Anti-wear composition for low sulfur, low sulfated ash and low phosphorus lubricating oil composition for heavy duty diesel engines

Abstract

The present invention is directed to a low sulfur, low sulfated ash and low phosphorus lubricating oil composition for low emission heavy duty diesel engines comprising (a) a major amount of an oil of lubricating viscosity and (b) at least 5 weight percent of an anti-wear additive composition comprising a metal salt of a Mannich condensation product based on the total weight of the lubricating oil. The present invention is also directed to a low sulfur, low sulfated ash and low phosphorus lubricating oil concentrate comprising (a) an oil of lubricating viscosity and (b) at least 5 weight percent of an anti-wear additive composition comprising a metal salt of a Mannich condensation product based on the total weight of the lubricating oil.

1 . A low sulfur, low sulfated ash and low phosphorus lubricating oil composition for low emission heavy duty diesel engines comprising: 
 (a) a major amount of an oil of lubricating viscosity;    (b) at least 5 weight percent of an anti-wear additive composition comprising a metal salt of a Mannich condensation product based on the total weight of the lubricating oil composition.    
   
   
       2 . The lubricating oil composition of  claim 1 , wherein the concentration of the Mannich condensation product is in the range of from about 5 weight percent to about 25 weight percent based on the total weight of the lubricating oil composition.  
   
   
       3 . The lubricating oil composition of  claim 2 , wherein the concentration of the Mannich condensation product is in the range of from about 7 weight percent to about 20 weight percent based on the total weight of the lubricating oil composition.  
   
   
       4 . The lubricating oil composition of  claim 3 , wherein the concentration of the Mannich condensation product is in the range of from about 9 weight percent to about 15 weight percent based on the total weight of the lubricating oil composition.  
   
   
       5 . The lubricating oil composition of  claim 1 , wherein in the anti-wear additive composition (b), the Mannich condensation product is a condensation product of an aldehyde having one carbon atom to about 20 carbon atoms, a nitrogen base selected from ammonia, a lower alkyl amine, a polyamine and mixtures thereof, and an alkylphenol.  
   
   
       6 . The lubricating oil composition of  claim 5 , wherein the alkyl group on the alkylphenol of the Mannich condensation product is a linear chain or a branched chain alkyl group or mixtures thereof.  
   
   
       7 . The lubricating oil composition of  claim 6 , wherein the alkyl group on the alkylphenol of the Mannich condensation product is a branched chain alkyl group.  
   
   
       8 . The lubricating oil composition of  claim 5 , wherein in the Mannich condensation product the alkyl group on the alkylphenol has from about 4 carbon atoms to about 60 carbon atoms.  
   
   
       9 . The lubricating oil composition of  claim 8 , wherein the alkyl group on the alkylphenol of the Mannich condensation product has from about 6 carbon atoms to about 40 carbon atoms.  
   
   
       10 . The lubricating oil composition of  claim 9 , wherein the alkyl group on the alkylphenol of the Mannich condensation product has from about 8 carbon atoms to about 20 carbon atoms.  
   
   
       11 . The lubricating oil composition of  claim 5 , wherein the alkyl group on the lower alkyl amine has from one carbon atom to about 10 carbon atoms and the polyamine has from 2 amine nitrogen atoms to about 12 amine nitrogen atoms and 2 carbon atoms to about 40 carbon atoms.  
   
   
       12 . The lubricating oil composition of  claim 11 , wherein the nitrogen base for the preparation of the Mannich condensation product is a lower alkyl amine, wherein the alkyl group has one carbon atom to about 10 carbon atoms.  
   
   
       13 . The lubricating oil composition of  claim 12 , wherein the lower alkyl amine is an alkyl mono-amine.  
   
   
       14 . The lubricating oil composition of  claim 11 , wherein the polyamine is a mono-alkylene polyamine, polyalkylene polyamine or mixtures thereof.  
   
   
       15 . The lubricating oil composition of  claim 5 , wherein the aldehyde used to prepare the Mannich condensation product is formaldehyde.  
   
   
       16 . The lubricating oil composition of  claim 5 , wherein the aldehyde used to prepare the Mannich condensation product is paraformaldehyde.  
   
   
       17 . The lubricating oil composition of  claim 5 , wherein in the anti-wear additive composition (b) the Mannich condensation product is prepared from an alkylphenol, wherein the alkyl group on the alkylphenol is a branched chain alkyl group having from about 8 carbon atoms to about 20 carbon atoms, paraformaldehyde and mono-methyl amine.  
   
   
       18 . The lubricating oil composition of  claim 1 , wherein the metal in the metal salt of Mannich condensation product is an alkali metal or an alkaline earth metal.  
   
   
       19 . The lubricating oil composition of  claim 18 , wherein the metal is an alkaline earth metal.  
   
   
       20 . The lubricating oil composition of  claim 19 , wherein the alkaline earth metal is calcium.  
   
   
       21 . The lubricating oil composition of  claim 1 , wherein the sulfur content is in the range of 0.0 weight percent to about 0.4 weight percent based on the total weight of the lubricating oil.  
   
   
       22 . The lubricating oil composition of  claim 21 , wherein the sulfur content is in the range of 0.05 weight percent to about 0.3 weight percent based on the total weight of the lubricating oil.  
   
   
       23 . The lubricating oil composition of  claim 22 , wherein the sulfur content is in the range of 0.1 weight percent to about 0.2 weight percent based on the total weight of the lubricating oil.  
   
   
       24 . The lubricating oil composition of  claim 1 , wherein the sulfated ash content is in the range of 0.2 weight percent to about 4.0 weight percent based on the total weight of the lubricating oil.  
   
   
       25 . The lubricating oil composition of  claim 24 , wherein the sulfated ash content is in the range of 0.3 weight percent to about 2.0 weight percent based on the total weight of the lubricating oil.  
   
   
       26 . The lubricating oil composition of  claim 25 , wherein the sulfated ash content is in the range of 0.5 weight percent to about 1.2 weight percent based on the total weight of the lubricating oil.  
   
   
       27 . The lubricating oil composition of  claim 1 , wherein the phosphorus content is in the range of 0.005 weight percent to about 0.06 weight percent based on the total weight of the lubricating oil.  
   
   
       28 . The lubricating oil composition of  claim 27 , wherein the phosphorus content is in the range of 0.015 weight percent to about 0.05 weight percent based on the total weight of the lubricating oil.  
   
   
       29 . The lubricating oil composition of  claim 28 , wherein the phosphorus content is in the range of 0.03 weight percent to about 0.04 weight  
   
   
       30 . The lubricating oil composition of  claim 1 , wherein the lubricating oil composition further comprises one or more lubricating oil additives selected from detergents, dispersants, anti-oxidants, viscosity index improvers, corrosion inhibitors, anti-wear agents, friction modifiers, pour point depressants and foam inhibitors.  
   
   
       31 . A low sulfur, low sulfated ash and low phosphorus lubricating oil concentrate for low emission heavy duty diesel engines comprising: 
 (a) from about 10 weight percent to about 90 weight percent of an oil of lubricating viscosity based on the total weight of the lubricating oil concentrate; and    (b) at least 5 weight percent of an anti-wear additive composition comprising a metal salt of a Mannich condensation product based on the total weight of the lubricating oil composition.    
   
   
       32 . A method for lubricating low emission heavy duty diesel engines, which comprises lubricating with a low sulfur, low sulfated ash and low phosphorus lubricating oil composition comprising: 
 (a) a major amount of an oil of lubricating viscosity; and    (b) at least 5 weight percent of an anti-wear additive composition comprising a metal salt of a Mannich condensation product based on the total weight of the lubricating oil composition.