Thermoplastic vulcanizates having improved fabricability

1. A process for preparing a thermoplastic vulcanizate composition having a dispersed, cross-linked rubber phase in a continuous thermoplastic polypropylene phase comprising:

a) providing into melt processing equipment at least the following components:

i) from 5 wt % to 10 wt %, based on the total weight of the thermoplastic vulcanizate, of at least one thermoplastic polypropylene homopolymer or copolymer having a melt temperature greater than 120° C., and a heat of fusion greater than 45 J/g;

ii) 6-12 wt. %, based on the total weight of the thermoplastic vulcanizate composition, at least one propylene copolymer having from 7 to 30 wt. % ethylene, based upon the weight of the propylene copolymer, a melting point less than 120° C., and a heat of fusion less than 45 J/g;

iii) from 15 wt % to 35 wt %, based on total weight of the thermoplastic vulcanizate, of at least one cross-linkable rubber, where, if including an ethylene copolymer rubber, said copolymer rubber having equal to or more than 40 wt. % the total copolymer rubber weight; and

iv) from about 30 to 250 parts by weight, per 100 parts by weight of the rubber, of an oil;

b) melt processing the blend of i), ii), of a);

c) dynamically vulcanizing the cross-linkable rubber iii) in the presence of the thermoplastic i) and copolymer ii), where said step of dynamically vulcanizing is effected by employing a phenolic resin cure system at a temperature of from 180° C. to 240° C.; and where prior to said step of dynamically vulcanizing, volatiles produced by said step of melt processing b) are vented from the melt processing equipment

d) removing a thermoplastic vulcanizate product of c) from the melt processing equipment,

wherein the dispersed, cross-linked rubber phase of the thermoplastic vulcanizate product d) consists of particles having an effective diameter not greater than 2 millimicrons, where said thermoplastic polypropylene homopolymer or copolymer and said propylene copolymer have at least 90% of the same tacticity, further comprising the step of fabricating the thermoplastic vulcanizate, where said step of fabricating includes (i) extruding at a pressure of not greater than 10 bar for at least 6 hours under die plug free conditions or (ii) injection molding the thermoplastic vulcanizate to form a molded part that is free of flow marks.

2. The process of claim 1 , wherein the polyolefinic thermoplastic resin component comprises a polypropylene homopolymer, isotactic polypropylene, an impact copolymer comprising polypropylene, or blends thereof.

3. The process of any of claims 1 , wherein the dispersed rubber component is fully vulcanized.

4. A molded article comprising a thermoplastic vulcanizate composition comprising

i) from 5 wt % to 10 wt %, based on the total weight of the thermoplastic vulcanizate, of at least one thermoplastic polypropylene homopolymer or copolymer having a melt temperature greater than 120° C., and a heat of fusion greater than 45 J/g;

ii) 6-12 wt. %, based on the total weight of the thermoplastic ulcanizates composition, at least one propylene copolymer having from 7 to 30 wt. % ethylene, based upon the weight of the propylene copolymer, a melting point less than 120° C., and a heat of fusion less than 45J/g;

iii) from 15 wt % to 35 wt %, based on total weight of the thermoplastic vulcanizate, of at least one cross-linkable rubber, where, if including an ethylene copolymer rubber, said copolymer rubber having equal to or more than 40 wt.% the total copolymer rubber weight; and

iv) from about 30 to 250 parts by weight, per 100 parts by weight of the rubber, of an oil;

wherein said thermoplastic vulcanizate composition 1 ) has a maximum compression set (CS max ) measured at 100° C. for 22 hours compression with 25% deformation not greater than that 12 points of a polypropylene-based TPV of the same hardness not containing a said propylene copolymer, and wherein said TPV has a distinct particulate rubber phase having a maximum diameter not exceeding 2 millimicrons when observed under an electron microscope, and wherein the molded article is free of flow marks.

5. The molded article of claim 4 , wherein the polypropylene homopolymer or copolymer comprises a polypropylene homopolymer, isotactic polypropylene, an impact copolymer comprising polypropylene, or blends thereof.

6. The molded article of claim 4 , wherein the rubber is an ethylene-propylene-diolefin copolymer rubber having an ethylene content equal to or greater than 40 wt. % the total copolymer rubber weight.

7. The molded article of claim 4 , wherein the rubber is fully vulcanized.

8. The molded article of claim 4 , wherein the thermoplastic vulcanizate has a Shore A Hardness of 90 or more.

9. The molded article of claim 4 , wherein the thermoplastic vulcanizate has a tensile strength of at least 9.0 MPa measured according to ISO 37-1,Type S2.

10. The molded article of claim 4 , wherein the thermoplastic vulcanizate composition has a percent elongation at break of at least 350% measured according to ISO 37-1.

11. The molded article of claim 4 , where the thermoplastic vulcanizate is characterized by a compression set of less than 34% at 100 C and 22 hours.