Ester Base Oil for Electric Vehicle Gearboxes

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Solution Overview

Problem

Current gear oils fail to meet the dynamic requirements of electric vehicles, particularly in terms of energy efficiency, thermal management, and compatibility with advanced electric vehicle technology, leading to a need for lubricant formulations with improved traction and thermal conductivity.

Innovation Solution

A base oil comprising a compound of formula (I), where R is independently selected from hydrogen, alkyl, or alkyl carbonyl, and X is an alkyl moiety with 1-20 carbon atoms, providing improved thermal conductivity and viscosity suitable for electric vehicle powertrains, and a gear oil formulation incorporating this base oil for enhanced performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional gear oils are used in electric vehicles, then lubrication function is provided, but energy efficiency is insufficient and thermal management is inadequate

Engineering Contradiction:
Improveenergy efficiencyVSAvoidthermal management capability
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters of the base oil by incorporating specific ester compounds (formula I) with controlled molecular structures (R groups, m values, and X alkyl moieties). This compositional parameter change simultaneously improves energy efficiency through reduced traction and enhances thermal management through improved thermal conductivity and oxidation stability, resolving the contradiction between energy efficiency and thermal management capability.

Inventive Principle:
Principle #35Parameter changes

2Ease of operation

If standard lubricant formulations are used, then basic lubrication is achieved, but traction properties are insufficient for electric vehicle requirements

Engineering Contradiction:
Improvetraction propertiesVSAvoidformulation complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent creates a composite lubricant formulation by combining specifically structured ester compounds (formula I) with conventional base oils and additives. The ester component provides superior traction properties through its molecular structure (controlled R groups, m ratios, and X alkyl chains), while the composite nature of the formulation integrates multiple functional components to achieve both improved traction and acceptable formulation complexity.

Inventive Principle:
Principle #40Composite materials

3Reliability

If mineral base oils are used, then cost-effectiveness is maintained, but oxidation stability and volatility are insufficient

Engineering Contradiction:
Improveoxidation stabilityVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the base oil composition from conventional mineral oils to specifically structured ester compounds (formula I) with controlled molecular parameters. This parameter change improves oxidation stability through the ester functional groups and enhances volatility resistance through appropriate molecular weight selection (controlled by R groups and m values), while the synthesis route remains cost-effective compared to more complex synthetic alternatives.

Inventive Principle:
Principle #35Parameter changes

4Duration of action of moving object

If high viscosity oils are used for long-life lubrication, then service life is extended, but fluidity at low temperature deteriorates

Engineering Contradiction:
Improveservice lifeVSAvoidlow temperature fluidity
Core Design Contradiction:
Duration of action of moving objectVSSpeed

Solution Approach 1:

The patent creates a composite oil system combining ester base stocks with viscosity modifiers and additives. The ester component provides long service life through superior oxidation stability, while the composite formulation includes viscosity index improvers that maintain fluidity at low temperatures. This composite approach allows the oil to achieve both extended service life and acceptable low-temperature fluidity.

Inventive Principle:
Principle #40Composite materials

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 base oil and gear oil formulation demonstrate reduced traction coefficients, improved thermal conductivity, and oxidative stability, optimizing energy efficiency and longevity in electric vehicle systems, particularly in powertrains and gearboxes.

Implementation Method 1

providing improved thermal conductivity and viscosity suitable for electric vehicle powertrains

Methodology Applied
Scientific EffectThermal conductivity: Conduction (thermal)

Implementation Method 2

provides improved coefficient of friction properties when in use

Methodology Applied
Scientific EffectLubrication: Lubrication

Implementation Method 3

reduced traction coefficients

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 4

oxidative stability

Methodology Applied
Scientific EffectOxidation: Oxidation

Data Source

PatentUS20240182807A1Base oil composition, formulation and use
Publication Date: 2024.06.06 CARGILL BIOINDUSTRIAL UK LTD
  • US20240182807A1 patent drawing
  • US20240182807A1 patent drawing
  • US20240182807A1 patent drawing

AI summary

The present invention relates to a base oil. The base oil as described herein provides utility inter alia in gear oil formulations, and in particular transmission fluids, and provides improved coefficient of friction properties when in use. More especially in some embodiments there is provided a gear oil formulation which is particularly suitable for use in electrical vehicles with or without integrated gear boxes.