Polyalpha-olefin compositions and processes to produce the same

• US 8,748,361 B2
• Filed: 06/02/2006
• Issued: 06/10/2014
• Est. Priority Date: 07/19/2005
• Status: Active Grant

• Current Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Original Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Inventors: Wu, Margaret May-Som, Baugh, Lisa Saunders, Canich, Jo Ann Marie, Chee, Chia Shian, Hagemeister, Mark Paul, Jackson, Andrew, Jiang, Peijun, Lee, Gordon H., Lo, Frederick Yip-Kwai, Rucker, Steven P., Tirmizi, Shakeel, Walzer, John F. Jr., Yang, Norman
• Primary Examiner(s): Goloboy, James
• Assistant Examiner(s): HINES, LATOSHA D
• Application Number:
  US11/995,118
• Publication Number:
  US 20090005279A1
• Time in Patent Office: 2,930 Days
• Field of Search: 508/517, 508/521, 508/523, 508/524, 508/591
• US Class Current: 508/591
• CPC Class Codes: C07C 11/02 Alkenes
• CPC Class Codes: C07C 2/02 by addition between unsaturated hydrocarbons
• CPC Class Codes: C07C 2/34 Metal-hydrocarbon complexes
• CPC Class Codes: C07C 5/05 Partial hydrogenation
• CPC Class Codes: C08F 10/14 Monomers containing five or more carbon atoms
• CPC Class Codes: C08F 110/14 Monomers containing five or more carbon atoms
• CPC Class Codes: C08F 210/04 Monomers containing three or four carbon atoms
• CPC Class Codes: C08F 210/14 Monomers containing five or more carbon atoms
• CPC Class Codes: C08F 2500/02 Low molecular weight, e.g. <100,000 Da.
• CPC Class Codes: C08F 2500/03 Narrow molecular weight distribution, i.e. Mw/Mn < 3
• CPC Class Codes: C08F 2500/17 Viscosity
• CPC Class Codes: C08F 2500/20 Activation energy or enthalpy
• CPC Class Codes: C08F 4/65908 in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
• CPC Class Codes: C08F 4/65912 in combination with an organoaluminium compound
• CPC Class Codes: C08F 4/65925 two cyclopentadienyl rings being mutually non-bridged
• CPC Class Codes: C08F 4/65927 two cyclopentadienyl rings being mutually bridged
• CPC Class Codes: C10M 107/10 containing aliphatic monomer having more than 4 carbon atoms
• CPC Class Codes: C10M 143/08 containing aliphatic monomer having more than 4 carbon atoms
• CPC Class Codes: C10M 2205/026 Butene
• CPC Class Codes: C10M 2205/0265 used as base material
• CPC Class Codes: C10M 2205/028 : containing aliphatic monomers having more than four carbon atoms
• CPC Class Codes: C10M 2205/0285 : used as base material
• CPC Class Codes: C10N 2020/011 : Cloud point
• CPC Class Codes: C10N 2020/013 : Iodine value
• CPC Class Codes: C10N 2020/019 : Shear stability
• CPC Class Codes: C10N 2020/02 : Viscosity; Viscosity index
• CPC Class Codes: C10N 2020/04 : Molecular weight; Molecular weight distribution
• CPC Class Codes: C10N 2020/065 : Saturated Compounds
• CPC Class Codes: C10N 2020/067 : Unsaturated Compounds
• CPC Class Codes: C10N 2020/071 : Branched chain compounds
• CPC Class Codes: C10N 2070/00 : Specific manufacturing methods for lubricant compositions

Abstract

This invention relates to a polyalpha-olefin (and hydrogenated analogs thereof) comprising more than 50 mole % of one or more C5 to C24 alpha-olefin monomers where the polyalpha-olefin has: a) 40 mole % or more of mm triads, b) a Bromine number of Y or greater, where Y is equal to 89.92*(V)′°5863, where V is the Kinematic Viscosity of the polyalpha-olefin measured at 100° C. in cSt, and c) 1,2 disubstituted olefins present at 7 mole % or more, preferably having Z mole % or more of units represented by the formula: where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, or 22, n is an integer from 1 to 350, and where Z=8.420*Log(V)−4.048, where V is the kinematic viscosity of the polyalpha-olefin measured at 1000 C in cSt This invention also relates to process to produce such polyalpha-olefins.

Claims

1. A polyalpha-olefin comprising more than 50 mole % of one or more C5 to C24 oligomer units where the polyalpha-olefin has:

a) 40 mole % or more of mm triads,

b) a Bromine number of Y or greater, where Y is equal to 89.92*(V)<sup>−

0.5863</sup>, where V is the Kinematic Viscosity of the polyalpha-olefin measured at 100°

C. in cSt, and

c) 1,2 disubstituted olefins present if Z is less than 7, then the range if Z or more, and if Z is more than 7, the range is 7 or more, where Z=8.420*Log(V)−

4.048 and V is the kinematic viscosity of the polyalpha-olefin measured at 100 °

C. in cSt.

2. A polyalpha-olefin comprising more than 50 mole % of one or more C5 to C24 oligomer units where the polyalpha-olefin if Z is less than 7, then the range is Z or more, and if Z is more than 7, the range is 7 or more of units represented by the formula:

3. A polyalpha-olefin as set forth in claim 2 where the polyalpha-olefin has:

a) less than 40 mole % of mm triads, and

b) a Bromine number of 1.8 or less.

4. A polyalpha-olefin as set forth in claim 2 where the polyalpha-olefin has:

a) less than 40 mole % of mm triads, and

b) a Bromine number of Y or greater, where Y=89.92×

(V)<sup>−

0.5363</sup>, where V is the kinematic viscosity in cSt measured at 100°

C.

5. A polyalpha-olefin as set forth in claim 2, where the polyalpha-olefin has:

a) 40 mole % or more of mm triads, and

b) a Bromine number of 1.8 or less.

10. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin is polydecene having an Mw/Mn of between 1 and 2.5.

11. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Bromine number of 1.8 or more.

12. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has an Mw/Mn of greater than 1 to 3.5.

13. The polyalpha-olefin of claim 2, wherein the polyalpha-olefin has an Mw/Mn of greater than 1 to 2.5.

14. The polyalpha-olefin of any of claim 2 wherein the polyalpha-olefin has a Kinematic viscosity at 100°

C. of from 1.5 to 5000 cSt.

15. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Kinematic viscosity at 100°

C. of from 2 to 3000 cSt.

16. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Kinematic viscosity at 100°

C. of from 3 to 1000 cSt.

17. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Kinematic viscosity at 40°

C. of from 4 to 100,000 cSt.

18. The polyalpha-olefin of any of claim 2 wherein the polyalpha-olefin has a Kinematic viscosity at 40°

C. of from 6 to 50,000 cSt.

19. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Kinematic viscosity at 40°

C. of from 10 to 30,000 cSt.

20. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Viscosity Index of 100 or more.

21. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Viscosity Index of 120 or more.

22. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Viscosity Index of 130 or more.

23. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Viscosity Index between 120 and 450.

24. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a pour point of 0°

C. or less.

25. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a pour point of −

30°

C. or less.

26. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a pour point between −

10°

C. and −

80°

C.

27. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a pour point between −

15°

C. and −

70°

C.

28. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a weight average molecular weight of 100,000 g/mol or less.

29. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a weight average molecular weight of 100 to 100,000 g/mol.

30. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a weight average molecular weight of 280 to 50,000 g/mol.

31. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a weight average molecular weight of 336 to 40,000 g/mol.

32. The polyalpha-olefin of claim 5 wherein the polyalpha-olefin has a KV₁₀₀ of less than 200 cSt.

33. The polyalpha-olefin of claim 2 where the oligomer units having 5 to 24 carbon atoms are present at 55 mole % or more.

34. The polyalpha-olefin of claim 2 produced from a feed of one or more alpha-olefin monomers wherein the alpha-olefin monomer(s) are selected from the group consisting of 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-eicosene, 1-uneicosene, 1-docosene, 1-tricosene, 1-tetracosene, 1-pentacosene, 1-hexacosene, 4-methyl-1-pentene, 4-phenyl-1-butene, and 5-phenyl-1-pentene.

35. The polyalpha-olefin of claim 2 wherein the alpha-olefin monomer(s) are selected from the group consisting of 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene and 1-hexadecene.

36. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin monomer(s) are selected from the group consisting of 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene and 1-hexadecene.

37. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin comprises octene, decene, and dodecene oligomer units.

38. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a dielectric constant of 2.5 or less (1 kHz at 23°

C.).

39. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has:

a) a kinematic viscosity of from 3 to 3000 cSt at 100°

C., and

b) a viscosity index of from 110 to 400, and

c) a pour point below −

10°

C., and

d) a flash point of 150°

C. or more, and

e) less than 6% viscosity loss in a tapered roller bearing shear stability test.

40. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has

a) a kinematic viscosity of from 3 to 3000 cSt at 100°

C., and

b) a viscosity index of from 135 to 400, and

c) a pour point below −

10°

C., and

d) a flash point of 200°

C. or more, and

e) less than 3% viscosity loss in a tapered roller bearing shear stability test.

41. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a specific gravity of 0.75 to 0.96 g/cm³.

42. The polyalpha-olefin of claim 2 where ethylene, propylene and butene oligomer units are present at less than 1 weight %.

43. The polyalpha-olefin of claim 2 where the oligomer units having 5 to 24 carbon atoms are present at 60 mole % or more.

44. The polyalpha-olefin of claim 2 where the oligomer units having 5 to 24 carbon atoms are present at 70 mole % or more.

45. The polyalpha-olefin of claim 2 where the oligomer units having 5 to 24 carbon atoms are present at 80 mole % or more.

46. The polyalpha-olefin of claim 2 where the oligomer units having 5 to 24 carbon atoms are present at 90 mole % or more.

47. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Bromine number of 3 or more.

48. The polyalpha-olefin of claim 2 wherein the polyalpha-olefin has a Bromine number of 5 or more.

6. A polyalpha-olefin comprising more than 50 mole % of one or more C5 to C24 oligomer units where the polyalpha-olefin has 40 mole % or more of mm triads and less than 300 ppm of a Group 4 metal.

7. A polyalpha-olefin comprising more than 50 mole % of one or more C5 to C24 oligomer units where the polyalpha-olefin has 40 mole % or more of mm triads and less than 100 ppm of a Group 13 metal.

8. A polyalpha-olefin comprising more than 50 mole % of one or more C5 to C24 oligomer units where the polyalpha-olefin has 40 mole % or more of mm triads and less than 600 ppm of aluminum.

9. A polyalpha-olefin comprising more than 50 mole % C5 to C24 oligomer units and having an Mw of 100,000 or less and an Mw/Mn of greater than 1 and less than 2.5.

49. A polyalpha-olefin comprising at least 50 mole % oligomer units having 5 to 24 carbon atoms and from 0.5 to 20 mole % ethylene oligomer units, where at least 80% of the ethylene oligomer units are present in the polyalpha-olefin are present in runs of 1 to 35 carbons or less as measured by Carbon 13 NMR.