CN115734998A - 基于油相容性聚酯的高粘度基础流体 - Google Patents
基于油相容性聚酯的高粘度基础流体 Download PDFInfo
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- CN115734998A CN115734998A CN202180046428.8A CN202180046428A CN115734998A CN 115734998 A CN115734998 A CN 115734998A CN 202180046428 A CN202180046428 A CN 202180046428A CN 115734998 A CN115734998 A CN 115734998A
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Abstract
本发明涉及聚酯,它们的制备方法和它们作为高粘度基础流体的用途。本发明进一步涉及包含这样的聚酯的润滑剂组合物,并涉及这样的组合物作为自动传动流体、手动传动流体、无级变速传动流体、齿轮油配制剂、工业齿轮油配制剂、轴流体配制剂、双离合传动流体、专用混合动力传动流体或作为液压油的用途。
Description
技术领域
本发明涉及聚酯,它们的制备方法和它们作为高粘度基础流体的用途。本发明进一步涉及包含这样的聚酯的润滑剂组合物,并涉及这样的组合物作为自动传动流体、手动传动流体、无级变速传动流体、差速齿轮油配制剂、工业齿轮油配制剂、轴流体配制剂、双离合传动流体、专用混合动力传动流体或作为液压油的用途。
背景技术
高粘度基础流体通常用于提升粘度指数(VI)和用于增稠具有很高的对剪切稳定性的要求的润滑剂配制剂。典型的应用是齿轮油,其由于在操作中高的机械应力和宽的温度范围而具有非常苛刻的要求。
高粘度基础流体已知具有30至1000cSt的100℃下运动粘度(KV100)。
工业齿轮箱预期在高热和重负荷的条件下运转;并且在环境中经常被灰尘、工艺碎屑和水污染。在没有充分保护的情况下,齿轮将会过早地磨损。这意味着必须更频繁地更换某些部件,必须更频繁地替换油,并且最糟糕的是,不得不会预见到有设备停工期。
目前的齿轮驱动设备被设计为在许多应用中运转,经常必须承受恶劣的环境。典型地,齿轮箱正在变得越来越小,并且由更轻的和更复杂的材料制成,然而它们必须比以往任何时候都更耐用。结果是,对齿轮油润滑剂提出了更大要求,并且必须更多地考虑使用高性能基础流体和添加剂。
这个市场中的典型产品是高粘度聚α烯烃(PAO)和茂金属催化的PAO(mPAO),其典型地以100℃下40至300cSt的粘度范围销售(Choudary等人,Lubricant Sciences(《润滑剂科学》),2012年,23-44)。基于高粘度PAO的配制剂已知在低温下具有最佳的性能,但它们的弱点是极性低。由于PAO基础油的非极性性质,分散抑制剂(DI)包和老化产品在所述油中溶解得不好,这导致各种问题。
较高的极性由以下物质提供:α-烯烃与马来酸酯的共聚物(US5,435,928)、α-烯烃与丙烯酸烷基酯的低聚物(US 3,968,148)或α-烯烃与甲基丙烯酸烷基酯的共聚物(US 5,691,284)。或者,可应用具有酯官能化单体的PAO(EP2970532)或聚乙烯基醚(US2013/0165360)。使用极性高粘度基础流体的巨大优点是:不必将极性低粘性流体(例如酯)用作DI包的增容剂。极性低粘性流体已知在涂料和密封剂的情况下会导致一些问题,而这对于高粘度流体而言不是太大问题。
酯流体通常被用作增容剂。已经有报道多种合适的二酯和多元醇酯(L.R.Rudnick,Synthetics,Mineral Oils,and Bio-Based Lubricants:Chemistry andTechnology(《合成物,矿物油和生物基润滑剂:化学和技术》),第2版,2013年,第51页及随后数页)。不幸的是,这些选项仅限于具有低分子量的酯,因为复杂的酯与在应用中使用的非极性基础油没有相容性。一个例外是由二聚体酸制成的聚酯,但由于所述二聚体酸的制备过程导致的环状结构,这些聚酯在润滑剂中提供低的性能(WO 01/46350)。
聚酯可由二酸和二醇制成。使用二聚体酸背后的构思是经由具有较大非极性的二酸引入油相容性。另一种可选方案是使用通过将α烯烃环氧化制备的二醇。这样的环氧化物可用于制备具有油相容性的聚亚烷基二醇(L.R.Rudnick,Synthetics,Mineral Oils,andBio-Based Lubricants:Chemistry and Technology,第2版,2013年,第123页及随后数页;EP 3315591)。所述二醇和二酸单元的碳数受到限制,因为长的直链碳链在聚合物中诱导结晶性,这会阻碍将所得聚酯作为润滑剂的应用。
进一步已经发现,由α-烯烃制成的环氧化物要么提供在基础油中低的溶解度,要么显示出过高的结晶度以至于不能被用作高粘度基础流体。
为了克服这个问题,现在已经令人惊奇地发现由内烯烃制备的环氧化物可用于制备令人惊奇地显示出低聚合物结晶性和良好油相容性的聚酯。
与由衍生自α-烯烃的环氧化物制成的聚酯相比,这种强的效果可归因于较短的侧链和大大增加的支化度的结合。
发明内容
发明详述
本发明的第一个目的涉及由衍生自内烯烃的内环氧化物,或由衍生自包含10-24个碳原子的内环氧化物的二醇,和包含5至13个碳原子的二羧酸制备的聚酯。
在所述聚酯中的碳与氧的摩尔比优选在4:1至12:1范围内,更优选在5:1至9:1范围内,和甚至更优选在6:1至7.5:1范围内。
根据本发明的聚酯的数均分子量Mn优选在1,000至15,000g/mol,优选2,000至10,000g/mol范围内。
优选地,根据本发明的聚酯具有在1.5至6范围内,优选在1.8至5范围内,更优选在2至4范围内的多分散指数(PDI)Mw/Mn。
Mw和Mn是通过尺寸排阻色谱法(SEC)使用可商购的聚甲基丙烯酸甲酯标准物测定的。所述测定是通过凝胶渗透色谱法采用THF作为洗脱剂进行的。
术语“内环氧化物”意思是指由内烯烃制备的环氧化物。
术语“内烯烃”意思是指含有内部不饱和双键的烯烃。内烯烃可由它们相应的α-烯烃通过异构化过程制备。已知几种催化剂用于将α-烯烃异构化成内烯烃。活性催化剂可达到热力学异构化极限,从而得到具有平衡分布的双键异构体的内烯烃。
内烯烃可由它们相应的α-烯烃通过异构化过程制备,并且是可商购获得的。
已知多种催化剂用于在烯烃类化合物的双键异构化中使用。
这些主要是沸石和分子筛以及树脂型酸性体系(US 5,849,974)。然而,这些催化剂中有许多会产生大量的聚合物和/或骨架异构化产物;即支化的烯烃或二聚体或低聚物。对于一些应用而言,希望将支化产物限制在尽可能少的量。因此,对于一些应用而言,希望使用的催化剂对双键异构化有选择性而不会使骨架结构异构化或形成二聚体或更高级低聚物。二聚体和更高级低聚物的形成是酸性催化剂体系的副反应。为了避免这些副反应,使用碱性催化剂或掺杂有碱金属或碱土金属的催化剂。
根据本发明使用的烯烃原料选自包含10至24个碳原子,优选12至20个碳原子,和最优选14至18个碳原子的α-烯烃。本发明不限于包含单一组分的原料;也可以使用也具有不同链长的多于一种的组分的混合物。
在另一个实施方案中,用作起始材料的烯烃原料是包含至少90重量%的单烯烃类直链α-烯烃的α-烯烃混合物。
在本发明中可用于环氧化的内烯烃包含不超过30摩尔%,优选不超过20摩尔%,优选不超过10摩尔%的位于α-位的双键,以避免所得聚酯的侧链结晶。
可在本发明中使用的二羧酸为饱和的直链脂族二羧酸,其选自胶酸(戊二酸)、2,2-二甲基胶酸(2,2-二甲基戊二酸)、肥酸(己二酸)、2,4,4-三甲基肥酸(2,4,4-三甲基己二酸)、蒲桃酸(庚二酸)、软木酸(辛二酸)、杜鹃花酸(壬二酸)、皮脂酸(癸二酸)、十一烷二酸、十二烷二酸、巴西基酸(十三烷二酸)和它们的混合物;优选的是杜鹃花酸(壬二酸)、皮脂酸(癸二酸)、十二烷二酸和它们的混合物。
用于制造二羧酸的主要工业方法是环状化合物的开环氧化。它们通常以工业规模制造,并且因此是可商购获得的。
在根据本发明的聚酯中,优选30%或更少,更优选20%或更少,更优选10%或更少的末端官能团是COOH-官能团。
根据本发明的聚酯的特征在于熔点为等于或低于-15℃,优选等于或低于-25℃;更优选地,它们不具有任何熔点。如果所述熔点更高,则所述聚酯不能被用作基础油。
本发明的聚酯的进一步的特征还在于玻璃化转变温度为等于或低于-50℃。
作为100℃下运动粘度测量的所述聚酯的本体粘度在40至2000cSt范围内,优选在100至1000cSt,更优选200至500cSt范围内。
本发明的第二个目的涉及如之前在本文中描述的聚酯作为在润滑剂配制剂中,尤其在齿轮油配制剂中的基础油的用途。
本发明的另一个目的涉及润滑齿轮的方法,该方法包括以下步骤:
(i)通过将如上文进一步描述的至少一种聚酯用作基础油来制备配制剂;
(ii)任选将所述聚酯与另一种基础油合并,所述另一种基础油选自API第II组油、API第III组油、API第IV组油和它们的混合物;和
(iii)将在(ii)中制备的配制剂应用于工业齿轮。
本发明的第三个目的涉及润滑组合物,其包含:
(A)20至60重量%的至少一种聚酯,该聚酯是由衍生自包含10至24个碳原子,优选12至20个碳原子,更优选14至18个碳原子的内烯烃的内环氧化物,或由衍生自该内环氧化物的二醇,和包含5至13个碳原子的二酸制备的;
(B)40至80重量%的基础油,该基础油选自API第II组油、API第III组油、API第IV组油和它们的混合物;和
(C)0至5重量%的一种或多种添加剂。
每种组分(A)、(B)和(C)的含量均基于所述基础油组合物的总重量计。在一个具体的实施方案中,组分(A)、(B)和(C)的比例总计达100重量%。
可使用的聚酯是如上文进一步描述的。
可在所述润滑组合物中使用的基础油包含具有润滑粘度的油。这样的油包括天然和合成的油,衍生自加氢裂化、加氢和加氢整理的油,未精制的、精制的、再精制的油或它们的混合物。
所述基础油还可以如由美国石油协会(API)规定的那样定义(参见“附件E—客车机油和柴油发动机油的API基础油可互换性指南(Appenix E-API Base OilInterchangeability Guidelines for Passenger Car Motor Oils and Diesel EngineOils)”的2008年4月版,第1.3节子标题1.3.“基料类别(Base Stock Categories)”)。
API目前定义了五组润滑剂基料(API 1509,附件E—客车机油和柴油发动机油的API基础油可互换性指南,2011年9月)。第I、II和III组是矿物油,它们由它们含有的饱和物和硫的量和由它们的粘度指数分类;第IV组是聚α烯烃;和第V组是所有其它物质,包括例如酯油。下表示例性说明了这些API分类。
合适的用于制备根据本发明的润滑组合物的非极性基础油的100℃下运动粘度(KV100)优选在5mm2/s至15mm2/s范围内,更优选在6mm2/s至113mm2/s范围内,和甚至更优选在8mm2/s至12mm2/s范围内,其是根据ASTM D445测定的。
本发明的特别优选的润滑剂包含至少一种选自API第II组油、API第III组油、聚α烯烃(PAO)和它们的混合物的基础油。
根据本发明可用的其它基础油是第II-III组的费-托(Fischer-Tropsch)衍生的基础油。
费-托衍生的基础油是本领域中已知的。术语“费-托衍生的”意思是基础油是或衍生自费-托工艺的合成产物。费-托衍生的基础油也可以被称为GTL(天然气合成油)基础油。可方便地用作本发明的润滑组合物中的基础油的合适的费-托衍生的基础油是例如公开在以下文献中的那些:EP 0 776 959、EP 0 668 342、WO 97/21788、WO 00/15736、WO 00/14188、WO 00/14187、WO 00/14183、WO 00/14179、WO00/08115、WO 99/41332、EP 1 029029、WO 01/18156、WO 01/57166和WO 2013/189951。
尤其对于齿轮油配制剂,使用的是API第II、III、IV组的基础油或它们的混合物。
根据本发明的润滑组合物可还含有作为组分(C)的另外的添加剂,其选自倾点降低剂、分散剂、消泡剂、清净剂、破乳剂、抗氧化剂、抗磨添加剂、极压添加剂、摩擦改进剂、防腐蚀添加剂、染料和它们的混合物。
优选的倾点降低剂例如选自烷基化的萘和酚类聚合物、聚甲基丙烯酸烷基酯、马来酸酯共聚物酯和富马酸酯共聚物酯,其可方便地被用作有效的倾点降低剂。所述润滑油组合物可含有0.1重量%至0.5重量%的倾点降低剂。优选地,使用不超过0.3重量%的倾点降低剂。
合适的分散剂包括聚(异丁烯)衍生物,例如聚(异丁烯)琥珀酰亚胺(PIBSI),包括硼化(borated)的PIBSI;和具有N/O官能团的乙烯-丙烯低聚物。
合适的消泡剂包括例如有机硅油、氟有机硅油和氟烷基醚。
优选的清净剂包括含有金属的化合物,例如酚盐;水杨酸盐;硫代膦酸盐,尤其是硫代焦膦酸盐、硫代膦酸盐和膦酸盐;磺酸盐和碳酸盐。这些化合物可尤其含有钙、镁和钡作为金属。这些化合物可优选以中性或高碱性形式使用。
优选的破乳剂包括环氧烷共聚物和(甲基)丙烯酸酯,其包含极性官能团。
合适的抗氧化剂包括例如酚类,例如2,6-二叔丁基苯酚(2,6-DTB)、丁基化的羟基甲苯(BHT)、2,6-二叔丁基-4-甲基苯酚、4,4'-亚甲基双(2,6-二叔丁基苯酚);芳族胺,尤其是烷基化的二苯胺,N-苯基-1-萘胺(PNA),聚合的2,2,4-三甲基二氢醌(TMQ);含有硫和磷的化合物,例如金属二硫代磷酸盐,例如二硫代磷酸锌(ZnDTP),“OOS三酯”=二硫代磷酸与来自以下物质的活化双键的反应产物:烯烃,环戊二烯,降冰片二烯,α-蒎烯,聚丁烯,丙烯酸酯,马来酸酯(当燃烧时无灰);有机硫化合物,例如二烷基硫醚,二芳基硫醚,聚硫醚,改性硫醇,噻吩衍生物,黄原酸酯(盐)(xanthate),硫代甘醇,硫代醛,含硫羧酸;杂环硫/氮化合物,尤其是二烷基二巯基噻二唑,2-巯基苯并咪唑;双(二烷基二硫代氨基甲酸)锌和亚甲基双(二烷基二硫代氨基甲酸酯);有机磷化合物,例如亚磷酸三芳基酯和三烷基酯;有机铜化合物和高碱性的钙基和镁基酚盐和水杨酸盐。
优选的抗磨和极压添加剂包括磷化合物,例如磷酸三烷基酯,磷酸三芳基酯,例如磷酸三甲苯基酯,胺中和的磷酸单和二烷基酯,乙氧基化的磷酸单和二烷基酯,亚磷酸酯,膦酸酯,膦;具有硫和磷的化合物,例如金属二硫代磷酸盐,例如二C3-12-烷基二硫代磷酸锌(ZnDTP),二烷基二硫代磷酸铵,二烷基二硫代磷酸锑,二烷基二硫代磷酸钼,二烷基二硫代磷酸铅,“OOS三酯”=二硫代磷酸与来自以下物质的活化双键的反应产物:烯烃,环戊二烯,降冰片二烯,α-蒎烯,聚丁烯,丙烯酸酯,马来酸酯,硫代磷酸三苯酯(TPPT);具有硫和氮的化合物,例如双(戊基二硫代氨基甲酸)锌或亚甲基双(二正丁基二硫代氨基甲酸酯);具有元素硫的硫化合物和H2S硫化的烃(二异丁烯,萜烯);硫化的甘油酯和脂肪酸酯;高碱性磺酸酯(盐);氯化合物或诸如石墨或二硫化钼的固体。
所用的摩擦改进剂可以包括机械活性化合物,例如二硫化钼、石墨(包括氟化石墨)、聚(三氟乙烯)、聚酰胺、聚酰亚胺;形成吸附层的化合物,例如长链羧酸、脂肪酸酯、醚、醇、胺、酰胺、酰亚胺;通过摩擦化学反应形成层的化合物,例如饱和脂肪酸、磷酸和硫代磷酸酯,黄原酸酯(盐)(xanthogenate)、硫化脂肪酸;形成聚合物状层的化合物,例如乙氧基化二羧酸偏酯、苯二甲酸二烷基酯、甲基丙烯酸酯、不饱和脂肪酸、硫化烯烃或有机金属化合物,例如钼化合物(二硫代磷酸钼和二硫代氨基甲酸钼MoDTC)和其与ZnDTP的组合,含铜的有机化合物。
上文列举的化合物中的一些可满足多种功能。例如,ZnDTP主要是抗磨添加剂和极压添加剂,但是也具有抗氧化剂和腐蚀抑制剂的特征(在此:金属钝化剂/减活剂)。
上文详述的添加剂尤其详细描述在T.Mang,W.Dresel(编者):“Lubricants andLubrication(《润滑剂和润滑》)”,Wiley-VCH,Weinheim 2001;R.M.Mortier,S.T.Orszulik(编者):“Chemistry and Technology of Lubricants(《润滑剂化学和技术》)”中。
分散剂(包括硼化的分散剂)优选以0重量%至2重量%的浓度使用,消泡剂以10至2500ppm的浓度使用,清净剂以0.05重量%至1重量%的浓度使用,破乳剂以0重量%至0.1重量%的浓度使用,抗氧化剂以0.5重量%至1.5重量%的浓度使用,抗磨和极压添加剂各自以0.1重量%至1重量%的浓度使用,摩擦改进剂以0.05重量%至2重量%的浓度使用,抗腐蚀添加剂以0.05至0.5重量%的浓度使用,和染料以0.01重量%至1重量%的浓度使用。所述浓度在每种情况下均基于所述润滑油组合物的总重量计。
优选地,在润滑油组合物中的一种或多种添加剂(C)的总浓度为基于所述润滑油组合物的总重量计的最高至5重量%,更优选0.1重量%至4重量%,更优选0.5重量%至3重量%。
本发明的另一个目的涉及制备根据本发明的聚酯的方法,该方法包括以下步骤:
(a)将包含10至24个碳原子,优选12至20个碳原子,更优选14至18个碳原子的α-烯烃异构化成内烯烃;
(b)将在步骤(a)中获得的内烯烃环氧化;
(c1)使在步骤(b)中获得的内环氧化物与包含5至13个碳原子的二羧酸反应,或
(c2)将在步骤(b)中获得的内环氧化物转变为相应的二醇,并使该二醇与包含5至13个碳原子的二羧酸反应;和
(d)分离所需的聚酯。
具体实施方式
本发明已通过以下非限制性实施例进一步示例性说明。
实验部分
缩写
ADI 己二酸
AN 酸值
AZE 壬二酸
BV40 40℃下本体粘度
CP 浊点
DDS 十二烷二酸
KV 根据ASTM D445测量的运动粘度
KV40 根据ASTM D445在40℃下测量的运动粘度
KV100 根据ASTM D445在100℃下测量的运动粘度
Mn 数均分子量
Mw 重均分子量
NS3 得自Nynas的环烷烃基础油,具有3cSt的KV40
OHN 羟基值
PDI 多分散指数
PP 倾点
SEB 癸二酸
TMAS 2,4,4-三甲基己二酸
VI 粘度指数
测试方法
关于根据本发明的聚酯和对比例的聚酯的分子量、PDI、100℃下本体粘度(BV100)、倾点(PP)、熔点Tm、玻璃化转变温度Tg、OH值和酸值对它们进行表征。
分子量是通过尺寸排阻色谱法(SEC)使用可商购聚甲基丙烯酸甲酯(PMMA)标准物测定的。所述测定是通过根据DIN 55672-1的凝胶渗透色谱法(GPC)采用THF作为洗脱剂进行的(流速:1mL/分钟;注射体积:100μl)。
根据ASTM D445测定本体粘度BV100。
根据ASTM D97测定倾点。
根据DSC方法DIN 11357-1通过差示扫描量热法(DSC)测定本发明中使用的聚酯的热性能(Tg和Tm)。
根据DIN 53240-2,以mg KOH/g聚合物为单位滴定测定所述聚酯的OH值。
根据DIN EN ISO 2114通过滴定法测定所述聚酯的酸值。将值报告为mg(KOH)/g(样品)。
将包括根据本发明的聚酯和对比例的聚酯的润滑组合物关于根据ASTM D445的40℃下运动粘度(KV40)和100℃下运动粘度(KV100),它们的根据ASTM D2270的粘度指数(VI),它们的根据ASTM D97的倾点和它们的根据ASTM D5773的浊点进行表征。
硅-铝混合氧化物的制备
将由45kg/h的CH3SiCl3和15kg/h的SiCl4组成的混合物的蒸气和0.6kg/h的氯化铝的蒸气借助于作为载气的氮气彼此分开地引入到混合室中。在燃烧器的混合室中将所述蒸气与14.6标准立方米/小时的氢气和129标准立方米/小时的经干燥空气混合,经由中心管(在所述中心管末端将反应混合物点燃)进料到水冷却的火焰管中并在那里燃烧。随后将形成的粉末沉积在过滤器中,并用400至700℃下的水蒸气处理。所述粉末含有99重量%的二氧化硅和1重量%的氧化铝。BET表面积为173m2/g。DBP值为326g/100g混合氧化物。
为了测定在具有约5nm厚度的表面层中的初级粒子的重量比率(Al2O3/SiO2)表面,采用XPS分析。这导致重量比率(Al2O3/SiO2)表面为0.0042。在总初级粒子中的重量比率(Al2O3/SiO2)总的测定是通过在粉末上进行的X-射线荧光分析实施的。其显示出重量比率(Al2O3/SiO2)总为0.010。这导致(Al2O3/SiO2)总/(Al2O3/SiO2)表面的值为2.4。
C14内烯烃的合成
以连续操作模式实施的α-十四碳烯(可商购自Shell或Chevron)的异构化反应在以下装置中进行,所述装置由进料容器,HPLC-泵,预热区,位于加热炉中的两个相继的管式固定床反应器,和产物容器组成。所述装置填充有6g新鲜的硅-铝混合氧化物作为催化剂。进料由α-十四碳烯组成,并将其经由所述HPLC泵首先泵送穿过所述预热区,在所述预热区进料液体被加热到反应温度,并然后从底部到顶部穿过第一个管式固定床反应器,和随后穿过第二个管式固定床反应器。这确保了所述反应器被液体完全充满。在所述反应区之后将反应混合物冷却到环境温度,并将其贮存在产物罐中。进料罐以及产物罐都用氮气吹扫。
反应条件:
WHSV值=3.0至3.9h-1
反应温度=160℃至180℃
压力=大气压
含钨催化剂溶液的制备
将2667g蒸馏水、133g H2O2(30重量%水溶液)、101g钨酸钠和160g磷酸(85重量%水溶液)混合并储存过夜。
C14内环氧化物的合成
将5010g C14-内烯烃和66.9g四烷基甲硫酸铵(55%水溶液)装入到配备有机械搅拌器的反应器中。随后将1500g所述含钨催化剂溶液泵入到所述反应器中并将所得反应混合物加热到80℃。在达到所需温度后,将四份1104g过氧化氢(22重量%水溶液)各自在20分钟内加料到所述反应容器中,每次加料随后是10分钟的计量加料暂停。将所得反应混合物在80℃以下进一步搅拌另外240分钟。随后,停止加热和搅拌并将反应混合物储存过夜以进行相分离。
C15-18内环氧化物的合成
将5667g包含C15-18个碳原子的内烯烃混合物和76g四烷基甲硫酸铵(55%水溶液)装入到配备有机械搅拌器的反应器中。随后将1275g所述含钨催化剂溶液泵入到所述反应器中并将所得反应混合物加热到80℃。在达到所需温度后,将四份1251g过氧化氢(22重量%水溶液)各自在20分钟内加料到所述反应容器中,每次加料随后是10分钟的计量加料暂停。将所得反应混合物在80℃以下进一步搅拌另外240分钟。随后,停止加热和搅拌并将反应混合物储存过夜以进行相分离。
通过经中性Al2O3过滤分离和纯化有机相。
聚酯的合成
在氮气鼓泡下,向配备有回流冷凝器、机械搅拌器、氮气入口和温度计的圆底烧瓶中装入环氧化物、酸和催化剂。随后,将反应混合物在“时间1”内加热到225℃。在另外的“时间2”之后,达到所需的酸值,并将反应停止。
用于制备实施例和对比例的环氧化物、酸和催化剂的量在下表1中示出。作为催化剂,总是使用2-乙基己酸锡(II)(可商购自TIB Chemicals AG)。
表1:用于制备实施例和对比例的反应混合物的组合物。
*)对比例
C10至C16α-烯烃和环氧化物购自Tokyo Chemical Industry。按照上文进一步给出的方案制备C14内环氧化物。
所得聚酯的反应时间和酸值在下表2中示出。
表2:所得聚酯的反应时间、羟基值(OHN)、酸值(AN)和C/O-比率。
*)对比例
**)在添加0.82g乙基己醇和额外7小时反应时间后
n.d.不可检测
表2说明了在整个25小时(实施例13)至49小时(实施例7)的反应时间后实施例的酸值在1.0(实施例12和13)至2.6(实施例8)mg KOH/g范围内。
在没有如实施例3那样进行的特殊封端的情况下,聚酯的端基可以是OH-或COOH-官能团。为了油相容性和润滑剂耐久性,不超过30%的末端官能团应当是COOH-官能团。
通过将存在于所述二醇和存在于所述二酸单体中的碳原子数相加并将所得数值除以四(4=在所得二酯单元中的氧原子数)来计算所述C/O比率。在这种简化的计算方法中忽略了端基的影响。对于单体混合物,使用平均碳量。所述实施例的所得比率在5.5(实施例6)至6.3(实施例8)之间。
所述C/O比率是所述聚合物的极性的简单量度。
根据本发明制备的聚酯的特性在下表3中示出。
表3:根据本发明制备的聚酯的特性。
*)对比例
**)未测量,因为粘度太高
根据本发明的聚酯的数均分子量在2,500g/mol至9,400g/mol范围内。它们显示出低于-28℃的熔融温度和远低于-50℃的玻璃化转变温度。
为了证实根据本发明的聚酯在基础油中的性能,制备含有不同量的所述聚酯的润滑组合物。
在下表4中呈现了诸如KV40、KV100和VI的典型性能参数的结果。
表4a:聚酯在环烷烃API第V组基础油中的特性。
*)对比例
n.d.=未明确
表4b:聚酯在API第I组基础油中的特性。
*)对比例
表4c:聚酯在API第III组基础油中的特性。
表4d:聚酯在API第III组基础油中的特性。
*)对比例
结论:
给出的实施例都是具有相当大非极性的聚酯(与可商购获得的聚酯相比),并且与环烷烃基础油具有相容性,已知所述环烷烃基础油与其它基础油相比具有良好的溶解力。对于作为齿轮油用增稠剂的广泛应用,需要与API第I-III组基础油具有相容性。
这种油相容性的主要参数是极性。所述C/O比率是显示不同聚酯的极性的一种非常简单的方式。如可从表4中看出的,具有低于5.5的C/O比率的实施例未显示出所需的溶解性。并且甚至在约5.5的C/O比率附近,也只有如作为本发明核心的含有特殊二醇单元的链端改性的实施例3和实施例6的特殊聚合物才显示出与API第I组基础油具有一定相容性。这里的一个例外是实施例17,它基于较长的C15-18环氧化物。尽管C/O比率低,但这些长侧链甚至能够使与己二酸形成的共聚物溶解在第III组基础油中。
如针对实施例6所示的,由衍生自内烯烃的单体单元引入的支链数也对聚酯在室温下的溶解度以及分子量有一些影响。较低分子量的聚酯与具有较高分子量的聚合物相比(例如实施例12与实施例16相比)显示出更好的油相容性。
所述聚酯的分子量对于调节溶解度来说不是很有帮助的手段,因为分子量是关于聚合物增稠剂性能的主要因素。分子量的调整平衡了增稠能力和剪切稳定性,这是增稠剂最基本的性能,并且所需的剪切稳定性水平基本上由应用来限定。对于齿轮油,已知剪切稳定性水平是非常严格的。这意味着重均分子量高于35,000g/mol的聚合物不适用于要求苛刻的应用。
此外,当仅考虑高于室温的粘度测量数据时,衍生自内烯烃的特殊二醇的效果并不大。然而,齿轮箱也在较低温度下操作,因此齿轮油还必须满足苛刻的低温要求。浊点测量表明在较低温度下发生相分离。纯Nexbase 3020样品的浊点测得为-37℃,这指示油的蜡质组分开始结晶的点。由于过程的速度,倾点测量并不总是对这种结晶敏感(由于PPD效应,它甚至可能是有益的),但齿轮油规格包括Brookfield(布氏)方法,在该方法中将油样品在低温下储存较长的时间。在这些测量中,也会检测到缓慢的结晶过程并且它们具有巨大的负面影响。
具有充分非极性且在Nexbase 3020中显示出良好溶解性的对比例9至11具有高于-20℃的浊点,这指示所述聚酯发生相分离。这得到了DSC测量的支持,所述DSC测量显示出这些聚酯的熔点高于-5℃。根据本发明的实施例不具有高于-15℃的熔点并且显示出与纯油类似的浊点,这表明在所需温度范围内具有优异的相容性。
在实施例14与实施例13的比较中可以看出限度。对于这些实施例,将C16末端环氧化物与C14内环氧化物混合。使用20摩尔%的末端环氧化物(实施例14),没有观察到对浊点的负面影响,而在30摩尔%的末端环氧化物(实施例13)的情况下,通过DSC测定到在-10℃附近的第二结晶峰,并且浊点增加。
关于低温性能的特殊行为也由实施例17显示出。尽管具有在-18℃下的相对高的熔点,但在Nexbase 3020中的溶液当下降到低于-40℃的温度的情况下仍保持澄清和液态,这表明这种样品具有出色的相容性。
Claims (14)
1.由衍生自包含10至24个碳原子的内烯烃的内环氧化物,或由衍生自该内环氧化物的二醇,和包含5至13个碳原子的饱和的直链脂族二羧酸获得的聚酯。
2.根据权利要求1所述的聚酯,其中所述内烯烃包含不超过30摩尔%,优选不超过20摩尔%的位于α-位的双键。
3.根据权利要求1或2所述的聚酯,其中所述内烯烃包含12至20个碳原子,优选14至18个碳原子。
4.根据权利要求1至3中任一项所述的聚酯,其中,所述二羧酸为饱和的直链脂族二羧酸,其选自胶酸(戊二酸)、2,2-二甲基胶酸(2,2-二甲基戊二酸)、肥酸(己二酸)、2,4,4-三甲基肥酸(2,4,4-三甲基己二酸)、蒲桃酸(庚二酸)、软木酸(辛二酸)、杜鹃花酸(壬二酸)、皮脂酸(癸二酸)、十一烷二酸、十二烷二酸、巴西基酸(十三烷二酸)和它们的混合物;优选的是杜鹃花酸(壬二酸)、皮脂酸(癸二酸)、十二烷二酸和它们的混合物。
5.根据权利要求1至4中任一项所述的聚酯,其中所述聚酯的特征在于熔点为等于或低于-15℃,优选等于或低于-25℃;更优选它们不具有任何熔点。
6.根据权利要求1至5中任一项所述的聚酯,其中所述聚酯的特征在于玻璃化转变温度为等于或低于-50℃。
7.根据权利要求1至6中任一项所述的聚酯,其中所述聚酯具有在1,000至15,000g/mol范围内的数均分子量Mn,所述数均分子量是通过尺寸排阻色谱法(SEC)使用聚甲基丙烯酸甲酯标准物测定的。
8.根据权利要求1至7中任一项所述的聚酯,其特征在于KV100在40至2000cSt范围内,优选在100至1000cSt范围内。
9.根据权利要求1至8中任一项所述的聚酯,其中碳与氧的摩尔比在4:1至12:1范围内,所述碳与氧的摩尔比是通过将存在于所述二醇中和存在于所述二酸单体中的碳原子数相加和将所得的数值除以作为在所得二酯单元中的氧原子的数目的4而计算出的。
10.根据权利要求1至9中任一项所述的聚酯作为在润滑剂配制剂中的基础油的用途,尤其是作为在齿轮油配制剂中的基础油的用途。
11.润滑组合物,其包含基于该润滑组合物的总重量计:
(A)20至60重量%的至少一种聚酯,该聚酯是由衍生自包含10至24个碳原子的内烯烃的内环氧化物,或由衍生自该内环氧化物的二醇,和包含5至13个碳原子的饱和的直链脂族二酸制备的;
(B)40至80重量%的基础油,该基础油选自API第II组油、API第III组油、API第IV组油和它们的混合物;和
(C)0至5重量%的一种或多种添加剂。
12.根据权利要求11所述的润滑组合物,其中组分(A)的内烯烃包含12至20个碳原子,优选14至18个碳原子。
13.根据权利要求11或12所述的润滑组合物,其特征在于所述一种或多种其它添加剂(C)选自倾点降低剂、分散剂、消泡剂、清净剂、破乳剂、抗氧化剂、抗磨添加剂、极压添加剂、摩擦改进剂、防腐蚀添加剂、染料和它们的混合物。
14.制备根据权利要求1至9中任一项所述的聚酯的方法,该方法包括以下步骤:
(a)将包含10至24个碳原子,优选12至20个碳原子,更优选14至18个碳原子的α-烯烃异构化成内烯烃;
(b)将在步骤(a)中获得的内烯烃环氧化;
(c1)使在步骤(b)中获得的内环氧化物与包含5至13个碳原子的饱和的直链脂族二羧酸反应,或
(c2)将在步骤(b)中获得的内环氧化物转变为相应的二醇,并使该二醇与包含5至13个碳原子的二羧酸反应;和
(d)分离所需的聚酯。
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WO2022003087A1 (en) | 2022-01-06 |
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