Compositions for generating high lubricity materials for lubricating mechanical devices and methods

Abstract

A system is provided for generating high lubricity species from a fuel when the fuel is used to operate a mechanical device such as an engine, thereby increasing the lubricity of the fuel and allowing the fuel to be used as a lubricant for various friction surfaces inside the engine, without the use of other additives or modifiers. In this aspect, embodiments of the present disclosure may include an apparatus having a first surface on which a film is deposited. The first surface of the apparatus and the associated membrane may be in continuous contact with the fuel. The device may include a second surface that is in periodic and / or repeated contact with the first surface, such as by sliding contact, rolling contact, a combination of both, etc.

Description

[0001] Cross-references to related applications

[0002] This is a non-provisional patent application claiming priority to U.S. Provisional Patent Application No. 63 / 531,295, filed August 7, 2023, entitled "System for Generating High-Lubricity Substances for Lubrication of a Mechanical Device". Technical Field

[0003] This invention generally relates to the lubrication of mechanical equipment. More specifically, this invention relates to a system for generating a highly lubricating substance for lubricating mechanical equipment. Background Technology

[0004] Engines such as internal combustion engines have a wide range of applications, from powering cars to generating electricity. These engines rely on a stable supply of fuels, typically hydrocarbon-based substances such as gasoline, diesel, or aviation fuel. However, these fuels can tend to be low in lubricity, meaning they cannot provide sufficient lubrication for the moving parts inside the engine. To provide this lubrication, a separate system is usually needed to supply lubricant, typically a long hydrocarbon-based oil, to critical wear surfaces. This oil provides protection against wear and tear on the engine but also reduces fuel efficiency, increases emissions, and raises maintenance costs.

[0005] The demand for these lubricants in engines necessitates their addition as additives to the fuel source or the incorporation of specialized systems during operation to circulate the lubricant to critical wear surfaces. This demand for lubrication can present significant challenges for operators. Either specialized supplemental lubricants must be obtained in specific proportions and added to the fuel, or the weight and complexity of the lubrication pump and recirculation system must be incorporated into the engine design. When using a lubricant recirculation system, due to the lubricant's lifespan, it requires periodic draining, flushing, and refilling, and system components may require maintenance to operate the engine. In either case, frequent lubricant combustion or overheating in the engine system significantly increases emissions and leads to substantial engine deposits, reducing efficiency and shortening engine life. Furthermore, lubricant leaks from the engine or during lubricant handling may require extensive remedial measures to mitigate environmental damage.

[0006] To address these issues, a system is needed that can increase fuel lubricity and improve the performance and efficiency of engine or mechanical systems without the use of additives or specialized lubricants.

[0007] In the prior art, several variables are cited as contributing to increased fuel lubricity, including fuel chemical composition, viscosity, and third bodies (3). rd The existence of bodies.

[0008] Heavy aromatics such as polycyclic aromatic hydrocarbons (PAHs) and nitrogen-containing heterocyclic polycyclic aromatic hydrocarbons (NPAHs) are the primary source of lubricity in petroleum distillate engine fuels. These chemicals bind to metal surfaces due to their geometry, forming slip surfaces. There is generally a proportional relationship between the fuel boiling point and the concentration of these chemicals, and therefore diesel fuel is more lubricating than kerosene, which in turn is more lubricating than gasoline. While diesel is more lubricating than the other oils mentioned, it is typically used at higher pressures, and several biodiesels do not contain these hydrocarbons, thus increasing wear in diesel applications.

[0009] Fluid viscosity is crucial for lubrication and low wear because it provides the hydrodynamic forces that separate two surfaces as they move relative to each other. Essentially, the surfaces that cause engagement slide along the fluid surface, rather than engaging with the counter surface.

[0010] Finally, the third-body particles act between the surfaces to form a solid lubricant boundary layer, filling in surface roughness and creating slip surfaces for the mating surfaces under higher pressure. These typically result in lower friction and wear.

[0011] It has been shown that adding graphite to the lubrication system can improve lubrication, increase power, and reduce wear.

[0012] Therefore, it is desirable to develop a method to improve fuel lubricity through a catalytic reaction that increases the concentration of heavy aromatics, increases viscosity, and / or generates third bodies in the fuel. Summary of the Invention

[0013] The following provides a simplified overview of one or more embodiments of this disclosure to offer a basic understanding of these embodiments. This overview is not a comprehensive summary of all contemplated embodiments and is neither intended to identify key or essential elements of all embodiments nor to describe the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments of the invention in a simplified form as a prelude to the more detailed description that follows.

[0014] Therefore, a first embodiment provides a method for generating a highly lubricating substance for lubricating mechanical equipment, the method comprising: providing a first component operatively coupled to the mechanical equipment, wherein the mechanical equipment is an engine, the first component including a surface on which a film is deposited; operating the engine with fuel, wherein operating the engine includes exposing the film to the fuel to generate a highly lubricating substance on the film surface; suspending at least a portion of the highly lubricating substance within the fuel; delivering the at least a portion of the highly lubricating substance via the fuel to a second component operatively coupled to the engine; and using the at least a portion of the highly lubricating substance to lubricate the second component.

[0015] In a first aspect of the first embodiment, generating the highly lubricating substance on the surface of the membrane further includes: positioning the fuel between the membrane on the surface of the first component and the surface of the third component operatively coupled to the engine; and bringing the membrane on the surface of the first component into contact with the surface of the third component.

[0016] In a second aspect, either alone or in combination with the first aspect of the first embodiment, the first component and the third component are integrally molded components within the engine.

[0017] In a third aspect, alone or in combination with any of the foregoing aspects of the first embodiment, the first component is a cylinder liner of a cylinder within the engine, wherein the third component is a piston or piston ring positioned within the cylinder.

[0018] In a fourth aspect, alone or in combination with any prior aspect of the first embodiment, the first component is housed in a means operatively coupled to the engine.

[0019] In a fifth aspect, alone or in combination with any prior aspect of the first embodiment, the device is located outside the engine, wherein the first component is substantially located within the fuel path of the engine's fuel delivery system.

[0020] In a fifth aspect, alone or in combination with any prior aspect of the first embodiment, the device is located outside the engine, wherein the first component is substantially located within the fuel path of the engine's fuel delivery system.

[0021] In a sixth aspect, alone or in combination with any of the foregoing aspects of the first embodiment, the highly lubricating substance is a suspension containing one or more carbon allotropes.

[0022] In a seventh aspect, alone or in combination with any of the foregoing aspects of the first embodiment, the highly lubricating substance is a suspension of a graphite structure in the fuel.

[0023] In the eighth aspect, alone or in combination with any of the foregoing aspects of the first embodiment, the second component is a bearing, a valve mechanism component, or a cam surface.

[0024] In a ninth aspect, alone or in combination with any of the foregoing aspects of the first embodiment, the membrane comprises copper and molybdenum nitride in a copper-to-molybdenum ratio between 1:30 and 1:2.

[0025] A second embodiment provides a system for generating a highly lubricating substance for lubricating mechanical equipment. The system includes: a mechanical device, wherein the mechanical device is an engine; a first component operatively coupled to the engine, wherein the first component has a surface on which a film is deposited; a second component operatively coupled to the engine, wherein the second component includes a surface in movable contact with the surface of the film; and a third component operatively coupled to the engine; wherein a highly lubricating substance is generated on the surface of the film when the film is placed in contact with the second component and fuel is positioned between the surface of the film and the surface of the second component; wherein at least a portion of the highly lubricating substance is suspended in the fuel in the engine.

[0026] In a first aspect of the second embodiment, the first component and the second component are integrally molded components within the engine.

[0027] In a second aspect of the second embodiment, alone or in combination with the first aspect or embodiment, the first component is a cylinder liner of a cylinder within the engine, wherein the second component is a piston or piston ring positioned within the cylinder.

[0028] In a third aspect of the second embodiment, either alone or in combination with any of the foregoing aspects or embodiments, the first component and the second component are housed in a device operatively coupled to the engine.

[0029] In a fourth aspect of the second embodiment, alone or in combination with any of the foregoing aspects or embodiments, the device is located outside the engine, wherein the first component and the second component are substantially located within the fuel path of the engine's fuel delivery system.

[0030] In a fifth aspect of the second embodiment, alone or in combination with any of the foregoing aspects or embodiments, the highly lubricating substance is a suspension containing one or more carbon allotropes.

[0031] In a sixth aspect of the second embodiment, alone or in combination with any of the foregoing aspects or embodiments, the highly lubricating substance is a graphite structure suspended in the fuel.

[0032] In a seventh aspect of the second embodiment, alone or in combination with any of the foregoing aspects or embodiments, the third component is a bearing, a valve mechanism component, or a cam surface.

[0033] In the eighth aspect of the second embodiment, alone or in combination with any of the foregoing aspects or embodiments, the membrane comprises copper and molybdenum nitrides.

[0034] In the ninth aspect of the second embodiment, alone or in combination with any of the foregoing aspects or embodiments, the ratio of copper to molybdenum is between 1:30 and 1:2.

[0035] The above overview is provided only to summarize some exemplary embodiments to provide a basic understanding of some aspects of this disclosure. Therefore, it should be understood that the above embodiments are merely examples and should not be construed as limiting the scope or spirit of this disclosure in any way. It should be understood that, in addition to those summarized herein, the scope of this disclosure also covers many potential embodiments, some of which will be further described below. Attached Figure Description

[0036] Having thus generally described various embodiments of this disclosure, reference will now be made to the accompanying drawings. In some embodiments described herein, the components shown in the drawings may or may not be present. Some embodiments may include fewer (or more) components than those shown in the figures.

[0037] Figure 1 A system for generating a highly lubricating substance for lubricating mechanical equipment, according to an embodiment of the present disclosure, is shown;

[0038] Figure 2 A mechanism for delivering a highly lubricating substance m according to an embodiment of the present disclosure is shown; and

[0039] Figure 3 A method for generating a highly lubricating substance for lubricating mechanical equipment is shown according to embodiments of the present disclosure.

[0040] Figure 4 This is a data graph from a cone-plate viscosity test, which is performed on hydrocarbon fuels that are not in contact with the membrane to be protected and crankcase effluent from systems in which mechanical components are coated with the membrane to be protected.

[0041] Figure 5 This is a scanning electron microscope (SEM) image of a highly lubricating substance formed in a fuel mixture after contact with the membrane to be protected.

[0042] Figure 6 This is an X-ray diffraction (XRD) pattern of a highly lubricating substance present in an effluent stream according to an exemplary embodiment of the present invention. Detailed Implementation

[0043] Embodiments of this disclosure will be described more fully below with reference to the accompanying drawings, which show some, but not all, embodiments of this disclosure. In fact, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments listed herein; rather, these embodiments are provided to enable this disclosure to meet applicable legal requirements. Where possible, unless expressly stated otherwise, any term expressed herein in the singular is intended to include the plural form as well, and vice versa. Furthermore, as used herein, the terms “a” and / or “an” should mean “one or more,” even if the phrases “a” or “a plurality” are used herein. Additionally, when something is said herein to be “based on” something else, it may also be based on one or more other things. In other words, unless expressly stated otherwise, “based on” as used herein means “at least partially based on” or “at least partially based on.” The same numbers always refer to the same elements.

[0044] As used herein, "film" or "coating" can refer to any continuous or discontinuous material that can be formed, deposited, coated, or placed on or near a structural surface. In some embodiments, a film may include nanomaterials such as nanoparticles, nanosheets, nanolayers, or other such nanostructures.

[0045] As used herein, “effluent” can mean any liquid discharge that flows out of mechanical equipment using the methods claimed to be protected.

[0046] As used in this article, "viscosity" or "viscousity" refers to the resistance of a fluid to deformation or flow. It describes how "thick" or "thin" a fluid is and quantifies its internal friction.

[0047] Various embodiments of this disclosure provide a system for generating a highly lubricating substance from fuel (e.g., hydrocarbon-containing fuel) when fuel is used to operate mechanical equipment such as engines (e.g., internal combustion engines, such as piston engines, turbine engines, rotary engines, jet engines, etc.), thereby increasing the lubricity of the fuel and allowing the fuel to be used as a lubricant for various friction surfaces inside the engine without the use of other additives or modifiers. In this regard, embodiments of this disclosure may include a device having a first surface on which a film is deposited. The first surface of the device and the associated film may be in continuous contact with the fuel (e.g., a hydrocarbon fuel intended for use inside an internal combustion engine). The fuel may be a hydrocarbon-based fluid, such as gasoline, diesel, biodiesel, jet fuel or aviation fuel, kerosene, etc. The device may include a second surface that is periodically and / or repeatedly contacted with the first surface, for example by sliding contact, rolling contact, a combination of both, etc. While the generation of highly lubricating substances inside engines is mentioned, it should be understood that the processes described herein are also applicable to lubricating other types of components (e.g., bearings, pumps, cams, other mechanical joints) in other types of mechanical equipment.

[0048] In one embodiment, the film may be a nanocomposite coating comprising metal M and / or metal nitrides (e.g., in the form of MaNx). In some embodiments, metal M may be selected from the group consisting substantially of metals Cu, Ni, Sc, Y, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, Ag, Au, Pd, Zn, Cd, Hg, Al, Ga, In, Pt, and W, and combinations thereof. In an exemplary embodiment, the film may comprise a combination of molybdenum nitride and copper and / or copper nitride. For example, the film may comprise molybdenum nitride particles dispersed with copper. In some embodiments, the film may comprise copper molybdenum nitride in the form of CuaMobNx. The film may comprise a combination of about 50 to 99.7 wt% molybdenum and about 50 to 0.3 wt% copper. In another embodiment, the film may comprise a combination of about 70 to 95 wt% molybdenum and about 30 to 3 wt% copper. In another embodiment, the film may comprise a combination of about 75 to 90 wt% molybdenum and about 8 to 25 wt% copper. In another embodiment, the membrane may comprise a combination of about 80 to 85% by weight molybdenum and about 13 to 20% by weight copper. In some embodiments, the copper to molybdenum ratio, in weight percent, may be between 1:30 and 1:2. Depending on the operating tolerances of the components within the machine or equipment, the membrane may be deposited on the surface of the components (e.g., to prevent adhesion or excessive friction due to the addition of the membrane). Thus, in some embodiments, the thickness of the membrane may range from about 0.1 micrometers to about 40 micrometers. In other embodiments, the thickness of the membrane may range from about 1 micrometer to about 10 micrometers. In still other embodiments, the thickness of the membrane may range from about 3 to about 6 micrometers.

[0049] Films can be deposited on the surface of one or more components of a machine or device, such as an engine (or any other surface or substrate), using various techniques including, but not limited to, physical vapor deposition (“PVD”), cathodic arc deposition (“arc PVD”), evaporation deposition, sputtering and / or magnetron sputtering, chemical vapor deposition (CVD), hybrid plasma-enhanced CVD (“PECVD”), low-pressure or ultra-high vacuum CVD (“LPCVD” or “UHVCVD”). In exemplary embodiments, PECVD can be used to deposit a film comprising copper and molybdenum nitrides onto a substrate (e.g., an internal component of an internal combustion engine). In such embodiments, the substrate can be placed in a low-pressure reaction chamber between the cathode and anode. For example, the reaction chamber may have an internal pressure range of approximately 0.005 Torr to 10 Torr. In other embodiments, the pressure of the reaction chamber may range from approximately 0.05 Torr to 5 Torr. In still other embodiments, the pressure of the reaction chamber may range from approximately 1 Torr to 2 Torr. In some embodiments, the substrate may be heated to a temperature between 200 degrees Fahrenheit and 1000 degrees Fahrenheit. In other embodiments, the substrate may be heated to a temperature between about 300 degrees Fahrenheit and about 800 degrees Fahrenheit. In still other embodiments, the substrate may be heated to a temperature between about 400 degrees Fahrenheit and about 600 degrees Fahrenheit.

[0050] Gaseous precursors and / or reactants (e.g., precursors or reactants containing copper, molybdenum, and / or nitrogen) may be introduced into a reaction chamber. Subsequently, a radio frequency (“RF”) potential or pulsed direct current (DC) may be used to generate plasma from the gaseous precursors and / or reactants within the reaction chamber (e.g., between the cathode and anode), thereby initiating a chemical reaction through which such precursors and / or reactants are transformed and deposited on a substrate as a film in solid form (e.g., a film containing molybdenum nitride and copper and / or copper nitride).

[0051] The process of bringing the first and second surfaces into contact with each other and disposing of both the hydrocarbon fuel and the deposited film between the first and second surfaces allows the film to convert at least a portion of the hydrocarbon fuel disposed between these surfaces into a highly lubricating substance. This highly lubricating substance may remain disposed on one or more surfaces as a durable friction layer, or it may be suspended within the hydrocarbon fuel. As the hydrocarbon fuel travels through the engine, the highly lubricating substance may come into contact with other surfaces in the engine that do not have a deposited film and are not in contact with it. When this occurs, the highly lubricating substance, when in contact with other surfaces and / or disposed adjacent to other surfaces, can provide the benefits of additional lubrication and wear protection to such surfaces without the need for a deposited film or coating. As a result, the engine can operate continuously on low-lubricating hydrocarbon fuels without the need for lubricant additives or a separate lubricant recirculation system.

[0052] In another embodiment, the film may be deposited on the surface of an engine component, wherein contact between such a surface and another surface results in the generation of a highly lubricating substance. For example, in an internal combustion piston-driven engine, at least a portion of the cylinder may be coated with a film that converts hydrocarbon fuel into a highly lubricating substance. In such an embodiment, the first surface may include the inner wall of the cylinder coated with the film, and the second surface may include another component of the engine (e.g., the outer surface of a piston and / or piston rings positioned inside the cylinder) such that at least a portion of the second surface contacts and / or is adjacent to the first surface. In an alternative embodiment, the first surface may include the outer surface of a piston and / or piston rings coated with the film, and the second surface may include the inner wall of the cylinder. Movement of the piston and other components in the engine can then generate and deliver the highly lubricating substance to other areas of the engine that do not have the conversion film, such as bearing or cam surfaces. When the highly lubricating substance comes into contact with these other areas, it reduces friction and wear rates of the components and allows for extended periods of operation without the need for externally added lubricating fuel additives or lubricant recirculation systems.

[0053] In another embodiment, the conversion film used to generate the highly lubricating substance when in contact with the second surface is a metal nitride coating comprising 50 to 99.7% by weight of molybdenum nitride and 50-0.3% by weight of copper or copper nitride. In such embodiments, the highly lubricating substance comprises graphite carbon in the form of lubricant graphite and exhibits improved chemical properties and viscosity. This graphite carbon is initially formed from the contact between the deposited film and the opposing surface. Instead of remaining as a durable coating on the surface of the deposited film, the graphite carbon is released from the surface and suspended in the hydrocarbon fuel stream, which increases the lubricity of the hydrocarbon fuel and thus enables the hydrocarbon fuel to be used as a lubricant for other components such as bearings of rotating parts, which may or may not have a deposited film on their surfaces.

[0054] The systems and methods described herein offer numerous advantages over existing lubrication technologies. For example, by frictionally generating a highly lubricating substance through the interaction between the contact surfaces and the fuel, the system can provide highly durable lubrication to the fuel contact surfaces of machines or equipment (such as internal combustion engines) without the need for additional lubricants (e.g., oils, greases, etc.) that could increase internal friction or resistance in the machine or equipment (e.g., due to the higher viscosity level of the additional lubricant). In turn, these contact surfaces (e.g., bearings, cams, shafts, pistons, cylinders, etc.) can move freely without jamming or excessive wear, thereby improving the operating efficiency of such machines or equipment. In fact, the durability of such a coating allows the machine to operate for short periods even when there is no fuel in the crankcase. Furthermore, the relatively small size of the highly lubricating substance allows the particles to travel (e.g., through the fuel) to various other uncoated parts in the fuel path, thereby providing lubrication to such uncoated parts. Finally, the elimination of the need for additional lubricants reduces emissions and / or sulfur effects associated with operating the machines.

[0055] Now turn to the attached image. Figure 1 A system for generating a highly lubricating substance for lubricating mechanical equipment according to an embodiment of the present disclosure is shown. In particular, the system can enrich hydrocarbon-based fuels with a highly lubricating substance that can be used to lubricate other surfaces within an engine. Thus, the system may include a device having a first plate 101 (which is rotatable) on a surface (e.g., a first surface) of which a film is deposited. The deposited film on the surface of the first plate 101 may come into contact with liquid hydrocarbon fuel 102. After contact with the hydrocarbon fuel 102, the surface of the first plate 101 may come into contact (e.g., sliding contact, rotational contact, etc.) with the surface (e.g., a second surface) of a second plate 103 (which is also rotatable). The action of the two plates rotating relative to each other, carrying fuel disposed between the first surface (on which the film is deposited) and the second surface, results in at least a portion of the hydrocarbon fuel being converted into a highly lubricating substance 104. The highly lubricating substance 104 may be, for example, a carbon-based material such as graphitic carbon. In this respect, the highly lubricating substance 104 may include one or more of various allotropes of carbon, such as graphite, graphene, fullerene, diamond-like carbon (“DL”), etc. In some embodiments, the high lubricating material 104 may include 10 to 100% by weight of graphite carbon. In other embodiments, the high lubricating material 104 may include 50 to 80% by weight of graphite carbon.

[0056] The highly lubricating material 104 is not a durable friction layer maintained on either surface of the two plates 101, 103, but rather can be suspended in the hydrocarbon fuel 102 and carried within the hydrocarbon fuel 102 to other engine parts or components, such as bearing 105, in the fuel path. When the highly lubricating material 104 comes into contact with other parts or components, such as bearing 105, it forms a temporary lubricating layer on the friction surface of such parts or components (e.g., bearing 105). This temporary lubricating layer reduces the coefficient of friction, reduces wear on components, extends component life, and improves component performance.

[0057] Figure 2 A delivery mechanism for a highly lubricating substance according to one embodiment of the present disclosure is illustrated. In such an embodiment, a first component 202 inside an engine (e.g., the internal portion of a cylinder, such as a cylinder wall) has a surface (e.g., a first surface) at least partially modified with a deposited film 204. The surface of the first component 202, including the deposited film 204, may engage in frictional contact (e.g., sliding or rotational contact) with an opposing surface (e.g., a second surface) of a second component 212 (e.g., a component that contacts at least a portion of the cylinder wall, such as a piston or piston ring). The frictional contact between the deposited film 204 and the opposing surface of the second component 212 chemically reacts with liquid hydrocarbon fuel 208 to generate a highly lubricating substance. The highly lubricating substance forms a temporary lubricating layer 206 on the deposited film 204 on the surface of the first component 202 and a temporary lubricating layer 210 on the opposing surface of the second component 212.

[0058] When liquid hydrocarbon fuel 208 comes into contact with the temporary lubrication layers 206 and 210 of the highly lubricating material, it carries away some of the highly lubricating material from the temporary lubrication layers 206 and 210, becoming enriched liquid hydrocarbon fuel 214 (liquid hydrocarbon fuel oil enriched with highly lubricating material). As the enriched liquid hydrocarbon fuel 214 moves through the engine, it enters other engine components 216 (e.g., cam surfaces, rotating shafts, bearings, etc.), which undergo wear (e.g., abrasive wear, sliding wear, rolling wear, rotational wear, etc.). At this time, the highly lubricating material in the enriched liquid hydrocarbon fuel 214 forms a temporary lubrication layer 218 on the other components 216. In some embodiments, the other components 216 may not have been modified with the deposited film 204 as the surface of the first component 202, and may not be in contact with the deposited film 204 as the opposing surface of the second component 212. In other words, because the highly lubricating substance is suspended in the enriched liquid hydrocarbon fuel 214, and the enriched liquid hydrocarbon fuel 214 is brought into contact with many components of the engine (e.g., other components 216), the highly lubricating substance forms a lubricating and wear-resistant film on the other components 216, which would otherwise not receive the lubrication required for long-term operation. Therefore, the system and method described herein allow the engine to continue operating even without additional lubrication of the other components 216. It should be understood that the above embodiments are provided for illustrative purposes and are not intended to limit the scope of the disclosure provided herein. For example, in other embodiments, the piston (or any other component with a wear surface) of the internal combustion engine, rather than the cylinder interior, may be coated with film 204. Furthermore, coating multiple components of the engine with film 204 is also within the scope of this disclosure.

[0059] Example:

[0060] A film containing copper and molybdenum nitrides was deposited on the inner surfaces of the internal combustion engine cylinders. This engine was reassembled and operated using only aviation turbine fuel (Jet A, jet A), allowing unburned fuel to recirculate into the crankcase and be applied to the bearings therein. No oils or additives were provided for lubrication. The engine was run in this manner for 500 hours, at which point the bearings that had not received the coating were inspected. During the inspection, the inner surfaces of the engine showed a thin film of poorly adhered graphite carbon. Despite prolonged operation without lubricant, the bearings showed no signs of excessive wear. The properties of the effluent fuel (crankcase effluent) were also tested.

[0061] Figure 3A method 300 for generating a highly lubricating substance for lubricating mechanical equipment is illustrated according to an embodiment of the present disclosure. As shown in block 302, the method includes providing a first component operatively coupled to a mechanical device, wherein the mechanical device is an engine, and the first component includes a surface on which a film is deposited. In an exemplary embodiment, a technique such as PECVD may be used to coat the first component with a film comprising copper and / or molybdenum nitrides. In some embodiments, the highly lubricating substance may be graphite carbon, which is generated when the surface of the film contacts or approaches a moving (e.g., rotating, sliding, etc.) opposing surface of a third component operatively coupled to the engine, while fuel is present between or near the film surface and the opposing surface. The first component may be, for example, an internal and / or integrally formed component of the engine, such as a cylinder wall of an internal combustion engine, and the third component may be a component that can contact or approach the cylinder interior (e.g., cylinder wall), such as a piston or piston ring. In such embodiments, the highly lubricating substance may be generated during normal operation of the engine. For example, fuel may be introduced into the cylinder such that fuel contacts the joint between the piston or piston ring and the cylinder wall. Therefore, when the piston or piston rings come into contact with or approach the cylinder wall and slide up and down on the cylinder wall in a reciprocating motion, the highly lubricating substance forms on the surface of the film on the cylinder wall.

[0062] In other embodiments, the first component may be part of a separate device operatively connected to the engine (e.g., a device specifically designed to generate a highly lubricating substance that is not necessarily dependent on engine operation). In such embodiments, the first component may be a first rotating plate within the device, the surface of which is coated with a copper and / or molybdenum film. The device may include a second rotating plate (e.g., a third component), the surface of which may be close to or in rotational and / or sliding contact with the film deposited on the first rotating plate (the opposite surface of the first plate surface). In some embodiments, a pump may be used instead of the second rotating plate. The first and second rotating plates may be located within the fuel path circulated by the engine's fuel delivery system, such that fuel passes between the surface of the first rotating plate containing the film and the opposite surface of the second rotating plate, thereby forming a highly lubricating substance on the surface of the film on the first rotating plate. In some embodiments, the device may be located inside the engine (e.g., within the engine housing). In other embodiments, the device may be located outside the engine (e.g., on a mounting bracket fixed to the outside of the engine) while still remaining at least partially within the fuel path of the engine's fuel delivery system.

[0063] Next, as shown in box 304, the method includes running an engine with fuel, wherein running the engine includes exposing the membrane to fuel to generate the highly lubricating substance on the surface of the membrane. When internal combustion is running, the fuel (e.g., a hydrocarbon fuel, such as gasoline, diesel, jet fuel, etc.) may contact the membrane on the surface of the first component and / or the opposing surface of the third component. In this respect, the hydrocarbon fuel may be located between the surface of the first component and the corresponding surface of the third component. When the hydrocarbon fuel interacts with the first component and / or the third component (e.g., through mechanical sliding or rotational contact between the first component and the third component), at least a portion of the hydrocarbon fuel may be converted into a highly lubricating substance (e.g., graphite carbon) that can be formed on the surface of the membrane on the first component.

[0064] Next, as shown in box 306, the method includes suspending at least a portion of a highly lubricating substance within the fuel. The highly lubricating substance may weakly adhere to the membrane of the first component such that when the fuel contacts the top layer of the highly lubricating substance, the fluid movement of the fuel is sufficient to remove some of the highly lubricating substance from the membrane of the first component. The particles of the highly lubricating substance carried away by the fluid movement of the fuel may then be suspended in the fuel, such that during engine operation, the particles may be carried along the fuel path to various other parts of the engine.

[0065] Next, as shown in box 308, the method includes delivering at least a portion of a highly lubricating substance via fuel to a second component operatively coupled to the engine. As previously described, the highly lubricating substance, already suspended in the fuel, can be carried to various other components in the engine by fluid movement of the fuel throughout the fuel delivery system. For example, the second component may be a component subject to wear (e.g., frictional contact with other components or surfaces). In this regard, the second component may be a component such as a bearing, rod or shaft surface (e.g., crankshaft, camshaft, etc.), valve mechanism component, cam surface, turbine, etc. In some embodiments, the second component may be an untreated component that has not been treated with a film (e.g., copper and / or molybdenum nitride coating) or an additional lubricant (e.g., oil or grease).

[0066] Next, as shown in box 310, the method includes lubricating the second component using at least a portion of the highly lubricating substance. In this regard, the highly lubricating substance suspended in the fuel may at least partially coat and / or adhere to the surface of the second component. Thus, when the second component comes into contact with another structure or component (e.g., a fourth component), the highly lubricating substance may be located between the second and fourth components to provide lubrication at the joint between them. As the engine continues to run, the highly lubricating substance may be continuously generated from the fuel, for example (through moving contact between the first and third components), and subsequently continuously delivered to other untreated components to provide them with lubrication. In this way, the method described herein allows the engine to continue running even without additives or additional lubricants, and its components are not subjected to excessive friction and wear.

[0067] Figure 4 The diagram shows the viscosity versus shear rate for a fuel not yet used in the claimed method (fresh jet A) and for crankcase effluent generated according to an exemplary embodiment of the invention (crankcase effluent). The x-axis represents the rate of fluid deformation, and the y-axis represents the flow resistance of the fluid. The lines corresponding to fresh jet A 404 and crankcase effluent 402 show that viscosity decreases with increasing shear rate. This characteristic is referred to as shear thinning. The steeper the slope of the line, the more pronounced the shear thinning behavior. As shown in 402, the shear thinning of the crankcase effluent is greater than that of fresh jet A as shown in 404. The decrease in viscosity of crankcase effluent 402 with increasing shear rate is more pronounced than that of fresh jet A 404.

[0068] In one exemplary embodiment of the invention as claimed, the highly lubricating material formed in the effluent comprises graphene oxide. An SEM image 500 of the highly lubricating material in the effluent visually corresponds to graphene oxide. In the SEM image, graphene oxide appears as a thin, typically wrinkled, network of sheets with irregular edges and a textured surface. These sheets can aggregate into clusters, and their appearance can vary based on the synthesis method and conditions.

[0069] Energy-dispersive X-ray spectroscopy (EDX) provides elemental composition information of the highly lubricating material by detecting X-rays emitted from the sample when it is irradiated with an electron beam. In one exemplary embodiment of the claimed invention, EDX testing of the effluent supports the formation of graphene oxide. The EDX test results show a significant amount of oxygen in addition to carbon, indicating the presence of graphene oxide rather than pure graphene.

[0070] The results of analyzing the effluent using X-ray diffraction are as follows: Figure 6As shown. The experimental setup used a SmartLab goniometer. The X-ray source operated at 40 kV and 44 mA, using Cu Kα radiation at a wavelength of 1.541862 Å. An SC-70 detector was used to capture the diffraction pattern, and the sample was mounted on a standard Z-stage. The optical configuration followed Bragg-Brentano focusing geometry.

[0071] The experiment was conducted in STEP scanning mode, with each step lasting 5.0 seconds and a scan step size of 0.0500 degrees. The scanning axis was θ (Theta) / 2-θ, covering a scan range of 5.0000 to 90.0000 degrees. The initial 2-θ angle was set to 5.0000 degrees, and Ω (Omega) was set to 2.5000 degrees.

[0072] This configuration includes a BB CBO selection slit, a Soller slit with an incident parallel slit angle of 5.0 degrees, and an incident slit with an angle of 2 / 3 degrees. A 10.0 mm length limiting slit is used along with a 2 / 3 degree receiving slit #1. The receiving optics are PSA_open, and the receiving parallel slit is also set to a 5.0 degree Soller slit and a 0.600 mm receiving slit #2. No filters are applied, and an attenuator with a factor of 1 / 10000 is used.

[0073] The diffraction beam monochromator was configured to be curved, and the monochromator slit was set to BBM. The peaks generated by the XRD scan provided crucial information about the interlayer spacing and the degree of oxidation of highly lubricating substances in the effluent.

[0074] Cross-referencing EDX and XRD data, the high oxygen content in EDX combined with the specific XRD peak pattern supports the identification of graphene oxide as a highly lubricating substance.

[0075] The lubricating properties of distillate motor fuels come from surface-active compounds in petroleum, particularly heavy aromatic compounds, such as polycyclic aromatic hydrocarbons (PAHs) with three or more fused rings and nitrogen-containing polycyclic aromatic hydrocarbons (NPAHs).

[0076] In an exemplary embodiment of the present invention, the concentration of the monoaromatic compound in the highly lubricating material is less than 16% by mass, preferably less than 15.8% by mass, and most preferably less than 15.6% by mass.

[0077] In one exemplary embodiment of the invention, the aromatic content was measured using supercritical fluid chromatography (SFC), ASTM D5186 for jet fuel A, and a fuel effluent containing highly lubricating substances. No observable differences in functional chemical composition were observed. The composition of each of the two fluids determined by SFC is shown below. The reporting limit (RL) is the value at or above which results are routinely reported. The dilution factor (DF) is the dilution applied to the sample during analysis to arrive at the final reported analyte result.

[0078] ASTM D5186[A] Aromatics for Jet Fuel A

[0079]

[0080] For effluent fuels containing aromatics that meet ASTM D5186[A]

[0081]

[0082] Comparing the chromatographic results of jet fuel A and the effluent fuels analyzed in the above embodiments, jet fuel A has a higher content of monoaromatic compounds but a lower content of polynuclear aromatic compounds compared to the effluent fuels.

[0083] A significant reduction in wear was observed by increasing the PAH content from 1.2% to 2.1%.

[0084] The kinematic viscosity (Kv) of the two fluids was measured using ASTM standard D-445 and reported at a temperature of 40°C. The results are as follows:

[0085] Jet fuel A: 1.368 mm 2 / s

[0086] Effluent fuel: 1.834 mm 2 / s

[0087] The effluent fuel has a high total aromatic content and viscosity, suggesting that it may be a more complex or heavier mixture of aromatic compounds.

[0088] In an exemplary embodiment, ASTM D6079 is used to perform tribological tests. Specifically, the lubricity of the fuel is evaluated by simulating the friction and wear conditions that occur in a diesel engine using a high-frequency reciprocating test bench (HFRR). The test measures the wear mark diameter on a steel test specimen to assess the fuel's effectiveness in reducing friction and preventing wear.

[0089] In one exemplary embodiment, a third body is generated in the effluent fuel by a reaction catalyzed by the claimed membrane. Tribological tests of the jet fuel A and the effluent fuel show that the third body can reduce wear by up to two orders of magnitude. When the third body is filtered out of the fuel, tribological tests of the two fluids show that the effluent fuel results in a reduction in wear, and the friction is half that of the jet fuel.

[0090] Raman spectroscopy and dynamic light scattering were also used to analyze the filtered effluent fuel.

[0091] In one embodiment of the invention, the claimed film induces a catalytic reaction upon contact with fuel, converting mononuclear aromatic compounds into polynuclear aromatic compounds. These polynuclear aromatic compounds bind to the surfaces of uncoated mechanical parts to improve lubricity and reduce wear on these surfaces.

[0092] As will be understood by those skilled in the art, this disclosure may be embodied as an apparatus (including, for example, a system, machine, device, computer program product, etc.), a method (including, for example, a business process, a computer-implemented process, etc.), a computer program product (including firmware, resident software, microcode, etc.), or any combination thereof. Many modifications and other embodiments of this disclosure envisioned herein will occur to those skilled in the art, and those to which such embodiments pertain will benefit from the teachings presented in the foregoing description and the associated drawings. Although the drawings show only certain components of the methods and systems described herein, it should be understood that various other components may also be part of this disclosure. Furthermore, in some cases, the above methods may include fewer steps, while in others additional steps may be included. In some cases, the steps of the above methods may be modified in any order and in any combination.

[0093] Therefore, it should be understood that this disclosure is not limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. A method for generating a highly lubricating substance for lubricating mechanical equipment, the method comprising: A first component is provided that is operatively coupled to the mechanical device, the first component including a surface on which a film is deposited; The mechanical device is operated using a hydrocarbon-based fluid, wherein operating the mechanical device includes exposing the membrane to the hydrocarbon-based fluid to generate the highly lubricating substance on the surface of the membrane; At least a portion of the highly lubricating substance is suspended in the hydrocarbon-based fluid; At least a portion of the highly lubricating substance is delivered via the hydrocarbon-based fluid to a second component operatively coupled to the mechanical device; as well as The second component is lubricated using at least a portion of the highly lubricating substance.

2. The method as described in claim 1, wherein, The generation of the highly lubricating substance on the surface of the film further includes: Positioning the hydrocarbon-based fluid between the membrane on the surface of the first component and the surface of the third component operatively coupled to the mechanical device; and The film on the surface of the first component is brought into contact with the surface of the third component.

3. The method as described in claim 1, wherein, The first component is housed in a device operatively coupled to the mechanical device.

4. The method of claim 1, wherein, The device is located outside the mechanical equipment, wherein the first component is substantially located within the path of the hydrocarbon-based fluid delivery system of the mechanical equipment.

5. The method of claim 1, wherein, The highly lubricating substance is a suspension containing one or more carbon allotropes.

6. The method of claim 1, wherein, The membrane contains a metal M selected from the group consisting essentially of metals Cu, Ni, Sc, Y, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, Ag, Au, Pd, Zn, Cd, Hg, Al, Ga, In, Pt, and W, and combinations thereof.

7. The method of claim 1, wherein, The membrane contains copper and molybdenum nitrides in a copper-to-molybdenum ratio between 1:3 and 1:

2.

8. A highly lubricating substance comprising one or more carbon allotropes, wherein, When the membrane is exposed to a hydrocarbon-based fluid, the highly lubricating substance is generated on the surface of the membrane.

9. The highly lubricating substance as described in claim 8, wherein, The film is deposited on the surface of a component of a mechanical device, the mechanical device comprising: A first component, which is operatively coupled to the mechanical device. Inlet flow of hydrocarbon-based fluids; The effluent includes: Hydrocarbon-based fluids; and At least a portion of the highly lubricating substance is suspended in the hydrocarbon-based fluid.

10. The highly lubricating substance as described in claim 8, wherein, The highly lubricating material also includes the graphite structure in the hydrocarbon-based fluid.

11. The highly lubricating substance as described in claim 8, wherein, The membrane contains a metal M selected from the group consisting essentially of metals Cu, Ni, Sc, Y, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, Ag, Au, Pd, Zn, Cd, Hg, Al, Ga, In, Pt, and W, and combinations thereof.

12. The highly lubricating substance as described in claim 8, wherein, The membrane contains copper and molybdenum nitrides in a copper-to-molybdenum ratio between 1:3 and 1:

2.

13. The highly lubricating substance of claim 9 further comprises that the concentration of a single aromatic compound in the effluent is less than the concentration of a single aromatic compound in the hydrocarbon-based fluid at the inlet flow of the mechanical equipment.

14. The highly lubricating substance of claim 9, further comprising: the concentration of polynuclear aromatic compounds in the effluent is greater than the concentration of polynuclear aromatic compounds in the hydrocarbon-based fluid at the inlet of the mechanical equipment.

15. The highly lubricating substance as described in claim 9, wherein, The effluent contains a fluid with a viscosity higher than that of the hydrocarbon-based fluid at the inlet of the mechanical equipment.

16. A system for generating a highly lubricating substance for lubricating mechanical equipment, the system comprising: The mechanical equipment, wherein the mechanical equipment is an engine; A first component, operatively coupled to the engine, wherein the surface of the first component has a film deposited thereon; A second component, operatively coupled to the engine, wherein the second component includes a surface that moves in contact with the surface of the membrane; as well as A third component, which is operatively coupled to the engine; When the membrane is placed in contact with the second component, and a hydrocarbon-based fluid is located between the surface of the membrane and the surface of the second component, a highly lubricating substance is generated on the surface of the membrane. At least a portion of the highly lubricating substance is suspended in the hydrocarbon-based fuel in the engine.

17. The system of claim 16, wherein, The first component and the second component are housed in a device operatively coupled to the engine.

18. The system of claim 16, wherein, The device is located outside the engine, wherein the first component and the second component are substantially located within the fuel path of the engine's fuel delivery system.

19. The system of claim 16, wherein, The highly lubricating substance is a suspension containing one or more carbon allotropes.

20. The system of claim 16, wherein, The membrane contains a metal M selected from the group consisting essentially of metals Cu, Ni, Sc, Y, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, Ag, Au, Pd, Zn, Cd, Hg, Al, Ga, In, Pt, and W, and combinations thereof.

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