Lubricant compositions comprising olefin copolymer dispersants in combination with additives

Abstract

Lubricating oil compositions including olefin copolymer dispersants comprising olefin copolymers derived from ethylene and one or more C 3 -C 10 alpha olefins in combination with various additives and related methods are generally described herein. The compositions may include one or more phosphorus-containing compound(s), detergents, friction modifiers, extreme pressure agents, and mixtures thereof.

What is claimed is: 
     
         1 . A lubricant composition comprising
 a base oil of lubricating viscosity;   an olefin copolymer dispersant;   one or more phosphorus-containing compound(s) in an amount to provide up to 5000 ppm phosphorus to the lubricant composition;   wherein an olefin copolymer of the olefin copolymer dispersant is derived from ethylene and one or more C 3  to C 10  alpha-olefins, the olefin copolymer having (i) a number average molecular weight of less than 5,000 g/mol as measured by GPC using polystyrene as a calibration reference, (ii) an ethylene monomer moiety content of greater than 40 mol %, as measured by  1 H-NMR spectroscopy, (iii) a terminal unsaturation of 70 mol % or greater, as measured by  13 C-NMR spectroscopy, and at least 70 mol % of the terminal unsaturation is selected from terminal vinylidene, one or more tri-substituted isomers of the terminal vinylidene, and any combinations thereof, as measured by  1 H-NMR spectroscopy; and (iv) an experimental average ethylene run length (n C2,Experimental ), as determined by  13 C NMR spectroscopy, of less than 2.6 and wherein:
     n   C2,Experimental   <n   C2,Statistical   (Equation 6)
 
   wherein the olefin copolymer dispersant is obtainable by reacting the olefin copolymer with an acylating agent to form an acylated copolymer and reacting the acylated copolymer with a nitrogen source; and   wherein the one or more phosphorus-containing compound(s) is independently selected from the group consisting of a thiophosphate, a dithiophosphate, a metal phosphate, a metal thiophosphate, a metal di-thiophosphate, a phosphate, a phosphite, a phosphonate, salts thereof, and mixtures thereof.   
     
     
         2 . The lubricant composition of  claim 1  wherein the acylating agent is maleic anhydride. 
     
     
         3 . The lubricant composition of  claim 2  wherein the nitrogen source is ammonia. 
     
     
         4 . The lubricant composition of  claim 2  wherein the nitrogen source is a polyalkylene polyamine. 
     
     
         5 . The lubricant composition of  claim 4  wherein the polyalkylene polyamine is selected from the group consisting of a mixture of polyethylene polyamines having an average of 5 nitrogen atoms, triethylenetetraamine, tetraethylenepentamine, and combinations thereof. 
     
     
         6 . The lubricant composition of  claim 1  wherein the ethylene monomer moiety content is at least 49 mol % and less than 80 mol %. 
     
     
         7 . The lubricant composition of  claim 6  wherein the ethylene monomer moiety content is at least 49 mol % and less than 60 mol %. 
     
     
         8 . The lubricant composition of  claim 1  wherein the one or more C 3  to C 10  alpha-olefins is selected from the group consisting of propylene, 1-butylene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, and 1-decene. 
     
     
         9 . The lubricant composition of  claim 8  wherein the one or more C 3  to C 10  alpha-olefins is propylene. 
     
     
         10 . The lubricant composition of  claim 1  wherein the one or more phosphorus-containing compound(s) comprises about 5 to about 20 weight percent phosphorus. 
     
     
         11 . The lubricant composition of  claim 1  wherein the one or more phosphorus-containing compound(s) is present in an amount to provide at least 50 ppm phosphorus. 
     
     
         12 . The lubricant composition of  claim 11  wherein the one or more phosphorus-containing compound(s) is present in an amount to provide between 300-1500 ppm phosphorus. 
     
     
         13 . The lubricant composition of  claim 11  wherein the phosphorus-containing compound is present in an amount to provide up to 900 ppm phosphorus. 
     
     
         14 . The lubricant composition of  claim 13  wherein the phosphorus-containing compound is present in an amount to provide up to 600 ppm phosphorus. 
     
     
         15 . The lubricant composition of  claim 1 , wherein the one or more phosphorus-containing compound(s) is independently selected from the group consisting of metal phosphate, metal thiophosphate, and metal dithiophosphate. 
     
     
         16 . The lubricant composition of  claim 15 , wherein the one or more phosphorus-containing compound(s) is metal dithiophosphate and includes 12 to 32 total carbon atoms within alkyl groups thereon, wherein each of the alkyl groups independently averages 3 to 8 carbon atoms. 
     
     
         17 . The lubricant composition of  claim 16 , wherein at least about 40% of the alkyl groups are independently derived from secondary alcohols. 
     
     
         18 . The lubricant composition of  claim 17 , wherein about 100% of the alkyl groups are independently derived from secondary alcohols. 
     
     
         19 . The lubricant composition of  claim 15 , wherein the metal of the one or more phosphorus-containing compound(s) is independently selected from the group consisting of aluminum, lead, tin, molybdenum, manganese, nickel, copper, titanium, tungsten, zirconium, or zinc. 
     
     
         20 . The lubricant composition of  claim 19  wherein the metal of the one or more phosphorus-containing compound(s) is zinc. 
     
     
         21 . The lubricant composition of  claim 20 , wherein the one or more phosphorus-containing compound(s) comprises about 6 to about 10 weight percent phosphorus, about 6 to about 9 weight percent zinc, and about 12 to about 18 weight percent sulfur. 
     
     
         22 . The lubricant composition of  claim 1 , wherein the one or more phosphorus-containing compound(s) has the formula: 
       
         
           
           
               
               
           
         
         wherein R is independently C 3  to C 8  alkyl chains so that the total number of carbon atoms in the alkyl chains is 12 to 32; and 
         A is aluminum, lead, tin, molybdenum, manganese, nickel, copper, titanium, tungsten, zirconium, or zinc. 
       
     
     
         23 . The lubricant composition of  claim 22  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of at least about 1300 g/mol. 
     
     
         24 . The lubricant composition of  claim 23  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of about 1390 g/mol. 
     
     
         25 . The lubricant composition of  claim 23  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of at least 1600 g/mol. 
     
     
         26 . The lubricant composition of  claim 25  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of about 1600 g/mol. 
     
     
         27 . The lubricant composition of  claim 23  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of about 1300 g/mol to about 2700 g/mol. 
     
     
         28 . The lubricant composition of  claim 27  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of about 1390 g/mol to about 2700 g/mol. 
     
     
         29 . The lubricant composition of  claim 22  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of about 2700 g/mol 
     
     
         30 . The lubricant composition of  claim 22  wherein R has at least 40% of the alkyl chains independently derived from secondary alcohols. 
     
     
         31 . The lubricant composition of  claim 22  wherein A is zinc and wherein R has about 40% of the alkyl chains independently derived from secondary alcohols and wherein the alkyl chains have an average of C 4  to C 5  carbon atoms. 
     
     
         32 . The lubricant composition of  claim 22  wherein A is zinc and wherein R has about 100% of the alkyl chains derived from secondary alcohols and wherein 50% of the alkyl chains are C 3  and 50% of the alkyl chains are C 6 . 
     
     
         33 . The lubricant composition of  claim 22  wherein A is zinc and wherein R has about 100% of the alkyl chains derived from secondary alcohols and wherein about 100% of the alkyl chains are C 6 . 
     
     
         34 . The lubricant composition of  claim 22  wherein A is zinc and wherein R has about 100% of the alkyl chains derived from primary alcohols and wherein about 100% of the alkyl chains are C 8 . 
     
     
         35 . The lubricant composition of  claim 22  wherein A is zinc and wherein the phosphorus-containing compound(s) is present in an amount to provide between 70-800 ppm phosphorus. 
     
     
         36 . The lubricant composition of  claim 1 , wherein the one or more phosphorus-containing compound(s) is independently selected from the group consisting of thiophosphate, dithiophosphate, phosphate, phosphite, phosphonate, salts thereof, and mixtures thereof. 
     
     
         37 . The lubricant composition of  claim 36 , wherein the one or more phosphorus-containing compound(s) is independently selected from the group consisting of dialkyl dithiophosphate ester, amyl acid phosphate, diamyl acid phosphate, dibutyl hydrogen phosphonate, dimethyl octadecyl phosphonate, salts thereof, and mixtures thereof. 
     
     
         38 . The lubricant composition of  claim 36 , wherein the one or more phosphorus-containing compound(s) has the formula: 
       
         
           
           
               
               
           
         
         wherein 
         R 1  is S or O; 
         R 2  is —OR″, —OH, or —R″; 
         R 3  is —OR″, —OH, H, or S R′″C(O)OH; 
         R 4  is —OR″; 
         R′″ is C 1  to C 3  branched or linear alkyl chain; 
         R″ is a C 1  to C 18  hydrocarbyl chain. 
       
     
     
         39 . The lubricant composition of  claim 38 , wherein the one or more phosphorus-containing compound(s) is present in an amount to provide about 80 to about 4500 ppm phosphorus to the lubricant composition. 
     
     
         40 . The lubricant composition of  claim 3   8 , wherein the one or more phosphorus-containing compound(s) comprises about 8 to about 16 weight percent phosphorus. 
     
     
         41 . The lubricant composition of  claim 38  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of at least about 1300 g/mol. 
     
     
         42 . The lubricant composition of  claim 41  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of about 1390 g/mol. 
     
     
         43 . The lubricant composition of  claim 41  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of at least about 1600 g/mol. 
     
     
         44 . The lubricant composition of  claim 43  wherein the olefin copolymer is derived from ethylene and propylene and has a number average molecular weight of about 1600 g/mol. 
     
     
         45 . The lubricant composition of  claim 41  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of at least about 1300 g/mol to about 2700 g/mol. 
     
     
         46 . The lubricant composition of  claim 45  wherein the one or more C 3  to C 10  alpha-olefins is propylene and the olefin copolymer has a number average molecular weight of at least about 1390 g/mol to about 2700 g/mol. 
     
     
         47 . The lubricant composition of  claim 38  wherein the olefin copolymer is derived from ethylene and propylene and has a number average molecular weight of about 2700 g/mol. 
     
     
         48 . The lubricant composition of  claim 38  wherein:
 R 1  is S; 
 R 2  is —OR″; 
 R 3  is SR′″COOH; 
 R 4  is —OR″; 
 R′″ is C 3  branched alkyl chain; 
 R″ is C 4 ; and wherein 
 the one or more phosphorus-containing compound(s) is present in an amount to deliver between 180-900 ppm phosphorus to the lubricating composition. 
 
     
     
         49 . The lubricant composition of  claim 38  wherein:
 R 1  is O; 
 R 2  is —OH; 
 R 3  is —OR″ or —OH; 
 R 4  is —OR″; 
 R″ is C 5 ; and wherein 
 the one or more phosphorus-containing compound(s) is present in an amount to deliver between 150-1500 ppm phosphorus to the lubricating composition. 
 
     
     
         50 . The lubricant composition of  claim 38  wherein:
 R 1  is O; 
 R 2  is OR″; 
 R 3  is H 
 R 4  is —OR″ 
 R″ is C 4 ; and wherein 
 the one or more phosphorus-containing compound(s) is present in an amount to deliver between 300-1550 ppm phosphorus to the lubricating composition. 
 
     
     
         51 . The lubricant composition of  claim 38  wherein:
 R 1  is O; 
 R 2  is —R″; 
 R 3  is —OCH 3  or —OH; 
 R 4  is —OCH 3 ; 
 R″ is C 18 ; and wherein 
 the one or more phosphorus-containing compound(s) is present in an amount to deliver between 80-850 ppm phosphorus to the lubricating composition. 
 
     
     
         52 . The lubricant composition of  claim 1 , wherein the olefin copolymer dispersant is present in an amount from about 1 weight percent to about 8 weight percent based on the lubricating composition. 
     
     
         53 . The lubricant composition of  claim 52 , wherein the olefin copolymer dispersant is present in an amount from about 1 weight percent and 4 weight percent based on the lubricating composition. 
     
     
         54 . The lubricant composition of  claim 1 , wherein the olefin copolymer dispersant comprises Formula V: 
       
         
           
           
               
               
           
         
         wherein 
         R 5  is a hydrocarbyl radical obtained from the olefin copolymer derived from ethylene and one or more C 3 -C 10  alpha-olefins; 
         R 6  is a divalent C 1 -C 6  alkylene; 
         R 7  is a divalent C 1 -C 6  alkylene; 
         each of R 8  and R 9 , independently, is H, C 1 -C 6  alkyl, or together with the N to which they are attached form a 5- or 6-membered ring optionally fused with one or more aromatic or non-aromatic rings; 
         R 10  is H; 
         n is 0, 1, 2, 3, 4, 5, 6, 7, or 8; and 
         y+z=1. 
       
     
     
         55 . The lubricant composition of  claim 54  wherein R 8  and R 9  together with the N to which they are attached form 
       
         
           
           
               
               
           
         
       
     
     
         56 . The lubricant composition of  claim 52  wherein R 8  and R 9  together with the N to which they are attached to, form a 5- or 6-membered ring, fused with an aromatic ring of having the following formula 
       
         
           
           
               
               
           
         
       
     
     
         57 . The lubricant composition of  claim 54 , wherein y=1 and R 5  is C 12 -C 30 . 
     
     
         58 . The lubricant composition of  claim 54  wherein the olefin copolymer dispersant is post-treated with boric acid and/or maleic anhydride. 
     
     
         59 . The lubricant composition of  claim 1 , wherein the base oil of lubricating viscosity is selected from a mineral oil, an animal oil, a vegetable oil, a synthetic oil, and mixtures thereof. 
     
     
         60 . The lubricant composition of  claim 59 , wherein the base oil of lubricating viscosity has less than about 25 ppm sulfur, a viscosity index greater than about 120, and a kinematic viscosity at 100° C. from about 2 to about 8 cSt. 
     
     
         61 . The lubricant composition of  claim 60  wherein the base oil of lubricating viscosity has less than about 25 ppm sulfur, a viscosity index greater than 120, and a kinematic viscosity at 100° C. of about 4 cSt. 
     
     
         62 . The lubricant composition of  claim 61  wherein the base oil of lubricating viscosity comprises C P  of greater than 55%, C A  of less than 1%, and C N  of greater than 30%; and a ratio of 1 ring naphthenes to 2-6 ring naphthenes of less than 1.5. 
     
     
         63 . The lubricant composition of  claim 1  wherein the olefin copolymer dispersant is a succinimide dispersant and wherein:
 the ethylene monomer moiety content is at least 49 mol % and less than 60 mol %, the one or more C 3  to C 10  alpha-olefins is propylene, and the olefin copolymer has Mn of at least 1300 g/mol; 
 the acylating agent is maleic anhydride and the nitrogen source is polyethylene polyamines having 5 or an average of 5 nitrogen atoms; and wherein 
 the one or more phosphorus-containing compound(s) is a zinc dithiophosphate delivering between 100 ppm and 1500 ppm phosphorus to the lubricant composition. 
 
     
     
         64 . The lubricant composition of  claim 63  wherein the zinc dithiophosphate wherein at least 40% of the alkyl chains thereon are derived from secondary alcohols. 
     
     
         65 . The lubricant composition of  claim 1  wherein the olefin copolymer dispersant is a succinimide dispersant and wherein:
 the ethylene monomer moiety content is at least 49 mol % and less than 60 mol %, the one or more C 3  to C 10  alpha-olefins is propylene, and the olefin copolymer has Mn of at least 1300 g/mol; 
 the acylating agent is maleic anhydride and the nitrogen source is a polyethylene polyamine having 5 or an average of 5 nitrogen atoms; and 
 the one or more phosphorus-containing compound(s) is independently selected from the group consisting of dialkyl dithiophosphate ester, amyl acid phosphate, diamyl acid phosphate, dibutyl hydrogen phosphonate, dimethyl octadecyl phosphonate, salts thereof, and mixtures thereof and delivers between 100 ppm and 1500 ppm phosphorus to the fluid.