A novel process for the preparation of highly saturated nitrile rubber latex has been developed. This process directly converts NBR latex into HNBR latex in one reaction step. The key to the process is the efficient in-situ generation of diimide within the latex by the oxidation of hydrazine hydrate in the presence of a catalyst. At 40–70°C, diimide smoothly and selectively reduces the olefinic bonds while leaving other functionalities unaffected. The process operates at ambient pressures and produces nitrogen and water as by-products. HNBR latex produced by this process has been applied to the manufacture of superior heat-resistant gasketing via the “Beater-Addition” method. This unique new form of HNBR maintains the well known benefits of HNBR (e.g., solvent, heat, and ozone resistance, etc.) while expanding its potential applications into latex-related products.

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Our unique diimide-based process for preparing HNBR latex from NDR latex without the use of hydrogen, noble metal catalysts or solvents has now been successfully extended to the preparation of hydrogenated thermoplastic elastomers latexes directly from SBR or BR latex precusors. Commercially available SBR latex such as SBR 1502 can be readily reduced to high saturation levels (95+%) via the diimide reduction technique. Latex cast films of the highly reduced elastomer show excellent ozone and oxidation resistance as expected. Unexpectedly however, the hydrogenated polymer films demonstrate high tensile strength and thermoplastic elastomer (TPE) behavior. The TPE properties have been found to be caused by polyethylene crystallites that exist even in the unstretched films under ambient conditions. Latex is an unusual physical form for a TPE material. As a latex, TPE elastomers can be fabricated into sheets or other products by simple dipping or spraying methods—methods not normally available to TPEs in bulk form. In this regard, HSBR or HBR could function as superior replacements for natural rubber (NR) latex in articles such as tubing, gloves, condoms etc., where ozone and oxidation resistance may be required or in applications where good strength properties coupled with the absence of potentially allergenic proteins and/or curatives may be desirable. Alternatively, HSBR or HBR latexes may also be conventionally coagulated and processed using standard rubber/TPE compounding techniques.

Hydrazine (diamide), N 2 H 4 , a colorless liquid having an ammoniacal odor, is the simplest diamine and unique in its class because of the N—N bond. Hydrazine and its simple methyl and dimethyl derivatives have endothermic heats of formation and high heats of combustion. Hence these compounds are used as rocket fuels. Other derivatives are used as gas generators and explosives. Hydrazine, a base slightly weaker than ammonia, forms a series of useful salts. As a strong reducing agent, hydrazine is used for corrosion control in boilers and hot‐water heating systems; also for metal plating, reduction of noble‐metal catalysts, and hydrogenation of unsaturated bonds in organic compounds. Hydrazine is also an oxidizing agent under suitable conditions. Having two active nucleophilic nitrogens and four replaceable hydrogens, hydrazine is the starting material for many derivatives, among them foaming agents for plastics, antioxidants, polymers, polymer cross‐linkers and chain‐extenders, as well as fungicides, herbicides, plant‐growth regulators, and pharmaceuticals. Hydrazine is also a good ligand; numerous complexes have been studied. Many heterocyclics are based on hydrazine, where the rings contain from one to four nitrogen atoms as well as other heteroatoms. The many advantageous properties of hydrazine assure continued‐commercial utility. Hydrazine is available in anhydrous form as well as aqueous solutions, typically 35, 51.2, 54.4, and 64 wt % N 2 H 4 (54.7, 80, 85, and 100% hydrazine hydrate). The commercially feasible processes involve partial oxidation of ammonia (or urea) using hypochlorite or hydrogen peroxide. Most hydrazine is produced by some variation of the Raschig process, which is based on the oxidation of ammonia using alkaline hypochlorite. Hydrazine is toxic and readily absorbed by oral, dermal, or inhalation routes of exposure.

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