Aluminum complex grease compositions

Abstract

The present disclosure provides grease compositions comprising aluminum complex thickeners as well as processes to prepare the grease compositions. The grease compositions of the present disclosure provide several benefits, as they can be bio-based and / or bio-derived as well as biogenic and biodegradable.

Description

ALUMINUM COMPLEX GREASE COMPOSITIONSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application Serial No. 63 / 538,532, filed on September 15, 2023, the entire disclosure of which is incorporated herein by reference in its entirety.BACKGROUND AND SUMMARY

[0002] Grease compositions have been used for many years and are advantageous due to performance properties including antiwear, rust prevention, and mechanical stability. However, recent challenges in the supply of the lithium-based markets have resulted in a need for grease compositions that include non-lithium based thickeners.

[0003] Moreover, worldwide demand for bio-lubricants is increasing due to changes in government regulations as well as expanded environmental awareness and sustainability by the public. In this regard, many grease compositions are generally deficient in their biodegradability and renewable carbon content. For instance, even current non-lithium alternatives such as greases containing an aluminum complex can be undesirable due to their use of fossil fuels and low biogenic carbon content.

[0004] Therefore, there exists an ongoing need for grease compositions containing aluminum complexes to provide sustainable solutions in order to meet environmental standards and achieve desirable carbon neutral goals. Accordingly, the present disclosure provides grease compositions comprising aluminum complexes that are environmentally friendly as well as processes to prepare the grease compositions.

[0005] The grease compositions of the present disclosure provide several benefits compared to the current state of the art. For example, the grease compositions can be synthetic and / or hydrocarbon-based and demonstrate comparable and superior performance to petroleum-based greases. Further, the grease compositions can be biobased and / or bio-derived as well as biogenic and biodegradable. Importantly, certain grease compositions are nontoxic and can meet NSF HX-1, Halal, and Kosher Parve requirements for incidental food contact. Moreover, the grease compositions can besubstantially free of undesirable components such as boric or phosphoric acids. Finally, the grease compositions have several applications, including marine, construction / mining, food, pharmaceutical, industrial, agriculture, and transportation.

[0006] Other objects, features and advantages of the present disclosure will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating specific embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.BRIEF DESCRIPTIONS OF THE DRAWINGS

[0007] The detailed description particularly refers to the accompanying figures in which:

[0008] FIGURE 1 shows the FTIR results observed for the grease composition of Example 1.

[0009] FIGURE 2 shows the FTIR results observed for the grease composition of Example 2.DETAILED DESCRIPTION

[0010] Various embodiments of the present disclosure are described herein as follows. In one aspect, a grease composition comprising a reactive aluminum source and a base oil is provided. By utilizing a base oil that is readily biodegradable, renewable, and / or synthetic, the resultant grease compositions comprising an aluminum complex thickener can demonstrate comparable and superior performance to petroleum-based greases that include aluminum. For instance, the aluminum complex greases can utilize a vegetable stearic acid oxo-aluminum stearate in a readily biodegradable synthetic hydrocarbon base oil. This thickener can be reacted with an aromatic carboxylic acid in renewable synthetic base oils and polymers to form aluminum stearoyl benzoyl hydroxide.

[0011] In an illustrative aspect, a grease composition is provided. The grease composition comprises aluminum complex thickener and a base oil.

[0012] In an embodiment, the aluminum complex thickener comprises oxoaluminum and C16-C18 alkyl ester in a synthetic carrier. For instance, benzoic acid can be added to open the aluminum stearate ring structure and complete the reaction to form a thickener, aluminum stearoyl benzoyl hydroxide. Stoichometric ratios of total acid to aluminum and benzoic acid to fatty acid are 2: 1 and 1 : 1, respectively. Modifying the benzoic acid to fatty acid and total acid to aluminum ratios can modify important properties such as the thickening efficiency, dropping point, and mechanical stability of the resultant grease compositions.

[0013] In an embodiment, the base oil is a synthetic base oil. In an embodiment, the base oil is a bio-based oil. In an embodiment, the synthetic base oil is a renewable base oil. In an embodiment, the synthetic base oil is a plant-derived base oil.

[0014] In an embodiment, the grease composition further comprises a second thickener. In an embodiment, the second thickener is a magnesium sulphonate thickener. In an embodiment, the second thickener is a calcium sulphonate thickener.

[0015] In an embodiment, the grease composition comprises biogenic carbon. In an embodiment, the biogenic carbon is present at 40-90%. In an embodiment, the biogenic carbon is present at 40-45%. In an embodiment, the biogenic carbon is present at 45-50%. In an embodiment, the biogenic carbon is present at 50-55%. In an embodiment, the biogenic carbon is present at 55-60%. In an embodiment, the biogenic carbon is present at 60-65%. In an embodiment, the biogenic carbon is present at 65- 70%. In an embodiment, the biogenic carbon is present at 70-75%. In an embodiment, the biogenic carbon is present at 75-80%. In an embodiment, the biogenic carbon is present at 80-85%. In an embodiment, the biogenic carbon is present at 85-90%. In an embodiment, the biogenic carbon is present at 90%. In an embodiment, the biogenic carbon is measured via ASTM D6866.

[0016] In an embodiment, the grease composition is bio-based. In an embodiment, the grease composition is bio-derived. In an embodiment, the greasecomposition is biogenic. In an embodiment, the grease composition is biodegradable. In an embodiment, the grease composition is nontoxic.

[0017] In an embodiment, the grease composition complies with OCED 201. In an embodiment, the grease composition complies with OCED 202. In an embodiment, the grease composition complies with OCED 209. In an embodiment, the grease composition complies with OCED 236. In an embodiment, the grease composition complies with OCED 301B.

[0018] In an embodiment, the grease composition is not derived from petroleum. In an embodiment, the grease composition is substantially free of boric acid. In an embodiment, the grease composition is substantially free of phosphoric acid.

[0019] In an embodiment, the grease composition comprises one or more performance additives. In an embodiment, the performance additive is an antioxidant additive. In an embodiment, the performance additive is an antiwear additive. In an embodiment, the performance additive is a corrosion inhibitor. In an embodiment, the performance additive is a rust inhibitor.

[0020] In an embodiment, the grease composition comprises a weld load of at least 160 kg. In an embodiment, the grease composition comprises a weld load of at least 250 kg. In an embodiment, the grease composition comprises a weld load of at least 315 kg. In an embodiment, the grease composition comprises a weld load of at least 400 kg. In an embodiment, the grease composition comprises a weld load of at least 500 kg. In an embodiment, the grease composition comprises a weld load of at least 620 kg. In an embodiment, the grease composition comprises a weld load of at least 800 kg. In an embodiment, the grease composition comprises a weld load of at least 1000 kg.

[0021] In an embodiment, the grease composition comprises a dropping point of at least 300°C.

[0022] In an embodiment, the grease composition is NSF H-l registered. In an embodiment, the grease composition is Kosher Parve certified. In an embodiment, the grease composition is Halal certified. In an embodiment, the grease composition is EU Ecolabel certified.

[0023] The following numbered embodiments are contemplated and are nonlimiting:1. A grease composition comprising an aluminum complex thickener and a base oil.2. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the aluminum complex thickener comprises oxoaluminum and C16-C18 alkyl ester in a synthetic carrier.3. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the base oil is a synthetic base oil.4. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the base oil is a bio-based oil.5. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the synthetic base oil is a renewable base oil.6. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the synthetic base oil is a plant-derived base oil.7. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition further comprises a second thickener.8. The grease composition of clause 7, any other suitable clause, or any combination of suitable clauses, wherein the second thickener is a magnesium sulphonate thickener.9. The grease composition of clause 7, any other suitable clause, or any combination of suitable clauses, wherein the second thickener is a calcium sulphonate thickener.10. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises biogenic carbon.11. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 40-90%.12. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 40-45%.13. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 45-50%.14. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 50-55%.15. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 55-60%.16. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 60-65%.17. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 65-70%.18. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 70-75%.19. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 75-80%.20. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 80-85%.21. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 85-90%.22. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is present at 90%.23. The grease composition of clause 10, any other suitable clause, or any combination of suitable clauses, wherein the biogenic carbon is measured via ASTM D6866.24. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is bio-based.25. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is bio-derived.26. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is biogenic.27. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is biodegradable.28. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is nontoxic.29. The grease composition of clause 28, any other suitable clause, or any combination of suitable clauses, wherein the grease composition complies with OCED 201.30. The grease composition of clause 28, any other suitable clause, or any combination of suitable clauses, wherein the grease composition complies with OCED 202.31. The grease composition of clause 28, any other suitable clause, or any combination of suitable clauses, wherein the grease composition complies with OCED 209.32. The grease composition of clause 28, any other suitable clause, or any combination of suitable clauses, wherein the grease composition complies with OCED 236.33. The grease composition of clause 28, any other suitable clause, or any combination of suitable clauses, wherein the grease composition complies with OCED 301B.34. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is not derived from petroleum.35. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is substantially free of boric acid.36. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is substantially free of phosphoric acid.37. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises one or more performance additives.38. The grease composition of clause 37, any other suitable clause, or any combination of suitable clauses, wherein the performance additive is an antioxidant additive.39. The grease composition of clause 37, any other suitable clause, or any combination of suitable clauses, wherein the performance additive is an antiwear additive.40. The grease composition of clause 37, any other suitable clause, or any combination of suitable clauses, wherein the performance additive is a corrosion inhibitor.41. The grease composition of clause 37, any other suitable clause, or any combination of suitable clauses, wherein the performance additive is a rust inhibitor.42. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 160 kg.43. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 250 kg-44. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 315 kg-45. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 400 kg-46. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 500 kg-47. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 620 kg-48. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 800 kg-49. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a weld load of at least 1000 kg-50. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition comprises a dropping point of at least 300°C.51. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is NSF H-l registered.52. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is Kosher Parve certified.53. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is Halal certified.54. The grease composition of clause 1, any other suitable clause, or any combination of suitable clauses, wherein the grease composition is EU Ecolabel certified.EXAMPLESEXAMPLE 1Exemplary Preparation of a Bioderived Aluminum Complex Grease Composition NSF Hl

[0024] In the instant example, an exemplary biobased aluminum complex grease composition was prepared. Table 1 shows the ingredients that were reacted in the instant example:Table 1

[0025] The renewable base oil was heated to 80°C in a mixer then charged with static acid. After the Hystrene dissolved, the temperature was increased to 88°C and benzoic acid was added while mixing. After the benzoic acid had completely dissolved, Dorox 417 was added and mixing continued, with a gradual increase in temperature to 104°C. The reaction was held for at least two and half hours before confirming conversion by FTIR (the triplet absorption peak at 1610 - 1570 cm’1and a hydroxyl absorption peak 998 cm’1were observed). The temperature was slowly increased to 204°C before the reaction was completed and the heat was turned off. The resultant grease composition was observed to have a smooth, white, thick appearance.

[0026] After the grease composition was cooled to room temperature, the sample was milled on a bench top Tri-roller mill. The grease consistency was measured according to ASTM D217 and the resultant grease composition had a cone penetration of 202 dmm. An additional 15% base oil was added with the performance additives to meet the target NLGI grade 2 with a cone penetration of 275 dmm.

[0027] The grease composition demonstrated performance properties according to ASTM methods as shown in Figure 1 and Table 2.Table 2EXAMPLE 2Exemplary Preparation of a Readily Biodegradable Aluminum Complex Grease Composition NSF Hl

[0028] In the instant example, an exemplary biobased aluminum complex grease composition was prepared. Table 3 shows the ingredients that were reacted in the instant example:Table 3

[0029] The renewable base oil was heated to 80°C in a mixer then charged with static acid. After the Hystrene dissolved, the temperature was increased to 88°C and benzoic acid was added while mixing. After the benzoic acid had completely dissolved, Dorox 417 was added and mixing continued, with a gradual increase in temperature to 104°C. The reaction was held for at least two and half hours before confirming conversion by FTIR (the triplet absorption peak at 1610 - 1570 cm’1and a hydroxyl absorption peak 998 cm'1were observed). The temperature was slowly increased to 204°C before the reaction was completed and the heat was turned off. The resultant grease composition was observed to have a smooth, white, thick appearance.

[0030] After the grease composition was cooled to room temperature, the sample was milled on a bench top Tri-roller mill. The grease consistency was measured according to ASTM D217 and the resultant grease composition had a cone penetration of 225 dmm. An additional 7.5% base oil was added with the performance additives to meet the target NLGI grade 2 with a cone penetration of 272 dmm.

[0031] The grease composition demonstrated performance properties according to ASTM methods as shown in Figure 2 and Table 4.Table 4EXAMPLE 3Exemplary Preparation of a Readily Biodegradable Aluminum Complex Grease Composition

[0032] In the instant example, an exemplary biobased aluminum complex grease composition was prepared. Table 5 shows the ingredients that were reacted in the instant example:Table 5

[0033] The renewable base oil was heated to 80°C in a mixer then charged with static acid. After the Hystrene dissolved, the temperature was increased to 88°C and benzoic acid was added while mixing. After the benzoic acid had completely dissolved, Dorox 417 was added and mixing continued, with a gradual increase in temperature to 104°C. The reaction was held for at least two and half hours before confirming conversion by FTIR (the triplet absorption peak at 1610 - 1570 cm'1and a hydroxyl absorption peak 998 cm'1were observed). The temperature was slowly increased to 204°C before the reaction was completed and the heat was turned off. The resultant grease composition was observed to have a smooth, white, thick appearance.

[0034] After the grease composition was cooled to room temperature, the sample was milled on a bench top Tri-roller mill. The grease consistency was measured according to ASTM D217 and the resultant grease composition had a cone penetration of 194 dmm. An additional 15% base oil was added with the performance additives to meet the target NLGI grade 2 with a cone penetration of 274 dmm.

[0035] The grease composition demonstrated performance properties according to ASTM methods as shown in Table 6.Table 6EXAMPLE 4Exemplary Preparation of a Readily Biodegradable Aluminum Complex Grease Composition

[0036] In the instant example, an exemplary biobased high performance aluminum complex grease composition was prepared. Table 7 shows the ingredients that were reacted in the instant example:Table 7

[0037] The process for the instant example is not typical of the process utilized to make an aluminum complex grease composition. A modified process was followed and the reaction produced the instant grease composition. The maximum process temperature was set to 204°C, at which point the thickener is formed and dispersed. The thickener formation was confirmed by the presence of the triplet absorption peak at 1610 - 1570 cm'1with a hydroxyl absorption peak 998 cm'1via FTIR.

[0038] The resultant grease composition was observed to have a smooth, yellow, buttery appearance.

[0039] After the grease composition was cooled to room temperature, the sample was milled on a bench top Tri-roller mill. The grease composition demonstrated performance properties according to ASTM methods as shown in Table 8.Table 8EXAMPLE 5Exemplary Preparation of a Bio-base Aluminum Complex Open Gear Lubricant

[0040] In the instant example, an exemplary biobased high performance aluminum complex-based open gear lubricant (F0124-010-018D) was prepared. Table 9 shows the ingredients that were reacted in the instant example:Table 9

[0041] The various components were combined, in order, without heating. The grease composition demonstrated performance properties according to ASTM methods as shown in Table 10.Table 10EXAMPLE 6Exemplary Preparation of Various Bio-base Aluminum Complex Base Grease Compositions

[0042] In the instant example, an exemplary biobased aluminum complex grease composition was prepared. Table 11 shows the ingredients that were reacted for preparation of the various grease compositions.Table 11Table 23 (continued)

Claims

CLAIMS1. A grease composition comprising an aluminum complex thickener and a base oil, wherein the grease composition comprises biogenic carbon, and wherein the biogenic carbon is present at 50-90%.

2. The grease composition of claim 1, wherein the grease composition is not derived from petroleum.

3. The grease composition of claim 1 or claim 2, wherein the base oil is a synthetic base oil.

4. The grease composition of claim 1 or claim 2, wherein the base oil is a bio-based oil.

5. The grease composition of claim 1 or claim 2, wherein the synthetic base oil is a renewable base oil.

6. The grease composition of claim 1 or claim 2, wherein the synthetic base oil is a plant-derived base oil.

7. The grease composition of claim 1 or claim 2, wherein the grease composition is bio-based.

8. The grease composition of claim 1 or claim 2, wherein the grease composition is bio-derived.

9. The grease composition of claim 1 or claim 2, wherein the grease composition is biogenic.

10. The grease composition of claim 1 or claim 2, wherein the grease composition is biodegradable.

11. The grease composition of claim 1 or claim 2, wherein the grease composition is nontoxic.

12. The grease composition of claim 1 or claim 2, wherein the grease composition is substantially free of boric acid.

13. The grease composition of claim 1 or claim 2, wherein the grease composition is substantially free of phosphoric acid.

14. The grease composition of claim 1 or claim 2, wherein the grease composition comprises a weld load of at least 400 kg.

15. The grease composition of claim 1 or claim 2, wherein the grease composition comprises a weld load of at least 620 kg.

16. The grease composition of claim 1 or claim 2, wherein the grease composition comprises a dropping point of at least 300°C.

17. The grease composition of claim 1 or claim 2, wherein the grease composition is NSF H-l registered.

18. The grease composition of claim 1 or claim 2, wherein the grease composition is Kosher Parve certified.

19. The grease composition of claim 1 or claim 2, wherein the grease composition is Halal certified.

20. The grease composition of claim 1 or claim 2, wherein the grease composition is EU Ecolabel certified.

21. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 50-55%.

22. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 55-60%.

23. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 60-65%.

24. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 65-70%.

25. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 70-75%.

26. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 75-80%.

27. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 80-85%.

28. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 85-90%.

29. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is present at 90%.

30. The grease composition of any of claims 1 to 20, wherein the biogenic carbon is measured via ASTM D6866.

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