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Rheology-modified, gel-free thermoplastic elastomer compositions comprising a melt blend of an ethylene/α-olefin polymer and a high melting polymer such as polypropylene or a propylene/α-olefin copolymer wherein the rheology modification is induced by a combination of a peroxide and a free

Rheology-modified, gel-free thermoplastic elastomer compositions comprising a melt blend of an ethylene/α-olefin polymer and a high melting polymer such as polypropylene or a propylene/α-olefin copolymer wherein the rheology modification is induced by a combination of a peroxide and a free radical coagent in a peroxide:coagent ratio of 1:4 to 1:20 and a maximum peroxide concentration of 0.075 wt %. The resulting compositions have an elastomeric phase, a non-elastomeric phase and certain physical properties that exceed those of a like composition that is rheology-modified by peroxide alone or peroxide and coagent in a 1:2 to 2:1 ratio. The compositions are used to make a variety of articles of manufacture, such as tubing and weatherstripping, via calendaring, extrusion, and molding techniques such as blow molding.

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What is claimed is: 1. A rheology-modified, gel-free thermoplastic elastomer composition comprising from 60 to 90 weight percent, based on the weight of the composition, of at least one elastomeric ethylene/alpha-olefin polymer or ethylene/alpha-olefin polymer blend, and from 10 to 40 weight percen

What is claimed is: 1. A rheology-modified, gel-free thermoplastic elastomer composition comprising from 60 to 90 weight percent, based on the weight of the composition, of at least one elastomeric ethylene/alpha-olefin polymer or ethylene/alpha-olefin polymer blend, and from 10 to 40 weight percent, based on the weight of the composition, of at least one high melting polymer selected from the group consisting of polypropylene homopolymers and propylene/ethylene copolymers, and wherein the rheology modification is induced by a combination comprising 0.075 weight percent or less peroxide, and a free radical coagent, and wherein the peroxide:coagent ratio is from 1:4 to 1:20, and the rheology-modified, gel-free thermoplastic elastomer composition has an STI of 15-30, a tan delta at 190�� C. of 1.05-1.40, and a gel content that is below detectable limits when using xylene as the solvent in ASTM D 2765-90, method B; and wherein the amount of peroxide is based on the weight of the high melting polymer and the weight of either the elastomeric polymer of the elastomeric polymer blend. 2. The composition of claim 1, wherein the peroxide concentration is 0.050 weight percent or less. 3. The composition of claim 1, wherein the peroxide is an organic peroxide. 4. The composition of claim 1, wherein the organic peroxide is selected from the group consisting of α,α'-bis(t-butylperoxy)-diisopropylbenzene; dicumyl peroxide; di-(t-amyl)peroxide; 2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3; 2,5 (t-amyl peroxy-2-ethylhexonate); 2,5-dimethyl-2,5-di-(t-butyl peroxy)hexane; di-t-butylperoxide; 2,5-di(t-amyl peroxy)-2,5-dimethyihexane; 2,5-di-(t-butylperoxy)-2,5-diphenylhexane; bis(alpha-methylbenzyl)peroxide; t-butyl perbenzoate; benzoyl peroxide; 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxonane; and bis(t-butylperoxy)-diisopropylbenzene. 5. The composition of claim 1, wherein the free radical coagent is selected from the group consisting of diallyl terephthalate; triallylcyanurate; triallylisocyanurate; 1,2-polybutadiene; divinyl benzene; trimethylolpropane trimethacrylate; polyethylene glycol dimethacrylate; ethylene glycol dimethacrylate; pentaerythritol triacrylate; allyl methacrylate; N,N'-m-phenylene bismaleimide; toluene bismaleimide-p-quinone dioxime; nitrobenzene; and diphenylguanidine. 6. The composition of claim 5, wherein the free radical coagent is selected from the group consisting of triallylcyanurate; 1,2-polybutadiene; divinyl benzene; and trimethylolpropane trimethacrylate. 7. The composition of claim 1, wherein the ethylene/α-olefin polymer has polymerized therein at least one α-olefin comonomer, the α-olefin containing from 3 to 20 carbon atoms. 8. The composition of claim 7, wherein the α-olefin contains from 3 to 10 carbon atoms. 9. The composition of claim 1, wherein the ethylene/α-olefin polymer is a diene-modified polymer, the diene being selected from the group consisting of norbornadiene, dicyclopentadiene, 1,4-hexadiene, piperylene, 5-ethylidene-2-norbornene and mixtures thereof. 10. The composition of claim 1, wherein the high melting polymer is a nucleated polymer. 11. The composition of claim 1, further comprising a process oil, in an amount within a range of from greater than 0 to about 50 weight percent, based on total composition weight. 12. The composition of claim 1 or claim 11, further comprising a filler, in an amount within a range of from about 0 to about 70 weight percent, based on total composition weight. 13. A process for preparing a rheology-modified, gel-free TPE composition, the process comprising: a) adding at least one peroxide and at least one free radical coagent, in a peroxide:coagent ratio of 1:4 to 1:20, and a maximum peroxide concentration of 0.075 weight percent, to a molten polymer blend that comprises from 60 to 90 weight percent, based on the weight of the composition, of an elastomeric ethylene/alpha-olefin polymer, and from 10 to 40 weight percent, based on the weight of the composition, of a high melting polymer, selected from the group consisting of polypropylene homopolymers and propylene/ethylene copolymers; and b) maintaining the polymer blend in a molten state, while subjecting it to conditions of shear, sufficient to disperse the peroxide and coagent throughout the molten polymer blend, effect rheology modification of the polymers, and preclude formation of insoluble polymer gels (determined using xylene as the solvent in ASTM D 2765-90, method B), and wherein sufficient rheology modification is measured by an STI of 15-30 and a tan delta of 1.05-1.40; and wherein the amount of peroxide is based on the weight of the high melting polymer and weight of the elastomeric polymer. 14. A process for preparing a rheology-modified, gel-free TPE composition, the process comprising: a) adding at least one peroxide and at least one free radical coagent, in a peroxide:coagent ratio of 1:4 to 1:20, and a maximum peroxide concentration of 0.075 weight percent to at least one component of a polymer blend, before the components are blended, the component polymers comprising an elastomeric ethylene/alpha-olefin polymer and a high melting polymer, selected from the group consisting of polypropylene homopolymers and propylene/ethylene copolymers; b) blending the component polymers; and c) converting the polymer blend to a molten polymer blend, while subjecting the blend to conditions of shear, sufficient to disperse the peroxide and coagent throughout the molten polymer blend, effect rheology modification of the polymers, and preclude formation of insoluble polymer gels (determined using xylene as the solvent in ASTM D 2765-90, method B), and wherein sufficient rheology modification is measured by an STI of 15-30 and a tan delta of 1.05-1.40; and wherein the amount of peroxide is based on the weight of the high melting polymer and the weight of the elastomeric polymer. 15. A process for preparing a rheology-modified, gel-free thermoplastic elastomer article of manufacture, the process comprising: a) adding at least one peroxide and at least one free radical coagent, in a peroxide:coagent ratio of 1:4 to 1:20, and a maximum peroxide concentration of 0.075 weight percent, to a molten elastomeric ethylene/alpha-olefin polymer or elastomeric ethylene/alpha-olefin polymer blend, to provide a rheology-modified ethylene/alpha-olefin polymer or ethylene/alpha-olefin polymer blend; b) adding to the rheology-modified polymer, or polymer blend, a high melting polymer, selected from the group consisting of polypropylene homopolymers and propylene/ethylene copolymers, to form a composite polymer blend; and c) converting the composite polymer blend into the article of manufacture, the article of manufacture having a smooth surface appearance and a gel content that is below detectable limits when using xylene as the solvent in ASTM D 2765-90, method B; and wherein the amount of peroxide is based on the weight of the high melting polymer and the weight of either the elastomeric polymer of the elastomeric polymer blend. 16. An article of manufacture having at least one component thereof fabricated from the composition of claim 1. 17. The article of claim 16, wherein the composition further comprises at least one additive selected from the group consisting of process oils and fillers. 18. The article of claim 17, wherein the process oil is present in an amount within a range of from greater than 0 to about 50 percent by weight, based on total composition weight. 19. The article of claim 17, wherein the filler is selected from the group consisting of glass, silica, carbon black, metal carbonates, metal sulfates, talc, clay and graphite fibers. 20. The article of claim 17, wherein the filler is present in an amount within a range of from greater than 0 to about 70 percent by weight, based on total composition weight. 21. The composition of claim 1, wherein the peroxide to coagent ratio is from 1:10 to 1:20. 22. The article of claim 16, wherein the article is an extruded profile. 23. The article of claim 16, wherein the article is an injected molded article. 24. The article of claim 16, wherein the article is a blow molded article. 25. The article of claim 16, wherein the article is a calendared article formed from a high product line speed process. 26. The article of claim 16, wherein the article is an automobile body part. 27. The article of claim 16, wherein the article is a polymer film or polymer sheet. 28. The article of claim 16, wherein the article is a recreational vehicle part. 29. The article of claim 16, wherein the article is a roofing membrane. 30. The article of claim 16, wherein the article is a footwear component.