Patent Application
20130012417
The present invention relates to a lubricating oil composition for high-temperature applications, and more specifically to one to be used for a chain, a roller chain, a chain conveyor, a bearing and the like.
There are a lot of sliding portions such as a chain, a gear and a bearing inside a tenter used for manufacturing an optical film and a food-packaging film. Since a lubricating oil used in such sliding portions is exposed to high temperatures, an amount of evaporation of the lubricating oil significantly affects a life time of a device. In other words, under such high temperatures, since the lubricating oil loses an inherent viscosity to form a thin film, it is necessary to restrain the amount of evaporation of the lubricating oil in order to keep lubricity thereof. In order to restrain the amount of evaporation, a high-molecular and highly viscous lubricating oil has been typically used for high-temperature applications.
However, such a lubricating oil causes a large power loss although having a small amount of evaporation, which makes overall performance of the lubricating oil unfavorable. Moreover, when such a lubricating oil is exposed to high temperatures while forming a thin film, the lubricating oil becomes solid though a large amount of residue remains. Thus, the lubricating oil not only loses characteristics as a liquid but also blocks a flow of the lubricating oil in a form of a solid sludge, which causes a poor lubrication of the sliding portions. Although such a disadvantage can be simply solved by increasing the amount of the lubricating oil in use, such a solution is not favorable in terms of costs and an environmental aspect. Consequently, as the lubricating oil used under high temperatures, a lubricating oil whose evaporation amount under high temperatures is restrained and whose fluidity is kept for a long time has been demanded. Moreover, in a tenter for manufacturing an optical film, a food-packaging film, a film for a solar battery panel and the like, since scattering of the lubricating oil on a product is extremely disfavored, reduction of the amount of the lubricating oil in use has also been demanded. Further, reduction of electrical power required for operating the device has also been demanded in terms of energy saving.
Accordingly, as such a lubricating oil for high-temperature applications, there has been proposed a lubricating oil composition that contains a polyol ester synthetic oil and a diphenylamine derivative having a C12-C72 fatty acid and/or an aryl alkyl group having a number average molecular weight of 400 to 800 (see Patent Literature 1).
Patent Literature 1: JP-A-2005-314650
However, even in the lubricating oil composition disclosed in Patent Literature 1, the lubricating oil does not always exhibit sufficient characteristics under high temperatures. For instance, the lubricating oil composition may become solid under high temperatures, or an antioxidant may become sludge to cause an oil path to be clogged.
An object of the invention is to provide a lubricating oil composition for high-temperature applications, in which, under high temperatures and in a thin film, an amount of evaporation of the lubricating oil composition is restrained and fluidity thereof is kept for a long time.
In order to solve the above problem(s), the invention provides a lubricating oil composition for high-temperature applications as follows:
The invention can provide a lubricating oil composition for high-temperature applications, in which, under high temperatures and in a thin film, the amount of evaporation of the lubricating oil composition is restrained and fluidity thereof is kept for a long time.
A lubricating oil composition for high-temperature applications according to the invention contains (A) a pyromellitate ester, (B) a sulfur-containing triazine antioxidant, and (C) a thiophosphoric acid ester antioxidant. The invention will be described below in detail.
The component (A) forming the lubricating oil composition for high-temperature applications of the invention (hereinafter, referred to as “the composition”) is a pyromellitate ester and corresponds to a base oil of the composition. For instance, a pyromellitate tetraester represented by the following formula (1) is preferably used.
In the pyromellitate tetraester represented by the formula (1), all functional groups of R1 to R4 are hydrocarbyl groups, which may be mutually the same or different. Each of these functional groups are preferably an alkyl group having 6 to 16 carbon atoms, more preferably 6 to 10 carbon atoms, in terms of evaporativity restraint and fluidity.
Examples of the pyromellitate tetraester represented by the formula (1) include tetra-n-octyl pyromellitate, tetra-3,5,5-trimethylhexyl pyromellitate, tetra-undecyl pyromellitate, and tetraisostearyl pyromellitate. The alkyl group preferably has a linear structure in terms of evaporativity restraint.
A content rate of the component (A) in the composition is preferably in a range of 10 mass % to 99 mass % of a total amount of the composition, more preferably in a range of 20 mass % to 96 mass %. When the content rate falls within the above range, the composition is excellent in a balance between evaporativity restraint and fluidity.
It is preferable that the base oil of the composition further contains polybutene or a polyalphaolefin in terms of thickening effects. When the base oil further contains polybutene or a polyalphaolefin, the composition can be effectively prevented from dropping off a chain and a gear even under high temperatures.
Polybutene is exemplified by a mixture of polyisobutylene and poly-n-butene formed by polymerization of olefins having 4 carbon atoms, preferably having a number average molecular weight of 300 to 1500. Polybutene or polyisobutylene having a number average molecular weight of 400 to 1300 is particularly preferable. The mass average molecular weight (Mn) can be measured by gel-chromatography. A polymer formed by 100% polyisobutylene or 100% poly-n-butene may be used as polybutene.
As the polyalphaolefin, a known alpha-olefin oligomer can be used as it is, or can be used after hydrogenation. As the alpha-olefin, 1-octene, 1-decene, 1-dodecene and 1-tetradecene are usable. As an oligomerization catalyst, a typically used BF3 complex catalyst, solid acid catalyst or metallocene complex catalyst for general purpose may be used. For hydrogenating the oligomer, a typical nickel catalyst such as sponge nickel and nickel diatomite and a noble metal catalyst such as palladium activated carbon or ruthenium activated carbon are preferable. Any types of catalysts including a support catalyst and a complex catalyst are usable. The above polyalphaolefin preferably has a kinematic viscosity at 100 degrees C. approximately in a range of 10 mm2/s to 400 mm2/s.
When either polybutene or the polyalphaolefin is used alone, a content of either one is preferably 40 mass % or less. When both polybutene and the polyalphaolefin are used in a mixture, a content of the mixture of polybutene and the polyalphaolefin is also preferably 40 mass % or less.
The component (B) forming the composition is a sulfur-containing triazine antioxidant. The sulfur-containing triazine antioxidant is preferably exemplified by 2,6-di-tert-butyl-4-(4,6-bis(octylthio)-1,3,5-triazine-2-ylamino)phenol.
The component (B) exhibits a low evaporativity, and also exhibits excellent anti-oxidation effect and sludge formation prevention effect even under high temperatures by being contained together with a later-described component (C).
A content rate of the component (B) in the composition is preferably in a range of 0.01 mass % to 5 mass % of the total amount of the composition, more preferably in a range of 0.1 mass % to 3 mass %.
The component (C) forming the composition is a thiophosphoric acid ester antioxidant. Examples of a thiophosphoric acid ester include a thiophosphite and a thiophosphate, particularly preferably, an alkyl thiophosphite and an aryl thiophosphate, examples of which include trilauryl trithiophosphite, triphenyl thiophosphate, trinonylphenyl thiophosphate and triphenyl phosphorothioate.
The component (C) exhibits a low evaporativity, and also exhibits excellent anti-oxidation effect and wear resistance even under high temperatures by being contained together with the aforementioned component (B).
A content rate of the component (C) in the composition is preferably in a range of 0.01 mass % to 10 mass % of the total amount of the composition, more preferably in a range of 0.5 mass % to 5 mass %, in terms of the above effects.
By blending an amine antioxidant as the component (D) in the composition, the anti-oxidation effect and the sludge formation prevention effect can be enhanced. The amine antioxidant is exemplified by a diphenylamine antioxidant, examples of which include diphenylamine, monooctyl diphenylamine, monononyl diphenylamine, 4,4′-dibutyl diphenylamine, 4,4′-dihexyl diphenylamine, 4,4′-dioctyl diphenylamine, 4,4′-dinonyl diphenylamine, tetrabutyl diphenylamine, tetrahexyl diphenylamine, tetraoctyl diphenylamine, tetranonyl diphenylamine, and 4,4′-bis(α,α-dimethylbenzyl)diphenylamine. The amine antioxidant is also exemplified by a naphthylamine antioxidant, examples of which include α-naphthylamine, phenyl-α-naphthylamine, butylphenyl-α-naphthylamine, hexylphenyl-α-naphthylamine, octylphenyl-α-naphthylamine, and nonylphenyl-α-naphthylamine. Among the above, the diphenylamine antioxidant is preferred to the naphthylamine antioxidant in terms of the effects.
A content rate of the component (D) in the composition is preferably in a range of 0.01 mass % to 10 mass % of the total amount of the composition, more preferably in a range of 0.1 mass % to 5 mass %, in terms of the above effects.
In the invention, a phenol antioxidant is preferably contained as the component (E) in terms of the anti-oxidation effect and the sludge formation prevention effect. Preferable examples of the phenol antioxidant include 2,6-di-tert-butyl-4-methylphenol, 2,6-di-tert-butyl-4-ethylphenol, 2,4,6-tri-tert-butylphenol, 2,6-di-tert-butyl-4-hydroxymethylphenol, 2,6-di-tert-butylphenol, 2,4-dimethyl-6-tert-butylphenol, 2,6-di-tert-butyl-4-(N,N-dimethylaminomethyl) phenol, 2,6-di-tert-amyl-4-methylphenol, 4,4′-methylenebis(2,6-di-tert-butylphenol), 4,4′-bis(2,6-di-tert-butylphenol), 4,4′-bis(2-methyl-6-tert-butylphenol), 2,2′-methylenebis(4-ethyl-6-tert-butylphenol), 2,2′-methylenebis(4-methyl-6-tert-butylphenol), 4,4′-butylidenebis(3-methyl-6-tert-butylphenol), 4,4′isopropylidenebis(2,6-di-tert-butylphenol), 2,2′-methylenebis(4-methyl-6-nonylphenol), 2,2′-isobutylidenebis(4,6-dimethylphenol), 2,2′-methylenebis(4-methyl-6-cyclohexylphenol), 2,4-dimethyl-6-tert-butylphenol, 4,4′-thiobis(2-methyl-6-tert-butylphenol), 4,4′-thiobis(3-methyl-6-tert-butylphenol), 2,2′-thiobis(4-methyl-6-tert-butylphenol), bis(3-methyl-4-hydroxy-5-tert-butylbenzyl) sulfide, bis(3,5-di-tert-butyl-4-hydroxybenzyl)sulfide, 2,2′-thio-diethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], tridecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythrityl-tetraxis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], octyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, and octyl-3-(3-methyl-5-tert-butyl-4-hydroxyphenyl)propionate.
A content rate of the component (E) in the composition is preferably in a range of 0.01 mass % to 10 mass % of the total amount of the composition, more preferably in a range of 0.1 mass % to 5 mass %, in terms of the above effects.
In the invention, the composition exhibits more excellent anti-oxidation effect and wear resistance even under high temperatures by containing a zinc dithiophosphate antioxidant as the component (F).
The zinc dithiophosphate antioxidant is exemplified by ZnDTP represented by the following formula (2).
In the formula (2), R5, R6, R7 and R8 each represent a primary or secondary alkyl group having 3 to 22 carbon atoms or a substituent selected from alkylaryl groups substituted by an alkyl group having 3 to 18 carbon atoms. R5, R6, R7 and R8 may be mutually the same or different.
In the invention, one of the ZnDTP may be used alone or two or more thereof may be used in combination. Particularly, ZnDTP containing zinc dithiophosphate of a secondary alkyl group as the main component is preferable for enhancing wear resistance.
Examples of the ZnDTP are zinc dipropyl dithiophosphate, zinc dibutyl dithiophosphate, zinc dipentyl dithiophosphate, zinc dihexyl dithiophosphate, zinc diisopentyl dithiophosphate, zinc diethylhexyl dithiophosphate, zinc dioctyl dithiophosphate, zinc dinonyl dithiophosphate, zinc didecyl dithiophosphate, zinc didodecyl dithiophosphate, zinc dipropylphenyl dithiophosphate, zinc dipentylphenyl dithiophosphate, zinc dipropylmethylphenyl dithiophosphate, zinc dinonylphenyl dithiophosphate, zinc didodecylphenyl dithiophosphate and zinc didodecylphenyl dithiophosphate.
A content rate of the component (F) in the composition is preferably in a range of 0.01 mass % to 10 mass % of the total amount of the composition, more preferably in a range of 0.02 mass % to 5 mass %, in terms of the above effects.
The composition may further contain various additives such as a detergent dispersant, a metal deactivator, and an antifoaming agent as long as the effects of the invention are not impaired.
The detergent dispersant is classified into a metal detergent and an ashless dispersant. Examples of the ashless dispersant include polybutenyl succinimide, polybutenyl benzylamine, and polybutenyl amine, each of which has a polybutenyl group having a number average molecular weight of 900 to 3500, and a derivative of a boron-modified substance and the like of those. One of the ashless dispersants may be contained alone or any two or more thereof may be contained in combination. A content of the ashless dispersant(s) is typically in a range of 0.01 mass % to 10 mass % of the total amount of the composition. Examples of the metal detergent include a sulfonate, a phenate, a salicylate and a naphthenate of an alkali metal (e.g., sodium (Na) and potassium (K)) or an alkaline earth metal (e.g., calcium (Ca) and magnesium (Mg)). One of the metal detergents may be used alone, or two or more thereof may be used in combination. A total base number and a content of the metal detergent(s) may be selected as needed depending on required performance of the lubricating oil. The total base number is typically 500 mgKOH/g or less according to a perchloric acid method, desirably in a range of 10 mgKOH/g to 400 mgKOH/g. A content of the metal detergent(s) is typically in a range of 0.1 mass % to 10 mass % or more of the total amount of the composition.
Examples of the metal deactivator include benzotriazole, a triazole derivative, a benzotriazole derivative and a thiadiazole derivative. A content of the metal deactivator is typically in a range of 0.01 mass % to 3 mass % or more of the total amount of the composition.
As the antifoaming agent, a liquid silicone is suitable, and a methylsilicone, a fluorosilicone, a polyacrylate and the like are usable. A content of the antifoaming agent is preferably in a range of 0.0005 mass % to 0.1 mass % of the total amount of the composition.
In the lubricating oil composition for high-temperature applications according to the invention, the amount of evaporation is significantly reducible and fluidity is maintainable for a long time, under high temperatures and in a thin film. The lubricating oil composition is suitably applicable to a chain, a chain roller, a chain conveyor, a bearing and the like used in a high-temperature furnace, a drying furnace, panelboard manufacturing equipment, a chemical fiber tenter, a resin film tenter and the like.
Next, the invention will be further described in detail with reference to Examples and Comparatives, which by no means limit the invention.
Base oils and additives described below were mixed at a predetermined content to prepare a lubricating oil composition, which was provided as a sample oil. Blend compositions are shown in Table 1.
Base Oil 1: Pyromellitate Ester (Component A)
(a tetraester mixture containing a linear alkyl group having 6 to 10 carbon atoms)
Base Oil 2: Trimellitic Acid Ester
(a triester containing a linear alkyl group having 10 carbon atoms as an alcohol residue)
Base Oil 3: Polyalphaolefin (PAO)
(Kinematic Viscosity at 100 degrees C.: 10 mm2/s)
Base Oil 4: Polybutene
(Kinematic Viscosity at 100 degrees C.: 800 mm2/s)
2,6-di-tert-butyl-4-(4,6-bis(octylthio)-1,3,5-triazine-2-ylamino)phenol
trinonylphenylthiophosphate
4-4′-bis(α,α-dimethylbenzyl)diphenylamine
octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate
ZnDTP (an alkyl group: a primary hexyl group
Detergent Dispersant: Ca salicylate
Metal deactivator: benzotriazole
Antifoaming Agent: silicone antifoaming agent
The above sample oils were evaluated according to the following method. Results are shown in Table 1.
The friction test for the sample oils was conducted with a ball-on-disc SRV reciprocating tester (manufactured by Optimol Ltd.) under the following conditions.
Ball material: 10 mm diameter, 52100 steel, Rc=60±2, Ra=0.025±0.005 μm
Disc material: 24 mm diameter, 7.85 mm thickness, 52100 steel, Rc=60±2, Rz=0.5 μm
A container and a thermostat air bath for the thermal stability test of lubricating oils (JIS K 2540) were used. A sample oil (1 g) was put in the container and was left to stand still for 20 hours at three temperatures of 190 degrees, 210 degrees C. and 230 degrees C. Subsequently, a residue of the sample oil was measured. The residue was divided by the original amount of the sample oil, and the obtained value was represented in percentage to provide a residual oil rate (%). Note that air was arranged to flow into the thermostat air bath at a flow rate of 10 L/hr.
In the above test, after calculating the residual oil rate, the container was inclined by 45 degrees. Fluidity of the residual oil (thin film residue) was evaluated based on the following scale.
A: The residual oil does not adhere and drops off the container within 15 minutes.
B: A part of the residual oil adheres while another part thereof drops off the container within 15 minutes.
C: The residual oil adheres and does not drop off the container even after the elapse of 15 minutes.
As shown in
Next, as shown in
Note that the spring adhesion test was conducted only for the sample oils of Example 5, Comparative 1 and Comparative 2.
From the results of Table 1, in all the sample oils of Examples 1 to 5 according to the invention, lubricity and wear resistance at high temperatures are, of course, excellent and the amount of evaporation is restrained in a thin film and under high temperatures while fluidity is kept for a long time. Accordingly, by using the lubricating oil composition for high-temperature applications according to the invention, a life time and a maintenance interval of a high thermal device (e.g., a chain and a bearing driven in an oven) can be prolonged. Moreover, reduction of power consumption required for operating the high thermal device can contribute to cost saving and energy saving.
On the other hand, in Comparatives 1 and 2, since the component (A) is not used as the base oil, the amount of evaporation is extremely large and fluidity declines in a short period of time in a thin film and under high temperatures. Moreover, lubricity and wear resistance are also poor. In Comparative 3, since the component (B) is not contained as an additive, fluidity under high temperatures declines in a short period of time. In Comparative 4, since the component (C) is not contained as an additive, lubricity and wear resistance are poor.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-064315 | Mar 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/056337 | 3/17/2011 | WO | 00 | 9/19/2012 |
