Compositions and methods for producing a lubricant

Abstract

Compositions for lubricants and methods for producing the same using spherical bismuth powder and spherical copper powder particles are disclosed. In at least one embodiment, the lubricant includes a base oil, a grease, a copper powder, comprising at least one spherical particle, and a bismuth powder, comprising at least one spherical particle. The lubricant can be used as an engine oil, a gear oil, a grease lubricant, or a spray lubricant. When applying the lubricant to an internal combustible engine, the heat and pressure within the engine compresses the lubricant to infuse the copper and bismuth powder particles to the internal surface of the engine. When used in internal combustible engines, the disclosed lubricants deliver outstanding wear resistance, improve gas mileage, extend interval times needed for oil changes, and also reduce engine exhaust emission.

We claim: 
     
         1 . A lubricant comprising:
 a base oil;   a grease;   a copper powder, comprising at least one spherical particle;   a bismuth powder, comprising at least one spherical particle.   
     
     
         2 . The lubricant of  claim 1 , wherein the copper powder is between 0.1% and 60% of the total weight of the lubricant. 
     
     
         3 . The lubricant of  claim 1 , wherein the bismuth powder is between 0.1% and 60% of the total weight of the lubricant. 
     
     
         4 . The lubricant of  claim 1 , wherein the lubricant is an engine oil. 
     
     
         5 . The lubricant of  claim 4 , wherein the base oil comprises a shear stabile polymer and at least one additive. 
     
     
         6 . The lubricant of  claim 1 , wherein the lubricant is a gear oil. 
     
     
         7 . The lubricant of  claim 6 , wherein the base oil comprises a top-treat additive package. 
     
     
         8 . The lubricant of  claim 1 , wherein the lubricant is a grease. 
     
     
         9 . The lubricant of  claim 8 , wherein the grease comprises a synthetic lubricating grease comprising a lithium complex. 
     
     
         10 . The lubricant of  claim 1 , wherein the lubricant is a spray lubricant. 
     
     
         11 . The lubricant of  claim 1 , wherein the at least one spherical particle of the copper powder is about 4.0 μm to 176.0 μm in size. 
     
     
         12 . The lubricant of  claim 11 , wherein the D50 particle size of the at least one particle of the copper powder is about 8 μm to 13 μm. 
     
     
         13 . The lubricant of  claim 1 , wherein the at least one spherical particle of the bismuth powder is about 0.9 μm to 32.0 μm in size. 
     
     
         14 . The lubricant of  claim 13 , wherein the D50 size of the at least one particle of the bismuth powder is about 5.0 μm to 15 μm. 
     
     
         15 . A method for producing a lubricant, the method comprising the steps of:
 selecting at least one base oil;   selecting at least one grease;   adding a first quantity of the at least one base oil to a first quantity of the at least one grease in a mixing container;   adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle;   adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle;   mixing the first quantity of the at least one base oil, the first quantity of the at least one grease, the copper powder, and the bismuth powder in the mixing container until well blended to form a lubricant composition.   
     
     
         16 . The method of  claim 15 , further comprising the step of mixing the first quantity of the at least one base oil and the first quantity of the at least one grease in the mixing container prior to adding the copper powder and bismuth powder to the mixing container. 
     
     
         17 . The method of  claim 16 , further comprising the step of mixing the lubricant composition with a second quantity of the at least one base oil to form an engine or gear oil lubricant. 
     
     
         18 . The method of  claim 17 , wherein the first quantity of the at least one base oil and the first quantity of the at least one grease is mixed in the mixing container at a high speed for 20 minutes; wherein the first quantity of the at least one base oil, the first quantity of the at least one grease, the spherical copper powder, and the spherical bismuth powder are mixed in the mixing container at a high speed for 45 minutes; and wherein the lubricant composition and the second quantity of the at least one base oil are mixed in the mixing container for 20 minutes. 
     
     
         19 . The method of  claim 16 , further comprising the step of mixing the lubricant composition with a second quantity of the at least one grease to form a grease lubricant. 
     
     
         20 . The method of  claim 15 , further comprising the steps of:
 applying the lubricant composition to an engine comprising at least one metal surface;   applying heat and pressure within the engine to compress the lubricant composition, wherein compressing the lubricant composition infuses the copper powder and the bismuth powder within the lubricant composition to the at least one metal surface of the engine; and   coating the at least one metal surface of the engine with the infused copper powder and bismuth powder.   
     
     
         21 . The method of  claim 15 , further comprising the step of mixing the lubricant composition with mineral spirits to form a spray lubricant.