Lubricant Compositions Containing Low Phosphorus and Low Sulphated Ash

Abstract

This invention relates to a lubricating oil composition having a phosphorus content of less than 800 ppm, such as less than or about 500 ppm, and a SASH content of less than 0.9%, such as less than or about 0.5%, comprising a dispersant mixture, the dispersant mixture comprising (1) 0.01-15 mass % based upon the total mass of the dispersant mixture, of an amide, imide, and/or ester functionalized partially or fully saturated polymer comprising C4-5 olefins having: i) an Mw/Mn of less than 2, ii) a Functionality Distribution (Fd) value of 3.5 or less, and iii) an Mn of 10,000 g/mol or more (GPC-PS) of the polymer prior to functionalization; and (2) 50-90 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl) succinimide(s), which is derived from a polyalkenyl-substituted succinic anhydride prepared using a chlorine-assisted alkylation process and a polyamine; and (3) 10-30 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl)succinimide(s), which is derived from a polyalkenyl succinic anhydride prepared using a halogen-free thermal alkylation process and a polyamine.

What is claimed is: 
     
         1 . An additive concentrate comprising a dispersant mixture, the dispersant mixture comprising
 (1) 0.01-15 mass % based upon the total mass of the dispersant mixture, of an amide, imide, and/or ester functionalized partially or fully saturated polymer comprising C 4-5  olefins having:
 i) an Mw/Mn of less than 2, 
 ii) a Functionality Distribution (Fd) value of 3.5 or less, and 
 iii) an Mn of 10,000 g/mol or more (GPC-PS) of the polymer prior to functionalization; and 
   (2) 50-90 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl) succinimide(s), which is derived from a polyalkenyl-substituted succinic anhydride prepared using a chlorine-assisted alkylation process and a polyamine (“chloro dispersant(s)”); and   (3) 10-30 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl)succinimide(s), which is derived from a polyalkenyl succinic anhydride prepared using a halogen-free thermal alkylation process and a polyamine (“thermal dispersant(s)”).   
     
     
         2 . The additive concentrate of  claim 1 , wherein the one or more thermal dispersant(s) is derived from a polyisobutylene succinic anhydride (“PIBSA”) and a polyamine (“PAM”), wherein the PIBSA is based upon a high terminal vinylidene content polyisobutylene (high reactive polyisobutylene, “HR-PIB”), and the PIBSA is based upon a polyisobutylene having a Mn of at least 1200 g/mol. 
     
     
         3 . The additive concentrate of  claim 1 , wherein the dispersant mixture comprises: 1) the functionalized polymer at 1 to 12 mass %, based upon the total mass of the dispersant mixture, 2) one or more chloro dispersant(s) at 55 to 85 mass %, based upon the total mass of the dispersant mixture, and 3) one or more thermal dispersant(s) at 12 to 25 mass %, based upon the total mass of the dispersant mixture. 
     
     
         4 . The additive concentrate of  claim 1 , wherein the dispersant mixture comprises the one or more chloro dispersant(s) and the one or more thermal dispersant(s) at a ratio of about 9:1 to about 3:2. 
     
     
         5 . The additive concentrate of  claim 1 , further comprising one or more antioxidant(s), wherein: 1) the one or more antioxidant(s) is at least one or more amine antioxidant(s), or 2) the one or more antioxidant(s) is a mixture of one or more amine antioxidant(s) and one or more phenol antioxidant(s), wherein the one or more amine antioxidant(s) and the one or more phenol antioxidant(s) are present at a ratio of about 5:2 to about 9:5. 
     
     
         6 . The additive concentrate of  claim 1 , wherein:
 (a) the dispersant mixture is present at 15 to 40 mass %, based upon the total mass of the additive concentrate; and   (b) one or more antioxidant(s) is optionally present at 5 to 25 mass %, based upon the total mass of the additive concentrate.   
     
     
         7 . The additive concentrate of  claim 1 , further comprising one or more additional additive(s) selected from the group consisting of detergents, friction modifiers, anti-foam agents, corrosion inhibitors/anti-rust agents, and anti-wear agents. 
     
     
         8 . The additive concentrate of  claim 1 , further comprising one or more triazole amine corrosion inhibitors. 
     
     
         9 . The additive concentrate of  claim 7 , wherein:
 i. one or more detergent(s) is present at 0.1-5 mass %, based upon the total mass of the additive concentrate, and   ii. optionally one or more friction modifier(s) is present at 0.01-1 mass %, based upon the total mass of the additive concentrate, and/or   iii. optionally, one or more anti-foam agent(s) is present at 0.001-0.5 mass %, based upon the total mass of the additive concentrate, and/or   iv. one or more corrosion inhibitor(s)/anti-rust agent(s) is present at 0.01-2 mass %, based upon the total mass of the additive concentrate, and/or   v. optionally, one or more anti-wear agent(s) is present at 0.1-5 mass %, based upon the total mass of the additive concentrate.   
     
     
         10 . A lubricating oil composition comprising or resulting from the admixing of:
 (A) at least 50 mass % of one or more base oil(s), based upon the total mass of the lubricating oil composition; and   (B) an additive concentrate comprising a dispersant mixture, the dispersant mixture comprising:   (1) 0.01-15 mass % based upon the total mass of the dispersant mixture, of an amide, imide, and/or ester functionalized partially or fully saturated polymer comprising C 4-5  olefins having:
 i) an Mw/Mn of less than 2, 
 ii) a Functionality Distribution (Fd) value of 3.5 or less, and 
 iv) an Mn of 10,000 g/mol or more (GPC-PS) of the polymer prior to functionalization; and 
   (2) 50-90 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl) succinimide(s), which is derived from a polyalkenyl-substituted succinic anhydride prepared using a chlorine-assisted alkylation process and a polyamine (“chloro dispersant(s)”); and   (3) 10-30 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl)succinimide(s), which is derived from a polyalkenyl succinic anhydride prepared using a halogen-free thermal alkylation process and a polyamine (“thermal dispersant(s)”).   
     
     
         11 . The lubricating oil composition of  claim 10 , wherein the one or more base oil(s) comprise one or more group III base oil(s) and optionally one or more group II base oil(s). 
     
     
         12 . The lubricating oil composition of  claim 10 , comprising 50-95 mass % of one or more base oil(s), based upon the total mass of the lubricating oil composition, comprising:
 (a) 25-65 mass % of one or more group III base oil(s) based upon the total mass of the lubricating oil composition; and   (b) 20-60 mass %, of one or more group II base oil(s) based upon the total mass of the lubricating oil composition.   
     
     
         13 . The lubricating oil composition of  claim 10 , comprising:
 (a) 1-12 mass % of dispersant mixture based upon the total mass of the lubricating oil composition;   (b) optionally, 0.1-10 mass % of one or more antioxidants(s) based upon the total mass of the lubricating oil composition;   (c) optionally, 0.01-3 mass % of one or more detergent(s) based upon the total mass of the lubricating oil composition;   (d) optionally, 0.001-0.2 mass % of one or more friction modifier(s) based upon the total mass of the lubricating oil composition;   (e) optionally, 0.001-0.1 mass % of one or more anti-foam agent(s) based upon the total mass of the lubricating oil composition;   (f) optionally, 0.001-1 mass % of one or more corrosion inhibitor(s)/anti-rust agent(s) based upon the total mass of the lubricating oil composition;   (g) optionally, 0.01-1.5 mass % of one or more anti-wear agent(s) based upon the total mass of the lubricating oil composition;   (h) optionally, 0.001-1 mass % of one or more pour point depressant(s) based upon the total mass of the lubricating oil composition, and/or   (i) optionally, 0.001-0.5 mass % of one or more viscosity modifier(s) based upon the total mass of the lubricating oil composition.   
     
     
         14 . The lubricating oil composition of  claim 10 , having a phosphorous content of less than 800 ppm, alternately less than 550 ppm, based upon the total mass of the lubricating oil composition, and/or having a sulfated ash (“SASH”) content of less than 0.9 mass %, alternately less than 0.5 mass %. 
     
     
         15 . The lubricating oil composition of  claim 10  wherein:
 1) the average piston cleanliness is at least 70% as determined by CEC L-118-21, and/or 
 2) wherein the average wear on gear train wheels is greater than 75% as determined by CEC L-118-21, and/or wherein 
 3) the average liner wear is less than 8 μm, as determined by CEC L-118-21, and/or 
 4) wherein the average turbocharger housing deposits are at least 30% as determined by CEC L-118-21, and/or 
 5) wherein the oxidation is less than 65 A/cm as determined by CEC L-118-21. 
 
     
     
         16 . A method of lubricating an internal combustion engine during operation of the engine comprising:
 (i) providing to a crankcase of the internal combustion engine the lubricating composition of  claim 10 ;   (ii) providing a fuel in the internal combustion engine; and   (iii) combusting the fuel in the internal combustion engine,   wherein the fuel is one or more of a hydrocarbon fuel, renewable fuel, hydrogen fuel, or any blend thereof.   
     
     
         17 . The method of  claim 16 , wherein the fuel comprises a hydrocarbon fuel and/or the engine is a diesel engine. 
     
     
         18 . A fuel composition comprising the lubricating composition of  claim 9  and one or more of hydrocarbon fuel hydrogen fuel, or any blend thereof. 
     
     
         19 . The fuel composition of  claim 18 , wherein the hydrocarbon fuel comprises a petroleum derived fuel and or a renewable fuel. 
     
     
         20 . A method of increasing the piston cleanliness of a lubricating oil composition,
 the method comprising including in the lubricating oil composition a dispersant mixture comprising:   1) 0.01-15 mass % based upon the total mass of the dispersant mixture, of an amide, imide, and/or ester functionalized partially or fully saturated polymer comprising C 4-5  olefins having:
 i) an Mw/Mn of less than 2, 
 ii) a Functionality Distribution (Fd) value of 3.5 or less, and 
 iii) an Mn of 10,000 g/mol or more (GPC-PS) of the polymer prior to functionalization; and 
   2) 50-90 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl) succinimide(s), which is derived from a polyalkenyl-substituted succinic anhydride prepared using a chlorine-assisted alkylation process and a polyamine (“chloro dispersant(s)”); and   3) 10-30 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl)succinimide(s), which is derived from a polyalkenyl succinic anhydride prepared using a halogen-free thermal alkylation process and a polyamine (“thermal dispersant(s)”),   
       wherein preferably the average piston cleanliness is increased to at least 70% as determined by CEC L-118-21. 
     
     
         21 . A method of improving the wear resistance of a lubricating oil composition,
 the method comprising including in the lubricating oil composition   1) a dispersant mixture comprising:
 i) 0.01-15 mass % based upon the total mass of the dispersant mixture, of an amide, imide, and/or ester functionalized partially or fully saturated polymer comprising C 4-5  olefins having: i) an Mw/Mn of less than 2, 
 ii) a Functionality Distribution (Fd) value of 3.5 or less, and 
 v) an Mn of 10,000 g/mol or more (GPC-PS) of the polymer prior to functionalization; and 
   2) 50-90 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl) succinimide(s), which is derived from a polyalkenyl-substituted succinic anhydride prepared using a chlorine-assisted alkylation process and a polyamine (“chloro dispersant(s)”); and   3) 10-30 mass % based upon the total mass of the dispersant mixture, of one or more poly(alkenyl)succinimide(s), which is derived from a polyalkenyl succinic anhydride prepared using a halogen-free thermal alkylation process and a polyamine (“thermal dispersant(s)”), wherein preferably the average wear on gear train wheels is at least 75% as determined by CEC L-118-21, and/or the average liner wear is less than 8 μm, as determined by CEC L-118-21.