Compositions with Fast and Slow Release Components

Abstract

The present invention relates to controlled release compositions that include: (a) a slow release component, comprising one or more performance additives in the form of a solid or semi-solid mass; and (b) a fast release component comprising (i) a matrix material and (ii) one or more additives that can be dissolved and/or dispersed into the matrix material as well as additive delivery systems and processes using such compositions, and which release one or more additives into a fluid.

1 . A composition comprising:
 (a) a slow release component comprising one or more performance additives in the form of a solid or semi-solid mass, wherein the additive components making up the mass are slowly released into a fluid; and   (b) a fast release component comprising:
 i. a matrix material which is soluble in the fluid; 
 ii. one or more additives that can be dissolved and/or dispersed into the matrix material; 
   wherein the additives within the matrix material are quickly released into the fluid; and wherein the weight ratio of components (a):(b) is 1:100 to 100:1.   
     
     
         2 . The composition of  claim 1  wherein components (a) and (b) are each in the form of one or more distinct layers, wherein the one or more layers each of (a) and (b) are combined to form a controlled release additive package, wherein the layers of (a) and (b) may be arranged such that either component (a) and/or (b) may form one or more external layers, internal layers, or interstitial layers of the controlled release additive package. 
     
     
         3 . The composition of  claim 1  wherein (a), the slow release component, comprises an additive gel formed by the gelation of at least two additives selected from the group consisting of detergents, dispersants, acids, bases, over based detergents and combinations thereof;
 wherein the detergent, when present, comprises a sulfonate, a phenate, a salicylate, a carboxylate and mixtures thereof; 
 wherein the dispersant, when present, comprises an N-substituted long chain alkenyl succinimides, polyisobutenyl succinimide, a high molecular weight ester, a Mannich base, an amine dispersant, a polymeric dispersant and mixtures thereof; 
 wherein the acid, when present, comprises and acid formed from a polymer containing acidic groups in the backbone, a polyacidic compound and mixtures thereof. 
 
     
     
         4 . The composition of  claim 1  wherein (a), the slow release component, comprises a solid that: (i) has a melting point from 40-250C, (ii) is at least partially soluble in the fluid, and (iii) is formed by mixing of one or more additives selected from the group consisting of viscosity modifiers, friction modifiers, ashless detergents, cloud point depressants, pour point depressants, demulsifiers, flow improvers, anti static agents, ashless dispersants, ashless antioxidants, antifoams, corrosion/rust inhibitors, extreme pressure/antiwear agents, wear reducing agents, seal swell agents, lubricity aids, antimisting agents and mixtures thereof. 
     
     
         5 . The composition of  claim 1  wherein (a), the slow release component, is more than 70 wt % dispersant and detergent. 
     
     
         6 . The composition of  claim 1  wherein (a), the slow release component, is more than 45 wt % detergent. 
     
     
         7 . The composition of  claim 1  wherein (b), the fast release component, comprises glycerol esters, borated glycerol esters, fatty phosphites, fatty acid amines, fatty epoxides, borated fatty epoxides, alkoxylated fatty amines, borated alkoxylated fatty amines, metal salts of fatty acids, sulfurized olefins, fatty imidazolines, condensation products of carboxylic acids and polyalkylene-polyamines, amine salts of alkylphosphoric acids, molybdenum-containing friction modifiers, or combinations thereof. 
     
     
         8 . The composition of  claim 1  wherein (a) the slow release component, and/or (b) the fast release component, further comprises one or more additional additives selected from the group consisting of viscosity modifiers, friction modifiers, ashless detergents, cloud point depressants, pour point depressants, demulsifiers, flow improvers, anti static agents, ashless dispersants, ashless antioxidants, antifoams, corrosion/rust inhibitors, extreme pressure/antiwear agents, wear reducing agents, seal swell agents, lubricity aids, antimisting agents and mixtures thereof. 
     
     
         9 . A process of releasing, at controlled rates, one or more additives into a fluid, wherein each additive or group of additives is released at an independent rate; wherein at least one additive or group of additives is released slowly over time into the fluid; and wherein at least one additive or group of additives is released quickly into the fluid; wherein the release of the additives into the fluid comprises the steps of:
 I. contacting the fluid with a composition comprising:
 (a) a slow release component comprising one or more performance additives in form of a solid or semi-solid mass, wherein the additive components making up the mass are slowly released into a fluid; and 
 (b) a fast release component comprising:
 i. a matrix material which is soluble in the fluid; 
 ii. one or more additives that can be dissolved and/or dispersed into the matrix material; 
 
   wherein the additives within the matrix material are quickly released into the fluid; and wherein the weight ratio of components (a):(b) is 1:100 to 100:1.   
     
     
         10 . The process of  claim 9  wherein no more than 80 wt % of (a), the slow release component, is released into the fluid over the first 50% or more of the service life of the fluid; and wherein at least 80 wt % of (b), the fast release component, is released into the fluid over the first 25% or less of the service life of the fluid. 
     
     
         11 . The process of  claim 9  wherein (a), the slow release component, and (b), the fast release component, are each in the form of one or more distinct layers, wherein the one or more layers each of (a) and (b) are combined to form a controlled release additive package, wherein the layers of (a) and (b) may be arranged such that either component (a) and/or (b) may form one or more external layers, internal layers, or interstitial layers of the controlled release additive package; and
 wherein one or more of the additive release packages are placed in contact with the fluid at one or more locations within a fluid system of a device that uses the fluid, resulting in the fast release of one more additives, and the slow release of one or more additives, into the fluid. 
 
     
     
         12 . The process of  claim 9  wherein (a), the slow release component, comprises an additive gel formed by the gelation of at least two additives selected from the group consisting of detergents, dispersants, acids, bases, over based detergents and combinations thereof;
 wherein the detergent, when present, comprises a sulfonate, a phenate, a salicylate, a carboxylate and mixtures thereof; 
 wherein the dispersant, when present, comprises an N-substituted long chain alkenyl succinimides, polyisobutenyl succinimide, a high molecular weight ester, a Mannich base, an amine dispersant, a polymeric dispersant and mixtures thereof; 
 wherein the acid, when present, comprises and acid formed from a polymer containing acidic groups in the backbone, a polyacidic compound and mixtures thereof. 
 
     
     
         13 . The process of  claim 9  wherein (a), the slow release component, comprises a solid that: (i) has a melting point from 40-250C, (ii) is at least partially soluble in the fluid, and (iii) is formed by mixing of one or more additives selected from the group consisting of viscosity modifiers, friction modifiers, ashless detergents, cloud point depressants, pour point depressants, demulsifiers, flow improvers, anti static agents, ashless dispersants, ashless antioxidants, antifoams, corrosion/rust inhibitors, extreme pressure/antiwear agents, wear reducing agents, seal swell agents, lubricity aids, antimisting agents and mixtures thereof. 
     
     
         14 . An additive delivery system that comprises a composition comprising:
 (a) a slow release component comprising one or more performance additives in form of a solid or semi-solid mass, wherein the additive components making up the mass are slowly released into a fluid; and   (b) a fast release component comprising:
 i. a matrix material which is soluble in the fluid; 
 ii. one or more additives that can be dissolved and/or dispersed into the matrix material; and 
   wherein the additives within the matrix material are quickly released into the fluid; and wherein the weight ratio of components (a):(b) is 1:100 to 100:1; and   where the additive delivery system further comprises a means of contacting the controlled release composition with the fluid, resulting in the fast release of one more additives, and the slow release of one or more additives, into the fluid.   
     
     
         15 . The additive delivery system of  claim 14  wherein the composition is contained within a fluid filter and wherein one or more additives are released into the fluid as it passes through the fluid filter and with a device that utilizes said fluid.  1 .