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  Diesel fuel compositionsRelated Patent Categories: Fuel And Related Compositions, Liquid Fuels (excluding Fuels That Are Exclusively Mixtures Of Liquid Hydrocarbons), Heterocyclic Carbon Compound Containing A Hetero Ring Having Chalcogen Or Nitrogen As The Only Ring Hetero AtomsThe Patent Description & Claims data below is from USPTO Patent Application 20070245620. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE DISCLOSURE [0001] The present application is directed to diesel fuel compositions, and more specifically, to diesel fuel compositions including a dispersant. BACKGROUND OF THE DISCLOSURE [0002] It has long been desired to maximize fuel economy and power in diesel engines while enhancing acceleration, preventing knocking, and preventing hesitation. It has been known to enhance gasoline powered engine performance by employing dispersants to keep valves and fuel injectors clean. However, dispersants used in gasoline are not necessarily effective in diesel fuel. The reasons for this unpredictability lie in the many differences between how diesel engines and gasoline engines operate and the chemical differences between diesel fuel and gasoline. [0003] Over the years, dispersant compositions for diesel fuel have been developed. Dispersant compositions known in the art for use in diesel fuel include compositions comprising polyalkylene succinimides, which are the reaction products of polyalkylene succinic anhydrides and amines. For example, U.S. Pat. No. 5,752,989, issued May 19, 1998 to Henly et al., teaches compositions comprising a mixture of polyalkylene succinimide dispersants and at least one oxygenate carrier selected from the group consisting of polyalkoxylated ether, polyalkoxylated phenol, polyalkoxylated ester and polyalkoxylated amine. U.S. Pat. No. 4,482,356, issued Nov. 13, 1984 to Hanlon ("Hanlon '356"), teaches compositions comprising hydrocarbyl-substituted succinimide and organic nitrate ignition accelerator. U.S. Pat. No. 4,482,357, issued Nov. 13, 1984 to Hanlon ("Hanlon '357"), teaches compositions comprising hydrocarbyl-substituted succinimide, a hydrocarbyl amine having from 3 to 60 carbons and from 1 to 10 nitrogens, and N,N'-disalicylidene-1,2-diaminopropane. U.S. Pat. No. 5,575,823, issued Nov. 19, 1996 to Wallace et al. teaches diesel fuels comprising an ashless dispersant, such as alkenyl succinimides of an amine, and cyclomatic manganese tricarbonyl. The disclosures of these dispersant compositions disclosed by Henly et al., Hanlon '356, Hanlon '357, and Wallace et al., are herein incorporated by reference in their entirety. [0004] However, diesel fuel compositions that include dispersants, such as succinimide dispersants, often still produce undesirable deposits on diesel engine injectors. Accordingly, improved dispersants which can reduce the amount of deposits are desired. SUMMARY OF THE DISCLOSURE [0005] In accordance with the disclosure, one aspect of the present application is directed to a diesel fuel composition having a mixture of a major portion of a hydrocarbon-based compression ignition fuel; and a minor portion of an additive comprising a polyalkylene succinimide dispersant, the dispersant being the reaction product of at least one amine and at least one polyalkylene succinic anhydride of formula I, wherein R.sup.1 is a polyalkenyl radical having a number average molecular weight ranging from about 600 to about 850. [0006] Another aspect of the present application is directed to a diesel fuel additive comprising a polyalkylene succinimide dispersant, the dispersant being the reaction product of at least one amine and at least one polyalkylene succinic anhydride of formula I above, wherein R.sup.1 is a polyalkenyl radical having a number average molecular weight ranging from about 600 to about 850. [0007] Another aspect of the present application is directed to a method for the production of a diesel fuel composition, the method comprising providing a major portion of a hydrocarbon-based compression ignition fuel, and providing a minor portion of an additive. The additive comprises a polyalkylene succinimide dispersant, the dispersant being the reaction product of at least one polyamine and at least one polyalkylene succinic anhydride of formula I above, wherein R.sup.1 is a polyalkenyl radical having a number average molecular weight ranging from about 600 to about 850. [0008] Additional objects and advantages of the disclosure will be set forth in part in the description which follows, and can be learned by practice of the disclosure. The objects and advantages of the disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. [0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed. DESCRIPTION OF THE EMBODIMENTS [0010] The dispersants of the present application are made by reacting a polyalkylene succinic anhydride with an amine to form a polyalkylene succinimide. The polyalkylene portion, or tail, of the polyalkylene succinimide molecule is considered to be nonpolar, while the succinimide is polar. It has been found that varying the molecular weight of the nonpolar polyalkylene portion relative to the weight of the polar portion of the molecule can have an effect on the ability of the dispersant to help reduce injector deposits in diesel fuels. [0011] The polyalkylene succinic anhydride reactant has the following Formula I: wherein R.sup.1 can be a polyalkenyl radical having a number average molecular weight from about 600 to about 850, and any number therebetween. For example, the number average molecular weight of R.sup.1 may range from about 700 to about 800, such as from about 720 to about 780. In yet other aspects, the number average molecular weight of R.sup.1 is about 750. Unless indicated otherwise, molecular weights in the present specification are number average molecular weights. [0012] The R.sup.1 polyalkenyl radicals can comprise one or more polymer units chosen from linear or branched alkenyl units. In some aspects, the alkenyl units may have from about 2 to about 10 carbon atoms. For example, the polyalkenyl radical may comprise one or more linear or branched polymer units chosen from ethylene radicals, propylene radicals, butylene radicals, pentene radicals, hexene radicals, octene radicals and decene radicals. In some aspects, the R.sup.1 polyalkenyl radical may be in the form of, for example, a homopolymer, copolymer or terpolymer. In an aspect, the polyalkenyl radical is isobutylene. For example, the polyalkenyl radical may be a homopolymer of polyisobutylene comprising from about 10 to about 60 isobutylene groups, such as from about 20 to about 30 isobutylene groups. The polyalkenyl compounds used to form the R.sup.1 polyalkenyl radicals may be formed by any suitable methods, such as by conventional catalytic oligomerization of alkenes. [0013] The polyalkylene succinic anhydrides can be made using any suitable method. Suitable methods for forming polyalkylene succinic anhydrides are well known in the art. One example of a known method for forming polyalkylene succinic anhydrides comprises blending polyalkylenes, such as those discussed above, and maleic anhydride. The polyalkylene and maleic anhydride reactants are heated to temperatures of, for example, about 150.degree. C. to about 250.degree. C., optionally, with the use of a catalyst such as chlorine or peroxide. In some aspects, approximately one mol of maleic anhydride can be reacted per mol of polyalkylene, such that the resulting polyalkenyl succinic anhydride has about 0.8 to about 1 succinic anhydride group per polyalkylene substituent. In aspects, the weight ratio of succinic anhydride groups to alkylene groups can range from about 0.5 to about 3.5, such as from about 1 to about 1.1. Another exemplary method of making the polyalkylene succinic anhydrides is described in U.S. Pat. No. 4,234,435, which is incorporated herein by reference in its entirety. [0014] In some aspects, the amine (to be reacted with the polyalkylene succinic anhydride) can be a linear, branched or cyclic alkyleneamine. For example, the amine can be an ethyleneamine, such as an ethyleneamine of the following Formula II: wherein R.sup.2 can be a hydrogen atom, a low molecular weight alkyl group having from about 1 to about 6 carbon atoms, and n can be an integer ranging from about 1 to about 6. In some aspects, R.sup.2 can be a hydrogen atom or an alkyl group having from about 1 to about 2 carbon atoms, and n can be an integer ranging from about 2 to about 4. Representative examples of R.sup.2 alkyl groups include methyl, ethyl, propyl or butyl. Representative examples of suitable ethyleneamines include ethylene diamine, propylene diamine, butylene diamine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, pentaethylene hexamine, dipropylene triamine and tripropylene tetramine. In one aspect, the amine is a linear, branched or cyclic tetraethylene pentamine. The amines can also be a polymer or copolymer of any one of the foregoing ethyleneamines ranging in molecular weight from about 100 to about 600. In some aspects, mixtures of two or more of the above ethyleneamines may be employed. [0015] In some aspects, the polyalkylene succinic anhydride of Formula I and the amine of Formula II can be reacted together at a mol ratio of about 1 to about 2 mols of polyalkylene succinic anhydride for 1 mol of the amine. For example, the mol ratio can be about 1.5 to about 2 mols of polyalkylene succinic anhydride of Formula I for 1 mol of the amine of Formula II. Examples of suitable polyalkylene succinimides have the Formulas III and IV, where R.sup.1, n and R.sup.2 are as defined above: [0016] Procedures for making the polyalkenyl succinimide are described in U.S. Pat. No. 3,219,666 and U.S. Pat. No. 4,098,585, which are herein incorporated by reference in their entirety. [0017] In some aspects of the present application, the dispersant products of this application can be used in combination with a diesel fuel soluble carrier. Such carriers can be of various types, such as liquids or solids, e.g., waxes. Examples of liquid carriers include mineral oil and oxygenates, such as liquid polyalkoxylated ethers (also known as polyalkylene glycols or polyalkylene ethers), liquid polyalkoxylated phenols, liquid polyalkoxylated esters, liquid polyalkoxylated amines, and mixtures thereof. Examples of the oxygenate carriers are found in U.S. Pat. No. 5,752,989, issued May 19, 1998 to Henly et. al., the description of which carriers is herein incorporated by reference in its entirety. Additional examples of oxygenate carriers include alkyl-substituted aryl polyalkoxylates described in U.S. Patent Publication No. 2003/0131527, published Jul. 17, 2003 to Colucci et. al., the description of which is herein incorporated by reference in its entirety. [0018] In other aspects, compositions of the present application may not contain a carrier. For example, some compositions of the present application may not contain mineral oil or oxygenates, such as those oxygenates described above. [0019] One or more additional optional compounds may be present in the fuel compositions of this application. For example, the fuels may contain conventional quantities of cetane improvers, corrosion inhibitors, cold flow improvers (CFPP additive), pour point depressant, solvents, demulsifiers, lubricity additives, friction modifiers, amine stabilizers, combustion improvers, dispersants other than those described above, antioxidants, heat stabilizers, conductivity improvers, metal deactivators, marker dyes, organic nitrate ignition accelerators, cyclomatic manganese tricarbonyl compounds, and the like. In some aspects, the compositions of the present application may contain about 10 weight percent or less, or in other aspects, about 5 weight percent or less, based on the total weight of the additive concentrate, of one or more of the above additives. Similarly, the fuels may contain suitable amounts of conventional fuel blending components such as methanol, ethanol, dialkyl ethers, and the like. [0020] In some aspects of the present application, suitable optional organic nitrate ignition accelerators include aliphatic or cycloaliphatic nitrates in which the aliphatic or cycloaliphatic group is saturated, contains up to about 12 carbons and, optionally, may be substituted with one or more oxygen atoms. Examples of organic nitrate ignition accelerators that may be used are methyl nitrate, ethyl nitrate, propyl nitrate, isopropyl nitrate, allyl nitrate, butyl nitrate, isobutyl nitrate, sec-butyl nitrate, tert-butyl nitrate, amyl nitrate, isoamyl nitrate, 2-amyl nitrate, 3-amyl nitrate, hexyl nitrate, heptyl nitrate, 2-heptyl nitrate, octyl nitrate, isooctyl nitrate, 2-ethylhexyl nitrate, nonyl nitrate, decyl nitrate, undecyl nitrate, dodecyl nitrate, cyclopentyl nitrate, cyclohexyl nitrate, methylcyclohexyl nitrate, cyclododecyl nitrate, 2-ethoxyethyl nitrate, 2-(2-ethoxyethoxy)ethyl nitrate, tetrahydrofuranyl nitrate, and the like. Mixtures of such materials may also be used. 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