Complex mixtures of ions and processes for deposition

Abstract

A composition and method for providing a silicon-nitrogen surface on metals wherein is reacted a source of silicon, a source of ammonium ions, an alkali metal hydroxide in an aqueous medium to produce an electrolyte solution comprising a complex ion mixture. The electrolyte solution can be used to deposit a silicon surface on conductive substrates. The electrolyte solution can be dehydrated in a hydrocarbon medium, thus providing novel materials for use as lubricating oil additives and as fuel additives. The fuels and lubricants can be used as carriers for depositing the complex to form a silicon/nitrogen and silicon/nitrogen bimetallic surfaces on metal surfaces including, but not limited to, metals in the combustion chamber either through an aqueous phase or through a hydrocarbon phase. These new silicon/nitrogen surfaces may significantly reduce coefficient of friction, smooth the flame front, reduce corrosion, enhance fuel economy, and reduce hydrocarbon emissions when used in internal combustion engines.

1 . A complex mixture of ions comprising an aqueous solution of ammonium hydroxide, a source of silicon ions selected from the group consisting of sodium silicate, ferrosilicon, potassium silicate, and combinations thereof, and an alkali metal hydroxide selected from the group consisting of sodium hydroxide, potassium hydroxide, and combinations thereof.  
   
   
       2 . The mixture of  claim 1  wherein the source of silicon ions is sodium silicate.  
   
   
       3 . The mixture of  claim 1  wherein the source of silicon ions is ferrosilicon.  
   
   
       4 . The mixture of  claim 1  wherein the source of silicon ions is potassium silicate.  
   
   
       5 . The mixture of  claim 1  wherein the alkali metal hydroxide is sodium hydroxide.  
   
   
       6 . The mixture of  claim 1  wherein the alkali metal hydroxide is potassium hydroxide.  
   
   
       7 . The mixture of  claim 1  further comprising a hydrocarbon base in which the mixture of ions is solubilized following dehydration.  
   
   
       8 . The mixture of  claim 7  further comprising a tertiary metal selected from the group consisting of molybdenum and tungsten.  
   
   
       9 . The mixture of  claim 8  wherein the tertiary metal is molybdenum.  
   
   
       10 . The mixture of  claim 8  wherein the tertiary mixture is tungsten.  
   
   
       11 . An additive prepared by the steps of preparing an inorganic aqueous mixture comprising silicon ions, ammonium ions, and alkali metal ions, heating said inorganic aqueous mixture, dehydrating, precipitating salts, and solubilizing in a hydrocarbon.  
   
   
       12 . The additive of  claim 11  wherein preparing the inorganic aqueous mixture comprises adding sodium silicate.  
   
   
       13 . The additive of  claim 11  wherein preparing the is inorganic aqueous mixture comprises adding potassium silicate.  
   
   
       14 . The additive of  claim 11  wherein preparing the inorganic aqueous mixture comprises adding ferrosilicon.  
   
   
       15 . The additive of  claim 12  wherein preparing the inorganic aqueous mixture comprises adding sodium hydroxide.  
   
   
       16 . The additive of  claim 12  wherein preparing the inorganic aqueous mixture comprises adding potassium hydroxide.  
   
   
       17 . The additive of  claim 16  wherein the hydrocarbon comprises an oil selected from the group consisting of solvent neutral oils, synthetic oils, mineral oils, methyl ester, and combinations thereof.  
   
   
       18 . The additive of  claim 17  wherein the hydrocarbon comprises a solvent neutral oil.  
   
   
       19 . The additive of  claim 17  wherein the hydrocarbon comprises a synthetic oil.  
   
   
       20 . The additive of  claim 17  wherein the hydrocarbon comprises a mineral oil.  
   
   
       21 . The of  claim 17  wherein the hydrocarbon comprises a methyl ester.  
   
   
       22 . A method for preparation of a performance enhancing engine additive comprising preparing an aqueous solution of a silicate selected from the group consisting of sodium silicate, potassium silicate, ferrosilicon, and combinations thereof adding ammonium hydroxide to the solution, mixing into the solution an alkali metal hydroxide selected from the group consisting of sodium hydroxide, potassium hydroxide, and combinations thereof, mixing a hydrocarbon with the solution,and heating to remove water and precipitate salts.  
   
   
       23 . The method of  claim 22  wherein the silicate is sodium silicate or potassium silicate.  
   
   
       24 . The method of  claim 22  wherein the silicate is ferrosilicon.  
   
   
       25 . The method of  claim 22  wherein the alkali metal hydroxide is sodium hydroxide.  
   
   
       26 . The method of  claim 22  wherein the alkali metal hydroxide is potassium hydroxide.  
   
   
       27 . The method of  claim 23  wherein the alkali metal hydroxide is potassium hydroxide.  
   
   
       28 . The method of  claim 22  wherein the hydrocarbon is selected from the group consisting of solvent neutral oils, synthetic oils, mineral oils, Penreco Drakeols, methyl esters, and combinations thereof.  
   
   
       29 . The method of  claim 28  wherein the hydrocarbon is a synthetic oil.  
   
   
       30 . The method of  claim 28  wherein the hydrocarbon is a synthetic oil.  
   
   
       31 . A composition for modifying a metal surface prepared by the steps of providing an aqueous solution comprising a silicate selected from the group consisting of sodium silicate, ferrosilicon, and potassium silicate and combinations thereof, ammonium hydroxide, an alkali metal hydroxide selected from the group consisting of sodium hydroxide, potassium hydroxide, and combinations thereof, mixing a hydrocarbon with the resulting solution, heating to remove water, and precipitate salts, and wherein the composition forms a coating upon contacting the metal surface.  
   
   
       32 . The composition to of  claim 31  wherein the preparation of said composition is further characterized by the step of combining the composition with a lubricating oil.  
   
   
       33 . The composition to of  claim 31  wherein the preparation of said composition is further characterized by combining the composition with a fuel.  
   
   
       34 . An inorganic aqueous composition with a pH greater than 9 and capable of solubilization in hydrocarbons for improving fuel economy, said solution being formed by combination of an alkali metal, a source of ammonium ions, and a source of silicon.  
   
   
       35 . The inorganic aqueous composition according to  claim 34  wherein the alkali metal is sodium.  
   
   
       36 . The inorganic aqueous composition according to  claim 34  wherein the alkali metal is potassium.  
   
   
       37 . The inorganic aqueous composition according to  claim 34  wherein the source of silicon is a silicate.  
   
   
       38 . The inorganic aqueous composition according to  34  wherein the source of silicon is ferrosilicon.  
   
   
       39 . The inorganic aqueous composition according to  claim 34  wherein the source of silicon is sodium silicate.  
   
   
       40 . The inorganic aqueous composition according to  claim 34  wherein the source of silicon is potassium silicate.  
   
   
       41 . The inorganic aqueous composition according to  claim 34  wherein the source of silicon is a metasilicate.  
   
   
       42 . The inorganic aqueous composition according to  claim 34  whrein the source of silicon is an orthosilicate.  
   
   
       43 . The inorganic aqueous composition according to  claim 34  wherein the source of ammonium ions is ammonium hydroxide.  
   
   
       44 . The composition of  claim 34  wherein said composition is modified by mixing with an oil-based hydrocarbon and then heating the mixture until salts are precipitated.  
   
   
       45 . The composition of  claim 44  wherein the oil-based hydrocarbon comprises a lubricating oil or a synthetic oil.  
   
   
       46 . The composition of  claim 44  wherein the oil-based hydrocarbon comprises a methyl ester.  
   
   
       47 . A method of preparing an inorganic aqueous composition comprising the steps of preparing a complex mixture of ions comprising a source of silicon ions, a source of ammonium ions, and a source of alkali metal ions, solubilizing said mixture in a hydrocarbon liquid to produce an additive, and applying said additive to an internal wear surface of an internal combustion engine.  
   
   
       48 . The method of  claim 47  wherein at least one additional metal from Groups I-VIII of the Periodic Table is also solubilized in the additive.  
   
   
       49 . The method of  claim 47  further comprising electrolessly depositing a silicon bimetallic surface on at least one conductive substrate.  
   
   
       50 . The method of  claim 47  further comprising electrolessly depositing a silicon bi-metallic surface on at least one conductive substrate.  
   
   
       51 . The method of  claim 50  wherein the internal combustion engine comprises a diesel engine.  
   
   
       52 . The method of  claim 50  wherein the internal combustion engine comprises a gasoline engine.  
   
   
       53 . The method of  claim 51  wherein the fuel consumption of the engine is improved by at least 5%  
   
   
       54 . The method of  claim 52  wherein the fuel consumption of the engine is improved by at least 5%.