Improved Metalworking Fluids

Abstract

The present invention provides biological emulsifiers for use in formulating metalworking fluids, methods for formulating metalworking fluids, and improved metalworking fluids.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 315,747, filed March 2, 2022, which is incorporated by reference in its entirety. [Background technology]

[0002] 2. Background of the Invention During metalworking, metals can be forged, rolled, stamped, hardened, shaped or ground into objects ranging from screws to large beams. Metalworking fluids (MWFs) are used in industrial machining and grinding operations to reduce heat and friction and to remove metal particles. MWFs can be oil-based or water-based fluids, including mixtures of oils, emulsifiers, detergents, adhesion inhibitors, corrosion inhibitors, extreme pressure additives, buffers, biocides and other additives, for example. For each manufacturing operation, metalworking fluids must be selected to meet the demands of the specific application.

[0003] The main types of MWFs include straight oils, which are undiluted mineral, animal, marine, vegetable, or synthetic oils; solubilized oils, which contain about 30-85% refined oil and an emulsifier to disperse the oil in water; and semi-synthetic fluids, which contain a portion of refined petroleum, about 30-50% water, and a number of other additives; and synthetic fluids, which contain no oil but are replaced by water-soluble substances such as detergents and other additives for cooling and lubrication.

[0004] For solubilized oils in particular, oil / water (O / W) emulsions are formed that utilize the lubricating properties of the oil and the cooling properties of the water to provide the desired MWF functionality. The stability of the O / W emulsion is key to successful formulation, and therefore emulsifiers are important additives. Typically, emulsifiers are surface active agents that promote the formation and stabilization of emulsions by reducing the interfacial tension between the water and oil phases of the fluid. The chemical structure of the emulsifier is preferably one that contains functional groups that are compatible with both the water and oil phases of the MWF. Emulsifiers currently in use include, for example, triethanolamine, sodium petroleum sulfonates, alkoxylated phosphate esters, alkylaryl ethoxylates, alcohol alkoxylates, fatty acid ethoxylates, ether-carboxylates, and amine ethoxylates.

[0005] During use, MWFs become mixed with metal particles, particulate matter, microorganisms, and other contaminants. Workers in machine finishing, machining, and other metalworking and metal forming operations can be exposed to MWFs and the contaminants mixed therein through inhalation of aerosols generated in the process, or through skin contact when handling parts, tools, and equipment covered in the fluid. This can lead to pathological lung conditions and skin irritation, and long-term exposure may be associated with certain types of cancer. Ethoxylates in particular contain the impurity 1,4-dioxane, a suspected carcinogen.

[0006] Measures such as worker training and machine modifications to prevent excessive contact with MWFs, as well as protective equipment such as masks, gloves, aprons, and specialised clothing, are important safety measures, but improvements in the ingredients and formulations of these fluids are needed to reduce the adverse effects of these fluids on workers and the environment. Summary of the Invention

[0007] BRIEF SUMMARY OF THE INVETION The present invention relates to improved metalworking fluids (MWFs) containing oil-in-water or water-in-oil emulsions. More specifically, the present invention provides novel emulsifiers for the formation of stable MWF emulsions, and MWF formulations containing same. Preferably, the emulsifiers are biological surfactants or derivatives thereof that can be used in MWF applications to replace, for example, ethoxylated surfactant emulsifiers. Advantageously, in some embodiments, the biological emulsifiers can be up to 100% biobased and biodegradable, can have low toxicity, and / or can perform as well or better than conventional emulsifiers and surfactants.

[0008] In preferred embodiments, the present invention provides microbially derived surfactants that serve a variety of purposes in metal processing. In some embodiments, the surfactants function as emulsifiers, dispersants, detergents, antifoams, and / or biocide components in MWF formulations. In certain preferred embodiments, the biological surfactants function as emulsifiers for MWFs, including O / W and / or W / O emulsions.

[0009] Advantageously, in certain embodiments, biological emulsifiers facilitate the formation of MWF emulsions by dispersing water-miscible oils in aqueous liquids, improve the stability of the emulsions, and / or prevent demulsification and / or precipitation of the oil and water phases, all without adversely affecting the functionality of the MWF.

[0010] In preferred embodiments, the biological emulsifiers are biosurfactants or biopolymers, including, for example, glycolipids, lipopeptides, flavolipids, phospholipids, fatty acid esters, and high molecular weight biopolymers such as lipoproteins, lipopolysaccharide-protein complexes, and / or polysaccharide-protein-fatty acid complexes, etc. In some embodiments, more than one of these may be used at a time.

[0011] In one embodiment, the biosurfactant is a glycolipid, such as, for example, a sophorolipid (SLP), a rhamnolipid (RLP), a cellobiose lipid, a trehalose lipid, or a mannosylerythritol lipid (MEL). In one embodiment, the biosurfactant is a lipopeptide, such as, for example, surfactin, iturin, fengycin, arthrofactin, viscosin, and / or lichenisin. In one embodiment, the surface active agent is another type of amphiphilic molecule, such as, for example, an esterified fatty acid, cardiolipin, emulsan, lipomanan, alasan, and / or liposan.

[0012] In specific embodiments, the biological emulsifier is a sophorolipid or derivatized SLP molecule. The SLP may include a mixture of molecular structures, such as lactone-type SLPs, linear SLPs, deacetylated SLPs, monoacetylated SLPs, diacetylated SLPs, esterified SLPs, SLPs with different hydrophobic chain lengths, SLPs with fatty acid-amino acid complexes attached, and others, including those specifically exemplified and / or not exemplified within this disclosure.

[0013] In specific preferred embodiments, the biosurfactant is a derivatized SLP or mixture of derivatized SLPs, where the molecular structure of the SLP molecules has been modified to produce SLP molecules that have increased resistance to unstable pH, high temperature and pressure environments, such as those encountered in some metal processing applications, and / or have improved antifoam properties, relative to other SLP molecules.

[0014] In certain embodiments, the present invention provides a method for producing and / or improving the stability of MWFs, including O / W emulsions and W / O emulsions, comprising mixing an oil with an aqueous liquid in the presence of a biological emulsifier according to the present invention.

[0015] In some embodiments, the methods include adding a biological emulsifier to an already formed O / W or W / O emulsion to improve emulsion stability or prevent emulsion destabilization.

[0016] In certain embodiments, an improved MWF composition is provided that includes an oil, an aqueous liquid, and a biological emulsifier according to the present invention. In certain embodiments, the oil is a petroleum-based oil, a mineral oil, an animal-derived oil, a vegetable-derived oil, or a synthetic oil. The oil may be present, for example, at 30-90% or 25-85% by total volume of the MWF.

[0017] In some embodiments, the MWF composition may include other additives, including, for example, detergents, anti-adhesive agents, corrosion inhibitors, extreme pressure additives, buffers, biocides, and others. In some embodiments, the biological emulsifier also serves one or more of these additional purposes.

[0018] Advantageously, the method is safe for use in the presence of metalworking workers, without harming the users and without releasing significant amounts of polluting and toxic compounds into the environment. Additionally, the compositions and methods utilize ingredients that are biodegradable and toxicologically safe. Thus, the present invention may be used in a variety of industries as a "green" additive for MWFs. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Detailed Description The present invention relates to improved metalworking fluids (MWFs) containing oil-in-water or water-in-oil emulsions. More specifically, the present invention provides novel emulsifiers for the formulation of stable MWF emulsions, and MWF formulations containing the same. Preferably, the emulsifiers are biological surfactants or derivatives thereof that can be used in MWF applications, for example, to replace ethoxylated surfactant emulsifiers. Advantageously, in some embodiments, the biological emulsifiers can be up to 100% biobased and biodegradable, can have low toxicity, and can perform as well or better than conventional emulsifiers and surfactants. Furthermore, in some embodiments, the biological emulsifiers can withstand high temperature and pressure environments such as those encountered in some metalworking applications, and can be used to reduce foaming.

[0020] Selected Definitions As used herein, the term "emulsion" refers to a type of mixture containing two immiscible liquid phases, one of which (the dispersed phase) is divided into small particles or droplets dispersed throughout the other (the continuous phase). Typically, one of the liquids is a lipid or oil and the other is aqueous, where the oil is either suspended in the water (oil-in-water, O / W) or the water is suspended in the oil (water-in-oil, W / O). Most emulsions contain dispersed droplets with diameters 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.

[0021] As used herein, the term "dispersion" refers to solid primary particles, aggregates, or agglomerates uniformly dispersed throughout a continuous medium (typically a liquid). These particles may range in size from 0.001 μm to 1 μm or greater for "suspension" dispersions, and from 0.001 μm to 1 μm for "colloidal" dispersions.

[0022] As used herein, the term "emulsifier" includes the expression "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 of the dispersed phase.

[0023] As used herein, a "biofilm" is a complex aggregate of microorganisms, such as bacteria, in which the cells are attached 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 capable of movement in liquid or on solid media.

[0024] As used herein, the terms "isolated" or "purified" when used in reference to a biological or natural substance, such as a nucleic acid molecule, a polynucleotide, a polypeptide, a protein, an organic compound such as a small molecule, a microbial cell / strain, or a host cell, means that the substance is substantially free of other compounds with which it is naturally associated, such as cellular material, i.e., the substance does not occur in nature free of these other compounds and / or has different or distinctive properties compared to those found in the naturally occurring substance.

[0025] In certain embodiments, a purified compound is at least 60% by weight of the desired compound. Preferably, the preparation is at least 75% by weight, more preferably at least 90%, and most preferably at least 99% or 100% (w / w) of the desired compound. Purity is measured by any appropriate standard method, for example, by column chromatography, thin layer chromatography, or high performance liquid chromatography (HPLC) analysis.

[0026] In certain embodiments, the biological emulsifier of the present invention is characterized as a "microbial-based composition," meaning a composition that includes components produced as a result of the growth of a microbial or other cell culture. Thus, a microbial-based composition may include the microorganism itself and / or by-products of microbial growth (e.g., biosurfactants, solvents, and / or enzymes). The cells may be in vegetative or spore form, or a mixture of both. The cells may be in planktonic or biofilm form, or a mixture of both. The cells may be live or inert, intact or lysed. The cells may be present in the form in which they have grown or in a concentration of, for example, at least 1 x 10 cells per milliliter of composition. 3 , 1×10 4 , 1×10 5 , 1×10 6 , 1×10 7 , 1×10 8 , 1×10 9 , 1×10 10 , or 1×10 11They may be removed from the medium in which they are present at concentrations of 100 or more. In one embodiment, the microorganism-based composition may only comprise the medium in which the cells have been grown and from which the cells have been removed (although in some cases some remaining cellular material may remain in the medium). By-products of growth may be present in the medium and may include, for example, metabolic products, cell membrane components, expressed proteins, and / or other cellular components. In one embodiment, the microorganism-based composition comprises only by-products of microbial growth.

[0027] In certain embodiments, the biological emulsifier of the present invention is characterized as a "microbe-based product", which is a product that is actually applied to achieve a desired result. The microbe-based product may simply be a microbe-based composition harvested from a microbial culture process. Alternatively, the microbe-based product may include additional components added. These additional components may include, for example, stabilizers, buffers, carriers, and other additives and / or adjuvants suitable for a particular application. The microbe-based product may also include a mixture of the microbe-based composition. The microbe-based product may also include one or more components of the microbe-based composition that have been processed in some manner, including but not limited to, filtration, centrifugation, dissolution, drying, purification, etc.

[0028] "Metabolite" refers to any substance produced by metabolism (e.g., growth by-products) or necessary to participate in a particular 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.

[0029] As used herein, "polymer" refers to any macromolecular compound prepared by linking together one or more similar molecular units called monomers. Polymers include synthetic and biologically synthesized polymers. The term polymer further includes the terms "biopolymer" and "biological polymer", which as used herein refer to naturally occurring polymeric substances or polymeric substances present in living organisms. One characteristic of biopolymers is their biodegradability. Biopolymers can include polynucleotides (e.g., RNA and DNA), polysaccharides (e.g., linearly linked polymeric carbohydrates), and polypeptides (i.e., short polymers of amino acids).

[0030] As used herein, "prevention" means to avoid, delay, forestall, or minimize the occurrence or progression of a particular event or condition (e.g., coalescence or precipitation). Prevention can include, but does not require, absolute or complete prevention, meaning that there is still a possibility that the occurrence or condition will develop later than if the preventative measure had not been taken. Prevention can include reducing the severity and / or extent of the occurrence of the event or condition and / or inhibiting the event or condition from progressing to a more severe or extensive extent.

[0031] As used herein, "decrease" means a negative change and "increase" means a positive change, where the change is 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 ​​in between.

[0032] As used herein, "surfactant" refers to a surface-active substance or compound that reduces the surface tension (or interfacial tension) between two phases. Surfactants act, for example, as cleaning agents, wetting agents, emulsifiers, foaming agents, and / or dispersing agents. "Biosurfactant" refers to a surface-active agent produced by living organisms and / or produced using naturally occurring substrates.

[0033] The transitional word "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 elements, steps, or ingredients not specified in the claim. The transitional phrase "consisting essentially of" limits the scope of the claim to those materials or steps specified and that do not "materially affect the basic and novel characteristics" of the claimed invention. Use of the term "comprising" contemplates other embodiments that "consist" or "consist essentially of" the recited ingredients.

[0034] As used herein, the term "or" is understood to be inclusive unless specifically stated or obvious from the context. As used herein, the terms "a," "an," and "the" are understood to be singular or plural, unless specifically stated or obvious from the context.

[0035] Unless specifically stated or obvious from the context, as used herein, the term "about" is understood to be within normal tolerances in the art, e.g., within 2 standard deviations of the mean. "About" may 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 stated value.

[0036] Ranges provided herein are understood to be shorthand for all values ​​within the range. For example, the range of 1-20 is understood to include any number, combination of numbers, or subrange from the group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, as well as all intervening decimal values ​​between said 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" that extend from either end of the range are specifically contemplated. For example, nested subranges within the exemplary range of 1-50 may include 1-10, 1-20, 1-30, and 1-40 in one direction, or 50-40, 50-30, 50-20, and 50-10 in the other direction.

[0037] The recitation of a list of chemical groups in any definition of a variable herein includes that definition of the variable as any single group or combination of the listed groups. The recitation of an embodiment of a variable or aspect herein includes that embodiment as any single embodiment or in combination with any other embodiment or portion thereof.

[0038] Any composition or method provided herein can be combined with one or more of any of the other compositions and methods provided herein.

[0039] Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof, and from the claims. All references cited herein are hereby incorporated by reference.

[0040] Biological emulsions and methods for producing metalworking fluids In one embodiment, the present invention provides a biological emulsifier comprising one or more microorganisms and / or one or more microbial growth by-products. In some embodiments, the emulsifier may serve a variety of additional purposes, including as a dispersant, a detergent, a biocide, and / or an antifoam agent.

[0041] Advantageously, in certain embodiments, biological emulsifiers 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 precipitation of dispersed components without adversely affecting the functionality of the MWF.

[0042] In certain embodiments, the biological emulsifier may include, for example, live and / or inactive microbial cells, fermentation medium, and / or microbial growth by-products. In one embodiment, the microbial growth by-products are separated from the microorganism that produced them. The growth by-products may be in purified or unpurified form. In some embodiments, the growth products are further modified after extraction and optional purification.

[0043] In one embodiment, the microbial growth by-products are one or more biological emulsifiers for use in formulating the MWF. Preferably, the emulsifier is a biosurfactant.

[0044] Advantageously, the biological emulsifiers of the subject compositions are non-toxic, biodegradable, and do not release polluting and / or harmful substances into the environment. Moreover, in preferred embodiments, these compounds exhibit greater thermal, salt, and pH stability than chemical stabilizers, such as chemical surfactants. Moreover, in certain embodiments, the dosage of biological emulsifiers required to stabilize emulsions or dispersions is less than that required for chemical stabilizers.

[0045] The surfactants of the present invention consist of two parts: a polar (hydrophilic) part and a non-polar (hydrophobic) part. These molecules, due to their structure, increase the surface area of ​​hydrophobic, water-insoluble substances, increasing the bioavailability of water for such substances, and by accumulating at interfaces, reduce the interfacial tension, leading to the formation of aggregated micellar structures in solution.

[0046] In certain embodiments, biological emulsifiers have a hydrophilic-lipophilic balance (HLB) value appropriate for the type of emulsion being formed. HLB is the balance between the size and strength of the hydrophilic and lipophilic moieties of a surface-active molecule. In water / oil and oil / water emulsions, the polar parts of the surface-active molecules orient towards the water and the non-polar groups orient towards the oil, thereby reducing the interfacial tension between the oil and water phases. An appropriate HLB is necessary to form a stable emulsion.

[0047] The HLB value ranges from 0 to 20. The lower the HLB value (e.g., 10 or less), the higher the oil solubility and the more suitable it is for water-in-oil emulsions, whereas the higher the HLB value (e.g., 10 or more), the higher the water solubility and the more suitable it is for oil-in-water emulsions.

[0048] Surface active agents according to the present invention include, for example, biosurfactants and / or biopolymers, which may include, for example, glycolipids, lipopeptides, flavolipids, phospholipids, fatty acid esters, and high molecular weight biopolymers such as lipoproteins, lipopolysaccharide-protein complexes, and / or polysaccharide-protein-fatty acid complexes.

[0049] In one embodiment, the surfactant is a glycolipid, such as, for example, a sophorolipid (SLP), a rhamnolipid (RLP), a cellobiose lipid, a trehalose lipid, or a mannosylerythritol lipid (MEL). In one embodiment, the surfactant is a lipopeptide, such as, for example, surfactin, iturin, fengycin, arthrofactin, viscosin, and / or lichenisin. In one embodiment, the surfactant is another type of amphiphilic molecule, such as, for example, an esterified fatty acid, cardiolipin, pullulan emulsan, lipomannan, alasan, and / or liposan.

[0050] Other biologically derived emulsifiers may also be utilized in accordance with the present invention, such as other biopolymers or polysaccharide-based substances (e.g., gums, starches, resins, gums, suberin, melanin, lignin, cellulose, xanthan gum, guar gum, welan gum, levan, xylinan, gellan gum, curdlan, pullulan, dextran, alginates), beta-glucans, mannoproteins, acids, solvents, enzymes, and / or proteins. These compounds are preferably derived from living organisms, including non-microbial organisms.

[0051] In some embodiments, the biological emulsifier is utilized in a crude form, where the biosurfactant molecules are present in the growth medium (e.g., broth) in which the microorganism is cultured and are collected therefrom without purification. The crude form may comprise, for example, at least 0.001%, 1%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 99% of the biological emulsifier in the growth medium. In alternative embodiments, the biological emulsifier is extracted from the growth medium and optionally derivatized and / or purified.

[0052] In a particular embodiment of the invention, sophorolipids (SLPs) are specific glycolipids of interest. Sophorolipids are glycolipid biosurfactants produced, for example, by various yeasts of the Starmerella clade. SLPs consist of the disaccharide sophorose linked to a long-chain hydroxy fatty acid. They may contain a partially acetylated 2-O-β-D-glucopyranosyl-D-glucopyranose unit β-glycosidically linked to 17-L-hydroxyoctadecanoic acid or 17-L-hydroxy-Δ9-octadecenoic acid. The hydroxy fatty acid may have, for example, 11 to 20 carbon atoms and may contain one or more unsaturated bonds. Furthermore, the sophorose residue may be acetylated at the 6 and / or 6' positions. The fatty acid carboxyl group may be free (acidic or linear form) or internally esterified at the 4'' position (lactone form). In most cases, fermentation of SLPs results in a mixture of hydrophobic (water-insoluble) SLPs, including, for example, lactone-type SLPs, monoacetylated linear SLPs, and diacetylated linear SLPs, and hydrophilic (water-soluble) SLPs, including, for example, non-acetylated linear SLPs.

[0053] As used herein, the terms "sophorolipid," "sophorolipid molecule," "SLP," or "SLP molecule" include all forms of SLP molecules and their isomers, including, for example, acidic (linear) SLPs and lactone-type SLPs. Additionally, monoacetylated SLPs, diacetylated SLPs, esterified SLPs, SLPs with different hydrophobic chain lengths, SLPs with fatty acid-amino acid complexes attached, and others, including those described and / or not described within this disclosure.

[0054] In some embodiments, the SLP molecules may be represented by general formula (1) and / or general formula (2), and may be represented by different fatty acid chain lengths (R 3 ) and possibly R 1 and / or R 2 is obtained as a collection of over 30 structural analogues that are acetylated or protonated. TIFF2025507828000001.tif41144

[0055] In the general formula (1) or (2), R 0 R can be either a hydrogen atom or a methyl group. 1 and R 2 Each independently represents a hydrogen atom or an acetyl group. 3 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.

[0056] Non-limiting examples of substituents include halogen atoms, hydroxyl, lower (C1-6) alkyl groups, halo lower (C1-6) alkyl groups, hydroxy lower (C1-6) alkyl groups, halo lower (C1-6) alkoxy groups, and others such as those described within the present disclosure. 3 can have, for example, 11 to 20 carbon atoms.

[0057] Fermentation of yeast cells on a culture substrate containing sugars and / or lipids and fatty acids with different carbon chain lengths can be used to produce a variety of SLPs. The yeast Starmerella (Candida) bombicola is one of the most widely recognized SLP-producing strains. Typically, the yeast produces both lactone-type SLPs and linear SLPs during fermentation, with approximately 60-70% of the SLPs containing lactone form and the remainder containing lactone form.

[0058] In certain specific embodiments, the biosurfactant is a sophorolipid or a mixture of SLP molecules including, for example, lactone-type SLPs, linear SLPs, deacetylated SLPs, monoacetylated SLPs, diacetylated SLPs, esterified SLPs, SLPs with different hydrophobic chain lengths, SLPs with fatty acid-amino acid complexes attached, and others including those specifically exemplified and / or not exemplified within this disclosure.

[0059] In specific preferred embodiments, the biosurfactant is a derivatized SLP or a mixture of derivatized SLPs, where the derivatized SLPs include linear or lactone-type SLPs that have been modified to have improved stability at higher pH, higher temperature and / or higher pressure; enhanced antifoam properties; and / or improved water or alcohol solubility compared to other SLP molecules.

[0060] In certain embodiments, derivatized SLPs include cyclic ether analogs of lactone-type SLPs. Advantageously, reducing the ester functionality of the SLPs to ester bonds can improve the stability of the lactone ring, thereby reducing pH instability and temperature and pressure sensitivity.

[0061] In certain embodiments, the derivatized SLPs comprise a peracetylated hydrophilic moiety. In certain embodiments, the hydrophilic moiety comprises a silyl functional group.

[0062] In certain embodiments, derivatized SLPs include fatty acids in which the carboxylic acid moiety has been converted to, for example, a methyl, ethyl, or isobutyl ester. In certain embodiments, the fatty acids include amino acids that retain the biobased carbon while adding an aromatic ring, such as, for example, phenylalanine methyl ester and / or tryptophan methyl ester.

[0063] In some embodiments, one or more of these modifications may alter the hydrophilicity and / or HLB of the derivatized SLPs so that they are more favorable for forming emulsions and / or reducing foaming.

[0064] In certain embodiments, the derivatized SLPs have a formula according to general formula (3), (4), (5), (6) or (7): TIFF2025507828000002.tif72128TIFF2025507828000003.tif226152TIFF2025507828000004.tif76139.

[0065] How to manufacture MWF In a preferred embodiment, a method is provided for producing a stable MWF characterized as an emulsion and / or dispersion, comprising mixing two or more components in the presence of a biological emulsifier of the present invention.

[0066] 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 is the ability of an emulsion or dispersion to resist forces acting on it that cause settling (the dispersed phase moves downwards), creaming (the dispersed phase moves upwards), flocculation / aggregation of dispersed phase particles or droplets, coalescence of dispersed phase droplets or particles, and / or phase inversion (e.g., W / O becomes O / W).

[0067] In one embodiment, the two or more components include a first component and a second component, where the first component is dispersed in the second component. Thus, in a preferred embodiment, the first component is characterized as the dispersed phase of the emulsion or dispersion and the second component is the continuous phase of the emulsion or dispersion.

[0068] In one embodiment, the first and second components are both liquids. Preferably, the two liquids, i.e., the first and second liquids, are not the same substance. In a particular embodiment, the MWF is an O / W emulsion, where the first liquid is a lipid and / or oil, and the second component is water or another aqueous liquid. In a particular embodiment, the MWF is a W / O emulsion, where the first component is water or another aqueous liquid, and the second liquid is a lipid and / or oil.

[0069] In some embodiments of the method, the biological emulsifier is added first to the second component (the continuous phase), followed by gradually adding the first component (the dispersed phase) to the second component with vigorous mixing. In some embodiments, the biological emulsifier is added after the first and second components have been contacted with each other, followed by mixing.

[0070] Preferably, the mixing step involves vigorous agitation such that the dispersed phase is broken down into small particles or droplets and uniformly dispersed throughout the continuous phase. The biological emulsifier coats the particles or droplets, thereby stabilizing the emulsion or dispersion.

[0071] In some embodiments, the mixing step is performed using, for example, a mill or homogenizer device. In some embodiments, the mixing step is performed manually, for example, using a whisk, blender, or film emulsifier. In some embodiments, ultrasonic or supersonic mixing techniques are used, where, for example, a metal tool is vibrated at high frequencies within the mixture to break up the dispersed phase into smaller particles or droplets.

[0072] In some embodiments, the mixing step is carried out at room temperature, e.g., 20-25° C., or under gentle controlled heating, e.g., at about 25-30° C. In certain embodiments, once formed, the MWF emulsion or dispersion can remain stable even under large temperature fluctuations.

[0073] Advantageously, the compositions and methods of the present invention may be effective in improving the stability of MWFs without adversely affecting their functionality.

[0074] In certain embodiments, the addition of a biological emulsifier according to the present methods increases the time that an emulsion or dispersion remains stable, for example, by at least 1 minute, 60 minutes, 1 day, 30 days, 1 month, 2 months, 3 months, 4 months, or more.

[0075] In some embodiments, the methods may be performed in combination or parallel with other methods for improving the quality of the MWF or the stability of the MWF emulsion or dispersion. For example, additional components, including solids, liquids and / or gases, as well as additional additives, may also be included in the MWF.

[0076] In some embodiments, the methods may be used to prevent spoilage of the MWF by contaminating microorganisms such as bacteria and fungi, where the biological emulsifier biosurfactant has antibacterial properties. In some embodiments, the methods may be used to reduce foam generated during use of the MWF, where the biological emulsifier biosurfactant has antifoam properties.

[0077] The method of the present invention may be carried out wherever the MWF is produced. The two or more components and the biological emulsifier may be stored on-site in separate containers. When the MWF is needed, the components and the biological emulsifier may be collected and / or piped directly into one container and homogenized therein. In one embodiment, the method is carried out at or near the location where the MWF is produced (e.g., less than 300, 250, 200, 150, 100, 75, 50, 25, 15, 10, 5, 3, or 1 mile from the location).

[0078] In one embodiment, the method may be performed in a large scale metalworking factory. In one embodiment, the method may be performed in a small scale metalworking shop or by a hobbyist metalworker.

[0079] Advantageously, the compositions and methods of the present invention utilize biodegradable and toxicologically safe ingredients and may serve as alternatives to potentially harmful emulsifiers such as, for example, ethoxylates, etc. Thus, the present invention may be used as a "green" additive and, in some embodiments, to improve the quality of MWF emulsions or dispersions.

[0080] metal working fluid In one embodiment, the invention provides a MWF produced according to the method. Preferably, the MWF is a mixture (e.g., an emulsion and / or dispersion) comprising two or more of the components and a biological emulsifier of the invention. In certain embodiments, the MWF is characterized as a solubilized oil or semi-synthetic liquid.

[0081] In one embodiment, the two or more components include a first component and a second component, where the first component is dispersed in the second component.

[0082] In one embodiment, the first and second components are both liquids. Preferably, the two liquids, i.e. the first liquid and the second liquid, are not the same substance.

[0083] In certain embodiments, the MWF is an O / W emulsion, where the first liquid is a lipid and / or oil and the second component is water or another aqueous liquid. In certain embodiments, the MWF is a W / O emulsion, where the first component is water or another aqueous liquid and the second liquid is a lipid and / or oil. In certain preferred embodiments, the oil is a mineral oil, an animal oil, a marine oil, a vegetable oil, or a synthetic oil.

[0084] In certain embodiments, the percentage of oil to the total amount of the MWF is about 10%-90%, about 20%-80%, or about 25%-75%.

[0085] In certain embodiments, the MWF comprises a biological emulsifier, e.g., an SLP of general formula (1)-(7), in an amount of from about 100 ppm to about 250,000 ppm, from about 200 ppm to about 100,000 ppm, from about 300 ppm to about 75,000 ppm, from about 400 ppm to about 50,000 ppm, or from about 500 ppm to about 25,000 ppm.

[0086] Additional components characterized as solids, liquids and / or gases, as well as, for example, buffers, stabilizers, anti-fog additives, foam inhibitors, surfactants, solubility enhancers, corrosion inhibitors, extreme pressure additives, and biocides (e.g., bactericides and fungicides), may also be included in the MWF, as can be determined by a metal processor or chemist having the benefit of this disclosure.

Claims

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

2. 2. The MWF of claim 1, wherein the SLPs are lactone-type SLPs, linear SLPs, derivatized lactone-type SLPs, derivatized linear SLPs, or a mixture of any of these.

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

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

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

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

8. 10. The MWF of claim 1, further comprising an additional biosurfactant selected from glycolipids, lipopeptides, flavolipids, phospholipids, fatty acid esters, lipoproteins, lipopolysaccharide-protein complexes, and polysaccharide-protein-fatty acid complexes.

9. 9. The MWF of claim 8, wherein the glycolipid is a sophorolipid, a rhamnolipid, a trehalose lipid, a cellobiose lipid and / or a mannosylerythritol lipid.

10. 9. The MWF of claim 8, wherein the lipopeptide is surfactin, iturin, fengycin, arthrofactin, viscosin and / or lichenisin.

11. 10. The MWF of claim 1, further comprising an additional component selected from a buffer, a stabilizer, an anti-fog additive, a foam inhibitor, a surfactant, a solubility enhancer, a corrosion inhibitor, an extreme pressure additive, and a biocide.

12. The SLPs are linear and have the following formula:

2. The MWF of claim 1, comprising one of:

13. Mixing two or more components, including a first component and a second component that are different from each other, in the presence of a biological emulsifier according to any one of claims 1 to 12.

1. A method for producing an MWF characterized as an emulsion or dispersion, comprising:

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

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

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

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

18. 14. The method of claim 13, comprising first adding the biological emulsifier to the second component and then gradually adding the first component to the second component with mixing.

19. 14. The method of claim 13, comprising adding the biological emulsifier to a premix of the first and second components while mixing.

20. 14. The method of claim 13, wherein the mixing step is carried out using a mill, a homogenizer device, a whisk, a blender, a film emulsifier, or an ultrasonic mixing device.

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