Patent Application
20170152457
The present invention relates to a lubricant composition, particularly to a lubricant composition for lubricating a bearing or other rolling components that maybe used under high temperature conditions (for example, temperatures of 180° C. or higher). The present invention also relates to a rolling bearing including the lubricant composition sealed therein.
In the industry, there have been attempts to improve performance of a lubricant for rolling components such as a rolling bearing by incorporating various additives into the lubricant. When a rolling bearing or the like is operated under high temperature conditions, a lubricant oil or a grease sealed in the bearing may be subjected to oxidative deterioration that is likely to accelerate breakage of a lubricating film, and thus the life of lubrication may be shortened. Especially, a lubricating film is more likely to be broken under high-temperature and high-speed conditions. The breakage of a lubricating film causes metal surfaces of rolling components to be contacted each other, thereby leading to problems such as increased frequency of heat generation and frictional wear. Therefore, in order to enhance the high-temperature endurance of lubricant oils or greases for rolling bearings or the like, one or more antioxidants such as an amine antioxidant, a phenolic antioxidant and an organozinc compound have been used alone or in combination of two or more.
For example, there has been proposed the use of phenolic antioxidants such as 2,2′-methylenebis(6-tert-butyl-4-methylphenol), amine antioxidants such as octylated diphenylamine, and sulfur antioxidants such as phenothiazine in a lubricant for a bearing (see Patent Document 1). Further, in an attempt to provide a grease composition for rolling bearings used in motors with reduced torque and noise, there has been proposed the use of a low-viscosity ester oil as a base oil, a metal soap as a thickener, and a combination of liquid hindered amine and triphenyl phosphorothionate as an antioxidant (see Patent Document 2).
Patent Document 1: JP 2005-188557 A
Patent Document 2: JP 2012-162657 A
The use of such antioxidants as described in Patent Document 1 or 2, however, may not always provide sufficient performance in high-temperature endurance, depending on the type of base oil to be used in combination with the antioxidant, temperature conditions at the time of lubrication, and so on. For instance, a phenyl ether synthetic oil which is one of base oils of lubricants has good thermal and oxidative stabilities; however, when used under high temperature conditions such as temperatures of 180° C. or higher, a lubricant containing such an oil may be incapable of providing sufficient high-temperature endurance, depending on the type of antioxidant employed.
The present invention is directed to overcoming the above-mentioned problems. It is an object of the present invention to provide a lubricant composition which can be used as a lubricant for a rolling component, the composition capable of maintaining enhanced lubrication performance over a long period of time even under high temperature conditions such as temperatures of 180° C. or higher, and a rolling bearing including the lubricant composition sealed therein.
The present invention provides a lubricant composition used for lubricating a rolling component, containing a base oil and an antioxidant, wherein the base oil is an oil mixture of an alkyl diphenyl ether oil and at least one oil selected from a poly-α-olefin (hereinafter also referred to as “PAO”) oil and an ester oil, and contains the alkyl diphenyl ether oil in an amount of 50% or more by weight of the total base oil; and the antioxidant is a compound represented by the following formula (1) or a polymer thereof, and is contained in an amount of 0.1% to 10% by weight of the total lubricant composition:
The base oil may contain the alkyl diphenyl ether oil in an amount of 70% to 90% by weight of the total base oil. The base oil may be an oil mixture of the alkyl diphenyl ether oil and the poly-α-olefin oil. The alkyl diphenyl ether oil may have a kinetic viscosity at 40° C. of 60 to 120 mm2/s.
The lubricant composition may be a grease containing a urea compound as a thickener.
The lubricant composition may be used under a high temperature condition of 180° C. or higher.
The present invention provides a lubricant composition-sealed bearing including the lubricant composition of the present invention sealed in a region to be lubricated.
The lubricant composition of the present invention is obtained by adding, as an antioxidant, a predetermined quinoline antioxidant to a base oil mixture containing a predetermined phenyl ether synthetic oil as a main ingredient. Therefore, the present invention can reduce oxidative deterioration of the lubricant in use under a high temperature condition of 180° C. or higher over a long period of time and thereby extend a lubricant life, as compared with other lubricants obtained by adding a different antioxidant to the same base oil. As a result, the present invention can increase the service life of a bearing or a similar rolling component including the lubricant composition sealed therein.
The lubricant composition of the present invention is used for lubricating a rolling component. In particular, the lubricant composition is used in a rolling bearing, a gear, or a component part thereof, and the composition is sealed in a region of the bearing or the like which is to be lubricated. It is envisaged that the lubricant composition is used at a temperature of, for example, 150° C. or higher, particularly 180° C. or higher, up to about 200° C. That is, the temperature range for the use of the composition is, for example, 150° C. to 200° C., more particularly 180° C. to 200° C.
The present invention includes two embodiments of lubricant composition as follows: (A) a lubricant oil containing a predetermined base oil and a predetermined quinoline antioxidant as essential components; and (B) a grease containing a predetermined base oil, a thickener, and a predetermined quinoline antioxidant as essential components.
The quinoline antioxidant used in the present invention is a compound represented by formula (1), namely 2,2,4-trimethyl-1,2-dihydroquinoline, or a dimeric or higher order condensate (polymer) thereof. A mixture of the compound and polymer may also be used.
The polymer corresponds to “TMDQ”, an anti-oxidizing agent of JIS K 6211, with physical properties including: a softening point of 80° C. to 110° C., a specific gravity of 1.06 to 1.11 and an ash content of 0.5% or less. Examples of commercially available products that can be used in the present invention include VANLUBE RD manufactured by Vanderbilt Chemicals, LLC and NOCRAC (registered trademark) 224 manufactured by Ouchi Shinko Chemical Industrial Co., Ltd.
When the above-mentioned lubricant composition is used as a lubricant oil, the quinoline antioxidant is contained in an amount of 0.1% to 10% by weight of the total lubricant composition. A quinoline antioxidant content of less than 0.1% by weight may not sufficiently improve the high-temperature endurance. A quinoline antioxidant content of more than 10% by weight may not only fail to improve the performance of the composition, but also cause some problems such as evaporation due to degraded materials of the antioxidant, thus leading to even worse performance in the high-temperature endurance. The amount of the quinoline antioxidant is preferably 0.3% to 10% by weight, more preferably 0.3% to 5% by weight, further preferably 0.3% to 2% by weight.
When the above-mentioned lubricant composition is used as a grease, the quinoline antioxidant is contained in an amount of 0.1 to 10 parts by weight based on the total 100 parts by weight of the base oil and thickener. A quinoline antioxidant content of less than 0.1 parts by weight may not sufficiently improve the high-temperature endurance. A quinoline antioxidant content of more than 10 parts by weight may not only fail to improve the performance of the composition, but also cause some problems such as evaporation due to degraded materials of the antioxidant, thus leading to even worse performance in the high-temperature endurance. The amount of the quinoline antioxidant is preferably 0.3 parts to 10 parts by weight, more preferably 0.3 parts to 5 parts by weight, further preferably 0.3 parts to 2 parts by weight.
The lubricant composition of the present invention contains an oil mixture of (X) an alkyl diphenyl ether oil that is an essential ingredient and (Y) at least one oil selected from a PAO oil and an ester oil, and the oil mixture contains the alkyl diphenyl ether oil in an amount of 50% or more by weight of the total base oil. In the base oil mixture, the weight ratio of (X) to (Y) is preferably X:Y=6:4 to 9:1, more preferably X:Y=7:3 to 9:1, particularly preferably X:Y=7.5:2.5 to 8.5:1.5. Especially, when the ratio is X:Y=7:3 to 9:1, that is, when the alkyl diphenyl ether oil is contained in an amount of 70% or more by weight of the total base oil, the quinoline antioxidant is more likely to be effective in improving the high-temperature endurance.
Examples of the alkyl diphenyl ether oil as an essential ingredient include a monoalkyl diphenyl ether oil represented by the following formula (2), a dialkyl diphenyl ether oil represented by the following formula (3) and a polyalkyl diphenyl ether.
In the formulae, R1, R2 and R3 each represent an alkyl group having 8 to 20 carbon atoms, and are each bonded to a phenyl ring or two phenyl rings. Especially, a dialkyl diphenyl ether oil having R2 and R3 is preferable in view of some properties such as heat resistance.
The PAO oil (synthetic hydrocarbon oil) is a mixture of a-olefin or isomerized α-olefin oligomers or polymers. Specific examples of α-olefins include 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-eicosene, 1-docosene and 1-tetradocosene; a mixture thereof is usually used.
Examples of the ester oil include diester oils such as dibutyl sebacate, di-2-ethylhexyl sebacate, dioctyl adipate, diisodecyl adipate, ditridecyl adipate, ditridecyl glutarate, and methyl acetyl ricinoleate, aromatic ester oils such as trioctyl trimellitate, tridecyl trimellitate and tetraoctyl pyromellitate, polyol ester oils such as trimethylol propane caprylate, trimethylol propane pelargonate, pentaerythritol-2-ethylhexanoate and pentaerythritol pelargonate, carbonate ester oils and phosphate ester oils.
In the base oil of the lubricant composition of the present invention, the alkyl diphenyl ether oil preferably has a kinetic viscosity at 40° C. of 50 to 200 mm2/s, more preferably 60 to 120 mm2/s. The total base oil (oil mixture) preferably has a kinetic viscosity at 40° C. of 30 to 200 mm2/s, more preferably 60 to 100 mm2/s in view of low-temperature property and heat resistance.
When the lubricant composition of the present invention is used as a grease, the composition additionally contains a thickener. The thickener used in the present invention is preferably a urea compound because of excellent durability against heat and advantageous performance in intervening into sliding portions of mechanical parts as well as in being adhered to the sliding portions.
The urea compound can be prepared by a reaction between a polyisocyanate component and a monoamine component. Examples of the polyisocyanate component include phenylene diisocyanate, tolylene diisocyanate, diphenyl diisocyanate, diphenylmethane diisocyanate, octadecane diisocyanate, decane diisocyanate and hexane diisocyanate. The monoamine component used in the present invention may be an aliphatic monoamine, an alicyclic monoamine or an aromatic monoamine. Examples of the aliphatic monoamines include hexylamine, octylamine, dodecylamine, hexadecylamine, octadecylamine, stearylamine and oleylamine. Examples of the alicyclic monoamines include cyclohexylamine. Examples of the aromatic monoamine include aniline and p-toluidine.
The thickener such as a urea compound is incorporated into the base oil to obtain a base grease. The base grease containing a urea compound as the thickener is prepared by reacting the polyisocyanate component with the monoamine component in the base oil. The thickener content in the base grease is preferably 1% to 40% by weight, more preferably 3% to 25% by weight. A thickener content of less than 1% by weight results in a poor thickening effect, thereby making it difficult to prepare a suitable grease. A thickener content of more than 40% by weight makes the resultant base grease too hard to give a desired effect.
It is preferred that the grease as described above have a worked penetration (JIS K 2220) within the range of 200 to 350. A worked penetration of less than 200 may reduce oil separation of the grease, thus leading to poor lubricating performance. On the other hand, a grease with a worked penetration of more than 350 is soft, and is undesirable because of easy flowing out from the area in which the grease is sealed.
The lubricant composition may contain one or more known additives other than the above-mentioned quinoline antioxidant as needed, to the extent that the purpose of the present invention is not impaired. Examples of such additives include metal inactivators such as benzotriazole, viscosity index improvers such as polymethacrylate and polystyrene, solid lubricants such as molybdenum disulfide and graphite, anticorrosives such as a metal sulfonate and a polyhydric alcohol ester, oil-based agents such as an ester and an alcohol, and other anti-wear agents. These can be added alone or in combination of two or more.
The composition of the present invention that contains the predetermined quinoline antioxidant with the predetermined base oil can exhibit advantageously improved high-temperature endurance as compared to a composition that contains a different antioxidant alone. Where appropriate, an aromatic amine antioxidant or a phenolic antioxidant may be used as another antioxidant in combination with the quinoline antioxidant.
The lubricant composition-sealed bearing (rolling bearing) including the lubricant composition of the present invention sealed therein will be described below with reference to
While
Because the lubricant composition-sealed bearing of the present invention includes the above-mentioned lubricant composition sealed therein, it is possible to reduce oxidative deterioration of the lubricant over a long period of time even under conditions of use at a high temperature of 180° C. or higher and a high speed, thereby achieving a long service life of the bearing.
The present invention is specifically illustrated, but not limited, by the following examples and comparative examples.
Each lubricant composition in Table 1 was evaluated for high-temperature endurance by measuring the rate of weight reduction of the composition which was left at a high temperature. As shown in Table 1, each base oil was an oil mixture of an alkyl diphenyl ether oil and a poly-α-olefin oil at a mixing ratio of 8:2 by weight. Each sample of the lubricant composition was left in a constant-temperature bath at 180° C. and at 120° C. in an air atmosphere for 0, 200, 400, 600, 800 and 1000 hours (up to 600 hours at 120° C.). The sample was taken out of the bath and weighed at each time point to determine the rate of weight reduction according to the following formula. The results are shown in Table 1 together with other details. The results of the high temperature exposure tests at 180° C. and at 120° C. are shown in
Rate of weight reduction (wt %)=100×(“weight (g) of lubricant composition before being left in constant-temperature bath”−“weight (g) of lubricant composition after being left in constant-temperature bath”)/“weight (g) of lubricant composition before being left in constant-temperature bath”
Each lubricant composition in Table 2 was evaluated for high-temperature endurance by measuring the rate of weight reduction of the composition which was left at a high temperature. As shown in Table 2, each base oil was an oil mixture of an alkyl diphenyl ether oil and a poly-α-olefin oil or an ester oil at a mixing ratio (by weight) as indicated in the table. In Table 2, superscripts 1) to 3) are the same as defined in Table 1. Each sample of the lubricant composition was left in a constant-temperature bath at 180° C. in an air atmosphere for 0, 200 and 400 hours. The sample was taken out of the bath and weighed at each time point to determine the rate of weight reduction according to the formula described above. The results are shown in Table 2 together with other details. The results of the high temperature exposure tests are shown in
6)KAOLUBE 262 manufactured by Kao Corporation, kinetic viscosity at 40° C.: 33.5 mm2/s
As shown in Tables 1 and 2 and
The lubricant composition of the present invention can be suitably applied for lubrication of rolling components such as a bearing for use under high temperature conditions (for example, temperatures of 180° C. or higher).
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-135545 | Jul 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/068752 | 6/30/2015 | WO | 00 |
