Combinations of phosphorus-containing compounds for use as anti-wear additives in lubricant composition

Abstract

The present disclosure relates to a lubricant composition comprising a first phosphorus compound, a second phosphorus compound, and a third phosphorus compound, wherein the first phosphorus compound is present in the lubricant composition in an amount to provide between about 120 and 350 ppm phosphorus. The lubricant composition may provide robust anti-wear and reduced pitting.

1 . A lubricant composition comprising:
 (a) a first phosphorus compound formed by:
 (i) reacting an O,O-dihydrocarbyl phosphorodithioic acid with an epoxide to form a product; 
 (ii) reacting the product with phosphorus pentoxide to produce an acid phosphate intermediate; and 
 (iii) neutralizing at least a major portion of the intermediate with at least one first amine; 
   (b) a second phosphorus compound formed by reacting a sulfur source with a dihydrocarbyl phosphite;   (c) a third phosphorus compound formed by reacting an acid phosphate with at least one second amine;   (d) wherein the first phosphorus compound is present in the lubricant composition to provide between about 120 and about 350 ppm phosphorus to the lubricant composition and said first and second amine may be the same or different.   
     
     
         2 . The lubricant composition of  claim 1 , wherein the total amount of phosphorus present in the lubricant composition is between about 500 and about 1500 ppm. 
     
     
         3 . The lubricant composition of  claim 1 , wherein the total amount of phosphorus present in the lubricant composition is between about 800 and about 1100 ppm. 
     
     
         4 . The lubricant composition of  claim 1 , wherein the O,O-di-hydrocarbyl phosphorodithioic acid is O,O-di(4-methyl-2-pentyl)phosphorodithioic acid. 
     
     
         5 . The lubricant composition of  claim 1 , wherein the O,O-di-hydrocarbyl phosphorodithioic acid is O,O′-di-n-hexylphosphorodithioic acid. 
     
     
         6 . The lubricant composition of  claim 1 , wherein the epoxide is selected from the group consisting of: ethylene oxide, propylene oxide, styrene oxide, alpha-methylstyrene oxide, p-methyl-styrene oxide, cyclohexene oxide, cyclopentene oxide, dodecene oxide, octadecene oxide, 2,3-butene oxide, 1,2-butene oxide, 1,2-octene oxide, 3,4-pentene oxide, and 4-phenyl-1,2-cyclohexene oxide. 
     
     
         7 . The lubricant composition of  claim 1 , wherein said first amine is selected from the group consisting of: aliphatic amines, aromatic amines, cyclo-aliphatic amines, heterocyclic amines, and carboxylic amines. 
     
     
         8 . The lubricant composition of  claim 1 , wherein said first amine is a mixture of C 11 -C 14  tertiary alkyl primary amines. 
     
     
         9 . The lubricant composition of  claim 1 , wherein the dihydrocarbyl phosphite is selected from the group consisting of dilauryl hydrogen phosphite, dibutyl hydrogen phosphite and dioleyl phosphite. 
     
     
         10 . The lubricant composition of  claim 1 , wherein the dihydrocarbyl phosphite is dibutyl hydrogen phosphite. 
     
     
         11 . The second phosphorus compound of the lubricant composition of  claim 1 , wherein the sulfur source is selected from the group consisting of elemental sulfur, sulfurized isobutylene, and polysulfide. 
     
     
         12 . The lubricant composition of  claim 1 , wherein the acid phosphate comprises a mono-hydrocarbyl acid phosphate, a di-hydrocarbyl phosphate, or a mixture of mono-hydrocarbyl acid phosphate and di-hydrocarbyl acid phosphate. 
     
     
         13 . The lubricant composition of  claim 1 , wherein the acid phosphate is selected from the group consisting of amyl acid phosphate, bis-2-ethylhexyl acid phosphate, and diamyl acid phosphate. 
     
     
         14 . The lubricant composition of  claim 1 , further comprising a major amount of a base oil. 
     
     
         15 . The lubricant composition of  claim 1 , further comprising an oil-soluble ashless dispersant selected from the group consisting of: a succinimide dispersant, a succinic ester dispersant, a succinic ester-amide dispersant, a Mannich base dispersant, phosphorylated forms thereof, and boronated forms thereof. 
     
     
         16 . The lubricant composition of  claim 1 , further comprising one or more of the following: an air expulsion additive, an antioxidant, a corrosion inhibitor, a foam inhibitor, a metallic detergent, an organic phosphorus compound, a seal-swell agent, a viscosity index improver, and an extreme pressure additive. 
     
     
         17 . A method of lubricating a machine part comprising lubricating said machine part with a lubricant composition including the lubricant composition of  claim 1 . 
     
     
         18 . The method of  claim 17 , wherein said machine part comprises a gear, an axle, a differential, an engine, a crankshaft, a transmission, or a clutch. 
     
     
         19 . The method of  claim 18 , wherein said transmission is selected from the group consisting of an automatic transmission, a manual transmission, an automated manual transmission, a semi-automatic transmission, a dual clutch transmission, a continuously variable transmission, and a toroidal transmission. 
     
     
         20 . The method of  claim 18 , wherein said clutch includes a continuously slipping torque converter clutch, a slipping torque converter clutch, a lock-up torque converter clutch, a starting clutch, one or more shifting clutches, or an electronically controlled converter clutch. 
     
     
         21 . The method of  claim 18 , wherein said gear is selected from the group consisting of an automotive gear, a stationary gearbox, and an axle. 
     
     
         22 . The method of  claim 18 , wherein said gear is selected from the group consisting of a hypoid gear, a spur gear, a helical gear, a bevel gear, a worm gear, a rack and pinion gear, a planetary gear set, and an involute gear. 
     
     
         23 . The method of  claim 18 , wherein said differential is selected from the group consisting of a straight differential, a turning differential, a limited slip differential, a clutch-type limited slip differential, and a locking differential. 
     
     
         24 . The method of  claim 18 , wherein said engine is selected from the group consisting of an internal combustion engine, a rotary engine, a gas turbine engine, a four-stroke engine, and a two-stroke engine. 
     
     
         25 . The method of  claim 18 , wherein said engine includes a piston, a bearing, a crankshaft, and/or a camshaft. 
     
     
         26 . A method for testing the lubricant properties of a composition using a testing apparatus comprising lubricating said testing apparatus with the lubricant composition of  claim 1 , said testing apparatus selected from the group consisting of: a Brookfield viscometer, any Vickers Test apparatus, an SAE No. 2 friction test machine, an electric motor-driven Hydra-Matic 4L60-E automatic transmission, ASTM D 471 or D 676 Elastomer Compatibility test equipment, NOACK volatility procedure machine, any test apparatus necessary for ASTM D 2882, D 5182, D 4172, D3233, and D2782 Wear Procedures, ASTM Foaming Procedure apparatus, test apparatus necessary for ASTM D 130 Copper Corrosion test, test equipment specified by the International Harvester Procedure Method BT-9 Rust Control test, test apparatus required by ASTM D 892 Foaming test, test apparatus required by ASTM D 4998 Gear Anti-Wear Performance test, Link M1158 Oil/Friction Machine, L-33-1 Test Apparatus, L-37 Test Apparatus, L-42 Test Apparatus, L-60-1 Test Apparatus, Strama 4-Square Electric Motor-Driven Procedure Machine, FZG Test Apparatus and parts, SSP-180 Procedure Machine, test apparatus for ASTM D 5579 High Temperature Cyclic Durability Procedure, Sauer-Danfoss Series 22 or Series 90 Axial Piston Pump, John Deere Synchro-Plus transmission, an SRV-friction wear tester, a 4-ball test apparatus, an LFW-1 test apparatus, a sprag clutch over-running wear test (SCOWT) apparatus, API CJ-4 engine tests, L-33 Moisture Corrosion Test, High-Temperature Cyclic Durability Test (ASTM D 5579), 288-hour VE engine oil performance test, L-38 standard lubricant test, Denison P46 Piston Pump Test Stand, Sundstrand Dynamic Corrosion Test Stand, a block-on-ring test apparatus, and any test apparatus required for performing test analysis under Mercon®, Mercon® V, Dexron® III, Dexron® III-H, Caterpillar® TO-4, Allison® C-4, JASO, GF-4, GF-5, MIL-E, MIL-L, and Sequences II through VIII. 
     
     
         27 . A method for improving the anti-wear properties of a lubricating fluid comprises including in a lubricating fluid an effective amount of the lubricant composition of  claim 1 . 
     
     
         28 . A method for improving the anti-wear and pitting properties of a lubricating fluid while lubricating an automotive component requiring lubrication, comprising:
 1) adding a lubricating fluid to an automotive component requiring lubrication, said fluid comprising (a) a base oil, and (b) a lubricant composition of  claims 1 ; and   2) operating the automotive component that contains the fluid.   
     
     
         29 . The method of  claim 28 , wherein the anti-wear and pitting performance of the fluid is improved relative to the performance of a lubricating fluid free of the lubricant composition of  claim 1 . 
     
     
         30 . The lubricant composition of  claim 1 , wherein the dihydrocarbyl phosphite is dioleyl phosphite.