S P E C I F I C A T I O N

TITLE OF THE INVENTION

EMULSIONS AND PRODUCTS THEREOF

BACKGROUND OF THE INVENTION

[0001] The present invention generally relates to emulsions and products thereof. More specifically, the present invention relates to emulsion-based lubricants that can be utilized in a variety of different lubricant-based applications.

[0002] Lubricants are generally known to have load bearing and friction- modifying properties. In use, these properties allow the lubricants to reduce friction between parts or components that are used in machine operations. For example, lubricants are utilized to lubricate gears and/or other machine parts during use. Lubricants are also widely used in the metal working processes, such as machining, cutting, drilling, grinding, turning, milling, tapping, broaching, drawing, stamping, hydroforming, and the like.

[0003] In metal working operations, it is necessary to lubricate the interface between the work piece and the tool. This can facilitate the metal working process in a number of different ways, such as by decreasing the force required to work the metal, by cooling the work piece, by removing chips from the cutting zone, by imparting a good surface finish, by extending the life of the tool, and the like.

[0004] General requirements for satisfactory lubricant use include emulsion stability under operating conditions and corrosion-inhibiting properties. Other considerations include cost and environmental factors (e.g, clean-up and disposal issues), and worker safety issues due to, for example, misting or foaming of the lubricant during use.

[0005] Known lubricant formulations are made from a variety of different materials, such as antifriction agents, extreme pressure additives, anti-wear additives, anticorrosion agents, surfactants, and biocides. For example, lubricant emulsions are generally known that contain water and relatively low viscosity naphthenic oils.

[0006] A need therefore exists to provide emulsions and products thereof, such as lubricants, that have improved performance characteristics, such as improved emulsion stability during use as a lubricant.

SUMMARY OF THE INVENTION

[0007] The present invention generally relates to emulsions and products thereof. The emulsions contain water and an oil component having a viscosity of at least about 150 centistokes at 4O ⁰ C. The emulsion can be utilized in a variety of different applications, such as a lubricant for use in metal working processes.

[0008] As a lubricant, the present invention displays enhanced emulsion stability, corrosion-inhibiting properties, and non-detectable volatile organic compounds. During metal working, for example, the lubricant produces minimal mist and/or foaming and can be removed and cleaned with relative ease after use as compared to known lubricants, such as lubricants with lower viscosity oil-based emulsions that utilize conventional soluble oils.

[0009] In an embodiment, the present invention provides an emulsion composition. The emulsion composition includes an oil component having a viscosity of about 150 centistokes at 40°C or greater; a surfactant; and water.

[0010] In another embodiment, the present invention provides a lubricant concentrate composition. The lubricant concentrate includes an emulsion including about 30 wt% to about 80 wt% oil having a viscosity of about 150 centistokes at 40 ⁰ C or greater; about 3 wt% to about 9 wt% surfactant; and about 30 wt% to about 70 wt% water.

[0011] In an embodiment, the present invention provides a lubricant. The lubricant includes a concentrate in dilute form wherein the concentrate includes an emulsion including about 2 wt% to about 70 wt% oil having a viscosity of about 150 centistokes at 4O ⁰ C or greater; about 0.10 wt% to about 10 wt% surfactant; and about 40 wt% to about 90 wt% water.

[0012] In a further embodiment, the present invention provides a method of processing an emulsion-based composition. The method includes preparing an emulsion mixture including an oil component having a viscosity of about 150 centistokes at 4O ⁰ C or greater, a surfactant, and water; and processing the emulsion mixture under simultaneous mixing operations at varying shear rates including a first mixing operation at about 15 rpm or greater, preferably from about 15 rpm to about 70 rpm and a second mixing operation during processing at about 400 rpm or greater, preferably from about 400 rpm to about 1800 rpm.

[0013] In an embodiment, the oil viscosity ranges from about 150 centistokes at 4O ⁰ C to about 2000 centistokes at 40°C, preferably from about 200 to about 2000, and more preferably from about 400 centistokes at 40°C to about 600 centistokes at 40°C associated with a white mineral oil-based emulsion and from about 1200 centistokes at 40°C to about 1500 centistokes at 40 ⁰ C associated with a synthetic oil based emulsion.

[0014] An advantage of the present invention is to provide an emulsion and product thereof that displays enhanced emulsion stability during use in a variety of water types and applications.

[0015] Another advantage of the present invention is to provide an emulsion and product thereof that displays enhanced corrosion-inhibiting properties.

[0016] Another advantage of the present invention is to provide an emulsion and product thereof that displays enhanced pH stability during use.

[0017] Another advantage of the present invention is to provide an emulsion and product thereof that resists contaminants including hydraulic fluids, way oils, gear oils, and other fluids which may enter the system during use.

[0018] Yet a further advantage of the present invention is to provide a lubricant and concentrate thereof that minimizes misting or foaming during use, such as in metal working operations.

[0019] Still yet a further advantage of the present invention is to provide a lubricant that can be readily cleaned or removed after use.

[0020] Another advantage of the present invention is to provide a lubricant that is bio-resistant.

[0021] Another advantage of the present invention is to provide a lubricant that displays non-detectable volatile organic compounds during use.

[0022] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention.

DETAILED DESCRIPTION OF THE INVENTION

[0023] The present invention generally relates to emulsions and products thereof. More specifically, the emulsions include water and an oil component having a

viscosity of at least about 150 centistokes at 40°C. The emulsion can be utilized in a variety of different applications, such as lubricant-based applications.

[0024] The lubricant can be effectively applied in any suitable way to reduce friction between parts or components that are used in machine operations. For example, the lubricants can be utilized to lubricate gears and/or other machine parts during use. The lubricant can also be applied in metal working processes, such as machining, cutting, drilling, grinding, turning, milling, tapping, broaching, drawing, stamping, hydroforming, and the like. The lubricant has been tested and demonstrated enhanced emulsion and pH stability and corrosion-inhibiting properties during use. During metal working, for example, the lubricant produced minimal mist and/or foaming and can be removed and cleaned with relative ease after use as compared to known lubricants, such as lubricants with lower viscosity oil-based emulsions that utilize conventional soluble oils.

[0025] In general, the emulsion includes an oil component, a surfactant, and water. The oil component can include petroleum-based oils, synthetic oils, vegetable oils, the like and combinations thereof and has a viscosity that is significantly higher than soluble oils typically used in known lubricant emulsions. The emulsion can include any number of additional, suitable and optional components, such as corrosion-inhibiting agents, biocides including bactericides and fungicides, and the like. Examples of commercially- available products include BIOBAN CS- 1246 (DOW CHEMICAL COMPANY) and GROTAN (TROY CHEMICAL CORP.).

[0026] In an embodiment, the emulsion includes about 30 wt% to about 80 wt% oil having a viscosity of about 150 centistokes at 40°C or greater; about 3 wt% to about 9 wt% surfactant; and about 30 wt% to about 70 wt% water. For example, the oil viscosity ranges from about 150 centistokes at 4O ⁰ C to about 2000 centistokes at 4O ⁰ C. Preferably, the oil viscosity ranges from about 200 centistokes at 40 ⁰ C to about 1500 centistokes at 40 ⁰ C, and more preferably from about 400 centistokes at 4O ⁰ C to about 600 centistokes at 40 ⁰ C associated with a white mineral oil-based emulsion and from about 1200 centistokes at 40 ⁰ C to about 1500 centistokes at 40 ⁰ C associated with a synthetic oil-based emulsion.

[0027] The emulsion components can include any number and suitable type of different components. As previously discussed, the oil type component has a viscosity

that is higher than oils typically used in known oil-based emulsions. This is believed to provide better lubrication and overall performance of the emulsion and products thereof. This is due to the method of formulation and mixing procedures. Examples of oils include petroleum-based oils, vegetable type oils, and synthetic oils with a viscosity that is at least 150 centistokes at 4O ⁰ C. Petroleum-based oils include paraffin-based oils, white mineral-based oils, and napthenic-based oils, such as CALPAR 2500 (CALUMET LUBRICANTS CO.), 150 BRIGHT STOCK (CITGO), CALUMET 750, and the like. Vegetable-based oils include canola-based oils (CARGILL), and the like. Synthetic oils include, for example, polyalphaolefins, such as DURASYN 180 (BP Amoco), SPECTRASYN 100 (EXXON MOBIL), and the like.

[0028] The surfactant component can include one or more suitable types of surfactants. The surfactant can include anionic, cationic, or nonionic surfactants. Examples include ethoxylated alcohols, such as tridecyl alcohol ethoxylate, polyalkoxylates, and the like. These types of surfactants are commercially available, for example, as TRYCOL series of ethoxylated alcohols commercially available from COGNIS CORPORATION, the T-DET series commercially available from HARCOS CHEMICALS INC., the CHEMAL Series commercially available from CHEMMAX INC., and other like suitable surfactants.

[0029] The amount of alkoxylate (e.g., ethoxylate) in the alkoxylated alcohols (e.g., ethoxylated alcohols) can vary in any suitable amount. In an embodiment, the amount of alkoxylate, such as ethoxylate, ranges from about 4 mole percent to about 14 mole percent.

[0030] The emulsions and products thereof can include additional other components. For example, water-soluble alkanolamines can be utilized. Examples include monoethanolamine, diethanolamine, triethanolamine, dimethylethanolamine, diethyl-ethanolamine, amino-ethyl-ethanolamine, methyl-diethanolamine, N-acetyl ethanolamine, phenylethanolamine, phenyldiethanolamine, mono-, di-, and triisopropanolamine, the like and combinations thereof.

[0031] Additional other additives can include, for example, biocides, oxidation inhibitors, corrosion inhibitors, metal deactivators, anti-wear agents, extreme pressure

additives, hydrodynamic additives, flow additives, defoamers, colorants, the like and combinations thereof.

[0032] As previously discussed, the emulsion can be utilized in a number of different applications including lubricant-based applications. The lubricant can be made as a concentrate where in use the emulsion is used as a formulary component lubricant that includes the concentrate in dilute form. The lubricant and concentrate thereof can include any number of different and suitable types of components such as, surfactants, biocides, oxidation inhibitors, corrosion inhibitors, extreme pressure additives, anti-wear additives, defoamers, colorants, the like and combinations thereof as previously discussed.

[0033] The emulsion is made from a process that utilizes both mechanical and chemical processes to promote the formation of a higher viscosity oil-based emulsion. The mechanical process utilizes multiple and simultaneous mixing operations that include low and high shear mixing where the oil, water, surfactant and other components are added at varying stages and varying amounts to facilitate the emulsification of the higher viscosity oil in water.

[0034] Illustrative Examples of the emulsions and products thereof, without limitation, are provided below in greater detail.

Emulsion Com osition I

[0035] The Emulsion Composition I was prepared as follows. The surfactant phase was first prepared by mixing ethoxylated alcohols I and II and 12 pounds of water in a drum mixer for at least 20 minutes in order to produce a homogenous mix while maintaining a temperature from 6O ⁰ F to 100°F, preferably from 70° F to 80° F. The mixing was conducted with the use of a wiper blade at 50 to 105 rates per minute (rpm), preferably 80 to 85 rpm. The ethoxylated alcohol I included ethoxylate from 10 mole percent to 14 mole percent. The ethoxylate alcohol II included ethoxylate from 4 mole percent to 8 mole percent.

[0036] The oil component was added at a rate of 8 pounds per minute (lbs/min). This flow rate can range from about 2.5 lbs/min to about 12.5 lbs/min, preferably from about 7.5 lbs/min to about 8.5 lbs/min. The oil component included a polyalphaolefm-based oil, namely, DURASYN 180 (BP AMOCO). This type of oil has a viscosity range of 1200 to 1350 centistokes at 40°C. The shear mixing was initiated at a rate of 400 rpm to 1800 rpm upon addition of the oil component.

[0037] 191 pounds of water was measured for addition to the reaction vessel. The water was added at a flow rate of 9 lbs/min. This can be added over an operating range from about 3.5 lbs/min to about 13.5 lbs/min, preferably from about 8.5 lbs/min to about 9.5 lbs/min. The shear mixing was shut-off after 70 lbs of water was added where the remaining amount of water was added under wiper blade mixing. Prior to completion of water addition, the biocide was added. The biocide was commercially available GROTAN (TROY CHEMICAL CORP.). Once all of the water and biocide were added, mixing with the wiper blade continued for another 5 minutes.

Emulsion Composition II

[0038] The Emulsion Composition II was prepared as follows. The surfactant component was prepared to produce a homogenous solution by adding the component into a drum mixer and mixing with wiper blades at a rate of 48 rpm for at least 20 minutes while maintaining a temperature from 70 ⁰ F to 80°F. The tridecyl alcohol ethoxylate included ethoxylate from 7 mole percent to 11 mole percent. A portion of the water was then added to the surfactant and mixed for an additional 30 minutes with the wiper blade. The shear mixing was initiated with the dispersion blade at a rate of 1000 rpm. Once initiated, the oil component was then added to the reaction vessel at a flow rate of 16 gallons per minute (gpm). This can be operated within the range of 5 gpm to 45 gpm, preferably within the range of 15 gpm to 17 gpm. The oil component was a petroleum-based oil, namely 150 BRIGHT STOCK (CITGO). This type of oil has a viscosity of 480 centistokes at 4O ⁰ C.

[0039] After the oil component was charged, compressed air was blown through the bottom of the reaction vessel. Agitation of the reaction mixture continued for another 20 minutes or until the temperature reached 130°F. The dispersion blade was shut-off and then the water charge was initiated. The remaining amount of water was added at a rate of 10 gpm that ranged from 5 gpm to 45 gpm, preferably from 9.5 gpm to 10.5 gpm. After another portion of water was added, the cooling water was shut-off. The compressed air injection was stopped after the additional water was added.

[0040] After the remaining water was charged, the water addition was stopped. Next, the biocide was added. The biocide was commercially available GROTAN (TROY CHEMICAL CORP.) The reaction mixture was agitated for another 60 minutes.

[0041] LUBRICANT CONCENTRATE COMPOSITIONS

[0042] The following tables provide a number of illustrative examples of lubricant concentrate compositions prepared according to various embodiments of the present invention. The various components of the lubricant concentrates were generally mixed and prepared under typical operating conditions. The resulting mixture formed a lubricant concentrate which can be diluted by any suitable factor and any suitable dilution agent, such as water, depending on the intended application.

Lubricant Concentrate Composition I

[0043] Lubricant Concentration Composition I included a petroleum oil-based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with 150 BRIGHT STOCK (EXXON MOBIL) at a viscosity of 480 centistokes at 4O ⁰ C. The biocide was BIOBAN CS 1246 (DOW CHEMICAL

COMPANY). The defoamer was LUBRIZOL 5674 (LUBRIZOL CORPORATION).

The colorant was PYLAM BLUE LIQUID LX 10754 (PYLAM PRODUCTS COMPANY, INC.).

Lubricant Concentrate Composition II

[0044] Lubricant Concentration Composition II included a petroleum oil-based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with 150 BRIGHT STOCK (EXXON MOBIL) at a viscosity of 480 centistokes at 40°C. The defoamer was LUBRTZOL 5674 (LUBRIZOL CORPORATION). The colorant was PYLAM BLUE LIQUID LX 10754 (PYLAM PRODUCTS COMPANY, INC.).

Lubricant Concentrate Composition III

[0045] Lubricant Concentration Composition III included a petroleum oil- based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with 150 BRIGHT STOCK (EXXON MOBIL) at a viscosity of 480 centistokes at 4O ⁰ C. The polyalkoxylate was TRITON series (Union Carbide

Corporation). The biocide was BIOBAN CS 1246 (DOW CHEMICAL COMPANY). The defoamer was LUBRIZOL 5674 (LUBRIZOL CORPORATION). The colorant was PYLAM BLUE LIQUID LX 10754 (PYLAM PRODUCTS COMPANY, INC.).

Lubricant Concentrate Composition IV

[0046] Lubricant Concentrate Composition IV included a polyalphaolefin- based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with DURASYN 180 (BP AMOCO) at a viscosity ranging from 1200 to 1350 centistokes at 4O ⁰ C. The biocide was BIOBAN CS 1246 (DOW CHEMICAL COMPANY). The defoamer was LUBRIZOL 5674 (LUBRIZOL CORPORATION). The colorant was KEYACID RED XB400.

Lubricant Concentrate Composition V

[0047] Lubricant Concentrate Composition V included a polyalphaolefm-based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with DURASYN 180 (BP AMOCO) at a viscosity ranging

from 1200 to 1350 centistokes at 4O ⁰ C. The colorant was KEYACID RHODAMINE WT LIQUID (KEYSTONE ANILINE CORPORATION).

Lubricant Concentrate Com osition VI

[0048] Lubricant Concentrate Composition VI included a polyalphaolefm- based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with DURASYN 180 (BP AMOCO) at a viscosity ranging from 1200 to 1350 centistokes at 4O ⁰ C. The biocide was BIOBAN CS 1246 (DOW CHEMICAL COMPANY). The polyalkoxylate was TRITON series (Union Carbide Corporation). The defoamer was LUBRIZOL 5674 (LUBRIZOL CORPORATION).

Lubricant Concentrate Composition VII

[0049] Lubricant Concentrate Composition VII included a petroleum oil-based emulsion prepared according to an embodiment of the present invention. The emulsion was prepared with 150 BRIGHT STOCK (EXXON MOBIL) with an extreme pressure additive (R.T. Vanderbilt Company, Inc.) at a viscosity of 480 centistokes at 4O ⁰ C. The colorant was KEYACID RED XB400 (KEYSTONE ANALINE CORPORATION).

[0050] Corrosion Protection Test

[0051] This test was conducted in the laboratory to evaluate corrosion protection properties of metal working fluid dilutions. Lubricant concentrates were initially prepared according to various embodiments of the present invention. Test solutions were then made by diluting the lubricant concentrate to 1 wt%, 3 wt%, and 5 wt%. The test solutions were diluted with deionized water and synthetic 28 grain hard water.

[0052] The test was conducted as follows. A filter paper was placed in a Petri dish and then covered with cast iron chips (CIC). The dish was then filled with the test solution. The test solution was aspirated out after 20 minutes. The cast iron chips were observed after a 24 hour period, and the presence of rust was identified by rust/brown spots on the filter paper. The rust spots were evaluated as compared to a standard for reference.

[0053] In general, the test results demonstrated enhanced corrosion protective properties as the amount (wt%) of lubricant concentrate in the test solution increased from 1 wt% to 5 wt%.

[0054] Falex Pin & Vee Block Test

[0055] This test was conducted under laboratory conditions to evaluate the wear properties of the lubricants. Lubricant concentrates made pursuant to various embodiments of the present invention were initially prepared from which test solutions were then made by diluting the lubricant concentrates to 5 wt%. The test solutions were diluted with water.

[0056] The test included the operation of a rotating steel journal at 290 rpm against two stationary v-blocks immersed in the lubricant sample. A load was applied in 250-lbf stepwise increments with load maintained constant for 1 minute at each load increment. The corresponding torque was measured at each load. The test was run until the steel journal broke. In general, the test lubricant solutions displayed enhanced wear properties. For example, as compared to a lubricant with a conventional soluble oil, at least twice as much load was applied to the rotating journal before the journal broke associated with use of the test lubricant made pursuant to an embodiment of the present invention.

[0057] Tank Test Evaluation

[0058] This test was conducted to simulate actual use conditions where a test sample was diluted and circulated within a tank (5 gallon aquarium tank). The test sample was made by diluting lubricant concentrates made pursuant to various embodiments of the present invention. In general, the test samples included 5 wt% of the lubricant concentrates.

[0059] The test tank was filled with 17 liters of synthetic hard water. The water was circulated in the tank with the use of a pump. The lubricant concentrate was added to the test tank to provide an amount of about 5 wt%. The tank was covered, and the circulated water was directed to create agitation. Water was circulated over a period of 30 days. Water was added daily or as required to maintain the initial levels. The test sample was monitored over the 30 day period for pH, bio-resistance properties, rust preventive properties and the like.

[0060] The pH was relatively constant at a pH of 8.8 to 8.9. The bio-resistant properties were monitored with the use of a microbiological dip slide for bacterial and fungal contamination (BIOSANS LABS. SANI-CHECK BF Indicator Dipslides). The test samples displayed no detectable biological activity. The rust preventive tests were conducted with the iron chips as before. In general, the test solutions displayed negligible or at most minimal rust activity during the test period.

[0061] Metal Working Field Test

[0062] A test was conducted to evaluate the performance of the lubricant under metal working operations. The test lubricant was made with Lubricant Concentrate Composition I formulation in diluted form pursuant to an embodiment as discussed above. The amount of the concentrate in the test lubricant ranged from 5.0 wt% to 10 wt% where the dilution was made with water.

[0063] The test lubricant displayed enhanced performance as compared to conventional soluble and semisynthetic metalworking fluids. The operating pH remained relatively constant within an operating range of 8.5 to 9.8. No noticeable change in appearance and clarity was identified. The biological testing indicated that the bacterial and fungal levels were undetectable.

[0064] The test lubricant remained stable over a period of at least 9 weeks as compared to the conventional soluble and semisynthetic metalworking fluids that

displayed instability after one or two weeks at most, and thus had to be replaced at that stage. The test lubricant produced less smoke and mist as compared to the conventional metalworking fluids during use.

[0065] As previously discussed, the emulsions and products thereof of the present invention can be applied in a number of different applications. For example, the emulsions can be further formulated to prepare lubricants and concentrates thereof. The lubricants can be used in metal working processes. In this regard, the lubricants can be applied to the surfaces of metal work pieces by spraying, dipping, roll-coating, or swabbing, or by drip application and spreading with a wiper blade or other suitable types of applications.

[0066] The lubricants are suitable for use with respect to a number of different materials. Examples include hot or cold-rolled carbon steels, steel alloy including stainless steel, galvanized iron and steel, copper, brass, bronze, aluminum, aluminum alloys, magnesium, and the like.

[0067] It should be appreciated that the emulsions and products thereof are not limited in application to metal working process but can be applied with respect to additional other types of processes, such as lubricant-based applications in general where the lubricant displays load bearing and friction modifying properties to reduce friction between operable machine parts components, acts as a medium to move chips created in machining, and prevents corrosion of parts and machines.

[0068] For example, the lubricant and concentrates thereof can be utilized in the cotton industry as applied to various types of cotton harvesting machinery. One specific example relates to the lubrication of a machine part that is operable against a gear. This specific type of machine part has a barb member that is utilized to grab or pick the cotton. The lubricant can be effectively utilized to lubricate the machine part to reduce friction between the part and the gear during use. A mist or spray associated with the lubricant is effectively minimized during use as well. This is advantageous because it minimizes the contact of same on the cotton as it is picked. The lubricants and concentrates thereof provide numerous other benefits as compared to conventional picker lubricants. For example, the lubricants of the present invention do not have a flash point and thus are not combustible like conventional grease. The lubricants can be readily washed with water, thus allowing the cotton to be cleaned of the lubricant

with relative ease as compared to conventional products. The lubricant of the present invention can also promote cooler running equipment due to the water content and cooling capabilities.

[0069] Other applications of the present invention include fire resistant hydraulic fluids, greases, lubricants for the mining industry and the like.

[0070] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. ^' Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.