CA2075599A1 - Thermoplastic films for heat seaming roof sheeting and method for covering roofs - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A laminate seam of flat rubber sheet material for roofing comprising two layers (10 11) of the sheet material at least one layer of which is uncured or cured and one layer of a thermoplastic film (14) interposed between the overlapped edges (12,13) of the two layers of sheeting material to form a seam without the use of an adhesive. A method for covering a roof comprises the steps of applying a thermoplastic film (14) to the edge (12) of at least one layer of a flat rubber sheet material (10);
applying a second layer of flat rubber sheet material (11) overlapping the thermoplastic film and the edge of the first flat rubber sheet material; heating the overlapped area to a temperature slightly above the peak melt temperature of the thermoplastic film; and, seaming the overlapped area under sufficient heat and pressure to provide an acceptable seam without the use of an adhesive.

Description

THEI~MOPLASTIC FILMS FOR HEA~T SEAMIN~ 9 SHEETING AND METIIOD FOR COVERING I~OOFS

TECHN~AL FIELD
5The present invention relates generally to sheeting material used for roofing.
More particularly a ~hin ~hermoplastic film is provided for seaming together tworeinforced or unreinforced rubber sheets comprising c~hylene-propylene-diene (EPDM) terpolymers, ethylene-propylene copolymers, or other similar olefin-type polymers, and mixtures thereof, as well as sheeting manufactured from butyl, neoprene, or other 10polymers, including polyvinyl chloride (PVC), chlorinated polyethylene (CPE), chlorosulfonated polye~hylene and the like. The rubber sheets may be sulfur cured or uncured, and scrim reinforced or not. A method is also provided for covering roofs which includes the step of employing the thin thermoplastic film of the present invention.
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BACKGROUND OF~ ~E lNVENTIO~
Polymeric roof sheeting is used as single ply roofing membrane for covering industrial and commercial flat roofs. Such membranes are generally applied to the roof surface in vulcanized or cured state.
~0Because of outstanding weathering resistance and flexibility, cured EPDM
based roof sheeting has rapidly gained acceptance. This material normally is prepared by vulcanizing the composition in the presence of sulfur or sulfur containing compounds such as rnercaptans. Our earlier U.S~ patent, No. 4,803,02~ also teaches the .us~ of : .
adiation crosslinking pro~no~ers in ~n EPDM sheeting composition which can be cured 25by ioni~ing radiation.
Notwithstanding the usefulness of radiation cunng and sulfur curing, a disadvantage of utilizing these elastomers is the lack of adhesion o~ EPDM, especially cured EPDM, to itself. Besides being highly labor intensive, this is a serious problem also because, in applying EPDM sheets to a roof, it is usually necessary to splice the 30cured EPDM sheets together~ This splice or seam area is subjected to~both silort term and long term stresses such as ~hose caused by roof movement, heavy winds, ~ee~e-thaw cycling and thermal cycling. Such stresses may manifest themselves in shear FIR.P~US0055 : - :

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forces or peel forces, i.e., the seam peels back w~der severe stress conditions or may cause a partially open seam (often referred lo as a fish-mouth condition) under less severe conditions.
In view of the foregoing problem, it has been necessary to utilize an adhesive S to bond the cured EPDM sheets together. As will be evident from the above discussion, an adhesive for bonding cured EPDM elastomer roofing sheets together must meet anumber of requirements which are extremely diff~cult to satisfy. Thus, the adhesive must provide sufficient seam peel and shear strength to permit the splice formed by bondin~ the cured EPDM roofing sheets together to resist both the short term and long 10 term stresses such as those discussed hereinabove. Moreover, the adhesive must be resistant to oxidation, hydrolysis and chemical attack from pooled water. ~dditionally, the adhesive must provide the important property often referred to in the adhesive art as "Quick Stick". The term "Quick Stick" refers to that charactenstic of the two sheets of material, which have been coated with an adhesive composition, to develop virtually 15 immediate adhesive strer~th when placed in contact with each other.
Quick Stick is an ex~remely important property in an adhesive which is utilized to splice cured EPDM elastomer roofing sheets together. Thus, adhesive compositions presently known, generally require anywhere from about two (2) to about . seven (7) days at room temperature (i.e. 22C) to attain maximum adhesive seam20 strength. At higher ambient temperature, this time period may be somewhat less but at a rninimum it will generally be at least 24 hours. The conventional procedure ~r ., , : ..
splicing the EPD~ ro~of!pg sheets togetheris to rna~ke th:e splice within a relati~!ely shor~
period of time after the adhesive coat~ng has been applied to each sheet, ~enerally within 30 minutes but often less. Accordingly, the adhesive composition must provide 25 sufficient immediate adhesive strength or Quick S~ick to permit the splice to withstand sttesses from winds, movernent, handling by installers, elc. until the adhesive achieves its maximum strength which as indicated will generally take from about two (2) to seven (7) days.
Commcrcial contact adhesives which are conventionaliy employed for 30 bonding cured EPDM elastomer roofing sheets together generally consist of solutions of neoprene or neoprene-type or butyl or butyl-type polymers in aromatic or aroma~ic-FIR.P.USOOSS

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- 3 - 2~7~9 ~3 aliphatic solvents con~ining 2-butanone often along with lackifying resins. Howeverl such adhesives have not proven to be very satisfactory due to their lower than desirable seam peel adhesion strengths. Thus, the neoprene or butyl-type adhesives often provide peel adhesion values at 22C of only 1 to 2 pounds per linear inch. Additionally, the 5 use of organic solvents in such systems would likely run afoul of environmental regulations, and which control the release of volatile organics.
Pressure sensitive and contact adhesive compositions containing neutralized, partially neutralized or unneutralized sulfonate elastome~s, tackifying resins and organic solvents or organic solvent mixtures are known in the prior art as shown by U.S. Pat.
No. 3,801,531 and 3,867,247.
U.S. Pat. No. 3,801,531 relates to pressure sensitive adhesive compositions which contain thiouronium derivatives of unsaturated elastomers or neutraliæd, partially neutralized or unneu~ralized sulfonated elastomers including sulfonated EPDM, tackifying resins including phenol formaldehyde or alkylphenol formaldehyde resins and organic solvents or crganic solvent mixtures including a preferred 90:10 mixture of toluene and isopropyl alcohol. However, the patent does not disclose or suggest the use of alkylphenols or ethoxylated alkylphenols in such compositions.
U.S. Pat. No. 3,867,247 relates to adhesive contact cements which contain neutralized, partially neutralized or unneutralized sulfonated butyl elastomers, tackifying ~0 resins including phenol formaldehyde or alkylphenol formaldehyde resins and organic solvents or organic solvent rnixtures including a preferred 90:10 mixture o~;toluene and ` isoprQpyl alcohol; However, ~e patent does not disclose or suggest the use of alkylphenols or ethoxylated alkylphenols in such compositions.
The adhesive compositions described in the aforementioned patents suffer from a significant disadvantage which materially limits their usefulness as a contact adhesive for bonding cured EPDM elastomer roofillg sheets together and that is their ~eficiency in Quick Stick properties~ Also the use of organic solvents in such systems would likely mn afoul of environmental regulations, which eontrol the release of volatile organics~
One adhesive system for EPDM elastomers that provides good Quick Stick is described in U.S. Pat~ No. 4,480,012, owned by the Assignee of record herein~ Such FIR.P~US0055 .
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adhesives comprise a neu~ralized sulfonated EPDM elastome~ic telpolymer; an organic hydrocarbon solven~; a para-allcylated phenol formaldehyde tackifying resin and an alkylphenol or ethoxylated alkylphenol. While the use of such adhesive compositions is an effective means of joining and sealing the edges of elastomeric roofing material, S if the use of adhesives could be eliminated, the additional labor material costs and related hardware necessary to apply the adhesive would effect a significant cost savings.
Moreover, elimination of ~he need to cure the material prior to its application to a roof would also be advantageous.
Co-pending application U.S. Pat Application Ser. No. 07/594,461 discloses 10 a sheeting material composition which eliminates the need for adhesives, solvents and the need for curing prior to application to the roof. While these advantages e~fect cost savings and are environmentally prudent7 a need exists for providing a roof covering system which bonds quicker and results in a stronger bond. The high rate of bonding would also ensure that the roofing is water tightj an important requiremeslt for most 15 applications. A seam of:variable width and hence streng~h is also desirable.

SUMMARY OF THE INVENTION
It is an object of the present invention to provide a thermoplastic film which replaces traditional adhesives for seaming together two reinforced or unreinforced, cured 20 or uncured EPDM or EPR roof sheeting ma~erials.
It is another object of the present invention to provide a thermoplastic film ` - .for EP~M and EPR roof. sheeting materi~ls ~4hich eliminates the ne~ for ~ solvent or non-solvent based splicing adhesive and the related labor and hardware necessary for mixing and application thereof.
~5 It is still another object of the present invention to provide a thermoplastic film for seaming together two EPl:)M, EPR or other olefin type roof sheeting materials, which do not necessarily require curing and which can be joined and seamed together at their edges without the use of adhesives, either solvent or non-solvent based.
It is a further object of the present invention to provide a thermoplas~ic film 30 as described above which results in a water tight fit between the r~f sheeting materials.

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. . . ~., :- . ~ . -Yet ~na~her Pbjoct o~ tlle present in~cnlion is ta providl~ ~ ~her~opl~ c film as described above whlch climinates the use o~ or~anic solvents ~n seaming ~o~eth~r EPI:)M or ~3PR roof shcc~;n~ materials. I
It is still an~thel obj~ct of th~ p~enl invcnlion 1~ pr~llide a th~rmopla~c film as describecl ~.bov~ which can ~e used to ~orm R s~m of vali~lc widlh and henc~
varied stren~,th ~etw~:n two layers ~f EPDM or EPR roof ~ee~ln~
` ln genc~al Ihc present inventlon ~late~ to a lamlnate~Eeam of flat nlbbor shee~ ma~cr;al for r~ofin& comprisin& two layers of ~heet rnatena1,f:~t least one layer of whlch js unc~red ar cur~; and one layer of a therm~plastic fllm 3lll~sed betw~cn the cdg~ area of the lwo layers c)f she~ mater~al, when th~ ed~ verlappcd to ~rm a seam wilhout th~ us~ of ar adh~slvo.
A molhod for covoring a tOO~ l9 also p~ovîdcd ~nd ~ pl~5es the 4~cps of applying a thermaplas~lc film t~ she cdg~ ~rca o~ at le~ss one Jayol ~f ~ ftat rubbor sheet material; applyin~ ~ ~cond lay~r of flat rubb~ ~h~ ~ 1 overlapping th~
thermoplastio fflm and the ~ of l rst n~t mbbor sh~ ial; h¢a~lng the rlapped areas ~o sll~htly abo~e th~ peak m~ temp~ Ure o~ tH4 ~h~rmopl~s~ic film snd 2ieamin~ tho overlapped ~ea~ uslng sufflclent he~ and pr~æur4 to provid~
~ccept~blc seam wi~hout ~h~ use of an adhe31v&. : I
~h~ toof ~heetln~ used lQ praclic~ ~hls ~nYentian may al~ b~ sulfur ~urable.
~o~h un~ured and aure~ ro~fin~ n~emb~ may ~p~lonally b~ 2~ rcln~.
~t least, on~ or In~r~ of ~h~ egoing ~ec~ which sl~ll heoom~ apparen~
to ~thosc skllle~ ln ~le ar~. ar~ ~scri~)ed in ,~tea~ d~tall wl~h rcferen~c to th~ :
specifieation which follows.

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~h~ drawing fl~ure is a venic~ 6ross-s~ctioll of l.w~ ~ingle ply ~PDM
rooflng mem~anes, jcllned at ~he seam area by a ~hernloplastic fl~, a~di~ o presenl in~en~i~n.

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~REF ERRED lEM~OD~MENT ~ ~E INViENTIVlY
As noted, the sheeting matenals used in ~he present invention comprise EPDM, EPR or other similar olefin type polymers. The term EPDM is used in the sense of its definition as found in ASTM-D-1418-85 and is Intended to mean a terpolymer of ethylene, propylene and a diene monomer with the residual unsaturation portion of the diene in ths side chain. Illustrative methods for prepanng such terpolymers are found in U.S. Pat. No. 3,280,082, the disclosure of which is incorporated herein by reference. The preferred polymers having from about 60 toabout 9S weight percent ethylene and from about zero to about 12 weight percent of the diene wi~h the balance of ~he polymer being propylene or some other similar olefin type polymer.
The diene monomer utilized in forming the EPDA~ terpolymer is preferably a non-conjugated diene. Illustrative examples of non-conjugated dienes which may be employed are dicyclopentadiene, allcyldicyclopentadiene, 1 ,4-pentadiene, 1 ,4-hexadiene, 1,S-hexadiene, 1,4-hept~diene~ 2-methyl-l,S-hexadiene, cyclooctadien~, 1,4 octadiene, 1 ,7-octadiene, 5-ethylidene-2-norbornene, S-n-propylidene-2-norbornene, 5-(2-methyl-2-butenyl)-2-norbornene and the like. A typical BPDM is Vistalon~ MD-744 (Exxon Chemical Co.) a te~polymer having a Mooney Viscosity (ML/4 at 125C) of about 52;
an ethylene/propylene (E/P) ratio of 61139 weight percent and 2.7 weight percent of unsaturation.
. Particularly useful and preferred i~i preparing a sulfur curab~ç EPDM
composition is Royalene~:3 180 ~Uniroya; ~:hem~c~l Go.) wl~ch has a M~ney Viscosity (ML14 at 125C) of about 54; an ethylene/propylene ratio of about 67/33 weight percent; about 2.2 weight percent of unsaturation (S-ethylidene-2-norbornene); about 2.7 ~5 percent by weight of crystallinity and a weight average molecular weight of approximately 313,000 to 355,000. Vistalon~ MD-744 (Exxon Chemical Co.) is another :seful sulfur curable EPDM rubber having a Mooney Viscosity (ML/4 at 12S C~ of about 53; an ethylene/propylene (EIP) ratio of about 60/40 wei~ht percent; about 2.7 weight percent of unsaturation (5-ethylidene-2-norbornene) and a weight average of approximately 360,000. Also useful are thermoplastic heat searnahle sheeting materials, i.e., EPDM's and EPR's having a high degree of crystallinity as opposed to amo~hous FIR.P.US0055 . .

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(non-crystalline) EPDM~s or EPR's. Examples thereof include Royalene~ 375 (Uniroyal Chemical Co.); and EPsyn~9 5508 and EPsyn~ MD~ 249 (Copolymer Rubber &
Chemical Corporation). Royalene0 375 has a Mooney Viscosity (ML14 at 125C) of about 50.8; an E/P ratio of 75/25 weight percent and about 2.0 weight percent ofS unsatura~ion (dicyclopentadiene) and a weight average molecular weight oî
approximately 190,000. EPsyn0 5508 has a Mooney Viscosity (ML14 at 125C) of about 55.~; an E/P ratio of 73l27 weight percent and about 3.7 weight percent ofunsaturation. EPsyn~ MDE 249, an expeAmental terpolymer has a Mooney Viscosity (ML/4 at 125C) of about 56; an E/P ratio of 71/29 weight percent and about 1.7 10 weight percent of unsa~lration (5-ethylidene-2-norbornene) can also be employed. A
more complete discussion of heat seamable malerials, is set forth in our copending application, U~S. Ser. No~ 07/594,457, the subject matter of which is incorporated herein by reference~
The term EPR is used in the sense of its definition as ~ound in ASTM D-1418-85 and is intended t~ mean a copolymer of ethylene and propylene. The preferred copolymers contain from about 30 to 95 weight pereent ethylene with the balance to total 100 weight percent being propylene~ A typical EPR is Vistalon~ 719 (Exxon Chemical Co~) having an EIP ratio of about 75/25 weight percent~
Also, useful as a roofing material in the present invention is a copolymer of ethylene and butene. This particular copolymer has about 82 weight percent ethylene with the balance to total 100 weight percent being ~utene. A typical ethylene/butene copol'ymer is .GERS:108~ (Union Carbide ,C~rporatior1) haYing`an MYv,' as rneas'ured by GPC of ai least about 221,000. Olher similar olefinic polyrners (e.g., ethyleneloctene copolymer) ean be used to practice this invention. Generally speaking any semi-crystalline polymer having more than about 2 percent by weight crystallinity andselected from the group consisting of polyolefins prepared from monomers containing at least 2 carbon atoms can be employed. For purposes of discussion herein, references to EPDM, BPR or similar olefinic polymers is intended to include any of the semi-crystalline polymers of the present invention.
The composition employed to form the sheeting material comprises 100 parts by weight of EPI)M, EPR, or olher similar olefinic type polymers, including mixtures FIR.P.US0055 - 8- ~~
of two or more types, to which are added fillers and processing materials as well æ
optionally other components including curatives, all of which are discussed hereinbelow.
With respect first to the fillers, suitable fillers are selected from the group consisting of reinforcing and non-reinforcing materials, and mixtures thereof, as are customarily added to rubber. Examples include such materials as carbon blaclc, ground coal, calcium carbonate, clay, silica, cryogenically ground mbber and the like.
Preferred fillers include carbon black, ground coal and cryogenically ground rubber.
Carbon black is used in an amount of about 20 parts to about 300 parts per 100 parts of polymer (phr), preferably in an amount of about 50 to abous 150 phr. The preferred range of carbon black herein (60 to 150 phr) is about equal to the amount of carbon black normally used in preparing sulfur cured EPDM roof sheeting. The carbon black useful herein is any carbon black. Preferred are furnace blacks such as QPP
(general purpose furnace), FEF (fast extrusion furnace) and SRF (semi-reinforcing furnace).
The ground c~al employed as a filler in the compositions of the invention is a dry, finely divided black powder derived from a low volatile bituminous coal. The ground coal has a particle size ranging from a minimum of 0.26 microns to a maximum of 2.55 microns with the average particle size of 0.69 ~t 0.46 as determined on 50 particles, using Transmission Electron Microscopy. The ground coal produces an aqueous slurry having a pH of about 7.0 when tested in accordance with ASTM I)-1512.
A preferred grour~d coal of this type is designated Austin Black which has a specific gravit~Y of ~1~.22 + ~.Q3; an ash content of 4.58% and a sul~ur content ~f ~;~5%. 'A'ustin Black is commercially available from Coal Fillers, Inc., P.O. Box 1063, B'luefield, Virginia. Amounts range from about 5 to 65 phr with about 15 to 35 being preferred.
Finally, essentially any cryogenically ground rubber may be employed as a filler in the composition of the invention. The preferred cryogenically ground rubbers are cryogenically ground EPDM, butyl, neoprene ~nd the like. A preferred cryogenically ground rubber is a cryogenically ground EPDM rubber. The preferredcryogenically ground EPDM rubber is a~ fine black rubbery powder having a specific gravity of 1.1~9 ~ 0.015 and a particle size ranging from about 30 to about 300 PlR.P.VS0055 ., ~ .. .. . . - :
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microns wi~h an average particle size ranging from about 50 to about 80 microns~Amoun~s range from about 5 to 40 phr with about 10 to 25 phr being preferred.
Mixtures of Aus~in black and cryogenically ground rubber useful herein may be utilized as a partial replacement for carbon black. Where mixtures of these two S fillers are employed the relative amounts thereof can be widely varied; the overall total not exceeding about 60 phr. The ratio of Austin black to cryogenically ground rubber may ran~e from a desired ratio of 2:1 to perhaps even a ratio of 3:1. Again, as noted hereinabove, other filler materials can be employed. Amounts of ~hese filler materials fall within the range of amounts normally employed in preparing sulfur cured 10 conventional roof sheeting.
Wi~h respect to the processing material, it is included to improve the processing behavior of the composition (i.e. reduce mixing time and increase rate of sheet forming and includes processing oils, waxes and the like). The processing oil is included in an amount ranging from about 20 parts to about 150 parts process oil per 100 parts EPDM ingredi~nt phr, preferably in an amount ranging from about 60 to about 100 phr. A preferred processing oil is a paraf~lnic oil, e.g. Sunpar 2280 which is available from the Sun Oil Company. Other petroleum derived oils includin~ naphthenic oils may be used.
Optional ingredients include, for example, other elastomers ~e.g., butyl elastomer, neutralized sulfonated EPDM, neutralized sulfonated butyl) in place of minor amounts of the EPDM, secondary inorganic fillers ~e.g., talc, mica, clay, silicates, .
.` whiting~ with total secon:dary filler content.usually ran~ing from abbut 10 to about 150 phr, and conventional amounts of other conventional agents, such as zinc oxide, stearic acid, antioxidants, antiozonants, flame retardants, and the like.
2S Regarding curatives, sulfur is preferred in amounts of about 0.3 to 2 phr.
As noted hereinabove, the roof sheeting compound is no~ cured prior to application and need not be cured subsequent thereto. The presence of sulfur enhances bonding of the seams.
The compounding ingredients can be admixed, u~ilizing an internal mixer (such as a Banbury mixer), an extruder, and/or a two-roll mill, or other mixers suitable for forming a viscous relatively uniform admixture. When utilizing a type B Banbury FIR.P.US0055 i ~ -- ~ ~ - , :' - 10 ~

internal mixer, in a preferred mode, ~he dry or powdery materials such as carbon black are added first followcd by the liquid process oil and finally the polymer (this type of mixing can be referred to as an upside-down mixing technique~.
The resulting admixture is sheeted to thickness rangin~g fram S to 200 mils, S preferably from 35 to 60 mils, by conventional sheeting methods, ~r example, milling, calenderin~ or extrusion. Preferably, the admixture is sheeted to at least 40 gauge ~0.040 inches) which is the minimum thickness specified in standards set by the Roofing Council of the Rubber Manufacturers Association for non-reinforced black EPDM
rubber sheets for use in roofing applications. In many cases, the admixture is sheeted 10 to 40-45 gauge thickness since this is the thickness for a large percentage of "single-ply"
roofing membranes used commercially. The sheeting can be cut to desired length and width dimensions at this time.
The present invention is practiced by utilizin~ a thermoplastic film between sheets of EPDM or EPR formed from materials as described herein. Once the first lS sheet is unrolled over tl~e roof substructure in an otherwise conventional fashion, a thermoplastic film is applied to the edge or edges of the first sheet material in the seam area. The next sheet is then applied onto the roof overlapping the thermoplastic film to form a seam. The width of the seam can vary depending on the requirements specified by the architect, building contractor or roofing contractor and thus, does not 20 constitute a limitation of the present invention. Generally, seam widths can vary between about 1 to 6 inches.
` With referçnce to the drawing. figure,` two layërs of roofing membranë sheet material, io and l l, are depicted witll the edge area 12 of sheet 10 bein~ overlapped by the edge area 13 of sheet 11 to form a seam. Interposed between these overlapped~5 edges, is a layer of thermoplastic film 14 which is employed according to the present inven~ion ~o form the seam, without the use of adhesives.
The thin thermoplastic film of the present invention may comprise a polyolefin prepared from a monomer or monomers having from 2 to about 8 carbon atoms, such as polyethylene, polypropylene, polybutene, polyoctene and the lil~e, as well 30 as ethylene-vinyl acetate copolymers and blends thereof. Generally, the thickness of the film can range between from about 2 ~o about 20 mils although greater thicknesses may FIR.P~US0055 . , .

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be employed and thus, are not precluded. For testing purposes, polyethylene films were primanly employed.
Infrared spectrum of these lin¢r films indicated the presence of only ethylene monomer uni~s. Mils of thickness and peak melt temperature (as determine using the 5 Differential Scanning Calorimeter) for each of the thermoplastic materials are provided in Table I.

Table I
THERMOPLASTIC FILMS
Seaming Material Thiclcness (mi!~ Tm. ~
y Dsc!
Red PE liner 3-4 108.7a Tr~nsparent PE liner 3 111.8a Embossed PE liner ~ 4-5 109.4a Pail liner-opaqueb 15-18 l3o.sa 15 High MW Polyethylene sheeting plS0C 6 139.4a p550C , 140.5a ,, ~ : . . . .. ..
a) Peak melt temperature 20 b) High density polyethylene c) STAMYLAN UH~

Next, heat and some pressure ate applied to the overlapped edges of two roof sheets to form a seam. At the location of the seam, temperature is conveniently applied ~5 from about 100 to 550C using a Leister hand-held heating gun and some pressure.
Genetally, the seam area should be hea~ed to slighlly above the melt temperature of ~he thetmoplastic film. Pressure can vary widely from a minimum of about 3 psi to as high PIRP.US0055 .~ -: .
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as 60 psi, typically so long as it is adequate to provide an acceptable, water tight seam.
Numerous techniques which ulilize heat and some pressure can be used to produce a fully acceptable seam as are known to those skilled in the art.
In order to demonstrate practice of the present invention, seams were formed S by bonding together layers of EPDM sheet material and various thermoplastic films.
These seams were prepared and subjected to both peel and shear adhesion tests, the results of which are provided in Tables III and IV. The EPDM sheeting compositions employed for the tests are shown in Table II hereinbelow. The compositions exemplified are submitted for the purpose of ~urther illustrating the nature of the present 10 invention and are not to be considered as a limitation on ~he scope thereof. Palts and percentages are by weight, unless otherwise indicated.
Compound Nos. 1 and 2 are typical EPDM polymers, which are not highly crystalline. Compound No. 3 is a hi~hly crystalline EPDM having greater than 2 percent crystallinity, derived from a high ethylene content, that is, greater than 75 15 weight percent. We have found such EPDM and EPR polymers to be useful as rooftop sheet material that is self-adhering i.e., no adhesive is required between overlapped layers to form the seam. Of course, the present invention can be employed with such materials as well as more highly crystalline EPDM and EPR polymers which do require the use of an adhesive or thermoplastic films of the present invention. A more complete 20 description of self-adhering rooftop materials is set ~orth in our copending application, U.S. Ser. No. 07/594,457, the subject matter of which is incorporaled herein.

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- 13- ~7~9 TABLE II
SULFUR CUl?.ED AND UNCURED BLACK EPDM SHEETING

~QmpQund No Royalene0 3180 100 100 EPsyn~ MD~ 249 ~ 100 HiStr GPF black 60 122 125 Hi-White~DRa 60 ---Austin Black --- 15 ---Paraffinic process oil 65 87 80 Zinc oxide ; 2.5 4 ---Stearic acid 1 1 ---Ma~nesium hydroxide 30 --- ---Cure Package 2.90 4.20 ---, TOTAL .321.40 333.2 305 , ~ . , . , ~ ,.. . . . . ... . . . . .. .. . . .. ..
Specific gravi~y (calc.) 1.2748 1.1322 1.1099 Scrim Reinforcement yes no yes a) airfloated soft clay from J.M. Huber Corp.
Detailed Peel and Shear AdhesiQn Test Proced~;
, Each of the above rubber compounds was subjected to adhion ~esting which necessitated the building of test pads comprising 6 x ::6 inch~ sheets, some reinforced by : FIR.P.U50055:

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a fiber reinforcement scrim, and some unreinforced, according to the following procedure:

1. A number of 6 x 6-inch rubber sheets approximately 45 mils (0.045-inches) in S thickness were prepared using factory calendered membrane sheeting, some reinforced with a scrim fabric and some unreinforced. Some of these membranes were vulcanized with sulfur and some were of the uncured variety.

2. A 6x6 inch sheet of the selected thermoplastic film was inserted between two 6x6 inch sheets of rubber.

3~ Most of the rubber film assemblies were formed with a hand-held Leister heating gun at 420C and 1.5-5 Ibs pressure to the seam itself. Pressure was applied to the seam during the heating process using a standard hand roller such as a 2 inch lS wide metal roller. -4. If the high MW polyelhylene film was used either (PlS0 or PSS0), the rubber/
thermoplastic film assembly was then pressed using a positive pressure mold for about five minutes at 149C.
S. . A clicker machine with a one-inch wide die was utilized to pre~are a number of ~ tesL specimens for seam peel (I~pe B, 9~ peel? and shear (Type A, 180 peel) adhesion testing.

6. Testing machine: Model 1130 Instron Universal Tester - a testing machine of the constant rate-ofjaw separation type. The nnachine was equipped with suitable grips capable of clamping the specirnens firmly and without slippage throughout the tests.

30 7. The one-inch wide specimens were tested at the rate (both crosshead and chart speed) of two inches per rninute using ~he adhesion test set forth in ASTM D-413 - E;IR.P.US0055 ,: . , .

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tmachine method). Bolh peel and shear adhesion strength were determined at room temperature (i.e., 23C) as well as occasionally at 70 and 100C.
Specimens were allowed 15 minutes to preheat prior to testing at elevated temperatures.

8. Adhesion strength is defined as:
peel adhesion strength (Ibs./inch) = pounds force x sample width;
shear adhesion strength (Ibs./square inch) = pounds force x sample width.

A number of test specimens were prepared for testing using the $ gallon pail liner. First, a 9 ~o 10 mil film of the liner was prepared by heating the pail liner between Mylar film in a positive pressure mold. The resulting 10 mil film was inserted between two layers of rubber and pressed in a 6x6 inch positive pressure mold for about S minutes at 149C. The pail liner has a peak melt temperature of about 129C to 130C.
Rubber test pads were prepared in a yositive pressure mold using about 138.8 lbs/in2 and about 13.9 lbs/in2 on the 6x6 inch rubber test pad. All Instron testing was conducted using a crosshead and chart speed of 2 ipm. All one inch wide testspecimens were preheated for 15 minutes when tested at an elevated temperature.
Table III below shows a comparison of peel adhesion properties of roof coverin& obtained using the ~hermoplast!c films of Tablè I in conjunction with the .. shee~ing of Table II ànd rQof coverif~g obt~ined usi~)g a regular adhesive (Exar~ple No.
1) and the sheeting of Table II. Roof sheeting formed from the compositions shown in Table II may optionally be scrim reinforced. Table IV shows a comparison of peel25 adhesion properties at elevated temperatures. Table V shows the sarne comparison for shear adhesion properties.
In the examples illustra~ed in l`ables III, IV and V, the control adhesive used was the commercially available lap splice adhesive Uniroyal SA-1065, a butyl based lap splice adhesive for EPDM roof sheet materials. The composition of the BPDM
30 shee~in~s used in Table III is provided in Table II.

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Peel adhesion as shown in Table III for the adhesive seamed conventional black EPDM membrane (control) a~ 23C was 1-7 Ibs/inch, while seam shear adhes;on at 23C in Table V was 27 Ibs/square inch. The control adhesion test samples were prepared using an unreinforced sulfur cured conventional black EPDM membrane S seamed with SA-1065, a lap splice adhesive commercially available from Uniroyal Chemical. A substantial increase in both peel and shear adhesion resulted using either lhe unreinforced, sulfur cured EPDM (II) sheeting nr the reinforced, uncured ~PDM
(III) sheet seamed with the HDPE (pail liner) or the ultra high MW polyethylene (P150/P550) relative to the adhesive seamed control. Both tlle sulfur cured and uncured 10 black EPDM (I - III) sheets were seamed with the polyethylene liners and gavecomparable andlor directionally improved seam peel adhesion results. These adhesion results demonstrate that the use of polyethylene films such as those comprising polyethylene and using sufficien~ heat and some pressure allows the formation ofacceptable seams without using adhesives. None of the experimental seams were wash 15 or scrubbed with gasoli5~e or organic solvents during seam preparation.
In conclusion, it should be clear from the foregoing examples and specification disclosure that the use of a thermoplastic film in conjunction with flat sheets featuring sulfur cured or uncured EPDM, EPR or other olefin type polymersallows such sheet rnaterial to be seamed along the overlapped edges, using sufficient 20 heat and some pressure, without the use of adhesives. Moreover, the sheet materials may not require that a dusting or release agent be applied to the surface of themembrane followed by a~toclave curing. ~Iso, roof sheeting material formed frorn the formulations shown in Table II may optionally be scrim reinforced. It is to be understood that the invention is not limited to the specific types of thermoplastic films 25 or }3PDM exemplified herein or by the disclosure of other typical EPDM, EPR or other olefin type polymers provided herein, the examples having been provided merely to demonstrate the practice of the subject invention. Those skilled in the art may readily select other thermoplastic films, or other EPDM, EPR or o~her similar olefin polymers including copolymers of ethylene and butene and elhylene and octene, according to the 30 disclosure made hereinabove. Similarly, lhe invenlion is not necessarily limited to the particular fillers and processing material exemplified or the amounts thereof PIR.P.US0055 :

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Claims (34)

1. A laminate seam of flat rubber sheet material for roofing comprising:
two layers of said sheet material, at least one layer of which is uncured or cured; and one layer of a thermoplastic film interposed between the edge area of said two layers of roofing membrane when said edge areas are overlapped to form a seam without the use of an adhesive.

2. A laminate seam of flat rubber sheet material, as set forth in claim 1, wherein said film is selected from the group consisting of polyolefins prepared from monomershaving from about 2 to 8 carbon atoms, ethylene-vinyl acetate copolymers and blends thereof.

3. A laminate seam of flat rubber sheet material, as set forth in claim 2, wherein each said layer of flat rubber sheet material comprises a polymeric composition of matter formed from a polyolefin copolymer, optionally modified by a diene momomer.

4. A laminate seam of flat rubber sheet material, as set forth in claim 3, wherein said polyolefin polymer is selected from the group consisting of EPDM and EPR
rubbers and said composition of matter further comprises from about 20 to 300 parts by weight of a filler selected from the group consisting of reinforcing and non-reinforcing materials and mixtures thereof per100 parts of said polymer, and from about 20 to 150 parts by weight of a processing material and mixtures thereof, per 100 parts of said polymer.

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5. A laminate seam of flat rubber sheet material, as set forth in claim 4, wherein said polymer comprises EPDM having an ethylene content of about 75 percent by weight and a weight average molecular weight of about 190,000.

6. A laminate seam of flat rubber sheet material, as set forth in claim 5, wherein said filler comprises about 110 parts by weight of carbon black and said composition of matter includes about 70 parts by weight of processing oil, per 100 parts of said polymer.

7. A laminate seam of flat rubber sheet material, as set forth in claim 6, further comprising from about 0.3 to 2 parts by weight of a curative, per 100 parts of said polymer.

8. A laminate seam of flat rubber sheet material, as set forth in claim 7, wherein said curative is sulfur.

9. A laminate seam of flat rubber sheet material, as set forth in claim 4, wherein said polymer comprises EPDM having an ethylene content of about 60 percent by weight and a weight average molecular weight of about 360,000.

10. A laminate seam of flat rubber, as set forth m claim 9, wherein said filler comprises about 110 parts by weight of carbon black and said composition of matter includes about 70 parts by weight of processing oil, per 100 parts of said polymer.

11. A laminate seam of flat rubber, further comprising from about 0.3 to 2 parts by weight of a curative, per 100 parts of said polymer.

12. A laminate seam of flat rubber sheet material, as set forth in claim 11, wherein said curative is sulfur.

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13. A laminate seam of flat rubber sheet material, as set forth in claim 4, wherein said polymer comprises EPDM having an ethylene content of about 67 percent by weight and a weight average molecular weight of about 313,000 to 355,000.

14. A laminate seam of flat rubber sheet material, as set forth in claim 13, wherein said filler comprises about 110 parts by weight of carbon black and said composition of matter includes about 70 parts by weight of processing oil, per 100 parts of said polymer.

15. A laminate seam of flat rubber sheet material, as set forth in claim 14, further comprising from about 0.3 to 2 parts by weight of a curative, per 100 parts of said polymer.

16. A laminate seam of flat rubber sheet material, as set forth in claim 15, wherein said curative is sulfur.

17. A laminate seam of flat rubber sheet material, as set forth in claim 4, exhibiting a seam peel adhesion value of at least about 2 pounds/inch, in the absence of anadhesive.

18. A laminate seam of flat rubber sheet material, as set forth in claim 4, exhibiting a shear adhesion value of at least about 15 pounds/square inch, in the absence of an adhesive.

19. A laminate seam of flat rubber sheet material, as set forth in claim 1, wherein said flat rubber sheet material is uncured.

20. A laminate seam of flat rubber sheet material, as set forth in claim 1, wherein said flat rubber sheet material is scrim-reinforced.

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21. A laminate seam of flat rubber sheet material, as set forth in claim 1, wherein said flat rubber sheet material is unreinforced.

22. A laminate seam of flat rubber sheet material, as set forth in claim 1, wherein said thermoplastic film has a thickness of from about 2 to 20 mils.

23. A method for covering a roof comprising the steps of:
applying a thermoplastic film to the edge area of at least one layer of a flat rubber sheet material;
applying a second layer of said flat rubber sheet material overlapping said thermoplastic film and the edge of said first flat rubber sheet material;
heating the overlapped areas to slightly above the peak melt temperature of the thermoplastic film, and seaming the overlapped areas under sufficient pressure to provide an acceptable seam without the use of an adhesive.

24. A method, as set forth in claim 23, wherein said step of heating is conducted under a temperature of at least about 100°C.

25. A method, as set forth in claim 23, wherein said thermoplastic film is selected from the group consisting of polyolefins prepared from monomers having from 2 to about 8 carbon atoms, ethylene-vinyl acetate copolymers and blends thereof.

26. A method, as set forth in claim 24, wherein each said layer of flat rubber sheet material comprises a polymeric composition of matter formed from a polyolefin polymer, optionally modified by a diene momomer.

27. A method, as set forth in claim 26, wherein said polyolefin polymer is selected from the group consisting of EPDM and EPR rubbers and said composition of matter further comprises FIR.P.US0055 from about 20 to 300 parts by weight of a filler selected from the group consisting of reinforcing and non-reinforcing materials and mixtures thereof per100 parts of said polymer; and from about 20 to 150 parts by weight of processing material and mixtures thereof per 100 parts of said polymer.

28. A method, as set forth in claim 27, wherein said filler comprises about 110 parts by weight of carbon black and said composition of matter includes about 70 partsby weight of processing oil.

29. A method, as set forth in claim 27, comprising the further step of:
adding from about 0.3 to 2 parts by weight of a curative, per 100 parts of said polymer to said composition of matter.

30. A method, as set forth in claim 29, wherein said curative is sulfur.

31. A method, as set forth in claim 23, wherein said flat rubber sheet material is uncured.

32. A method, as set forth in claim 23, wherein said flat rubber sheet material is scrim-reinforced.

33. A method, as set forth in claim 23, wherein said flat rubber sheet material is unreinforced.

34. A method, as set forth in claim 23, including the step of selecting a thermoplastic film having a thickness of at least 2 mils.

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