FORM-2
THE PATENTS ACT. 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003 COMPLETE SPECIFICATION
(See Section 10; Rule 13)
1. TITLE OF THE INVENTION:
"THE WIRE ROPE LUBRICANT & THE PROCESS OF MANUFACTURING THE SAME."
2. APPLICANTS:
(a) NAME: HINDUSTAN PETROLEUM CORPORATION LIMITED.
(b) NATIONALITY: INDIAN COMPANY.
(c) ADDRESS: RESEARCH & DEVELOPMENT CENTRE,
PLOT D-500, TTC AREA OF MIDC, NAVI MUMBAI-400 705, MAHARASHTRA, INDIA.
The following specification describes the nature of the invention and the manner in which it is to be performed:-


THE WIRE ROPE LUBRICANT & THE PROCESS OF MANUFACTURING THE SAME.
3. PREAMBLE TO THE DESCRIPTION
Field of Invention
The present invention relates to the composition of the wire rope lubricant and the process of manufacturing the same.
Background of the Invention & the Related Art
This invention relates to protective the lubricant composition, especially suitable for applications to the wire ropes, metallic strands and other metallic articles. The wire ropes, i.e., cables, are used for many types of materials handling work. They are used for light and heavy, short and long hauling, pulling and dragging. Often the wire ropes are used under the extreme temperature conditions found especially in the machine rooms, the store rooms, the deserts and in the arctic climates. The wire ropes also are exposed to the water, the dirt, the chemicals and other corrosive contaminants. The wire ropes are subjected to such uses and conditions that, they need to be protected by the lubricants, which should withstand the great pressures created by the heavy load on them, protect against the wearing out due to the friction created by the strands rubbing with each other, protect against the corrosion and not to melt and/or drip or become soft and/or tacky at the high temperature conditions or not tend to chip or crack in the cold temperature conditions.
It is observed often, that, the lubricants for the wire ropes can provide this protection only if the lubricants have good lubricating properties, relatively high softening points and good wetting properties. The lubricant's composition should have good penetrating properties at the elevated temperature conditions. The wire


rope lubricant's composition needs good water repellency, a glossy finish and high softening points to prevent the lubricant from becoming too soft or sticky for the use at the ambient or the elevated temperature conditions or from the melting or the running when used under extremely hot temperature conditions. The high penetration values insure that, the lubricant will not become brittle and tend to break under very cold temperature conditions. The wire rope lubricant is normally applied to the wire ropes at elevated temperatures by dipping the same in the molten lubricant. The lower viscosities at higher temperature will help the lubricant for easy handling and will penetrate inside the strands and provide an even, full and continuous coating of the wire rope.
4. DESCRIPTION OF THE INVENTION
Summary of the Invention
The present invention under consideration provides the unique composition of the wire rope lubricant. The major portion of the composition is of Bitumen 30/40 to obtain the higher drop melting point and the body to lubricant. To obtain the good wetting property, solid fatty oil is selected. This has given not only good wetting property, but also a lower softening property to avoid embrittlement to lubricant. A partially oxidized polyethylene wax is used to get the higher drop melting point and good water repellency. The bitumen 30/40 was heated above its melting point. In this the molten bitumen oxidized polyethylene wax was added. This mixture
was heated till (above 110°C) the oxidized polyethylene wax is completely mixed
in the bitumen and becomes uniform. This mixture then cooled upto 90°C. Further, the Hydrogenated castor oil is added to mix well and homogenous and cooled. The composition of the wire rope lubricant is designed in such a way that, it will protect the strands of the wire rope against the external corrosive contaminants and minimize external and internal wear generated by the heavy load and the internal friction of the strands. Also, the composition is designed in such a way that, it has a good coverage, good water repellency and water resistance.


This invention describes the composition of the wire rope lubricant and the preparation of the wire rope lubricant having good covering properties, good water repellency, water resistant properties, good corrosion properties, good lubricity properties and having a lower softening point and a higher drop melting point.
For better the corrosion resistant against sea water and minimization of the wearing of the strands of the wire rope the lubricant should have very good corrosion resistant property with good wetting characteristic and an anti-wear property. The performance of the wire rope lubricant was bench marked with respect to the corrosion protection and the adhesiveness on the wire rope. This is performed by conducting the salt spray test and the drop melting point. The product was subjected to the salt spray test till the corrosion of the wire ropes taking place in the salty atmosphere. This performance is witnessed by a strong coating formed by the wire rope compound on the wire rope. This test was continued till 720 hours. If, the coating is not strong, the wire rope compound is not having good water repellency & the wetting characteristics, the water will penetrate into the strands and over a period of time the blistering of coating will take place on the coating and the repturing of coating will take place. This will result in the corrosion of the strands and the wearing out of the strands. The anti-wear property of product is measured by conducting four ball weld load and the wear scar diameter. The flexibility of coating is measured by checking the softening and the drop melting point. If, the lubricant is having a higher melting point, the same will tend to crack at the lower temperature conditions in use in the high seas. To take care of this situation the lower softening vegetable oil was added in the composition. The oxidized polyethylene wax lubricant blend remains within the strands & core to maintain good fatigue resistance of the strands & the core and exhibits sufficient elasticity during bending and stretching of the wire rope. The wire rope lubricant composition does not contain any water soluble corrosive acid components. Due to the smooth and glossy coating the lubricant


will not attract any dust and dirt from the surrounding environment. The lubricant composition is free from water and other impurities.
The properties of wire rope lubricant are mentioned in the table 1.
Table 1: The Test Results of the prepared wire rope lubricant

Characteristics Typical Test Results Test Method
Appearance Black Visual
Flash Point, 0C >250 ASTM D 92
Drop Point,°C, 84 ASTM D 127
Softening point, °C 65 ASTM D 127
Breaking Point, °C -30 DIN 52012
Penetration (Needle), 1/10 mm @25 °C 20-25 ASTM D 1321
Content of water soluble corrosive acids Free from water soluble corrosive acids ™
Processing temperature 110U-130°C. -
Salt spray test, hrs. Pass 720 hrs. ASTM B 117
Conclusions
The wire rope lubricant composition prepared by using the above mentioned new ingredients, has a better wetting/penetration property and a good adhesion property. The developed product has a good corrosion inhibition property as evidenced by the salt spray test. Based on these results, it can be concluded that, the product will give good protection to the wire ropes in high seas and the other related applications. Due to a good wetting characteristic, the lubricant will be able to give a good anti-wear property to the strands during the working and there will


be less a friction of them with each other. Due to the lower softening point and the higher drop melting point, the product will not tend to crack in cold climate conditions and will remain flexible for a longer time period with the better adhesive property.


5. WE CLAIM:
1. The wire rope lubricant having a good corrosion, wetting, penetrating properties and having a good adhesiveness on the wire ropes and the process of manufacturing the said wire rope lubricant.
2. The wire rope lubricant and the process of manufacturing the said wire rope lubricant as claimed in claim 1 above, having the raw material composition of, the Bitumen 30/40 grade (having penetration of 30/40, 1/10 mm.), the polyethylene wax copolymer and the Hydrogenated castor oil.
3. The wire rope lubricant and the process of manufacturing the said wire rope lubricant as claimed in claims 1 & 2 above, having the process of manufacturing as:
(a) The heating of the Bitumen (having penetration of 30/40, 1/10 mm) to
1200C .
(b) The mixing of the Bitumen 30/40 grade (having penetration of 30/40, 1/10 mm) to make the same uniform.
(c) The addition of the polyethylene wax copolymer in the above heated Bitumen (having penetration of 30/40, 1/10 mm) and through mixing of the said polyethylene wax copolymer with bitumen (having penetration of 30/40,1/10 mm) to make the mixture uniform.
(d) Further, the cooling of the above mixture upto 90°C.
(e) Further, the addition of the Hydrogenated castor oil in the above referred mixture and through mixing of the same thoroughly and allowing the mixture to cool.


3. The wire rope lubricant and the process of manufacturing the said wire rope lubricant as claimed in claims 1, 2 & 3 above, the total amount of the additives present ranging from about 20 to 30% by wt based on final product.

ABSTRACT
This invention reveals the development of a protective lubricant composition, especially suitable for applications to the wire ropes, metallic strands and other metallic articles, which are primarily used in the high seas and other salty atmosphere. The wire ropes, i.e. cables, are used in ships, fisheries and other types of materials handling in high seas. These wire ropes are used for light and heavy, short and long hauling, pulling and dragging operation in extreme temperature conditions and in the high salty atmosphere. Therefore these wire ropes need to be protected by the lubricants which can withstand the great pressures, protect against corrosion, and not melt and/or drip or become soft and/or tacky at high temperature conditions and/or not tend to chip or crack in cold temperature conditions. The wire rope lubricant's composition should have high softening points and penetration power at wide temperature range. Additionally, wire rope lubricant's composition should have a relatively low viscosity under such conditions, so that, the composition can be easily handled as by pumping and will provide an even, full and continuous coating of the wire rope. In order to get these properties we have attempted to develop the wire rope lubricant which contains, the asphalts, a very good wetting additive and the water repellent agent which will be suitable at a wide temperature range and will give the protective properties in highly salty atmosphere in high seas.