Solid lubricant composition

A method for preparing a solid lubricant composition suitable for reducing friction and wear of a metallic surface when rubbed onto the surface in a thin film, comprising the steps of:

• (a) mixing a polymeric carrier, a lubricating oil, a solid lubricating powder selected from one or more of the group consisting of copper, lead, antimony, zinc, bismuth, tin, aluminum, magnesium, selenium, arsenic, cadmium, tellurium, graphite, and alloys thereof, in powdered form and a surface active agent;
• (b) extruding the mixture under pressure while heating it, thereby subjecting the mixture to a shearing force and a compaction that prevents the solid lubricant composition from being brittle;
• (c) forming the mixture into a desired shape;
• and
• (d) curing the mixture.

A method for lubricating a moving metallic surface to reduce friction and wear, using a solid lubricant composition comprising a polymeric carrier, a lubricating oil, a solid lubricating powder selected from one or more of the group consisting of copper, lead, antimony, zinc, bismuth, tin, aluminum, magnesium, selenium, arsenic, cadmium, tellurium, graphite, and alloys thereof, in powdered form, and a surface active agent, comprising the steps of:

• (a) forming the solid lubricant composition into a desired shape;
• (b) biasing the formed solid lubricant composition against the moving metallic surface;
• (c) depositing a thin film of the solid lubricant composition on the moving metallic surface;
• and
• (d) applying pressure to attach and embed the solid lubricant powder into the metallic surface.

A solid lubricant composition comprising:

• (a) from about 16% to about 70% by weight of a polymeric carrier;
• (b) from about 5% to about 65% by weight of a lubricating oil, said oil being soluble in said polymeric carrier;
• (c) from about 5% to about 65% by weight of a tackifier;
• (d) from about 10% to about 65% by weight of a solid lubricating powder selected from one or more of the group consisting of copper, lead, antimony, zinc, bismuth, tin, aluminum, magnesium, selenium, arsenic, cadmium, tellurium, graphite, and alloys thereof in powdered form;
• and
• (e) from about 0.25% to about 18% by weight of a surface active agent comprising a metallic dithiophosphate and an organic molybdenum compound.

An article of solid lubricant composition, comprising:

• first and second distinct compositions, the first composition comprising a core covered by a layer of the second composition, said solid lubricant composition including a polymeric carrier, a lubricating oil, a solid lubricating powder and a surface active agent, the first composition being substantially softer than the second composition, wherein the first composition comprises:
• (a) from about 16% to about 70% weight of the polymeric carrier;
• (b) from about 5% to about 65% by weight of the lubricating oil;
• (c) from about 5% to about 65% by weight of a tackifier;
• (d) from about 10% to about 65% by weight of the solid lubricating powder;
• and
• (e) from about 0.25% to about 18% by weight of the surface active agent;
• and wherein the second composition comprises a polymer material.

A method for making an article of solid lubricant composition comprising a polymeric carrier, a lubricating oil that is soluble in the polymeric carrier, a solid lubricating powder and a surface active agent, said method comprising the steps of:

• extruding a first composition as a core of the article, and extruding a second composition as a composition as a substantially concentric layer around said core, the second composition sealingly enclosing the first composition along a longitudinal axis of the core and being substantially harder than the first composition wherein the first composition comprises:
• (a) from about 16% to about 70% by weight of the polymeric carrier;
• (b) from about 5% to about 65% by weight of the lubricating oil;
• (c) from about 5% to about 65% by weight of a tackifier;
• (d) from about 10% to about 65% by weight of the solid lubricating powder;
• and
• (e) from about 0.25% to about 18% by weight of the surface active agent, and
• wherein the second composition comprises:
• (a) from about 16% to about 70% by weight of the polymeric carrier;
• (b) from about 5% to about 65% by weight of the lubricating oil;
• (c) from about 10% to about 65% by weight of the solid lubricating powder;
• (d) from about 0.25% to about 18% by weight of the surface active agent.

A method for producing a strand of solid lubricant composition having a relatively soft inner core and a relatively harder outer layer concentric to the core, comprising the steps of:

• (a) mixing from about 16% to about 70% by weight of a polymeric carrier, from about 5% to about 65% by weight of a lubricating oil, from about 5% to about 65% by weight of a tackifier and from about 0.25% to about 18% by weight of a surface active agent;
• (b) extruding the mixture of step (a) to form the core;
• (c) mixing from about 30% to about 60% by weight of a polymeric carrier and from about 40% to about 70% by weight of a solid lubricating powder;
• and
• (d) extruding the mixture of step (c) about the core as the outer layer of the strand, said outer layer acting as a barrier to prevent oil and tackifier bleeding from the core.

An article of solid lubricant composition comprising first and second compositions, wherein the first composition comprises:

• (a) from about 16% to about 70% by weight of the polymeric carrier;
• (b) from about 5% to about 65% by weight of the lubricating oil;
• (c) from about 5% to about 65% by weight of a tackifier;
• (d) from about 10% to about 65% by weight of the solid lubricating powder;
• and
• (e) from about 0.25% to about 18% by weight of the surface active agent, and wherein the second composition comprises:
• (a) from about 16% to about 70% by weight of the polymeric carrier;
• (b) from about 5% to about 65% by weight of the lubricating oil;
• (c) from about 10% to about 65% by weight of the solid lubricating powder;
• (d) from about 0.25% to about 18% by weight of the surface active agent;
• said first and second compositions being combined to form said article so that the center of said article is substantially softer than the outer surface of said article.