Amidized Olefin Copolymer Lubricant Additive
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Solution Overview
Problem
Existing methods for preparing highly grafted multifunctional olefin copolymers face challenges such as requiring low molecular weight polymers and achieving only partial conversion to imide groups, leading to inadequate dispersancy and viscosity index improvements in lubricating oils.
Innovation Solution
A process involving grafting ethylenically unsaturated carboxylic acid materials onto ethylene and alpha-olefin copolymers, followed by reaction with polyamines, to produce a highly grafted, multi-functional olefin copolymer with enhanced molecular weight and improved functional group conversion, resulting in a novel additive for lubricating oils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to prepare highly grafted multifunctional olefin copolymers, then the polymer can be produced, but the conversion to imide groups is only partial (not more than 80%), leading to inadequate dispersancy and viscosity index improvements
Solution Approach 1:
The patent applies parameter changes by modifying the reaction conditions, specifically using a two-stage process where the first stage uses conventional free radical grafting and the second stage uses a cationic grafting mechanism. This change in reaction mechanism (from free radical to cationic) enables complete conversion of anhydride groups to imide groups, resolving the partial conversion problem and achieving the desired dispersancy and viscosity index improvements.
2Productivity
If existing methods are used, then polymer production is achieved, but the molecular weight is reduced due to mechanical shearing during free-radical grafting
Solution Approach 1:
The patent segments the grafting process into two distinct stages: first stage uses free radical mechanism for initial grafting, and the second stage uses cationic mechanism for complete conversion. This segmentation allows each stage to be optimized independently, maintaining molecular weight while achieving complete functional group conversion in the final product.
Solution Approach 2:
The patent introduces an intermediary approach by using two different reaction mechanisms (free radical and cationic) in sequence. The first mechanism initiates the grafting process, and the second mechanism completes the conversion without the mechanical shearing problems of the first, thus preserving molecular weight while achieving complete conversion.
3Ease of manufacture
If low molecular weight polymers are used as starting material, then grafting can proceed, but the final polymer lacks sufficient viscosity index improvement capability
Solution Approach 1:
The patent changes the reaction parameters by employing a cationic grafting mechanism in the second stage, which allows complete conversion of anhydride groups to imide groups. This produces a highly grafted polymer with sufficient molecular weight and functionality to provide both ease of manufacture and reliable viscosity index improvement in lubricating oils.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process yields a highly grafted, multi-functional olefin copolymer with improved viscosity index, dispersancy, and antioxidant properties, enabling extended lubricant drain intervals and enhanced fuel economy.
Implementation Method 1
copolymer prepared from ethylene and at least one C3 to C23 alpha-olefin and, optionally, a polyene is grafted with an ethylenically unsaturated carboxylic acid material
Implementation Method 2
the grafted copolymer is reacted with a polyamine compound, resulting in an imidized copolymer
Data Source
AI summary
The invention relates to a process for an additive composition comprising an amidized or imidized polymer. The invention further relates to a highly grafted, multi-functional lubricant additive useful to improve the viscosity index and dispersancy properties of a lubricating oil composition. The present invention also relates to a method of extending lubricant drain intervals and improving fuel economy and fuel economy durability. The additive composition is prepared by: (A) reacting an olefin copolymer of ethylene and at least one C3 to C23 &agr; -olefin comprising from about 15 to 80 mole percent of ethylene, from about 20 to 85 mole percent of said C3 to C23 &agr; -olefin and from about 0 to 15 wt percent of a polyene, said copolymer having a number average molecular weight ranging from 1,000 to 500,000, with an olefinic carboxylic acid acylating agent, said process comprising heating said polymer to a molten condition at a temperature in the range of 60° C. to 240° C., grafting, in a first extruder or a first mixing device, said olefinic carboxylic acylating agent onto said copolymer, optionally subsequently reducing the molecular weight of said copolymer at a temperature in the range of 250° C. to 350° C., thereby producing a grafted, reduced molecular weight acylated copolymer having a number average molecular weight ranging from 1,000 to 80,000 and having at least 0.2-20 molecules of said carboxylic acid acylating agent grafted per 1000 C atoms of said olefin copolymer, and (B) reacting, in a second extruder or a second mixing device, said acylated copolymer made in (A) with a polyamine.