Calcium Hydroxyapatite Grease Thickener Yield
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Solution Overview
Problem
Existing overbased calcium sulfonate greases require high amounts of expensive overbased oil-soluble calcium sulfonate to achieve desired thickener yield and high temperature utility, and prior art does not provide effective solutions for improving thickener yield and dropping point when using poor quality overbased oil-soluble calcium sulfonates.
Innovation Solution
Incorporating calcium hydroxyapatite as a calcium-containing base in the manufacturing process of overbased calcium sulfonate greases, allowing for reduced amounts of overbased oil-soluble calcium sulfonate while maintaining acceptable penetration measurements and high temperature utility, even with poor quality overbased oil-soluble calcium sulfonates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high amounts of overbased oil-soluble calcium sulfonate are used, then desired thickener yield and high temperature utility are achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines overbased oil-soluble calcium sulfonate with calcium hydroxyapatite to form a composite grease system. This composite approach allows the calcium hydroxyapatite particles to contribute to the thickener structure and high-temperature stability, reducing the amount of expensive overbased calcium sulfonate needed while maintaining or improving performance.
Solution Approach 2:
The patent changes the chemical composition parameters by introducing calcium hydroxyapatite (Ca5(PO4)3(OH)) as an additional calcium-containing base component. This parameter change enables the system to achieve the same or better thickener yield and dropping point with reduced quantities of the primary thickener agent.
2Quantity of substance
If poor quality overbased oil-soluble calcium sulfonate is used, then manufacturing cost decreases, but thickener yield and dropping point deteriorate
Solution Approach 1:
Calcium hydroxyapatite acts as an intermediary component that compensates for the deficiencies in poor quality overbased calcium sulfonate. The calcium hydroxyapatite provides additional calcium ions and hydroxide groups that enhance the thickening mechanism and raise the dropping point, effectively mediating the poor performance characteristics of the low-quality sulfonate.
Solution Approach 2:
By creating a composite system with calcium hydroxyapatite, the patent transforms poor quality overbased calcium sulfonate into a functional grease thickener system. The calcium hydroxyapatite particles provide structural support and chemical reactivity that compensates for the impurities and lower performance of the poor quality sulfonate, achieving acceptable dropping points and thickener yield at lower cost.
3Quantity of substance
If reduced amounts of overbased oil-soluble calcium sulfonate are used, then manufacturing cost decreases, but thickener yield deteriorates
Solution Approach 1:
The patent employs a composite thickener system where calcium hydroxyapatite particles serve as a secondary thickening agent. This composite approach enables the system to achieve adequate thickener yield with reduced amounts of overbased calcium sulfonate, as the calcium hydroxyapatite contributes to the grease structure formation and viscosity development.
Solution Approach 2:
The calcium hydroxyapatite particles provide localized thickening functionality within the grease matrix. By distributing calcium hydroxyapatite throughout the system, the patent creates localized regions of enhanced thickening capability that compensate for the reduced overall quantity of overbased calcium sulfonate, maintaining acceptable thickener yield at lower material costs.
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 use of calcium hydroxyapatite enables the production of greases with improved thickener yield and dropping points above 575 F, using less overbased oil-soluble calcium sulfonate, thus reducing costs and enhancing grease performance.
Implementation Method 1
react with and neutralize complexing acids
Implementation Method 2
convert the amorphous calcium carbonate to a very finely divided dispersion of crystalline calcium carbonate
Implementation Method 3
convert the amorphous calcium carbonate to a very finely divided dispersion of crystalline calcium carbonate
Implementation Method 4
react a stoichiometric excess amount of calcium oxide (CaO) or calcium hydroxide (Ca(OH)2) as the base source with an alkyl benzene sulfonic acid, carbon dioxide (CO2)
Data Source
AI summary
An overbased calcium sulfonate grease composition comprising a reduced amount of overbased calcium sulfonate, calcium hydroxyapatite, base oil, one or more converting agents, and one or more complexing acids if a complex grease is desired. The calcium sulfonate grease composition improves thickener yield and expected high temperature utility as demonstrated by dropping point. A method of making the composition comprising the steps of mixing the calcium sulfonate and base oil, adding the calcium carbonate either before or after conversion, adding one or more converting agents, and adding one or more complexing acids. All or a portion of one or more of the complexing acids may be added with or prior to the one or more converting agents.