Process for preparing thermoplastic vulcanizates

Abstract

This invention includes a process for forming a thermoplastic vulcanizate comprising: (a) admixing a C—H insertion curing agent with at least one elastomeric phase polymer to form a first admixture; (b) admixing at least one non-elastomeric polyolefin with the first admixture to form a second admixture; and (c) heating the second admixture to a temperature at least the decomposition temperature of the curing agent to crosslink the elastomeric phase while mixing the admixture to an extent sufficient to result in the formation of a thermoplastic material, hereinafter referred to as a thermoplastic vulcanizate, and optionally including an additional step (d) of shaping the resulting thermoplastic vulcanizate, especially by heating and foaming or molding the TPV. The C—H insertion curing agent is preferably selected from alkyl and aryl azides (R—N,), acyl azides (R—C(O)N,), azidoformates (R—O—C(O)—N,), sulfonyl azides (R—SO,—N,), phosphoryl azides ((RO),—(PO)—N,), phosphinic azides (R,—P(O)—N,) and silyl azides (R,—Si—N,), with poly(sulfonyl azide) most preferred. Additionally, the invention includes a thermoplastic vulcanizate comprising a blend of: (1) an elastomeric phase crosslinked using a C—H insertion curing agent dispersed in; (2) at least one non-elastomeric thermoplastic polyolefin. The invention also includes a foamable composition comprising (1) an elastomeric phase crosslinked using a C—H insertion curing agent dispersed in; (2) at least one non-elastomeric thermoplastic polyolefin; and (3) from about 0.1 to about 25 percent by weight based on the combined weight of components (1) and (2) of at least one foaming agent as well as a fabricated part, cable jacket, cable insulation, or foam comprising the thermoplastic vulcanizate or the invention or resulting from the process of the invention.