Complex mixtures of ions and processes for deposition

Abstract

A composition and method for providing a wear-resistant and fuel-saving coating on metals, particularly metal surfaces within internal combustion engines. A source of ammonium ions, an alkali metal in an aqueous medium, and the coating metal to be applied to the surface are combined to produce an electrolyte solution comprising a complex ion mixture. The electrolyte solution can be used to deposit the coating metal on conductive substrates. The coating metal may comprise phosphorus, sulfur, carbon, bismuth, boron, silicon, and combinations thereof. The electrolyte solution can be dehydrated in a hydrocarbon medium, thus providing novel materials for use as lubricating oil additives and as fuel additives. These new 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 . An additive for improving engine performance comprising, in aqueous solution, ammonium, an alkali metal, and a coating component selected from the group consisting of phosphorus, sulfur, carbon, bismuth, boron, silicon, and combinations thereof.  
   
   
       2 . The additive of  claim 1  further comprising a hydrocarbon oil.  
   
   
       3 . An engine additive consisting essentially of a source of ammonium ions, a source of alkali metal ions, a coating component, and a hydrocarbon.  
   
   
       4 . The additive of  claim 3  wherein the coating component is selected from the group consisting of phosphorus, sulfur, carbon, bismuth, boron, silicon, and combinations thereof.  
   
   
       5 . The additive of  claim 3  wherein the coating component is selected from the group consisting of ammonium phosphate, ammonium sulfate, ammonium acetate, ammonium borate, metallic bismuth dissolved in sulfuric acid solution, ferrosilicon, and combinations thereof.  
   
   
       6 . The additive of  claim 3  wherein the hydrocarbon comprises an oil selected from the group consisting of solvent neutral oils, synthetic oils, mineral oils, vegetable oils, methyl esters, and combinations thereof.  
   
   
       7 . A method for preparing an additive for improving fuel performance comprising the steps of preparing an aqueous mixture comprising ammonium, an alkali metal, and a coating component selected from the group consisting of phosphorus, sulfur, carbon, bismuth, boron, silicon, and combinations thereof, and heating the aqueous mixture.  
   
   
       8 . The method of  claim 7  further comprising dehydrating the aqueous mixture.  
   
   
       9 . The method of  claim 8  further comprising precipitating salts.  
   
   
       10 . The method of  claim 9  further comprising solubilizing in a hydrocarbon oil.  
   
   
       11 . An 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 coating component selected from the group consisting of phosphorus, sulfur, carbon, bismuth, boron, silicon, and combinations thereof.  
   
   
       12 . The aqueous composition according to  claim 11  wherein the alkali metal is sodium.  
   
   
       13 . The aqueous composition according to  claim 11  wherein the alkali metal is potassium.  
   
   
       14 . The aqueous composition according to  claim 11  wherein the source of ammonium ions is selected from the group consisting of ammonium phosphate, ammonium sulfate, ammonium acetate, ammonium borate, ammonium hydroxide, and combinations thereof.  
   
   
       15 . The aqueous composition according to  claim 11  wherein said aqueous composition is solubilized in a hydrocarbon oil selected from the group consisting of solvent neutral oils, synthetic oils, mineral oils, vegetable oils, methyl esters, and combinations thereof, such that the solubilized composition is miscible and stable in diesel fuel.  
   
   
       16 . A method of preparing an aqueous composition comprising providing a source of ammonium ions, providing a source of alkali metal ions, providing a coating component, 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.  
   
   
       17 . The method of  claim 16  wherein the coating component is selected from the group consisting of phosphorus, sulfur, carbon, bismuth, boron, silicon, and combinations thereof.  
   
   
       18 . The method of  claim 17  wherein the hydrocarbon liquid is selected from the group consisting of solvent neutral oils, synthetic oils, mineral oils, vegetable oils, methyl esters, and combinations thereof.  
   
   
       19 . The method of  claim 18  wherein the source of ammonium ions is selected from the group consisting of ammonium phosphate, ammonium sulfate, ammonium acetate, ammonium borate, ammonium hydroxide, and combinations thereof.  
   
   
       20 . The method of  claim 19  further comprising dehydrating the aqueous mixture and precipitating salts.  
   
   
       21 . The method of  claim 19  wherein at least one additional metal from Groups I-VIII of the Periodic Table is also solubilized in the additive.  
   
   
       22 . The method of  claim 19  further comprising electrolessly depositing a silicon surface on at least one conductive substrate.  
   
   
       23 . The method of  claim 16  wherein the internal combustion engine comprises a diesel engine.  
   
   
       24 . The method of  claim 16  wherein the internal combustion engine comprises a gasoline engine.  
   
   
       25 . The method of  claim 16  wherein the fuel consumption of the engine is improved by at least 5%.