Composition and Method of Manufacturing and Using Extremely Rheopectic Sulfonate-Based Greases

A sulfonate-based grease composition comprising the following ingredients:

• overbased calcium sulfonate, overbased magnesium sulfonate, and a facilitating acid, and wherein the composition (1) has an unmilled, unworked penetration greater than 360;
• (2) has an unmilled worked 60 stroke penetration value that is less than its unmilled unworked penetration value;
• (3) is Newtonian prior to milling or shearing;
• or (4) any combination thereof.

A method for making a sulfonate-based grease comprising the steps of:

• adding and mixing (1) overbased calcium sulfonate having amorphous calcium carbonate dispersed therein, (2) overbased magnesium sulfonate, (3) a facilitating acid, (4) water, (5) optionally base oil, and (6) optionally one or more conventional non-aqueous converting agents to form a first mixture;
• converting the first mixture to a converted mixture by heating until conversion of the amorphous calcium carbonate contained in the overbased calcium sulfonate to a crystalline form has occurred;
• and
• wherein (1) all of the overbased calcium sulfonate is added after adding and mixing the overbased magnesium sulfonate and facilitating acid or (2) a first portion of the overbased calcium sulfonate is added and mixed with the overbased magnesium sulfonate prior to adding the facilitating acid and a second portion of the overbased calcium sulfonate is added and mixed after adding the facilitating acid.

A method for making an extremely rheopectic sulfonate-based grease comprising the steps of:

• adding and mixing (1) overbased calcium sulfonate having amorphous calcium carbonate dispersed therein, (2) overbased magnesium sulfonate, (3) a facilitating acid, (4) water, (5) optionally base oil, and (6) optionally one or more conventional non-aqueous converting agents to form a first mixture;
• converting the first mixture to a converted mixture by heating until conversion of the amorphous calcium carbonate contained in the overbased calcium sulfonate to a crystalline form has occurred;
• and
• wherein the overbased calcium sulfonate (1) comprises benzene rings having more than one alkyl group;
• (2) is a natural calcium sulfonate;
• (3) comprises benzene rings that are sterically hindered;
• or (4) a combination thereof.

A method of using an extremely rheopectic sulfonate-based grease comprising:

• providing an unmilled and unsheared extremely rheopectic sulfonate based-grease composition comprising the following ingredients:
• overbased calcium sulfonate, overbased magnesium sulfonate, and a facilitating acid, and wherein the composition (1) has an unmilled, unworked penetration greater than 360;
• (2) has an unmilled worked 60 stroke penetration value that is less than its unmilled unworked penetration value;
• (3) is Newtonian prior to milling or shearing;
• or (4) any combination thereof;
• and
• applying shearing forces to the unmilled and unsheared extremely rheopectic sulfonate-based grease composition to form a thickened sulfonate-based grease;
• and
• wherein the shearing forces are applied by pumping the extremely rheopectic sulfonate-based grease, spraying the extremely rheopectic sulfonate-based grease, movement of a bearing or gear in contact with the extremely rheopectic sulfonate-based grease or a combination thereof.

A method of using an extremely rheopectic sulfonate-based grease comprising:

• providing an unmilled and unsheared extremely rheopectic sulfonate based-grease composition comprising the following ingredients:
• overbased calcium sulfonate, overbased magnesium sulfonate, and a facilitating acid, wherein the overbased calcium sulfonate (1) comprises benzene rings having more than one alkyl group;
• (2) is a natural calcium sulfonate;
• (3) comprises benzene rings that are sterically hindered;
• or (4) a combination thereof;
• and
• applying shearing forces to the unmilled and unsheared extremely rheopectic sulfonate-based grease composition to form a thickened sulfonate-based grease;
• and
• wherein the shearing forces are applied by pumping the extremely rheopectic sulfonate-based grease, spraying the extremely rheopectic sulfonate-based grease, movement of a bearing or gear in contact with the extremely rheopectic sulfonate-based grease or a combination thereof.