Composition for producing highly lubricating substances for lubricating mechanical devices, as well as methods for using and producing the same.

Abstract

A system is provided that increases the lubricity of a fuel by creating a highly lubricating substance from the fuel while the fuel is being used to operate a mechanical device such as an engine, thereby enabling the fuel to be used as a lubricant for various tribological surfaces inside an engine without the use of further additives or modifiers. In this regard, one embodiment of the present 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. The device may also have a second surface that is in periodic and / or repeatedly in contact with the first surface, such as by sliding contact, rolling contact, a combination of the two, and / or similar.

Description

Technical Field

[0001] Cross-Reference to Related Applications This application is a patent application claiming priority to Provisional Patent Application No. 63 / 531,295, filed on August 7, 2023, and entitled "System for Generating High-Lubricity Substances for Lubrication of a Mechanical Device".

[0002] The present disclosure relates generally to lubrication of mechanical devices. More particularly, the present disclosure relates to a system for generating high-lubricity substances for lubrication of a mechanical device.

Background Art

[0003] Engines such as internal combustion engines are used in a wide range of applications ranging from powering automobiles to power generation. These engines rely on a steady supply of fuel, which is generally a hydrocarbon-based material such as gasoline, diesel, or aviation fuel. However, these fuels tend to have poor lubricity, which can mean that they do not provide sufficient lubrication for moving components inside the engine. To provide this lubrication, a separate system is often required to supply a lubricant, which is typically a long-chain hydrocarbon-based oil, to critical wear surfaces. While this oil provides protection against wear and tear in the engine, it also reduces fuel efficiency, increases exhaust emissions, and increases maintenance requirements.

[0004] The need for these lubricants in an engine requires either that they be added to the fuel source as additives, or that a special system be incorporated to deliver the lubricant to critical wear surfaces during operation. This lubrication requirement can pose considerable difficulties to the operator. Further special lubricants may need to be available and added to the fuel in specific ratios, or the weight and complexity of the lubrication pump and recirculation system may need to be incorporated into the engine design. If a lubricant recirculation system is used, the lubricant will require periodic draining, flushing, and replenishment due to its lifespan, and the system components may require maintenance to keep the engine running. In either case, the burning or overheating of the lubricant, which frequently occurs in engine systems, can significantly increase exhaust emissions and cause widespread engine deposits, which can reduce efficiency and shorten engine life. Furthermore, lubricant leaks from the engine or during lubricant handling may require extensive remediation to mitigate environmental damage.

[0005] To address these problems, there is a need for a system that can increase the lubricity of fuel and improve the performance and efficiency of an engine or mechanical system without using additives or special lubricants.

[0006] There are several variables, including the chemical composition, viscosity, and presence of a third body of the fuel, that have been listed in the conventional art as contributing to increased fuel lubricity.

[0007] Heavy aromatic hydrocarbons, such as polycyclic aromatic hydrocarbons (PAHs) and nitrogen heterocyclic polycyclic aromatic hydrocarbons (NPAHs), are the primary lubricants in petroleum distillate automotive fuels. These chemicals bond to metal surfaces, creating sliding surfaces due to their geometric shapes. Generally, there is a proportional relationship between the fuel boiling point and the concentration of these chemicals; therefore, the lubricity of diesel fuel is higher than that of kerosene, which is higher than that of gasoline. While diesel is smoother than the others listed, it is generally under much higher pressures, and some biodiesels do not contain these hydrocarbons, potentially leading to increased wear in diesel applications.

[0008] Fluid viscosity is important for lubrication and lower wear because it provides the fluid force that separates two surfaces as they move relative to each other. Essentially, it causes the interface surface to slide along the fluid surface rather than in contact with the opposing surface.

[0009] Finally, third-body particles work to fill in surface roughness at higher pressure interfaces and form a solid lubricant boundary layer between surfaces, creating a sliding surface. These particles generally result in lower friction and wear.

[0010] The addition of graphite to lubrication systems has been shown to improve lubrication, increase power, and reduce wear.

[0011] Therefore, it is desirable to devise methods for increasing the lubricity of a fuel by increasing the concentration of heavy aromatic hydrocarbons, increasing viscosity, and / or catalyzing reactions that produce a third form in the fuel. [Overview of the project]

[0012] The following provides a brief overview of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This overview is not intended to be a comprehensive outline of all intended embodiments, nor is it intended to identify essential or important elements of all embodiments, nor to explicitly define the scope of any or all embodiments. Its sole purpose is to present, in a concise form, some concepts of one or more embodiments of the present invention as a prelude to the more detailed descriptions to be presented later.

[0013] Accordingly, the first embodiment provides a method for producing a highly lubricating substance for lubricating a mechanical device, comprising: preparing a first component operably coupled to a mechanical device, the mechanical device being an engine, the first component having a surface on which a film is deposited; operating the engine with fuel, the operation of the engine including exposing the film to the fuel to produce a highly lubricating substance on the surface of the film; suspending at least a portion of the highly lubricating substance in the fuel; transporting at least a portion of the highly lubricating substance to a second component operably coupled to the engine via the fuel; and lubricating the second component with at least a portion of the highly lubricating substance.

[0014] In a first aspect of the first embodiment, generating a highly lubricating substance on the surface of the film further includes placing fuel between the film on the surface of the first component and the surface of the third component which is operably coupled to the engine, and bringing the film on the surface of the first component into contact with the surface of the third component.

[0015] In the second embodiment, the first and third components are integrated components within the engine, either alone or in combination with the first embodiment of the first embodiment.

[0016] In a third embodiment, either alone or in combination with any of the earlier embodiments of the first embodiment, the first component is a cylinder liner for a cylinder in an engine, and the third component is a piston or piston ring positioned within the cylinder.

[0017] In a fourth embodiment, the first component is housed in a device that is operably coupled to an engine, either alone or in combination with any of the earlier embodiments of the first embodiment.

[0018] In the fifth embodiment, either alone or in combination with any of the earlier embodiments of the first embodiment, the device is located outside the engine, and the first component is substantially located within the fuel path of the engine's fuel delivery system.

[0019] In the fifth embodiment, either alone or in combination with any of the earlier embodiments of the first embodiment, the device is located outside the engine, and the first component is substantially located within the fuel path of the engine's fuel delivery system.

[0020] In the sixth embodiment, the highly lubricating substance is a suspension containing one or more carbon allotropes, either alone or in combination with any of the earlier embodiments of the first embodiment.

[0021] In the seventh embodiment, the highly lubricating substance is a suspension of graphite structures in the fuel, either alone or in combination with any of the earlier embodiments of the first embodiment.

[0022] In the eighth embodiment, the second component is a bearing, a valve train component, or a cam surface, either alone or in combination with any of the earlier embodiments of the first embodiment.

[0023] In the ninth embodiment, the film comprises copper and molybdenum nitride, either alone or in combination with any of the earlier embodiments of the first embodiment, having a copper-to-molybdenum ratio between 1:30 and 1:2.

[0024] A second embodiment provides a system for producing a highly lubricious substance for lubricating a mechanical device, the system comprising: a mechanical device that is an engine; a first component operably coupled to the engine, wherein a film is deposited on a surface of the first component; a second component operably coupled to the engine, the second component comprising a surface in movable contact with a surface of the film; and a third component operably coupled to the engine, wherein when the film contacts the second component with fuel disposed between the surface of the film and the surface of the second component, the film produces the highly lubricious substance on the surface of the film, and at least a portion of the highly lubricious substance is suspended in the fuel in the engine.

[0025] In a first aspect of the second embodiment, the first component and the second component are integrated components within the engine.

[0026] In a second aspect of the second embodiment, alone or in combination with the first aspect or any embodiment, the first component is a cylinder liner of a cylinder in the engine, and the second component is a piston or a piston ring disposed within the cylinder.

[0027] In a third aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the first component and the second component are housed in a device that is operably coupled to the engine.

[0028] In a fourth aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the device is located external to the engine, and the first component and the second component are located substantially within a fuel path of a fuel delivery system of the engine.

[0029] In the fifth aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the highly lubricious material is a suspension comprising one or more carbon allotropes.

[0030] In the sixth aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the highly lubricious material is a suspension of graphite structures in fuel.

[0031] In the seventh aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the third component is a bearing, a valve train component, or a cam surface.

[0032] In the eighth aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the film comprises copper and molybdenum nitride.

[0033] In the ninth aspect of the second embodiment, alone or in combination with any of the preceding aspects or embodiments, the ratio of copper to molybdenum is between 1:30 and 1:2.

[0034] The above summary is presented solely for the purpose of summarizing several exemplary embodiments to provide a basic understanding of some aspects of the present disclosure. Accordingly, it will be understood that the embodiments described above are merely examples and should not be construed in any way as narrowing the scope or spirit of the present disclosure. It will be understood that the scope of the present disclosure encompasses many possible embodiments in addition to the embodiments summarized herein, some of which are further described below.

[0035] Having thus generally described embodiments of the present disclosure, reference will now be made to the accompanying drawings. Components illustrated in the drawings may or may not be present in the specific embodiments described herein. Some embodiments may include fewer (or more) components than those illustrated in the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] [Figure 1] This figure shows a system for generating a highly lubricating substance for lubricating mechanical devices, according to one embodiment of the present disclosure. [Figure 2] This figure shows a mechanism for transporting highly lubricating substances according to one embodiment of the present disclosure. [Figure 3] This figure shows a method for producing a highly lubricating substance for lubricating mechanical devices, according to one embodiment of the present disclosure. [Figure 4] This is a plot of data from cone plate viscosity measurement tests for hydrocarbon fuels not in contact with the film described in the claims, and for crankcase emissions from systems in which components of mechanical devices are coated with the film described in the claims. [Figure 5] This is a scanning electron microscope (SEM) image of a highly lubricating substance formed in a fuel mixture after contact with the film described in the claims. [Figure 6] This is a graph of the X-ray diffraction (XRD) pattern of a highly lubricating substance present in the exhaust gas flow according to an exemplary embodiment of the present invention as described in the claims. [Modes for carrying out the invention]

[0037] Next, embodiments of the Disclosure will be described more fully below with reference to the accompanying drawings, which illustrate some, though not all, embodiments of the Disclosure. In fact, the Disclosure can be embodied in many different forms and should not be construed as being limited to the embodiments described herein, but rather these embodiments are provided to satisfy the legal requirements to which the Disclosure is applicable. Where possible, any term expressed in the singular form herein is intended to include the plural form and vice versa, unless expressly stated otherwise. Similarly, wherever used herein, the terms “one (a)” and / or “one (an)” shall mean “one or more,” even where the phrase “one or more” is also used herein. Furthermore, wherever something “based on” something else herein, it may also be based on one or more other things. In other words, wherever used herein, “based on” means “at least partially based on” or “at least partially based on” unless expressly stated otherwise. Similar numbers refer to similar elements throughout.

[0038] As used herein, “film” or “coating” may refer to any continuous or discontinuous material that can be formed, deposited, layered, or arranged on or adjacent to the surface of a structure. In some embodiments, the film may include nanomaterials such as nanoparticles, nanosheets, nanolayers, or other such nanostructures.

[0039] As used herein, “effluent” may refer to any wastewater discharged from a mechanical device using the method described in the claims.

[0040] As used herein, "viscosity" refers to the resistance of a fluid to deformation and flow. Viscosity indicates how "thick" or "thin" a fluid is and quantifies the internal friction of the fluid.

[0041] Embodiments of the present disclosure provide a system that increases the lubricity of a fuel (e.g., a hydrocarbon-containing fuel) by creating a highly lubricating substance from the fuel while the fuel is being used to operate a mechanical device such as an engine (e.g., an internal combustion engine such as a piston engine, turbine engine, rotary engine, jet engine, and / or similar), thereby enabling the fuel to be used as a lubricant for various tribological surfaces inside an engine without the use of further additives or modifiers. In this regard, one embodiment of the present 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, and / or similar. The device may also include a second surface that is in periodic and / or repeatedly in contact with the first surface, such as by sliding contact, rolling contact, a combination of the two, and / or similar. While this document mentions the generation of highly lubricating substances within an engine, it should be understood that the processes described herein can also be applied to lubricate other types of components in other types of mechanical devices (e.g., bearings, pumps, cams, and other mechanical interfaces).

[0042] In one embodiment, the film may be a nanocomposite coating comprising a metal M and / or a metal nitride (e.g., in the form of MaNx). In some embodiments, the metal M can be selected from the group of metals essentially consisting of Cu, Ni, Sc, Y, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, Ag, Au, Pd, Zn, Cd, Hg, Al, Ga, In, Pt, and W, as well as combinations thereof. In exemplary embodiments, the film may include a combination of molybdenum nitride and copper and / or copper nitride. For example, the film may include molybdenum nitride particles with scattered copper. In some embodiments, the film may include copper molybdenum nitride in the form of CuaMobNx. The film may include a combination of about 50–99.7 wt.% molybdenum and about 50–0.3 wt.% copper. In another embodiment, the film may include a combination of approximately 70–95 wt.% molybdenum and approximately 30–3 wt.% copper. In yet another embodiment, the film may include a combination of approximately 75–90 wt.% molybdenum and approximately 8–25 wt.% copper. In yet another embodiment, the film may include a combination of approximately 80–85 wt.% molybdenum and approximately 13–20 wt.% copper. In some embodiments, the wt.% ratio of copper to molybdenum can be between 1:30 and 1:2. The film may be deposited on the surface of a component in a machine or device according to the operating tolerance of the component (for example, to prevent constraint or excessive friction caused by adding the film). Thus, in some embodiments, the film thickness may range from approximately 0.1 microns to approximately 40 microns. In other embodiments, the film thickness may range from approximately 1 micron to approximately 10 microns. In yet another embodiment, the film thickness may range from approximately 3 to approximately 6 microns.

[0043] The film can be deposited on the surface (or any other surface or substrate) of one or more components of a machine or device such as an engine by a variety of techniques, including but not limited to physical vapor deposition ("PVD"), cathode arc deposition ("Arc-PVD"), evaporation deposition, sputtering and / or magnetron sputtering, chemical vapor deposition ("CVD"), hybrid plasma-enhanced CVD ("PECVD"), low-pressure CVD or ultra-high vacuum CVD ("LPCDV" or "UHVCVD"), and / or similar. In an exemplary embodiment, PECVD can be used to deposit a film containing copper and molybdenum nitride onto a substrate (e.g., an internal component of an internal combustion engine). In such an embodiment, 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 ranging from about 0.005 Torr to 10 Torr. In another embodiment, the pressure of the reaction chamber may range from about 0.05 Torr to 5 Torr. In yet another embodiment, the pressure of the reaction chamber may range from about 1 Torr to 2 Torr. In some embodiments, the substrate can be heated to a temperature between 200°F and 1000°F. In other embodiments, the substrate can be heated to a temperature between approximately 300°F and 800°F. In yet another embodiment, the substrate can be heated to a temperature between approximately 400°F and 600°F.

[0044] A gaseous precursor and / or reactant (e.g., a precursor or reactant containing copper, molybdenum, and / or nitrogen) can be introduced into the reaction chamber. A chemical reaction is then induced by generating a plasma in the reaction chamber (e.g., between the cathode and anode) from the gaseous precursor and / or reactant using a radio frequency ("RF") potential or pulsed direct current (DC), which alters such precursor and / or reactant so that it can be deposited onto a substrate as a film in solid form (e.g., a film containing molybdenum nitride and copper and / or copper nitride).

[0045] The process involves bringing a first surface and a second surface into contact with each other and placing both hydrocarbon fuel and a vapor-deposited film between the first and second surfaces, thereby converting at least a portion of the hydrocarbon fuel placed between the surfaces into a highly lubricating substance. The highly lubricating substance can remain on one or more of the surfaces as a durable tribological layer, or it can be suspended in the hydrocarbon fuel. As the hydrocarbon fuel moves through the engine, the highly lubricating substance may come into internal contact with other surfaces of the engine that do not have a vapor-deposited film and are not in contact with the film. When this occurs, the highly lubricating substance, when in contact with and / or adjacent to other surfaces, can provide additional lubrication and wear protection to such surfaces without the need for a vapor-deposited film or coating. As a result, the engine can operate continuously with low-lubricity hydrocarbon fuel without the need for lubrication additives or a separate lubricant recirculation system.

[0046] In another embodiment, the film can be deposited on the surface of an engine component, and contact between such surface and another surface results in the creation of a highly lubricating substance. For example, at least a portion of a cylinder in a piston-driven internal combustion engine 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 ring located inside the cylinder) such that at least a portion of the second surface is in contact with and / or adjacent to the first surface. In an alternative embodiment, the first surface may include the outer surface of a piston and / or piston ring coated with the film, and the second surface may include the inner wall of the cylinder. In this case, the movement of the piston and other components in the engine generates the highly lubricating substance, which can be transported to other areas of the engine that do not have the conversion film, such as bearings or cam surfaces. When highly lubricating materials come into contact with these other areas, they reduce the friction and wear rate of the components, allowing for long-term operation without the need for external addition of fuel lubrication additives or lubricant recirculation systems.

[0047] In yet another embodiment, the conversion film used to create a highly lubricating substance when in contact with a second surface is a metal nitride coating containing 50-99.7 wt.% molybdenum nitride and 50-0.3 wt.% copper or copper nitride. In such embodiments, the highly lubricating substance includes a form of graphitic carbon similar to graphite lubricants, exhibiting improved chemical properties and viscosity. This graphitic carbon is initially formed from contact between the deposited film and the opposing surface. Rather than remaining as a durable coating on the surface of the deposited film, the graphitic carbon is released from the surface and suspended in the hydrocarbon fuel flow, increasing the lubricity of the hydrocarbon fuel, thereby allowing the hydrocarbon fuel to act as a lubricant for other components, such as bearings for rotating components, which may or may not have a deposited film on their surface.

[0048] The systems and methods described herein offer numerous advantages over existing lubrication techniques. For example, by tribocatalytically generating highly lubricating substances through interaction between the contact surface and the fuel, the system can provide highly durable lubrication of the fuel contact surfaces of a machine or device (e.g., an internal combustion engine) without the need for additional lubricants (e.g., oils, greases, and / or similar) which could increase internal friction or resistance of the machine or device (e.g., due to higher viscosity levels of the additional lubricants). Similarly, the efficiency of operation of such a machine or device is increased by allowing contact surfaces (e.g., bearings, cams, shafts, pistons, cylinders, and / or similar) to move freely without trapping or excessive wear. In fact, the durability of such coatings can allow 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 substances allows the particles to move (e.g., via the fuel) to various other uncoated components in the fuel path, providing lubrication for such uncoated components. Finally, the absence of additional lubricants reduces the effects of exhaust and / or sulfur associated with operating the machine.

[0049] Referring here to the figures, Figure 1 shows a system for generating a highly lubricating substance for lubricating mechanical devices according to one embodiment of the present disclosure. In particular, the system can enrich a hydrocarbon fuel with a highly lubricating substance that can be used to lubricate other surfaces in an engine. Thus, the system may include a device having a first plate 101 (which may be rotatable) having a surface (e.g., a first surface) on which a film is deposited. The deposited film on the surface of the first plate 101 can come into contact with a liquid hydrocarbon fuel 102. After contact with the hydrocarbon fuel 102, the surface of the first plate 101 can come into contact (e.g., sliding contact, rotational contact, and / or similar) with the surface (e.g., the second surface) of a second plate 103 (which may also be rotatable). The movement of the two plates rotating relative to each other with the fuel positioned between the first surface (on which the film is deposited) and the second surface causes at least a portion of the hydrocarbon fuel to be converted into the highly lubricating substance 104. The highly lubricated substance 104 can be, for example, a carbon-based material such as graphitic carbon. In this regard, the highly lubricated substance 104 can include one or more of various allotropes of carbon, such as graphite, graphene, fullerene, diamond-like carbon ("DL"), and / or similar. In some embodiments, the highly lubricated substance 104 can contain IO~100 wt.% of graphitic carbon. In other embodiments, the highly lubricated substance 104 can contain 50~80 wt.% of graphitic carbon.

[0050] The highly lubricating substance 104 is suspended in the hydrocarbon fuel 102 and can be transported within the hydrocarbon fuel 102 to other engine parts or components in the fuel path, such as bearings 105, rather than remaining as a durable tribological layer on either surface of the two plates 101, 103. When the highly lubricating substance 104 comes into contact with other parts or components, such as bearings 105, it forms a temporary lubricating layer on the tribological surface of such parts or components (e.g., bearings 105). This temporary lubricating layer reduces the coefficient of friction, reduces wear on the components, extends the service life of the components, and improves the performance of the components.

[0051] Figure 2 shows a mechanism for transporting a highly lubricating substance according to one embodiment of the present disclosure. In this embodiment, a first component 202 inside the engine (e.g., the inner part of the cylinder, such as the cylinder wall) has a surface (e.g., the first surface) that is at least partially modified with a vapor-deposited film 204. The surface of the first component 202, including the vapor-deposited film 204, can be in tribological contact (e.g., sliding or rotational contact) with an opposing surface (e.g., the 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 tribological contact between the vapor-deposited film 204 and the opposing surface of the second component 212 chemically reacts with the liquid hydrocarbon fuel 208 to create a highly lubricating substance. The highly lubricating substance forms a temporary lubrication layer 206 on the vapor-deposited film 204 on the surface of the first component 202 and a temporary lubrication layer 210 on the opposing surface of the second component 212.

[0052] When the liquid hydrocarbon fuel 208 comes into contact with the temporary lubrication layers 206, 210 of highly lubricating substances, it removes some of the highly lubricating substances from the temporary lubrication layers 206, 210, becoming enriched liquid hydrocarbon fuel 214 (a liquid hydrocarbon fuel qualitatively improved with highly lubricating substances, a liquid hydrocarbon fuel rich in highly lubricating substances). As the enriched liquid hydrocarbon fuel 214 moves through the engine, it comes into contact with other components of the engine 216 (e.g., cam faces, rotating shafts, bearings, and / or similar) that may be subject to wear (e.g., abrasive wear, sliding wear, rolling wear, rotational wear, and / or similar), at which point the highly lubricating substances in the enriched liquid hydrocarbon fuel 214 form a temporary lubrication layer 218 on the other components 216. In some embodiments, other components 216 may not be modified with the vapor-deposited film 204, as well as the surface of the first component 202, and may not be in contact with the vapor-deposited film 204, as well as the opposing surface of the second component 212 in other cases. However, since a highly lubricating substance is suspended in the enriched liquid hydrocarbon fuel 214 and the enriched liquid hydrocarbon fuel 214 comes into contact with many parts of the engine (e.g., other components 216), the highly lubricating substance forms an abrasion-resistant lubricating film on the other components 216 that would otherwise not receive the lubrication required for long-term operation. Thus, the systems and methods described herein allow the engine to continue operating even if the other components 216 do not receive further lubrication. It should be understood that the embodiments described above are provided for illustrative purposes and are not intended to limit the scope of the disclosure presented herein. For example, in other embodiments, instead of the inside of a cylinder, the piston of an internal combustion engine (or any other component having a wear surface) may be coated with the film 204. Furthermore, the coating of multiple engine components with the film 204 falls within the scope of this disclosure. [Examples]

[0053] A film containing copper and molybdenum nitride was deposited on the inner surface of the internal combustion engine cylinder. This engine was reassembled so that unburned fuel was recirculated into the crankcase and applied to the internal bearings, and it was operated using only aviation turbine fuel (Jet A). No oil or additives of any kind were supplied to provide lubrication. The engine was operated in this manner for 500 hours, at which point the uncoated bearings were inspected. During the inspection, it was shown that the inner surface of the engine was coated with a thin film of graphite-like carbon with insufficient adhesion. Despite extended operation without lubrication, the bearings showed no signs of excessive wear. The properties of the exhaust fuel (crankcase exhaust) were also tested.

[0054] Figure 3 shows a method 300 for producing a highly lubricating substance for lubricating a mechanical device, according to one embodiment of the present disclosure. As shown in block 302, the method comprises preparing a first component operably coupled to a mechanical device, the mechanical device being an engine, and the first component having a surface on which a film is deposited. In exemplary embodiments, the first component may be coated with a film containing copper and / or molybdenum nitride using a technique such as PECVD. In some embodiments, the highly lubricating substance may be graphitic carbon produced when the surface of the film comes into contact with, or comes into contact with, a movable (e.g., rotating, sliding, and / or similar) opposing surface of a third component operably coupled to the engine, while fuel is between the surface of the film and the opposing surface, or in close proximity to the surface of the film and the opposing surface. The first component may be, for example, an internal and / or integral component of an engine, such as the cylinder wall of an internal combustion engine, and the third component may be a component such as a piston or piston ring that can come into contact with or come into contact with the inside of the cylinder (e.g., the cylinder wall). In such embodiments, a highly lubricating substance can be created during the normal operation of the engine. For example, fuel can be introduced into the cylinder so that it contacts the interface between the piston or piston ring and the cylinder wall. Thus, as the piston or piston ring contacts or approaches the cylinder wall and slides back and forth along the cylinder wall in a reciprocating motion, a highly lubricating substance is formed on the surface of a film on the cylinder wall.

[0055] In other embodiments, the first component may be part of a separate device (e.g., a device specifically constructed to generate a highly lubricating substance, not necessarily dependent on the operation of the engine) that can be operably connected to the engine. In such embodiments, the first component is a first rotating plate within the device, the surface of which is coated with a copper and / or molybdenum film. The device includes a second rotating plate (e.g., a third component), the surface of which (the surface opposite to the surface of the first plate) may be in close proximity to, or in rotational and / or sliding contact with, the film deposited on the first rotating plate. In some embodiments, a pump may be used as the second rotating plate. The first and second rotating plates may be placed in a path of fuel circulated by the engine's fuel delivery system, so that the highly lubricating substance is formed on the surface of the film on the first rotating plate as the fuel passes between the surface of the first rotating plate and the opposing surface of the second rotating plate, including the film. In some embodiments, the device may be placed inside the engine (e.g., inside the engine housing). In other embodiments, the device may be located outside the engine (for example, mounted on an external mount to the engine) while still remaining at least partially within the fuel path of the engine's fuel delivery system.

[0056] Next, as shown in block 304, the method includes operating an engine with fuel, which includes exposing a film to fuel to generate a highly lubricating substance on the surface of the film. As internal combustion proceeds, the fuel (e.g., hydrocarbon fuels such as gasoline, diesel, jet fuel, and / or similar) can come into contact with the film on the surface of the first component and / or the opposing surface of the third component. In this regard, the hydrocarbon fuel can be positioned between the surface of the first component and the opposing surface of the third component. As the hydrocarbon fuel interacts with the first component and / or the third component (e.g., by mechanical sliding or rotational contact between the first and third components), at least a portion of the hydrocarbon fuel may be converted into a highly lubricating substance (e.g., graphite carbon), which can form on the surface of the film of the first component.

[0057] Next, as shown in block 306, the method includes suspending at least a portion of a highly lubricating substance in the fuel. The highly lubricating substance can be weakly adhered to the film of the first component so that when the fuel comes into contact with the upper layer of the highly lubricating substance, the flow of the fuel is sufficient to remove a portion of the highly lubricating substance from the film of the first component. The particles of the highly lubricating substance removed by the flow of the fuel can then be suspended in the fuel, and so that the particles can then be carried along the fuel path to various other parts of the engine during engine operation.

[0058] Next, as shown in block 308, the method includes transporting at least a portion of a highly lubricating substance to a second component operably coupled to the engine via fuel. As previously stated, the highly lubricating substance suspended in the fuel can be transported to various other components of the engine by the fluid movement of the fuel throughout the fuel delivery system. For example, the second component may be a component that is 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, a rod or shaft surface (e.g., a crankshaft, camshaft, and / or similar), a valve train component, a cam surface, a turbine, and / or similar. In some embodiments, the second component may be an untreated component that has not been treated with a film (e.g., a copper and / or molybdenum nitride coating) or an additional lubricant (e.g., oil or grease).

[0059] Next, as shown in block 310, the method includes lubricating the second component with at least a portion of a highly lubricating substance. In this regard, the highly lubricating substance suspended in the fuel can 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 can be positioned between the second and fourth components to provide lubrication for the interface between the second and fourth components. As the engine continues to operate, the highly lubricating substance can be continuously generated from the fuel (e.g., by the moving contact between the first and third components) and subsequently continuously delivered to other untreated components to provide lubrication to them. Thus, the method described herein can enable the engine to continue operating without the engine components experiencing excessive friction and wear, even in the absence of additives or further lubricants.

[0060] Figure 4 shows viscosity versus shear rate plots for fuel not used in the method described in the claims (fresh jet A) and for crankcase ejection (crankcase ejection) produced by exemplary embodiments of the present invention as described in the claims. The x-axis represents the rate at which the fluid is deformed, and the y-axis represents the fluid's resistance to flow. The lines corresponding to fresh jet A 404 and crankcase ejection 402 show that viscosity decreases as the shear rate increases. This property is known as shear thinning. The steeper the slope of the line, the more pronounced the shear thinning behavior. The shear thinning of the crankcase, as shown in 402, is greater than that of fresh jet A, as shown in 404. As the shear rate increases, the viscosity of crankcase ejection 402 decreases more significantly than that of fresh jet A 404.

[0061] In exemplary embodiments of the present invention as described in the claims, the highly lubricating substance formed in the waste includes graphene oxide. SEM image 500 of the highly lubricating substance in the waste is visually consistent with graphene oxide. In the SEM image, graphene oxide appears as a thin mesh, often as wrinkled sheets with irregular edges and a textured surface. These sheets can aggregate to form clusters and can take on a variety of appearances depending on the synthesis method and conditions.

[0062] An energy-dispersive X-ray spectrometer (EDX) provides elemental composition information of a highly lubricating material by detecting X-rays emitted from a sample when the sample is irradiated with an electron beam. The EDX test of the emissions in the exemplary embodiment of the present invention described in the claims supports the formation of graphene oxide. The EDX test results show the significant presence of oxygen in addition to carbon, which indicates the presence of graphene oxide rather than pure graphene.

[0063] Figure 6 shows the results of X-ray diffraction analysis of the emissions. A SmartLab goniometer was used for the experimental setup. The X-ray source was operated at 40 kV and 44 mA using Cu Kα radiation with a wavelength of 1.541862 Å. With the sample mounted on a standard Z stage, the diffraction pattern was captured using an SC-70 detector. The optical system configuration followed the Bragg-Brentano focusing geometry.

[0064] The experiment was conducted in STEP scan mode, with a duration of 5.0 seconds per step and a scan step size of 0.0500 degrees. The scan axis was theta / 2-theta, covering a scan range of 5.0000 to 90.0000 degrees. The starting 2-theta angle was set to 5.0000 degrees, and the omega angle was set to 2.5000 degrees.

[0065] The configuration included a BB CBO selection slit, a solar slit with a 5.0-degree angle to the incident parallel slit, and an incident slit with a 2 / 3-degree angle. A 10.0 mm longitudinal limiting slit was used along the 2 / 3-degree receiving slit #1. The receiving optical device was set to PSA_open, and similarly, a receiving parallel slit set to the 5.0-degree solar slit and a 0.600 mm receiving slit #2 were used. No filter was applied, and a 1 / 10000 attenuator was used.

[0066] The diffraction beam monochromator was configured to be curved, and the monochromator slit was set to the beam-beam spectroscopy (BBM). The peaks obtained by the XRD scan provide crucial information regarding the interlayer spacing and oxidation degree of highly lubricating substances in the waste.

[0067] Cross-referencing of EDX and XRD data, the high oxygen content from EDX combined with specific XRD peak patterns supports the identification of graphene oxide as present in highly lubricating materials.

[0068] The lubrication properties of distilled automotive fuels are derived from surface-active compounds in petroleum, particularly heavy aromatic compounds such as polycyclic aromatic hydrocarbons (PAHs) having three or more condensed rings and nitrogen-containing polycyclic aromatic hydrocarbons (NPAHs).

[0069] In exemplary embodiments of the present invention, the concentration of the monocyclic aromatic compound in the highly lubricating substance is less than 16% by mass, preferably less than 15.8% by mass, and most preferably less than 15.6% by mass.

[0070] In exemplary embodiments of the present invention, the aromatic content of jet fuel A and a fuel containing highly lubricating substances was measured using supercritical fluid chromatography (SFC), ASTM D5186, for the exhaust flow. No significant differences in functional chemical composition were observed by chromatography. The compositions determined by SFC for each of the two fluids are shown below. The reporting limit (RL) is the value at which the result is greater than or equal to the value for which the result is reported as specified. The dilution factor (DF) is the dilution applied to the sample during analysis to arrive at the final reported analytical result.

[0071] [Table 1]

[0072] [Table 2]

[0073] Comparing the chromatographic results of jet fuel A and exhaust fuel analyzed in the above example, jet fuel A has a higher monocyclic aromatic content but a lower polynuclear aromatic content compared to exhaust fuel.

[0074] A dramatic reduction in wear was observed by increasing the PAH content from 1.2% to 2.1%.

[0075] The following are the results of measuring the kinematic viscosity (Kv) of two fluids at a temperature of 40°C using the ASTM standard D-445. Jet fuel A: 1.368 mm 2 / s Emission fuel: 1.834mm 2 / s

[0076] The exhaust fuel has a higher total aromatic content and viscosity, which suggests that the exhaust fuel may be a more complex or heavier aromatic mixture.

[0077] In exemplary embodiments, tribological testing was performed using ASTM D6079. Specifically, the lubricity of the fuel was evaluated by simulating the friction and wear conditions occurring in a diesel engine using a high-frequency reciprocating rig (HFRR). The test evaluates the effectiveness of the fuel in reducing friction and preventing wear by measuring the wear mark diameter on steel specimens.

[0078] In an exemplary embodiment, the catalytic reaction by the film described in the claims generated a third body in the exhaust fuel. Tribological tests of jet fuel A and the exhaust fuel showed that the third body could reduce wear by up to two orders of magnitude. After filtering the third body from the fuel, tribological tests of the two fuels showed that the exhaust fuel exhibited reduced wear and half the friction compared to jet fuel A.

[0079] The filtered exhaust fuel was also analyzed using Raman spectroscopy and dynamic light scattering.

[0080] In one embodiment of the present invention, the film described in the claims converts monocyclic aromatic compounds into polynuclear aromatic compounds by inducing a catalytic reaction upon contact with fuel. These polynuclear aromatic compounds adhere to the surface of uncoated mechanical components, resulting in increased lubricity and reduced wear on the surface of those components.

[0081] As will be understood by those skilled in the art, this disclosure can be embodied as apparatus (e.g., including systems, machines, devices, computer program products, and / or similar), as methods (e.g., including business processes, computer implementation processes, and / or similar), as computer program products (including firmware, resident software, microcode, and similar), or as any combination thereof. Many modifications and other embodiments of this disclosure described herein will come to mind for those skilled in the art in which these embodiments relating are of interest to the teachings presented in the above specification and the accompanying drawings. It will be understood that the drawings merely illustrate certain components of the methods and systems described herein, and that various other components may also form part of the disclosure herein. In addition, the methods described above may, in some cases, include fewer steps, while in other cases they may include more steps. In some cases, modifications to the steps of the methods described above may be made in any order and in any combination.

[0082] Therefore, it should be understood that this disclosure is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Certain terms are used herein, but these terms are used merely for general and descriptive purposes and not for limitation.

Claims

1. A method for producing a highly lubricating substance for lubricating mechanical devices, To prepare a first component operably coupled to the mechanical device, wherein the first component comprises a surface on which a film is deposited. Operating the mechanical device using a hydrocarbon fluid, wherein operating the mechanical device includes exposing the film to the hydrocarbon fluid to generate the highly lubricating substance on the surface of the film. At least a portion of the aforementioned highly lubricating substance is suspended in the hydrocarbon fluid, To transport at least a portion of the highly lubricating substance to a second component operably coupled to the mechanical device via the hydrocarbon fluid, The second component is lubricated using at least a portion of the highly lubricating substance. Methods that include...

2. Generating the highly lubricating substance on the surface of the film is Distributing the hydrocarbon fluid between the film on the surface of the first component and the surface of the third component operably coupled to the mechanical device, The film on the surface of the first component is brought into contact with the surface of the third component, The method according to claim 1, further comprising:

3. The method according to claim 1, wherein the first component is housed in a device operably coupled to the mechanical device.

4. The method according to claim 3, wherein the device is located outside the mechanical device, and the first component is substantially located within the path of the hydrocarbon fluid delivery system of the mechanical device.

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

6. The method according to claim 1, wherein the film comprises a metal M selected from the group of metals essentially consisting of 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 according to claim 1, wherein the film comprises copper and molybdenum nitride having a copper-to-molybdenum ratio between 1:3 and 1:

2.

8. A highly lubricating substance comprising one or more carbon allotropes, wherein the substance is formed on the surface of the film when the film is exposed to a hydrocarbon fluid.

9. The film is deposited on the surface of a component of a mechanical device, and the mechanical device is A first component operably coupled to the mechanical device, Inlet flow of hydrocarbon fluid, It is waste, The hydrocarbon fluid, and At least a portion of the suspension of the highly lubricating substance in the hydrocarbon fluid Discharges including, A highly lubricating substance according to claim 8, comprising the following:

10. The highly lubricating substance according to claim 8, further comprising a graphite structure in the hydrocarbon fluid.

11. The highly lubricating substance according to claim 8, wherein the film comprises a metal M selected from the group of metals essentially consisting of 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 according to claim 8, wherein the film comprises copper and molybdenum nitride having a copper-to-molybdenum ratio between 1:3 and 1:

2.

13. The highly lubricating substance according to claim 9, wherein the concentration of monocyclic aromatic compounds in the discharge is lower than the concentration of monocyclic aromatic compounds in the hydrocarbon fluid in the inlet flow of the mechanical device.

14. The highly lubricating substance according to claim 9, wherein the concentration of the polynuclear aromatic compound in the discharge is higher than the concentration of the polynuclear aromatic compound in the hydrocarbon fluid in the inlet flow of the mechanical device.

15. The highly lubricating substance according to claim 9, wherein the discharge includes a fluid having a higher viscosity than the hydrocarbon fluid in the inlet flow of the mechanical device.

16. A system for producing a highly lubricating substance for lubricating mechanical devices, wherein the system is The engine is the aforementioned mechanical device, A first component operably coupled to the engine, wherein the surface of the first component has a film deposited thereon, A second component operably coupled to the engine, the second component having a surface that makes movable contact with the surface of the film, A third component operably coupled to the engine, Equipped with, When the film comes into contact with the second component with a hydrocarbon fluid placed between the surface of the film and the surface of the second component, a highly lubricating substance is generated on the surface of the film. A system wherein at least a portion of the aforementioned highly lubricating substance is suspended in a hydrocarbon fuel in the engine.

17. The system according to claim 16, wherein the first and second components are housed in a device operably coupled to the engine.

18. The system according to claim 17, wherein the device is located outside the engine, and the first and second components are substantially located within the fuel path of the engine's fuel delivery system.

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

20. The system according to claim 16, wherein the film comprises a metal M selected from the group of metals essentially consisting of 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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