Viscosity index improver for lubricant compositions
A lubricant composition comprises a base oil and a viscosity modifier including an ethylene/α-olefin interpolymer. The ethylene/α-olefin interpolymer is a block copolymer having at least a hard block and at least a soft block. The soft block comprises a higher amount of comonomers than the hard block. The block copolymer has a number of unique characteristics disclosed here. Such block copolymers offer the possibility of improved low temperature performance and flexibility in formulating motor oil, gear lubricants and greases, etc.
1. A lubricant composition comprising:
(i) a base oil; and
(ii) an ethylene/α-olefin interpolymer, wherein the ethylene/α-olefin interpolymer comprises two or more intramolecular segments or blocks characterized by possessing a most probable molecular weight distribution, wherein the ethylene/α-olefin interpolymer comprises a hard segment and a soft segment, and:
(a) has a Mw/Mn from about 1.7 to about 3.5;
(b) has an ethylene content in the hard segment in the range of from 70 wt % to 85 wt % based on based on total monomer content in hard segment;
(c) (i) has a hard segment in an amount of at least 40%, at least one melting point, Tm, in degrees Celsius and an amount of ethylene in weight percent, wt % C 2 , wherein the numerical values of Tm and wt % C 2 correspond to the relationship:
90° C.≧ Tm≧ 4.1276(wt % C 2 )−244.76;
or
(ii) has a hard segment composition of less than 40%, at least one melting point, Tm, in degrees Celsius and an amount of ethylene in weight percent, wt % C 2 , wherein the numerical values of Tm and wt % C 2 correspond to the relationship:
80° C.≧ Tm≦ 4.1276(wt % C 2 )−264.95;
or
(iii) is characterized by an average block index greater than zero and up to about 1.0; or
(iv) has a molecular fraction which elutes between 0° C. and 130° C. when fractionated using low temperature TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer; or
(v) has a relationship between ethylene content in wt % and log molecular weight such that a line plotted of ethylene content vs log molecular weight as measured by GPC-IR has an absolute slope, m, of equal to or less than 4; and,
(d) has a turbidity measurement of a 1.0 wt % solution of the ethylene/α-olefin interpolymer in oil or a 1.5 wt % solution in dodecane of less than or equal to that of a comparable copolymer wherein the comparable copolymer has the same DSC enthalpy (J/g) at greater than 55° C. within ±5 J/g and the same overall ethylene content within 10%; and,
has a soft segment comprising 35 wt % to 80 wt % comonomer.
2. The lubricant composition of claim 1 , wherein the α-olefin is styrene, propylene, 1-butene, 1-hexene, 1-octene, 4-methyl- 1-pentene, norbornene, 1-decene, 1,5-hexadiene, or a combination thereof.
3. The lubricant composition of claim 1 , wherein the base oil is selected from the group consisting of the base stocks of API Groups I, II, III, IV and V and combinations thereof.
4. The lubricant composition of claim 1 , wherein the base oil is a natural oil, a synthetic oil or a combination thereof.
5. The lubricant composition of claim 1 , wherein the lubricant composition further comprises at least an additive.
6. The lubricant composition of claim 5 , wherein the additive is a detergent, a dispersant, a friction modifier, a pour point depressant, a demulsifier, an anti-foam, a corrosion inhibitor, an anti-wear agent, an antioxidant, a rust inhibitor, a thickener or a combination thereof.
7. The lubricant composition of claim 1 , wherein the lubricant composition is a motor oil, a transmission fluid, a gear oil, a power steering fluid, a shock absorber fluid, a brake fluid, a hydraulic fluid or a grease.
8. The lubricant composition of claim 7 , wherein the lubricant composition is a motor oil.
9. The lubricant composition of claim 8 , wherein the motor oil further comprises a pour point depressant, a detergent, a dispersant, an anti-wear, an antioxidant, a friction modifier, a rust inhibitor or a combination thereof.
10. The lubricant composition of claim 7 , wherein the lubricant composition is a transmission fluid.
11. The lubricant composition of claim 10 , wherein the transmission fluid further comprises a friction modifier, a detergent, a dispersant, an antioxidant, an anti-wear agent, an extreme pressure agent, a pour point depressant, an anti-foam, a corrosion inhibitor or a combination thereof.
12. The lubricant composition of claim 7 , wherein the lubricant composition is a gear oil.
13. The lubricant composition of claim 12 , wherein the gear oil further comprises an anti-wear, an extreme pressure agent, a rust inhibitor or a combination thereof.
14. The lubricant composition of claim 7 , wherein the lubricant composition is a grease.
15. The lubricant composition of claim 14 , wherein the grease further comprises a thickener, a complexing agent, an antioxidant, an anti-wear agent, an extreme pressure agent, an anti-foam, a corrosion inhibitor or a mixture thereof.