DILUTE COOLANT

Abstract: A pre-diluted coolant which does not require dilution with water for use and thus can be directly utilized in internal-combustion engine systems is disclosed. The pre-diluted coolant comprises, as its base component, deionized water where metal corrosive ions and scale forming ions are removed, ethylene glycol aqueous solution prepared using such deionized water, or propylene glycol aqueous solution prepared using such deionized water. The pre-diluted coolant provides excellent metal corrosion inhibition and scale formation inhibition.

Description: TECHNICAL FIELD This invention generally relates to a pre-diluted coolant for direct use in internal-combustion engine systems, which requires no dilution with water. More particularly, this invention relates to a pre-diluted coolant that can excellently inhibit metal corrosion and scale formation in cooling systems and improve lubrication of mechanical seals of water pumps. BACKGROUND ART Conventionally, cooling systems of internal-combustion engines utilize coolants which are prepared by diluting glycol-based or alcohol-based coolant compositions with conventional water. It is known that a conventional cooling system which comprises various metallic parts such as aluminum, aluminum alloy, cast iron, steel, brass, solder and copper parts suffers from metal corrosion, chiefly through contact with water and air contained in the coolant flowing through the cooling system. It is also known that water conventionally used to dilute coolant compositions generally contains, among other substances or hard water elements, ions such as chlorine ions, sulfuric acid ions and bicarbonate ions which are known to be metal corrosive ions. These metal corrosive ions accelerate metal corrosion, especially under high temperature and pressure environments such as in cooling systems. In order to inhibit metal corrosions in cooling systems, it is conventional to selectively blend in coolant compositions metal corrosion inhibitors such as phosphates, amine salts, silicates, borates, nitrites and dibasic acids. However, blending of such additives would raise additional problems. Phosphates tend to cause eutrophication in rivers or ponds when coolants containing phosphates are disposed of into rivers or ponds, which would increase BOD and COD in the waters. Increased BOD or COD would propagate algae, which are known to generate harmful red tides or become slimes that are to be accumulated on the riverbeds or pond beds. Amine salts and nitrites when they coexist in coolants would chemically react with each other and produce nitrosoamine which is known to be a carcinogenic compound, while silicates are generally unstable in coolants and would easily gel when the temperature of the coolants rapidly changes or the pH value of the coolants changes and/or other salts coexist, leading to degradation in metal corrosion inhibition. Borates are apt to corrode aluminum or aluminum alloy while nitrites will quickly degrade in coolants and lose their expected property in the coolants. Besides chlorine ions, sulfuric acid ions and bicarbonate ions, hard water element ions such as calcium ions and magnesium ions are often melted in diluting water. Calcium and magnesium ions are known to be scale forming ions. Phosphates or dibasic acids contained in coolant compositions would chemically react with calcium and magnesium ions contained in diluting water and would form scales or precipitation in coolants. Scales formed as such would seriously affect corrosion inhibition function of phosphoric acids or dibasic acids, might clog circulation passages of cooling systems and/or would lower heat transfer function of coolants at high-temperature sections or spots such as cylinder head portions and valves by adhering thereto and may eventually physically damage such portions as well. When a coolant composition containing "large" quantity of foregoing metal corrosion inhibitors is used, following. problems would occur. Water or glycol in coolants where those metal corrosion inhibitors are melted would locally evaporate in the vicinities of hot spots such as mechanical seals of water pumps, and locally lower solubility of metal corrosion inhibitors in the coolants, producing precipitation of the metal corrosion inhibitors, which would adhere to the mechanical seals and eventually damage the sealing property of the mechanical seals. The inventors of the present invention aimed at solving such water-related problems and have arrived at the present invention. Accordingly, it is a chief object of the present invention to provide for a use of a pre-diluted coolant that does not require dilution with water and thus is capable of effectively inhibiting metal corrosions and scale forming as well as improving lubrication of mechanical seals of water pumps altogether without suffering negative aspects of conventional coolant compositions. Other objects of the present invention will become apparent from the descriptions that follow. SUMMARY OF THE INVENTION The present invention is as set out in the accompanying claims. In particular, the present invention is directed to the use of deionized water free, or ethylene glycol aqueous solution prepared using such deionized water, or propylene glycol aqueous solution prepared using such deionized water in or as the base component in a pre-diluted coolant for direct use in internal-combustion engine systems, wherein said pre-diluted coolant is free of conventional water. A pre-diluted coolant used in the present invention which does not require later dilution with water can be directly used in the cooling system of an internal-combustion engine. The pre-diluted coolant used in the present invention is characterized in that its chief component is deionized water where metal corrosive ions and scale forming ions are removed, or ethylene glycol aqueous solution prepared using such deionized water, or propylene glycol aqueous solution also prepared using such deionized water. The term "deionized water" as used herein means water containing practically no metal corrosive ions such as chlorine ions, sulfuric acid ions and bicarbonate ions or scale forming ions such as calcium ions and magnesium ions. Such deionized water may be pure water or its practical equivalent. Such pure water may be aqueous electrolytic solution with specific resistance 10 x 10,000 Ω. cm or over prepared, e.g., by utilizing an ion-exchange resin, or may be nuclear reactor water having specific resistance 100 x 10,000 Ω. cm or over. Since such deionized water (metal corrosive ions and scale forming ions are removed) is pre-blended in the pre-diluted coolant of the present invention, negative aspects that would otherwise be caused by the ions in the coolant can be effectively avoided. In addition, it has become possible or feasible to substantially reduce contents of conventional metal corrosion inhibitors in coolants since progress of possible metal corrosions in cooling systems would be sufficiently slowed or inhibited by utilization of deionized water without relying much on metal corrosion inhibitors. Local evaporation of water or glycols in the vicinities of mechanical seals would not seriously or materially affect the physical feature of the seals, because precipitation of metal corrosion inhibitors would effectively be prevented due to their limited use as will be readily appreciated by people skilled in the related art. Further, as the pre-diluted coolant used in the present invention does not practically contain scale forming ions and contains only minimum amounts of metal corrosion inhibitors, scale formation through chemical reaction between scale forming ions and certain metal corrosion inhibitors such as phosphoric acids and dibasic acids would be effectively inhibited, preventing scale precipitation and accumulation in the coolant. The pre-diluted coolant used in the present invention selectively contains in an effective amount or amounts at least one metal corrosion inhibitor selected from alkali metal salts and amine salts of phosphoric acids, benzoic acid and alkali metal salts, ammonium salts and amine salts thereof, alkylbenzoic acids having a chemical structure R-C6H4-COOH (R is a C1-C5 alkyl group) and alkali metal salts, ammonium salts and amine salts thereof, alkoxybenzoic acids having a chemical structure RO-C6H4-COOH (R is a C1-C5 alkyl group) and alkali metal salts, ammonium salts and amine salts thereof, cinnamic acids, alkylcinnamic acids and alkoxycinnamic acids having a chemical structure R-C6H4-CH=CHCOOH (R is a C1-C5 alkyl or alkoxyl group) and alkali metal salts, ammonium salts and amine salts thereof, other aromatic carboxylates, C6-C12 aliphatic monobasic acids and C6-C12 aliphatic dibasic acids and their alkali metal salts, ammonium salts and amine salts, other aliphatic carboxylates, aromatic polyvalent carboxylic acids, molybdates, tungstates, vanadates, alkali metal salts of nitric acid, alkali metal salts of silicic acids, alkali metal salts of boric acids, alkali metal salts of nitrous acid, triazole hydrogencarbonate, mercaptobenzothiazole, strontium compounds, 2-phosphonobutane-1,2,4 tricarboxylic acid and alkali metal salts thereof. BRIEF DESCRIPTION OF THE DRAWING FIG.1 is a schematic view of a mechanical seal leakage unit test system. EMBODIMENT/COMPARISON TESTING A number of test samples were prepared and named Embodiments ("Emb." for short) 1-7 and Comparisons ("Com." for short) 1-7 as provided in Table 1. Ethylene glycol and water were respectively mixed in the indicated weight ratios, where the indicated percentages by weight of the additives were respectively blended. Metal corrosion tests were carried out using these samples in accordance with JIS2234-1994. II (an officially recognized Japanese test standard). Tables II-1 and II-2 show the metal corrosion test results and evaluations. The deionized (good) water used to prepare Embodiments 1-7 was ion-exchange water or distilled water with ion concentrations of chlorine 10mg/litter or lower and sulfuric acid 10mg/litter or lower, with hardness (measured in CaCO3) 20mg/litter or lower. Bad water (1) was tap water, having ion concentrations of chlorine 49mg/litter and sulfuric acid 38mg/litter with hardness (CaCO3) 89mg/litter. Bad water (2) was ionized water containing sodium sulfate 148mg/litter, sodium chloride 165mg/litter and sodium hydrocarbon 138mg/litter. Bad water (3) was ion exchange water containing calcium chloride 275mg/litter, sodium sulfate 148mg/litter, sodium chloride 165mg/litter and sodium hydrocarbon 138mg/litter. In Tables II-1 and II-2, the numerals (5), (6) and (7) respectively signify the following. Numeral (5) - There is no showing of corrosion except at the contacting portions between the test sample and spacer. Change in color is not questioned. Numeral (6) - There is no showing of foam overflow. Numeral (7) - There is no significant change in color. There is no significant phase separation or gelation. Embodiment 2 and Comparison 2 were further subjected to both a mechanical seal leakage unit testing and stability testing in hard water. The test conditions are provided in Table III and the test system shown in Fig.1 was utilized. The test results are given in Table IV. Mechanical Seal Leakage Unit Test Conditions Concentration v/v% 50 Time h 200 Temperature °C 90 Revolution r.p.m. 6500 External Pressure kg/cm2 1.0 The stability test was conducted using 200ml test samples in glass beakers which had been left for 24 hours at room temperatures. The test samples were centrifuged under the JIS K 2503 test conditions (an official Japanese testing standard). Amounts of precipitation were then measured. Embodiment 2 Comparison 2 Leakage ml <1 18 Precipitation v/v% 0 1.2

Claims: Use of deionized water free of corrosive ions and scale forming ions and having a specific resistance of at least 10 x 10,000 Ωcm, or ethylene glycol aqueous solution prepared using such deionized water, or propylene glycol aqueous solution prepared using such deionized water in or as the base component in a pre-diluted coolant for direct use in internal-combustion engine systems, wherein said pre-diluted coolant is free of conventional water. Use according to claim 1, wherein said base component contains at least one other ingredient, in an effective amount or amounts, selected from the metal inhibitor group consisting of alkali metal salts and amine salts of phosphoric acids, aromatic carboxylates including benzoic acid and alkali metal salts, ammonium salts and amine salts thereof, alkylbenzoic acids having a chemical structure R-C6H4-COOH (R is a C1-C5 alkyl group) and alkali metal salts, ammonium salts and amine salts thereof, alkoxybenzoic acids having a chemical structure RO-C6H4-COOH (R is a C1-C5 alkyl group) and alkali metal salts, ammonium salts and amine salts thereof, cinnamic acids, alkylcinnamic acids and alkoxycinnamic acids having a chemical structure R-C6H4-CH=CHCOOH (R is a C1-C5 alkyl or alkoxyl group) and alkali metal salts, ammonium salts and amine salts thereof, aliphatic carbokylates including C6-C12 aliphatic monobasic acids and C6-C12 aliphatic dibasic acids and their alkali metal salts, ammonium salts and amine salts, aromatic polyvalent carboxylic acids, molybdates, tungstates, vanadates, alkali metal salts of nitric acid, alkali metal salts of silicic acids, alkali metal salts of boric acids, alkali metal salts of nitrous acid, triazole hydrogencarbonate, mercaptobenzothiazole, strontium compounds, 2-phosphonobutane-1,2,4 tricarboxylic acid and alkali metal salts thereof. Use according to claim 1 or 2, wherein alkali metal salts and amine salts of phosphoric acids, alkali metal salts of silicic acids, alkali metal salts of boric acids, alkali metal salts of nitrous acid, aliphatic monobasic acids and aliphatic dibasic acids are excluded and not contained in said base component, wherein at least one of 0.1-5.0 wt.% of p-tert butyl benzoic acid and alkali metal salts thereof, and at least one of 0.01-1.0 wt.% of triazoles are contained in said base component. Use according to claim I or 2, wherein 0.01-8.0 wt.% of alkylbenzoic acids having a chemical structure R-C6H4-COOH (R is a C1-C5 alkyl group) or their alkali metal salts, ammonium salts or amine salts are contained in said base component. Use according to claim 1 or 2, wherein 0.01-8.0 wt.% of alkoxybenzoic acids having a chemical structure RO-C6H4-COOH (R is a C1-C5 alkyl group) or their alkali metal salts, ammonium salts or amine salts are contained in said base component. Use according to claim 1 or 2, wherein 0.01-8.0 wt.% of cinnamic acids, alkylcinnamic acids or alkoxycinnamic acids having a chemical structure R-C6H4-CH=CHCOOH (R is H, or a C1-C5 alkyl or alkoxyl group), or their alkali metal salts, ammonium salts or amine salts are contained in said base component. Use according to claim 1 or 2, wherein alkali metal salts and amine salts of phosphoric acids, alkali metal salts of silicic acids, alkali metal salts of boric acids and alkali metal salts of nitrous acid are excluded and not contained in said base component, wherein 0.1-4.0 wt.% of at least one of sebacic acid and alkali metal salts thereof, and 0.1-3.0 wt.% of at least one of p-tert butylbenzoic acids and alkali metal salts thereof are contained in said base component. Use according to claim 1 or 2, wherein phosphates, amine salts, silicates, borates and nitrites are excluded and not contained in said base component, wherein 0.1-0.4 wt.% of at least one of sebacic acid and alkali metal salts thereof, 0.1-3.0 wt.% ofat least one of undecanoic diacid and dodecanoic diacid and their alkali metal salts, and 0.01-1.0 wt.% of at least one of triazoles are contained in said base component. Use according to claim 1 or 2, wherein 0.02-5.0 wt.% ofat least one of C6-C12 aliphatic monobasic acids and their salts, and 0.02-5.0 wt.% of at least one of alkoxybenzoic acids having a C1-C5 alkoxyl group and their salts are contained in said base component. Use according to claim 9, further containing 0.1-1.0 wt.% of at least one of triazoles. Use according to claim 9 or 10, wherein amine salts and borates are excluded and not contained. Use according to claim 1 or 2, wherein 0.02-5.0 wt.% of at least one of hexanoic acid and heptanoic acid and their salts, and 0.02-5.0 wt.% of at least one of alkylbenzoic acids having a C1-C5 group and salts thereof are contained in said base component. Use according to claim 12, further containing 0.01-1.0 wt.% of at least one of triazoles. Use according to claim 12 or 13, wherein amine salts and borates are excluded and not contained. Use according to claim 1 or 2, wherein 0.02-5.0 wt.% of at least one of C6-C12 aliphatic monobasic acids and salts thereof, and 0.02-5.0 wt.% of at least one of cinnamic acids, alkylcinnamic acids and alkoxycinnamic acids having a chemical structure R-C6H4-CH=CHCOOH (R is a C1-C5 alkyl group or alkoxyl group) and their alkali metal salts, ammonium salts and amine salts are contained in said base component. Use according to claim 15, further containing 0.01-1.0 wt.% of at least one of triazoles. Use according to claim 15 or 16, wherein amine salts and borates are excluded and not contained. Use according to claim 1 or 2, wherein 0.01-8.0 wt.% of at least one of p-toluic acid salts and 0.002-1.0 wt.% of at least one of molybdates are contained in said base component. Use according to claim 18, further containing 0.01-8.0 wt.% of at least one of benzoates. Use according to claim 18, further containing 0.01-8.0 wt.% of p-tert butylbenzoic acid. Use according to any of claims 18-20, wherein nitrites are excluded and not contained. Use according to claim 1 or 2, wherein 0.01-8.0 wt.% of at least one ofbenzoates, 0.01-8.0 wt.% of p-tert butylbenzoic acid and 0.002-1.0 wt.% of at least one of molybdates are contained in said base component. Use according to claim 22, further containing 0.01-8.0 wt.% of at least one of p-toluic acid salts. Use according to claim 22 or 23, wherein nitrites are excluded and not contained. Use according to claim 1 or 2, wherein 0.01-8.0 wt.% of at least one of benzoates and 0.01-8.0 wt.% of at least one of p-toluic acid salts are contained in said base component. Use according to claim 25, further containing 0.01-8.0 wt.% of p-tert butylbenzoic acid. Use according to claim 25 or 26, wherein nitrites are excluded and not contained. Use according to claim 1 or 2, wherein 0.00002-0.1 wt.% of at least one of strontium compounds is contained in said base component. Use according to claim 1 or 2, containing in said pre-diluted coolant 0.01-3.0 wt.% of at least one of phosphoric acids and salts thereof, 0.001-0.5 wt.% of at least one of momolybdic acid, tungstic acid and vanadic acid and their salts, and 0.001-0.5 wt.% of at least one of triazoles and salts thereof. Use according to claim 1 or 2, wherein 0.002-1.0 wt.% of at least one of 2-phosphonobutane=1,2,4 tricarboxylic acids and aqueous solutions thereof, at least one of phosphates, at least one of nitrates, at least one of benzoates and at least one of triazoles are contained in said base component. Use according to claim 30, wherein 0.002-2.0 wt.% of at least one of phosphates, 0.002-1.0 wt.% of at least one of nitrates, 0.02-6.0 wt.% of at least one of benzoates, and 0.01-2.0 wt.% of at least one of triazoles are contained in said base component.

Inventors: KAWAI MASARU, MIYAKE YUJI, MORI YASUAKI, KAWAI, MASARU, MIYAKE, YUJI, MORI, YASUAKI
Applicants: SHISHIAI KK, SHISHIAI-KABUSHIKIGAISHA
Application year: 1998
Main classification: C09K5
IPC codes: C23F11, C09K5