Process for forming thermoplastic vulcanizates and extruded articles therefrom

1. A process for preparing a modified thermoplastic vulcanizate compositions, the process comprising the steps of:

i. providing a molten thermoplastic vulcanizate, where the thermoplastic vulcanizate includes cured ethylene-propylene-diene rubber dispersed within a matrix of propylene polymer, where the propylene polymer comprises at least 97 wt % of propylene-derived units, based on the weight of the propylene polymer, and where the thermoplastic vulcanizate is prepared by dynamically vulcanizing the ethylene-propylene-diene rubber with a non-peroxide curative to provide a degree of cure where less than 5 wt % of the rubber is extractable by cyclohexane at 23° C., and where the thermoplastic vulcanizate comprises from 75 to 90 wt % of the ethylene-propylene-diene rubber and from 10 to 30 wt % of the propylene polymer based on the entire weight of the ethylene-propylene-diene rubber and the propylene polymer combined;

ii. introducing 100 to 700 parts by weight of peroxide per million parts by weight of the thermoplastic vulcanizate to the molten thermoplastic vulcanizate to produce the modified thermoplastic vulcanizate composition,

where the modified thermoplastic vulcanizate is further formed into an extrudate characterized by an extrusion surface roughness (ESR) of 76 to 108 microinches and where the ESR of the extrudate of the modified thermoplastic vulcanizate is at least 27.5% less than an ESR of an extrudate formed from the same thermoplastic vulcanizate not modified with the peroxide.

2. The process of claim 1 , where the rubber has a degree of cure where less than 3 wt % rubber is extractable by cyclohexane at 23° C.

3. The process of claim 1 , where the amount of the peroxide introduced with the molten thermoplastic vulcanizate is at least 200 ppm and less than 700 parts by weight of the peroxide per million parts by weight of the thermoplastic vulcanizate.

4. The process of claim 1 , where the modified extrudate of the modified thermoplastic vulcanizate is characterized by the ESR of from 76 to 100 microinches.

5. A continuous process for preparing thermoplastic vulcanizates, the process comprising the steps of:

i. dynamically vulcanizing a rubber that is undergoing mixing with a polypropylene by using a non-peroxide curative within a first stage of the process to form a cured thermoplastic vulcanizate that is in a molten state, where the thermoplastic vulcanizate is cured such as to provide a degree of cure where the rubber has a crosslink density of at least 10×10 −5 moles per milliliter of rubber, and where the thermoplastic vulcanizate comprises from 75 to 90 wt % of the rubber and from 10 to 30 wt % of the polypropylene, based on the entire weight of the rubber and the polypropylene combined;

ii. maintaining the cued thermoplastic vulcanizate in a molten state until a second stage; and

iii. introducing 100 to 700 parts by weight of peroxide per million parts by weight of the thermoplastic vulcanizate to the molten cured thermoplastic vulcanizate in the second stage of the process to form a modified thermoplastic vulcanizate,

where the modified thermoplastic vulcanizate is further fabricated into an extrudate characterized by an extrusion surface roughness (ESR) of 76 to 108 microinches and where the ESR of the extrudate of the modified thermoplastic vulcanizate is at least 27.5% less than an ESR of an extrudate formed from the same thermoplastic vulcanizate not modified with the peroxide.

6. The process of claim 5 , where the non-peroxide curative in the first stage comprises a phenolic resin curative.

7. The process of claim 5 , where said first stage and said second stage of the process take place within a single reactive extruder.

8. The process of claim 5 , where said first stage and said second stage of the process take place in separate extruders.

9. The process of claim 5 , where said rubber is an olefinic elastomeric copolymer.

10. The process of claim 5 , where the peroxide is selected from the group consisting of di-tert-butyl peroxide, dicumyl peroxide, t-butylcumyl peroxide, α,α-bis(tert-butylperoxy)diisopropyl benzene 2,5-dimethyl-2,5-di(t-butylperoxy)hexane (DBPH), 1,1-di(tert-butylperoxy)-3,3,5-trimethyl cyclohexane, n-butyl-4-4-bis(tert-butylperoxy) valerate, benzoyl peroxide, lauroyl peroxide, dilauroyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy) hexyne-3, and mixtures thereof.

11. The process of claim 5 , where the peroxide is selected from the group consisting of diaryl peroxides, ketone peroxides, peroxydicarbonates, peroxyesters, dialkyl peroxides, hydroperoxides, peroxyketals and mixtures thereof.

12. The process of claim 5 , where the amount of the peroxide introduced with the molten thermoplastic vulcanizate is at least 200 ppm and less than 700 ppm parts by weight of the peroxide per million parts by weight of the thermoplastic vulcanizate.

13. A process for producing modified thermoplastic vulcanizates, the process comprising the steps of:

i. introducing rubber and a polypropylene into a reactive extruder;

ii. introducing a non-peroxide curative into the reactive extruder at a location downstream of the location of said introducing the rubber and the polypropylene;

iii. mixing the rubber, the polypropylene, and the curative;

iv. allowing said curative to cure the rubber and thereby cause phase inversion of the rubber within the polypropylene to form a thermoplastic vulcanizate, where the rubber is cured to have a degree of cure, such that less than 5 wt % of the rubber is extractable by cyclohexane at 23° C., and where the thermoplastic vulcanizate comprises from 75 to 90 wt % of the rubber and from 10 to 30 wt % of the polypropylene, based on the entire weight of the rubber and the polypropylene combined; and

v. introducing 100 to 700 parts by weight of peroxide per million parts by weight of the thermoplastic vulcanizate into the reactive extruder at a location downstream of the phase inversion of the rubber to produce the modified thermoplastic vulcanizate,

where the modified thermoplastic vulcanizate is further prepared into an extrudate characterized by an extrusion surface roughness (ESR) of 76 to 108 microinches and where the ESR of the extrudate of the modified thermoplastic vulcanizate is at least 27.5% less than an ESR of an extrudate formed from the same thermoplastic vulcanizate not modified with the peroxide.

14. The process of claim 13 , where the rubber has a degree of cure where less than 3 wt % rubber is extractable by cyclohexane at 23° C.