Abstract: The present invention describes thermoplastic vulcanizates (TPVs) and methods for forming TPVs that include addition of a masterbatch comprising antioxidant (AO) additives to improve UV weatherability of TPVs. The hindered phenol antioxidants have a melting point of 85° C. or less, and comprise an alkyl chain longer than 12 carbons. A method may comprise compounding a carbon black, carrier resin, and hindered phenol antioxidant to form a masterbatch and dynamically vulcanizing the masterbatch, a vulcanizable elastomer, a thermoplastic resin, and a process oil to yield a TPV.

Abstract: Foam pellets comprising a thermoplastic vulcanizate (TPV) and thermo-expandable microspheres, the foam pellet having a specific gravity of 0.2 to 1.0 and the TPV being composed of an at least partially vulcanized rubber component and a thermoplastic component. The foam pellets may be subsequently processed to form various foam articles without the need to include a foaming agent during processing.

Abstract: Masterbatch compositions comprising encapsulated stannous chloride for use in the production of thermoplastic vulcanizates, and methods related thereto. For example, the present disclosure provides for a composition comprising stannous chloride powder encapsulated in a carrier compound, the carrier compound being solid at a temperature in the range of 15.5° C. to 260° C. (60° F. to 500° F.).

Abstract: The present disclosure relates to TPV compositions suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. The TPV compositions comprise an at least partially vulcanized rubber component dispersed within a thermoplastic component comprising a thermoplastic resin and a propylene-based elastomer, oil, and optionally one or more additives. According to some aspects, the TPV composition may be made in part by preloading some portion of process oil prior to addition of the curative. TPV compositions provided herein are particularly suitable for foaming with thermo-expandable microsphere foaming agents.

Abstract: Described herein are thermoplastic elastomer compositions that comprise 30-60 wt % of a thermoplastic vulcanizate, 5 to 25 wt % of a thermoplastic resin, 5 to 25 wt % of a high density polyethylene, and 5 to 40 wt % of a ultrahigh molecular weight polyethylene. The thermoplastic elastomer compositions may be particularly useful in forming laminates, such as slip coat laminates for glass run channels.

Abstract: Methods of making thermoplastic vulcanizate are provided, including the steps of (a) extruding an elastomeric component and a thermoplastic polymer component to form a dynamically vulcanized melt; (b) passing the dynamically vulcanized melt into a vessel, comprising two intermeshing, counter-rotating twin screws, to produce a uniform dynamically vulcanized melt; and (c) filtering the uniform dynamically vulcanized melt and recovering a thermoplastic vulcanizate.

Abstract: A process for producing a thermoplastic vulcanizate, the process comprising: (i) charging a reactor with an oil-extended olefinic copolymer rubber, where the rubber is synthesized by a single-site catalyst, characterized by a multi-modal molecular weight distribution, and includes greater than 10 parts by weight extender oil per 100 parts by weight rubber; (ii) charging the reactor, contemporaneously or sequentially with respect to the rubber, with a thermoplastic resin, an oil, and a cure system to provide a pre-vulcanized mixture; and (iii) mixing the rubber, thermoplastic resin, oil, and cure system at a temperature above the melt temperature of the thermoplastic resin to thereby cause dynamic vulcanization of the rubber and produce the thermoplastic vulcanizate.

Abstract: In methods for forming thermoplastic vulcanizates, and thermoplastic vulcanizates formed by such methods, a masterbatch comprising one or more additives in a carrier resin comprising propylene- or ethylene-based copolymer is added to the thermoplastic vulcanizate formulation. The resulting thermoplastic vulcanizate may additionally be passed through a 200 mesh or finer screen and thereafter extruded. The thermoplastic vulcanizates may exhibit increased extrusion throughput rates and enhanced surface smoothness.

Abstract: The present disclosure relates to TPV compositions suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. The TPV compositions comprise an at least partially vulcanized rubber component dispersed within a thermoplastic component comprising a thermoplastic resin and a propylene-based elastomer, oil, and optionally one or more additives. According to some aspects, the TPV composition may be made in part by preloading some portion of process oil prior to addition of the curative. TPV compositions provided herein are particularly suitable for foaming with thermo-expandable microsphere foaming agents.

Abstract: A masterbatch for use in the production of thermoplastic vulcanizates comprises stannous chloride powder and zinc oxide powder encapsulated together in a polymer, such as an ethylene propylene diene terpolymer.

Abstract: Provided are methods of making thermoplastic vulcanizates and thermoplastic vulcanizates made therefrom. The methods can comprise adding vulcanizable elastomer to a reactor; adding a masterbatch comprising a thermoplastic resin and a metal oxide to the reactor; adding a curative to the reactor; and dynamically vulcanizing the elastomer.

Abstract: Provided herein are thermoplastic vulcanizates that comprise rubber, broad molecular weight distribution polypropylene, and oil, where the rubber forms a rubber phase that is dispersed and at least partially cross-linked within a continuous thermoplastic component that comprises the broad molecular weight distribution polypropylene. The broad molecular weight distribution polypropylene preferably has a molecular weight distribution (Mw/Mn) of greater than 4; a melt flow rate of greater than 1 g/10 min; and a weight average molecular weight (Mw) of greater than 380,000 daltons.

Abstract: The present disclosure relates to a method for making thermoplastic vulcanizates comprising dynamically vulcanizing an elastomer in an extrusion reactor with a curative in the presence of a thermoplastic resin to form a thermoplastic vulcanizate. Process oil is added to the extrusion reactor at a first, second, and third location, where the amount of process oil introduced at the first oil injection location is less than that introduced at the second oil injection location, where the third oil injection location is downstream of where the curative is introduced to the extrusion reactor, and where the thermoplastic vulcanizate comprises at least 25 wt % of oil based on the weight of the thermoplastic vulcanizate.

Abstract: In methods for forming thermoplastic vulcanizates, and thermoplastic vulcanizates formed by such methods, a masterbatch comprising one or more additives in a carrier resin comprising propylene- or ethylene-based copolymer is added to the thermoplastic vulcanizate formulation. The resulting thermoplastic vulcanizate may additionally be passed through a 200 mesh or finer screen and thereafter extruded. The thermoplastic vulcanizates may exhibit increased extrusion throughput rates and enhanced surface smoothness.

Abstract: Described herein are thermoplastic vulcanizates comprising thermoplastic resin, an at least partially vulcanized rubber dispersed in the thermoplastic resin, and process oil. The process oil in the thermoplastic vulcanizate may be selected from extension oil, free oil, curative-in-oil, and/or combination thereof. At least a portion of the process oil in the thermoplastic vulcanizate is a low aromatic/sulfur content oil and has an aromatic content of less than 5 wt %, and a sulfur content of less than 0.03 wt %, based on the weight of that portion of the process oil. The thermoplastic vulcanizate exhibits improved gravimetric fogging properties.

Abstract: In methods for forming thermoplastic vulcanizates, and thermoplastic vulcanizates formed by such methods, a masterbatch comprising one or more additives in a carrier resin comprising propylene- or ethylene-based copolymer is added to the thermoplastic vulcanizate formulation. The resulting thermoplastic vulcanizate may additionally be passed through a 200 mesh or finer screen and thereafter extruded. The thermoplastic vulcanizates may exhibit increased extrusion throughput rates and enhanced surface smoothness.

Abstract: A process for producing a thermoplastic vulcanizate, the process comprising: (i) charging a reactor with an oil-extended olefinic copolymer rubber, where the rubber is synthesized by a single-site catalyst, characterized by a multi-modal molecular weight distribution, and includes greater than 10 parts by weight extender oil per 100 parts by weight rubber; (ii) charging the reactor, contemporaneously or sequentially with respect to the rubber, with a thermoplastic resin, an oil, and a cure system to provide a pre-vulcanized mixture; and (iii) mixing the rubber, thermoplastic resin, oil, and cure system at a temperature above the melt temperature of the thermoplastic resin to thereby cause dynamic vulcanization of the rubber and produce the thermoplastic vulcanizate.

Abstract: Provided are methods of making thermoplastic vulcanizates and thermoplastic vulcanizates made therefrom. The methods can comprise adding vulcanizable elastomer to a reactor; adding a masterbatch comprising a thermoplastic resin and a metal oxide to the reactor; adding a curative to the reactor; and dynamically vulcanizing the elastomer.

Abstract: A masterbatch for use in the production of thermoplastic vulcanizates comprises stannous chloride powder and zinc oxide powder encapsulated together in a polymer, such as an ethylene propylene diene terpolymer.

Abstract: Described herein are thermoplastic elastomer compositions that comprise 30-60 wt % of a thermoplastic vulcanizate, 5 to 25 wt % of a thermoplastic resin, 5 to 25 wt % of a high density polyethylene, and 5 to 40 wt % of a ultrahigh molecular weight polyethylene. The thermoplastic elastomer compositions may be particularly useful in forming laminates, such as slip coat laminates for glass run channels.