Patent Grant
8375755
This application is the U.S. national phase of International Application No. PCT/JP2008/051670, filed 1 Feb. 2008, which designated the U.S. and claims priority to Japan Application No. 2007-022883, filed 1 Feb. 2007, the entire contents of each of which are hereby incorporated by reference.
The present invention relates to a metal working fluid composition, which can widely be used in the metal working techniques such as the cutting, grinding, form rolling, press working and plastic working techniques and a metal working method, which makes use of the foregoing metal working fluid composition and the present invention, more particularly, relates to a water-soluble metal working fluid composition, which is used after it is diluted with water, in particular, a water-soluble metal working fluid composition, which is excellent in the antiseptic properties, as well as a metal working method, which makes use of the foregoing metal working fluid composition.
In general, there has been used a cutting/grinding fluid composition in the cutting/grinding processes. As the most important function of the cutting/grinding fluid composition, there can be listed, for instance, the lubricating action and the cooling action and these actions would permit the improvement of productivity such as the elongation of the service life of tools used in the metal working and the improvement of the precision of the finished plane of a subject to be processed and the improvement of the production efficiency.
It has been known, for a long time, that there are two types of metal working fluid compositions and more specifically, the non-water-soluble type one, on the one hand, which is used in the form of a stock solution and the water-soluble type one, on the other hand, which is used after it is diluted with water. In this respect, the use of the water-soluble type one has recently become the leading mainstream in this art while taking into consideration the saving of natural resources, the protection of the environment (working environment and the environment of the earth) and any risk of causing a fire.
The use of a water-soluble type metal working fluid composition would result in the reduction of the risk of causing a fire. On the contrary, in case of the water-soluble type metal working fluid composition, the organic components present therein should be diluted with water upon its practical use, and therefore, various problems arise such that microorganisms are easily proliferated in the diluted fluid composition, that the latter gives out bad smells due to the putrefaction thereof and that the quality thereof is accordingly impaired. For this reason, the diluted metal working fluid composition should frequently be replaced with fresh one within a short period of time and this in turn becomes a cause of the wasteful use of the natural resources and the pollution of the environment of the earth.
As means for solving the foregoing problems, there have been known, for instance, a water-soluble metal working fluid composition which makes use of peppermint oil (see Patent Document 1 specified below); a water-soluble metal working fluid composition which makes use of cinnamon oil (see Patent Document 2 specified below); a water-soluble metal working fluid composition which makes use of an aromatic amine or an alicyclic amine (see Patent Document 3 specified below); a water-soluble fluid composition for the grinding process, which makes use of a benzolic compound and a para-oxy-benzoic acid ester compound (see Patent Document 4 specified below); an antibacterial water-soluble fluid composition for the cutting process, which makes use of alkylene diamine (see Patent Document 5 specified below); a water-soluble fluid composition for the cutting process, which makes use of a fatty acid alkanolamide-ethylene oxide adduct and an alkylamine-ethylene oxide adduct, an alicyclic amine-ethylene oxide adduct or a fatty acid-higher alcohol adduct (see Patent Document 6 specified below); a water-soluble fluid composition for the cutting/grinding processes which makes use of a primary, secondary or tertiary alkylamine, aromatic diamine-oxyalkylene adduct, or an alicyclic diamine-oxyalkylene adduct (see Patent Document 7 specified below); a fluid composition comprising a primary alkanolamine, a carboxylic acid having 6 to 24 carbon atoms, and a specific alkylene-diamine (see Patent Document 8 specified below); and a microorganism-killing composition comprising, in combination, an N-substituted benzo-isothiazoline type compound (such as N-butylbenzoisothiazolin-3-one) and non-N-substituted benzo-isothiazoline type compound having a microorganism-killing action (such as bactericidal, fungicidal or algicidal actions) (see Patent Document 9 specified below).
However, any sufficient effect of preventing putrefaction of the fluid composition cannot be ensured through the use of these water-soluble metal working fluid compositions, or the metal working fluid compositions each showing such an effect make use of, for instance, a halogen atom-containing compound, a polycyclic aromatic compound, a phenolic compound or a metal salt. Some of them are compounds whose use is restricted by PRTR and the use thereof would be apprehensive of adversely affecting the human bodies.
It is an object of the present invention to provide a metal working fluid composition, which can widely be applied to the metal working techniques such as cutting, grinding, form rolling, press working and plastic working techniques. In particular, it is an object of the present invention to provide a water-soluble metal working fluid composition, which is excellent in the ability of preventing putrefaction, and a metal working method which makes use of the foregoing metal working fluid composition.
The inventors of this invention have conducted various studies to eliminate the foregoing problems, have found that the use of specific antiseptic agents in combination permits the achievement of a considerably excellent antiseptic effect as compared with that accomplished by the use of a water-soluble metal working fluid composition which comprises a conventional antiseptic agent and have thus completed the present invention. According to the present invention, there are thus provided, as will be detailed below, a water-soluble metal working fluid composition and a metal working method which makes use of the metal working fluid composition.
The metal working fluid composition according to the present invention permits the efficient practice of cutting, grinding, form rolling, press working and plastic working of metallic materials. In addition, the fluid composition of the present invention is excellent in the antiseptic properties and it is seldom that the fluid composition adversely affects the environment of the earth and the human bodies. The fluid composition of the present invention comprises a morpholine compound and a thiazoline compound and further an optional surfactant in combination and therefore, the fluid composition is significantly improved in the antiseptic properties and the service life of the metal working fluid composition can thus significantly be extended, as compared with conventionally known metal working fluid compositions. As a result, the fluid composition of the present invention would permit the saving of natural resources, and the reduction of the amount of waste matter (waste fluid) and accordingly, the use thereof would result in the reduction of any adverse effect on the environment of the earth.
Examples of morpholine compounds (component A) preferably used in the fluid composition of the present invention include morpholine, N,N-methylene-bis-morpholine, N-(2-aminoethyl) morpholine, N-(3-amino-propyl) morpholine, 4-trityl morpholine, and 4-phenyl morpholine. Particularly preferably used herein is N,N-methylene-bis-morpholine.
Examples of isothiazoline compounds (component B) preferably used in the fluid composition of the present invention include N-methylbenzo-iso-thiazolin-3-one, N-ethylbenzo-isothiazolin-3-one, N-propylbenzo-iso-thiazolin-3-one, N-n-butyl-benzoisothiazolin-3-one, N-isobutyl-benzo-iso-thiazolin-3-one, N-pentyl-benzoisothiazolin-3-one, N-isopentyl-benzo-iso-thiazolin-3-one, N-hexyl-benzoisothiazolin-3-one, N-allyl-benzo-isothiazolin-3-one, and N-(2-butenyl)-benzoisothiazolin-3-one. Among them, preferably used herein is N-n-butyl-benzoisothiazolin-3-one.
It is preferred to incorporate a surfactant (component C) to the fluid composition of the present invention. Usable herein as such a surfactant may be a nonionic surfactant, an anionic surfactant, a cationic surfactant or an amphoteric surfactant, with a nonionic surfactant and an anionic surfactant being particularly preferably used in the present invention. These surfactants serve as emulsifying agents for diluting the metal working fluid composition of the present invention with water. Moreover, the isothiazoline compound is hardly soluble in water and therefore, the surfactant may likewise serve as a dispersion-stabilizer for maintaining the dispersion stability of the isothiazoline compound when diluting the fluid composition with water and practically using the same.
Examples of such nonionic surfactants usable herein are polyoxyethylene alkyl ether types, polyoxyethylene alkyl phenyl ether types, polyoxyethylene fatty acid ester types, polyoxyethylene castor oil types, polyoxyethylene fatty acid diester types, polyoxyethylene rosin ester types, polyoxyethylene lanolin ether types, polyoxyethylene polyhydric alcohol ether types, polyoxyethylene polyhydric alcohol fatty acid ester types, polyhydric alcohol fatty acid ester types, ethylene oxide-propylene oxide block polymer types, ethylene oxide-propylene oxide random polymer types, propylene oxide polymer types, and polyhydric alcohol-alkylene oxide polymer types.
Examples of such anionic surfactants usable herein are fatty acid derivatives (such as fatty acid soap, naphthenic acid soap and fatty acid amides), sulfuric acid ester type compounds (such as alcohol sulfuric acid ester salts, olefin sulfuric acid ester salts, polyoxyethylene alkyl ether sulfuric acid ester salts, and fatty acid polyhydric alcohol sulfuric acid ester salts), sulfonic acid type compounds (such as alkane sulfonic acid salts, petroleum sulfonic acid salts, α-olefin sulfonic acid salts, alkyl-naphthalene sulfonic acid salts, and phosphoric acid ester types (such as alkyl phosphoric acid ester salts and polyoxyethylene alkyl-phenol ether phosphoric acid ester salts). In this respect, the foregoing nonionic and anionic surfactants may be used in combination. Furthermore, also usable herein include known cationic surfactants and amphoteric surfactants.
The rate (by mass) of the morpholine compound present in the metal working fluid composition of the present invention preferably ranges from 0.01 to 10.0% by mass and more preferably 0.05 to 5.0% by mass on the basis of the total mass of the fluid composition (the stock liquid prior to the dilution thereof with water; those in the following description are shown in the same way also, unless otherwise specified). If the content of this component is less than the lower limit, there is observed such a tendency that the desired antiseptic effect can be accomplished only with great difficulty, while even if the content of this component exceeds the upper limit, any intended effect in proportion to the added amount thereof cannot be expected in some cases.
The rate (by mass) of the isothiazoline compound present in the metal working fluid composition of the present invention preferably ranges from 0.001 to 5.0% by mass and more preferably 0.005 to 3.0% by mass on the basis of the total mass of the fluid composition. This is because if the content of this component is less than the lower limit, there is observed such a tendency that the desired antiseptic effect can be accomplished only with great difficulty, while even if the content of this component exceeds the upper limit, any intended effect in proportion to the added amount thereof cannot be expected in some cases.
The rate (by mass) of the surfactant present in the metal working fluid composition of the present invention preferably ranges from 0.1 to 80.0% by mass and more preferably 0.2 to 50.0% by mass on the basis of the total mass of the fluid composition. In this respect, if the amount of the surfactant is less than the lower limit specified above, there is observed a tendency such that it is difficult to dilute the resulting fluid composition with water, that it would also be difficult to stably disperse the isothiazoline compound in the diluted fluid composition and that the desired antiseptic properties can thus be imparted to the resulting fluid composition only with great difficulty.
The metal working fluid composition of the present invention comprises a base oil as the need arises. Examples of such base oils include mineral oils, polyol esters, fats and oils, polyglycols, poly(α-olefins), normal paraffins, iso-paraffins, alkyl-benzenes, and polyethers. These base oils may be used alone or as a blend oil comprising a plurality of these base oils. Preferably used herein include mineral oils, polyglycols and alkyl-benzenes.
Further, the metal working fluid composition of the present invention may likewise comprise, as the occasion may demand, an anti-foaming agent and other additives (such as an extreme pressure additive, an anticorrosive agent, a viscosity index improver, an antioxidant, a detergent-dispersant, a coloring agent and an aromatic).
The metal working fluid composition of the present invention may be any one of emulsion type, soluble type and solution types and it is in general used after it is diluted with water to give a dilute liquid having a concentration ranging from about 1 to 30% by mass.
Each of the metal working fluid compositions specified in the following Tables 1 to 4 were evaluated and inspected for antiseptic properties according to the antiseptic test detailed below.
The fluid compositions listed in Tables 1 and 3 are water-soluble metal working fluid compositions, each of which is prepared using a mineral oil or a synthetic base oil (an alkyl-benzene), while the fluid compositions shown in Tables 2 and 4 are water-soluble metal working fluid compositions, each of which is prepared using a naturally occurring base oil (such as rapeseed oil).
Test for Evaluating Antiseptic Properties
Each fluid composition was diluted with sterilized water to give a diluted fluid composition having a concentration of 2% by mass, then 10 mL of a putrefactive bacteria-containing liquid (*1) as specified below was added to 100 mL of the diluted composition, the resulting mixture was subjected to shaking culture at 30° C. for 2 weeks and then the number of viable bacterial bodies (viable count) was determined.
(*1): Putrefactive Bacteria-Containing Liquid:
The putrefactive liquid used herein was a putrefactive bacteria-containing liquid prepared by cultivating the foregoing mixture at 25° C. for 24 hours wherein the number of viable bacterial bodies was adjusted to the level of not less than 107.
Evaluation Criteria:
The bacterial counts, the numbers of mold, yeast and anaerobic bacterial cells or the pollution level were evaluated using SAN-AI Biochecker (available from SAN-AI Petroleum Co., Ltd.).
Regarding the bacterial counts and the number of yeast cells, the number of microorganisms present in 1 mL of each sample was evaluated according to the following 8-stage criteria: 0, 103 cells>, 103 cells, 104 cells, 105 cells, 106 cells, 107 cells, 107 cells<, and a sample containing bacterial cells of less than 103 cells was judged to be acceptable (◯).
On the other hand, regarding the numbers of mold and anaerobic bacterial cells, the pollution level was evaluated according to the following 4-stage criteria: zero, slight (low degree), medium (medium degree) and heavy (high degree), and a sample having a pollution level of zero was defined to be acceptable (◯).
Test for Confirming the Stability of Diluted Liquid:
Using prepared hard water (water prepared by diluting 0.0757 g of calcium chloride.2H2O with distilled water to give one liter of an aqueous solution thereof; having a German hardness of 3 degrees; a Ca hardness of 54 ppm, see JIS K 2221 “Cutting Fluid Composition: Test Thereof for Emulsion Stability”), each fluid composition is diluted with water to give a dilute liquid having a concentration of 5%, the conditions thereof immediately after the preparation and after the elapse of 24 hours from the preparation are visually observed. The evaluation criteria used herein are as follows:
◯: Acceptable: The sample is uniformly dissolved in water and does not cause any separation and is free of the formation of any cream layer;
x: Unacceptable: The sample undergoes phase separation and forms a cream layer.
Tables 1 to 4 show the compositions or formulations used in Examples and Comparative Examples and the results obtained in the foregoing evaluation tests. As will be seen from the results listed in Tables 1 to 4, the water-soluble metal working fluid compositions of the present invention prepared in Examples 1 to 11, each of which comprises the component (A) and the component (B) are found to be excellent in the antiseptic properties. Therefore, the water-soluble metal working fluid composition of the present invention can stably be used as the metal working lubricating agent upon processing of a variety of metals over a long period of time.
Contrary to this, the water-soluble metal working fluid compositions prepared in Comparative Examples 1 to 12, each of which is free of at least one of the component (A) and the component (B) are found to be insufficient in antiseptic properties.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-022883 | Feb 2007 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/051670 | 2/1/2008 | WO | 00 | 7/30/2009 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2008/093844 | 7/8/2008 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20100077817 A1 | Apr 2010 | US |
