is followed by a capping of a hindered aromatic amine. The reaction product of the present invention preferably is prepared using ethylene-propylene copolymer (EPM) or ethylene-propylene diene terpolymer (EPDM) as a polymer base, a vinylbenzyl chloride and N-phenyl-p-phenylene diamine as modifying agents. The lubricant additive of the present invention comprises an oil of lubricating viscosity and an effective amount of the reaction product. The lubricating oil will be characterized by having viscosity index improver, dispersancy, antiwear and antioxidant properties. The methods of preparation are also contemplated. This invention, as discussed briefly above, is directed to a polymer comprising an oil-soluble, substantially linear, carbon-carbon backbone polymer bearing functional units thereon, derived from an unsaturated monomer containing chlorine group such as vinyl benzyl chlorine and hindered aromatic anine such as N-phenyl-p-phenylene diamine. The polymer or copolymer substrate employed in the additive of the invention may be prepared from ethylene and propylene or it may be prepared from ethylene and a higher olefin within the range of C₃ to C₁₀ alpha-monoolefins. More complex polymer substrates often designated as interpolymers may be prepared using a third component. The third component generally used to prepare an interpolymer substrate is a polyene monomer selected from non-conjugated dienes and trienes. The non-conjugated diene component is one having from 5 to 14 carbon atoms in the chain. Preferably, the diene monomer is characterized by the presence of a vinyl group in its structure and can include cyclic and bicyclo compounds. Representative dienes include 1,4-hexadiene, 1,4-cyclohexadiene, dicyclopentadiene, 5-ethylidene-2-norbornene, vinylnorbornene, 5-methylene-2-norbornene, 1,5-heptadiene, and 1,6-octadiene. A mixture of more than one diene can be used in the preparation of the interpolymer. A preferred non-conjugated diene for preparing a terpolymer or interpolymer substrate is 5-ethylidene-2-norbornene. The preferred carbon-carbon backbone polymers include those selected from the group consisting of ethylene-propylene copolymers (EPM or EPR) and ethylene-propylene-diene terpolymers (EPDM or EPT). When the charge polymer is an ethylene-propylene copolymer (EPM), it may be formed by copolymerization of ethylene and propylene under known conditions, preferably Ziegler-Natta reaction conditions. The preferred EPM copolymers contain units derived from the ethylene in amount of 40-90 mole %, preferably 55-80 mole %, say 59 mole %, the remainder being derived from propylene. The molecular weight M n of the EPM copolymers which may be employed may be about 5,000 to about 1,000,000, preferably about 20,000 to about 200,000, and most preferably about 80,000. The molecular weight distribution may be characterized by Mw/Mn of less than about 15, preferably 1.2-10, say 1.8. When the charge polymer is ethylene-propylene-diene terpolymer (EPT or EPDM), it may be formed by copolymerization of ethylene, propylene, and diene monomers. The diene monomer is commonly a non-conjugated diene typified by dicyclopentadiene; 1,4-hexadiene; ethylidene norbornene or vinyl norbornene. Polymerization is effected under known conditions generally comparable to those employed in preparing the EPM products. The preferred terpolymers contain units derived from ethylene in amount of 40-90 mole %, preferably 50-65 mole %, more preferably 59 mole % and units derived from propylene in an amount of 20-60 mole %, preferably 30-50 mole %, more preferably 41 mole % and units derived from diene third monomer in amount of 0.1-15 wt%, preferably 0.1-3 wt%, more preferably 0.3 wt%. The molecular weight M n of the terpolymers may typically be 5,000 to 500,000, preferably 20,000 to 200,000, and most preferably 80,000. Molecular weight distribution of the useful polymers is preferably narrow viz a M w /M n of typically less than 10, preferably 1.5-5, more preferably 2.2. According to the process of this invention, the additive may be prepared in a one-step or two-step procedure. In one step process, a functional monomer derived from an unsaturated chloride such as vinyl benzyl chloride (VBC) or croton chloride (CC) and aromatic amine such as N-phenyl-phenylene diamine (NPPDA) is grafted onto the polymer. In a two-step process unsaturated chloride is,first grafted onto the polymer followed by capping using the amine. The two processes are described, respectively, below. In the one-step process, a monomer derived from unsaturated chloride such as vinyl benzyl chloride (VBC), and aromatic amine such as N-phenyl-phenylene diamine (NPPDA) is grafted onto polymer. 1. Preparation of grafting Monomers: where: R₁ is an organic linear, cyclic or heterocyclic, and aromatic or heteroaromatic unit composed of hydrocarbon and/or contain one or more atom of oxygen, nitrogen, sulfur or phosphorus. R₂ is an organic linear, cyclic or heterocyclic, and aromatic group composed of hydrocarbon and/or contain one or more atoms of oxygen, nitrogen, sulfur or phosphorus. R₃ is hydrogen or R₂ 2. Grafting Reaction where P is a carbon-carbon polymer TWO-STEP PROCESS In the two-step process unsaturated chloride is grafted onto the carbon-carbon polymer under elevated temperatures with addition of a free radical initiator. The grafting reaction is followed by capping with an amine. The following reactions illustrate the process of the invention: 1. Grafting Reaction 2. Capping Reaction where P, R₁, R₂ and R₃ are as defined above for the one step reaction. It is a feature of the process of this invention that the graft monomer may be grafted onto carbon-carbon backbone polymers in the presence of a free radical initiator. Any of the typical free radical initiators, such as dicumyl peroxide, 2,2'Azobis(2-methyl-N-[1,1-bis(hydroxymethyl)ethyl]propionamide, di-tert-butylperoxide, azobisisobutyronitrile, diacetylperoxide, and diisopropylperoxidicarbonate may be employed in this process. The reaction product of the present invention preferably is prepared using such materials as: vinyl benzyl chloride crotonyl chloride 3-chloro-2-methyl propene and an amine, such as N-phenyl p-phenylenediamine In the practice of the process of this invention, 100 weight parts of charge EPM or EPT may be added to 100-1000 weight parts, preferably 300-60 weight parts of diluent-solvent. Typical diluent-solvent may be a hydrocarbon solvent such as mineral oil, n-hexane, n-heptane, or tetrahydrofuran. Preferred solvent may be a commercial hexane containing principally hexane isomers or a commercial mineral grafting oil. Reaction mixture may then be heated under nitrogen to reaction conditions of 60°C-180°C, preferably 150°C-170°C, More preferably 155°C. When n-hexane or other low boiling solvent is used, reaction is carried out in pressure reactor at 15-300 psig, preferably 180-220 psig, more preferably 200 psig. It is known that 1 psig = 6.895 KPa gauge pressure. In the grafting reaction of the one-step process, a graft monomer typically prepared from vinylbenzyl chloride and N-phenyl-p-phenylene diamine, is admitted in an amount of about 1-20 weight parts, preferably 3 to 8 weight parts. There is also added a free radical initiator in solution in grafting solvent. Typical free radical initiators may include dicumyl peroxide, or di-t-butyl peroxide. The solvent is preferably the same as that in which the EPM or EPT is dissolved. The initiator may be added in an amount of 0.2-20 weight parts, preferably 1.5 to 4.0 weight parts. The preferred free radical initiator is a dicumyl peroxide (DICUP). The reaction is carried out at a temperature at least as high as the decomposition temperature of the initiator, typically 150°C-160°C or higher for the time needed for bonding the graft reactive monomer onto the base EPM or EPT polymer. In the two-step process, the grafting reaction is performed as described above except that unsaturated chloride such as vinylbenzyl chloride instead of a functional monomer containing aromatic amine is charged. When grafting reaction is completed, amidization reaction is performed. Amidization may be carried out by adding the graft polymer containing chlorine groups to a reaction vessel together with inert-diluent solvent. In the preferred embodiment, reaction may be carried out in the same solvent and in the same reaction medium as that in which the polymer is dissolved. In carrying out the present process, the graft polymer bearing pendant chloride groups may be reacted with an aromatic amine containing at least one non-tertiary nitrogen atom. An amine, typically N-phenyl-p-phenylene diamine is added to the reaction vessel. The amount of amine added is preferably 0.1-5 moles, more preferably 1.2 moles per mole of chlorine compound charged during the first step. The amidization reaction is carried out over 0.1-10 hours, preferably 2-4 hours at 100-180°C, more preferably 155°C with agitation. The product graft polymer may be characterized by the presence of pendant reactive groups containing aromatic amine bonded to the polymer backbone through the residue of the unsaturated chloride, the latter being bonded to the polymer backbone through one of the carbon atoms which formed the ethylenically unsaturated double bond. Typically, the graft product polymer may contain 0.05-10 units derived from graft monomer and amine per 1000 carbon atoms of the charge backbone polymer. For ease of handling, enough mineral oil, such as SUS 100 oil typified by SNO-100 is then added to obtain a fluid concentrate product at room temperature. The product is typically obtained as a solution of 4 to 20 parts in 80 to 96 parts of oil. When the grafting reaction is carried out in hexane (or other low boiling solvent), a stripping step is included. The fluid solution (a lubricating additive) is used for further testing. It is a feature of this invention that the so-prepared polymer solution in oil may find use in lubricating oils as multifunctional additive (e.g., dispersant viscosity index improvers which provide antiwear and antioxidant properties, etc.) when present in effect amount of 1.0 to 20 wt%, preferably 3-15 wt%, preferably 9 wt%. Lubricating oils in which the multi-functional additives of this invention may find use may include automotive, aircraft, marine, railway, etc., oils; oils used in spark ignition or compression ignition; summer or winter oils, etc. Typically, the lubricating oils may be characterized by a b.p. of 299°C (570°F) to 349°C (660°F), preferably 321°C (610°F); an e.p. of 399°C (750°F) to 649°C (1200°F), preferably 549°C (1020°F) ; an API gravity of 25 to 31, preferably 29. A typical lubricating oil in which the polymer of this invention may be present may be a standard SAE 5W-30 hydrocarbon motor oil formulation having the composition as set forth below in Table 1. Use of the additive of this invention makes it possible to readily increase the viscosity index by 25-40 units, preferably 35 units, and to obtain improved ratings on the tests measuring the dispersancy of the system. The viscosity index is determined by ASTM Test D-445. The present invention comprises making dispersant, antiwear and antioxidant VI improvers by derivatizing hydrocarbon polymers such as ethylene-propylene copolymer (EPM) or ethylene-propylene-diene terpolymer (EPDM) with, pendant units containing hindered aromatic amine. Addition of the above invention additives to a lubricating oil may be facilitated by use of a concentrate containing 1 to 20 wt%, preferably 4 to 14 wt% of polymer. The tests and analysis used, according to the present invention, are provided below. 1. Oxidation Stability The antioxidant activity of the new multi-functional VI improver was examined by a proprietary test called the Bench Oxidation Test (BOT). In this test, the polymer solution is diluted with SNO-130 oil. The mixture is heated with stirring and air agitation. Samples are withdrawn periodically for analysis, by differential infrared analysis (DIR) to observe changes in the intensity of the carbonyl vibration band at 1710 cm⁻¹. Higher carbonyl group intensity indicates a lower thermal oxidative stability of the sample. The result reported, as oxidation index, indicates the change in the intensity of the carbonyl vibration band at 1710 cm⁻¹ after 144 hours of oxidation. A lower rating indicates better thermal oxidative stability of the mixture. 2. Dispersancy The sample is blended into a formulated oil, not containing a dispersant, to form 10.0 wt% viscosity index improver solution. That blend is tested for dispersancy in the prototype VE Test. In this test, the turbidity of an oil containing an additive is measured after heating the test oil to which has been added a standard blow-by. The result correlates with dispersancy and is compared to three standards (excellent, good, fair) tested simultaneously with the test sample. The numerical rating decreases with an increase in dispersant effectiveness. 3. Antiwear Properties Antiwear performance of a new VI improver was determined by a Four-Ball Test (NMS-82-79, ASTM D-2266, ASTM4172). The VI improver solutions in formulated oil, having Kinematic Viscosity at 100°C around 16 cSt were evaluated. In this test, four balls are arranged in an equilateral tetrahedron. The lower three balls are clamped securely in a test cup filled with lubricant and the upper ball held by a chuck which is motor driven, causing the upper ball to rotate against the fixed lower balls. Load is applied in an upward direction through a weight/lever arm system. Heaters allow operation at elevated oil temperatures. The test speeds available for each tester are 600 rpm, 1200 rpm, and 1800 rpm. Results are reported as average scar diameter (mm). The amount of hindered aromatic amine incorporated onto OCP in the grafting process is determined by IR-analysis of isolated rubber. The amount of aromatic amine on the polymer is determined by aromatic stretch at 1600 cm⁻¹. The rubber is isolated from solution by multiple precipitation using cyclohexane as a solvent and acetone as precipitator. The rubber (isolated as a solid) is dried in vacuum at 60°C for 36 hours. The practice of the process of this invention will be more apparent to those skilled in the art from the following examples wherein, as elsewhere in this specification, all parts are parts by weight unless otherwise set forth. Control examples are designated by an asterisk*. EXAMPLE I In this example, a monomer was prepared from vinyl benzyl chloride (VBC) and-N-phenyl-p-phenylenediamine (NPPDA). 18.42g (0.1 mole) of NPPDA is dissolved in 190 ml THF and mixed with 67.02 (1.2 mole) of calcium oxide. Then 15.62g (0.1 mole) of VBC is added dropwise and mixture is heated at 70-80°C for 2 hours. Solid calcium chloride is removed by ultra-centrifugion and THF is distilled of under vacuum using a rotovapor. The product is used as it is for grafting reaction. EXAMPLE II The monomer prepared as described in Example 1 is grafted onto EPM containing around 0.3 mole% of vinyl norbornene in the presence of free radical initiator, dicumyl peroxide. EPM (Mn = 80,000 as measured by SEC) containing approximately 60 mole% of ethylene is used. 100 w. parts of EPM dissolved in 210 parts of mineral grafting oil (SN-130) is heated to 155°C (with stirring under nitrogen). 6.0 w. parts of monomer of Example 1 in 3.0 w. parts of grafting oil is added followed by 2.24 wt parts dicuml peroxide dissolved in 6wt parts of oil. The mixture is stirred using above conditions for 2 hours. Then, the solvent neutral oil (SNO-100) is added to give a solution containing 13.0 wt% polymer. This solution is used for further testing. EXAMPLE III In this Example, 100 w parts of EPM dissolved in 210 parts of mineral grafting oil (SN-130) is heated to 155°C (with stirring under nitrogen) . 4.0 w parts of VBC in 3.0 w parts of grafting oil is added followed by 1.48 wt. parts dicumyl peroxide dissolved in 5 wt. parts of oil. The mixture is stirred using above conditions for 2 hours. Then, 5.8 wt. parts of NPPDA is added and the reaction mixture is stirred and heated at 155-165°C for 2 hours. Then, the solvent neutral oil (SNO-100) is added to give a solution containing 13.0 wt% polymer. This solution is used for further testing. EXAMPLE IV * In this example, 13.0 wt.% EPM solution in mineral oil is prepared. 100 wt parts of EPM which is used in the Example 1, is added to 218 wt. parts of SN-130 and 451.2 wt. parts of SNO-100. The mixture is heated to 155°C with stirring and under nitrogen for 3 hours until the rubber is completely dissolved. RESULTS The evaluation data for the samples of Examples II, III, and IV* are listed below in Table 2. The sample numbers are related to the example numbers. As seen below in Table 2, samples of Examples II and III containing units derived from vinyl benzyl chloride and NPPDA showed good antioxidant and dispersant or antiwear properties. By contrast, the reference sample IV* which contains unmodified EPM did not give any antiwear, dispersancy or antioxidancy performance. The above data indicate that EPM or EPDM copolymers containing pendant units derived from vinyl benzyl chloride and N-phenyl-p-phenylene diamine form multi-functional VI improvers exhibiting dispersant, antiwear and antioxidant performance in motor oils.

Claims: A method of preparing a polymer composition containing a substantially linear carbon-carbon backbone which comprises: forming a reaction mixture containing a substantially linear, carbon-carbon backbone olefin copolymer; graft polymerizing onto said substantially linear carbon-carbon backbone olefin copolymer, under graft polymerization reaction conditions in the presence of free radical initiator, either in a one-step process a graft functional monomer derived from unsaturated chloride and hindered aromatic amine or, in a two-step process an unsaturated chloride, followed by capping the graft polymer with an aromatic hindered amine. A method as claimed in Claim 1, wherein said backbone olefin copolymer is a copolymer of ethylene-propylene or a terpolymer of ethylene-propylene-diene. A method as claimed in Claim 1 or Claim 2, wherein in the one-step process said graft functional monomer is derived from vinyl benzyl chloride and N-phenyl-p-phenylene diamine. A method of preparing a substantially linear olefin copolymer composition as claimed in Claim 1 or Claim 2, wherein said graft functional monomer contains an ethylenically unsaturated carbon-carbon double bond and a chloride group thereby forming a graft polymer bearing a pendant chlorine group and amidizing said graft polymer bearing a pendant chlorine group with an aromatic hindered amine containing a non-tertiary amino nitrogen atom amine. A method as claimed in Claim 4, wherein said graft monomer is vinyl benzyl chloride. A method as claimed in Claim 5, wherein said aromatic hindered amine is N-phenyl-p-phenylene diamine. A lubricating oil additive comprising a major portion of lubricating oil and a minor effective viscosity index improving portion of a substantially linear graft polymer formed by a process as claimed in any one of Claims 1 to 3. A lubricating oil additive as claimed in Claim 7 wherein said minor effective viscosity index improving portion of said graft polymers is 0.1-20 wt% based on oil composition.

Inventors: BIGGS ROBERT THOMAS, KAPUSCINSKI MARIA MAGDALENA, NALESNIK THEODORE EUGENE, SCHLICHT RAYMOND CHARLES, BIGGS, ROBERT THOMAS, KAPUSCINSKI, MARIA MAGDALENA, NALESNIK, THEODORE EUGENE, SCHLICHT, RAYMOND CHARLES
Applicants: TEXACO DEVELOPMENT CORP, TEXACO DEVELOPMENT CORPORATION
Application year: 1992
Main classification: C08F255
IPC codes: C10M149, C10M143