Novel Grease and Methods of Making the Same

Abstract

The present disclosure relates to a high performance calcium sulfonate greases with enhanced performance benefits and methods for making the same.

What is claimed is: 
     
         1 . A complex grease comprising:
 preformed calcium acetate from about 0.25 wt % to about 5 wt %;   an overbased calcium sulphonate detergent from about 10 wt % to about 30 wt %; and   an oil of lubricating viscosity.   
     
     
         2 . The complex grease of  claim 1 , wherein the complex grease has a penetration of about 230 to about 340 as measured by ASTM D217. 
     
     
         3 . The complex grease of  claim 1 , wherein the complex grease has a drop point of from about 250° C. to about 400° C. 
     
     
         4 . The complex grease of  claim 1 , wherein an infrared spectrum of the grease comprises an absorbance peak at 1569 cm −1 ±1. 
     
     
         5 . The complex grease of  claim 4 , wherein the infrared spectrum of the grease further comprises and an absorbance peak at 883 cm −1 ±1. 
     
     
         6 . The complex grease of  claim 1 , wherein the ratio of preformed calcium acetate to overbased calcium sulphonate detergent is from about 1:2 to about 1:100. 
     
     
         7 . The complex grease of  claim 1 , wherein the ratio of peak intensity (% T) of the absorbance peak at 1569 cm −1 ±1 to grease penetration measured by ASTM D217 is from about 1:2.4 to about 1:3.4. 
     
     
         8 . The complex grease of  claim 1 , wherein the preformed calcium acetate is from about 0.5 wt % to about 3.5 wt %. 
     
     
         9 . The complex grease of  claim 1 , wherein the overbased calcium sulphonate detergent is from about 20 wt % to about 30 wt %. 
     
     
         10 . The complex grease of  claim 1 , wherein the oil of lubricating viscosity is selected from the group consisting of group I, group II, group III, group IV and group V oils, or is selected from a mixture of one or more oils of group I, group II, group III, group IV and group V base oils. 
     
     
         11 . The complex grease of  claim 1 , wherein the overbased calcium sulphonate detergent has a total base number (TBN) from about 300 to about 400. 
     
     
         12 . The complex grease of  claim 1 , wherein the complex grease further comprises one or more complexing acids selected from the group consisting of a long chain carboxylic acid, a short chain carboxylic acid, boric acid, phosphoric acid, and alkyl benzene sulphonic acid. 
     
     
         13 . The complex grease of  claim 12 , wherein at least one of the complexing acids is C 1 -C 20  alkyl benzene sulphonic acid. 
     
     
         14 . The complex grease of  claim 13 , wherein the C 1 -C 20  alkyl benzene sulphonic acid is dodecylbenzene sulfonic acid. 
     
     
         15 . The complex grease of  claim 12 , wherein the complex grease comprises at least two complexing acids. 
     
     
         16 . The complex grease of  claim 15 , wherein the at least two complexing acids comprise dodecylbenzene sulfonic acid and 12-hydroxystearic acid. 
     
     
         17 . The complex grease of  claim 1 , wherein the complex grease further comprises one or more converting agents selected from the group consisting of alcohols, ethers, glycols, glycol ethers, glycol polyethers, carboxylic acids, inorganic acids, organic nitrates, compounds that contain active hydrogen, and compounds that contain tautomeric hydrogen. 
     
     
         18 . The complex grease of  claim 1 , wherein the complex grease further comprises one or more additives selected from the group consisting of antioxidants, rust inhibitors, metal deactivators, antiwear agents, antiscuffing agents, extreme pressure agents, foam inhibitors, demulsifiers, friction modifiers, viscosity modifiers, and pour point depressants. 
     
     
         19 . A calcium sulfonate grease prepared according to the steps of:
 a) providing preformed calcium acetate dissolved in water in a vessel;   b) providing an oil of lubricating viscosity to the dissolved preformed calcium acetate in water in the vessel from step a),   c) heating the oil and preformed calcium acetate mixture of step b); and   d) providing an overbased calcium sulfonate detergent to the oil and preformed calcium acetate mixture in the vessel from step c).   
     
     
         20 . The grease according to  claim 19 , wherein an infrared spectrum of the grease comprises an absorbance peak at 1569 cm −1 ±1 and 883 cm −1 ±1.