Polymer compositions for the preparation of polymeric articles including personal protective devices such as a condom
Polymeric condoms made from a copolymer of acrylonitrile, butadiene, and unsaturated carboxylic acid, processed through specific vulcanization methods, address material incompatibilities and production challenges, resulting in stronger, more elastic, and lubricant-compatible condoms.
Patent Information
- Authority / Receiving Office
- AU · AU
- Patent Type
- Applications
- Current Assignee / Owner
- LIFESTYLES HEALTHCARE PTE LTD
- Filing Date
- 2024-12-19
- Publication Date
- 2026-07-16
AI Technical Summary
Existing personal protective devices, such as condoms, face challenges with materials that are not thin, strong, non-allergenic, and compatible with both water and oil-based lubricants, while also requiring high elasticity and transparency, and are difficult to produce at an affordable cost.
The development of polymeric articles using a copolymer of acrylonitrile, butadiene, and an unsaturated carboxylic acid, which are processed through pre- and post-vulcanization methods to create a homogeneous, crosslinked structure, allowing for thinner, more elastic, and compatible condoms.
The resulting condoms exhibit improved strength, elasticity, and compatibility with lubricants, offering a better fit and production efficiency, while avoiding allergic reactions and synthetic production challenges.
Smart Images

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Abstract
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from Australian Provisional Patent Application No 2023904197 filed on 22 December 2023, the contents of which are incorporated herein by reference in their entirety. TECHNICAL FIELD
[0002] The present disclosure is directed to polymeric articles comprising one or more layers comprising a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid. The articles may take the form of a personal protective device, optionally a condom, for example a male condom. BACKGROUND
[0003] Personal protective devices, such as condoms, are typically made of a flexible polymeric substance such as natural rubber latex, synthetic polyisoprene, or polyurethane, in order to provide protection against chemicals, abrasions, germs, viruses, and microbes among many uses.
[0004] Natural rubber (NR), sourced from Hevea Brasiliensis and / or guayule, has a high level of stereo-regularity. Of the polyisoprene polymer content of a NR latex, about 98% by weight is cA-1,4 isoprene units and about 2% by weight is trans-XA, isoprene units. NR latex is also a highly branched polymer with a high molecular weight and a wide molecular weight distribution. These characteristics of the NR result in vulcanized rubber products having a unique combination of strength and elasticity. However, NR also contains proteins that produce dermal allergic reactions in some susceptible individuals. As a consequence, various synthetic latex alternatives have been developed, such as polyisoprene latex (PT) and polyurethane latex (PU).
[0005] Synthetic polyisoprene resins have been developed to provide benefits of NR, and to eliminate a potential for protein allergy. Some synthetic polyisoprenes, such as those produced by anionic addition polymerisation, typically consist of lower levels of stereo-regularity (i.e., -90-92% cis- 1,4 isoprene) and reduced molecular weight. While PU can be used to achieve smaller thicknesses, the resultant articles possess an inherent weakness and typically exhibit poorer tensile properties, and provide a generally looser fit than is typical for articles produced from NR. PU exhibits low elastic retention, meaning that it is difficult for the article to remain in place if the fit is loose. Furthermore, the material properties of PU are such that it is often difficult to produce articles of a particular size and / or shape.
[0006] One major disadvantage exhibited by articles produced from NR, is that their prophylactic use is incompatible with oil-based personal lubricant, as exposure to oils significantly impacts the tensile properties of the articles. Articles produced from PU possess a similar problem, in that they are incompatible for use with water-based lubricants. Accordingly, there is an ongoing need to identify new materials that can be used to develop personal protective devices, which ideally possess one or more characteristics selected from, but not limited to: thin, strong, non-allergenic, and / or are compatible with water and / or oilbased lubricants. A particular challenge remaining unmet is the development of a polymeric article that is thinner, has a higher transparency, is sensorial, offers better fit, and exhibits higher elasticity than PU, which does not attract the synthetic / production challenges associated with NR or PI, and which can be produced at an affordable cost.
[0007] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims. SUMMARY
[0008] Articles, for example in the form of personal protective devices, produced from polymers of nitrile, may offer a potential solution to the current above and other problems, and / or offers an alternative option as a material. While polymeric nitrile materials have been used for the manufacture of female prophylactic devices, such materials have long been considered unsuitable for use in the manufacture of male condoms for a variety of reasons. Firstly, it was previously understood that the physical properties of known polymeric nitrile materials (e.g. higher modulus of elasticity) can result in the polymeric articles manufactured therefrom exhibiting insufficient softness for use as a male condom. In contrast, female condoms typically require a harder material, with a greater thickness, owing to the strong ring that is required at the open end of the condom, so that the shape may be altered to facilitate use. Moreover, the more stringent requirements for male condoms (yis-a-vis female condoms) in terms of physical / tensile properties (namely, that male condoms need to be far thinner and far softer than female condoms), which result from the different manner of use, discourages the use of known polymeric nitrile materials (perceived as having generally poorer tensile properties [<?.g. lower elongation at break, lower mechanical strength to break] in comparison to other materials, e.g. PI, PU and NR), for male condoms. Secondly, known polymeric nitrile materials have not been demonstrated to produce cured layers at suitable thicknesses for use in a male condom. Despite this, the inventors of the present disclosure, have surprisingly discovered that carboxylated nitrile butadiene rubber exhibit elastic and tensile properties that render the material suitable for use in the manufacture of condoms, such as male condoms. Further, particular manufacturing processes, such as prevulcanisation of the compounded XNBR latex, can be utilised to provide XNBR condoms with preferable tensile and elastic properties.
[0009] Disclosed herein are polymeric articles (and methods of manufacture thereof) comprising one or more layers comprising a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0010] Herein the copolymer comprising the monomers butadiene, acrylonitrile and an unsaturated carboxylic acid, may be referred to as “XNBR” or the “nitrile copolymer”.
[0011] In one aspect, the present disclosure provides for a polymeric article, comprising one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0012] In another aspect, the present disclosure provides for a condom comprising: • a tubular shaft having a tip on a closed end of the tubular shaft and an open end opposite the closed end on the tubular shaft; and • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0013] In another aspect, the present disclosure provides for a condom comprising: • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid, wherein the condom is a male condom.
[0014] In another aspect, the present disclosure provides for a condom, optionally a male condom, comprising particles of a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid that are pre-vulcanized and cured, wherein the particles are bonded to each other through intra-particle crosslinks and inter-particle crosslinks, wherein the intra-particle crosslinks and the inter-particle crosslinks are optionally substantially uniform in the condom.
[0015] In another aspect, the present disclosure provides a condom comprising: • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid, wherein the condom is optionally a male condom and the copolymer comprises less than 10 % w / w of the unsaturated carboxylic acid.
[0016] In another aspect, the present disclosure provides for a packaged condom comprising a condom according to any aspect, embodiment, or example described herein.
[0017] In another aspect, the present disclosure provides for a latex comprising particles of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0018] In another aspect, the present disclosure provides for a method of forming a condom, the method comprising: crosslinking a latex according to any aspect, embodiment, or example described herein.
[0019] In another aspect, the present disclosure provides for a condom produced according to a method according to any aspect, embodiment, or example described herein.
[0020] In another aspect, the present disclosure provides for a male condom produced according to a method according to any aspect, embodiment, or example described herein
[0021] In another aspect, the present disclosure provides for a use of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid in the formation of a latex to form a condom.
[0022] In another aspect, the present disclosure provides for a use of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid in the formation of a latex to form a male condom.
[0023] Embodiments according to the present disclosure include polymeric articles, and methods for manufacturing polymeric articles, for example substantially as shown in and / or described in connection with at least one of the figures, as set forth more completely in the claims, are disclosed. Various advantages, aspects, and novel features of the present disclosure may be more fully understood from the following description and drawings.
[0024] The present disclosure may provide one or more of the following advantages: - Articles that provide, reduced, negligible or no permanent deformation. - Increased resistant to one or more solvents, for example an article such as a condom produced via the methods described herein may not dissolve in one or more solvents, or have an increased tolerance to the one or more solvents when compared to articles produced from alternative materials (such as polyisoprene, polyurethane and / or natural rubber). - Increased resistance to one or more oils and / or hydrocarbons. - Low or reduced shrinkage.
[0025] The foregoing summary is not intended, and should not be contemplated, to describe each embodiment or every implementation of the present disclosure. Other and further embodiments are described below.
[0026] It will be appreciated that the embodiments of each aspect of the present disclosure may equally be applied to each other aspect, mutatis mutandis. BRIEF DESCRIPTION OF DRAWINGS
[0027] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarised above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. It is to be understood that elements and features of one embodiment may be in other embodiments without further recitation It is further understood that, where possible or relevant, identical reference numerals have been used to indicate comparable elements that are common to the figures.
[0028] Figure 1 depicts a TEM micrograph of a crosslinked network of a condom comprising the nitrile copolymer (XNBR), with the scale indicating 5 gm. The TEM micrographs represent the XNBR crosslinked network. The dark areas are the XNBR stained with osmium tetroxide. The light areas (polystyrene voids) are polystyrene that embedded in XNBR condom pieces which indicate the weak area in XNBR condom pieces. The XNBR latex particles are clearly visible on the micrograph. The boundary of these particles is clearly defined. The intra- and inter-particle crosslinked can be seen. The latex particles distribution is relatively uniform.
[0029] Figure 2 depicts a TEM micrograph of the crosslink network for an XNBR condom, with the scale indicating 2 gm. The TEM micrographs represent the XNBR crosslinked network The dark areas are the XNBR rubber stained with osmium tetroxide. The light areas (polystyrene voids) are polystyrene that embedded in XNBR condom pieces which indicate the weak area in XNBR condom pieces. The XNBR latex particles are clearly visible on the micrograph. The boundary of these particles is clearly defined. The intra- and inter-particle crosslinked can be seen. The latex particles distribution is relatively uniform.
[0030] Figure 3 depicts a TEM micrograph of the crosslink network for an XNBR condom, with the scale indicating 1 gm. The TEM micrographs represent the XNBR crosslinked network. The dark areas are the XNBR rubber stained with osmium tetroxide. The light areas (polystyrene voids) are polystyrene that embedded in XNBR condom pieces which indicate the weak area in XNBR condom pieces. The XNBR latex particles are clearly visible on the micrograph. The boundary of these particles is clearly defined. The intra- and inter-particle crosslinked can be seen. The latex particles distribution is relatively uniform.
[0031] Figure 4 depicts a TEM micrograph for an XNBR condom (image B), with the scale indicating 1 pm. The TEM micrographs represent the XNBR crosslinked network. The dark areas are the XNBR rubber stained with osmium tetroxide. The light areas (polystyrene voids) are polystyrene that embedded in XNBR condom pieces which indicate the weak area in XNBR condom pieces. The XNBR latex particles are clearly visible on the micrograph. The boundary of these particles is clearly defined. The intra and inter-particle crosslinked can be seen. The latex particles distribution is relatively uniform. Image A is a cartoon depicting with labelled features of the micrograph.
[0032] Figure 5 is a photograph of NR condoms lubricated with either silicone oil, palm oil, mineral oil, Petroleum jelly or paraffin oil
[0033] Figure 6 is a photograph of XNBR condoms lubricated with either silicone oil, palm oil, mineral oil, Petroleum jelly or paraffin oil.
[0034] Figure 7 is a photograph of PI condoms lubricated with either silicone oil, palm oil, mineral oil, Petroleum jelly or paraffin oil.
[0035] Figure 8 is a photograph of PU condoms lubricated with either silicone oil, palm oil, mineral oil, Petroleum jelly or paraffin oil.
[0036] Figure 9 is a photograph of XNBR condoms after dry stripping (left) and wet stripping (right).
[0037] Figure 10 is a photograph of XNBR condoms made with latex formulation F. 1 with no pre-vulcanisation (left), 24 hours of pre-vulcanisation (middle), and 48 hours of prevulcanisation (right).
[0038] Figure 11 is a photograph of an XNBR condom produced with the addition of a heat sensitizer (F.3) DESCRIPTION OF EMBODIMENTS Terms and Definitions
[0039] Before describing embodiments of the present disclosure in detail, the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. The embodiments described herein should not necessarily be limited to specific compositions, materials, designs or equipment, as such may vary. All technical and scientific terms used herein have the usual meaning conventionally understood by persons skilled in the art to which this disclosure pertains, unless context defines otherwise.
[0040] The definitions are provided to aid in describing particular embodiments, and are not intended to limit the claimed invention, because the scope of the invention is limited only by the claims.
[0041] All references, including publications, patent applications and patents, cited herein, unless described otherwise, are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0042] Unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. Throughout this disclosure, unless specifically stated otherwise or the context requires otherwise, reference to a single step, composition of matter, group of steps or group of compositions of matter shall be taken to encompass one and a plurality (i.e., one or more) of those steps, compositions of matter, groups of steps or groups of compositions of matter. Thus, as used herein, the singular forms “a”, “an” and “the” include plural aspects unless the context clearly dictates otherwise. For example, reference to “a” includes a single as well as two or more; reference to “an” includes a single as well as two or more; reference to “the” includes a single as well as two or more and so forth.
[0043] Those skilled in the art will appreciate that the disclosure herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the disclosure includes all such variations and modifications. The disclosure also includes all of the examples, steps, features, methods, compositions, articles, formulations, uses and processes, referred to or indicated in this specification, individually or collectively, and any and all combinations or any two or more of said steps or features.
[0044] The term “and / or”, e.g., “X and / or Y” shall be understood to mean either “X and Y” or “X or Y” and shall be taken to provide explicit support for both meanings or for either meaning.
[0045] Unless otherwise indicated, the terms “first,” “second,” etc., are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of lower-numbered item (e g., a “first” item) and / or a higher-numbered item (e.g., a “third” item).
[0046] As used herein, the phrase “at least one of’ or “one or more of’ when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of’ means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example and without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C, or some other suitable combination.
[0047] It is to be appreciated that certain features that are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination.
[0048] Throughout the present specification, various aspects and components of the disclosure can be presented in a range format. The range format is included for convenience and should not be interpreted as an inflexible limitation on the scope of the present disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range, unless specifically indicated. For example, description of a range such as from 1 to 5 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 5, from 3 to 5 etc., as well as individual and partial numbers within the recited range, for example, 1, 2, 3, 4, 4.5 and 5, unless where integers are required or implicit from context. This applies regardless of the breadth of the disclosed range. Where specific values are required, these will be indicated in the specification.
[0049] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
[0050] Throughout this specification, the term “consisting essentially of’ is intended to exclude elements which would materially affect the properties of the claimed composition, although may include elements that do not materially affect properties.
[0051] The terms “comprising”, “comprise” and “comprises” herein are intended to be optionally substitutable with the terms “consisting essentially of’, “consist essentially of’, “consists essentially of’, “consisting of’, “consist of’ and “consists of’, respectively, in every instance.
[0052] Herein, unless indicated otherwise, the term “about” encompasses a 10% tolerance in any value or values connected to the term.
[0053] The terms “emulsion”, “dispersion”, “latex” and “suspension” are generally analogous and indicate a system in which small particles of a substance, such as rubber particles, are mixed with a fluid solvent (such as water and / or alcohols and / or other organic fluids) but are at least partially undissolved and kept dispersed by agitation (mechanical suspension) and / or by the molecular forces in a surrounding medium (colloidal suspension). Emulsions contemplated herein may further comprise typical and suitable components for rubber or elastomeric formulations and compounds, such as accelerators, such as, for example: guanidines, thiazoles, thiurams, sulfenamides, thioureas, dithiocarbamates, and xanthates. Depending on a specific application, exemplary non-limiting examples of accelerators may include one or more of: hexamethylene tetramine (HMT), heptaldehyde-aniline condensation product (BA), diphenyl guanidine (DPG), N, N’-diorthotolyl guanidine (DOTG), 2-mercaptobenzothiazole (MBT), 2-2’-dithiobis(benzothiazole) (MBTS), zinc-2-mercaptobenzothiazole (ZMBT), zinc-O,O-di-N-phosphorodithioate (ZBDP), N-cy cl ohexyl-2-benzothiazole sulfenamide (CBS), N-tert-butyl-2-benzothiazole sulfenamide (TBBS), 2-(4-morpholinothio)-benzothiazole (MBS), N,N’-dicyclohexyl-2-benzothiazole sulfenamide (DCBS), ethylene thiourea (ETU), di-pentamethylene thiourea (DPTU), dibutyl thiourea (DBTU), tetramethylthiuram monosulfide (TMTM), tetramethylthiuram disulfide (TMTD), dipentamethylenethiuram tetrasulfide (DPTT), tetrabenzylthiuram disulfide (TBzTD), zinc dimethyldithiocarbamate (ZDMC), zinc diethyldithiocarbamate (ZDEC), zinc dibutyldithiocarbamate (ZDBC), zinc dibenzyldithiocarbamate (ZDBC), and / or zinc-isopropyl xanthate (ZIX). Emulsions contemplated herein may further comprise activators, such as, but not limited to: zinc oxides, cross-linking agents and curatives, such as: elemental sulfur, mono-sulfidic donors, disulfidic donors, such as tetramethyl thiuram disulfide and tetraethyl thiuram disulfide; and / or polysulfidic donors, such as xanthogen polysulfide and di pentamethylene thiuramtetrasulfide. Emulsions contemplated herein may further comprise anti-oxidants and / or anti-ozonants. Phenolic antioxidants may be used. At least one suitable anti-oxidant which may be used is a butylated reaction product of p-cresol and dicyclopentadiene. Emulsions contemplated herein may further comprise, surfactants, such as sodium dodecyl sulfates and polyvinyl alcohols. Emulsions contemplated herein may further comprise rheology-modifiers, such as various clays and aluminosilicates, pH adjusters, such as hydroxides, such as potassium hydroxide, pigments, processing agents, and / or fillers as are known to those in the art.
[0054] The term “polymer” generally includes, but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, etc. It will be understood that “copolymer” refers to any polymer that is the reaction product of at least two different monomers (e.g. a terpolymer, which is the product of three different monomers, will therefore be understood to be an example of a copolymer). In one embodiment the copolymer is a terpolymer. Furthermore, unless otherwise specifically limited, the term “polymer” includes all possible geometrical configurations of the molecule. These configurations include, but are not limited to isotactic, syndiotactic and random symmetries. The polymer may be produced by an appropriate method known in the art.
[0055] Herein, unless defined otherwise, “the copolymer”, “a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid” refers to a copolymer which is formed from the monomers acrylonitrile, butadiene and an unsaturated carboxylic acid, and optionally one or more other monomers. In one embodiment the copolymer may be formed solely from acrylonitrile, butadiene and an unsaturated carboxylic acid. In another embodiment the copolymer may be formed from acrylonitrile, butadiene and an unsaturated carboxylic acid and at least one other monomer.
[0056] Herein the terms “article” and “polymeric article” may be used interchangeably.
[0057] As used herein, the term “butadiene” is intended to refer to the substance known as 1,3-butadiene or buta-l,3-diene, with CAS Number 106-99-0.
[0058] Herein a reference may be made to one or more standards, for example ISO 23409:2011, 1804074:2015, and / or ASTM D3492-16. The version of the referenced standard is the last reviewed version at 22 December 2023.
[0059] Herein “curing”, for example a “curing step” relates to the toughening or hardening of a polymer material by crosslinking of polymer chains, brought about by electron beams, heat or chemical additives. In one embodiment, the application of heat is used to initiate or promote curing. In some embodiments the term is used for processes that do not require the presence of one or more sulfur containing crosslinking agents.
[0060] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Nitrile Polymeric Articles
[0061] Embodiments described in this disclosure, briefly summarised above and discussed in greater detail below, comprise polymeric articles, including articles, for example personal protective equipment such as condoms, including thin-walled condoms (for example, those less than 55 pm).
[0062] The present disclosure provides for a polymeric article comprising one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0063] hi one or more embodiments, the unsaturated carboxylic acid is selected from, but not limited to: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof.
[0064] hi one or more embodiments, the unsaturated carboxylic acid is acrylic acid or methacrylic acid. Tn some embodiments, the unsaturated carboxylic acid is acrylic acid. Tn some embodiments, the unsaturated carboxylic acid is methacrylic acid.
[0065] The present disclosure also provides for a condom, for example a male condom, comprising: • a tubular shaft having a tip on a closed end of the tubular shaft and an open end opposite the closed end on the tubular shaft; and • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0066] The present disclosure also provides a condom, optionally a male condom, comprising particles of a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid that are pre-vulcanized and cured, wherein the particles are bonded to each other through intra-particle crosslinks and inter-particle crosslinks, wherein the intraparticle crosslinks and the inter-particle crosslinks are substantially uniform in the condom.
[0067] hi one embodiment the condom is a male condom. Herein “male condom” would be understood to be a covering comprising at least one layer of a composition as described herein, which is intended to be worn over a penis, for example for during intercourse.
[0068] The present disclosure also provides for a packaged condom comprising a condom according to any aspects, embodiments or examples disclosed herein. Composition
[0069] In some embodiments, the polymeric article or condom comprises one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid. In some embodiments, the one or more layers comprise an elastomeric layer. In one embodiment the polymeric article or condom comprises at least one layer of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid. In one embodiment, the polymeric article or condom comprises a single elastomeric layer. In another embodiment, the polymeric article or condom comprises a plurality of layers of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid; for example 2, 3 or 4 layers. The inclusion of more than one layer may provide the advantage of less risk of holes or defects in the article and / or greater tensile strength during manufacture and / or use.
[0070] In one embodiment the copolymer as described or defined herein is a terpolymer of acrylonitrile, butadiene and acrylic acid. In another embodiment, the copolymer as described or defined herein is a terpolymer of acrylonitrile, butadiene and methacrylic acid.
[0071] It will be understood that there is no particular limitation as to unsaturated carboxylic acids that are suitable. Examples of unsaturated carboxylic acids include, but are not limited to, acrylic acid, methacrylic acid, itaconic acid, maleic acid, and fumaric acid. In some embodiments, the unsaturated carboxylic acid is acrylic acid, methacrylic acid, or a combination thereof. In some embodiments, the unsaturated carboxylic acid is acrylic acid, hi some embodiments, the unsaturated carboxylic acid is methacrylic acid.
[0072] Monomer content, for example acrylonitrile content, butadiene content and carboxylic acid content, may be determined by any suitable method known in the art. For example, acrylonitrile content may be determined by analysing the nitrogen content of the copolymer, butadiene content (including trans-\,4, cis-1,4 and / or 1,2 addition content, these being possible residues resulting from butadiene polymerisation) as well as carboxylic acid content may be determined by Fourier transform infrared spectroscopy (FTIR).
[0073] In some embodiments, the acrylonitrile content (in % w / w) of the copolymer is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80. hi some embodiments, the acrylonitrile content (in % w / w) of the copolymer is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the acrylonitrile content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the acrylonitrile content (in % w / w) of the copolymer is between about 10% and about 50%, between about 20% and about 40%, between about 20% and about 30%, between about 25% and about 35%, between about 25% and about 30%, between about 30% and about 35%, or between about 35% and about 45%.
[0074] In some embodiments, the butadiene content (in % w / w) of the copolymer is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80. In some embodiments, the butadiene content (in % w / w) of the copolymer is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the butadiene content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the butadiene content (in % w / w) of the copolymer is between about 10% and about 50%, between about 60% and about 80%, between about 60% and about 70%, between about 20% and about 40%, between about 25% and about 35%, between about 25% and about 30%, between about 30% and about 35%, or between about 35% and about 45%.
[0075] In some embodiments, the CZ5-1,4 content (in % w / w) of the copolymer is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40. In some embodiments, the cis-1,4 content (in % w / w) of the copolymer is less than about: 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the cis-1,4 content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the cis-1,4 content (in % w / w) of the copolymer is between about 5% and about 40%, between about 10% and about 30%, between about 15% and about 25%, or between about 20% and about 25%. In some embodiments, the trans-\,4 content (in % w / w) of the copolymer is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50. In some embodiments, the Zrarw-l^ content (in % w / w) of the copolymer is less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the trans-\,4 content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the trans-\,4 content (in % w / w) of the copolymer is between about 5% and about 50%, between about 10% and about 45%, between about 30% and about 45%, or between about 35% and about 45%. In some embodiments, the 1,2-addition content (in % w / w) of the copolymer is about, or greater than about: 30, 25, 20, 15, 10, or 5. In some embodiments, the 1,2-addition content (in % w / w) of the copolymer is less than about: 30, 25, 20, 15, 10, or 5. In some embodiments, the 1,2-addition content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the 1,2-addition content (in % w / w) of the copolymer is between about 5% and about 30%, between about 10% and about 20%, between about 10% and about 15%.
[0076] In some embodiments, the unsaturated carboxylic acid content (in % w / w) of the copolymer is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, 7, 7.2, 7.4, 7.6, 7.8, 8, 8.2, 8.4, 8.6, 8.8, 9, 9.2, 9.4, 9.6, 9.8,10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80. In some embodiments, the unsaturated carboxylic acid content (in % w / w) of the copolymer is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 9.8, 9.6, 9.4, 9.2, 9, 8.8, 8.6, 8.4, 8.2, 8, 7.8, 7.6, 7.4, 7.2, 7, 6.8, 6.6, 6.4, 6.2, 6, 5.8, 5.6, 5.4, 5.2, 5, 4.8, 4.6, 4.4, 4.2, 4, 3.8, 3.6, 3.4, 3.2, 3, 2.8, 2.6, 2.4, 2.2, 2, 1.8, 1.6, 1.4, 1.2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In some embodiments, the unsaturated carboxylic acid content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the unsaturated carboxylic acid content (in % w / w) of the copolymer is between about 0.1% and about 20%, between about 0.1% and about 10%, between about 1% and about 9%, between about 2% and about 8%, between about 3% and about 7%,or between about 5% and about 15%.
[0077] hi some embodiments, the carboxylic acid group content (in % w / w) of the copolymer is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, 7, 7.2, 7.4, 7.6, 7.8, 8, 8.2, 8.4, 8.6, 8.8, 9, 9.2, 9.4, 9.6, 9.8, or 10. In some embodiments, the carboxylic acid group content (in % w / w) of the copolymer is less than about: 10, 9.8, 9.6, 9.4, 9.2, 9, 8.8, 8.6, 8.4, 8.2, 8, 7.8, 7.6, 7.4, 7.2, 7, 6.8, 6.6, 6.4, 6.2, 6, 5.8, 5.6, 5.4, 5.2, 5, 4.8, 4.6, 4.4, 4.2, 4, 3.8, 3.6, 3.4, 3.2, 3, 2.8, 2.6, 2.4, 2.2, 2, 1.8, 1.6, 1.4, 1.2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In some embodiments, carboxylic acid group content (in % w / w) of the copolymer is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the carboxylic acid group content (in % w / w) of the copolymer is between about 0.1% and about 10%, between about 1% and about 9%, between about 2% and about 8%, between about 3% and about 7%, or between about 5% and about 15%.
[0078] hi some embodiments, the one or more layers comprise particles of the copolymer. In some embodiments, at least a portion of the particles are pre-vulcanized cured synthetic particles, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. The “%”, may be a numerical fraction, w / w% or w / v%.
[0079] In some embodiments, at least a portion of the particles (for example about or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%), of the copolymer have a size (in A) of about, or greater than about: 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700 or 1800. In some embodiments, at least a portion of the particles (for example about or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%), of the copolymer have a size (in A) less than about 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 200 or 100. In some embodiments, at least a portion of the particles (for example about or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%), of the copolymer have a size (in A) in a range provided by any two of the previously described upper and / or lower amounts, e.g. at least a portion of the particles of the copolymer have a size (in A) between about 800 and about 1800, between about 900 and about 1700, between about 1000 and about 1600, or between about 1100 and about 1500. The person skilled in the art will appreciate that particle size may be determined one of any number of methods known in the art, for example a light scattering or dynamic light scattering method such as laser light scattering method. Particle size may be determined according to a recognised standard, e.g. ISO 22412:2017. Any suitable particle size analyser may be used, e.g. the NICOMPN3000.
[0080] hi some embodiments, at least a portion of the particles are crosslinked, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the particles comprise intra-particle crosslinking, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the particles comprise inter-particle crosslinking, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the particles comprise both interparticle crosslinking and intra-particle crosslinking, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the intra-particle crosslinking and / or the interparticle crosslinking comprises sulfur crosslinks. In some embodiments, at least a portion of the intra-particle crosslinking and / or the inter-particle crosslinking does not comprise sulfur crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%. In one embodiment, at least a portion of intra and / or inter crosslinking, may be a result of the introduction of a crosslinking agent, for example, one or more metal salts, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide. In some embodiments, a portion of the crosslinking agent may be incorporated into at least a portion of crosslinks in a particle and / or article as described herein.
[0081] hi one or more embodiments, at least a portion of the particles are bonded to each other by inter-particle sulfur-crosslinks. Tor example, about, at least, or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% of the particles. The “%”, may be a numerical fraction, w / w% or w / v%. In some embodiments, the portion of the particles bonded to each other by inter-particle sulfur-crosslinks (in % w / w or w / v%) is in a range provided by any two of the previously described upper and / or lower amounts. In one or more embodiments, the intra-particle sulfur-crosslinks and the inter-particle sulfur crosslinks are uniform or substantially unform in the polymeric articles.
[0082] hi one or more embodiments, about, at least, or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% of the particles, for example copolymer particles, used in the formation of an article (for example a condom), are pre-vulcanized, for example pre-vulcanized to introduce intra-particle crosslinks such as sulfur crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%.
[0083] hi one or more embodiments, less than, or less than about: 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, or 5%, of the particles, for example copolymer particles, used in the formation of an article (for example a condom), are pre-vulcanized, for example to introduce intra-particle crosslinks, such as sulfur crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%.
[0084] hi one or more embodiments the sulfur crosslinking, for example intra and / or inter particle crosslinking, may comprise, mono-sulfidic, di-sulfidic, and / or poly-sulfidic crosslinks. Herein, the poly-sulfidic crosslinks comprise at least 3 sulfur atoms. In yet another embodiment, about, at least, or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% of the intra- and / or inter particle crosslinking comprises mono-sulfidic, di-sulfidic, and / or poly-sulfidic crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%
[0085] In one or more embodiments, the polymeric article (for example a prophylactic article), comprises a cured or post-vulcanized composition comprising post-vulcanized or cured synthetic particles present in an amount of, about, at least, or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% of the particles. The “%”, may be a numerical fraction, w / w% or w / v%.
[0086] hi some embodiments, the copolymer or the particles thereof comprise crosslinking, optionally ionic crosslinking, between at least a portion of unsaturated carboxylic acid units. There is no particular limitation on cross-linkers that may be used to effect the crosslinking, optionally ionic crosslinking. Suitable examples include, but are not limited to, metal salts, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide At least a portion or a fragment of a crosslinking agent may be incorporated into a crosslink unit in the copolymer and / or one or more particles (for example in at least a portion of intra and / or inter particle crosslinking).
[0087] In some embodiments crosslinking may occur between two or more functional groups (such as a carbonyl group and / or an alkene group), present on the same copolymer chain, two or more different functional groups on two or more different copolymer chains, or between two or more particles, following the introduction of a crosslinking agent.
[0088] hi some embodiments, the particles comprise intra-particle and / or inter-particle crosslinking comprising sulfur crosslinks and / or ionic crosslinks between at least a portion of unsaturated carboxylic acid units (for example acrylic acid units).
[0089] hi some embodiments, the condom, or the polymeric article, or at least one layer thereof, comprises a structure (optionally a cured or post-vulcanized structure) having a molecular weight between crosslinks (Mc) of less than about: 6000, 5500, 5000, 4500, 4000, 3500, 3000, 2500, 2000, 1950, 1900,1850, 1800, 1750, 1700, 1650, 1600,1550, 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1150, 1100, 1050, 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 200, 150 or 100 g / mol. In some embodiments, the condom, or the polymeric article, or at least one layer thereof, comprises a structure (optionally a cured or post-vulcanized structure) having a Mc of greater than about 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350,1400, 1450, 1500, 1550, 1600, 1650,1700, 1750, 1800, 1850, 1900, 1950, 2000, 2500, 3000, 3500, 4000, 4500, 5000, 5500 or 6000 g / mol. In some embodiments, the condom, or the polymeric article, or at least one layer thereof, comprises a structure (optionally a cured or post-vulcanized structure), having a Me in a range provided by any two of the previously described upper and / or lower amounts, for example, the condom, or the polymeric article, or at least one layer thereof, comprises a structure (optionally a cured or post-vulcanized structure), having a Me of: between about 100 g / mol and about 6000 g / mol, between about 100 g / mol and about 5000 g / mol, between about 2000 g / mol and about 5000 g / mol, between about 3000 g / mol and about 5000 g / mol, between about 100 g / mol and about 2000 g / mol, between about 100 g / mol and about 1000 g / mol, between about 200 g / mol and about 900 g / mol, between about 300 g / mol and about 800 g / mol, between about 450 g / mol and about 850 g / mol, between about 550 g / mol and about 750 g / mol, between about 600 g / mol and about 700 g / mol, or between about 650 g / mol and about 700 g / mol. Methods for determining the Me are disclosed in US Patent Nos.: 8,087,412; 8,464,719; 9,725,539; and 10,538,609, the contents of which are incorporated herein by reference in their entirety.
[0090] In one embodiment the Mc value may be defined by (Equation 1), (Equation 2) and / or (Equation 3), each as described herein.
[0091] hi one embodiment the Mc value may be defined by (Equation 4), (Equation 5) and / or (Equation 6), each as described herein.
[0092] In some embodiments, at least one of: an anti-viral, an anti-microbial, an antifungal, a vasodilator, a benzocaine, a flavour, a scent, an active ingredient, a warming liquid or gel, a sensitizing agent, a desensitizing agent, a spermicide, a lubricant, a cooling agent, a moisturising agent (e.g. hyaluronic acid), an arousal agent (e.g. L-arginine), or mixture thereof, is disposed on or in at least a portion of the polymeric article, such as a condom (for example a male condom). In some embodiments, at least one lubricant is disposed on or in at least a portion of the polymeric article or condom. In some embodiments, at least one lubricant is selected from, but not limited to: oil-based lubricants, silicon based-lubricants, water-based lubricants, or a mixture thereof.
[0093] In another embodiment, the condom, or the polymeric article, or at least one layer thereof, does not substantially comprise a heat sensitising agent. In another embodiment, the condom, or the polymeric article, or at least one layer thereof, does not comprise a heat sensitising agent. In another embodiment, the condom, or the polymeric article, or at least one layer thereof, comprises no more than 5, 4, 3, 2, 1, 0.1 ,or 0.01% (w / w) of heat sensitising agents.
[0094] In some embodiments, the condom, or the polymeric article, or at least one layer thereof, does not comprise an epoxy compound comprising three or more glycidyl ether groups, in an amount (% w / w), of about or greater than about: 0.5, 2, 4, 6, 8, 10, 12, 14, 16, 18, or 20. In some embodiments, the condom, or the polymeric article, or at least one layer thereof, does not comprise an epoxy compound comprising three or more glycidyl ether groups. In some embodiments, the condom, or the polymeric article, or at least one layer thereof, does not comprise an epoxy compound in an amount (% w / w), of about or greater than about: 0.5, 2, 4, 6, 8, 10, 12, 14, 16, 18, or 20. In some embodiments, the condom, or the polymeric article, or at least one layer thereof, does not comprise an epoxy compound.
[0095] In some embodiments, the condom, or the polymeric article, or at least one layer thereof, does not comprise a spacer group separating an ethylenically unsaturated group and an acid functional group by at least 4 atoms, in an amount (% w / w), of about or greater than about: 0.5, 2, 4, 6, 8, 10, 12, 14, 16, 18, or 20. In some embodiments, the condom, or the polymeric article, or at least one layer thereof, does not comprise a spacer group separating an ethylenically unsaturated group and an acid functional group by at least 4 atoms.
[0096] In some embodiments, the condom, or the polymeric article, or at least one layer thereof does not comprise a vinyl aromatic monomer in an amount (% w / w), of about or greater than about: 0.5, 2, 4, 6, 8, 10, 12, 14, 16, 18, or 20. In some embodiments, the condom, or the polymeric article, or at least one layer thereof does not comprise a vinyl aromatic monomer. Compatibility
[0097] In some embodiments, the polymeric article or condom is compatible with at least one lubricant or oil selected from, but not limited to: oil-based lubricants, silicon based-lubricants, water-based lubricants, or mixtures thereof. In some embodiments, the polymeric article or condom is compatible with oil-based lubricants. In some embodiments, the polymeric article or condom is compatible with silicon based-lubricants. In some embodiments, the polymeric article or condom is compatible with water-based lubricants. Suitable examples include, but are not limited to hybrid lubricants comprising a silicone-based lubricant and a water-based lubricant, petroleum jelly (e g. Petroleum jelly), organic lubricants (e g. butter or, vegetable oil). In some embodiments, the article is compatible with at least one lubricant or oil selected from mineral oil (including baby oil), palm oil, cyclomethicone, paraffin oil, silicon based-lubricants, or a mixture thereof. Physical Properties
[0098] An article described herein, for example a condom, may be tested to identify and / or quantify a particular characteristic. The characteristic may be selected from, but not limited to: burst pressure, burst volume, force at break, tensile strength, elongation at break and / or shelflife), using a known standard known in the art. In addition, other physical defects such as holes and / or visual defects may also be assessed. The known standard may be selected from, but not limited to one or more of: ISO 23409:2011, 1804074:2015, and / or ASTM D3492-16. The version of the referenced standard is the last reviewed version at 22 December 2023.
[0099] In some embodiments, the article has a thickness (in pm), or about, or greater than about: 1, 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100. In some embodiments, the article has a thickness (in pm) less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 2 or 1. In some embodiments, the article has a thickness (in pm) in a range provided by any two of the previously described upper and / or lower amounts, e.g., the article has a thickness (in pm) in the range of about 1 pm to about 100 pm, about 20 pm to about 100 pm, about 20 pm to about 80 pm, about 20 pm to about 60 pm, or about 20 pm to about 40 pm. In one embodiment the article has a thickness in a range of about 10 pm to about 40 pm, or about 20 pm to about 40 pm, or about 30 pm to about 40 pm.
[0100] An article described herein may be analysed to assess and / or quantify one or more characteristics, for example one or more of: burst pressure, burst volume, force at break, tensile strength, and / or elongation at break. In addition, other physical defects such as holes and / or visual defects may also be assessed.
[0101] In one embodiment, the burst pressure of an article or condom defined herein may be in a range of about 1.0 kPa to about 3.0 kPa, for example measured according to one or more of ISO 23409:2011,1804074:2015, and / or ASTM D3492-16. In another embodiment the burst pressure of the article is, is about, at least, or at least about: 0.80, 0.85, 0.90, 0.95, 1.00, 1.05, 1.10, 1.15, 1.20, 1.25, 1.30, 1.35, 1.40, 1.45, 1.50, 1.55, 1.60, 1.65, 1.70, 1.75, 1.80, 1.85, 1.90, 1.95, 2.00, 2.05, 2.10, 2.15, 2.20, 2.25, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65, 2.70, 2.75, 2.80, 2.85, 2.90, 2.95 or 3.00 kPa. In some embodiments, the burst pressure (in kPa) is in a range provided by any two recited values.
[0102] In one embodiment, the burst volume of an article or condom defined herein (in L) may be, may be about, or may be at least about: 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, or 15. The burst volume may be measured according to one or more of ISO 23409:2011,1804074:2015, and / or ASTM D3492-16. In some embodiments, the burst volume (in L) is in a range provided by any two recited values.
[0103] In one embodiment, the force at break (in N), of an article or condom defined herein may be, may be about, or may be at least about: 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40. The force at break may be measured according to one or more of ISO 23409:2011, 1804074:2015, and / or ASTM D3492-16. In some embodiments, the force at break (in N) is in a range provided by any two recited values. The version of the referenced standard is the last reviewed version at 22 December 2023.
[0104] hi one embodiment, the tear strength (in N / mm), of an article or condom defined herein may be, may be about, or may be at least about: 1.00, 1.50, 2.00, 2.50, 3.00, 3.50, 4.00 or 4.50. The tear strength may be measured according to one or more of ASTM D624:1991, or ISO34-1:2022; preferably ISO34-1:2022. In some embodiments, the tear strength (in N / mm) is in a range provided by any two of the above recited values. The version of the referenced standard is the last reviewed version at 22 December 2023.
[0105] hi one embodiment, the tensile strength (in kPa) of an article or condom defined herein may be, may be about, or may be at least about: 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30. The tensile strength may be measured according to one or more of ISO 23409:2011, IS04074:2015, and / or ASTM D3492-16. In some embodiments, the tensile strength (in kPa) is in a range provided by any two recited values. The version of the referenced standard is the last reviewed version at 22 December 2023.
[0106] hi one embodiment, the elongation at break (in %), of an article or condom defined herein may be, may be about, or may be at least about: 250, 270, 290, 310, 330, 350, 370, 390, 410, 430, 450, 470, 490, 510, 530, 550, 570, 590, 610, 630, 650, 670, 690, 710, 730, or 750. The elongation at break may be measured according to one or more of ISO 23409:2011, 1804074:2015, and / or ASTM D3492-16. In some embodiments, the force at break (in %) is in a range provided by any two recited values. The version of the referenced standard is the last reviewed version at 22 December 2023.
[0107] Accordingly, the present disclose also provides a use of a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid, in the formation of a latex to form a condom, wherein the copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid, latex and condom may be any described according to any aspect, embodiment or example herein.
[0108] The copolymer as described herein may be produced by an appropriate method known in the art, for example via radical polymerisation using an appropriate initiator. Latex
[0109] The present disclosure also provides for a latex, or latex composition, comprising particles of a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid.
[0110] The present disclosure also provides for a latex, or latex composition, comprising particles of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid, when used to provide a polymeric article described in accordance with any one of the aspects, embodiments, or examples disclosed herein, or to provide a condom described in accordance with any one of the aspects, embodiments, or examples disclosed herein. For example a male condom.
[0111] It will be understood that there is no particular limitation as to unsaturated carboxylic acids that are suitable. Examples of unsaturated carboxylic acids include, but are not limited to, acrylic acid, methacrylic acid, itaconic acid, maleic acid, and fumaric acid. In some embodiments, the unsaturated carboxylic acid is acrylic acid, methacrylic acid, or a combination thereof. In some embodiments, the unsaturated carboxylic acid is acrylic acid, hi some embodiments, the unsaturated carboxylic acid is methacrylic acid.
[0112] In one embodiment at least a portion of the particles in the latex comprise a copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid In another embodiment at least a portion of the particles in the latex comprise a copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid.
[0113] hi some embodiments, the acrylonitrile content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80. In some embodiments, the acrylonitrile content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the acrylonitrile content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the acrylonitrile content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 10% and about 50%, between about 20% and about 40%, between about 20% and about 30%, between about 25% and about 35%, between about 25% and about 30%, between about 30% and about 35%, or between about 35% and about 45%.
[0114] In some embodiments, the butadiene content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80. In some embodiments, the butadiene content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the butadiene content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the butadiene content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 60% and about 80%, between about 60% and about 70%, between about 10% and about 50%, between about 20% and about 40%, between about 25% and about 35%, between about 25% and about 30%, between about 30% and about 35%, or between about 35% and about 45%.
[0115] hi some embodiments, the cm-1,4 content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40. In some embodiments, the cm-1,4 content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the cm-1,4 content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the cm-1,4 content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 5% and about 40%, between about 10% and about 30%, between about 15% and about 25%, or between about 20% and about 25%. In some embodiments, the trans-\A content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50. In some embodiments, the trans-\,4 content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, the trans-\,^ content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the trans-1,4 content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 5% and about 50%, between about 10% and about 45%, between about 30% and about 45%, or between about 35% and about 45%. In some embodiments, the 1,2-addition content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 30, 25, 20, 15, 10, or 5. Tn some embodiments, the 1,2-addition content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 30, 25, 20, 15, 10, or 5. In some embodiments, the 1,2-addition content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the 1,2-addition content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 5% and about 30%, between about 10% and about 20%, between about 10% and about 15%.
[0116] hr some embodiments, the unsaturated carboxylic acid content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, 7, 7.2, 7.4, 7.6, 7.8, 8, 8.2, 8.4, 8.6, 8.8, 9, 9.2, 9.4, 9.6, 9.8,10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80. In some embodiments, the unsaturated carboxylic acid content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 9.8, 9.6, 9.4, 9.2, 9, 8.8, 8.6, 8.4, 8.2, 8, 7.8, 7.6, 7.4, 7.2, 7, 6.8, 6.6, 6.4, 6.2, 6, 5.8, 5.6, 5.4, 5.2, 5, 4.8, 4.6, 4.4, 4.2, 4, 3.8, 3.6, 3.4, 3.2, 3, 2.8, 2.6, 2.4, 2.2, 2, 1.8, 1.6, 1.4, 1.2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, orO.l. In some embodiments, the unsaturated carboxylic acid content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e g., the unsaturated carboxylic acid content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 0.1 % and about 20%, between about 0.1% and about 10%, between about 1% and about 9%, between about 2% and about 8%, between about 3% and about 7%, or between about 5% and about 15%.
[0117] In some embodiments, the carboxylic acid group content (in % w / w) of the copolymer, in the latex or the latex composition, is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, 7, 7.2, 7.4, 7.6, 7.8, 8, 8.2, 8.4, 8.6, 8.8, 9, 9.2, 9.4, 9.6, 9.8, or 10. In some embodiments, the carboxylic acid group content (in % w / w) of the copolymer, in the latex or the latex composition, is less than about: 10, 9.8, 9.6, 9.4, 9.2, 9, 8.8, 8.6, 8.4, 8.2, 8, 7.8, 7.6, 7.4, 7.2, 7, 6.8, 6.6, 6.4, 6.2, 6, 5.8, 5.6, 5.4, 5.2, 5, 4.8, 4.6, 4.4, 4.2, 4, 3.8, 3.6, 3.4, 3.2, 3, 2.8, 2.6, 2.4, 2.2, 2, 1.8, 1.6, 1.4, 1.2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In some embodiments, carboxylic acid group content (in % w / w) of the copolymer, in the latex or the latex composition, is in a range provided by any two of the previously described upper and / or lower amounts, e.g., the carboxylic acid group content (in % w / w) of the copolymer, in the latex or the latex composition, is between about 0.1 % and about 10%, between about 1% and about 9%, between about 2% and about 8%, between about 3% and about 7%, or between about 5% and about 15%.
[0118] hr some embodiments, the latex or latex composition comprises particles of the copolymer.
[0119] In some embodiments, at least a portion of the particles (for example about or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%), of the copolymer, in the latex or the latex composition, have a size (in A) of about, or greater than about: 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700 or 1800. In some embodiments, at least a portion of the particles (for example about or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%), of the copolymer, in the latex or the latex composition, have a size (in A) less than about 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 200 or 100. In some embodiments, at least a portion of the particles (for example about or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%), of the copolymer, in the latex or the latex composition, have a size (in A) in a range provided by any two of the previously described upper and / or lower amounts, e.g. at least a portion of the particles of the copolymer, in the latex or the latex composition, have a size (in A) between about 800 and about 1800, between about 900 and about 1700, between about 1000 and about 1600, or between about 1100 and about 1500. The person skilled in the art will appreciate that particle size may be determined one of any number of methods known in the art, for example a light scattering or dynamic light scattering method such as laser light scattering method. Particle size may be determined according to a recognised standard, e.g. ISO 22412:2017. Any suitable particle size analyser may be used, e.g. the NICOMP N3000.
[0120] In some embodiments, at least a portion of the particles in the latex are crosslinked, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95, or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the particles in the latex comprise intra-particle crosslinking, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the particles in the latex comprise inter-particle crosslinking, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the particles in the latex comprise both inter-particle crosslinking and intra-particle crosslinking, for example about or at least about (in %): 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95; or less than about (in %): 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In some embodiments, at least a portion of the intra-particle crosslinking and / or the inter-particle crosslinking, in the latex comprises sulfur crosslinks. In some embodiments, at least a portion of the intra-particle crosslinking and / or the inter particle crosslinking, in the latex, does not comprise sulfur crosslinks The “%”, may be a numerical fraction, w / w% or w / v%. In one embodiment, at least a portion of intra and / or inter crosslinking, in the latex, may be a result of the introduction of a crosslinking agent, for example, one or more salts, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide. In some embodiments, a portion of the crosslinking agent, optionally added to the latex, may be incorporated into at least a portion of crosslinks in particles in a latex as described herein.
[0121] In one or more embodiments, about, at least, or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% of the particles in the latex, are pre-vulcanized, for example pre-vulcanized to introduce intra-particle crosslinks such as sulfur crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%.
[0122] In one or more embodiments, less than, or less than about: 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, or 5%, of the particles in the latex, are pre-vulcanized, for example to introduce intra-particle crosslinks, such as sulfur crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%.
[0123] In one or more embodiments the sulfur crosslinking, for example intra and / or inter particle crosslinking, in the latex, may comprise, mono-sulfidic, di-sulfidic, and / or poly-sulfidic crosslinks. Herein, the poly-sulfidic crosslinks comprise at least 3 sulfur atoms. In yet another embodiment, about, at least, or at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% of the intra- and / or inter particle crosslinking, in the latex, comprises mono-sulfidic, di-sulfidic, and / or poly-sulfidic crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%
[0124] In some embodiments, the copolymer or the particles of the latex or latex composition comprise crosslinking, optionally ionic crosslinking, between at least a portion of unsaturated carboxylic acid units in the copolymer of the particles of the latex. There is no particular limitation on crosslinkers that may be used to effect the crosslinking, optionally ionic crosslinking. Suitable examples include, but are not limited to, salts, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide. At least a portion or a fragment of a crosslinking agent may be incorporated into a crosslink unit in one or more particles (for example in at least a portion of intra and / or inter particle crosslinking).
[0125] In some embodiments crosslinking in the latex may occur between two or more functional groups (such as a carbonyl group or an alkene group), present on the same copolymer chain, two or more different functional groups on two or more different copolymer chains, or between two or more particles, following the introduction of a crosslinking agent.
[0126] hi some embodiments, the particles comprise intra-particle and / or inter-particle crosslinking, optionally comprising sulfur crosslinks and / or ionic crosslinks between at least a portion of unsaturated carboxylic acid units (e.g. acrylic acid units), of the particles of the latex.
[0127] The latex or latex composition may further comprise sufficient and / or additional water, optionally deionised water, to yield a solids content in the range of about 40% to about 70% by weight. Tn some embodiments, the total solid content of the latex is in a range of about 40% to about 60%. In some embodiments, the total solid content of the latex is in a range of about 40% to about 55%. In some embodiments, the total solid content of the latex is in a range of about 55% to about 60%. In some embodiments, the total solid content of the latex is in a range of about 41% to about 55%. In some embodiments, the total solid content of the latex is in a range of about 44% to about 46%. In some embodiments, the total solid content of the latex is in a range of about 43.5% to about 45.5%. In some embodiments, the total solid content of the latex is in a range of about 44.5% to about 45.5%. In some embodiments the solid content of the latex, may be, or be modified to be, about or at least about (in %): 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or 70. In some embodiments the solid content of the latex, may be, or be modified to be, less than about: 70, 69, 68, 67, 66, 65, 64, 63, 62, 61, 60, 59, 58, 57, 56, 55, 54, 53, 52, 51, 50, 49, 48, 47, 46, 45, 44, 43, 42, 41, or 40., about (in %). Tn some embodiments, the solid content of the latex (in %),may be in a range provided by any two of the previously described upper and / or lower amounts. The “%”, may be a numerical fraction, w / w% or w / v%.
[0128] In some embodiments, the pH of the latex is in a range of about 6 to about 12, about 9 to about 11, about 8 to about 10, or about 8.6 to about 9.3. In some embodiments the pH of the latex or the latex composition is about, at least about, or less than about: 6.00, 6.25, 6.50, 6.75, 7.00, 7.25, 7.50, 7.75, 8.00, 8.25, 8.50, 8.75, 9.00, 9.25, 9.50, 9.75, 10.00, 10.25, 10.50, 10.75, 11.00, 11.25, 11.50, 11.75, or 12.00. In yet another embodiment, the pH is in a range between any of these recited values.
[0129] In some embodiments, the latex comprises a pre-vulcanization composition. In some embodiments, the latex comprises a crosslinking composition, wherein the crosslinking composition does not comprise sulfur, but does comprise crosslinker, which is optionally a metal salt, optionally selected from, but not limited to: a metal oxide or metal halide, or mixtures thereof. In some embodiments, the latex comprises a postvulcanization composition.
[0130] The latex described herein, which may for example be used in the formation of one more polymeric articles, for example a condom as described herein, may have a viscosity (for example, when measured according to e.g. ISO1652-2011) of less than about 150 cps, for example in a range of about 10 to about 120 cps, in a range of about 10 to about 90 cps, in a range of about 15 to about 60 cps, or in a range of about 20 to about 30 cps. In some embodiments, the latex has a viscosity (in cps), of less than about: 150, 140, 130, 120, 100, 90, 80, 70, 60, 50, 40, 30, 20 or 10 (for example when measured according to ISO1652-2011).
[0131] The latex described herein may comprise residual solvent, for example one or more organic solvents used in the formation of an article, such as a condom (e.g., a male condom). In one embodiment the rubber comprises less than, or less than about: 1500 ppm, 1250 ppm, 1000 ppm, 750 ppm, 500 ppm, 250 ppm, 100 ppm, or 50 ppm, of one or more solvents. In some embodiments, the latex further comprises at least one component selected from, but not limited to: an activator, a crosslinking agent, a curative, a mono-sulfidic donor, a disulfidic donor, a polysulfidic donor, an anti-oxidant and / or an anti-ozonant, a surfactant, a rheology-modifier, a pH adjuster, a pigment, a processing agent, a filler, or a mixture thereof. Optionally, the aqueous latex compositions may further comprise one or more thickeners (for example a cellulose such as hydroxyethyl cellulose) and / or stabilisers / surfactants. In another embodiment, one or more heat sensitising agents may be used. In another embodiment, the latex does not substantially comprise a heat sensitising agent. Tn another embodiment, the latex does not comprise a heat sensitising agent. Tn another embodiment, the latex comprises no more than 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.1 ,or 0.01% (w / w) of heat sensitising agents. Colourants and / or pigments may optionally be added to the aqueous latex compositions. In some embodiments, the latex further comprises and / or consists of at least one, two, three, four, five, six, seven, eight, nine or ten components selected from an activator, a crosslinking agent, a curative, a mono-sulfidic donor, a disulfidic donor, a polysulfidic donor, an anti-oxidant and / or an antiozonant, a surfactant, a rheology-modifier, a pH adjuster, a pigment, a processing agent, a filler, thickeners, stabilisers, surfactants, colourants, pigments, or a mixture thereof, optionally wherein one or more components are selected from the group consisting of lauramidopropyl betaine, sodium lauriminodipropionate, sulfated oleic acid, polyether-modified siloxanes, ammonium hydroxide, potassium hydroxide, zinc oxide, sulfur, zinc diethyldithiocarbamate (ZDEC), sodium dibuthyl dithiocarbamate (SDBC), butylated reaction products of p-cresol & dicyclopentadiene, and / or mixtures thereof. Methods of Forming a Condom
[0132] The present disclosure also provides for a method of forming an article, for example a condom, the method comprising crosslinking a latex according to any one of the aspects, embodiments or examples described herein. In one embodiment, the crosslinking comprises steps to introduce at least one of intra-particle crosslinking and / or inter-particle crosslinking in a latex as defined herein. In one embodiment the method comprises one or more steps to introduce only inter-particle crosslinking, in the formation of the article, for example a condom. Tn another embodiment the method comprises one or more steps to introduce both intra-particle and inter-particle crosslinking, in the formation of the article, for example a condom.
[0133] In one embodiment, a crosslinking step comprises the instruction of at least one crosslinking agent. In another embodiment, 1 or 2 different crosslinking agents are used for intra and / or inter-particle crosslinking. In another embodiment, more than 2 crosslinking agents are used for intra and / or inter-particle crosslinking. The at least one crosslinking agent may be a salt, for example a metal salt, such as a metal halide such as calcium halide, zinc halide or copper halide, or a metal oxide, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide. In some embodiments, a portion of the at least one crosslinking agent may be incorporated into at least a portion of crosslinks in a particle and / or article as described herein. The at least one crosslinking agent may comprise sulfur. Examples of cross-linking agents comprising sulfur include, but are not limited to: elemental sulfur, mono-sulfidic donors, disulfidic donors, such as tetramethyl thiuram disulfide and tetraethyl thiuram disulfide; and / or polysulfidic donors, such as xanthogen polysulfide and dipentamethylene thiuramtetrasulfide, and mixtures thereof.
[0134] In some embodiments of the method, the condom is formed: - using one or more crosslinkers, wherein each of the one or more crosslinkers do not comprise sulfur, and cured in a curing step; or - using no pre-vulcanisation step and a post-vulcanisation step only; or - using a pre-vulcanization step and a post-vulcanization step.
[0135] In some embodiments, at least a portion of the intra-particle crosslinking and / or the inter-particle crosslinking does not comprise sulfur crosslinks. The “%”, may be a numerical fraction, w / w% or w / v%.
[0136] In one or more embodiments, at least a portion of the particles are bonded to each other by inter-particle sulfur-crosslinks. In one or more embodiments, the intraparticle sulfur-crosslinks and the inter-particle sulfur crosslinks are uniform or substantially unform in the polymeric articles.
[0137] Herein, the method may further comprise the introduction of a composition comprising at least one conventional emulsion additives, such as: stabilisers, pH control agents, antioxidants, and preservatives, etc.
[0138] Herein the method may comprise the introduction of a non-sulfur containing crosslinker before a curing step. There is no particular limitation on cross-linkers that may be used to effect the crosslinking, optionally ionic crosslinking Suitable examples include, but are not limited to, salts, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide.
[0139] In one embodiment, the method comprises a curing step. For example, the method does not comprise the use of sulfur (e.g. in a pre-vulcanization or postvulcanization step), for example as a crosslinking agent.
[0140] In one embodiment the method comprises a pre-vulcanization step. In another embodiment, the method comprises a post-vulcanization step. In another embodiment the method comprises a pre-vulcanization step and a post-vulcanization step. In yet another embodiment the method comprises only a post-vulcanization step.
[0141] In one or more embodiment, the method may further comprise the introduction of a pre-vulcanization composition and / or a post-vulcanization composition, optionally along with conventional emulsion additives, such as stabilisers, pH control agents, antioxidants, and preservatives, etc. Tn one embodiment the method comprises the introduction of a pre-vulcanization composition and a post-vulcanization composition. In another embodiment, the method comprises the introduction of only a pre-vulcanizing composition. In another embodiment, the method comprises the introduction of only a post-vulcanizing composition.
[0142] A typical XNBR latex composition is provided in terms of 100 parts by weight of dry rubber (PHR), wherein the “rubber” comprises the copolymer as described herein. During compounding, the components of the latex composition may be suspended in water.
[0143] In one embodiment of method as described herein, the pH of a latex is in a range of about 6 to about 12, or about 8 to about 10, or about 8.6 to about 9.3. In some embodiments the pH of the latex or the latex composition is about, at least about, or less than about: 6.00, 6.25, 6.50, 6.75, 7.00, 7.25, 7.50, 7.75, 8.00, 8.25, 8.50, 8.75, 9.00, 9.25, 9.50, 9.75, 10.00, 10.25, 10.50, 10.75, 11.00, 11.25, 11.50, 11.75, or 12.00. In yet another embodiment, the pH is in a range between any of these recited values.
[0144] In one embodiment, a pH adjustor may be used / present, for example ammonium hydroxide and / or potassium hydroxide. In another embodiment no pH adjustors are used / present. In another embodiment one or more pH adjustors may be present in an amount of greater than 0 but less or equal to about 5 PHR, for example in a range of (PHR) greater than 0, but present in an amount equal to, equal to about, at least or at least about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3..0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5.0. In yet another embodiment, tire pH adjustor is present in a range between any of these recited values.
[0145] For the methods disclosed herein (for example in a pre-vulcanizing composition) sulfur may be present in the range of about 0.1 to about 2 PHR, for example about 0.6 to about 1.8 PHR, or about 0.6 to about 1.2 PHR. In one embodiment, sulfur may be present (for example in a pre-vulcanizing composition) in an amount (PHR) equal to, equal to about, at least or at least about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0. In yet another embodiment, sulfur may be present (for example in a pre-vulcanizing composition), in an amount in a range between any of these recited values.
[0146] hi one embodiment, a pre-vulcanizing composition is not used, and instead an alternative crosslinking system is used. This alternative crosslinking system may comprise one or more salts, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide.
[0147] Herein, an accelerator package may include at least one of: zinc diethyldi thiocarbamate (ZDEC) and / or zinc dibutyldithiocarbamate (ZDBC) accelerator, and / or sodium dibutyldithiocarbamate (SDBC) accelerator, a diisopropyl xanthogen polysulfide (DIXP) accelerator and / or a dipentamethylene thiuramtetrasulfide (DPTT) accelerator. The total accelerator content (for example in a pre-vulcanizing or post-vulcanizing composition), may be in the range of about 0.6 to about 2.5 PHR. One or more accelerators may be present. In one embodiment, the total accelerator content (for example in a pre-vulcanizing composition) is in an amount (PHR) equal to, equal to about, at least or at least about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, or 2.5. In yet another embodiment, the total accelerator content (for example in a pre-vulcanizing composition) is in an amount in a range between any of these recited values.
[0148] The pre-vulcanizing composition may comprise a zinc oxide activator. In some embodiments, the pre-vulcanisation composition comprises sulfur, an accelerator and zinc oxide. In some embodiments, the post-vulcanisation composition comprises sulfur, an accelerator and zinc oxide. In some embodiments, both the pre- and postvulcanisation composition comprise sulfur, an accelerator and zinc oxide.
[0149] For the methods described herein, one or more anti-oxidants and / or antiozonants may be used (for example in a pre-vulcanizing composition). For example, one or more anti-oxidants and / or anti-ozonants in a range of about 0.1 to about 1.5 PHR, for example in an amount (PHR) equal to, equal to about, at least, or at least about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5. In yet another embodiment, the total content of the one or more anti-oxidants and / or anti-ozonants is in an amount in a range between any of these recited values.
[0150] For the methods described herein, one or more surfactants may be used (for example in a pre-vulcanization composition). The one or more surfactants may include one or more anionic surface active agents (e.g., a carboxylate, sulfonates, and / or sulfates) and / or non-ionic surface active agents. The surfactant may be a salt of a fatty acid, such as sodium stearate, sodium oleate, or potassium caprylate. Some embodiments comprise more than one surfactant, e.g., potassium caprylate, also known as potassium salt of octanic acid and sodium dodecyl benzene sulfonate (SDBS). Exemplary embodiments include, but are not limited to, compositions comprising a surfactant package comprising: potassium caprylate, sodium dodecyl benzene sulfonate (SDBS) and polyoxyethylene cetyl / stearyl ether in the range of 0.3 to approximately 1.5 PHR. Further examples of suitable surfactants include, but are not limited to: ammonium lauryl sulfate, monosodium n-lauryl-beta-iminodipropionic acid, silicone surfactants (e.g. a polyether modified siloxane) The pre-vulcanization composition may optionally comprise a detackifier, such as an anionic microcrystalline wax emulsion . An antioxidant and preservative package may comprise a butylated reaction product of p-cresol and, optionally, dicyclopentadiene in the range of about 0.3 to about 1.0 PHR. Further suitable examples include, but are not limited to: alkylated phenols and polyphenols. One or more surfactants may be present. In one embodiment, one or more surfactants are present in a range of about 0.3 PHR to about 3.0 PHR, for example about 0.8 PHR to about 1.0 PHR. In one embodiment, the total surfactant content (for example in a prevulcanizing composition), is in an amount (PHR) equal to, equal to about, at least or at least about: 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0. In yet another embodiment, the total surfactant content (for example in a pre-vulcanizing composition), is in an amount in a range between any of these recited values.
[0151] The sulfur in a pre-vulcanizing composition and / or post-vulcanizing composition may be elemental sulfur, for example elemental sulfur comprising a high soluble sulfur content, optionally of the Ss ring structure. For the methods disclosed herein, at least one an accelerator may be used (for example in a pre-vulcanization composition). For example, an accelerator that can break or disrupt the Ss sulfur ring structure is zinc dithiocarbamate. Reference to “high soluble sulfur content” means having enough soluble sulfur present to form sufficient to permeate into latex particles or particles of the copolymer, in an aqueous latex emulsion and crosslink during curing, optionally to achieve commercially acceptable articles, such as condoms, such as a male condom.
[0152] hr one embodiment, the pre-vulcanization of latex particles in the latex may occur over a period of time at a chosen temperature to a desired degree of prevulcanization. The degree of pre-vulcanization at different points after initial compounding of the synthetic latex particles may be monitored by at least one of four tests. An equilibrium-swelling test, which uses any suitable solvent, measures the equilibrium swelling of films dried down from the synthetic latex. A relaxed modulus test gauges the vulcanization of the relaxed modulus at 100% extension (MR100) of films dried down from the dissolved latex. Similarly, a pre-vulcanized relaxed modulus test (PRM) measures the relaxed modulus at 100% extension of the pre-vulcanized films.
[0153] A Swell Index (SI) test may be used to measure the level of crosslinking by immersing the dried casted film sample in an appropriate solvent (e.g. acetone or butanone) and calculate the swollen rate. Other suitable solvents include, but are not limited to: ketones, acetate esters, chlorinated organic compounds, methyl isobutyl ketone, butyl acetate, ethyl butyl acetate, ethyl hexyl acetate, methyl glycol acetate, chlorobutadiene, tetrachloroethylene, benzochloride, benzoyl chloride, benzyl chloride, benzyl di chloride, chlorodiphenyl, monochlorobenzene, o-dichlorobenzene, trichlorobenzene, or a mixture thereof. An exemplified process includes one or more of the following steps: • Casting a film of the compounded latex to produce film thickness of 0.10 - 0.15 mm and dry the film at 50+ / -3 °C for 10 minutes and / or leave the film at ambient temperature until it is fully dried. • Peeling off the film with the powder such as corn starch or calcium carbonate (CaCO i) to prevent the film surface being stick to itself. • Cutting a disc sample with a die cutter. • Submerging the disc film into the solvent for 60 minutes. • Measuring the diameter of the swollen film. • Calculating the % swollen by subtract the original disc diameter from the swollen film diameter and divided by the original film diameter.
[0154] The latex particles may progress from a non-crosslink stage (index >220%), to a partial crosslink stage (index <220%), then to a semi-crosslink stage (index <180%) and finally to a fully crosslink stage (index <100%) as pre-vulcanizing sulfur is incorporated within the particle.
[0155] Compounding methods according to embodiments of the disclosure may include the mixing the latex together with one or more chemical additives and stirring periodically and examining for permeation of pre-vulcanization agents into the latex particles. By way of example, and without limitation, this may be done with an indexing test with a suitable solvent.
[0156] The residual sulfur concentration may be measured by a process known in the art, for example test method UPB / P / 004 by the Rubber Research Institute of Malaysia. The residual sulfur may be in a range of about 0.1% w / w to about 2.0% w / w, or about 0.8% w / w to about 1.5% w / w. For example, the residual sulfur may be present in an amount (% w / w) of, about, at least, or at least about: 00.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0. Tn yet another embodiment, the residual sulfur is present in a range between any of these recited values. Similarly, the residual zinc oxide concentration may be measured by any process known in the art. The residual zinc oxide may be in a range of about 0.1% w / w to about 2.0% w / w, or about 0.8% w / w to about 1.5%. For example, the residual zinc oxide may be present in an amount (% w / w) of, about, at least, or at least about: 00.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or2.0. In yet another embodiment, the residual zinc oxide is present in a range between any of these recited values.
[0157] In one embodiment the introduction of a pre-vulcanization composition can provide sulfur to latex particles in the aqueous synthetic emulsion for pre-vulcanizing the intra-particle regions. During pre-vulcanization, the ring structure of the sulfur can be broken by the catalytic action of the accelerator, e.g., zinc dithiocarbamate, which can penetrate the copolymer particles and initially interacts with the butadiene double bonds therein. In another embodiment, the pre-vulcanization composition does not comprise, sulfur or a sulfur-containing crosslinking age, and optionally comprises a crosslinking agent which is a salt, for example, metal halides such as calcium halide, zinc halide or copper halide, and oxides of metals, for example multivalent metals such as zinc oxide, magnesium oxide and calcium oxide.
[0158] hi one embodiment the pre-vulcanization step comprises exposing a latex to a temperature (in °C) of about, or at least about: 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80. The temperature may be in a range of any two of these values. The exposure to the temperature may be for a period of time of (in hours) of about, or at least about: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47 or 48. The time may be in a range of any two of these times. Alternatively, the exposure to the temperature may be for a period of time of (in days) of about or at least about: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14. The time may be in a range of any two of these times.
[0159] hi one embodiment the post-vulcanization step comprises the introduction of a post-vulcanization composition, which may comprise amorphous or polysulfur, which may be insoluble at a latex emulsion temperature of about 20 to about 40 °C, but may be soluble at a vulcanization or cure temperature, e.g., about 110 to about 150 °C (such as about, or at least about: 110, 115, 120, 125, 130, 135, 140, 145, or 150 °C, or any range there between). The temperature may be about 100 to about 200 °C, for example about or at least about: 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, or 200 °C, or any range there between. The postvulcanization composition may comprise accelerators such as, but not limited to one or more of: zinc diethyldithiocarbamate (ZDEC), zinc dibutyldithiocarbamate (ZDBC), sodium diethyldithiocarbamate (SDEC), sodium dibutyldithiocarbamate (SDBC), a thiuram compound and a xanthogen. Examples of suitable xanthogens include, but are not limited to: diisopropyl xanthogen polysulfide (DIXP), diisopropyl xanthogen, tetraethylthiuram disulfide, and xanthogen sulfide. DIXP is a suitable xanthogen owing to its polysulfidic donor properties. The post-vulcanization composition may further comprise a thiuram accelerator. An example of a polysulfidic thiuram accelerator is dipentamethylene thiuramtetrasulfide (DPTT). Another example of a thiuram compound is tetrabenzyl thiuram disulfide. Zinc oxide may also be added as an activator.
[0160] For the methods described herein a curing or post-vulcanization step may provide the ability to crosslink regions between the particles or inter-particle regions thereby assuring a high quality substantially uniformly cured copolymer product.
[0161] For the methods described herein, a curing step (for example for methods that do not comprise the use of sulfur as a crosslinking agent), may comprise the activation of inter-particle cross-linking at a temperature of about 100 °C to about 150 °C, or about 110 °C to about 140 °C, or about 120 °C to about 130 °C (such as about, or at least about: 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, or 150 °C, or any range there between). The curing can result in a more homogeneous latex coating having greater strength and / or elongation properties. The composition produced may be stable for up to approximately 5 days at 20 °C to 25 °C and may be useful for a production line.
[0162] For the methods described herein, a post-vulcanization step may comprise the activation of inter-particle cross-linking at a temperature of about 100 °C to about 150 °C, or about 110 °C to about 140 °C, or about 120 °C to about 130 °C (such as about, or at least about: 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, or 150 °C, or any range there between). In addition, post-vulcanization processes may also crosslink the copolymer particles with sulfur or another crosslinker. Such post-vulcanization can result in a more homogeneous latex coating having greater strength and / or elongation properties. The composition produced may be stable for up to approximately 5 days at 20 °C to 25 °C and may be useful for a production line. Dipping Conditions
[0163] The present disclosure further provides a method of forming a polymeric article comprising one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid. The method comprises disposing an elastomeric coating of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid on a former and curing the elastomeric coating to form an elastomeric layer of the polymeric article. The disposing step may comprise dipping a coagulant-free or coagulant coated former in an emulsion of the copolymer, which may be an aqueous latex composition, optionally having pre-vulcanized particles, at least once to form a thin layer of latex or elastomeric coating with individual particles of pre-vulcanized copolymer on the surface of the former. The former can be any suitable former as is known in the art, for example a former comprising or consisting of steel, glass, a ceramic, PVC or another appropriate material known in the art. The present inventive composition is particularly useful for layering onto fonners for condoms.
[0164] The method of dipping for the condoms using the copolymer latex composition may be within a 5-day (the average lifetime of copolymer latex emulsion tank), 7-day, 14-day, 28-day period or even longer. In one embodiment, a condom former is dipped in the composition in a first dip. The wall thickness of the latex coating is controlled by, inter alia, the viscosity of latex, which is a function of the total solids content of the composition in the dip tank. The speed of movement of the formers while dipping can also effect the wall thickness. The latex coating that coats the formers is dried at an appropriate temperature, for example about 70 to about 90 °C for an appropriate period of time, for example about 1 to about 3 minutes. The latex coating on the former is, optionally, dipped again into the composition to apply a second dip coating. The latex coating after the second dip is dried at an appropriate temperature, for example about 70 to about 90 °C for an appropriate period of time, for example about 1 to about 3 minutes. The open end of the condom may then be rolled to create a bead ring, which is distal to a tip of a closed end of the condom. Accordingly, in some embodiments the layer thickness is controlled by adapting at least one of: the viscosity of the latex; the total solid content of the latex; the speed of the former in a dip tank, or a mixture thereof.
[0165] hr some embodiments, the method comprises a step of: • dipping a condom former into the latex at least once, to coat a layer of the latex onto the condom former.
[0166] hi some embodiments, the method comprises a step of: • dipping a condom former into the latex at least twice, to coat a layer of the latex onto the condom former, with an optional drying step after each dipping step.
[0167] In some embodiments, after at least one dip a formed layer is dried in a drying step, optionally at a temperature in a range of about 50 °C to about 110 °C, about 60 °C to about 90 °C, about 70 °C to about 90 °C, or about 70 °C to about 80 °C. For example, the temperature (°C), can be about or at least about: 50, 52.5, 55, 57.5, 60, 62.5, 65, 67.5, 70, 72.5, 75, 77.5, 80, 82.5, 85, 87.5, 90, 92.5, 95, 97.5, 100, 102.5, 105, 107.5, or 110. In yet another embodiment, the temperature is in a range between any of these recited values.
[0168] In some embodiments, the drying step occurs after each dip, optionally at a temperature in a range of about 50 °C to about 110 °C, about 60 °C to about 90 °C, about 70 °C to about 90 °C, or about 70 °C to about 80 °C. For example, the temperature (°C), can be about or at least about: 50, 52.5, 55, 57.5, 60, 62.5, 65, 67.5, 70, 72.5, 75, 77.5, 80, 82.5, 85, 87.5, 90, 92.5, 95, 97.5, 100, 102.5, 105, 107.5, or 110. In yet another embodiment, the temperature is in a range between any of these recited values.
[0169] In some embodiments, the method comprises a step of beading and / or ring formation on an open end of the condom.
[0170] The coating can be post-vulcanized by heating the coating to an appropriate temperature, for example about 100 to about 150 °C for an appropriate period of time. For example, the temperature (°C), can be about or at least about: 90, 92.5, 95, 97.5, 100, 102.5, 105, 107.5, 110, 112.5, 115, 117.5, 120, 122.5, 125, 127.5, 130, 132.5, 135, 137.5, 140, 142.5, 145, 147.5, or 150. In yet another embodiment, the temperature is in a range between any of these recited values. The temperature may be about 100 to about 200 °C, for example about or at least about: 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, or 200 °C, or any range there between. The appropriate period of time may be about 10 minutes to about 15 minutes, in order to form a layer, for example an elastomeric layer, of a condom. During this period, the inter-particle regions can be cross-linked. The intra-particle regions can also undergo further crosslinking, producing a more homogeneous latex product. The condom is optionally leached in water at approximately 70 °C to 80 °C for about 1 to about 2 minutes to remove residual surfactants and cross-linking agents from the condom. Thus, in some embodiments, the method comprises a step of leaching. The condom may optionally be dipped into a silica dispersion. The condom may then be stripped from the former. Optionally, the stripping is dry stripping with a brush. Optionally, the stripping is wet stripping, optionally with a water jet. The latex articles, such as condoms, produced can potentially display higher strength and improved stretch. Thus, in some embodiments, the method comprises a step of stripping of the condoms from the former. The stripping may be dry stripping, or wet stripping. The copolymer articles are free from irritation-causing proteins that cause latex sensitivity issues.
[0171] Some embodiments according to the present disclosure may comprise the use of a coagulant solution to wet the former and may include an exemplary aqueous solution of 5% calcium nitrate, although other concentrations are possible as are known to those in the art, such as an aqueous solution ranging in concentration from 6-40% calcium nitrate. Other salts, such as calcium chloride, calcium citrate, aluminium sulfate, and the like and / or mixtures thereof may be used. Furthermore, the coagulant solution may be aqueous, alcoholic, or a mixture of aqueous and alcoholic solutions / solvents. Weaker acid solutions may also be used as coagulants, such as formic acid, acetic acid, and other low pKa acids (for example an acid with a pKa in a range of about 3 to about 7), as are known to those in the art. In some embodiments, there is no coagulate used.
[0172] Embodiments according to the disclosure may comprise the use of prevulcanizing and post-vulcanizing methods, the technology of which is disclosed in commonly-assigned US Patent Nos. 8,087,412; 8,464,719; 9,725,539; and 10,538,609 which are incorporated by reference in entirety. Coaling
[0173] In some embodiments, the method comprises a step of applying a coating material or at least one compound or composition to the condom. In some embodiments, the coating material, compound or composition is applied by at least one of: spraying, dipping, sponging, rolling, dosing, or a mixture thereof. Suitable coating materials, compounds or compositions for application to the condom include anti- viral, anti-microbial, anti-fungal, vasodilator, benzocaine, flavour, scent, active ingredient, warming liquid or gel, sensitizing agent, desensitizing agent, spermicide, lubricant, or mixtures thereof. In some embodiments, the method further comprises a step of disposing at least one lubricant, in or on at least a portion of the condom. In some embodiments, the method further comprises a step of disposing at least one sensitizing agent, in or on at least a portion of the condom. In some embodiments, the method further comprises a step of disposing at least one desensitizing agent, in or on at least a portion of the condom. In some embodiments, the method further comprises a step of disposing at least one flavour, in or on at least a portion of the condom. In some embodiments, the method further comprises a step of disposing at least one scent, in or on at least a portion of the condom. In some embodiments, the method further comprises a step of disposing at least one spermicide, in or on at least a portion of the condom. In some embodiments, the method further comprises a step of disposing at least one warming liquid or gel, in or on at least a portion of the condom.
[0174] In some embodiments, the method further comprises a step of placing the condom in packaging, optionally a foil packaging
[0175] In some embodiments, the method provides a condom according to any aspect, embodiment, or example described herein.
[0176] In some embodiments, the method provides a condom comprising a tubular shaft having a tip on a closed end of the tubular shaft and an open end opposite the closed end on the tubular shaft. EXAMPLE EMBODIMENTS
[0177] The following are Example Embodiments according to the various aspects described herein: 1. A polymeric article, comprising one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid. 2. The polymeric article according to Example Embodiment 1, wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof. 3. The polymeric article according to Example Embodiment 1 or Example Embodiment 2, wherein the unsaturated carboxylic acid is selected from the group consisting of: methacrylic acid, acrylic acid, or a mixture thereof. 4. The polymeric article according to any one of the preceding Example Embodiments, wherein the unsaturated carboxylic acid is acrylic acid. 5. The polymeric article according to any one of the preceding Example Embodiments, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid. 6. The polymeric article according to any one of the preceding Example Embodiments, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid. 7. The polymeric article according to any one of the preceding Example Embodiments, wherein the article is a condom, optionally a male condom. 8. The polymeric article according to any one of the preceding Example Embodiments, wherein the acrylonitrile content of the copolymer (in % w / w), is in a range of about 10% to about 50%, optionally about 20% to about 40%. 9. The polymeric article according to any one of the preceding Example Embodiments, wherein the carboxylic acid group content of the copolymer (in % w / w) is in a range of about 0.1% to about 10%, optionally about 1% to about 8%, optionally about 3% to about 7%. 10 The polymeric article according to any one of the preceding Example Embodiments, wherein at least two portions of the copolymer, or two or more copolymer chains, are crosslinked, optionally via two more carbonyl units. 11. The polymeric article according to any one of the preceding Example Embodiments, wherein the one or more layers comprise particles of the copolymer. 12. The polymeric article according to Example Embodiment 10, wherein at least a portion of the particles have a size in the range of about 800 A to about 1800 A, optionally in a range of about 1100 A to about 1500 A. 13 The polymeric article according to Example Embodiment 11 or Example Embodiment 12, wherein at least a portion of the particles are pre-vulcanized, post-vulcanized or cured synthetic particles. 14. The polymeric article according to any one of Example Embodiments 11 to 13, wherein at least a portion of the particles are crosslinked, optionally ionic crosslinking, and optionally between two or more functional groups present on the same or different copolymers and / or particles. 15. The polymeric article according to Example Embodiment 14, wherein the functional groups are carboxylic acid units or alkene units. 16. The polymeric article according to any one of Example Embodiments 11 to 15, wherein at least a portion of the particles comprise intra-particle crosslinking. 17. The polymeric article according to any one of Example Embodiments 11 to 16, wherein at least a portion of the particles comprise inter-particle crosslinking. 18 The polymeric article according to any one of Example Embodiments 11 to 17, wherein at least a portion of the particles comprise intra-particle crosslinking and interparticle crosslinking. 19. The polymeric article according to any one of Example Embodiments 16 to 18, wherein the intra-particle crosslinking and / or the inter-particle crosslinking comprises sulfur crosslinks. 20. The polymeric article according to any one of Example Embodiments 16 to 18, wherein at least a portion of the intra-particle and / or inter-particle crosslinking does not comprise sulfur crosslinks. 21. The polymeric article according to any one of the preceding Example Embodiments, wherein the polymeric article has a thickness in the range of from about 20 pm to about 100 pm, optionally in a range of about 20 pm to about 80 pm, about 20 pm to about 60 pm, about 20 pm to about 40 pm, or about 20 pm to about 30 pm. 22 The polymeric article according to any one of the preceding Example Embodiments, wherein at least one layer of the polymeric article or the polymeric article comprises a crosslinked structure, optionally a cured or post-vulcanised structure, having a molecular weight between crosslinks (Mc) of: less than about 6000, 5500, 5000, 4500, 4000, 3500, 3000, 2500, 2000, 1950, 1900, 1850, 1800, 1750, 1700, 1650, 1600, 1550, 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1150, 1100, 1050, 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 200, 150 or 100 g / mol. 23. The polymeric article according to any one of the preceding Example Embodiments, wherein at least one: anti- viral, anti-microbial, anti-fungal, vasodilator, benzocaine, flavour, scent, active ingredient, warming liquid or gel, sensitizing agent, desensitizing agent, spermicide, lubricant, or mixture thereof is disposed on or in at least a portion of the polymeric article. 24. The polymeric article according to any one of the preceding Example Embodiments, wherein at least one lubricant, optionally selected from the group consisting of: oilbased lubricants, silicon based-lubricants, water-based lubricants, or a mixture thereof, is disposed on or in at least a portion of the polymeric article. 25. The polymeric article according to any one of the preceding Example Embodiments, wherein the polymeric article has a burst pressure in a range of about 1 kPa to about 3 kPa, when measured according to ISO 23409:2011, IS04074:2015, and / or ASTM D3492-16. 26. The polymeric article according to any one of the preceding Example Embodiments, wherein the polymeric article has a burst volume in a range of about 5 L to about 15 L, when measured according to TSO 23409:2011, TS04074:2015, and / or ASTM D3492-16 27. The polymeric article according to any one of the preceding Example Embodiments, wherein the polymeric article has a force at break in a range of about 10 N to about 30 N, when measured according to ISO 23409:2011, 1804074:2015, and / or ASTM D3492-16. 28. The polymeric article according to any one of the preceding Example Embodiments, wherein the polymeric article has a tensile strength in a range of about 5 MPa to about 30 MPa, when measured according to 1804074:2015, and / or ASTM D3492-16. 29. The polymeric article according to any one of the preceding Example Embodiments, wherein the polymeric article has an elongation at break in a range of about 250% to about 750%, when measured according to 1S04074:2015, and / or ASTM D3492-16. 30. The polymeric article according to any one of the preceding Example Embodiments, wherein the condom is compatible with at least one lubricant or oil selected from the group consisting of: a silicon lubricant, a hydrocarbon petroleum-based oil, vegetable oil, or a mixture thereof 31. A condom comprising: • a tubular shaft having a tip on a closed end of the tubular shaft and an open end opposite the closed end on the tubular shaft; and • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid. 32. A condom comprising: • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid, wherein the condom is a male condom. 32A. A condom comprising particles of a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid that are pre-vulcanized and cured, wherein the particles are bonded to each other through intra-particle crosslinks and inter-particle crosslinks, wherein the intra-particle crosslinks and the inter-particle crosslinks are optionally substantially uniform in the condom. 32B A condom comprising: • one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid, wherein the condom is optionally a male condom and the copolymer comprises less than 10 % w / w of the unsaturated carboxylic acid. 33 The condom according to Example Embodiment 31, Example Embodiment 32, Example Embodiment 32A or Example Embodiment 32B,wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof. 34. The condom according to any one of Example Embodiments 31 to 33, wherein the unsaturated carboxylic acid is methacrylic acid, acrylic acid, or a mixture thereof. 35. The condom according to any one of Example Embodiments 31 to 34, wherein the unsaturated carboxylic acid is acrylic acid. 36. The condom according to any one of Example Embodiments 31 to 35, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid. 37. The condom according to any one of Example Embodiments 31 to 34, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid. 38 The condom according to any one of Example Embodiments 31 to 37, wherein the acrylonitrile content of the copolymer (in % w / w) is in a range of about 10% to about 50%, optionally about 20% to about 40%. 39. The condom according to any one of Example Embodiments 31 to 38, wherein the carboxylic acid group content of the copolymer (in % w / w) is in a range of about 0.1% to about 10%, optionally about 1% to about 8%, optionally about 3% to about 7%. 40. The condom according to any one of Example Embodiments 31 to 39, wherein the one or more layers comprise particles of the copolymer. 41 The condom according to any one of Example Embodiments 31 to 40, wherein the one or more layers comprise particles of the copolymer wherein at least a portion of the particles have a size in the range of about 800 A to about 1800 A, optionally in a range of about 1100 A to about 1500 A. 42. The condom according to Example Embodiment 40 or Example Embodiment 41, wherein the particles are pre-vulcanized cured synthetic particles. 43. The condom according to any one of Example Embodiments 40 to 42, wherein at least a portion of the particles are crosslinked, optionally ionic crosslinking, and optionally between two or more functional groups present on the same or different copolymers and / or particles. 44. The condom according to Example Embodiment 43, wherein the functional groups are carboxylic acid units or alkene units. 45 The condom according to any one of Example Embodiments 40 to 44, wherein at least a portion of the particles comprise intra-particle crosslinking 46. The condom according to any one of Example Embodiments 40 to 45, wherein at least a portion of the particles comprise inter-particle crosslinking. 47. The condom according to any one of Example Embodiments 40 to 46, wherein at least a portion of the particles comprise intra-particle crosslinking and inter-particle crosslinking. 48. The condom according to any one of Example Embodiments 40 to 47, wherein the intra-particle crosslinking and / or the inter-particle crosslinking comprises sulfur crosslinks. 49. The condom according to any one of Example Embodiments 40 to 47, wherein at least a portion of the intra-particle and / or inter-particle crosslinking does not comprise sulfur crosslinks. 50. The condom according to any one of Example Embodiments 31 to 49, wherein the condom has a thickness in the range of from about 20 pm to about 100 pm, optionally in a range of about 20 pm to about 80 pm, about 20 pm to about 60 pm, about 20 pm to about 40 pm. 51. The condom according to any one of Example Embodiments 31 to 49, wherein at least one layer of the condom or the condom comprises a crosslinked structure, optionally a cured or post-vulcanised structure, having a molecular weight between crosslinks (Me) of: less than about 2000, 1950, 1900, 1850, 1800, 1750, 1700, 1650, 1600, 1550, 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1150, 1100, 1050, 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 200, 150 or 100 g / mol. 52. The condom according to any one of Example Embodiments 31 to 51, wherein at least one: anti- viral, anti-microbial, anti-fungal, vasodilator, benzocaine, flavour, scent, active ingredient, warming liquid or gel, sensitizing agent, desensitizing agent, spermicide, lubricant, or mixture thereof is disposed on or in at least a portion of the condom. 53. The condom according to any one of Example Embodiments 31 to 52, wherein at least one lubricant, optionally selected from the group consisting of: oil-based lubricants, silicon based-lubricants, water-based lubricants, or a mixture thereof, is disposed on or in at least a portion of the condom. 54. The condom according to any one of Example Embodiments 31 to 53, wherein the condom has a burst pressure in a range of about 1 kPa to about 3 kPa, when measured according to ISO 23409:2011,1804074:2015, and / or ASTM D3492-16. 55 The condom according to any one of Example Embodiments 31 to 53, wherein the condom has a burst volume in a range of about 5 L to about 15 L, when measured according to ISO 23409:2011,1804074:2015, and / or ASTM D3492-16. 56. The condom according to any one of Example Embodiments 31 to 55, wherein the condom has a force at break in a range of about 10 N to about 30 N, when measured according to ISO 23409:2011,1804074:2015, and / or ASTM D3492-16. 57. The condom according to any one of Example Embodiments 31 to 56, wherein the condom has a tensile strength in a range of about 5 MPa to about 30 MPa, when measured according to 1804074:2015, and / or ASTM D3492-16. 58. The condom according to any one of Example Embodiments 31 to 57, wherein the condom has an elongation at break in a range of about 250% to about 750%, when measured according to 1804074:2015, and / or ASTM D3492-16. 59. The condom according to any one of Example Embodiments 31 to 58, wherein the condom is compatible with at least one lubricant or oil selected from the group consisting of: a silicon oil or lubricant, a hydrocarbon petroleum-based oil or lubricant, vegetable oil, or a mixture thereof. 60 A packaged condom comprising the condom according to any one of Example Embodiments 31 to 59. 61. A latex comprising particles of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid. 62. The latex according to Example Embodiment 61, wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof. 63. The latex according to Example Embodiment 61 or Example Embodiment 62, wherein the unsaturated carboxylic acid is methacrylic acid, acrylic acid, or a mixture thereof 64. The latex according to any one of Example Embodiments 61 to 63, wherein the unsaturated carboxylic acid is acrylic acid. 65. The latex according to any one of Example Embodiments 61 to 64, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid. 66. The latex according to any one of Example Embodiments 61 to 64, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid. 67. The latex according to any one of Example Embodiments 61 to 66 when used to produce the polymeric article according to any one of Example Embodiments 1 to 30, or the condom according to any one of Example Embodiments 31 to 60. 68. The latex according to any one of Example Embodiments 61 to 67, wherein the acrylonitrile content of the copolymer (in % w / w) is in a range of about 10% to about 50%, optionally about 20% to about 40%. 69 The latex according to any one of Example Embodiments 61 to 68, wherein the carboxylic acid group content of the copolymer (in % w / w) is in a range of about 0.1% to about 10%, optionally about 1% to about 8%, optionally about 3% to about 7%. 70. The latex according to any one of Example Embodiments 61 to 69, wherein the latex comprises particles of the copolymer. 71. The latex according to any one of Example Embodiments 61 to 70, wherein the latex comprises particles of the copolymer wherein at least a portion of the particles have a size in the range of about 800 A to about 1800 A, optionally in a range of about 1100 A to about 1500 A. 72. The latex according to Example Embodiment 70 or Example Embodiment 71, wherein at least a portion of the particles are pre-vulcanized, post-vulcanized, or cured synthetic particles. 73. The latex according to any one of Example Embodiments 70 to 72, wherein at least a portion of the particles are crosslinked, optionally ionic crosslinking, and optionally between two or more functional groups present on the same or different copolymers and / or particles. 74. The latex according to Example Embodiment 73, wherein the functional groups are carboxylic acid units or alkene units. 75. The latex according to any one of Example Embodiments 70 to 74, wherein at least a portion of the particles comprise intra-particle crosslinking. 76. The latex according to any one of Example Embodiments 70 to 75, wherein at least a portion of the particles comprise inter-particle crosslinking. 77. The latex according to any one of Example Embodiments 70 to 76, wherein at least a portion of the particles comprise intra-particle crosslinking and inter-particle crosslinking. 78. The latex according to any one of Example Embodiments 70 to 77, wherein the intraparticle crosslinking and / or the inter-particle crosslinking comprises sulfur crosslinks. 79. The latex according to any one of Example Embodiments 70 to 78, wherein at least a portion of the intra-particle and / or inter-particle crosslinking does not comprise sulfur crosslinks. 80. The latex according to any one of Example Embodiments 61 to 79, wherein the total solid content of the latex (in % w / w) is in a range of about 40% to about 70%, about 40% to about 60%, about 40% to about 55%, about 50% to about 70%, about 55 % to about 60%, or about 44% to about 46%. 81 The latex according to any one of Example Embodiments 61 to 80, wherein the pH is in a range of about 6 to about 12, optionally in a range of about 8 to about 10, or about 9 to about 11, or about 8.6 to about 9.3. 82. The latex according to any one of Example Embodiments 61 to 81, wherein the latex comprises a pre-vulcanization composition. 83. The latex according to Example Embodiment 82, wherein the pre-vulcanization composition comprises at least one component selected from the group consisting of: sulfur, an accelerator, an activator and mixtures thereof. . 84. The latex according to any one of Example Embodiments 61 to 83, wherein the latex comprises a crosslinking composition, optionally comprising a metal salt, and optionally a metal oxide. 85. The latex according to any one of Example Embodiments 61 to 84, wherein the viscosity of the latex is in a range of about 10 cps to about 120 cps or about 10 cps to about 90 cps, when measured according to TSOI652-2011. 86 The latex according to any one of Example Embodiments 61 to 85, wherein the latex further comprises at least one component selected from the group consisting of: an activator, a crosslinking agent, a curative, a mono-sulfidic donor, a disulfidic donor, a polysulfidic donor, an anti-oxidant and / or an anti-ozonant, a surfactant, a rheologymodifier, a pH adjuster, a pigment, a processing agent, a filler, or a mixture thereof. 87 The latex according to any one of Example Embodiments 61 to 86, wherein the latex further comprises at least one component selected from the group consisting of: a surfactant, an activator, an accelerator, a crosslinker, an antioxidant, and mixtures thereof 88. The latex according to any one of Example Embodiments 61 to 87, wherein the latex does not comprise a coagulant. 89. A method of forming a condom, the method comprising: • crosslinking a latex according to any one of Example Embodiments 61 to 88. 90. The method according to Example Embodiment 89, wherein at least one crosslinking agent is introduced into the latex, wherein the at least one crosslinking agent is a metal salt, is optionally selected from the group consisting of: a metal oxide or metal halide, or mixtures thereof. 91. The method according to Example Embodiment 89 or Example Embodiment 90, wherein at least one crosslinking agent is introduced into the latex, wherein the at least one crosslinking agent comprises sulfur, optionally selected from the group consisting of: elemental sulfur, mono-sulfidic donors, disulfidic donors, tetramethyl thiuram disulfide, tetraethyl thiuram disulfide, polysulfidic donors, xanthogen polysulfide, dipentamethylene thiuramtetrasulfide and mixtures thereof. 92. The method according to any one of Example Embodiments 89 to 91, wherein the method comprises one or more steps to introduce intra-particle crosslinking. 93. The method according to any one of Example Embodiments 89 to 91, wherein the method comprises one or more steps to introduce intra-particle crosslinking and interparticle crosslinking. 94. The method according to any one of Example Embodiments 89 to 93, wherein the condom is a male condom. 95. The method according to any one of Example Embodiments 89 to 94, wherein the method comprises a step of introducing a composition comprising at least one component selected from the group consisting of: stabilisers, pH control agents, antioxidants, and preservatives, and mixtures thereof. 96 The method according to any one of Example Embodiments 89 to 95, wherein the method comprises at least one step selected from the group consisting of: - a pre-vulcanization step; - a post-vulcanization step; and - a pre-vulcanization step and a post-vulcanization step. 97. The method according to any one of Example Embodiments 89 to 96, wherein the method comprises a post-vulcanization step, but does not comprise a pre-vulcanization step. 98 The method according to any one of Example Embodiments 89 to 97, wherein the method comprises a pre-vulcanizing step comprising the of introduction of a prevulcanization composition, optionally comprising at least one component selected from the group consisting of: a sulfur containing crosslinker, an accelerator (optionally ZDEC and / or SDBC), an activator (optionally ZnO), and mixtures thereof. 99. The method according to any one of Example Embodiments 89 to 98, wherein the method comprises a post-vulcanizing step comprising the introduction of a postvulcanization composition, optionally comprising at least one component selected from the group consisting of: a sulfur containing crosslinker, an accelerator (optionally ZDEC and / or SDBC), an activator (optionally ZnO), and mixtures thereof. 100. The method according to any one of Example Embodiments 89 to 99, wherein the method comprises a post-vulcanization step or curing step comprising exposure of a formed condom to temperature of about 100 °C to about 150 °C, or about 110 °C to about 140 °C, or about 120 °C to about 130 °C. 101 The method according to any one of Example Embodiments 89 to 100, wherein the method comprises the step of: • dipping a condom former into the latex at least once, to coat a layer of the latex onto the condom former. 102. The method according to any one of Example Embodiments 89 to 101, wherein the method wherein, the method comprises the step of: • dipping a condom former into the latex at least twice, to coat a layer of the latex onto the condom former, with an optional drying step after each dipping step. 103. The method according to Example Embodiment 89 or Example Embodiment 102, wherein, after at least one dip a formed layer is dried in a drying step, optionally at a temperature in a range of about 60 °C to about 90 °C, or in a range of about 70 °C to about 80 °C. 104 The method according to Example Embodiment 103, wherein the drying step occurs after each dip, optionally at a temperature in a range of about 60 °C to about 90 °C , or in a range of about 70 °C to about 80 °C. 105. The method according to any one of Example Embodiments 89 to 104, wherein the method comprises a step of beading and / or ring formation on an open end of the condom. 106. The method according to any one of Example Embodiments 89 to 105, wherein the method comprises a step of leaching. 107 The method according to any one of Example Embodiments 89 to 106, wherein the condom is as defined according to any one of Example Embodiments 31 to 59. 108. The method according to any one of Example Embodiments 89 to 107, wherein the method comprises a step of applying a coating material or at least one compound or composition to the condom. 109. The method according to Example Embodiment 108, wherein the coating material, compound or composition is applied by at least one of: spraying, dipping, sponging, rolling, dosing, or a mixture thereof. 110. The method according to any one of Example Embodiments 89 to 109, wherein the method further comprises a step of disposing at least one lubricant, in or on at least a portion of the condom. 111. The method according to any one of Example Embodiments 89 to 110, wherein the method further comprises a step of placing the condom in packaging, optionally a foil packaging. 112. A condom produced according to the method according to any one of Example Embodiments 89 to 111. 113. A male condom produced according to the method according to any one of Example Embodiments 89 to 111. 114. Use of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid in the formation of a latex to form a condom. 115. Use of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid in the formation of a latex to form a male condom. 116. The use according to Example Embodiment 114 or Example Embodiment 115, wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof. 117 The use according to any one of Example Embodiments 114 to 116, wherein the unsaturated carboxylic acid is methacrylic acid, acrylic acid, or a mixture thereof. 118 The use according to any one of Example Embodiments 114 to 117, wherein the unsaturated carboxylic acid is acrylic acid. 119. The use according to any one of Example Embodiments 114 to 118, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid. 120. The use according to any one of Example Embodiments 114 to 118, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid. EXAMPLES
[0178] The present disclosure is now described further in the following non-limiting examples. General Experimental
[0179] Typical properties of an exemplary copolymer latex are presented in Table 1 below. Carboxylic acid-modified nitrile-based copolymer latex compositions, preparation methods thereof are disclosed in US20160244575A1, the contents of which is incorporated herein by reference in their entirety. Acrylonitrile butadiene compositions 1-7 are presented in Table 2 below. A typical dipping method for producing a condom is presented in Table 3 below. Table 1. Typical copolymer latex properties. ____________________________ Characteristic Value / Observation Appearance Milky white liquid Total solid content (%) 44.5-45.5 Viscosity (cps) Max 100 pH (25°C) 8.6-9.3 Surface tension (Dyn / cm) 28-38 Particle size (A) 1100-1500 Acrylonitrile content, % 10-50 Carboxylic group content, % 0.1-10 Table 2. Acrylonitrile butadiene aqueous compositions 1-7. Component Quantity Per Hundred Dry Rubber (PHR) 1 2 3 4 5 6 7 Acrylonitrile butadiene rubber 100 100 100 100 100 100 100 Surfactant - 0.6 0.6 0.6 0.6 0.6 0.6 Silicone surfactant 1 - - - - - pH adjuster 1 0.3 0.3 - - - 0.6 0.6 pH adjuster 2 - - - - 1 - - Activator and crosslinker 1.4 1.4 1.4 1.4 1.4 1.4 1.4 Crosslinker 1 1 1.2 1 1 1 1 Accelerator 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Accelerator 2 - 0.2 0.1 0.2 0.2 0.2 0.2 Antioxidant 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Processing agent - - 1 Table 3. Typical dipping method for producing a condom using acrylonitrile butadiene composition.__________________________________________________________________ Process Time (Minutes) Temperature (°C) First dip (thickness of coating may be controlled by latex viscosity , TSC and former speed in dip tank - - First drying of latex coating 1-3 70-90 Second dip (optional) - - Second drying of latex coating (optional) 1-3 70-90 Bcading / nng formation on the open end of the condom - - Post-vulcanization / Curing 11-15 110-140 Leaching - - Stripping of the condoms from the former - - Example 1: Condoms
[0180] Nitrile male condoms can be produced with various differences in thickness, depending on the latex total solid content (TSC), viscosity, and (dipping) machine speed. Multiple XNBR, NR, PT and PU condoms were produced or obtained (with the XNBR condoms produced according to the method in Table 3, using the compositions of Table 2) The thickness of all condoms was found to be between 30 and 40 microns, with the exception of the PU condoms. For each condom, the burst pressure, burst volume, force at break, tensile strength and elongation at break were examined in accordance with ISO4074, and the ranges presented in Table 4. Table 4. Physical properties of condoms produced from acrylonitrile butadiene (XNBR), natural rubber (NR), polyisoprene (PI) and polyurethane (PU). Properties XNBR Condom NR Condom PI Condom PU Condom Thickness, mm 0.030-0.040 0.034-0.038 0.033-0.038 0.020-0.029 Burst pressure, kPa 1.68-2.39 0.50-1.50 0.45-1.10 2.45-9.20 Burst volume, L 8.23-10.81 6.50-35 3.00-55.00 5.00-10.50 Force at Break, N 18.05-25.04 41.37-49.21 32.43-48.32 31.90-57.61 Tensile strength, Mpa 9.09-16.55 24.88-29.85 22.72-33.81 25.03-46.06 Elongation at break, % 310-667 759-777 914-987 514-572
[0181] The nitrile condom was found to exhibit superior burst pressure compared to the natural rubber and polyisoprene condoms.
[0182] The properties of the XNBR condom produced according to the above composition were compared against those of condoms produced from pure XNBR and XNBR + Zinc Oxide. The results are presented in Table 5, and demonstrate that condoms of varying thicknesses, softness and strengths can be produced by adjusting the composition. Table 5. Physical properties of XNBR condoms: (1) pure XNBR, (2) XNBR + ZnO and (3) XNBR Compositions of Table 2, Properties XNBR Condom 1 2 3 Thickness, mm 0.029-0.034 0.029-0.034 0.030-0.040 Burst pressure, kPa 0.35-0.85 0.85-1.70 1.68-2.39 Burst volume, L 2.50-28.00 3.00-15.50 8.23-10.81
[0183] Cross-link density was determined according to the Flory-Rehner method, the data for which presented in Table 6. Under testing, all types of condom samples were immersed in a solvent for 7 days, and then the crosslink density and average molecular weight between crosslinks were calculated. Acetone was used as a solvent for XNBR and NR condoms, and toluene was used for PI and PU condoms. The following equations were used to calculate crosslink density and average molecule weight between crosslinks: n = - ) (Equation 1) n — — (Equation 2) =--------- (Equation 3) m1(<7s-<7r) + m2<7r n = crosslink density (mol / g), Vs = molar volume of solvent (toluene = 106.2 cm3, acetone = 73.4 cm3); Vr = volume fraction of rubber in swollen gel; X = rubber-solvent interaction parameter (NR / PI-toluene = 0.393, PU-toluene = 0.56, XNBR-acetone = 0.36); mi = weight of rubber before swelling; m2 = weight of rubber after swelling; or = density of rubber (NR / P1 = 0.92 g / cm3, PU = 1.2 g / cm3, XNBR = 0.98 g / cm3); os = density of solvent (toluene = 0.867 g / cm3, acetone = 0.79 g / cm3); Mc = average molecular weight between crosslink (g / mol).
[0184] References highlighting where and how the crosslink density and molecular weight between crosslinks (Me) may be calculated may be found at: G. Hoti et al., Materials (Basel). 2021 Jan 20;14(3):478; Y. Wang et al., Polymers 2024, 16(21), 2957; C. Hiranobe et al., Materials Research. 2021; 24(suppl. 1): e20210041; Z. Yude, Polymer Science - Series A, 57(3), pp. 350-358; each of which are incorporated by reference. Table 6, Crosslink density and molecular weight between crosslinks. XNBR Condom NR Condom PI Condom PU Condom Crosslink density', mol / g 7.42xl0-4 6.00xl0’5 5.57xl0’5 7.66xl0’5 Mc, g / mol 674 8330 8980 6530
[0185] XNBR exhibited the highest crosslink density amongst the NR, PI and PU condoms.
[0186] Transmission electron microscopy (TEM) was performed on the XNBR condom. Figures 1 to 4 depict transmission electron microscope images of the crosslink network in the acrylonitrile butadiene condom. The TEM micrographs represent the XNBR crosslinked network. The dark areas represent XNBR rubber stained with osmium tetroxide. The light areas (polystyrene voids) are polystyrene embedded in the XNBR condom pieces, which indicate a weak area in the XNBR condom pieces. The XNBR latex particles are clearly visible on the micrograph. The boundary of these particles is clearly defined. The intra and inter-particle crosslinking can clearly be seen. The latex particles distribution is relatively uniform.
[0187] Compatibility of the XNBR, NR, PI and PU condoms with various oils was examined in accordance with 1S019671:2018, with the results presented in Tables 710. All condoms were tested with baby oil (mineral oil), palm oil (cooking oil), D5 cyclomethicone, and liquid paraffin (as positive control to represent the incompatible oil for NR / PI condom) For each condom and oil, burst pressure, burst volume, break force and elongation at break was determined. NR and PI condoms were found to be incompatible with baby oil, palm oil and liquid paraffin because the whole of the 95% confidence interval for the percentage ratio (vs the negative control) falls outside the range of 80% to 120% for at least one tensile property. XNBR exhibited superior baby oil, palm oil and liquid paraffin resistance than both the NR and PI condoms. Table 7. The 95% confidence interval for the percentage ratio (relative to negative control) for tensile properties for NR condom adapted from condom compatibility ISO19671:2018 test method. Oil Type % Changed vs Negative control Burst Pressure Burst Volume Break force Elongation at Break Silicone lubricant 91.41 - 108.59 84.70- 109.33 95.42- 112.95 97.14- 102.03 Baby oil (mineral oil) 74.14-91.16 84.29- 103.21 49.86 -71.88 77.14-82.91 Palm oil 73.21-91.11 76.24-96.67 52.66 -76.31 77.00-82.63 Cyclomethicone (D5) 82.35 - 105.14 89.48 - 106.26 94.80- 111.70 97.10-101.68 Paraffin highly liquid 73.08-91.24 87.98- 105.46 42.02 - 74.22 67.94-86.66 Table 8. The 95% confidence interval for the percentage ratio (relative to negative control) for tensile properties for XNBR condom adapted from condom compatibility ISO 19671 test method. Oil Type %Changed vs Negative Control Burst Pressure Burst Volume Break force Elongation at Break Silicone lubricant 82.48 - 102.72 85.84- 103.27 96.85 - 119.14 99.60- 103.67 Baby oil (mineral oil) 80.82 - 100.22 84.29- 103.21 81.76- 107.09 95.67-99.92 Palm oil 67.61 - 84.14 76.24-96.67 70.74-97.04 93.21 -98.47 Cyclomethicone (D5) 82.35 - 105.14 83.43 - 104.85 94.45 - 118.02 99.17- 103.43 Paraffin highly liquid 80.55 - 100.59 87.98 -105.46 80.00- 105.69 96.68- 100.97 Table 9. The 95% confidence interval for the percentage ratio (relative to negative control) for tensile properties for Pl condom adapted from condom compatibility ISO 19671 test method. Oil Type %Changed vs Negative Control Burst Pressure Burst Volume Break force Elongation at Break Silicone lubricant 85.90- 102.07 83.96- 100.92 88.69 - 101.51 99.11 - 100.96 Baby oil (mineral oil) 62.81 -77.44 51.74- 70.61 9.16-54.69 57.53-73.83 Palm oil 47.53 -61.03 76.24- 96.67 12.70-58.12 62.64-75.34 Cyclomethicone (D5) 80.50-95.46 85.10- 102.48 88.76 - 102.22 97.80- 100.04 Paraffin highly liquid 55.01-71.40 39.20-61.33 1.12-47.33 53.87- 67.18 Table 10. The 95% confidence interval for the percentage ratio (relative to negative control) for tensile properties for PU condom adapted from condom compatibility ISO 19671 test method. Oil Type % Changed vs Negative Control Burst Pressure Burst Volume Break force Elongation at Break Silicone lubricant 99.99-119.08 84.04-119.45 80.28-99.93 99.41-104.22 Baby oil (mineral oil) 91.93-109.02 80.87-1 10.33 80.60-100.48 99.84-105.94 Palm oil 79.26-96.33 64.53-98.47 61.08-83.66 95.53-100.64 Cyclomethicone (D5) 87.19-104.77 80.31-109.07 92.38-112.33 101.67-106.46 Paraffin highly liquid 83.39-100.19 80.45-110.08 82.05-103.17 97.52-102.92
[0188] The appearance of XNBR, NR, PI, and PU condoms at 7 days after treatment with various oil including silicone oil, palm oil, baby oil, Petroleum jelly and paraffin oil are shown in Figures 2-5. The palm oil, baby oil, Petroleum jelly and paraffin oil can be observed to permanently deform the NR, and PI condom shape. This deformation was not observed for the XNBR condom. Example 2: Condoms (continued)
[0189] A series of further investigations were undertaken to determine the effects, if any, on the resultant XNBR condom as a result of (1) dry stripping vs wet stripping; (2) prevulcanisation in addition to post-vulcanisation vs post-vulcanisation alone; and (3) the inclusion of a heat sensitizer. Dry stripping vs wet stripping
[0190] Condoms were formed according to the process described in Table 3, adopting either of the following sets of steps (Table 11) after leaching to strip the condom. A visual comparison of the methods is presented in Figure 9. Table 11. Dry stripping vs wet stripping Step Dry Stripping Wet Stripping 1 Dip in powder slurry - 2 Brushing strip Brushing / water jet strip 3 - Wash with powder slurry 4 Tumble drying Tumble drying Pre-vulcanisation in addition to post-vulcanisation vs post-vulcanisation alone
[0191] Three formulations were compounded according to Table 12. For the latex, a carboxylic acid-modified nitrile-based copolymer latex was used having approximately 24-28% acrylonitrile content, approximately 3-10% carboxylic acid content, and approximately 63-67% butadiene content. Table 12. Latex Formulations investigated re pre- / post-vulcanization. Latex and Chemicals Part per hundred of rubber (phr) F.l F.l F.3 Latex NBR latex 100 100 100 Stabilizer / Wetting agent Amphoteric surfactant 0 0.6 0 Heat sensitizer PEG 12-Dimethicone 0 0 0.6 Activator Zinc Oxide 1.4 1.4 1.4 Crosslinker Sulfur 1.0 1.0 1.0 Accelerator ZDEC 0.5 0.5 0.5 SDBC 0.2 0.2 0.2 Antioxidant Polyphenolic antioxidant 0.6 0.6 0.6 Stabilizer / diluent Ammonia solution (1 % w / w) To achieve TSC of 43.5% by dilution
[0192] Condoms with thickness 25-30 microns were prepared from the above three latex formulations at different maturation times (1, 24 and 48 hours) at 25 °C after completion of the compounding step. The 1-hour examples are representative of less or minimal pre-vulcanization. Table 13. Physical properties of XNBR condoms produced from Fl, F.2 and F.3 with no pre-vulcanisation (1 hour) or pre-vulcanisation (24 and 48 hours)_____________________ Property F.l F.2 F.3 1 hr 24 hr 48 hr 1 hr 24 hr 48 hr 1 hr 24 hr 48 hr Burst pressure (kPa) 0.27 0.35 0.43 0.28 0.53 0.55 0.20 0.45 0.43 Burst volume (L) 6.67 12.67 17.50 5.50 9.59 14.50 16.67 3.33 8.33 Tensile strength (MPa) 1.48 2.64 8.27 5.28 8.32 5.43 n / a 2.72 3.95 Elongation at break (%) 1446 1047 861 1186 630 736 1064 808 844 Tear Strength (N / mm) 3.14 2.60 2.64 3.70 n.m. 2.64 4.47 4.42 4.07 nm. = not measured
[0193] It was observed that pre-vulcanization significantly improved the physical properties of the condom. The burst pressure and tensile strength were observed to increase when the latex formulation was pre-vulcanized at 24 hours or 48 hours. Elongation at break was observed to decrease with increased pre-vulcanisation, due to the development of crosslink density during pre-vulcanization. Another benefit observed in the above formulations is that pre-vulcanization improved the latex coating. This was found to the case even in the case where no wetting agent or heat sensitizer was present in the formulation. XNBR condoms produced from F.l exhibited crack and flow mark during dipping at 1 hour maturation but after 24 hours maturation, the coating issue was observed to be reduced, with the coating smooth after 48 hours of maturation (Figure 10).
[0194] Crosslink density and molecular weight between crosslinks (Me) was investigated for the produced XNBR condoms. Three 2 cm diameter size circle samples were cut from each condom sample fortesting of crosslink density. The samples were immersed in Toluene and left to swell overnight in a closed plate. The swollen weight was determined before and after swelling overnight. The crosslink density was calculated according to the equations below: n - - — X (Equation 4) Vs wr Vr ~ wr W.-Wr (Equation 5) --Lq--2----L Pr Ps Me- Pr / n (Equation 6) n Crosslink density per unit volume (mol / cm3) K molar volume of acetone (73.7 ml / mol) Pr Volume fraction of rubber in swollen gel x XNBR-acetone interaction parameter (0.345) Wr weight of rubber before swelling Ws weight of rubber after swelling Pr density of XNBR (0.998 g / cm1) Ps density of acetone (0.791 g / cm3)
[0195] References highlighting where and how the crosslink density and molecular weight between crosslinks (Me) may be calculated may be found at: G. Hoti et al., Materials (Basel). 2021 Jan 20;14(3):478; Y. Wang et al., Polymers 2024, 16(21), 2957; C. Hiranobe et al., Materials Research. 2021; 24(suppl. 1): e20210041; Z. Yude, Polymer Science - Series A, 57(3), pp. 350-358; each of which are incorporated by reference. Table 14. Crosslink density and molecular weight between crosslinks (Mc) for XNBR condoms produced from F. 1, F.2 and F.3 with differing extent of pre-vulcanization. Formulation Maturation time (hr) Crosslink density MC F.l 24 2.02E-04 4932 F.l 48 3.02E-04 3308 F.2 24 3.29E-04 3034 F.2 48 5.50E-04 1813 F.3 24 2.58E-04 3871 F.3 48 5.23E-04 1909
[0196] The elastic recovery of the produced XNBR condoms was also examined, whereby a sample was stretched 200 mm from its original shape, and held for 40 minutes, and then released. Recovery was examined at 0 min and 60 min after stretching was ceased (at room 61 temperature) The results are presented in Figure 12 Pre-vulcanization was found to improve the elasticity, with faster shape recovery over the non-pre-vulcanized samples. Heat sensitizers
[0197] From the XNBR condoms produced above, the addition of a heat sensitizer in F 3 was not found (see Figure 11) to exhibit the coating issue that was observed for the other formulations when after 1 hour pre-vulcanization.
Claims
1. A condom comprising:• a tubular shaft having a tip on a closed end of the tubular shaft and an open end opposite the closed end on the tubular shaft; and• one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid.
2. A condom comprising:• one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid,wherein the condom is a male condom.
3. A condom, optionally a male condom, comprising particles of a copolymer of acrylonitrile, butadiene and an unsaturated carboxylic acid that are pre-vulcanized and cured, wherein the particles are bonded to each other through intra-particle crosslinks and interparticle crosslinks, wherein the intra-particle crosslinks and the inter-particle crosslinks are optionally substantially uniform in the condom.
4. A condom comprising:• one or more layers comprising a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid,wherein the condom is a male condom and the copolymer comprises less than 10 % w / w of the unsaturated carboxylic acid5. The condom according to any one of claims 1 to 4, wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof.
6. The condom according to any one of claims 1 to 5, wherein the unsaturated carboxylic acid is methacrylic acid, acrylic acid, or a mixture thereof.
7. The condom according to any one of claims 1 to 6, wherein the unsaturated carboxylic acid is acrylic acid.8 The condom according to any one of claims 1 to 7, wherein the copolymer is: - a terpolymer of acrylonitrile, butadiene and acrylic acid; or- a terpolymer of acrylonitrile, butadiene and methacrylic acid.
9. The condom according to any one of claims 1 to , wherein the acrylonitrile content of the copolymer (in % w / w) is in a range of about 10% to about 50%, optionally about 20% to about 40%.
10. The condom according to any one of claims 1 to 9, wherein the carboxylic acid group content of the copolymer (in % w / w) is in a range of about 0.1% to about 9%, optionally about 1% to about 8%, optionally about 3% to about 7%.
11. The condom according to any one of claims 1 to 10, wherein the one or more layers comprise particles of the copolymer12. The condom according to any one of claims 1 to 11, wherein the one or more layers comprise particles of the copolymer wherein at least a portion of the particles have a size in the range of about 800 A to about 1800 A, optionally in a range of about 1100 A to about 1500 A.
13. The condom according to claim 11 or claim 12, wherein the particles are prevulcanized cured synthetic particles.
14. The condom according to any one of claims 11 to 13, wherein at least a portion of the particles are crosslinked, optionally ionic crosslinking, and optionally between two or more functional groups present on the same or different copolymers and / or particles.
15. The condom according to claim 14, wherein the functional groups are carboxylic acid units or alkene units.
16. The condom according to any one of claims 11 to 15, wherein at least a portion of the particles comprise intra-particle crosslinking.
17. The condom according to any one of claims 11 to 18, wherein at least a portion of the particles comprise inter-particle crosslinking.
18. The condom according to any one of claims 11 to 18, wherein at least a portion of the particles comprise intra-particle crosslinking and inter-particle crosslinking.
19. The condom according to any one of claims 11 to 18, wherein the intra-particle crosslinking and / or the inter-particle crosslinking comprises sulfur crosslinks.
20. The condom according to any one of claims 11 to 18, wherein at least a portion of the intra-particle and / or inter-particle crosslinking does not comprise sulfur crosslinks.
21. The condom according to any one of claims 1 to 20, wherein the condom has a thickness in the range of from about 20 pm to about 100 pm, optionally in a range of about 20 pm to about 80 pm, about 20 pm to about 60 pm, about 20 pm to about 40 pm.
22. The condom according to any one of claims 1 to 20, wherein at least one layer of the condom or the condom comprises a crosslinked structure, optionally a cured or postvulcanised structure, having a molecular weight between crosslinks (Mc) of: less than about 6000, 5500, 5000, 4500, 4000, 3500, 3000, 2500, 2000, 1950, 1900, 1850,1800, 1750, 1700, 1650, 1600, 1550, 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1150, 1100, 1050, 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 200, 150 or 100 g / mol.
23. The condom according to any one of claims 1 to 22, wherein at least one: anti- viral,anti-microbial, anti-fungal, vasodilator, benzocaine, flavour, scent, active ingredient, warming liquid or gel, sensitizing agent, desensitizing agent, spermicide, lubricant, or mixture thereof is disposed on or in at least a portion of the condom.
24. The condom according to any one of claims 1 to 23, wherein at least one lubricant, optionally selected from the group consisting of: oil-based lubricants, silicon based-lubricants, water-based lubricants, or a mixture thereof, is disposed on or in at least a portion of the condom.
25. The condom according to any one of claims 1 to 24, wherein the condom has a burstpressure in a range of about 1 kPa to about 3 kPa, when measured according to ISO 23409:2011,1804074:2015, and / or ASTM D3492-16.
26. The condom according to any one of claims 1 to 25, wherein the condom has a burst volume in a range of about 5 L to about 15 L, when measured according to ISO 23409:2011, 1804074:2015, and / or ASTM D3492-16.
27. The condom according to any one of claims 1 to 26, wherein the condom has a force at break in a range of about 10 N to about 30 N, when measured according to ISO 23409:2011,1804074:2015, and / or ASTM D3492-16.
28. The condom according to any one of claims 1 to 27, wherein the condom has a tensile strength in a range of about 5 MPa to about 30 MPa, when measured according to 1804074:2015, and / or ASTM D3492-16.29 The condom according to any one of claims 1 to 28, wherein the condom has an elongation at break in a range of about 250% to about 750%, when measured according to 1804074:2015, and / or ASTM D3492-16.
30. The condom according to any one of claims 1 to 29, wherein the condom is compatible with at least one lubricant or oil selected from the group consisting of: a silicon oil or lubricant, a hydrocarbon petroleum-based oil or lubricant, vegetable oil, or a mixture thereof.
31. A packaged condom comprising the condom according to any one of claims 1 to 30.
32. A latex comprising particles of a copolymer comprising acrylonitrile, butadiene andan unsaturated carboxylic acid.33 The latex according to claim 32, wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof.
34. The latex according to claim 32 or claim 33, wherein the unsaturated carboxylic acid is methacrylic acid, acrylic acid, or a mixture thereof.
35. The latex according to any one of claims 32 to 34, wherein the unsaturated carboxylic acid is acrylic acid.
36. The latex according to any one of claims 32 to 35, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid.
37. The latex according to any one of claims 32 to 35, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid.
38. The latex according to any one of claims 32 to 37 when used to produce the polymeric article according to any one of claims 1 to 30, or the condom according to any one of claims 31 to 60.
39. The latex according to any one of claims 32 to 38, wherein the acrylonitrile content of the copolymer (in % w / w) is in a range of about 10% to about 50%, optionally about 20% to about 40%.
40. The latex according to any one of claims 32 to 39, wherein the carboxylic acid group content of the copolymer (in % w / w) is in a range of about 0.1% to about 10%, optionally about 1% to about 8%, optionally about 3% to about 7%.
41. The latex according to any one of claims 32 to 40, wherein the latex comprises particles of the copolymer.
42. The latex according to any one of claims 32 to 41, wherein the latex comprises particles of the copolymer wherein at least a portion of the particles have a size in the range of about 800 A to about 1800 A, optionally in a range of about 1100 A to about 1500 A.43 The latex according to claim 41 or claim 42, wherein at least a portion of the particles are pre-vulcanized, post-vulcanized, or cured synthetic particles.
44. The latex according to any one of claims 41 to 43, wherein at least a portion of the particles are crosslinked, optionally ionic crosslinking, and optionally between two or more functional groups present on the same or different copolymers and / or particles.
45. The latex according to claim 44, wherein the functional groups are carboxylic acid units or alkene units.
46. The latex according to any one of claims 41 to 45, wherein at least a portion of the particles comprise intra-particle crosslinking.
47. The latex according to any one of claims 41 to 46, wherein at least a portion of the particles comprise inter-particle crosslinking.
48. The latex according to any one of claims 41 to 47, wherein at least a portion of the particles comprise intra-particle crosslinking and inter-particle crosslinking.49 The latex according to any one of claims 41 to 48, wherein the intra-particle crosslinking and / or the inter-particle crosslinking comprises sulfur crosslinks.
50. The latex according to any one of claims 41 to 49, wherein at least a portion of the intra-particle and / or inter-particle crosslinking does not comprise sulfur crosslinks.
51. The latex according to any one of claims 32 to 50, wherein the total solid content of the latex (in % w / w) is in a range of about 40% to about 70%, about 40% to about 60%, about 40% to about 55%, about 50% to about 70%, about 55 % to about 60%, or about 44% to about 46%.
52. The latex according to any one of claims 32 to 51, wherein the pH is in a range of about 6 to about 12, optionally in a range of about 8 to about 10, or about 9 to about 11, or about 8.6 to about 9.3.53 The latex according to any one of claims 32 to 52, wherein the latex comprises a pre-vulcanization composition.
54. The latex according to claim 53, wherein the pre-vulcanization composition comprises at least one component selected from the group consisting of: sulfur, an accelerator, an activator and mixtures thereof.
55. The latex according to any one of claims 32 to 54, wherein the latex comprises a crosslinking composition, optionally comprising a metal salt, and optionally a metal oxide.
56. The latex according to any one of claims 32 to 55, wherein the viscosity of the latex is in a range of about 10 cps to about 120 cps or about 10 cps to about 90 cps, when measured according to ISO 1652-2011.
57. The latex according to any one of claims 32 to 56, wherein the latex further comprises at least one component selected from the group consisting of: an activator, a crosslinking agent, a curative, a mono-sulfidic donor, a disulfidic donor, a polysulfidic donor, an anti-oxidant and / or an anti-ozonant, a surfactant, a rheology-modifier, a pH adjuster, a pigment, a processing agent, a filler, or a mixture thereof.
58. The latex according to any one of claims 32 to 57, wherein the latex further comprises at least one component selected from the group consisting of: a surfactant, an activator, an accelerator, a crosslinker, an antioxidant, and mixtures thereof.
59. The latex according to any one of claims 32 to 58, wherein the latex does not comprise a coagulant.
60. A method of forming a condom, the method comprising:• crosslinking a latex according to any one of claims 32 to 59.
61. The method according to claim 60, wherein at least one crosslinking agent is introduced into the latex, wherein the at least one crosslinking agent is a metal salt, is optionally selected from the group consisting of: a metal oxide or metal halide, or mixtures thereof.62 The method according to claim 60 or claim 61, wherein at least one crosslinking agent is introduced into the latex, wherein the at least one crosslinking agent comprises sulfur, optionally selected from the group consisting of: elemental sulfur, mono-sulfidic donors, disulfidic donors, tetramethyl thiuram disulfide, tetraethyl thiuram disulfide, polysulfidic donors, xanthogen polysulfide, dipentamethylene thiuramtetrasulfide and mixtures thereof.
63. The method according to any one of claims 60 to 62, wherein the method comprises one or more steps to introduce intra-particle crosslinking.
64. The method according to any one of claims 60 to 63, wherein the method comprises one or more steps to introduce intra-particle crosslinking and inter-particle crosslinking.
65. The method according to any one of claims 60 to 64, wherein the condom is a male condom.
66. The method according to any one of claims 60 to 65, wherein the method comprises a step of introducing a composition comprising at least one component selected from the group consisting of: stabilisers, pH control agents, antioxidants, and preservatives, and mixtures thereof.
67. The method according to any one of claims 60 to 66, wherein the method comprises at least one step selected from the group consisting of:- a pre-vulcanization step;- a post-vulcanization step; and- a pre-vulcanization step and a post-vulcanization step.
68. The method according to any one of claims 60 to 67, wherein the method comprises a post-vulcanization step, but does not comprise a pre-vulcanization step.
69. The method according to any one of claims 60 to 68, wherein the method comprises a pre-vulcanizing step comprising the of introduction of a pre-vulcanization composition, optionally comprising at least one component selected from the group consisting of: a sulfur containing crosslinker, an accelerator (optionally ZDEC and / or SDBC), an activator (optionally ZnO), and mixtures thereof.70 The method according to any one of claims 60 to 69, wherein the method comprises a post-vulcanizing step comprising the introduction of a post-vulcanization composition, optionally comprising at least one component selected from the group consisting of: a sulfur containing crosslinker, an accelerator (optionally ZDEC and / or SDBC), an activator (optionally ZnO), and mixtures thereof.
71. The method according to any one of claims 60 to 70, wherein the method comprises a post-vulcanization step or curing step comprising exposure of a formed condom totemperature of about 100 °C to about 150 °C, or about 110 °C to about 140 °C, or about 120 °C to about 130 °C72. The method according to any one of claims 60 to 71, wherein the method comprises the step of:• dipping a condom former into the latex at least once, to coat a layer of the latex onto the condom former.•73. The method according to any one of claims 60 to 72, wherein the method wherein, the method comprises the step of:• dipping a condom former into the latex at least twice, to coat a layer of the latex onto the condom former, with an optional drying step after each dipping step.74 The method according to claim 60 or claim 73, wherein, after at least one dip a formed layer is dried in a drying step, optionally at a temperature in a range of about 60 °C to about 90 °C, or in a range of about 70 °C to about 80 °C.
75. The method according to claim 74, wherein the drying step occurs after each dip, optionally at a temperature in a range of about 60 °C to about 90 °C , or in a range of about 70 °C to about 80 °C.
76. The method according to any one of claims 60 to 75, wherein the method comprises a step of beading and / or ring formation on an open end of the condom.
77. The method according to any one of claims 60 to 76, wherein the method comprises a step of leaching.78 The method according to any one of claims 60 to 77, wherein the condom is as defined according to any one of claims 1 to 30.
79. The method according to any one of claims 60 to 78, wherein the method comprises a step of applying a coating material or at least one compound or composition to the condom.
80. The method according to claim 79, wherein the coating material, compound or composition is applied by at least one of: spraying, dipping, sponging, rolling, dosing, or a mixture thereof.
81. The method according to any one of claims 60 to 80, wherein the method further comprises a step of disposing at least one lubricant, in or on at least a portion of the condom.
82. The method according to any one of claims 60 to 81, wherein the method further comprises a step of placing the condom in packaging, optionally a foil packaging.
83. A condom produced according to the method according to any one of claims 60 to 82.84 A male condom produced according to the method according to any one of claims 60 to 82.
85. Use of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid in the formation of a latex to form a condom.
86. Use of a copolymer comprising acrylonitrile, butadiene and an unsaturated carboxylic acid in the formation of a latex to form a male condom.
87. The use according to claim 85 or claim 86, wherein the unsaturated carboxylic acid is selected from the group consisting of: itaconic acid, maleic acid, fumaric acid, methacrylic acid, acrylic acid, or a mixture thereof.88 The use according to any one of claims 85 to 87, wherein the unsaturated carboxylic acid is methacrylic acid, acrylic acid, or a mixture thereof.
89. The use according to any one of claims 85 to 88, wherein the unsaturated carboxylic acid is acrylic acid.
90. The use according to any one of claims 85 to 89, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and acrylic acid.7291. The use according to any one of claims 85 to 89, wherein the copolymer is a terpolymer of acrylonitrile, butadiene and methacrylic acid.