Emulsions and products thereof

Abstract

Emulsions and products thereof are provided. The emulsions at least include an oil component having a viscosity that is 150 centistokes at 40° C. or greater, a surfactant, and water. The emulsion components are processed by mixing with multiple and simultaneous mixing operations including at high and low shear mixing rates. The emulsions can be utilized in a variety of products including lubricants and concentrates thereof suitable for use in a number of applications including lubricant-based applications, such as metal working processes.

1 . An emulsion composition comprising: 
 an oil component having a viscosity of about 150 centistokes at 40° C. or greater;    a surfactant; and    water.    
   
   
       2 . The emulsion composition of  claim 1 , wherein the oil is selected from the group consisting of a synthetic oil, a vegetable oil, and a petroleum-based oil.  
   
   
       3 . The emulsion composition of  claim 1 , wherein the emulsion includes at least 30 wt% oil, at least 3 wt% surfactant, and at least 30 wt% water.  
   
   
       4 . The emulsion composition of  claim 1 , wherein the surfactant includes an ethoxylated alcohol having ethoxylate in an amount from about 4 mole percent to about 14 mole percent.  
   
   
       5 . The emulsion composition of  claim 1 , wherein the oil includes a petroleum-based oil having a viscosity that ranges from about 400 centistokes at 40° C. to about 600 centistokes at 40° C.  
   
   
       6 . The emulsion composition of  claim 1 , wherein the oil includes a synthetic oil having a viscosity that ranges from about 1200 centistokes at 40° C. to about 1500 centistokes at 40° C.  
   
   
       7 . A lubricant concentrate composition comprising an emulsion including about 30 wt% to about 80 wt% oil having a viscosity of about 150 centistokes at 40° C. or greater; about 3 wt% to about 9 wt% surfactant; and about 30 wt% to about 70 wt% water.  
   
   
       8 . The lubricant concentrate of  claim 7 , wherein the oil is selected from the group consisting of a synthetic oil, a vegetable oil, and a petroleum-based oil.  
   
   
       9 . The lubricant concentrate of  claim 7 , wherein the surfactant includes an ethoxylated alcohol having ethoxylate in an amount from about 4 mole percent to about 14 mole percent.  
   
   
       10 . The lubricant concentrate of  claim 7 , wherein the oil has a viscosity that ranges from about 200 centistokes at 40° C. to about 2000 centistokes at 40° C.  
   
   
       11 . A lubricant comprising a concentrate in dilute form, the concentrate including an emulsion including an oil having a viscosity of about 150 centistokes at 40° C. or greater; a surfactant; and water.  
   
   
       12 . The lubricant of  claim 11 , which includes at least 2 wt% oil, at least 0.1 wt% surfactant, and at least 40 wt% water.  
   
   
       13 . The lubricant of  claim 11 , wherein the oil is selected from the group consisting of a synthetic oil, a vegetable oil, and a petroleum-based oil.  
   
   
       14 . The lubricant of  claim 11 , wherein the surfactant includes an ethoxylated alcohol having ethoxylate in an amount from about 4 mole percent to about 14 mole percent.  
   
   
       15 . The lubricant of  claim 11 , wherein the oil has a viscosity that ranges from about 200 centistokes at 40° C. to about 1500 centistokes at 40° C.  
   
   
       16 . A method for processing an emulsion-based composition, the method comprising: 
 preparing an emulsion mixture including an oil component having a viscosity of about 150 centistokes at 40° C. or greater, a surfactant, and water; and    processing the emulsion mixture under simultaneous mixing operations including at varying shear rates.    
   
   
       17 . The method of  claim 16 , wherein the emulsion mixture includes about 30 wt% to about 80 wt% oil, about 3 wt% to about 9 wt% surfactant, and about 30 wt% to about 70 wt% water.  
   
   
       18 . The method of  claim 16 , wherein the oil is selected from the group consisting of a synthetic oil, a vegetable oil, and a petroleum-based oil.  
   
   
       19 . The method of  claim 16 , wherein the mixing operations are conducted at shear rates varying from about 15 rpm to about 1800 rpm.  
   
   
       20 . The method of  claim 16 , wherein the mixing operations are conducted at a first shear rate that ranges from about 15 rpm to about 70 rpm and a second shear rate that ranges from about 400 rpm to about 1800 rpm.