Source: http://www.google.com/patents/US20020135105?dq=6,373,753
Timestamp: 2017-11-18 18:25:20
Document Index: 83781172

Matched Legal Cases: ['§119', 'art 1', 'art 2', 'art 1', 'art 2', 'art 1', 'art 2', 'arts 1', 'art 1', 'arts 1', 'art 1', 'arts 1', 'art 1', 'arts 1', 'art 1']

Patent US20020135105 - Methods of making compositions comprising thermoplastic and curable polymers ... - Google Patents
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...http://www.google.com/patents/US20020135105?utm_source=gb-gplus-sharePatent US20020135105 - Methods of making compositions comprising thermoplastic and curable polymers and articles made from such methods
Publication number US20020135105 A1
Application number US 10/094,805
Also published as CA2440427A1, CA2440427C, DE60229728D1, EP1377428A1, EP1377428A4, EP1377428B1, US7037459, US7790291, US20060273493, US20110024934, WO2002072333A1
Publication number 094805, 10094805, US 2002/0135105 A1, US 2002/135105 A1, US 20020135105 A1, US 20020135105A1, US 2002135105 A1, US 2002135105A1, US-A1-20020135105, US-A1-2002135105, US2002/0135105A1, US2002/135105A1, US20020135105 A1, US20020135105A1, US2002135105 A1, US2002135105A1
Inventors Mark Easter
Original Assignee Easter Mark R.
US 20020135105 A1
1. 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.
2. A method of producing an article of manufacture comprising a thermoplastic polymer and a microwave, dielectric or radio frequency curable polymer comprising introducing said thermoplastic polymer and said microwave, dielectric or radio frequency curable polymer separately into a die or mold where said polymers come into intimate contact, and curing said microwave, dielectric or radio frequency curable polymer by exposure to microwave, dielectric or radio frequency energy.
3. A method for producing an article of manufacture comprising a thermoplastic polymer and a curable polymer, said method comprising the steps of:
calendering said thermoplastic polymer into a first sheet,
calendering said curable polymer into a second sheet,
pressing said first sheet together with said second sheet, and
curing said curable polymer.
4. The method of claim 3 wherein said curable polymer is selected from moisture-curable and microwave, dielectric or radio frequency curable polymers.
5. The method according to claim 1 wherein said polymers are introduced by a method selected from extrusion, injection and co-molding.
6. The method according to claim 2 wherein said polymers are introduced by a method selected from extrusion, co-extrusion, injection and co-molding.
7. The method according to claim 1 wherein said thermoplastic polymer is coextruded completely over and around said moisture-curable polymer.
8. The method according to claim 2 wherein said a thermoplastic polymer is coextruded completely over and around said microwave, dielectric or radio frequency energy curable polymer.
9. The method according to claim 1 wherein said moisture-curable polymer is coextruded completely over and around said thermoplastic polymer.
10. The method according to claim 2 wherein said microwave, dielectric or radio frequency curable polymer is co-extruded completely over and around said thermoplastic polymer.
11. The method according to claim 3 further comprising selecting a third sheet selected from a thermoplastic sheet and a curable polymer sheet and forming a laminate comprising at least three layers from said first, second and third sheets.
12. The method according to claim 1 wherein said thermoplastic polymer is molded over said moisture-curable polymer.
13. The method according to claim 1 wherein said moisture-curable polymer is molded over said thermoplastic polymer.
14. The method according to claim 2 wherein said thermoplastic polymer is molded over said microwave, dielectric or radio frequency curable polymer.
15. The method according to claim 2 wherein said microwave, dielectric or radio frequency curable polymer is molded over said thermoplastic polymer.
16. The method according to claim 1 wherein said thermoplastic polymer includes a foaming agent.
17. The method according to claim 2 wherein said thermoplastic polymer includes a foaming agent.
18. The method according to any of claims 2, 4, 6, 8, 10, 14, 15 or 17 wherein said microwave, dielectric or radio frequency curable polymer includes a foaming agent.
19. The method according to any of claims 1, 5, 7, 9, 12, 13 or 16 wherein said moisture-curable polymer includes a foaming agent.
20. The method according to claim 18 wherein the microwave, dielectric or radio frequency energy aids in the foaming due to the heat generated in the system by said microwave, dielectric or radio frequency energy that also cures the curable polymer.
21. The method according to claim 18 wherein the thermoplastic polymer is foamed and the microwave, dielectric or radio frequency energy aids in the foaming of the foaming agent in the thermoplastic polymer when excited by the microwave, dielectric or radio frequency energy.
22. The method according to claim 16 or claim 17 wherein the thermoplastic polymer is foamed by the foaming agent due to a change in pressure upon exiting the die.
23. The method according to claim 19 wherein the moisture-curable polymer is foamed by the foaming agent due to a change in pressure upon exiting the die.
24. The method according to any of claims 1, 2 or 3 wherein the thermoplastic polymer is selected from polyolefins having 2 to 20 carbon atoms; EP, EPR or EPDM rubbers; styrene/butadiene polymers, copolymers or block copolymers; polypropylene or polypropylene copolymers; styrene homopolymers or copolymers; thermoplastic elastomers; nylon 6, nylon 6-6 or nylon 12, and polyester resins.
25. The method according to 1 wherein the moisture-curable polymer is selected from RTV silicon compounds; styrenic homopolymers or copolymers; polyethylene, polyolefins comprising repeating units having from 3 to 20 carbon atoms; co-polymers of ethylene and a mono-unsaturated ester as well as terpolymers of these polymers; nitrile rubber, EP, EPR and EPDM rubbers, and butyl rubber.
26. The method according to claim 2 wherein the microwave curable polymer is selected from RTV silicon compounds, styrenic homopolymers or copolymers, polyethylene, polyolefins comprising repeating units having from 3 to 20 carbon atoms; co-polymers of ethylene and a mono-unsaturated ester as well as terpolymers of these polymers, nitrile rubber, SBS, SBR, EP, EPR and EPDM rubbers, and butyl rubber.
27. The method according to claim 2 wherein the microwave curable polymer, dielectric or radio frequency curable polymer is selected from co-polymers of ethylene and a mono-unsaturated ester, ethylene vinyl acetate and nitrile rubber.
28. The method according to claim 2 wherein the microwave, dielectric or radio frequency curable polymer further comprises from 0.1% up to about 50% by weight, based on the curable polymer, of an additive selected from carbon black, carbon soot, carbon fibrils, nanotubes, ethoxylated amines, a monoglycol ester of fatty acid, a diglycol ester of fatty acid, a polyglycol ester of a fatty acid, water and combinations of these polarizing materials, wherein the polarity of the additive causes heating by dielectric loss upon the application of microwave, dielectric or radio frequency energy.
29. The method according to claim 2 wherein the microwave, dielectric or radio frequency curable polymer further comprises a heat activated cure system selected from sulfur cure systems and organic peroxides.
30. The method according to claim 1 or claim 2 wherein migration of the curable polymer into the thermoplastic polymer causes interfacial cross links and improves the adhesion of the thermoplastic and curable polymers.
31. The method according to claim 1 wherein the moisture cure system is vinyl trimethoxy silane, organic peroxide and dibutyl tin dilaurate catalyst.
32. The method according to claim 2 wherein the microwave, dielectric or radio frequency curable polymer is cured by microwave energy in the frequency range of about 915 to about 2,415 MHz.
33. The method according to claim 2 wherein the microwave, dielectric or radio frequency curable polymer is cured by energy in the frequency range of less than about 900 MHz.
34. The method according to claim 1 or claim 2 wherein said article has a circular cross-sectional shape.
35. The method according to claim 1 or claim 2 wherein said article of manufacture is electrically conductive wire or cable.
This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Serial No. 60/274,632, filed Mar. 12, 2001.
[0023]FIG. 1 shows a cross section of a co-extruded or molded profile.
[0024]FIG. 2 shows a cross section of a co-extruded profile where a portion is co-extruded completely over and around another portion.
[0025]FIG. 3 shows a cross section of a co-extruded profile having a portion with a hollow section.
[0026]FIG. 4 shows a cross section of an article with a circular cross-sectional shape.
[0027]FIG. 5 shows a cross section of a calendered profile.
In one embodiment of the invention, a thermoplastic polymer is coextruded with a moisture-curable polymer. Both may be coextruded at high temperatures and speed. The coextruded article is then cooled in water. The water starts the curing process of the moisture-curable polymer as it cools both polymers in the article. The moisture-curable polymer can cure after sufficient time at room temperature or the cure may be accelerated by placing the entire article in a chamber containing high humidity, typically at 60-70 C, well below the melting point of the thermoplastic polymer. Uses of these articles may include but are not limited to weather stripping where either part of the weather-stripping may come into contact with heat or is clamped into an attachment where low compression set and creep and higher modulus are desired and the other part is desired to be soft, foamed or the like.
In an other embodiment of the invention, a thermoplastic polymer is coextruded completely over and around a moisture curable polymer. Both may be coextruded at high temperatures and speed. The coextruded article is then cooled in water. The water starts the curing process of the moisture-curable polymer as it cools both polymers in the article. The amount of water necessary for curing will quickly diffuse through the thermoplastic polymer or water may be introduced into hollow portions of the article. The moisture-curable polymer can cure after sufficient time at room temperature or the cure may be accelerated by placing the entire article in a chamber containing high humidity, typically at 60-70 C, well below the melting point of the thermoplastic polymer. Uses of these articles may include but are not limited to weather stripping where the outside is desired to be soft and pliable or foamed and the inside is desired to be stiff and creep and higher modulus resistant and have good elastic recovery.
In another embodiment of the invention, a moisture-curable polymer is coextruded completely over and around a thermoplastic polymer. Both may be coextruded at high temperatures and speed. The coextruded article is then cooled in water. The water starts the curing process of the moisture-curable polymer as it cools both polymers in the article. The moisture-curable polymer can cure after sufficient time at room temperature or the cure may be accelerated by placing the entire article in a chamber containing high humidity, typically at 60-70 C, well below the melting point of the thermoplastic polymer. Uses of these articles may include but are not limited to weather stripping where the outside is desired to have elastic recovery, abrasion and heat resistance and the inside is desired to be soft and resilient.
In another embodiment, a thermoplastic polymer is molded over a moisture-curable polymer. Both may be molded at the same rates as if they were thermoplastic. The article may then be cured over time at room temperature or cured at a faster rate in a warm water bath or high a chamber containing high humidity, typically at 60-70 C, well below the melting point of the thermoplastic polymer. Use for these articles include but are not limited to handles for ovens, pots or heating devices where the metal attachment might be very hot and cause a thermoplastic to melt and where the outside of the handle is desired to be soft and grippable.
In another embodiment a moisture-curable polymer is molded over curable a thermoplastic polymer. Both may be molded at the same rates as if they were thermoplastic. The article may then be cured over time at room temperature or cured at a faster rate in a warm water bath or high a chamber containing high humidity, typically at 60-70 C, well below the melting point of the thermoplastic polymer. Use for these articles include but are not limited to handles for tools or bumpers where the inside is desired to be soft and absorb shock and where the outside is desired to be hard, abrasion resistant or heat resistant.
In each of these embodiments the thermoplastic polymer may be but is not limited to a polyolefin with 2 to 20 carbon atoms, EP, EPR or EPDM rubbers, a polypropylene or polypropylene copolymer, styrenic homopolymers or copolymers, thermoplastic elastomer containing pre crosslinked EPDM or other rubber such as Santoprene® from Advanced Elastomer Systems, acrylonitrile/styrene/butadiene polymers, copolymers, terpolymers and block copolymers and terpolymers, nylon 6 or nylon 6-6 or nylon 12, and polyester resins, or combinations of the foregoing thermoplastic polymers. The thermoplastic polymers may contain foaming agents. It should be noted that some or all of these polymers may be able to be crosslinked with the proper additives under the proper conditions but primarily are intended to be used as thermoplastics in the present invention.
[0059]FIGS. 1 through 5 show very general cross sections of co-extruded, co-molded or calendered articles that are objects of the invention. These profiles may take on almost any shape that is required for their function in their end use. The drawings are not meant to be limiting as to shape or size. The objects of the invention may also have several areas of thermoplastic and thermoset materials if desired.
[0060]FIG. 1 shows a cross section of a co-extruded or molded profile where either part 1 or part 2 may be the thermoplastic part. Whichever part (i.e. part 1 or part 2)that is not thermoplastic may be microwave or moisture-curable depending on the properties desired.
[0061]FIG. 2 shows a cross section of a co-extruded profile where part 1 is coextruded completely over and around part 2, where either parts 1 and 2 may be the thermoplastic part and either other part 1 or 2 that is not thermoplastic maybe microwave or moisture-curable depending on the properties desired.
[0062]FIG. 3 shows a cross section of a co-extruded profile where either parts 1 and 2 may be the thermoplastic part and either other part 1 or 2 that is not thermoplastic may be microwave or moisture-curable depending on the properties desired and 3 may be a hollow section that may be desired for function, for example, for cooling or uniform extrusion or material savings or may carry an electrical conductor.
[0063]FIG. 4 shows a cross section of a co-molded article where either parts 1 and 2 may be the thermoplastic part and either other part 1 or 2 that is not thermoplastic may be microwave or moisture-curable depending on the properties desired and 3 is hollow section to be used for attachment, for example.
[0064]FIG. 5 shows a cross section of a calendered profile where either parts 1 and 2 may be the thermoplastic part and either other part 1 or 2 that is not thermoplastic may be microwave or moisture-curable depending on the properties desired.
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U.S. Classification 264/474, 219/678, 264/405
International Classification B29C47/06, B29C35/02, B29C35/08, B29C44/04
Cooperative Classification Y10T428/31663, B29C35/0266, B29C2035/0855, B29C44/04, B29L2031/3462, B29C47/0021, B29K2995/0005, B29C2035/0861, B29C47/06, B29C47/003
European Classification B29C35/02K, B29C47/06, B29C44/04
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:EASTER, MARK R.;REEL/FRAME:012759/0105