Structured assembly lubricant

Abstract

A two-phase structured lubricant includes from about 5 wt% to 95 wt% of a liquid component, and from about 5 wt% to 95 wt% of a structured component. The structured component recrystallizes or solidifies around the liquid component.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 63 / 370,542, filed on August 5, 2022, entitled “Structured Assembly Lubricant,” the disclosure of which is incorporated herein by reference in its entirety for all purposes.

[0003] Related technologies

[0004] The present disclosure relates to lubricants, and more particularly to lubricants for assembly applications.

[0005] background

[0006] Lubricants are often used in assembly and / or maintenance applications. For example, assembly lubricants are used to provide lubrication and reduce friction between components. The lubricity provided by the assembly lubricant disappears after a certain amount of time, or the assembly lubricant is removed, causing the components to no longer slide over each other easily. There are many challenges in designing and manufacturing high-performance lubricants that are compatible with various components (such as internal combustion engines, manual transmission systems, automatic transmission systems, transfer cases (for vehicles), differential gear systems, gear systems, electric vehicles, electric vehicle transmission systems, etc.). Summary of the invention

[0007] In one embodiment, the two-phase structured lubricant includes about 5 weight percent (wt.%) to 95 wt.% of a liquid component and about 5 wt.% to 95 wt.% of a structuring component. The structuring component recrystallizes or solidifies around the liquid component.

[0008] In one embodiment, the method for preparing a two-phase structured lubricant includes mixing and heating a liquid component, which is about 5% to 95% by weight of the two-phase structured lubricant. The method includes mixing the structured component with the heated liquid component. The structured component is about 5% to 95% by weight of the two-phase structured lubricant. The method includes melting the structured component and mixing the structured component with the liquid component to form a uniform mixture. The method further includes cooling the uniform mixture to form a two-phase structured lubricant.

[0009] In another embodiment, a method of assembling a system using a two-phase structured lubricant includes applying the two-phase structured lubricant to assemble the system, and applying a standard lubricant to the assembled system. The two-phase structured lubricant includes about 5 weight percent (wt.%) to 95 weight percent of a liquid component and about 5 weight percent to 95 weight percent of a structured component. The structured component recrystallizes or solidifies around the liquid component.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 An exemplary method of preparing the two-phase structured lubricant disclosed herein is shown;

[0012] Figure 2 shows example structural analysis results for a two-phase lubricant disclosed herein; and

[0013] Figure 3 An exemplary method of using the two-phase structured lubricant disclosed herein is shown. DETAILED DESCRIPTION

[0014] The present disclosure relates to compositions and methods for preparing structured lubricants having desirable properties for use in the assembly of various lubricated engineering components such as internal combustion engines, manual / automatic transmissions, transfer cases, and differential gear drives to aid in the assembly process and provide lubrication during initial start-up of these systems.

[0015] The lubricants disclosed herein are designed to provide a viscous, semi-solid structure that aids in the assembly of systems by adhering to components and holding them in place.

[0016] The lubricants disclosed herein are designed to provide tribological and corrosion protection to components during transportation or storage prior to initial startup.

[0017] The lubricants disclosed herein are designed to provide tribological protection to assembled components during initial startup to prevent excessive wear or damage to the components.

[0018] The lubricants disclosed herein are designed to have the following features and / or properties: allowing the lubricant to be quickly replaced by a standard lubricant present in a system (e.g., a system assembled using the lubricant disclosed herein). A standard lubricant refers to a lubricant that is typically used to provide lubrication during operation of a system (e.g., a system assembled using the lubricant disclosed herein).

[0019] The lubricants disclosed herein are designed to have minimal or negligible impact on the performance attributes of standard lubricants or lubrication systems.

[0020] In addition, modern electric vehicle (EV) drivetrains typically contain sensitive electronic components in addition to their gear trains. As a safety factor, lubricants used in these applications are designed to have very low levels of conductivity to prevent short circuits or other dangerous situations. The lubricants disclosed herein are designed to provide enhanced tribological protection for components during startup without significantly affecting the conductivity of the system's standard lubricant.

[0021] The lubricant system disclosed herein consists of two phases: a liquid phase consisting of a lubricating base oil, and a solid phase that provides structure to the system. It is desirable to have a structured phase in the system that provides high viscosity and low temperatures and shear rates, but exhibits extreme shear-thinning behavior and has a melting point significantly below the normal operating temperature of the system.

[0022] The system is made by first blending the lubricant base with the desired additives (to improve performance) under mild heating. The structural phase is then formed by adding a crystallized hydrocarbon wax and / or petrolatum and heating until the system forms a single-phase homogeneous system. The system is then cooled to allow the wax distributed throughout the lubricant base to recrystallize. Upon completion, a strong, ductile material is formed that exhibits the desired properties, including extreme shear-thinning behavior, improved friction properties, no / minimal effect on conductivity, and a well-defined melting point.

[0023] Lubricant preparation

[0024] The lubricant system disclosed herein comprises two phases: a liquid phase consisting of a lubricating base oil, and a solid phase or structured phase that provides structure to the lubricant system. It is desirable to have a structured phase in the lubricant system disclosed herein that provides high viscosity and high shear rates at low temperatures while exhibiting extreme shear-thinning behavior and having a melting point significantly below the normal operating temperature of the system.

[0025] Examples of two-phase structured lubricants disclosed herein are shown in Table 1. These materials include a solid structuring component and a liquid lubricant component.

[0026] Table 1

[0027]

[0028] Formulation I includes about 5 weight % (wt.%) to about 30 weight % of wax (e.g., solid structuring component) and about 70 weight % to about 95 weight % of lubricating oil (e.g., liquid lubricant component). In some aspects of the invention, the formulation includes a structuring component and a lubricating oil, wherein the structuring component is a wax having a content of about 1 weight % to about 35 weight %, the lubricating oil content is about 65 weight % to about 99 weight %, and the total amount of the structuring component and the liquid component is 100%. In some aspects, formulation I includes a structuring component and a lubricating oil, wherein the structuring component is a wax having a content of about 5 weight % to about 30 weight %, the lubricating oil is a liquid component having a content of about 70 weight % to about 95 weight %, and the total amount of the structuring component, the liquid component and additives (including, for example, friction reducers, antiwear agents, extreme pressure (EP) agents, corrosion inhibitors and oxidation inhibitors) is 100%. In some aspects of the invention, the formulation includes a structuring component and a lubricating oil, wherein the structuring component is a wax in an amount of 5% to 35% by weight, the lubricating oil is in an amount of 70% to 95% by weight, and the total amount of the structuring component, the liquid component, and any additional additives is 100%. Of course, in some aspects of the invention, the formulation includes a structuring component and a lubricating oil, wherein the structuring component is a single amount (such as 25% by weight) of wax in an amount ranging from about 5% to about 30% by weight, and the lubricating oil is in an amount ranging from about 65% to about 95% by weight (such as 75% by weight). In still another aspect of the invention of Formulation I, the wax is present in a single amount ranging from about 5 wt% to about 30 wt% (e.g., 20 wt%), the lubricating oil is present in a single amount ranging from about 65 wt% to about 95 wt% (e.g., 70 wt%), and up to 10 wt% of additives (e.g., friction reducers, antiwear agents, extreme pressure (EP) agents, corrosion inhibitors, or oxidation inhibitors) are added to Formulation I such that the sum of all components is 100 wt%. Formulation II includes about 75 wt% to about 95 wt% petrolatum (e.g., a solid structuring component) and about 5 wt% to about 25 wt% lubricating oil (e.g., a liquid lubricant component). In some aspects of the invention, the formulation includes a structuring component and a lubricating oil, wherein the structuring component is petrolatum in an amount ranging from about 70 wt% to about 99 wt%, the lubricating oil is present in an amount ranging from about 1 wt% to about 30 wt%, and the sum of the structuring component and the liquid component is 100%. In some aspects, Formulation II includes a structuring component and a lubricating oil, wherein the structuring component is petrolatum in an amount of about 75 wt % to about 95 wt %, the lubricating oil is a liquid component in an amount of about 5 wt % to about 25 wt %, and the sum of the structuring component, the liquid component, and additives (including, for example, friction reducers, antiwear agents, extreme pressure (EP) agents, corrosion inhibitors, and oxidation inhibitors) is 100%.In some aspects of the invention, the formulation comprises a structuring component and a lubricating oil, wherein the structuring component is petrolatum in an amount of 75% to 95% by weight, the lubricating oil is in an amount of 5% to 25% by weight, and the sum of the structuring component, the liquid component, and any additional additives is 100%. Of course, in some aspects of the invention, the formulation comprises a structuring component and a lubricating oil, wherein the structuring component is a single amount (such as 80% by weight) of petrolatum in an amount ranging from about 75% to about 95% by weight, and the lubricating oil is in a single amount (such as 20% by weight) in an amount ranging from about 5% to about 25% by weight. In still another aspect of the invention of Formulation II, the content of petrolatum is a single amount (such as 70 wt%) in the range of about 75 wt% to about 95 wt%, the content of lubricating oil is a single amount (such as 20 wt%) in the range of about 5 wt% to about 25 wt%, and 10 wt% of an additive (such as a friction reducer, an anti-wear agent, an extreme pressure (EP) agent, a corrosion inhibitor or an oxidation inhibitor) is added to the formulation so that the total of all components is 100 wt%.

[0029] The wax in Formulation I can be a metastable crystalline hydrocarbon wax made from synthetic and / or natural waxes, such as rice bran wax, carnauba wax, polyethylene wax, polypropylene wax, and the like.

[0030] The petrolatum in Formulation II may be a modified refined petrolatum made from a commercial source of petrolatum derived from a heavy oil / wax blend produced during the oil refining process.

[0031] The lubricating oil in formulations I and II can be any hydrocarbon lubricating oil selected based on performance and compatibility with the system of interest. For example, the lubricating oil can be a hydrocarbon lubricating oil, such as Group IV oil developed by the American Petroleum Institute (API), silicone oil, fluorinated oil, etc.

[0032] In addition to the core components (solid structuring component and liquid lubricant component), the two-phase structured lubricant disclosed herein may also contain additives and / or colorants based on the needs of the system. For example, Formulation I and / or Formulation II may contain colorants and / or performance enhancing additives to improve tribological properties, antioxidant properties, or anti-corrosion properties, etc.

[0033] The use of colorants can vary significantly to provide color to distinguish the two-phase structured lubricants disclosed herein from ordinary lubricants. The colorant can include oil-soluble organic compounds and / or various inorganic compounds. The colorant can be about 0.01% to 0.05% by weight of the two-phase structured lubricant disclosed herein.

[0034] The additives may include one or more of the following: friction reducers, anti-wear agents, extreme pressure (EP) agents, corrosion inhibitors, and oxidation inhibitors.

[0035] The friction reducer can be about 0.01 wt % to 5 wt % of the two-phase structured lubricant disclosed herein. The friction reducer includes one or more of the following: organic modifiers (long chain esters, alkanolamines, and variants based on C, N, O, and H elements), dialkyl molybdenum dithiophosphates and derivatives, molybdenum dithiocarbamates and derivatives, antimony dithiocarbamates, dimercaptothiadiazoles and derivatives, dialkyl tungsten dithiophosphates and derivatives, ashless dithiophosphates / salts, and amine phosphates / salts and derivatives.

[0036] The antiwear agent can be about 0.01 wt % to 5 wt % of the two-phase structured lubricant disclosed herein. The antiwear agent comprises one or more of the following: zinc dialkyl dithiophosphate or ZDDP (primary, secondary, mixed), dithiophosphate esters / salts, amine sulfurized dithiophosphate esters / salts, polysulfides, phosphate esters, dialkyl dithiocarbamate / salts, dialkyl ammonium tungstate, borates, amine phosphates / esters and organic sulfur-phosphates / esters.

[0037] The EP agent can be about 0.01 wt % to 5 wt % of the two-phase structured lubricant disclosed herein. The EP agent includes one or more of the following: calcium carbonate, molybdenum disulfide, dithiophosphates / salts, amine sulfurized phosphates / salts, amine sulfurized phosphites / salts, sulfurized isobutylene and derivatives, sulfurized olefins and derivatives, sodium / potassium borate salts, zinc dithiophosphates, sulfurized fatty acid esters, sulfurized triglycerides, dialkyl pentasulfides, antimony dialkyl dithiocarbamates and derivatives, amine phosphates / salts and derivatives, thiadiazole derivatives, organic dibutyl dithiocarbamates / salts and derivatives, and calcium sulfonates and derivatives.

[0038] The corrosion inhibitor can be about 0.01 wt % to 5 wt % of the two-phase structured lubricant disclosed herein. The corrosion inhibitor includes one or more of the following: amine carboxylates, borates, carboxylates, alkyl phosphates, pyridinyl benzyl quaternary ammonium compounds, imidazolines, calcium sulfonates, hydroxy aminophosphoric acids, and benzotriazole / toluenetriazole.

[0039] The oxidation inhibitor may be about 0.01 wt % to 5 wt % of the two-phase structured lubricant disclosed herein. The oxidation inhibitor includes one or more of phenolic antioxidants, aromatic amines, and butylated phenols.

[0040] In some embodiments, the two-phase structured lubricant may include a combination of Formulation I and Formulation II. For example, the two-phase structured lubricant disclosed herein may include about 5 wt % to 95 wt % of a structuring component (wax and / or petrolatum) and about 5 wt % to 95 wt % of a liquid component (lubricating oil).

[0041] Batching process

[0042] Figure 1 An exemplary method (100) for preparing a two-phase structured lubricant based on the formulation shown in Table 1 is shown. Method 100 includes mixing and heating liquid components (step 102). In order to prepare a two-phase structured lubricant based on formulation I, the amount of lubricant added to the container is predetermined so that the amount of lubricant is about 70% by weight to 95% by weight of the two-phase structured lubricant. In order to prepare a two-phase structured lubricant based on formulation II, the amount of lubricant added to the container is predetermined so that the amount of lubricant is about 5% by weight to 25% by weight of the two-phase structured lubricant. The container can be any suitable vessel for mixing and heating the substances contained therein. For example, the container can be a mixer or a vessel with a stirring blade, and the container is connected to or equipped with a heating element to heat the substances contained therein.

[0043] The liquid component (lubricating oil) is mixed at any suitable rate to achieve effective mixing. The mixing rate can be based on the material and quantity of the material in the container, the size of the mixer / mixing blade, the size of the container, etc. The mixing rate can be about 400 revolutions per minute (rpm) to 1000 rpm, about 500 rpm to 900 rpm, about 600 rpm to 800 rpm, about 650 rpm to 750 rpm, or about 700 rpm.

[0044] The liquid component (lubricating oil) is heated to a temperature equal to or a certain degree above the melting temperature of the structuring component of the two-phase structured lubricant, for example: about 1 degree Celsius (°C) to 10°C, about 1°C to 5°C, or about 3°C ​​above the melting temperature of the structuring component of the two-phase structured lubricant.

[0045] For preparing a two-phase structured lubricant based on Formulation I, the structuring component is a wax, and its melting temperature may be about 45°C to 125°C, about 55°C to 115°C, about 65°C to 105°C, about 75°C to 95°C, or about 85°C; therefore, in step 102, the liquid component (lubricating oil) is heated to a degree slightly higher than about 45°C to 125°C, about 55°C to 115°C, about 65°C to 105°C, about 75°C to 95°C, or about 85°C.

[0046] For the preparation of the two-phase structured lubricant based on Formulation II, the structuring component is petrolatum, which has a melting temperature of about 20°C to 100°C, about 30°C to 90°C, about 40°C to 80°C, about 50°C to 70°C, or about 60°C; therefore, in step 102, the liquid component (lubricating oil) is heated to a temperature slightly higher than about 20°C to 100°C, about 30°C to 90°C, about 40°C to 80°C, about 50°C to 70°C, or about 60°C.

[0047] Method 100 includes mixing a structured component with a heated liquid component (step 104). To prepare a two-phase structured lubricant based on formulation I, the amount of wax mixed with the heated liquid component (lubricating oil) is predetermined so that the amount of wax is about 5% to 30% by weight of the two-phase structured lubricant. To prepare a two-phase structured lubricant based on formulation II, the amount of wax added in formulation II is predetermined so that the amount of petrolatum is about 75% to 95% by weight of the two-phase structured lubricant.

[0048] Method 100 includes melting a structuring component and mixing the structuring component with a liquid component to form a mixture (step 106). The heating in step 102 is maintained to melt the structuring component (wax in formulation I and petrolatum in formulation II) added in step 104. The structuring component and the liquid component (lubricant) are mixed at any suitable rate to achieve effective mixing to form a single-phase system (homogeneous mixture). The single-phase system (homogeneous mixture) formed in step 106 may have a relatively clear or transparent appearance. The mixing rate may be based on the amount of the materials (structuring component and lubricant component), the relative proportion of the materials in the container, the size of the mixer / agitator blade, the size of the container, etc. The mixing rate may be about 400 rpm to 1000 rpm, about 500 rpm to 900 rpm, about 600 rpm to 800 rpm, about 650 rpm to 750 rpm, or about 700 rpm. In step 106, the duration of heating and mixing may be any effective duration to form a single-phase system (homogeneous mixture). In step 106, the duration of heating and mixing may depend on the materials and amounts of the substances (structuring component and liquid component), the relative proportions of the substances in the container, the size of the mixer / stirrer blades, the size of the container, etc.

[0049] Method 100 may include mixing additives into the mixture (step 108). The amount of additives and / or colorants added is based on a predetermined calculation such that the amount of additives is about 0.01% to 5% by weight of the two-phase structured lubricant and / or the amount of colorants is about 0.01% to 0.05% by weight of the two-phase structured lubricant. The additives and / or colorants may be added in steps 102, 104, or 106 such that the additives and / or colorants form a single-phase system (homogeneous mixture) with the liquid component and the structured component. In some embodiments, step 108 may be omitted.

[0050] Method 100 includes cooling the mixture to form a two-phase structured lubricant (step 110). Once a single-phase system (homogeneous mixture) is formed, heating and mixing are stopped, and the mixture is cooled to room temperature at an effective cooling rate so that the mixture forms a two-phase structured lubricant. For Formulation I, the wax in the mixture recrystallizes around the lubricating oil phase to form a two-phase structured lubricant with high stiffness and viscosity. For Formulation II, as the mixture cools, the wax component solidifies and dominates the properties of the mixture, forming a rigid two-phase structured lubricant.

[0051] The cooling rate can be based on the material and amount of the substance (liquid component and structured component), the relative proportion of the substance in the container, the size of the container, etc. The mixture can be cooled naturally, or can be cooled with an auxiliary cooling method (e.g., convection cooling, conduction cooling). The cooling in step 110 can be about 1°C to 5°C per minute.

[0052] The two-phase structured lubricant prepared by method 100 is metastable and exhibits structural and thermal properties significantly different from those of a single component (e.g., only a liquid component or only a structured component). The two-phase structured lubricant prepared by method 100 has a significantly suppressed melting point (e.g., compared to a single component) and exhibits extreme shear thinning behavior.

[0053] Test Results

[0054] The formulations shown in Table 1 were evaluated by tribological testing and by measuring the effect on electrical conductivity.

[0055] Table 2 shows the structural stability data of the two-phase structured lubricant formulations shown in Table 1 (e.g., Formulation I and Formulation II) based on ASTM D217 (0 work and 60 work), ASTM D1831 (rolling stability) tests, and the melting temperature based on differential scanning calorimetry (DSC) measurements.

[0056] Table 2

[0057]

[0058] In particular, the grease consistency of the two-phase structured lubricant disclosed herein is tested using ASTM D217 (Standard Test Method for Cone Penetration of Grease). The ASTM D217 test results of Formulation I at zero cone penetration and 60 strokes cone penetration are 215 (unit: 0.1 mm) (mm / 10) and 425 mm / 10, respectively. The ASTM D217 test results of Formulation II at zero cone penetration and 60 strokes cone penetration are 220 mm / 10 and 235 mm / 10, respectively.

[0059] The consistency change of the two-phase structured lubricant disclosed herein was tested using ASTM D1831 (Standard Test Method for Rolling Stability of Greases). The ASTM D1831 test result of Formulation I was liquid. The ASTM D1831 test result of Formulation II was 266.5 mm / 10.

[0060] The melting temperatures of Formulations I and II based on DSC measurements were 65°C and 40°C, respectively.

[0061] Table 3 shows the tribological data for the two-phase structured lubricant formulations shown in Table 1 (e.g., Formulation I and Formulation II), which were tested based on ASTM D2266 (wear scar), ASTM D2596 (maximum no-seizure load and weld load), ASTM D5706 (rolling pass load), and ASTM D7594 (wear scar / coefficient of friction).

[0062] Table 3

[0063]

[0064] In particular, the anti-wear properties of the two-phase structured lubricants disclosed herein were tested using ASTM D2266 (Standard Test Method for Anti-Wear Properties of Greases, Four-Ball Method). The ASTM D2266 test results for Formulation I and Formulation II were 0.39 mm and 0.43 mm, respectively.

[0065] The load-carrying properties of the two-phase structured lubricants disclosed herein were tested using ASTM D2596 (Standard Test Method for Measuring Extreme Pressure Properties of Greases, Four-Ball Method). The ASTM D2596 maximum no-seizure loads for Formulation I and Formulation II were 63 kilograms (kg) and 126 kg, respectively. The ASTM D2596 welds for Formulation I and Formulation II were both 200 kg.

[0066] The extreme pressure properties of the two-phase structured lubricants disclosed herein were tested using ASTM D5706 (Standard Test Method for Determining Extreme Pressure Properties of Greases Using a High Frequency Linear Oscillating Tester). The ASTM D5706 rolling pass load for both Formulation I and Formulation II was 2000 Newtons (N).

[0067] The anti-wear performance and friction coefficient of the two-phase structured lubricant disclosed herein were tested using ASTM D7594 (fretting wear resistance of grease under high Hertzian contact pressure using high frequency linear vibration). The ASTM D7594 test results for Formulation I and Formulation II were 0.486 mm / 0.128 and 0.562 mm / 0.119, respectively.

[0068] Table 4 shows the fluid compatibility data of the two-phase structured lubricant formulations (e.g., Formulation I and Formulation II) shown in Table 1, which were diluted with a standard electric vehicle transmission fluid at a ratio of two-phase structured lubricant: standard electric vehicle transmission fluid = 50:1 parts. The fluid compatibility data was tested based on the High Frequency Reciprocating Rig (HFRR) test (friction test and wear scar area test), ASTM D2266 (wear scar) and conductivity test (at 25°C). These tests were conducted based on the diluted formulations to show the effect of the two-phase structured lubricant formulation on the performance of the natural lubricant.

[0069] Table 4

[0070]

[0071]

[0072] In particular, the lubrication effect of the two-phase structured lubricant disclosed herein and the conventional electric vehicle (EV) base fluid was measured using the HFRR test. The friction coefficients of Formulations I and II and the conventional EV base fluid measured by the HFRR test were 0.106, 0.128, and 0.115, respectively. The wear scar areas of Formulations I and II and the conventional EV base fluid measured by the HFRR test were 11242 square millimeters (mm 2 )、22066mm 2 and 19767mm 2 .

[0073] The extreme pressure properties of the two-phase structured lubricant disclosed herein and the conventional EV base fluid were tested using ASTM D2266 (Standard Test Method for Wear Resistance of Greases, Four-Ball Method). The ASTM D2266 wear scars of Formulation I and Formulation II and the conventional EV base fluid were 0.459 millimeters (mm), 0.51 mm, and 0.41 mm, respectively.

[0074] The conductivity of Formulation I and Formulation II and the traditional EV base fluid tested at 25°C were 6000 picoSiemens / cm (pS / cm), 6800 pS / cm and 4300 pS / cm, respectively.

[0075] Based on the data shown in Table 4, the performance of the two-phase structured lubricant disclosed in this article is highly compatible with traditional EV base fluids.

[0076] Figure 2The exemplary structural analysis results of the two-phase structured lubricant formulation disclosed herein are shown. Graph 200 shows the DSC spectrum of the two-phase structured lubricant based on formulation I. Series 202 and 204 show the heating rate and cooling rate, respectively. The sharp peaks in the DSC spectrum indicate the crystalline nature of the two-phase structured lubricant. In particular, the sharp melting peak and solidification peak indicate a higher level of order and crystallinity.

[0077] Graph 206 shows the DSC spectrum of the two-phase structured lubricant based on formulation II. Series 208 and 210 show the heating rate and cooling rate, respectively. The broad peaks in the DSC spectrum indicate the metastable semi-solid nature of the two-phase structured lubricant. In particular, the broad melting peak and solidification peak indicate a waxy phase transition.

[0078] Figure 3 An exemplary method 300 for using the two-phase structured lubricant disclosed herein in a system is shown. The method 300 includes obtaining a two-phase structured lubricant for assembling a system (step 302). The two-phase structured lubricant can be based on the formulation disclosed in Table 1 and Figure 1 The two-phase structured lubricant is obtained or prepared by the method 100 disclosed in . The formulation of the two-phase structured lubricant with the desired properties is selected for a specific system. The system can be any assembly system of lubricated engineering components, such as internal combustion engines, manual transmission systems, automatic transmission systems, transfer cases (in vehicles), differential gear systems, gear systems, electric vehicles, electric vehicle transmission systems, etc.

[0079] The method 300 includes applying a two-phase structured lubricant to assemble a system (step 304). The two-phase structured lubricant is used during the assembly of the system to provide lubrication and assist in the assembly process.

[0080] Method 300 includes applying a standard lubricant to the assembled system (step 306). Once the system is assembled (ready to operate), the standard lubricant is applied to the system to replace the two-phase structured lubricant. The standard lubricant refers to a lubricant that is typically used to provide lubrication during operation of a system (e.g., a system assembled using the two-phase structured lubricant disclosed herein). The two-phase structured lubricant disclosed herein is designed to have the following features and / or properties: allowing the lubricant to be quickly replaced by a standard lubricant present in the system.

Claims

1. A two-phase structured lubricant, comprising: about 5 weight percent (wt.%) to 95 weight percent liquid component; and About 5% to 95% by weight of a structuring component, wherein: The structuring component recrystallizes or solidifies around the liquid component.

2. The two-phase structured lubricant according to claim 1, wherein: The liquid component is about 70% to 95% by weight and comprises lubricating oil; the structuring component is about 5% to 30% by weight and comprises wax.

3. The two-phase structured lubricant according to claim 2, comprising one or more properties, wherein the properties comprise: ASTM D217 test result is 215mm / 10; ASTM D217 60 stroke result is 425mm / 10; and ASTM D1831 test results for liquids.

4. The two-phase structured lubricant according to claim 2, comprising one or more properties, wherein the properties comprise: ASTM D2266 wear scar = 0.39 mm; ASTM D2596 maximum no-seizure load = 63kg; ASTM D2596 welding load = 200kg; ASTM D5706 rolling pass load = 2000N; and ASTM D7594 wear scar / friction coefficient = 0.486 mm / 0.

128.

5. The two-phase structured lubricant according to claim 2, when the two-phase structured lubricant is diluted with a standard electric vehicle transmission fluid at a ratio of two-phase structured lubricant: standard electric vehicle transmission fluid = 1:50 parts, the two-phase structured lubricant is tested to contain one or more properties, wherein, The properties include: HFRR friction coefficient = 0.106; HFRR wear scar area = 11242 mm 2 ; ASTM D2266 wear scar = 0.459 mm; and Conductivity at 25°C = 6000 pS / cm.

6. The two-phase structured lubricant according to claim 1, wherein: The liquid component is about 5% to 25% by weight and comprises lubricating oil; the structuring component is about 75% to 95% by weight and comprises petrolatum.

7. The two-phase structured lubricant according to claim 6, comprising one or more properties, wherein the properties include: ASTM D217 test result is 220mm / 10; ASTM D217 60 stroke result is 235mm / 10; ASTM D1831 test result is 266.5mm / 10; and Melting point = 40°C.

8. The two-phase structured lubricant according to claim 6, comprising one or more properties, wherein the properties include: ASTM D2266 wear scar = 0.43 mm; ASTM D2596 maximum no-seizure load = 126kg; ASTM D2596 welding load = 200kg; ASTM D5706 rolling pass load = 2000N; and ASTM D7594 wear scar / friction coefficient = 0.562 mm / 0.

119.

9. The two-phase structured lubricant according to claim 6, when the two-phase structured lubricant is diluted with a standard electric vehicle transmission fluid at a ratio of two-phase structured lubricant: standard electric vehicle transmission fluid = 1:50 parts, the two-phase structured lubricant is tested to contain one or more properties, wherein, The properties include: HFRR friction coefficient = 0.128; HFRR wear scar area = 22066mm 2 ; ASTM D2266 wear scar = 0.51 mm; and Conductivity at 25°C = 6800 pS / cm.

10. The two-phase structured lubricant according to claim 1, further comprising a balance of additives and / or colorants.

11. A method for preparing a two-phase structured lubricant, the method comprising: mixing and heating the liquid components, wherein: The liquid component is about 5% to 95% by weight of the two-phase structured lubricant; mixing a structuring component with the heated liquid component, wherein the structuring component is about 5% to 95% by weight of the two-phase structured lubricant; melting the structuring component and mixing with the liquid component to form a homogeneous mixture; and The homogeneous mixture is cooled to form the two-phase structured lubricant.

12. The method of claim 11, comprising mixing additives and / or colorants into the homogeneous mixture.

13. The method of claim 11, comprising mixing the liquid components at about 400 revolutions per minute (rpm) to 1000 rpm, about 500 rpm to 900 rpm, about 600 rpm to 800 rpm, about 650 rpm to 750 rpm, or about 700 rpm.

14. The method of claim 11, comprising heating the liquid component to a temperature equal to the melting temperature of the structuring component, or heating the liquid component to a temperature of about 1 degree Celsius (°C) to 10°C, about 1°C to 5°C, or about 3°C ​​higher than the melting temperature of the structuring component.

15. The method according to claim 14, wherein: The structuring component has a melting temperature of about 45°C to 125°C, about 55°C to 115°C, about 65°C to 105°C, about 75°C to 95°C, or about 85°C.

16. The method according to claim 14, wherein: The structuring component has a melting temperature of about 20°C to 100°C, about 30°C to 90°C, about 40°C to 80°C, about 50°C to 70°C, or about 60°C.

17. The method of claim 11, comprising mixing the structuring component and the heated liquid component at about 400 rpm to 1000 rpm, about 500 rpm to 900 rpm, about 600 rpm to 800 rpm, about 650 rpm to 750 rpm, or about 700 rpm.

18. The method of claim 11, comprising cooling the homogeneous mixture at a cooling rate of about 1 degree Celsius per minute (°C / min) to 5°C / min.

19. A method of assembling a system using a two-phase structured lubricant, the method comprising: applying the two-phase structured lubricant to assemble a system; and Use standard lubricants on assembled systems where: Two-phase structured lubricant containing: about 5 weight percent (wt.%) to 95 weight percent liquid component; and About 5% to 95% by weight of a structuring component, wherein the structuring component recrystallizes or solidifies around the liquid component.

20. The method according to claim 19, wherein: The system is an internal combustion engine, a manual transmission system, an automatic transmission system, a transfer case in a vehicle, a differential gear system, a gear system, an electric vehicle, or an electric vehicle transmission system.

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