Polyphenylene sulfide alloy coated wire

A process for making an electrically conductive wire comprising the steps of:

• (1) extruding a partially grafted polymer around a wire, wherein said partially grafted polymer comprises:
• (a) from 40% to 90% by weight polyphenylene sulfide;
• (b) from 9% to 50% by weight of a polymeric grafting agent, said grafting agent comprising a copolymer wherein for every one hundred parts by weight copolymer (i) at least 50 parts by weight are derived from ethylene comonomer;
• (ii) from 0.5 to 15 parts by weight are derived from one or more reactive comonomer selected from the group consisting of:
• an unsaturated epoxide of 4 to 11 carbon atoms;
• an unsaturated isocyanate of 2 to 11 carbon atoms;
• an unsaturated alkoxy silane and an unsaturated alkyl silane, wherein the alkoxy and the alkyl group is from 1 to 12 carbon atoms;
• and an unsaturated oxazoline;
• and (iii) from 0 to 49 parts by weight are derived from an optional third comonomer selected from the group consisting of:
• an alkyl acrylate, alkyl methacrylate, vinyl ether, carbon monoxide, and sulfur dioxide, where the alkyl and ether groups are of 1 to 12 carbon atoms;
• and
• (c) from 1% to 20% by weight of an ethylene copolymer, wherein for every one hundred parts by weight ethylene copolymer (i) at least 50 parts by weight are derived from ethylene comonomer, (ii) from 1 to 35 parts by weight are derived from an acid-containing unsaturated carboxylic acid or anhydride comonomer, and (iii) from 0 to 49 parts by weight are derived from a comonomer selected from the group consisting of alkyl acrylate, alkyl methacrylate, vinyl ether, carbon monoxide, and sulfur dioxide, and further wherein the acid groups are neutralized from 0 to 100% by a metal ion;
• and
• (2) recovering electrically conductive wire wherein said wire meets SAE J1678 specifications at 125° C. or higher at a thickness of said polymer of less than 12 mils.