Phosphorus-Containing Lubricant for Catalyst Protection
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Solution Overview
Problem
Phosphorus in engine lubricants contaminates emissions control system catalysts, reducing their effectiveness, despite efforts to reduce phosphorus levels in engine oils, as existing approaches do not adequately balance engine lubrication with phosphorus reduction.
Innovation Solution
A lubricating oil composition comprising a zinc salt of a mixture of phosphorus-containing compounds with specific carbon atom distributions and hydrogen content, which reduces phosphorus contamination in exhaust gases, thereby improving emissions control system efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorus-containing lubricants (ZDDPs) are used to provide extreme pressure and antiwear protection, then engine lubrication performance is improved, but catalyst contamination in emissions control systems increases
Solution Approach 1:
The patent modifies the molecular structure parameters of phosphorus-containing compounds by controlling the average total number of carbon atoms in hydrocarbyl groups (6-12 carbons) and the beta-carbon hydrogen content (at least 7.25 hydrogens), which changes the volatility and decomposition characteristics of the lubricant, thereby reducing phosphorus emissions while maintaining lubrication performance
Solution Approach 2:
The patent uses a composite approach by combining specific phosphorus-containing compounds with defined molecular characteristics into a lubricant formulation that achieves both protective lubrication and reduced emissions, creating a material with dual optimized properties
2Object-generated harmful factors
If phosphorus concentration in engine oil is reduced to limit catalyst contamination, then emissions control system efficiency is improved, but engine lubrication and extreme pressure protection deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of phosphorus-containing compounds by specifying molecular weight characteristics (carbon atom count and beta-carbon hydrogen content), which optimizes the balance between phosphorus emission levels and lubrication effectiveness, allowing reduced phosphorus concentration while maintaining protection
3Reliability
If conventional phosphorus-containing lubricants are used, then adequate engine lubrication is achieved, but phosphorus contribution to exhaust gas increases
Solution Approach 1:
The patent modifies physical-chemical parameters of phosphorus-containing compounds including molecular weight (controlled by carbon atom count) and hydrogen content at beta-carbon positions, which reduces the tendency of phosphorus to volatilize and appear in exhaust gases while preserving lubrication film formation and protective functions
Data Source
AI summary
An internal combustion engine with a catalyst-containing exhaust-gas aftertreatment device is lubricated with a composition of a base oil; and a zinc salt of a mixture of phosphorus-containing compounds having hydrocarbyl groups R1 and R2 where the average total number of carbon atoms in R1 plus R2 for the mixture of phosphorus-containing compounds is at least 9.5, where 4 to 30 weight percent of such groups contain 2 to 4 carbon atoms and where in less than 8 mole percent of the phosphorus-containing molecules in the mixture of phosphorus- containing compounds each of R1 and R2 contain 2 to 4 carbon atoms.