Reinforced metal working fluid

Abstract

The invention provides a bio-emulsifier for preparing a metal working fluid, a method for preparing the metal working fluid and a reinforced metal working fluid.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 315,747, filed on March 2, 2022, the contents of which are incorporated herein by reference in their entirety. Background Art

[0003] During metalworking, metals are formed into objects of varying sizes, from screws to beams, by forging, rolling, stamping, curing, forming or grinding. Metalworking fluids (MWFs) are used to reduce heat and friction and remove metal particles in industrial machining and grinding operations. MWFs can be oil-based or water-based fluids that include, for example, a mixture of oils, emulsifiers, detergents, anti-weld agents, corrosion inhibitors, extreme pressure additives, buffers, biocides and other additives. For each manufacturing job, a metalworking fluid must be selected to meet the needs of the specific application.

[0004] The main types of MWFs include firstly straight run oils, i.e. undiluted mineral, animal, marine, vegetable or synthetic oils. The second type is soluble oils, which contain about 30% to 85% of refined oil and an emulsifier for dispersing the oil in water. Other types include semi-synthetic fluids, which contain a portion of refined petroleum, about 30% to 50% of water and a variety of other additives, and synthetic fluids, which do not contain oil but use water-soluble materials such as detergent components and other additives for cooling and lubrication.

[0005] In some embodiments, the emulsifier is a kind of key additive.For soluble oil, form oil / water (O / W) emulsion, this emulsion utilizes the lubricity of oil and the cooling property of water to provide the desired MWF function.The stability of O / W emulsion is the key to the success of formulation.Therefore, emulsifier is a kind of key additive.Usually, emulsifier promotes the formation of emulsion and the stabilization of surfactant by the interfacial tension between the water phase and the oil phase of reducing fluid.The chemical structure of emulsifier preferably makes it contain the functional group compatible with the water phase and the oil phase of MWF.The emulsifier used at present comprises such as triethanolamine, sodium petroleum sulfonate, alkoxylated phosphoric acid ester, alkyl aryl ethoxylate, alcohol alkoxylate, fatty acid ethoxylate, ether carboxylate and amine ethoxylate etc.

[0006] During use, MWFs are mixed with metal particles, particulate matter, microorganisms, and other contaminants. Workers engaged in mechanical finishing, machining, and other metalworking and metal forming operations may be exposed to MWFs and contaminants mixed in MWFs through inhalation of aerosols produced during the process, or through skin contact when handling parts, tools, and equipment covered with fluids. This can result in long-term exposure that may induce pathological lung disease and skin irritation associated with certain types of cancer. In particular, ethoxylates contain 1,4-dioxane as an impurity, which is a suspected carcinogen.

[0007] Although protective gear such as masks, gloves, aprons, and special clothing are important safety precautions, and measures such as training workers and modifying machinery to prevent overexposure to MWFs are taken, improvements in ingredients and formulations are needed to reduce the adverse effects of these fluids on workers and the environment. Summary of the invention

[0008] The present invention relates to improved metalworking fluids (MWFs) including oil-in-water or water-in-oil emulsions. More specifically, the present invention provides novel emulsifiers for formulating stable MWF emulsions, and MWF formulations including the emulsifiers. Preferably, the emulsifier is a biosurfactant or a derivative thereof, which can be used to replace ethoxylated surfactant emulsifiers and the like in MWF applications. Advantageously, in some embodiments, the bioemulsifier can be up to 100% bio-based and biodegradable, can have low toxicity, and / or can perform at levels that meet or exceed those of traditional emulsifiers and surfactants.

[0009] In preferred embodiments, the present invention provides a microbially derived surfactant having multiple uses in metal processing. In some embodiments, the surfactant is used as an emulsifier, dispersant, detergent, defoamer and / or biocide component in MWF formulations. In certain preferred embodiments, the biosurfactant is used as an emulsifier for MWFs including O / W emulsions and / or W / O emulsions.

[0010] Advantageously, in certain embodiments, the bioemulsifier promotes the formation of MWF emulsions by dispersing water-soluble oils in aqueous fluids; improving the stability of the emulsion; and / or preventing demulsification and / or sedimentation of the oil and water phases, all without adversely affecting the function of the MWF.

[0011] In preferred embodiments, the bioemulsifier is a biosurfactant or biopolymer comprising, for example, glycolipids, lipopeptides, flavin lipids, phospholipids, fatty acid esters, high molecular weight biopolymers (such as lipoproteins, lipopolysaccharide-protein complexes, etc.), and / or polysaccharide-protein-fatty acid complexes. In some embodiments, more than one of these may be used at one time.

[0012] In one embodiment, the biosurfactant is a glycolipid, such as a sophorolipid (SLP), a rhamnolipid (RLP), a cellobiose lipid, a trehalose lipid, or a mannoerythritol lipid (MEL). In one embodiment, the biosurfactant is a lipopeptide, such as surfactin, iturin, fengycin, sphingomyelin, mucin, and / or lichenin. In one embodiment, the surfactant is another type of amphiphilic molecule, such as an esterified fatty acid, cardiolipin, an emulsifier, lipman, arasan, and / or a lipid emulsifier.

[0013] In a specific embodiment, the bioemulsifier is a sophorolipid or a derivative SLP molecule. SLP (including SLPs specifically exemplified and / or not specifically exemplified in the present disclosure) may include a mixture of molecular structures, such as lactone SLPs, linear SLPs, deacetylated SLPs, monoacetylated SLPs, diacetylated SLPs, esterified SLPs, SLPs with different hydrophobic chain lengths, SLPs attached with fatty acid-amino acid complexes, etc.

[0014] In a particularly preferred embodiment, the biosurfactant is a derivative SLP or a mixture of derivative SLPs, wherein the molecular structure of the SLP molecule has been altered to produce an SLP molecule having a higher tolerance to pH instability, high temperature and high pressure environments (such as those encountered in certain metal processing applications), and / or having enhanced defoaming properties compared to other SLP molecules.

[0015] In certain embodiments, the present invention provides methods of producing and / or enhancing the stability of MWFs, including O / W emulsions and W / O emulsions, wherein the method comprises mixing oil in an aqueous fluid in the presence of a bioemulsifier of the present invention.

[0016] In some embodiments, the method includes adding a bioemulsifier to an already formed O / W emulsion or W / O emulsion to improve the stability of the emulsion or prevent the emulsion from destabilizing.

[0017] In certain embodiments, enhanced MWF compositions are provided, wherein the compositions include oil of the present invention, aqueous fluids and bioemulsifiers. In certain embodiments, the oil is a petroleum-based oil, mineral oil, animal-derived oil, plant-derived oil or synthetic oil. Relative to the cumulative volume of the MWF, the oil may be present in a ratio of 30% to 90% or 25% to 85% or the like.

[0018] In some embodiments, the MWF composition may include other additives, including, for example, detergents, anti-weld agents, corrosion inhibitors, extreme pressure additives, buffers, biocides, etc. In some embodiments, the bioemulsifier also serves one or more of these additional purposes.

[0019] Advantageously, the methods of the present invention are safe to use in the presence of metal workers, do not cause harm to the user, and do not release large amounts of pollutants and toxic compounds into the environment. In addition, the compositions and methods use components that are biodegradable and toxicologically safe. Therefore, the present invention can be used in a variety of industries as a "green" additive for MWF. DETAILED DESCRIPTION

[0020] The present invention relates to improved metalworking fluids (MWFs) comprising oil-in-water or water-in-oil emulsions. More specifically, the present invention provides novel emulsifiers for formulating stable MWF emulsions, and MWF formulations comprising the emulsifiers. Preferably, the emulsifier is a biosurfactant or a derivative thereof, which can be used to replace ethoxylated surfactant emulsifiers, etc. in MWF applications. Advantageously, in some embodiments, the bioemulsifier can be up to 100% bio-based and biodegradable, can have low toxicity, and can perform at levels reaching or exceeding those of traditional emulsifiers and surfactants. In addition, in some embodiments, the bioemulsifier can withstand increased heat and pressure environments (such as those encountered in some metalworking applications) and can also be used to reduce foam.

[0021] Selected Definitions

[0022] As used herein, the term "emulsion" refers to a mixture comprising two immiscible liquid phases, wherein one of the liquid phases (the dispersed phase) is divided into small particles or droplets dispersed in the other liquid phase (the continuous phase). Typically, one of the liquids is a lipid or oil and the other is a water-based liquid in which oil is suspended in water (oil-in-water, O / W) or water is suspended in oil (water-in-oil, W / O). Most emulsions contain dispersed droplets having a diameter of about 1 nm to about 1 μm or more, about 10 nm to about 500 nm, or about 100 nm to about 250 nm.

[0023] As used herein, the term "dispersion" refers to solid primary particles, agglomerates or aggregates uniformly dispersed in a continuous medium (usually a liquid). For "suspended" dispersions, the size of these particles ranges from 0.001 μm to 1 μm or larger; for "colloidal" dispersions, the size of these particles ranges from 0.001 μm to 1 μm.

[0024] As used herein, the term "emulsifier" encompasses the phrase "stabilizer" and refers to a substance that promotes uniform separation and distribution of droplets and / or particles throughout the continuous phase of an emulsion and / or dispersion and promotes the stability of the emulsion and / or dispersion, thereby preventing coalescence and / or precipitation from the dispersed phase.

[0025] As used herein, "biofilm" is a complex aggregate of microorganisms (e.g., bacteria) in which cells adhere to each other and / or to a surface. Cells in a biofilm are physiologically distinct from planktonic cells of the same organism, which are single cells that can move in a liquid or solid medium.

[0026] As used herein, when the terms "isolated" or "purified" are used in conjunction with biological or natural materials (such as nucleic acid molecules, polynucleotides, polypeptides, proteins, etc.), organic compounds (such as small molecules, microbial cells / strains or host cells, etc.), it means that the material is substantially free of other compounds associated with it in nature, such as cellular materials. In other words, these materials would not exist naturally without these other compounds; and / or these materials have different or unique characteristics compared to the materials in the natural material.

[0027] In certain embodiments, the purified compound is at least 60% by weight of the compound of interest. Preferably, the preparation is at least 75%, more preferably at least 90%, and most preferably at least 99% or 100% (w / w) by weight of the desired compound. Purity is measured by any appropriate standard method such as column chromatography, thin layer chromatography, or high performance liquid chromatography (HPLC) analysis.

[0028] In certain embodiments, the bioemulsifier of the present invention is characterized as a "microbial-based composition", which refers to a composition comprising components generated by the growth of microorganisms or other cell cultures. Therefore, a microbial-based composition may include the microorganism itself and / or byproducts of microbial growth (e.g., biosurfactants, solvents and / or enzymes). The cells may be in a vegetative state or in spore form, or a mixture of the two. The cells may be in a planktonic form or in a biofilm form, or a mixture of the two. The cells may be active or inactive, intact or lysed. The cells may be removed from the culture medium in which they were grown, or at least 1x10 per ml of the composition. 3 , 1x10 4 , 1x10 5 , 1x10 6 , 1x10 7 , 1x10 8 , 1x10 9 , 1x10 10 or 1x10 11In one embodiment, the composition based on microorganisms may include only the culture medium in which the cells are grown and the cells are removed (although in some cases, some residual cellular material may also remain in the culture medium). Growth byproducts may be present in the culture medium and may include, for example, metabolites, cell membrane components, expressed proteins, and / or other cellular components. In one embodiment, the composition based on microorganisms includes only microbial growth byproducts.

[0029] In certain embodiments, the bioemulsifier of the present invention is characterized as "based on microbial products", which are products that are applied in practice to achieve the desired results. Based on microbial products can simply be compositions based on microorganisms harvested from microbial culture processes. Alternatively, based on microbial products can include other ingredients that have been added. These additional ingredients can include, for example, stabilizers, buffers, carriers and other additives and / or adjuvants that are suitable for specific applications. Based on microbial products can also include mixtures based on microbial compositions. Based on microbial products can also include one or more components based on microbial compositions, which have been processed in a certain manner, such as but not limited to filtration, centrifugation, cracking, drying, purification, etc.

[0030] "Metabolite" refers to any substance produced by metabolism (e.g., a growth byproduct) or a substance necessary to participate in a specific metabolic process. Examples of metabolites include, but are not limited to, enzymes, acids, solvents, alcohols, proteins, carbohydrates, vitamins, minerals, trace elements, amino acids, polymers, and biosurfactants.

[0031] As used herein, "polymer" refers to any macromolecular compound prepared by combining one or more similar molecular units (called monomers). Polymers include synthetic polymers and biosynthetic polymers. The term polymer also includes the term "biopolymer (biopolymer, biological polymer)". As used herein, they refer to natural polymers or polymers present in organisms. One characteristic of biopolymers is their biodegradability. Biopolymers can include polynucleotides (e.g., RNA and DNA), polysaccharides (e.g., linearly linked polymer carbohydrates) and polypeptides (i.e., short polymers of amino acids).

[0032] As used herein, "prevention" means avoiding, delaying, pre-empting, or minimizing the occurrence or progression (e.g., aggregation or precipitation) of a particular event or situation. Prevention may include, but does not require, absolute or complete prevention, meaning that the event or situation may still develop later without preventive measures. Prevention may include reducing the severity and / or extent of the occurrence of an event or situation, and / or inhibiting the progression of an event or situation to a more severe or extensive degree.

[0033] As used herein, "decrease" refers to a negative change and "increase" refers to a positive change, wherein the change can be at least 0.001%, 0.01%, 0.1%, 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99% or 100%, including all values ​​therebetween.

[0034] As used herein, "surfactant" refers to a surface-active substance, or a compound that reduces the surface tension (or interfacial tension) between two phases. Surfactants are used as detergents, wetting agents, emulsifiers, foaming agents and / or dispersants, etc. "Biosurfactant" refers to a surfactant produced by an organism and / or using a substrate of natural origin.

[0035] The transitional term "comprising," which is synonymous with "including" or "containing," is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. In contrast, the transitional phrase "consisting of" excludes any element, step, or ingredient not specified in the claim. The transitional phrase "consisting essentially of" limits the scope of the claim to the specified materials or steps "and those that do not materially affect the basic, novel characteristic." Use of the term "comprising" refers to other embodiments consisting of "consisting of" or "consisting essentially of" the recited components.

[0036] Unless otherwise specified or obvious from the context, the term "or" as used herein should be understood to be inclusive. Unless otherwise specified or obvious from the context, the terms "a", "an", and "the" as used herein should be understood to be singular or plural.

[0037] Unless otherwise specified or apparent from the context, as used herein, the term "about" should be understood to be within the normal tolerance range in the art, such as within 2 standard deviations of the mean. "About" can be understood to be within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05% or 0.01% of the specified value.

[0038] The ranges provided herein are understood to be shorthand expressions of all numerical values ​​within the range. For example, a range of 1 to 20 may be understood to include any number, combination of numbers, or subranges in the group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, and all decimal values ​​between the above integers, such as 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, and 1.9. With respect to subranges, "nested subranges" extending from either end of the range are particularly contemplated. For example, a nested subrange of an exemplary range of 1 to 50 may include 1 to 10, 1 to 20, 1 to 30, and 1 to 40 in one direction, or 50 to 40, 50 to 30, 50 to 20, and 50 to 10 in another direction.

[0039] The recitation of a list of chemical groups in any definition of a variable herein includes definitions of that variable as any single group or combination of the listed groups. The recitation of an embodiment for a variable or aspect herein includes that embodiment as any single embodiment or in combination with any other embodiment or portion thereof.

[0040] Any composition or method provided herein can be combined with one or more of any other compositions and methods provided herein.

[0041] Other features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments thereof and from the claims.All references cited herein are hereby incorporated herein by reference.

[0042] Bioemulsifier and method for preparing metalworking fluid

[0043] In one embodiment, the present invention provides a biological emulsifier comprising one or more microorganisms and / or one or more microbial growth byproducts. In some embodiments, the emulsifier can be used for various other purposes, including as a dispersant, detergent, antimicrobial agent and / or defoaming agent.

[0044] Advantageously, in certain embodiments, bioemulsifiers promote the formation of MWF emulsions and / or dispersions, improve the stability of MWFs characterized as emulsions and / or dispersions, and prevent demulsification and / or sedimentation of dispersed components without adversely affecting the function of the MWF.

[0045] In certain embodiments, bioemulsifiers of the present invention may include, for example, active and / or inactive microbial cells, fermentation media and / or microbial growth byproducts. In one embodiment, microbial growth byproducts are separated from the microorganisms that generate them. Growth byproducts may be in purified form or in unpurified form. In certain embodiments, growth products are further modified after extraction and optional purification.

[0046] In one embodiment, the microbial growth byproduct is one or more bioemulsifiers used to formulate the MWF. Preferably, the emulsifier is a biosurfactant.

[0047] Advantageously, the bioemulsifier according to the composition of the present invention is a non-toxic, biodegradable bioemulsifier and does not discharge pollutants and / or harmful substances into the environment. In addition, in a preferred embodiment, these compounds exhibit greater thermal stability, halogenated stability and pH stability than chemical stabilizers (e.g., chemical surfactants). In addition, in certain embodiments, the dosage of the bioemulsifier required for stabilizing the emulsion or dispersion is lower than the dosage required for the chemical stabilizer.

[0048] The surfactants according to the invention consist of two parts: a polar (hydrophilic) part and a non-polar (hydrophobic) part. Due to their structure, these molecules increase the surface area of ​​hydrophobic water-insoluble substances, increase the water bioavailability of these substances, accumulate at interfaces, thereby reducing interfacial tension and leading to the formation of aggregated micellar structures in solution.

[0049] In certain embodiments, the bioemulsifier has a hydrophilic-lipophilic balance (HLB) value suitable for the type of emulsion formed. HLB is a balance of the size and strength of the hydrophilic and lipophilic parts of the surfactant molecule. In water / oil and oil / water emulsions, the polar parts of the surfactant molecules are oriented toward the water and the non-polar groups are oriented toward the oil, thereby reducing the interfacial tension between the oil phase and the water phase. An appropriate HLB is required to form a stable emulsion.

[0050] The HLB value ranges from 0 to 20, with lower HLB values ​​(e.g., 10 or lower) being more oil-soluble and suitable for water-in-oil emulsions, while higher HLB values ​​(e.g., 10 or higher) being more water-soluble and suitable for oil-in-water emulsions.

[0051] Surfactants according to the present invention include biosurfactants and / or biopolymers, etc. These may include, for example, glycolipids, lipopeptides, flavin lipids, phospholipids, fatty acid esters and high molecular weight biopolymers (e.g., lipoproteins, lipopolysaccharide-protein complexes), and / or polysaccharide-protein-fatty acid complexes, etc.

[0052] In one embodiment, the surfactant is a glycolipid, such as a sophorolipid (SLP), a rhamnolipid (RLP), a cellobiose lipid, a trehalose lipid, or a mannoerythritol lipid (MEL). In one embodiment, the surfactant is a lipopeptide, such as surfactin, iturin, fengycin, sphingomyelin, mucin, and / or lichenin. In one embodiment, the surfactant is other types of amphiphilic molecules, such as esterified fatty acids, cardiolipin, pullulan emulsifier, lipman, arasan, and / or lipid emulsifier.

[0053] According to the present invention, other biologically derived emulsifiers may also be used, such as other biopolymers or polysaccharide-based substances (e.g., rubber, starch, resin, gum, suberin, melanin, lignin, cellulose, xanthan gum, guar gum, welan gum, fructan, xylan, gellan gum, curdlan, pullulan, glucan, alginate), beta-glucan, mannoprotein, acid, solvent, enzyme and / or protein. These compounds are preferably derived from organisms, including non-microbial organisms.

[0054] In some embodiments, the bioemulsifier is used in a raw form, wherein the biosurfactant molecules are present in a growth medium (e.g., broth) in which the microorganism is cultured and collected therefrom without purification. The raw form may include, for example, at least 0.001%, 1%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 99% of the bioemulsifier in the growth medium. In other embodiments, the bioemulsifier is extracted from the growth medium and optionally derivatized and / or purified.

[0055] In certain embodiments of the present invention, sophorolipids (SLPs) are specific glycolipids of interest. Sophorolipids are glycolipid biosurfactants produced by various yeasts of, for example, Candida pseudospermum branches. SLPs are composed of the disaccharide sophorose connected to long-chain hydroxy fatty acids. They can include partially acetylated 2-O-β-D-pyranose glucopyranose syl-D-pyranose glucopyranose units, which are connected to 17-L-hydroxyoctadecenoic acid or 17-L-hydroxy-Δ9-octadecenoic acid in a β-glycoside manner. Hydroxy fatty acids can have, for example, 11 to 20 carbon atoms, and can contain one or more unsaturated bonds. In addition, the sophorose residue can be acetylated at the 6-position and / or 6'-position. The fatty acid carboxyl group can be free (acidic or linear form) or can be lactonized (lactone form) at the 4" position. In most cases, fermentation of SLP produces a mixture of hydrophobic (water-insoluble) SLPs, including, for example, lactone SLPs, monoacetylated linear SLPs, and diacetylated linear SLPs, and hydrophilic (water-soluble) SLPs (including non-acetylated linear SLPs, etc.).

[0056] As used herein, the term "sophorolipid", "sophorolipid molecule", "SLP" or "SLP molecule" includes all forms of SLP molecules and isomers thereof, including, for example, acidic (straight chain) SLP and lactone SLP. It further includes monoacetylated SLP, diacetylated SLP, esterified SLP, SLP with different hydrophobic chain lengths, SLP attached with fatty acid-amino acid complexes, and others, including SLP described and / or not described in the present disclosure.

[0057] In some embodiments, the SLP molecule can be represented by the general formula (1) and / or the general formula (2), and as 30 or more fatty acid chain lengths (R 3 ) and, in some cases, in R 1 and / or R 2 Acetylation or protonation occurs at the site.

[0058]

[0059] In the general formula (1) or (2), R 0 It can be a hydrogen atom or a methyl group. 1 and R 2 are each independently a hydrogen atom or an acetyl group. 3 It is a saturated aliphatic hydrocarbon chain, or an unsaturated aliphatic hydrocarbon chain having at least one double bond, and may have one or more substituents.

[0060] Non-limiting examples of substituents include halogen atoms, hydroxyl groups, lower (C1-6) alkyl groups, halo lower (C1-6) alkyl groups, hydroxy lower (C1-6) alkyl groups, halo lower (C1-6) alkoxy groups, and the like, such as those described in the present disclosure. 3 It may have, for example, 11 to 20 carbon atoms.

[0061] Fermentation of yeast cells in a medium containing sugars and / or lipids and fatty acids with different carbon chain lengths can be used to produce a variety of SLPs. The yeast "Bombus spp." (Candida spp.) is one of the most well-known producers of SLPs. Typically, yeast produces lactone SLPs and linear SLPs during fermentation, with about 60% to 70% of the SLPs comprising the lactone form and the remainder being the linear form.

[0062] In certain specific embodiments, the biosurfactant is a sophorolipid, or a mixture of SLP molecules (including, for example, lactone SLP, linear SLP, deacetylated SLP, monoacetylated SLP, diacetylated SLP, esterified SLP, SLP with different hydrophobic chain lengths, SLP attached with fatty acid-amino acid complexes, etc.), including SLPs specifically exemplified and / or not specifically exemplified in the present disclosure.

[0063] In a particularly preferred embodiment, the biosurfactant is a derivatized SLP, or a mixture of derivatized SLPs, wherein the derivatized SLP includes a linear SLP or a lactone SLP that is modified to have improved stability, enhanced defoaming properties, and / or greater water solubility or alcohol solubility than other SLP molecules at higher pH, higher temperature and / or higher pressure.

[0064] In certain embodiments, the derivatized SLP comprises a cyclic ether analog of a lactone SLP. Advantageously, reducing the ester functionality of the SLP to an ester bond can enhance the stability of the lactone ring, thereby reducing pH instability and temperature and pressure sensitivity.

[0065] In certain embodiments, the derivatized SLP comprises a peracetylated hydrophilic moiety. In certain embodiments, the hydrophilic moiety comprises a silicon-based functional group.

[0066] In certain embodiments, the derived SLPs include fatty acids in which the carboxylic acid moiety is converted to a methyl ester, ethyl ester, or isobutyl ester, etc. In certain embodiments, the fatty acids include amino acids that retain the biobased carbon while adding an aromatic ring, such as phenylalanine methyl ester and / or tryptophan methyl ester.

[0067] In some embodiments, one or more of these modifications may alter the hydrophilicity and / or HLB of the derivatized SLP, making it more conducive to emulsion formation and / or reducing foaming.

[0068] In certain embodiments, the derived SLP has a formula according to formula (3), (4), (5), (6) or (7): (3)

[0070] (4)

[0072] (5)

[0074] (6)

[0076] (7)

[0078]

[0079] Methods for producing MWF

[0080] In a preferred embodiment, a method of preparing a stable MWF characterized as an emulsion and / or dispersion is provided, wherein the method comprises mixing two or more ingredients in the presence of a bioemulsifier of the present invention.

[0081] As used herein, the "stability" of an emulsion or dispersion refers to the resistance of the emulsion or dispersion to changes in its physicochemical properties. In other words, stability refers to the ability of an emulsion or dispersion to resist forces acting on it that would result in sedimentation (downward movement of the dispersed phase), emulsification (upward movement of the dispersed phase), flocculation / aggregation of dispersed phase particles or droplets, coalescence of dispersed phase droplets or particles, and / or phase change (e.g., W / O to O / W).

[0082] In one embodiment, the two or more components include a first component and a second component, wherein the first component is dispersed in the second component. Thus, in a preferred embodiment, the first component is characterized as a dispersed phase of an emulsion or dispersion, and the second component is a continuous phase of an emulsion or dispersion.

[0083] In one embodiment, the first component and the second component are both liquids. Preferably, the two liquids (i.e., the first liquid and the second liquid) are not the same substance. In certain embodiments, the MWF is an O / W emulsion, wherein the first liquid is a lipid and / or an oil, and the second component is water or another aqueous fluid. In certain embodiments, the MWF is a W / O emulsion, wherein the first component is water or another aqueous fluid, and the second liquid is a lipid and / or an oil.

[0084] In some embodiments of the methods of the present invention, the bioemulsifier is first added to the second component (continuous phase), and then the first component (dispersed phase) is gradually added to the second component while actively mixing. In some embodiments, the bioemulsifier is added after the first component and the second component have contacted each other, and then mixing is performed.

[0085] Preferably, mixing includes vigorous stirring to break the dispersed phase into small particles or droplets and disperse them evenly throughout the continuous phase. The biological emulsifier coats the particles or droplets, thereby stabilizing the emulsion or dispersion.

[0086] In some embodiments, mixing is performed using, for example, a grinder or homogenizer. In some embodiments, mixing is performed manually using a blender, a stirrer, or a membrane emulsifier, etc. In some embodiments, ultrasonic or supersonic mixing techniques are used, in which, for example, a metal tool vibrates at a high frequency in the mixture to break the dispersed phase into smaller particles or droplets.

[0087] In some embodiments, mixing is performed at room temperature (e.g., 20° C. to 25° C.), or at mild controlled heat (e.g., about 25° C. to 30° C.). In certain embodiments, once formed, the MWF emulsion or dispersion is stable even under significantly varying temperatures.

[0088] Advantageously, the compositions and methods of the present invention are effective in enhancing the stability of MWFs without adversely affecting their function.

[0089] In certain embodiments, the addition of a bioemulsifier according to the methods of the present invention serves to increase the time that an emulsion or dispersion is stable by at least 1 minute, 60 minutes, 1 day, 30 days, 1 month, 2 months, 3 months, 4 months, or more.

[0090] In some embodiments, these methods can be combined or implemented simultaneously with other methods for improving the quality of MWF and improving the stability of MWF emulsions or dispersions. For example, MWF can also contain other components such as solids, liquids and / or gases, as well as other additives.

[0091] In some embodiments, the methods of the present invention can be used to prevent MWF from deteriorating due to contaminating microorganisms (e.g., bacteria and fungi), wherein the biosurfactant of the bioemulsifier has antimicrobial properties. In some embodiments, the methods of the present invention can be used to reduce the foam generated during the use of MWF, wherein the biosurfactant of the bioemulsifier has foam suppression properties.

[0092] Method of the present invention can be implemented anywhere in producing MWF. Two or more compositions and biological emulsifier can be stored in a separate container on site. When MWF is needed, composition and biological emulsifier can be collected and / or directly piped into a container and homogenized therein. In one embodiment, the method is implemented in the place or near it of producing MWF (for example, less than 300 miles, 250 miles, 200 miles, 150 miles, 100 miles, 75 miles, 50 miles, 25 miles, 15 miles, 10 miles, 5 miles, 3 miles or 1 mile from the place).

[0093] In one embodiment, the method can be implemented in a large metal processing plant. In one embodiment, the method can be implemented in a smaller scale metal processing shop or by amateur metal workers.

[0094] Advantageously, the compositions and methods of the present invention utilize biodegradable and toxicologically safe components and can serve as a substitute for potentially harmful emulsifiers (e.g., ethoxylates). Thus, the present invention, in some embodiments, can be used as a "green" additive to improve the quality of MWF emulsions or dispersions.

[0095] Metalworking Fluids

[0096] In one embodiment, the invention provides a MWF produced according to the inventive method. Preferably, the MWF is a mixture (e.g., an emulsion and / or dispersion) comprising two or more components, and a bioemulsifier of the present invention. In certain embodiments, the MWF is characterized as a soluble oil or a semi-synthetic fluid.

[0097] In one embodiment, the two or more components include a first component and a second component, wherein the first component is dispersed in the second component.

[0098] In one embodiment, the first component and the second component are both liquids. Preferably, the two liquids (ie, the first liquid and the second liquid) are not the same substance.

[0099] In certain embodiments, the MWF is an O / W emulsion, wherein the first liquid is a lipid and / or an oil, and the second component is water or another aqueous fluid. In certain embodiments, the MWF is a W / O emulsion, wherein the first component is water or another aqueous fluid, and the second liquid is a lipid and / or an oil. In certain preferred embodiments, the oil is a mineral oil, an animal oil, a marine oil, a vegetable oil or a synthetic oil.

[0100] In certain embodiments, the percentage of oil relative to the total amount of MWF is about 10% to 90%, about 20% to 80%, or about 25% to 75%.

[0101] In certain embodiments, the MWF includes a bioemulsifier, such as a SLP of formula (1) to (7), at a rate of about 100 ppm to about 250,000 ppm, about 200 ppm to about 100,000 ppm, about 300 ppm to about 75,000 ppm, about 400 ppm to about 50,000 ppm, or about 500 ppm to about 25,000 ppm.

[0102] Other ingredients characterized as solids, liquids and / or gases may also be included in the MWF, as well as, for example, buffers, stabilizers, anti-mist additives, foam inhibitors, tensides, solubilizers, corrosion inhibitors, extreme pressure additives and biocides (e.g., bactericides and fungicides), as may be determined by a metalworker or chemist having the benefit of the present invention.

Claims

1. A metalworking fluid (MWF) comprising a mixture of two or more components and a bioemulsifier, wherein the bioemulsifier comprises one or more biosurfactants, wherein at least one of the one or more biosurfactants is a sophorolipid (SLP).

2. The MWF according to claim 1, wherein the SLP is a lactone SLP, a linear SLP, a derivatized lactone SLP, a derivatized linear SLP, or a mixture of any of these.

3. The MWF of claim 1 characterized as an emulsion or dispersion.

4. The MWF of claim 1, wherein the two or more components include a first component and a second component, and wherein the first component is dispersed in the second component.

5. The MWF of claim 4, wherein the first component is a first liquid and the second component is a second liquid, the first liquid being different from the second liquid.

6. The MWF according to claim 5, wherein the first liquid is a lipid and / or an oil and the second component is water or an aqueous fluid.

7. The MWF of claim 6, wherein the first liquid is a mineral oil, an animal-based oil, a plant-based oil, or a synthetic oil.

8. The MWF according to claim 1, further comprising an additional biosurfactant selected from glycolipids, lipopeptides, flavin lipids, phospholipids, fatty acid esters, lipoproteins, lipopolysaccharide-protein complexes, and polysaccharide-protein-fatty acid complexes.

9. The MWF according to claim 8, wherein the glycolipid is a sophorolipid, a rhamnolipid, a trehalolipid, a cellobiose lipid and / or a mannoerythritol lipid.

10. The MWF according to claim 8, wherein the lipopeptide is surfactin, iturin, fengycin, sphingomyelin, mucin and / or lichenin.

11. The MWF of claim 1, further comprising an additional ingredient selected from the group consisting of a buffer, a stabilizer, an anti-mist additive, a foam inhibitor, a surfactant, a solubilizer, a corrosion inhibitor, an extreme pressure additive, and an anti-biocide.

12. The MWF of claim 1, wherein the SLP is linear and has one of the following formulae: A) B) C) D) E) 13. A method of producing a MWF characterized as an emulsion or dispersion, the method comprising mixing two or more components in the presence of a bioemulsifier according to any one of claims 1 to 12, wherein the two or more components comprise a first component and a second component that are different from each other.

14. The method of claim 13, wherein the first component is the dispersed phase of the emulsion or the dispersion and the second component is the continuous phase of the emulsion or the dispersion.

15. The method of claim 13, wherein the first component is a first liquid and the second component is a second liquid.

16. The method of claim 13, wherein the first liquid is a lipid and / or an oil and the second component is water or an aqueous fluid.

17. The method of claim 16, wherein the oil is a mineral oil, an animal-based oil, a plant-based oil, or a synthetic oil.

18. The method of claim 13, comprising first adding the bioemulsifier to the second component and then gradually adding the first component to the second component while mixing.

19. The method of claim 13, comprising adding the bioemulsifier to a premix of the first component and the second component while mixing.

20. The method of claim 13, wherein the mixing is performed using a grinder, a homogenizer, a blender, a stirrer, a membrane emulsifier, or an ultrasonic mixing tool.

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