Methods of making compositions comprising thermoplastic and curable polymers and articles made from such methods

Abstract

Manufactured articles and methods of producing such articles are disclosed where the article has a thermoplastic polymer component and a curable polymer component. The curable polymer may be moisture-curable polymer, or microwave, dielectric or radio frequency curable polymer. The articles may be manufactured by a variety of polymer processing methods including extrusion, co-extrusion, co-molding, injection molding and calendering. A variety of articles and shapes may be made by the method including electric wire and cable, and weatherstripping.

1 - 35 . (canceled) 
     
     
         36 . A method of producing an article of manufacture comprising a thermoplastic polymer and a moisture-curable polymer, said method comprising introducing said thermoplastic polymer and said moisture-curable polymer separately into a die or mold wherein said polymers come into intimate contact, and curing said moisture-curable polymer by exposure to moisture wherein said moisture curable polymer comprises hydrolysable silane groups. 
     
     
         37 . The method according to  claim 36  wherein said hydrolysable silane groups are present in the moisture-curable polymer by grafting. 
     
     
         38 . The method according to  claim 36  wherein said hydrolysable silane groups are present in the moisture-curable polymer by copolymerization. 
     
     
         39 . The method according to  claim 36  wherein said moisture curable polymer is olefin based. 
     
     
         40 . The method according to  claim 39  wherein said moisture curable polymer is polyethylene based. 
     
     
         41 . The method according to  claim 36  wherein said moisture curable polymer further comprises a catalyst. 
     
     
         42 . The method according to  claim 41  wherein said catalyst is selected from the group consisting of peroxide, dibutyl tin dilaurate, carboxylate of zinc, carboxylate of lead, carboxylate of iron, carboxylate of cobalt, acid catalyst, base catalyst or mixtures thereof. 
     
     
         43 . The method according to  claim 36  wherein the moisture cure system is vinyl trimethoxy silane, organic peroxide and dibutyl tin dilaurate catalyst. 
     
     
         44 . A method according to  claim 36  wherein said cured moisture-curable polymer can not be further shaped by heat. 
     
     
         45 . The method according to  claim 36  wherein said thermoplastic polymer is co-extruded completely over and around said moisture-curable polymer. 
     
     
         46 . The method according to  claim 36  wherein said moisture-curable polymer is co-extruded completely over and around said thermoplastic polymer. 
     
     
         47 . The method according to  claim 36  wherein said thermoplastic polymer is molded over said moisture-curable polymer. 
     
     
         48 . The method according to  claim 36  wherein said moisture-curable polymer is molded over said thermoplastic polymer. 
     
     
         49 . The method according to  claim 36  wherein said thermoplastic polymer includes a foaming agent. 
     
     
         50 . The method according to  claim 36  wherein migration of the moisture-curable polymer into the thermoplastic polymer causes interfacial cross links and improves the adhesion of the thermoplastic and moisture curable polymers. 
     
     
         51 . The method according to  claim 36  wherein said article has a circular cross-sectional shape. 
     
     
         52 . The method according to  claim 36  wherein said article of manufacture is electrically conductive wire or cable.