Polymers bearing groups derived from N-substituted lactams and their use as lubricating oil additives
BACKGROUND OF THE INVENTION 
     The present invention is directed to polymers bearing groups derived from N-substituted lactams and their use as additives for improving the viscosity index and the dispersing power of lubricating oils. 
     From U.S. Pat. No. 3,137,222, it is known to use copolymers of methacrylates and N-vinylpyrrolidone to increase the viscosity index and the dispersing power of lubricating oils. 
     These copolymers are prepared by radical polymerization and, therefore, have a broad molecular distribution, making them sensitive to shear and of little effect on the thickening power or viscosity index of an oil. 
     By the present invention, new polymers are provided which can be used as additives to improve the viscosity index and the dispersing power of lubricating oils. 
     It is, therefore, an object of the present invention to provide novel polymeric additives for lubricating oils which impart excellent dispersing properties and improve the viscosity index of lubricating oils. 
     It is also an object of the invention to provide a novel process for producing the novel additives of the invention. 
     It is a further object of the invention to provide novel lubricating oils containing the novel additives of the invention. 
     Other objects of the invention will be apparent to those skilled in the art from the present description. 
     General Description of the Invention 
     The polymers of the novel additives of the present invention are obtained by subjecting a living polymer of number average molecular weight Mn of between about 20,000 and 300,000, and preferably between about 30,000 and 150,000, prepared by anionic polymerization of at least one C 4  -C 6  conjugated diene and possibly at least one compound selected from among vinyl aromatic compounds, to a functionalization operation by reaction with an N-substituted lactam of the formula: ##STR1## in which Z represents a C 1  -C 20 , and preferably C 1  -C 10 , alkyl radical, a C 2  -C 10 , and preferably a C 2  -C 4  alkenyl radical, a phenyl radical possibly substituted by a C 1  -C 10 , and preferably C 1  -C 5 , alkyl group, &#34;n&#34; representing a whole number of from about 2 to 11, and preferably from about 3 to 5, and particularly equal to 3; and to hydrogenation. 
     A variant method of preparing the said polymers comprises subjecting the said living polymer to a metalation operation before functionalization by the said N-substituted lactam and in carrying out the hydrogenation operation prior to the metalation operation or subsequent to the functionalization operation. 
     In accordance with this variant, it is preferable to effect the hydrogenation operation prior to the metalation and functionalization operations in order to obtain polymers of better polydispersity index. 
     Among the living polymers which may be employed, mention may be made of: 
     (1) those obtained by anionic polymerization of at least one diene, such as butadiene, isoprene, or dimethyl butadiene, 
     (2) the random or block copolymers obtained by anionic polymerization of at least one of the above-mentioned dienes and of a vinyl aromatic compound, such as styrene and α-methylstyrene, 
     (3) the &#34;star&#34; copolymers obtained from at least one of the above-mentioned dienes, possibly mixed with a vinyl aromatic compound of the styrene or α-methylstyrene type and divinylbenzene. 
     The said living polymers can be prepared at a temperature of between about minus 80° and plus 150° C., and preferably between about 0° and 100° C., in the presence of hydrocarbon solvents, such as cyclohexane, hexane, heptane, dodecane, benzene, toluene, xylene, etc., the lubricating oil additive support oils and/or polar solvents, such as ethers of the type of dioxan or tetrahydrofuran, the methylethers of diethylene or triethylene glycol, the amines of the tetramethylene diamine type, and the phosphoramides of the hexamethylphosphoramide type. Mixtures of solvents which may contain up to 15 percent polar solvent will preferably be employed. 
     The catalysts which may be used to carry out the anionic polymerization operation are organometallic catalysts well known to the man skilled in the art, preferably organolithium catalysts such as n-butyllithium, sec-butyllithium, phenyllithium, 1,4-dilithiobutane, 1,4-dilithio-1,1,4,4-tetraphenylbutane, naphthalene lithium, or organo-sodium naphthalenes, such as naphthalene sodium. 
     The amount of catalyst to be used is such that the ratio of the rate of monomer(s) to amount of catalyst in mols is equal to the number average molecular weight Mn of the polymer to be obtained. 
     The so-called &#34;star&#34; polymers can be prepared by the method of operation described in Belgian Pat. No. 850,336, excluding the polymerization step. 
     As is known to the man skilled in the art, the living polymers obtained by anionic polymerization in the presence of an organometallic compound have a metal atom disposed at one end of said polymer when the organometallic compound used is monofunctional and a metal atom arranged at each end of said polymer when the organometallic compound used is bifunctional. 
     The metalation operation, optionally employed, can be carried out in accordance with the known metalation techniques, for instance, treatment of the polymer with a complex consisting of a diamine and an organic compound of an alkali metal (French patent published under U.S. Pat. No. 2,047,980). For the satisfactory conduct of this operation, it is effected with the use of a complex consisting of N,N,N&#39;N&#39;-tetramethyleneethylene diamine and a butyllithium, in particular sec-butyllithium, with a molar ratio of diamine to butyllithium of between about 0.5 and 1.2, and preferably between about 0.7 and 1. 
     This operation is carried out at a temperature of between about -80° and +100° C., and preferably between about 0° and 80° C., for generally 1 to 24 hours, in the presence of an inert solvent of the type cited above as polymerization solvent, and more particularly hydrocarbon solvents. 
     The amount of metalation complex employed is such that the number of mols of organometallic compound of said complex per mol of polymer is less than about 50 and preferably between about 2 and 10. 
     The metalated polymer obtained has a carbanion site at the end of the chain, as well as one or more carbanion sites along the chain. 
     Among the lactams which can be used for carrying out the functionalization operation, mention may be made of N-methylcaprolactam, N-ethylcaprolactam, N-vinylcaprolactam, and very particularly, N-methylpyrrolidone, N-ethylpyrrolidone, and N-vinylpyrrolidone. 
     The said operation is desirably carried out at a temperature of between about 10° and 80° C., and preferably between about 30° and 60° C. This operation is rapid; it generally takes less than an hour. 
     The amount of lactam to be used is such that the molar ratio of N-substituted lactam to organometallic compound(s) used for the polymerization and, if applicable, the metalation (that is to say, the ratio of mols of N-substituted lactam to number of carbanion sites) is at least 1. 
     When the living polymer has not undergone a metalation operation, this ratio is preferably from about 1 to 3; when the living polymer has undergone a metalation operation, this ratio is preferably from about 1 to 2. 
     The functionalized polymers obtained can possibly be deactivated by addition of a deactivating agent, such as water, alcohols of the type of methanol, ethanol, isopropanol, etc., and C 1  -C 5  aliphatic carboxylic acids. This operation takes place instantaneously in the cold by means of a stoichiometric amount of deactivating agent referred to the quantity of organometallic compound(s) employed. 
     The hydrogenation step is preferably carried out in the presence of catalytic systems obtained by reaction of derivatives of transition metals, such as nickel or cobalt carboxylates or acetylacetonates, with organo-reducing compounds, such as organoaluminum compounds, organolithiums or their hydrides, the hydrides of lithium or aluminum, and the mixed hydrides of lithium and aluminum. Conventional hydrogenation techniques employing catalysts having a base of Raney nickel or platinum or palladium deposited on carbon can also be employed. 
     The solvents which can be used to effect the hydrogenation step are the same as those used to carry out the anionic polymerization step. 
     In order to have good stability to thermal oxidation, at least 85 percent, and preferably at least 95 percent, of the olefin, double bonds must be hydrogenated. 
     The hydrogenation catalyst can be eliminated by filtration, centrifuging, or treatment by an absorbent earth. 
     An important object of the invention is polymers obtained by a variant of the method of operation described above, which variant consists in effecting a grafting operation after the metalation operation and prior to the functionalization operation. The said operation is carried out by adding to the medium a C 4  -C 6  conjugated diene and/or a vinyl aromatic monomer, such as styrene or α-methylstyrene. 
     The grafting operation is effected at a temperature of between -80° and +150° C., and preferably between 0° and 100° C., generally for 1 to 3 hours, and more particularly for 1 or 2 hours. 
     The amount of grafting monomer to be used is such that the weight of grafts corresponds to about 1 to 30 percent, and preferably about 1 to 10 percent of the weight of grafted polymer. 
     Another important object of the present invention is the use of the new polymers having groups derived from N-substituted lactams as additives which make it possible to improve the viscosity index and the dispersing power of lubricating oils. 
     The oils which can be used are oils of naphthene base, paraffin base, or mixed base. They can be derived from coal or synthetic products such as alkylene polymers, polymers of the alkylene oxide type prepared by polymerizing alkylene oxide in the presence of water or alcohols. The alkylbenzenes, dialkylbenzenes, polyphenyls, alkylbiphenylethers and polymers of silicon can also be employed. 
     The amount of additive to be added is between about 0.1 and 10 percent of the weight of lubricating oil, and preferably between about 1 and 5 percent. 
     One can also use additional additives to obtain the required stability, an additional detergency and dispersing power, and the anti-wear and anti-corrosion properties required in modern lubricating compositions. 
    
    
     SPECIFIC DESCRIPTION OF THE INVENTION 
     In order to disclose more clearly the nature of the present invention, the following examples illustrating the invention are given. It should be understood, however, that this is done solely by way of example and is intended neither to delineate the scope of the invention nor limit the ambit of the appended claims. In the examples which follow, and throughout the specification, the quantities of material are expressed in terms of parts by weight, unless otherwise specified. 
     EXAMPLE 1--Comparative Test 
     1180 g. of cyclohexane which has been dried over a molecular sieve and degasified with argon are introduced into a reactor, followed by 0.95 g. of dimethylether of dioxyethylene glycol. 146 g. of butadiene and 3×10 -3  mols of butyllithium are then added. Polymerization is allowed to take place for 3 hours at 60° C. under argon and 2.310 -3  mols of isopropanol are added. 
     1050 g. of the above solution are then taken and 180 mg. are added thereto of a catalyst having a base of triethylaluminum and cobalt octoate (3.6 percent Co and 6.3 percent Al). A pressure of 50 bars is maintained for 2 hours at 100° C. After verification of the olefin unsaturation by NMR, the solution is treated with 2 g. of Clarsil MO2 (registered trademark) an adsorbent earth comprising an aluminum silicate containing about 70.5 percent silica and about 15 percent aluminum oxide, at 80° C. for 2 hours and then filtered so as to retain less than 10 ppm. of cobalt. 
     The solution is then mixed with 200 Neutral lubricating oil so as to obtain, after evaporation of the cyclohexane under vacuum at 120° C., a 2 percent solution by weight of polybutadiene. 
     The following properties are then determined: 
     the thickening power. It is expressed by the concentration of polymer necessary to obtain a viscosity of 14 cst (centistokes) at 100° C., in 200 Neutral oil. 
     the VIE (Viscosity Index Extended), in accordance with ASTM Standard 2270. 
     the dispersing power, in accordance with the method described by V. A. Gates, et al., in SAE preprint No. 572 (1955) or by A. Schilling in &#34;Les Huiles Pour Moteurs et le Graissage des Moteurs,&#34; (&#34;Motor Oils and the Lubrication of Engines&#34;), published by Technip, Volume 1, page 89 (1962). 
     The method is carried out using an SAE 30 oil containing 2 percent of product prepared above and 1 percent sludge. 
     The mixture of treated oil and sludge is separated into six fractions which are agitated and subjected to one of the following six heat treatments: 
     one fraction subjected to 50° C. for 10 minutes 
     one fraction subjected to 50° C. for 10 minutes in the presence of 1 percent water 
     one fraction subjected to 200° C. for 10 minutes 
     one fraction subjected to 200° C. for 10 minutes in the presence of 1 percent water 
     one fraction subjected to 250° C. for 10 minutes 
     one fraction subjected to 280° C. for 10 minutes. 
     One drop of each mixture obtained after heat treatment is deposited on a filter paper. Rating is effected at the end of 24 hours; for each spot there is calculated the percentage of dispersed product referred to the drop of oil by forming the ratio of the respective diameters of the drop of oil and the dispersed product. The higher the percentage of dispersed product, the better the dispersion with respect to the sludge. 
     The properties of the product are set forth in Table I, below. 
     EXAMPLE 2 
     A polymerization operation is carried out as in Example 1, starting with: 
     146 g. of butadiene, and 
     3×10 -3  mols of n-butyllithium. 
     The operation takes place for 3 hours at 60° C., whereupon 3×10 -3  mols of N-methylpyrrolidone are added (which represents a molar ratio of N-methylpyrrolidone to n-butyllithium of 1 or a molar ratio of N-methylpyrrolidone to polymer of 1). The functionalization operation is carried out for 45 minutes at 60° C. 
     The medium is then deactivated by addition of 2.3×10 -3  mols of isopropanol at room temperature. 
     1050 g. of resultant solution are taken and a hydrogenation operation is carried out as in the preceding example using 360 mg. of hydrogenation catalyst. 
     The polymer obtained is formed of chains containing a single recurrent unit derived from the N-methylpyrrolidone at the chain end. 
     EXAMPLE 3 
     This example is carried out under conditions similar to those of Example 2, but replacing the N-methylpyrrolidone by the same amount of N-vinylpyrrolidone. 
     EXAMPLE 4 
     This example is carried out under conditions similar to those of Example 3, using 9×10 -3  mols of N-vinylpyrrolidone, which corresponds to a molar ratio of N-vinylpyrrolidone to n-butyllithium of 3, or a ratio of N-vinylpyrrolidone to polymer of 3. 
     The polymer is formed of chains containing a single recurrent unit derived from the N-vinylpyrrolidone at the chain end. 
     EXAMPLE 5 
     This example is carried out under conditions similar to those of Example 3, using 146 g. of a mixture of butadiene and styrene in a weight ratio of 50:50. 
     EXAMPLE 6 
     This example is carried out under conditions similar to those described in Example 3, using 146 g. of a mixture of butadiene and styrene in a weight ratio of 70:30. 
     EXAMPLE 7 
     This example is carried out under conditions similar to those of Example 6, using: 
     146 g. of a 70:30 mixture of butadiene and styrene 
     1.5×10 -3  mols of n-butyllithium 
     1.5×10 -3  mols of N-vinylpyrrolidone. 
     EXAMPLE 8 
     This example is carried out under conditions similar to those of Example 3, using 146 g. of a 70:30 by weight mixture of isoprene and styrene and effecting the functionalization operation for 55 minutes at 30° C., instead of 45 minutes at 60° C. 
     EXAMPLE 9 
     This example is carried out under conditions similar to those of Example 2, using: 
     146 g. of butadiene 
     3×10 -3  mols of 1,1-dilithio-1,1,4,4-tetraphenylbutane 
     6×10 -3  mols of N-methylpyrrolidone which represents a molar ratio of N-methylpyrrolidone to organolithium of 2, or a molar ratio of N-methylpyrrolidone to polymer of 2. 
     The polymer obtained is formed of chains containing two recurrent units derived from N-methylpyrrolidone, namely, one unit at each chain end. 
     EXAMPLE 10 
     A polymerization operation is carried out as in Example 1 with: 
     146 g. of butadiene, and 
     3×10 -3  mols of n-butyllithium. 
     The operation is carried out for 3 hours at 60° C. The medium is cooled to 20° C., and 15×10 -3  mols of sec-butyllithium and 15×10 -3  mols of N,N,N&#39;,N&#39;-tetramethylene ethylene diamine (TMEDA) are added. 
     The metalation operation is carried out for 2 hours at 50° C., with agitation. 
     18×10 -3  mols of N-methylpyrrolidone are then added, this representing a molar ratio of N-methylpyrrolidone to organometallic compound (n-butyllithium+sec-butyllithium) of 1. The functionalization operation is carried out for 45 minutes at 60° C. 
     1050 g. of the resultant solution are taken and a hydrogenation operation is carried out, as in Example 1, using 720 mg. of catalyst. 
     The polymer obtained contains several nitrogen units per chain, with one unit at one end. 
     EXAMPLE 11 
     A polymerization operation is carried out as in Example 10 with: 
     146 g. of butadiene and 
     3×10 -3  mols of n-butyllithium for 3 hours at 60° C., followed by a metalation operation using 15×10 -3  mols of sec-butyllithium and 15×10 -3  mols of TMEDA, for 2 hours at 50° C., with agitation. 
     30×10 -3  mols of styrene are then added to effect a grafting operation. The latter is effected at 60° C. for 2 hours. 
     18×10 -3  mols of N-methylpyrrolidone are then added; the functionalization operation is carried out for 55 minutes at 30° C. 
     1050 g. of the resultant solution are taken and a hydrogenation operation carried out as in Example 2. 
     The grafted polymer obtained contains several recurrent nitrogen units per chain, with one unit at one end. 
     EXAMPLE 12 
     A polybutadiene sequence is effected as in Example 1, starting from: 
     146 g. of butadiene and 
     3×10 -3  mols of n-butyllithium for 3 hours at 60° C. 3×10 -3  mols of styrene are then added and the polymerization operation is continued for 2 hours at 60° C. in order to produce a very short styrene sequence. 
     A hydrogenation operation is carried out in accordance with the manner of operation described in Example 1. The reaction mixture is filtered over adsorbent earth and dried over a molecular sieve. 
     15×10 -3  mols of sec-butyllithium and 15×10 -3  mols of TMEDA are added and a metalation operation is carried out in the manner described in Example 10. Then 15×10 -3  mols of N-methylpyrrolidone are added and heating is effected at 60° C. for 45 minutes. 
     The copolymer obtained contains several nitrogen units per chain, with one unit at one end. 
     EXAMPLE 13 
     The conditions of Example 12 are repeated, the hydrogenation operation being carried out after the functionalization operation. 
     EXAMPLE 14 
     This example is carried out under conditions similar to those of Example 12 with 15×10 -3  mols of N-vinylpyrrolidone instead of N-methylpyrrolidone. 
     EXAMPLE 15 
     This example is carried out under conditions similar to those of Example 10, with: 
     146 g. of butadiene 
     1.5×10 -3  mols of n-butyllithium 
     16.5×10 -3  mols of N-vinylpyrrolidone. 
     EXAMPLE 16 
     This example is carried out under conditions similar to those of Example 12, with: 
     146 g. of butadiene 
     3×10 -3  mols of n-butyllithium 
     24×10 -3  mols of sec-butyllithium 
     24×10 -3  mols of TMEDA 
     27×10 -3  mols of N-methylpyrrolidone 
     The properties of the polymers prepared in Examples 2 to 16 are set forth in Tables I to IV, inclusive, below: 
     
                       TABLE I                                                     
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EXAMPLES     1       2       3     4     5                                
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Monomers     Bu      Bu      Bu    Bu    Bu/Iso                           
Organolithium                                                             
             Buli    Buli    Buli  Buli  Buli                             
Lactam       --      NMP     NVP   NVP   NVP                              
Lactam/polymer                                                            
 molar        0       1       1     3     1                               
 ##STR2##    51,300  49,000  53,900                                       
                                   50,500                                 
                                         65,000                           
 ##STR3##    67,200  65,900  80,800                                       
                                   74,500                                 
                                         90,000                           
% hydrogenation                                                           
             98      97      98    99    99                               
dispersive                                                                
 power                                                                    
 50° C.                                                            
             44      88      93    93    88                               
 50° C. + H.sub.2 O                                                
             43      92      93    93    90                               
200° C.                                                            
             36      90      91    91    65                               
200° C. + H.sub.2 O                                                
             39      84      84    89    79                               
250°  36      83      82    82    62                               
280°  35      78      79    91    62                               
Σ      233     515     522   529   446                              
VIE          140     135     138   134   136                              
thickening                                                                
 power       2.2     2       1.8   1.9   1.8                              
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 In All Tables:                                                           
 Bu: butadiene                                                            
 Buli: butyllithium                                                       
 ##STR4##                                                                 
 ##STR5##                                                                 
 NMP: Nmethylpyrrolidone                                                  
 NVP: Nvinylpyrrolidone                                                   
 dili:                                                                    
 Iso: isoprene 1,4,4-tetraphenylbutane-                                   
 Sty: styrene                                                             
 
    
     
                       TABLE II                                                    
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EXAMPLES     6        7        8      9                                   
______________________________________                                    
Monomers     Bu/Sty   Bu/Sty   Iso/Sty                                    
                                      Bu                                  
Organolithium                                                             
             Buli     Buli     Buli   dili                                
Lactam       NVP      NVP      NVP    NMP                                 
Lactam/polymer                                                            
 molar        1        1        1      1                                  
 ##STR6##    56,000   112,000   84,000                                    
                                       78,800                             
 ##STR7##    65,000   130,000  120,000                                    
                                      140,000                             
% hydrogenation                                                           
             98       99       98     98                                  
dipersive                                                                 
 power                                                                    
 50° C.                                                            
             90       84       89     92                                  
 50° C. + H.sub.2 O                                                
             89       86       92     91                                  
200° C.                                                            
             85       82       90     58                                  
200° C. + H.sub.2 O                                                
             89       83       86     85                                  
250° C.                                                            
             83       80       85     49                                  
280° C.                                                            
             80       78       79     49                                  
Σ      516      493      521    424                                 
VIE          138      142      132    139                                 
thickening                                                                
 power       2.1      1.6      1.7    1.7                                 
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                       TABLE III                                                   
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EXAMPLES    10         11         12                                      
______________________________________                                    
Monomers    Bu         Bu/Sty     Bu/Sty                                  
Lactam      NMP        NMP        NMP                                     
Lactam/organo-                                                            
 lithium (molar)                                                          
             1          1          1                                      
 ##STR8##   54,000     33,500     49,500                                  
 ##STR9##   76,000     70,000     71,000                                  
% hydrogenation                                                           
            99         98         100                                     
dispersive                                                                
 power                                                                    
 50° C.                                                            
            82         82         95                                      
 50° C. + H.sub.2 O                                                
            87         85         95                                      
200° C.                                                            
            73         82         91                                      
200° C. + H.sub.2 O                                                
            75         87         86                                      
250° C.                                                            
            70         86         93                                      
280° C.                                                            
            65         85         80                                      
Σ     452        507        530                                     
VIE         131        128        132                                     
thickening                                                                
 power      1.9        2.1         2                                      
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                       TABLE IV                                                    
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EXAMPLES     13       14       15     16                                  
______________________________________                                    
Monomers     Bu/Sty   Bu/Sty   Bu     Bu                                  
Lactam       NMP      NVP      NVP    NMP                                 
Lactam/organo-                                                            
 lithium (molar)                                                          
              1        1        1      1                                  
 ##STR10##   47,500   52,600   110,000                                    
                                      53,250                              
 ##STR11##   73,000   74,650   178,200                                    
                                      79,250                              
% hydrogenation                                                           
             100        98.5   98     97                                  
dispersive                                                                
 power                                                                    
 50° C.                                                            
             84       89       90     93                                  
 50° C. + H.sub.2 O                                                
             88       91       91     93                                  
200° C.                                                            
             72       88       88     90                                  
200° C. + H.sub.2 O                                                
             68       90       89     90                                  
250° C.                                                            
             63       87       87     93                                  
280° C.                                                            
             63       83       82     85                                  
Σ      438      528      527    544                                 
VIE          131      138      135    133                                 
thickening                                                                
 power        2       1.9      1.5    1.8                                 
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     As can be seen from the foregoing Tables, the additives of the invention impart excellent properties to lubricating oils. 
     The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed.