Formulation of a metal working fluid

Abstract

This invention relates to a composition that is a novel improvement of non-oil containing metal working fluids, also known as synthetic metal working fluids. The invention is a non-oil containing metalworking lubricant composition, having an engineered particle size of greater than 200 nanometers upon dilution. The expansive particle size results in a substantial increase in lubricity, suitable for the heavy-duty operations previously attainable only with oil-containing products. Additionally, this non-oil containing metalworking lubricant incorporates the best of the positive attributes of oil-containing products into its composition, including excellent corrosion inhibition and heavy-duty operation capable lubricity.

1 . A metal working fluid composition with a volume average particle size of 125 nm or greater when diluted between 0.1 and 50 percent comprised of:
 (a) one or more polymeric lubricity agent;   (b) one or more carboxylic acid salt;   (c) one or more emulsifying/dispersing agent;   (d) a transport component.   
   
   
       2 . The composition of  claim 1  including one or more oils at less than 10 percent. 
   
   
       3 . The composition of  claim 1  wherein the transport component is water. 
   
   
       4 . The composition of  claim 1  including a corrosion inhibiting component. 
   
   
       5 . The composition of  claim 4  wherein the corrosion inhibiting component consisting of one or more of the following: alkali and alkanolamine salts of carboxylic acids, undecandioic/dodecandioic acid and its salts, C 4-22  carboxylic acids and their salts, boric acids, compounds and their salts, tolytriazole and its salts, benzotriazoles and its salts, imidazolines and its salts, alkanolamines and amides, sulfonates, alkali and alkanolamine salts of naphthenic acids, phosphate ester amine salts, alkali nitrites, alkali carbonates, carboxylic acid derivatives, alkylsulfonamide carboxylic acids, arylsulfonamide carboxylic acids, fatty sarkosides, phenoxy derivatives and sodium molybdate. 
   
   
       6 . The composition of  claim 1  wherein the pH is 3 or greater. 
   
   
       7 . The composition of  claim 1  including an alkalinity agent. 
   
   
       8 . The composition of  claim 7  wherein the alkalinity agent is one or more of the following:
 alkanolamines—primary, secondary and tertiary, aminomethylpropanol (AMP-95), diglycolamine (DGA), monoethanolamine (MEA), monoisopropanolamine (MIPA), butylethanolamine (NBEA), dicylclohexylamine (DCHA), diethanolamine (DEA), butyldiethanolamine (NBDEA), triethanolamine (TEA), metal alkali hydroxides, potassium hydroxide, sodium hydroxide, magnesium hydroxide, lithium hydroxide, metal carbonates and bicarbonates, sodium carbonate, sodium bicarbonate, potassium carbonate and potassium bicarbonate.   
   
   
       9 . The composition of  claim 7  wherein the alkalinity agent is a metal alkali hydroxide. 
   
   
       10 . The composition of  claim 1  including an anti foaming agent. 
   
   
       11 . The composition of  claim 1  including a biocide and/or a fungicide. 
   
   
       12 . The composition of  claim 1  wherein the polymeric lubricity agent is a block copolymer. 
   
   
       13 . The composition of  claim 12  wherein the polymeric lubricity agent is one or more of the following: block copolymers consisting of a central polyoxypropylene block with a polyoxyethylene chain at either end, block copolymers consisting of a central polyoxyethylene block with a polyoxypropylene chain at either end, tetrablock copolymers derived from the sequential addition of ethylene oxide and propylene oxide to ethylenediamine, ethylene oxide/propylene oxide copolymers having at least one terminal hydroxyl group, water-soluble lubricant base stocks of random copolymers of ethylene oxide and propylene oxide, a water-soluble polyoxyethylene or polyoxypropylene alcohol or a water-soluble carboxylic acid ester of such alcohol, alcohol-started base stocks of all polyoxypropylene groups with one terminal hydroxyl group, monobasic and dibasic acid esters, polyol esters, polyalkylene glycol esters, polyalkylene glycols grafted with organic acids, phosphate esters, polyisobutylenes, polyacrylonitriles, polyacrylamides, polyvinylpyrrolidones, polyvinyl alcohols and copolymers of acrylic acid or methacrylic acid and an acrylic ester. 
   
   
       14 . The composition of  claim 12  wherein the block copolymer is polypropylene glycol block copolymer. 
   
   
       15 . The composition of  claim 12  wherein the block copolymer is polyethylene glycol block copolymer. 
   
   
       16 . The composition of  claim 12  wherein the block copolymer is polyethylene glycol/polypropylene glycol block copolymer. 
   
   
       17 . The composition of  claim 1  wherein the one or more carboxylic acid salt is an alkali and/or alkanolamine salts of C 4 -C 22  carboxylic/fatty acids and esters. 
   
   
       18 . The composition of  claim 1  wherein the carboxylic acid salt is comprised of one or more of the following: caproic/hexanoic acid, enanthic/heptanoic acid, caprylic/octanoic acid, pelargonic/nonionic acid, isononanoic acid, capric/decanoic acid, neodecanoic acid, lauric/dodecanoic acid, stearic/octadecanoic acid, arachidic/eicosanoic acid, palmitic/hexadecanoic acid, erucic acid, oleic acid, arachidonic acid, linoleic acid, linolenic acid, myristic/tetradecanoic acid, behenic/docosanoic acid, alpha-linolenic acid, docosahexaenoic acid, ricinoleic acid, butyric acid, lard oil, tallow oil, butter, coconut oil, palm oil, cottonseed oil, wheat germ oil, soya oil, olive oil, corn oil, sunflower oil and rapeseed/canola oil. 
   
   
       19 . The composition of  claim 1  wherein the emulsifying/dispersing agent is one or more of the following: alkanolamides, alkylaryl sulfonates, alkylaryl sulfonic acids, amine oxides, amide and amine soaps, block copolymers, carboxylated alcohols, carboxylic acids/fatty acids, ethoxylated alcohols, ethoxylated alkylphenols, ethoxylated amines/amides, ethoxylated fatty acids, ethoxylated fatty esters and oils, ethoxylated phenols, fatty amines and esters, glycerol esters, glycol esters, imidazolines and imidazoline derivatives, lignin and lignin derivatives, maleic or succinic anhydrides, methyl esters, monoglycerides and derivatives, naphthenic acids, olefin sulfonates, phosphate esters, polyethylene glycols, polyols, polymeric (polysaccharides, acrylic acid, acrylamide), propoxylated & ethoxylated fatty acids, alcohols or alkyl phenols, quaternary surfactants, sarcosine derivatives, soaps, sorbitan derivatives, sucrose and glucose esters and derivatives, sulfates and sulfonates of oils and fatty acids, sulfates and sulfonates ethoxylated alkylphenols, sulfates of alcohols, sulfates of ethoxylated alcohols, sulfates of fatty esters, sulfonates of dodecyl and tridecylbenzenes, sulfonates of naphthalene and alkyl naphthalene, sulfonates of petroleum, sulfosuccinamates, sulfosuccinates and derivatives, tridecyl and dodecyl benzene sulfonic acids. 
   
   
       20 . The composition of  claim 1  wherein the metalworking fluid composition, when diluted between 0.1 and 50 percent comprises a lubricity, as measured by tapping torque instruments, of less than 8000 Newton-cm −1 . 
   
   
       21 . A metal working fluid composition comprised of:
 (a) 1 to 80 percent one or more block copolymers;   (b) 1 to 40 percent one or more carboxylic acid salts;   (c) 1 to 20 percent of one or more emulsifying agents;   (d) a transport component.   
   
   
       22 . A metal working fluid composition comprised of:
 (a) 5 to 40 percent one or more block copolymers;   (b) 3 to 30 percent one or more carboxylic acid salts;   (c) 2 to 12 percent of one or more emulsifying agents;   (d) a transport component.   
   
   
       23 . A metal working fluid composition comprised of:
 (a) 15 to 25 percent one or more block copolymers;   (b) 5 to 15 percent one or more carboxylic acid salts;   (c) 3 to 8 percent of one or more emulsifying agents;   (d) a transport component.