MXPA98009606A - Compositions of tiles for roofing, based on e - Google Patents

Abstract

A roof covering element for inclined roofs, for example a roof tile, comprising 100 parts by weight of at least one ethylene-propylene-diene terpolymer, of about 50 to 600 parts by weight of a filling selected from the group consisting of reinforcing and non-reinforcing materials, and mixtures thereof per 100 parts by weight of an EPDM terpolymer and from about 0 to 120 parts by weight of at least one impact modifying polymer, per 100 parts by weight of the ethylene-propylene terpolymer -diene, the cover element has a Shore "A" hardness without aging at about 23 ° C of at least 70 and more preferably a limiting oxygen index (LOI), at least 30% oxygen when tested in accordance with ASTM D2863 -91. The use of flame retardant additives is also convenient

Description

BACKGROUND TEXTURE COMPOSITIONS, BASED ON EPDM TECHNICAL FIELD This invention relates generally to roofing elements, preferably for roofing, of the type commonly known as shingles. More particularly, the present invention relates to tiles of high durometer value, of the type used to replace shingles made of shale or slate, wood, asphalt or other hard, natural materials. Specifically, the invention relates to tiles comprising at least 45%, and preferably 50 to 100% ethylene-propylene-diene terpolymer (EPDM), as the rubber component thereof, and having a Shore hardness "A" of at least 70, when tested (without aging) at room temperature (23 ° C). More preferably, the tiles have a limiting oxygen index (LOI) of at least 30, when tested in accordance with ASTM D2863-91. BACKGROUND OF THE INVENTION Tiles with a high durometer value used to cover inclined ceilings are already known in the art. Typically these tiles are used to replace tiles, loose staves, or other deck elements made of slate, wood, asphalt or other hard or natural materials known in the art. These tiles are essentially designed to correspond in size, shape and texture of the tile they replace, thus maintaining essentially the same installation pattern or architectural perspective for the roof in which they are placed. To date, mixtures of vulcanized waste rubber or ground rubber and polyolefin resin have been consistently employed to produce these high-value durometer roof covering elements. For example, U.S. Patent Nos. Nos. 5,312,573 and 5,157,082 relate to processes for the production of useful articles made from recycled vulcanized rubber, preferably from tires, and polyolefin resins such as polyethylene or polypropylene. In each case, the main component of the polymer mixture is the vulcanized inert rubber. More particularly, the inert vulcanized waste rubber is often recycled or recovered from recycled tires, as previously noted, or from rubber compounds that do not meet the specifications, available from tire manufacturing facilities, or various other industrial facilities. This rubber typically includes rubber materials such as natural rubber, synthetic polyisoprene, styrene-butadiene rubber (SBR), polybutadiene, butyl rubber (IIR) or the like or mixtures and aggregates thereof. While said rubber may be particularly useful for the processes developed in the aforementioned patents, these rubbers are not easily converted into new products and often must be employed with additional polymeric and / or compatibilizing ingredients in order to form the desired articles. For example, both patents noted previously require the use of additional thermoplastic resins such as polyethylene and prepropylene or their copolymers. In the proportion that the EPDM can be included in the ground vulcanized or waste rubber products of the prior art, the EPDM has not been employed in significant portions and is essentially inert in the waste rubber compositions, acting mostly as filling material since the rubber has already been cured. However, a single layer laminate or roof membrane based on EPDM has quickly become accepted as an effective cover and barrier to prevent moisture penetration through industrial and commercial flat roofs. These EPDM membranes have outstanding flexibility and weather resistance. These membranes are typically applied to the roof surface in a vulcanized or cured state, but are flexible enough to be transported in the form of a roll. However, these membranes are not used in sloped ceilings and do not have the required hardness to be suitable for use in sloped ceilings. Traditional asphalt roof tiles are well known, but typically do not withstand the weather well at cold temperatures. These traditional tiles are also somewhat susceptible to hail damage. Furthermore, it is known that shingles of this type do not provide the resistance to thermal insulation, ozone, oxidation and moisture in roof finishing membranes employing EPDM. Slate-based shingles, while suitable for most purposes, are very heavy and very expensive compared to asphalt shingles or polymeric shingles. In this way, none of these alternatives, ie shingles with asphalt or slate, are particularly convenient. Tiles of the type previously described, in general, are flat, rigid, mouldable sheets essentially of any size or shape. When the tile to be developed will replace slate tiles or asphalt, it has been found that the production of a rectangular tile that has a thickness of approximately .635 cm (.25"), with an approximate length of 45.72 cm (18") and width approximately 30.48 cm (12"), it is convenient, however, it will be appreciated that other sizes and shapes may be more suitable and preferred when used to replace shingles of other types or when the shingles or asphalt that are replaced are not Same size or general shape and the present invention shall not be limited thereto.Tables of the type described herein shall preferably have a Shore "A" hardness (tested without aging at room temperature) of at least 70. Tiles having lower hardness tester they are not particularly suitable for use on sloping roofs where slate or asphalt shingles are replaced, it is also considered convenient to provide shingles that are more fire resistant than asphalt shingles According to this, these shingles should preferably have an LOI of at least 30% when tested in accordance with ASTM 2863-91. The oxygen index measurement is used as an indicator of the flame retardant properties. Shingles that do not have an LOI of at least 30% will not be flame retardant enough to obtain a Class A fire rating for shingles in accordance with the UL 790 Flame-scatter test performed by Underwriter Laboratories, Northbrook, IL . SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a high durometer tile capable of being used in sloped roofs.

Another object of the present invention is to provide a tile as before, comprising ethylene-propylene-diene terpolymer as the main polymer component of the tile. Now another object of the present invention is to provide a tile as before, which has superior weather resistance and superior performance at low temperature compared to traditional asphalt shingles. Yet another object of the present invention is to provide a tile as before, which provides superior heat resistance and ozone aging compared to traditional asphalt shingles. Still another object of the present invention is to provide a tile as before, which has better resistance to hail damage, compared to traditional asphalt shingles. Still another object of the present invention is to provide a tile as before, which is curable with sulfur. Still another object of the present invention is to provide a tile as before, which has increased fire resistivity compared to traditional asphalt shingles.

A further object is to provide a method for covering a sloped ceiling using the shingles described herein. At least one or more of the above objectives, just with the advantages thereof, versus the prior art relating to roof covering elements and particularly tiles, which will be apparent from the specification that follows, are achieved by the invention as it is described and claimed below. In general, the present invention provides a roof covering element, for use in sloped roofs, the roofing element comprises 100 parts by weight of at least one ethylene-propylene-diene terpolymer, and from 0 to about 120 parts by weight of at least one impact modifying polymer, per 100 parts of the ethylene-propylene-diene terpolymer, the cover member has a non-aged Shore "A" hardness of 23 ° C of at least 70. More preferably, the cover element has a limiting oxygen index of at least 30 when tested in accordance with ASTM D2863-91. Other aspects of the present invention are achieved by providing a tile comprising a polymer component consisting of at least 45 to 100% by weight of at least one ethylene-propylene-diene terpolymer and from 0 to 55% by weight of at least one impact modifying polymer, wherein the tiles contain 100 parts by weight of at least one ethylene-propylene-diene terpolymer; from about 50 about 600 of at least one filler selected from the group consisting of combustible and non-combustible fillers, per 100 parts by weight of the ethylene-propylene-diene terpolymer; and from about 30% to about 105 of at least one processing material per 100 parts by weight of the ethylene-propylene-diene terpolymer; wherein the tile has a Shore "A" hardness of at least 70, and more preferably a limiting oxygen index of at least 30. The present invention also includes a method for covering an inclined roof, comprising the step of placing a plurality of roof tiles in a pre-selected installation pattern, each tile includes 100 parts by weight of at least one ethylene-propylene-diene terpolymer containing up to about 2% crystallinity and from 0 to about 120 parts by weight of at least one impact modifying polymer, and having an un-aged Shore "A" hardness at 23 ° C of at least 70. More preferably, the covering element has a limiting oxygen index of at least 30 when tested in accordance with ASTM D2863-91, and further includes from about 50 to about 600 of at least one filler selected from the group consisting of combustible and non-combustible fillers, per 100 parts by weight of terpolymer ethylene-propylene-diene, and at about 30 to 105 parts of at least one material of crushing or by 100 parts by weight of the ethylene-propylene-diene terpolymer. PREFERRED MODALITY FOR CARRYING OUT THE INVENTION The present invention is directed to the use of ethylene-propylene-diene terpolymers as the main polymeric component for high-durometer tiles suitable for use in sloped ceilings in a construction or to replace other traditional tiles typically used on sloped roofs. The invention seeks to take advantage of the outstanding resistance to weathering and low temperature performance of ethylene-propylene-diene terpolymers (EPDM), while maintaining the high durometer properties required of commercial shingles of the type used in sloped roofs. In the preferred embodiment, the high durometer tiles of the present invention are designed to closely match the size, color, shape and texture of the slate or asphalt shingles. By closely matching the design of the original slate or asphalt shingles on old roofs, the installer can maintain essentially the same installation pattern or architectural perspective for the roof as they were originally present. The shingles of the present invention are generally flat, rigid, mouldable sheets essentially of any size or shape suitable for use in the roof to be replaced. In the present invention, tiles can be molded essentially by any process known in the art, but are preferably injection molded or compression molded. These processes allow the finished product to have an appearance that is very similar to that of the original slate or asphalt shingles. In general, shingles of the present invention are preferably rectangular or in a manner substantially similar to that of the original tile being replaced. For roofs that originally have slate tiles or asphalt, it has been found that rectangular tiles are particularly preferred, each having approximately a thickness of .635 cm (.25") to approximately 45.72 cm (18") long and approximately 30.48. cm (12") wide It will be appreciated, however, that these sizes and shapes may be more suitable and preferred when used to replace shingles of other types or when the slate or asphalt shingles being replaced are not of the same size or In any event, it will be appreciated that the size, color and shape and texture of the tile can be determined during the molding process, thus, the shingles of the present invention can not be limited to this. They can essentially take any shape and have any desired color or texture and therefore do not need to comply with any specific dimensional requirements.Again, preferably, they are molded to appear very similar to the tiles that they replace. The roof covering elements, ie shingles of the present invention should also be easy to install. Preferably, the shingles of the present invention should weigh approximately the same as the asphalt shingles they replace and are generally lighter in weight than slate. Therefore, no additional reinforcement or support is necessary for the roof, and the tiles can essentially affect the same installation pattern as used to install the original seal cover elements. Typically, high-durometer tiles are installed with roofing nails. Holes for these nails can be molded into each tile, typically at their corners. Alternatively, the tiles may simply be susceptible to penetration of the nail without cracking or fracturing. Nail gun can be used to connect tiles to the ceiling with nails. The shingles of the present embodiment are also typically marked such that as they are placed on the roof, sections of 17.78 to 20.32 cm (7 or 8") below are exposed, advantageously, the shingles can also be cut with a razor to allow the installer In any preferred embodiment, tabs are formed on the sides of the tile to properly align the shingles and ensure consistent lateral spacing.As noted previously, the shingle of the present invention contains minus 45% EPDM, preferably about 50 to 100% EPDM, more preferably about 80 to 100% of EPDM as the polymer component of the composition.When an additional polymer component is employed, the aggregate component is preferably one or more polyolefin resins such as polyethylene or polypropylene or a copolymer of ethylene and propylene (EPDM). Alternatively or in addition, other copolymers such as ethylene-butene copolymers or ethylene-octene copolymers can be employed. In any case, these polymers, ie those different from EPDM, act as impact modifiers and reinforce or otherwise increase the durometer value of the composition, but they are not added in an amount that will be greater than 55% of the total content. of the virgin polymer of the tile. For purposes of this description, these polymers other than EPDM will be referred to as "impact modifying polymers". Furthermore, there are no polymers that improve adhesive or polymeric tackifying agents added to the composition, as often found in roofing membranes based on EPDM for flat roofs. The term EPDM is used in the sense of its definition as found in ASTM D-1418-94 and is intended to mean a terpolymer of ethylene, propylene and a diene monomer. Although not to be limited thereto, illustrative methods for preparing these terpolymers are found in U.S. Pat. No. 3,280,082, the description of which is incorporated herein by reference. Other illustrative methods can be found, for example, in Rubber and Chemistry &; Technology (Rubber and Chemical and Technology), Vol. 45, No. 1, Division of Rubber Chemistry (March 1992); Morton, Rubber Technology, 2nd edition, Chapter 9, Van Nostrand Reinhold Company, New York (1973); Polymer Chemistry of Synthetic Elastomers, Part II, High Polymer Series, Volume 23, Chapter 7, John Wiley & Sons, Inc. New York (1969); Encyclopedia of Polymer Science and Technology, Volume 6, pages 367-68, Interface Publishers, a division of John Wiley & Sons, Inc., New York (1967); Encyclopedia of Polymer Science and Technology, Volume 5, page 494, Interface Publishers, a division of John Wiley & Sons, Inc., New York (1966); and Synthetic Rubber Manual, 8a. edition, International Institute of Synthetic Rubber Producers, Inc. (1980). The preferred EPDM terpolymers of the present invention are substantially amorphous. That is, at least one terpolymer of EDPM used to produce the tile of the present invention should have less than about 2% crystallinity and preferably less than about 1.1% crystallinity. More particularly, the EDPM tile composition of the present invention should have about 80 to 100 parts by weight of at least one EPDM terpolymer having up to about 2% crystallinity and 0 to about 20 parts by weight of an EPDM terpolymer which it has more than about 2% crystallinity. More preferably, the composition should include at least 95 parts and still more preferably 100 parts by weight of amorphous EPDM having up to 2% crystallinity and optionally up to about 5 parts by weight of crystalline or semicrystalline EPDM having more than 2% crystallinity . Even more preferably, the composition includes about 95 to 100 parts by weight of an amorphous EPDM containing up to 1.1% crystallinity and 0 to about 5 parts by weight of an EPDM having more than 1.0% crystallinity. Any EPDM containing up to about 2% and more preferably 1.1%, of crystallinity, of the ethylene component and exhibiting the properties discussed previously, should be suitable for use in the present invention. Typically, amorphous EPDMs having less than about 65% by weight of ethylene and from about 1.5 to about 4% of the diene monomer with the remainder of the terpolymer being propylene or some other similar olefin type polymer, is desired. These EPDMs also preferably exhibit a Mooney viscosity (ML / 1 + 4 at 125 ° C) of about 40 to 65 and more preferably about 45 to 55. Preferably, the EPDM has no more than about 4% and more preferably no less of 2% by weight of unsaturation. The diene monomer used to form the EPDM terpolymer is preferably a non-conjugated diene. Illustrative examples of non-conjugated dienes which may be employed are dicyclopentadiene, alkyldicyclopentadiene, 1,4-hexadiene, 1,5-hexadiene, 1, -heptadiene, 2-methyl-1,5-hexadiene, cyclooctadiene, 1,4-octadiene, , 7-octadiene, 5-ethylidene-2-norbornene, 5-n-propylidene-2-norbornene, 5- (2-methyl-2-butenyl) -2-norbornene and the like. Typical EPDM terpolymers having less than 2% crystallinity are available from Exxon Chemical Co. under the tradename Vistalon ™ of Uniroyal Chemical Co. under the tradename Royalene ™ and of DSM Copolymer under the tradename Keltan ™. For example, a preferred Mooney low amorphous EPDM terpolymer is available from Uniroyal Chemical Co., under the trademark Royalene and has a Mooney viscosity (ML / 4 at 125 ° C) of about 46 + 5, an ethylene content from about 69 to about 70% by weight and between 2.4 and 3.2 percent by weight of unsaturation. Another convenient Royalene EPDM terpolymer has a superior Mooney viscosity (ML / 4 at 125 ° C) of about 62 + 5, an ethylene content of about 70% by weight and about 2.7% by weight of unsaturation. Another example of an EPDM having less than 2% by weight crystallinity is available from DSM copolymer under the Keltan brand. This amorphous EPDM terpolymer has a Mooney viscosity (ML / 4 at 125 ° C) of about 50 + 5, an ethylene content of about 70% by weight about 2.6 weight percent unsaturation, and a specific gravity of about 0.87 to 23 ° C.

Yet another example of an EPDM having less than 2% by weight of crystallinity is also available from Exxon Chemical Co. under the same Vistalon brand. This amorphous EPDM terpolymer has a Mooney viscosity (ML / 1 + 4 at 125 ° C) of about 62 + 5, an ethylene content of about 69% by weight and about 2.7% by weight of unsaturation. It will be appreciated that the shingles of the present invention may comprise 100 parts by weight of an amorphous EPDM, as the sole elastomeric polymer for the composition. However, it is contemplated that more than one EPDM having less than 2 wt% crystallinity may be employed. For example, the shingles of the present invention can include a flame retardant package that includes an amorphous EPDM as the polymeric binder as well as the amorphous EPDM component. As detailed more specifically below, commercially available flame retardant packages from Anzon Chemical Company under the trademark Fyrebloc, include from about 10 to 20% by weight of EPDM, and more preferably, from about 15 to 17.5% by weight of EPDM, such as polymer binder for the total flame retardant package. In this way, the amount of EPDM employed includes the EPDM of the flame retardant package as well as that which is formulated hard as the virgin EPDM polymer and the tile composition.

It will also be noted that certain fillers such as cryogenically ground EPDM rubber may include EPDM polymers. However, because these fillings are not virgin EPDM terpolymers, they have not been considered in the calculation of parts or percentages employed. It will be appreciated that if all the EPDM terpolymer is taken into account, the present tile composition will include more than 50% EPDM in the total polymer content. When EPDM terpolymers having more than 2% crystallinity of the ethylene component are employed, these EPDMs should preferably contain at least about 65% by weight of ethylene and from about 2 to about 4% by weight of the diene monomer, with the remainder of the terpolymer which is propylene or some other similar olefin-type polymer. Although not necessarily limiting, these EPDMs should also exhibit a Mooney viscosity (ML / 4 at 125 ° C) of at least about 45 and not more than about 60 and should have less than about 3.5 wt% unsaturation. However, 45 to 50 is preferred. Unconjugated dienes, as exemplified above, will also be used for these types of EPDMs alike. It will be appreciated, however, that the total EPDM terpolymers used are characterized by having 2% or less of crystallinity.

As previously noted, at least one impact modifying polymer selected from the group consisting of polyolefin resins or copolymers thereof can be mixed with the EPDM to form the polymer component in the EPDM-based tile composition. by the term "impact modifying polymer", it is understood that these polymers provide the tile composition with more rigidity and can increase the impact resistance of the composition. Essentially, any polyolefin resin or its copolymer capable of imparting the previously described characteristics may be suitable for the tile composition of the present invention. Preferably, 0 to about 20% by weight of the total roof composition can be made from these impact modifying polymers. More particularly, from 0 to about 120 parts, and more preferably from 0 to about 50 parts by weight of these polymer resins or their copolymers can be employed, per 100 parts of EPDM. Particularly preferred, with respect to polyolefin resins, are low density polyethylene (LDPE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE) and atactic and isotactic polypropylene. Suitable copolymers include, but are not necessarily limited to, ethylene-propylene copolymers, ethylene-butene copolymers and ethylene-octene copolymers. In general, preferred polyolefin resins and their copolymers will provide high impact strength to the resulting tile composition. A particularly useful polyolefin resin is LDPE 722 M, a low density polyethylene commercially available from Dow Plastics. LDPE 722 M has a melt flow index of 8 grams / 10 minutes, peak melting temperature of 112 ° C as determined by DSC and a specific gravity of 0.9160 at 23 ° C. Differential Scanning Calorimetry (DSC) is used to measure the emission or heat consumption that accompanies a physical change or a chemical reaction as a function of temperature or time in the range of -150 ° C to 725 ° C. Also of particular use are certain LLDPEs, which are also considered ethylene-octene copolymers, such as those available from Dow Plastics under the Dowlex® brand. There is a variety of ethylene-octene Dowlex copolymers, which generally differ in their peak melting temperatures and specific gravity. For example, Dowlex 2027 has a peak melting temperature of 113 ° C as determined by DSC and a specific gravity of 0.941 g / cc at room temperature, while Dowlex 2038 and Dowlex 2045 have peak melting temperatures of 127 ° C and 124 ° C. ° C, respectively, and specific gravities of 0.935 g / cc 0.920 g / cc, respectively. A preferred HDPE resin is Nova 79 G produced by NOVA Chemical Ltd. This resin has a peak melting temperature of 132 ° C and a specific gravity of about 0.96 at 23 ° C. Another suitable HDPE is 62013 commercially available from Dow Plastics. HDPE 62013 has a peak melting temperature of 131 ° C and a specific gravity of 0.945 at 23 ° C. Other resins that may have utility in this invention include an amount of HDPE resins produced by Dow Plastics. Some of the typical properties of these resins are illustrated in the Table below. TABLE I Comparison of High Density Polyethylene Resins (HDPE) Suitable Brand melting index (MI) Specific gravity (grams / 10 minutes) (grams / ce) 04352N 4 0.952 06153C 6.3 0.953 08254N 7 0.954 10062N 10 0.962 12350N 12 0.960 17350N 17 0.950 25355N 25 0.955 TABLE I (Cont.) Comparison of High Density Polyethylene Resins (HDPE) Suitable Brand melting index (MI) Specific gravity (grams / 10 minutes) (grams / ce) 30360M 30 0.960 40360M 38 0.958 Also ethylene-propylene copolymers (EPMS) such as those available from Exxon Chemical Company under the trademark Vistalon ™ and DSM copolymer under the trademark Keltan ™ are preferred. The term EPM is used in the sense of its definition as ASTM D-1418-94 is found and is meant to mean an ethylene-propylene copolymer. Some typical properties of ethylene-propylene copolymers include having an ethylene content of from about 45% to about 72% by weight, a Mooney viscosity (ML / 4 at 125 ° C) of about 25 to 55, a transition temperature vitrea from about -40 ° C to about -60 ° C. Ethylene-propylene copolymers are without any unsaturation, and these polymers have excellent resistance to ozone aging and long-term heat, as well as providing a smooth appearance to the molded tile. A typical EPM suitable for use in the present invention is available from DSM Copolymer under the trademark Keltan® 740. This EPM has a Mooney viscosity (ML / 4 at 125 ° C) of about 63 and an ethylene content of about 60 weight percent. . Other EPMs are also suitable. For example Keltan® 3300A and 4200A have Mooney viscosities (ML / 4 at 125 ° C) of about 35 and about 40, respectively, while Vistalon® 808 and 878 have Mooney viscosities (ML / 4 at 125 ° C) of about 46 and 53 , respectively. These ethylene-propylene copolymers are available in dense or friable bales. Still another suitable copolymer of propylene and ethylene is Pro-Fax SR-549M produced by Montell. This resin has a peak melting temperature of 162 ° C, a range of melt index of 11-15, an izod range at 23 ° C of about 1.5 to 2, and a specific gravity of about 0.95 at 23 ° C. Other suitable copolymers include those saturated ethylene-octene copolymers that provide excellent weather resistance and are available from Dow Plastics under the Engage brand. For example, Engage® 8100 and Engage® 8200 have octene contents of approximately 24 and 25 weight percent respectively. These general-purpose elastomers have Mooney viscosities (ML / 4 at 121 ° C) in the range of about 23 to 35 and specific gravities of about 0.87 to 230 ° C.

When these polyolefin resins and their copolymers are mixed with the EPDM of the tile composition, the polymer blend to be employed in the tile composition generally includes major amounts of EPDM and only minor amounts of the impact modifier polymer (s). In fact, the polymer blend typically includes less than 100 parts by weight of EPDM and up to about 120 parts by weight of an impact modifying polymer, based on the weight of the EPDM. While more than one impact modifier polymer may be employed, the total amount of all these types of polymers combined shall not exceed the amount of EPDM (including cryogenically ground EPDM rubber and virgin EPDM for flame retardants and the like) provided. In addition to EPDM terpolymers and impact modifying polymers such as resin and polyolefin their copolymers, as discussed previously, the tile composition of the present invention may also include fillers, crush aids and curatives as well as other optional components including activators and fire retardant packages, all of which are discussed below. The amount of fillers, crushing materials, curing agents and their reagents employed in the tile composition will be expressed below as parts by weight per hundred parts by weight of the EPDM terpolymer, since EPDM is the base component of the composition. Accordingly, when the term "phr" is used, it will be understood to mean parts by weight per 100 parts by weight of the EPDM terpolymer, even if an additional impact modifier polymer is employed. With respect to fillers, suitable fillers are chosen from the group consisting of combustible and non-combustible materials and their mixtures. Examples of combustible materials include organic materials such as carbon black and coal or mineral coal. Examples of non-combustible materials include both organic and inorganic materials such as cryogenically milled EPDM rubber or at room temperature, clay, mineral fillers and the like. In general, these materials can be added to the formulation in amounts in the range of 50 to 600 parts by weight, per hundred parts of the EPDM terpolymer. Organic combustible materials such as carbon black can be employed in amounts in the range of about 5 parts to about 185 parts or 100 parts of EPDM terpolymer (phr), depending substantially on whether the resulting tile composition will be pyro-resistant. If the tile will be pyro-resistant, carbon black and other combustible materials should be limited and preferably used in amounts in the range of about 5 to about 70 phr. If pyro-resistance is not considered, much higher charges of carbon black can be employed, preferably in the range of about 50 to about 200 phr. The carbon black used herein can be any carbon black suitable for the purposes previously described. They are preferred in furnace blacks such as GPF (general purpose furnace), FEF (fast extrusion furnace), ISRF (semi-reinforcement furnace). Particularly preferred are black N650 HiStr GPF, a petroleum derivative, black reinforcing filler, having an average particle size of about 60 nm and a specific gravity of about 1.80 g / cc. Other combustible materials such as ground carbon black can also be used as part of the filler in the tile compositions of the present invention. Ground mineral coal is a dry, finely divided black powder derived from a low volatitility bituminous mineral coal. The ground imeral carbon typically has a particle size in the range of a minimum of 0.26 miera to a maximum of 2.55 microns, with the average particle size of 0.69 ± 0.46 as determined in 50 particles using Transmission Electron Microscopy. The milled coal produces an aqueous sludge that has a pH of about 7.0, when tested in accordance with ASTM D-1512. A preferred ground mineral coal of this type is designated Austin Black, which has a specific gravity of melting of 1255 ± 0.03, an ash content of about 4.58% and a sulfur content of about 0.65%. Austin Black, is commercially available from Coal Fillers, Inc. of Bluefield, Virginia. Amount in the range of about 5 to about 65 phr, with about 15 to about 35 phr preferred if employed. With respect to non-combustible materials, there are many types of materials that can be used as non-combustible fillers for the tile composition of the present invention. A particularly useful and preferred non-combustible material is cryogenically ground rubber. In essence, any rubber ground cryogenically or at room temperature can be used as a filler in the tile composition. Cryogenically grinded or room temperature rubber is crushed EPDM rubber or at room temperature. The preferred ground EPDM rubber is a fine black rubber powder having a specific gravity of about 1.16 + 0.015 g / cc and a particle size in the range of about 30 to about 300 microns, with an average particle size in the range from about 40 to 80 microns.

When carbon black is included in the tile composition, the amount of ground EPDM rubber may be in the range of about 25 to about 100 per 100 parts of the EPDM terpolymer. In the absence of any carbon black, the amount of rubber ground cryogenically or at room temperature may be significantly higher, from about 50 to about 600 parts by weight per 100 parts of EPDM terpolymer (phr). It has been found that these ground rubbers provide significant reduction in the cost of the composition while maintaining the desired properties of the composition since the ground rubber is essentially inert. Also particularly useful and preferred with respect to non-combustible materials are non-black mineral mineral fillers. This mineral fillers are essentially organic materials that generally help in reinforcement, resistance to thermal aging, green resistance performance, and flame resistance. There are a number of different inorganic materials that fall into this category of filler. For example, this mineral fillers include a number of different types of clays, including hard clays, mild clays, chemically modified clays, water washed clays, and calcined clays. Other examples of mineral fillers suitable for use in the present invention include mica, talcum, alumina trihydrate, antimony dioxide, calcium carbonate, titanium dioxide, silica and certain mixtures thereof. Still other inorganic components such as magnesium hydroxide, and calcium borate ore or may also be employed. In some cases, these fillers can completely or partially replace "black" fillings, ie carbon black and other petroleum-derived materials. In general, however, one or more of these mineral fillers are used in amounts in the range of about 2.5 parts to about 250 parts by weight, per 100 parts of EPDM terpolymer. Any of four basic types of clay are normally used as fillers for rubber elastomers. The different types of clay fillings include clays floated in air, washed with water, calcined, and treated superficially or chemically modified. Clays floated in air are the least expensive and most widely used. They are divided into two general groups, hard and soft, and offer a wide range of reinforcement and loading possibilities. Clays can be used in the amount of from about 20 parts to about 300 parts per 100 parts of EPDM (phr), preferably in an amount of about 65 to 210 phr. Preferred air-floated hard clays are commercially available from J.M. Huber Corporation, under the Barden RMR, and LGBMR brands of Kentucky-Tennessee Clay Company Kaolin Division, Sandersville, GA, under the trade name SuprexR. The soft clays floated in the air can be used in amounts in the range of about 20 parts to about 300 parts per 100 parts of EPDM (phr) preferably in an amount of about 75 to 275 phr. Preferred air-floated soft clays are available from J.M. Huber Corporation under the brand name K-78MR., Evans Clay Company under the brand name Hi-White RMR and Kentucky-Tennessee Clay Company, Koalin Division, Sandersville, GA, under the brand name ParagonR. Particularly preferred is the Hi-White RMR, a soft clay floated in the air which is characterized by having a pH of approximately 6.25 ± 1.25, an oil absorption of 33 grams / 100 grams of clay, a particle size of 68% + 3 , and a specific gravity of approximately 2.58. This clay is also thinner than two microns. Clays washed with water are usually considered as semi-reinforcing fillers. This particular class of clays is more closely controlled for the particle size by the fractionation process with water. This process allows the production of clays within controlled particle size ranges. The preferred amounts of clays washed with water are very similar to the preferred amounts of soft clays floated in the air mentioned previously. Some of the preferred water-washed clays include PolyfilMR DL, Polyfil F, PolyfilMR FB, PolyfiMR HG-90, PolyfilMR K and Polyfim XB; all commercially available J.M. Huber Corporation. The third type of clay includes calcined clay. Clays usually contain approximately 14% hydration water, and most of this can be removed by calcination. The amount of bound water that is removed determines the degree of calcination. The preferred ranges of calcined clays are very similar to the preferred amounts of the above-mentioned air-floated hard clays. Some of the preferred calcined clays include Polyfil ^ 40, PolyfilMR 70, and PoliyfilMR 80, all commercially available from J.M Huber Corporation. The last type of clay includes chemically modified reinforcing clays. The interlacing ability is imparted to the clay by modifying the surface of the individual particles with a polyfunctional silane coupling agent. Chemically modified clays are employed in the amount of from about 20 parts to about 300 parts per 100 parts of EPDM (phr), preferably in an amount of about 60 to 175 phr. Normally, the specific gravity of most of these clays is approximately 2.60 at 25 ° C. Preferred chemically modified clays are commercially available from J.M. Huber Corporation and include those available under the NucapR, NulokR and PolyfilR brands. Other preferred chemically modified clays are commercially available from the Kentucky-Tennessee Clay Company under the trademarks MercapMR 100 and Mercap ** 200. As an alternative to clays, a silicate may have utility in the present invention. For example, synthetic amorphous calcium silicates, such as those commercially available from J.M. Huber Company under the brand HubersorbMR. A particular silicate, Hubersorb ™ 600, is characterized by having an average particle size of 3.2 microns (by the Coulter Counter method) oil absorption of 450 ml / 100 grams of calcium silicate, a BET surface area (nitrogen absorption process) Brunaver-Emmet-Teller) of 300 m2 / gram and a pH (5% solution) of 10. Other silicates that can be employed in the composition of the present invention include precipitated amorphous aluminosilicate sodium silicates available from JM Huber Company under the ZeolexR brand. Zeolex 23 has a BET surface area of about 75 m2 / gram, a refractive index at 20 ° C of about 1.51, and an approximate pH of 10.2 determined by sludge forming 20 grams of silicate with 80 grams of deionized water. In comparison, Zeolex 80 has a BET surface area of about 115 m2 / grams, a refractive index at 20 ° C of about 1.55, and a pH of about 7. Average particle size, density, physical form and absorption properties d acite are similar to each other. Reinforcing silicas which can also be used as non-black fillers, preferably in conjunction with one or more of the chemically modified clays noted above. Silica (silicon dioxide) uses silicon element and combines it in a very stable way with two oxygen atoms. In general, silicas are classified as moist hydrated process silicas, because they are produced by a chemical reaction in water, from which they precipitate as ultrafine spherical particles. However, there are actually two different forms of silica, crystalline and amorphous (non-crystalline). The basic crystalline form of silica is quartz, although there are two other crystalline forms of silica that are less common tridymite and cristobalite. On the other hand, the silicon and oxygen atoms can be arranged in an irregular form as can be identified by X-ray diffraction. This form of silica is classified, amorphous (non-crystalline) because there is no detectable crystalline silica as determined by diffraction of X-rays. The most detectable crystalline silica, that is, a fine, amorphous, fine-particle hydrated particle, is available from PPG Industries, Inc. and JM Huber Corporation in a granular form with low dust content. These silicas are typically available from PPG Industries under the brands HiSilR and SileneR. Reinforcing silicas have generally been characterized in terms of surface area (mVgram by the BET procedure) or particle size as determined either by electron microscopy or the Coulter Counter method. These silicas can be used in an amount of about 10 parts to about 110 parts per 100 parts of EPDM terpolymer (phr), preferably in an amount of about 10 to 30 phr. The useful upper range is limited by the high viscosity imparted by fillers of this type. Still other fillers, include calcium carbonate, titanium dioxide, talc (magnesium silicate), mica, mixtures of aluminum silicate, sodium and potassium) alumina trihydrate antimony trioxide, magnesium hydroxide and ore or calcium borate mineral . The amount of these fillers can vary significantly depending on the number and amount of other particulate fillers employed, but typically they are employed in amounts in the range of about 25 to about 250 parts by weight, with 100 parts by weight of the terpolymer in EPDM. The most preferred of these mineral fillers include 100% magnesium hydroxide (200 parts or less) or mixtures of magnesium hydroxide (less than 100 parts) in combination with alumina trihydrate (less than 100 parts) and Mistron steam talcum (less than 50 parts). Parts on 100 parts of terpolymer EPDM are by weight, unless otherwise indicated. A particularly useful form of talc is Mistron Steam (MVT) commercially available from luzenac America, Inc. Mistron Steam (MVT) is a white, soft, ultrafine sheeting powder that has a specific gravity of 2.75. Steam Mistron Steam (MVT) is chemically ground magnesium silicate having an average particle size of 1.7 microns, an average surface area of 18 mV gram and a volume density (derived) of .32 g / cc (20 lbs / ft3) ). Alumina trihydrate is a white, crystalline, odorless, finely divided powder that has the chemical formula A1203.3H20. The alumina trihydrate is used in the present invention to improve the green strength of the EPDM terpolymer or the other polyolefins. Preferably, the alumina trihydrate has an average particle size in the range of about 0.1 micron to about 5 micron, and more preferably from about 0.5 micron to about 2.5 micron. A preferred ground alumina trihydrate for use with the invention is designated H-15 (or ATH-15), and has a specific gravity of about 2.42, and an ash content of about 64-65% by weight. ATH-15 is commercially available from Franklin Industrial Minerals, of Dalton, Georgia. Other alumina trihydrates produced by Franklin Industrial Minerals which are considered useful in this invention, include those designated H-100, H-105, H-109, and H-990. Alumina trihydrate can also be advantageously employed as a flame retardant and smoke suppressant in the EPDM-based tile composition of the present invention. Other sources of alumina trihydrate are Micral 1000 and Micral 1500, available from J. M. Huber Corporation of Norcross, Georgia, having an average particle size of about 1.1 microns and about 1.5 microns, respectively. Both alumina trihydrates have a specific gravity of approximately 2.52, and an ash content of approximately 64-65% by weight and is the ignition loss (LOI) at 537.8 ° C (1000 ° F) of approximately 34.65 weight percent . Other alumina trihydrates produced by this corporation which is considered to have a utility of this invention, include those designated as Micral 932 and Micral 532 as well as superfine alumina trihydrates including SB632 and SB-805. Another particularly useful mineral filler is calcium borate ore. This filler is available in various particle size grades from American Borate Company, Virginia Beach, Virginia, under the Colemanitee brand and has the chemical formula Ca2B6Ou-5H20. Colemanite has a specific gravity of approximately 2.4. This ore has an average particle size of from about 0.1 to about 5 microns and more preferably from about 0.5 to about 2.5 microns. Still another mineral filler that may be particularly convenient for use in the tile composition of the present invention is magnesium hydroxide. Magnesium hydroxide Mg (0H) 2) is a finely divided white powder that is an extremely effective smoke suppressant as well as a flame retardant additive. It is well documented that Mg (OH) 2 is highly effective in reducing smoke. In this way, this mineral filler is considered particularly useful where the resistivity to fire and smoke is of concern. For that purpose, this mineral filler will sometimes replace other mineral fillers such as silica or any of the clays in the composition. Commercial grades of magnesium hydroxide are available from Martin Marietta Magnesia Specialties, Inc. under the trade name MagShield. MagShield S is a magnesium hydroxide of standard size with an average particle size of about 6.9 microns. MagShield M has an average size of approximately 1.9 microns. Both of those magnesium hydroxide grades are approximately 98.5 percent pure, have approximately 0.3 percent loss on drying and approximately 30.9 percent by weight loss of ignition, and a specific gravity of approximately 2.38 at 23 ° C. Clay, titanium dioxide, alumina trihydrate, magnesium hydroxide, talc and mica can also be used to develop a gray tile. The desirable gray color can be obtained through the use of different combinations of non-black mineral fillers. It will be appreciated that in order to provide the gray color, it is also necessary to substantially reduce the amount of carbon black in the formulation. The tile composition of the present invention may also contain one or more processing materials. Processing materials are generally included to improve the processing behavior of the composition (i.e. reduce the mixing time and increase the speed of sheet formation) and include processing oils, waxes and other similar additives. A processing oil may be included in an amount in the range of about 30 parts to about 105 parts of processing oil per 100 parts of EPDM terpolymer (phr), preferably an amount in the range of about 60 phr to about 85 phr. A preferred processing oil is a paraffinic oil, for example Sunpar 2280, which is available from Sun Oil Company. Other petroleum-derived oils, including naphthenic oils, are also useful. Liquid halogenated paraffins can serve as softeners or extenders and are also often convenient as flame retardant additives. A preferred liquid chlorinated paraffin is Doverguard 5761, which characterizes approximately 59% by weight of chlorine and can be used both as a softener as well as as a flame retardant additive. This liquid paraffin has an approximate viscosity of 20 poises at 25 ° C and a specific gravity of approximately 1,335 at 23 ° C. Another liquid paraffin having utility of this invention is a flame retardant additive based on liquid bromochlorinated paraffin, ie Doverguard 8207A having 30 and 29% by weight of bromide and chlorine respectively. Doverguard 8207A has a specific gravity of approximately 1.42 at 50 ° C. Both halogenated liquid paraffins are commercially available from Dover Chemical Corporation, a subsidiary of ICC Industries, Inc. A homogenizing agent may also be added, generally in an amount of less than 10 parts by weight, and preferably in an amount of about 2 to 5 parts by weight. by weight per 100 parts of ETDM terpolymer. A particularly convenient homogenizing agent is available in flake or tablet forms from Struktol Company under the trademark Struktol 40 MS. The preferred homogenizing agent is composed of a mixture of dark brown aromatic hydrocarbon resins having a specific gravity of approximately 1.06 g / cc at 23 ° C. Still another type of useful processing aids are phenolic resins. Phenolic resins are known which provide tackiness and green strength as well as long-aging properties to the composition. When employed, these fillers are typically used in minor amounts of less than 10 parts by weight, more preferably 2 to 3 parts by weight, approximate per 100 of the EPDM terpolymer. In addition to the above ingredients that are mixed to form a masterbatch in the preferred embodiment, activators such as zinc oxide and stearic acid can optionally be added to and become part of the masterbatch. Amounts of these activators may vary depending on processing needs, but it is conventional to add approximately 5 phr of zinc oxide and approximately one phr of stearic acid to the master batch. These activators are particularly useful with sulfur curing packages as explained below. A flame retardant package can also be added to the composition where increased pyro-resistance is desired. There are a variety of flame retardant packages commercially available for use with rubber compositions. In general, the flame retardant system incorporated in the tile composition can be made from different types of materials including proportions of decabromodiphenyl oxide (DBDPO) or related bromine-containing additives and antimony trioxide. Various inorganic materials, clay, alumina trihydrate, magnesium hydroxide, silica, mica, talc and zinc carbonate, can be used as part of the filler system as well as fire retardant additives. Certain halogenated paraffins can be employed as the softener or extender and still impart flame resistance to the tile composition. A particularly useful flame retardant package is available from Anzon Chemical Company. This package is 85% active and contains 15% by weight of EPDM terpolymer as a binder for the package. The package also includes a mixture of antimony trioxide and decabromodiphenyl oxide. Another useful flame retardant package is also available from Anzon Chemical Company of Philadelphia, Pennsyivania, and is 82.5 percent active. The flame retardant package contains 17.5 weight percent EPDM as the binder. Zinc borate, decabromodiphenyl oxide and antimony trioxide are additionally included in the package. It will be appreciated that, when employed, these packages are used in amounts in the range of about 50 to 70 parts by weight per 100 parts of EPDM. As discussed previously, it will also be desired that this flame retardant package may contain a portion of the EPDM terpolymer employed in the composition. The tile composition may also include a cure pack containing a curing agent and at least one organic accelerator in order to effect complete entanglement or curing of the composition before use in a roof. The composition is typically vulcanized for a period of time at a high temperature to ensure interlacing. The polymer composition can be cured using any of several well-known curing agents, but preferably the curing package of the present invention includes sulfur and one or more sulfur vulcanization accelerators. In general, the accelerator / sulfur cure package employed in the tile composition of the present invention is provided in amounts in the range of about 1.5 to about 10 phr, depending on the amount of sulfur employed. As noted, the sulfur curing and sulfur-containing systems employed in the present invention typically include one or more sulfur vulcanization accelerators. Convenient accelerators commonly employed include for example thioureas such as ethylene thiourea, N, N-dibutyl thiourea, N, N-diethyl thiourea and the like; monosulfides and disulfides thiuram such as tetramethylthiuram monosulfide (TMTMS). tetrabutylthiura disulfide (TBTDS), tetramethylthiuram disulfide (TMTDS), tetraethylthiuram monosulfide (TETMS), dipentamethylene diuram hexasulfide (DPTH) and the like; benzothiazole sulfenamides such as N-oxydiethylene-2-benzothiazole sulfenamide, N-cyclohexyl-2-benzothiazole sulfenamide, N, N-diisopropyl-2-benzothiazole sulfenamide, N-tert-butyl-2-benzothiazole sulfenamide (TBBS) and the like; other thiazole accelerators such as Captax (MBT) or Altax (MBTS), 2-mercaptoimidazoline, N, N-diphenylguanadine, N, N-di- (2-methylphenyl) -guanadine, 2-mercaptobenzothiazole, 2- (morpholinodithio) enzyothiazole disulfide, zinc 2-mercaptobenzothiazole and the like; dithiocarbonates such as tellurium diethyldithiocarbamate, copper dimethyldithiocarbamate, bismuth dimethyldithiocarbamate, cadmium diethyldithiocarbamate, lead dimethyldithiocarbamate, zinc diethyldithiocarbamate, zinc dimethyldithiocarbonate and zinc dibutyldithiocarbamate (ZDBDC). It will be appreciated that the foregoing list is not exclusive, and that other vulcanizing agents known in the art to be effective in curing EPDM terpolymers used in the polymer blend can also be employed. For a list of additional vulcanizing agents, see "The Vanderbilt Rubber Handbook", RT Vanderbilt Co., Norwalk CT 06855 (1990). It will also be understood that sulfur donor type accelerators can be used in place of elemental sulfur or in conjunction with it. Suitable amounts of sulfur to be used in the cure package can be easily determined by those skilled in the art and generally range from about 0.25 to 2.0 phr, while the amount of accelerator can also be easily determined by those skilled in the art. the specialty and be generated in the range of about 1.5 to about 10 phr, depending on the amount of sulfur, the selected vulcanization accelerators and the final destination or use of the tile composition based on EPDM. It will be appreciated that the sulfur and sulfur accelerators can be added in adequate amounts to cure tile compositions in the roof. In this way, when used as a curable roof tile in a hot climate, different accelerators and / or their quantities known to those skilled in the art can be selected compared to those accelerators for use in rooftop curing in climates. cooler In order to be curable on the roof, the tile compositions are not completely cured before application and do not require subsequent cure. The presence of the cure package allows the tile composition to cure at temperatures of at least about 50 ° C, easily obtained when exposed to sunlight in most climates.

Accelerators generally require a metal oxide, ie zinc oxide for curing activation in most types of rubber. Zinc oxide is almost always the selection metal oxide, due to its effectiveness and lack of toxicity. The amount of zinc oxide may vary, but about 1 to about 10 parts in the formulation have been found to give the desired effect. Also, in order to initiate the vulcanization process, a small amount (generally about 1 to 2 parts by weight) of stearic acid is present in the tile composition. Using heat, both zinc oxide and stearic acid act as curing activators in the presence of sulfur, one or more accelerators and unsaturated rubber to help promote the formation of sulfur entanglement during the vulcanization process. Some of the initial chemical reactions that are carried out during the early stages in the vulcanization process include reacting zinc oxide with stearic acid to form salts of even higher vulcanization activity. The zinc oxide itself acts as a cure activator or vulcanization promoter, accelerating the reaction rate of the elemental sulfur with the unsaturation in the diene portion of the terpolymer. In addition to its use as a curing component, the sulfur component of the present invention can also be used in conjunction with zinc oxide to improve the thermal aging resistance of the composition. During the molding process, vulcanization temperatures as high as 210 ° C are generally adequate to complete the vulcanization in about one to seven minutes. The vulcanization time can be further reduced by raising the molding temperature during the vulcanization process. Other ingredients may also be included in the tile composition. For example, additional conventional rubber formulation additives such as antioxidants, antiozoning agents and the like may be included in conventional amounts typically in the range of about .25 to about 4 phr. The formulation ingredients can preferably be mixed or formulated in a Brabender ™ mixer or an internal type B mixer (such as a Banbury mixer) or any other suitable mixer to prepare relatively viscous uniform blends. When using an internal Banbury type B mixer or a Brabender mixer, in a preferred mode, dry or powdery materials (for example carbon black, mineral filler, zinc oxide, stearic acid, flame retardant additives, etc.) are added in the mixing cavity first followed by any liquid process oil or softeners (eg process oil, plasticizers, etc.). ) and finally the polymeric components (for example EPDM, EPM, LDPE, HDPE, etc.). This type of mixing can be referred to as a face-down mixing technique. The mixing time may vary from about 2.5 minutes to 5 to 6 minutes, depending on the melting characteristics of the resins containing polyethylene and polypropylene. The dropping or pouring temperature of the first stage mixture (masterbatch) is usually from about 163 to 185 ° C. The master batch is refined and re-rolled in a mixture of two hot rollers. The temperature of the grinding rollers is usually in the range of about 116 ° C to about 160 ° C. In a matter of minutes, the re-laminated plate material is cut to the desired dimensions and strip by strip is added to the cavity of the mixing chamber. After approximately 50% of the rubberized masterbatch is added to the mixer, the cure pack is discharged into the mixing chamber followed by the addition of the remainder of the masterbatch. The temperature of the gummed mixture is allowed to reach temperatures as high as about 150 ° C (300 ° F) for a very short period of time (about 2 minutes or less). The second (final) mixture is quickly re-rolled to the desired dimensions, again using a mixture of two hot rollers. The total mixing time involves the second stage mixing (final usually is not more than about two minutes). Fully formulated and freshly prepared test specimens are cured with pressure approximately 40 minutes at 160 ° C (320 ° F). Typical test properties performed include those tests that indicate stress-strain properties, tear resistance, resistance to ozone aging, weather resistance, hardness, water adsorption, resistance to thermal aging and oxygen index measurements. In order to demonstrate the practice of the present invention, various tile compositions prepared according to the concepts of the present invention were formulated in a Brabender ™ mixer using the mixing technique of the steps described above. Dry or powdered materials (eg carbon black, mineral filler, zinc oxide, stearic acid, flame retardant additives, etc.) were charged to the mixing cavity first. Next, any process oil or softeners, (for example process oil, plasticizers, etc.) were added. Finally, the elastomeric components, (for example EPDM, EPM, LDPE, LLDPE, HDPE, etc.) were added to the mixer cavity.

The following examples are presented to further illustrate the nature of the present invention and shall not be construed as limiting its scope. The parts and percentages will be by weight unless otherwise indicated. The composition of each of the prepared tile formulations is illustrated in Table II below: TABLE II Compositions of TE to EPDM Compounds Nos. 1 EPDMA 100 100 91.52 91.52 EPDM-91. 52 91. 52 90. 11 90 eleven Carbon Black 155 155 50 50 50 50 110 110 Carbon Black 10 - - - - 10 10 Coal fill Mineral - 15 15.98 15.98 15.98 15.98 20.05 20.05 Process Oil6 85 49 49 45 45 95 95 100 TABLE II (Contd) Tile Compositions EPDM Compounds Nos. 1 Homogeizing Agent 2.5 2.5 - Phenolic Resin 2.5 2.5 Clay11 95 95 95 95 Talco1 - - 27 27 27 27 40 40 Fyrebloc 1DB-385R3J - - 65 65 65 65 F rebloc lDB-582R3k - - - 56.5 56.5 Zinc oxide 5 5 5 5 5 Stearic acid 1 1 1.48 1.48 1.48 1.48 1.48 1.48 Ethylene / Octane copolymer - 20 50 30 TABLE II (Cont.) EPDM tile compositions Compounds Nos. 1 Ethylene / Octene copolymer - - - 30 -Lote Maestro 361 366 399.98 419.98 445.98 425.98 428.14 463.14 Sulfur and Curing Ingredients 3.90 3.90 3.95 3.95 4.85 4.85 3.65 3.65 TOTAL 364.9 369.9 403.93 423.93 450.83 430.83 431.79 466.79 TABLE II (continued) Compositions of Te to EPDM Compounds Nos. 9 10 11 12 13 14 15 16 EPDMb 100 100 100 100 100 100 100 100 Carbon black 35 32.5 32.5 30 30 28 28 15 Mineral Coal Filling _ 17.5 TABLE II (continued) Compositions of Teia EPDM Compounds Nos. 9 10 11 12 13 14 15 16 Chlorinated Paraffinic Oil "15 15 15 Process Oil3 37 37 37 49 49 49 49 45 Alumina trihydrate 85 85 85 60 60 - 160 Mgp hydroxide 85 85 85 100 100 160 - 170 Agent Homoge-nizantef 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 Zinc Oxide 4 4 4 4 4 4 4 4 Stearic Acid 1.25 1.25 1.25 1 1 1 1 1 HDPEq - - 65 100 100 100 110 Ethylene / Octene copolymer 70 75 80 TABLE II (continued) Tile Compositions EPDM Compounds Nos. 9 10 11 12 13 14 15 16 Ground rubber Cryogenically 55 60 70 100 100 100 100 100 Lot Master 489.75 497.25 512.25 511.5 546.5 544.5 544.5 565 Sulfur and Curing Ingredients 4.55 4.55 4.55 4.60 4.60 4.60 4.60 4.70 TOTAL 494.3 501.8 516.8 516.1 551.1 549.1 549.1 569.7 a. Amorphous EPDM Royalene from Alta Mooney b. Amorphous EPDM Royalene from Baja Mooney C. Black N-650 HiStr GPF d. Black N-330 HAF e. Sunpar Process Oil 2280 f. Struktol 40 MS g. Phenolic Resin Sovereign Chemical Co. h. Soft Clay floated to the Air (HiW ite R) i. Steam Steam Mistron (MVT) j. FR package (1DB-385RC) k. FR package (IDB-582R3) 1. Dowlex 2045 m. Engage EC 81 00 n. Chlorinated paraffinic oil 5761 (59% by weight chlorine) or. Micral 1000 p. MagShield S q. Resin Nova 79G r. Cryogenically Ground EPDM Rubber (Mesh 80) The examples illustrated in Table II comprise tile compositions based on EPDM. Examples 1 to 2 comprise 10 parts by weight of a 65 Mooney amorphous EPDM terpolymer, about 155 parts of carbon black N-650 HiStr GPF, about 10 parts of carbon N-330 HAF (Example 1), about 15 parts of mineral coal filler (Example 2) about 85 parts of paraffinic process oil, a processing aid, a phenolic resin, zinc oxide and stearic acid. These ingredients are mixed to form a master batch of rubber. Approximately 3.9 parts of a mixture of sulfur and sulfur vulcanization accelerators are then added to form the tile composition. Examples 3 to 4 include a high Mooney amorphous EPDM terpolymer, approximately 50 parts of N-650 HiStr GPF black, approximately 16 parts of mineral coal filler, approximately 49 parts of paraffinic process oil, approximately 65 parts of a package flame retardant, and identified as Fyrebloc 1DB-385R3 and 122 parts of a mixture of clay and talc. The types of curatives employed in Examples 3 to 4 were identical to those used in Examples 1 to 2. Examples 4 to 8 comprise a low Mooney EPDM terpolymer, of about 5 to 120 pallets of a mixture of carbon black N-330 and N-650, from approximately 16 to 20 parts of mineral coal filler, from about 45 to 100 parts of paraffinic process oil as well as clay, talc, a flame retardant package and the same sulfur vulcanization accelerators that are used in the Examples 1 to 4. Examples 9 to 16 include 100 parts of a low Mooney amorphous EPDM, of about 15 to 35 parts of black N-650 HiStr GPF, about 17.5 parts of mineral carbon filler (Example 16 only), approximately 37 to 49 parts of paraffinic process oil, approximately 15 parts of chlorinated paraffinic oil, approximately 160 to 170 parts of a mixture of alumina trihydrate and magnesium hydroxide, approximately between 75 to 100 parts of an LLDPE or HDPE resin and 55 to 100 parts of a cryogenically ground EPDM rubber (80 mesh) and the same sulfur vulcanization accelerators as used in Examples 1 to 8.

The ingredients were mixed for about 2.5 minutes to about 6 minutes, depending on the specific melting characteristics of the resins containing polyethylene and polypropylene employed. The first step mixing or pouring temperature (master batch) was between about 163 ° C and 185 ° C. The master batch is worked or refined, and re-rolled into a mixture of two hot rollers. The temperature in the rolling rolls was between about 116 ° C to 160 ° C. In a matter of minutes, the re-laminated plate material is cut to the desired dimensions and added strip by strip to the cavity of the mixing chamber. After approximately 50% of the master masterbatch has been added to the mixer, the sulfur cure pack is discharged into the mixing chamber followed by addition of the remainder of the first stage mix or master batch. The temperature of the rubber mixture is allowed to reach temperatures as high as about 150 ° C for only a very short period of time (about 2 minutes or less). The second stage mixture is rapidly re-rolled to the desired dimensions again using a mixture of two hot rolls. The total mixing time involving the second stage mixing for each composition was less than about 2 minutes. The recently prepared fully formulated test specimens were then cured by press for 30 minutes at 160 ° C. Various tests were then performed on each specimen. The results of these tests are illustrated in Table III below. Specifically, curing characteristics, viscosity and toasting measurements, strain-strain-tensile data, ripping properties with C-matrix, cured composite hardness of cured tile compositions were determined by each example of the present invention. The curing characteristics (curing speed, curing state, etc.) of the fully formulated tile compositions were determined using a Monsanto oscillating disc rheometer according to ASTM D 2084. The matrix oscillated at a 3 ° arc, 160 ° C during the current test. The processing characteristics of the tile compositions were determined using a Monsanto Mooney viscometer tester (MV-2000E). The specific test conditions involved using a matrix connection with large rotor (diameter 3.82 cm (1.5")) operating at 135 ° C during the current test.The Mooney viscometer provides useful information that involves viscosity in the uncured, formulated state, and processing safety (toasting) of fully formulated tile compositions. This test method (ASTM D 1696-89) can be used to determine incipient cure time and to determine the curing characteristics of the vulcanizable compounds.When testing, each of the tile compositions (Examples 1 to 16) were compression molded to a thickness of approximately 1143 mm (45 mils) and cut into a plurality of bell-shaped test specimens in accordance with ASTM D 412 (Straight and bell-shaped specimens Method A ). Each test specimen is tested using a crosshead speed of 50.8 cm (20") per minute in an Instron Universal Table Model Tester 4301. The initial jaw clearance was 5.08 cm (2") The universal tester (a type test machine with constant-jaw ratio separation) is equipped with convenient fasteners capable of holding test specimens without slippage. traction and elongation at rupture, and the test results were calculated in accordance with ASTM D 412. All bell-shaped test specimens were allowed to set at room temperature for approximately 24 hours before carrying out the test at 23 ° C. ° C using the appropriate metal matrix (matrix at an angle C of 90 °)Tearing specimens with C-matrix were also cut and tested under the same conditions as the bell-shaped specimens. Again, the test specimens were allowed to set for approximately 24 hours before carrying out the test at 23 ° C. Shore hardness "A", which measures the hardness of cured rubber vulcanizate, is measured with an indentation or indentation hardness testing machine. Cured compound hardness measurements are based on initial indentation (instantaneous) or indentation after a specified period of time (residence time) or both. Each vulcanized cured rubber is allowed to set for approximately 24 hours before testing. Increasing the level of impact modifying polymer increases the hardness of the tile composition. The limiting oxygen index (LOI) is determined = Limiting Oxygen Index) for a number of tile compositions. LOI is defined to mean the minimum concentration of oxygen, expressed as a volume percent, in a nitrogen oxygen mixture that will support flaming combustion of a material initially at room temperature under the test conditions set forth in ASTM D 2863-91. Convenient test equipment to determine the LOI of plastic and rubber materials is the Stanton-Redcroft FTA flammability test unit. Custom Scientific Instruments (CSI), Inc., a subsidiary of Atlas Electric Devices Company, also commercially produces these flammability test units. TABLE III Properties of tile compositions Compounds Nos. Rheometer at 320 ° F (160 ° C), mini-matrix. Arc of 3 ° Toast time, minutes 3:51 4:11 5:08 5:34 Time to 50% cure, minutes 7:40 8:11 10:26 10:01 Time at 90% cure, minutes 19:04 21:25 23:29 22:21 Minimum torque, kg-cm 7.38 7.03 10.15 9.46 (lb-in) (6.4) (6.1) (8.8) (8.2) Maximum torque, kg-cm 56.74 51.08 32.98 31.59 (lb-in) (49.2) (44.3) (28.6) (27.4) Mooney toast at 135 ° C (277 ° F) - large rotor Minimum viscosity, Mu 41.4 39.4 49.2 49.8 T5, minutes 14.06 14.84 20.9 22.7 T35, minutes 23.5 25.4 35.9 36.8 Stress-strain properties at 23 ° C (73 ° F) cured plates 40 minutes at 160 ° C Module 100%, kg / cm2 41.13 36.90 33.74 39.72 (psi) (585) (525) (480) (565) TABLE III Composition Properties of Teia Compounds Nos. Module 300%, kg / cm2 109.32 95.26 53.43 58.35 (psi) (1555) (1355) (760) (830) Stress at break, kg / cm2 119.86 109.32 89.63 100.25 (psi) (1705) (1555) (1275) (1426) Elongation at rupture,% 395 450 635 685 Tearing properties with matrix C at 23 ° C (73 ° F) - plates cured 40 minutes at 160 ° C 42.72 37.18 39.68 42.54 kg / cm (lb / inch) (239) (208) (222) (238) Shore Hardness "A" at 23 ° C (73 ° F) - no aging Units 70 70 71 72 TABLE III (continued) Composition Properties of Teia Compounds Nos. Rheometer at 320 ° F (160 ° C), mini-matrix. Arc of 3rd Toast time, minutes 4:30 4:59 5:49 9:05 Time at 50% cure, minutes 8:44 10:00 11:35 10:06 Time at 90% cure, minutes 20:37 19:49 22:18 15:32 Minimum torque, kg-cm 9.63 9.17 6.80 5.3 (lb-in) (8.35) (7.95) (5.90) (4.6) TABLE III (continued) Composition Properties of Teia Compounds Nos. Maximum torque, kg-cm 31.02 32.17 54.44 45.2 (lb-in) (26.9) (27.9) (47.3) (39.2) Mooney toast at 135 ° C (277 ° F) - large rotor Minimum viscosity, Mu 40.8 40.9 44.5 37.9 T5, minutes 17.2 17.9 18.9 17.63 T35, minutes 33.7 36.4 34.7 38.52 Stress-strain properties at 23 ° C (73 ° F) - plates cured 40 minutes at 160 ° C Module 100%, kg / cm2 (psi) 47.80 32.69 37.96 44.99 (680) (465) (540) (640) Module 300%, kg / cm2 (psi) 64.32 47.80 81.19 87.87 (915) (680) (1155) (1250) Stress at break, kg / cm2 103.06 96.66 105.24 118.10 (psi) (1466) (1375) (1497) (1680) Elongation at rupture,% 630 567 535 550 Tear properties matrix C at 23 ° C (73 ° F) - plates cured 40 minutes at 160 ° C 47.37 37.18 39.68 42.54 kg / cm (lb / inch) (265) (208) (195) (256) Shore hardness " A "at 23 ° C (73 ° F) - no aging Units 86 78 74 85 TABLE III (continued) Properties of Composite Tile Compositions Nos. 10 11 12 Rheometer at 160 ° C (320 ° F), mini-matrix. Arc of 3 ° Toast time, minutes 4:49 5:20 5:20 4:03 Time at 50% cure, minutes 8:30 9:17 8:50 5:00 Time at 90% cure, minutes 15 : 47 16:25 15:47 9:22 Minimum torque, kg-cm 9.26 9.14 9.80 11.07 (lb-in) (8.03) (7.93) (8.50) (9.6) Maximum torque, kg-cm 35.74 34.31 32.17 18.25 (lb-in) (30.99) (29.75) (27.9) (15.83) Stress-strain properties at 23 ° C (73 ° F) cured plates 40 minutes at 160 ° C Module 100%, kg / cm2 35.50 35.85 35.85 36.77 (psi) (505) (510) (510) (523) Module 300%, kg / cm2 45.69 48.16 48.86 48.16 (psi) (650) (685) (695) (685) Breaking stress, 97.72 96.31 90.68 70.3 kg / cm2 (psi) (1390) (1370) (1290) (1000) Elongation at rupture,% 638 600 568 565 Tear properties matrix C at 23 ° C (73 ° F) plates cured 40 minutes at 160 ° C 42.89 41.65 41.83 45.76 kg / cm (lb / inch) (240) (233) (234) (256) TABLE III (continued) ) Composition Properties of Teia Compounds Nos. 10 11 12 Shore hardness "A" at 23 ° C (73 ° F) - no aging Units 75 75 75 81 limiting oxygen index - plates cured 40 minutes a 160 ° C% 02 31.7 31.3 32 32 32 TABLE III (continued) Composition Properties of Teia Compounds Nos. 13 14 15 16 Rheometer at 160 ° C (320 ° F), mini-matrix. Arc of 3rd Toast time, minutes 3:42 5:19 3:19 4:17 Time at 50% cure, minutes 6:09 8:00 6:02 6:34 Time at 90% cure, minutes 13: 07 16:28 13:21 14:48 Minimum torque, kg-cm 12.39 11.65 14.18 13.03 (lb-in) (10.75) (10.1) (12.3) (11.3) Maximum torque, kg-cm 26.75 26.09 32.06 25.14 (lb-in) (23.2) (22.63) (27.8) (21.8) Stress-strain properties at 23 ° C (73 ° F) plates cured 40 minutes at 160 ° C TABLE III (continued) Composition Properties of Teia Compounds Nos. 13 14 15 16 Module 100%, kg / cm2 50. 61 47.45 48.43 52.73 (psi) (720) (675) (689) (750) Module 300%, kg / cm2 61. 51 57.65 57.50 60.11 (psi) (875) (820) (818) (855) Stress at break, 80.85 74.87 74.17 77.33 kkgg // ccmm2"((ppssii)) (1150) (1065) (1055) (1100) Elongation at break,% 535 525 525 555 Tear properties matrix C at 23 ° C (73 ° F) plates cured 40 minutes at 160 ° C 21.37 20.25 19.05 21.51 kg / cm (lb / inch) (304) (288) (271) (306) Shore hardness "A" at 23 ° C (73 ° F) - no aging Units 86 88 85 90 limiting oxygen index - plates cured 40 minutes a 160 ° C% 02 31.3 31.7 31.7 31.7 As illustrated in Table III above, the physical properties of each of the rubber compounds were measured and reported. EPDM-based tile compositions resulting in examples 1 to 8 (Table II) can be characterized as having tensile stress measurements exceeding 5.27 kg / cm2 (75 psi) and tearing values with C matrix between 224.8 and 305.58 kg / cm (195 and 265 lbs / in) at 23 ° C. The values of elongation at break easily exceed the minimum limit of ultimate elongation at 300% at 23 ° C. All cured composite hardness values exceed the minimum limit of 70 as determined using the portable hardness tester (type A) manufactured by Shore Instrument and Manufacturing Co., NYC. Examples 9 to 16 include 100 parts of a low Mooney amorphous EPDM terpolymer, from about 15 to 35 parts of black N-650 HiStr GPF, about 17.5 parts of mineral carbon filler (Example 16 only), from about 37 to 49 paraffinic process oil parts, about 15 chlorinated paraffinic parts (Examples 9 to 11) of about 160 to 170 parts of a mixture of alumina trihydrate and magnesium hydroxide, of about 65 to 100 parts either of a LLDPE or HDPE resin and 55 to 100 parts of a cryogenically ground EPDM rubber (80 mesh) and the same sulfur vulcanization accelerators as used in Examples 1 to 8. These examples also exhibit excellent aging properties without aging. Tensile strength values for examples 9 to 16 are in the range between 70.3 and 97.7 kg / cm2 (1000 and 1390 psi) while the tearing properties C at 23 ° C were 268.68 kg / cm (233 lbs / in ) or higher. The values of elongation at break easily exceed the minimum limit of ultimate elongation of 300% at 23 ° C. All cured composite hardness values easily exceed the minimum limit of 70 as determined using a portable hardness tester (type A) manufactured by Shore Instrument and Manufacturing Co., NYC. Reducing the level of the paraffinic process oil has no significant influence on LOI determinations in Examples 9-16. Also, varying the concentrations of ATH and magnesium hydroxide had virtually no influence on the curing speed at 160 ° C and the LOI test results, while the HDPE level is increased both the tear resistance with C matrix is increased as well. as composite hardness. Examples 9 to 16 easily exceed the LOI minimum limit of 30 when tested in accordance with ASTM D 2863-91. In this way, it should be evident that the shingles and the method for covering a roof according to the present invention are highly effective in providing long-term weathering and high durometer. The invention is particularly suitable for replacing asphalt shingles, but not necessarily limited to them. The shingles and the method of the present invention can also be used to replace essentially any hard natural material previously employed as a roof covering element in a sloped roof. Based on the above description, it should now be apparent that the use of a tile described here carries out the previously established objectives. Therefore, it will be understood that any apparent variations fall within the scope of the claimed invention and thus the selection of the specific component elements can be determined without departing without departing from the spirit of the invention described and presented herein. In particular, any fillers or processing aids used in accordance with the present invention is not necessarily limited to those indicated in the examples. In contrast, other fillers and processing aids or any other ingredient described but not used in the specific examples can be employed in the present invention, the invention is not limited by the scope of these examples or the preferred embodiment. On the contrary, the scope of the invention will include all modifications and variations that fall within the scope of the appended claims.

Claims (37)

1. CLAIMS 1.- An element for roof cover, for use in inclined roofs, the cover element is characterized in that it comprises: 100 parts by weight of at least one ethylene-butylene-diene terpolymer, and from 0 to approximately 120 parts in weight of at least one impact modifying polymer, per 100 parts of the ethylene-propylene-diene terpolymer, the covering element has a Shore "A" hardness not aged at approximately 23 ° C of at least 70.
2. 2. - The element of roof covering according to claim 1, characterized in that the ethylene-propylene-diene terpolymer at least includes from about 80 to 100 parts by weight of at least one EPDM containing up to about 2% crystallinity and from 0 to about 20 parts by weight of at least one EPDM containing more than 2% by weight of crystallinity.
3. 3. - The roof covering element according to claim 2, characterized in that the ethylene-propylene-diene terpolymer at least includes from about 95 to 100 parts by weight of at least one EPDM containing up to about 1.1% crystallinity and from 0 to about 5 parts by weight of at least one EPDM containing more than 1.1% by weight of crystallinity.
4. 4. - The roof covering element according to claim 1, characterized in that the at least one impact modifying polymer is at least one polyolefin resin selected from the group consisting of polyethylene, polypropylene, ethylene and propylene copolymers, copolymers of ethylene and butene and copolymers of ethylene and octene.
5. 5. - The roof covering element according to claim 1, characterized in that the cover element contains from 0 to about 50 parts by weight of the impact modifying polymer at least, per 100 parts by weight of the ethylene-propylene terpolymer -Diene.
6. 6. - The roof covering element according to claim 1, characterized in that the cover element has a limiting oxygen index of at least 30% when tested in accordance with ASTM D2863-91.
7. 7. - The roof covering element according to claim 6, characterized in that the cover element is a tile and has a "class A" fire rating according to the UL 790 flame-scatter test performed by Underwriter Laboratories, Northbrook, IL.
8. 8. - The roof covering element according to claim 1, characterized in that it also comprises from about 50 to about 600 parts by weight of at least one filler selected from the group consisting of combustible and non-combustible materials and their mixtures, by 100 parts by weight of the ethylene-propylene-diene terpolymer; and from about 30% to 105 parts by weight of a processing material, per 100 parts by weight of the ethylene-propylene-diene terpolymer.
9. 9. - The roof covering element according to claim 8, characterized in that the filling comprises at least one organic combustible material selected from the group consisting of carbon black and ground mineral coal.
10. 10. - The roof covering element according to claim 8, characterized in that at least one filler includes at least one non-combustible material selected from the group consisting of cryogenic or environmentally ground rubber, and mineral fillers.
11. 11. - The roof covering element according to claim 10, characterized in that the mineral fillers are selected from the group consisting of clay, mica, talcum, alumina trihydrate, antimony trioxide, calcium carbonate, titanium dioxide, silica, magnesium hydroxide, calcium borate ore and mixtures thereof.
12. 12. - The roof covering element according to claim 8, characterized in that the processing aid as a minimum includes at least one oil or processing wax selected from the group consisting of paraffinic oils, Naphthenic oils and liquid halogenated paraffins.
13. 13. - The roof covering element according to claim 8, characterized in that the processing aid at least includes an additive selected from the group consisting of at least one aromatic hydrocarbon resin and a phenolic resin.
14. 14. - The roof covering element according to claim 8, characterized in that the filling at least includes a flame retardant package containing antimony trioxide and an ethylene-propylene-diene terpolymer.
15. 15. - The roof covering element according to claim 8, characterized in that it further comprises from about 1.5 to about 10 parts by weight of a cure package, per 100 parts by weight of the ethylene-propylene-diene terpolymer.
16. 16. A tile, characterized in that it comprises: a polymeric component comprising: at least 45 to 100% by weight of at least one ethylene-propylene-diene terpolymer; and from 0 to 55% by weight of at least one impact modifying polymer, and wherein the tiles contain 100 parts by weight of at least one ethylene-propylene-diene terpolymer; from about 50 to about 60 parts by weight of at least one filler selected from the group consisting of combustible and non-combustible fillers, per 100 parts by weight of the ethylene-propylene-diene terpolymer; and from about 30 to about 105 parts by weight of at least one processing material, per 100 parts by weight of the ethylene-propylene-diene terpolymer; where the tile has a Shore "A" hardness of at least 70.
17. 17.- The tile in accordance with the claim 16, characterized in that at least one ethylene-propylene-diene terpolymer includes from about 80 to 100 parts by weight of at least one EPDM containing up to about 2% crystallinity and from 0 to about 20 parts by weight of at least one EPDM which contains more than 2% crystallinity.
18. 18.- The tile in accordance with the claim 17, characterized in that the ethylene-propylene diene terpolymer at least includes from about 95 to 100 parts by weight of at least one EPDM containing up to about 1.1% crystallinity and from 0 to about 5 parts by weight of at least one EPDM which contains more than 1.1% crystallinity.
19. 19. - The tile in accordance with the claim 16, characterized in that the at least one impact modifying polymer is at least one polyolefin resin selected from the group consisting of polyethylene, polypropylene, ethylene and propylene copolymers, copolymers of ethylene and butene and copolymers of ethylene and octene.
20. 20. The tile according to claim 1, characterized in that the tile contains from 0 to about 50 parts by weight of the impact modifying polymer at least, per 100 parts by weight of the ethylene-propylene-diene terpolymer.
21. 21. The tile according to claim 16, characterized in that the tile has a limiting oxygen index of at least 30 when tested in accordance with ASTM D2863-91.
22. 22. The tile in accordance with the claim 21, characterized in that the tile has a "Class A" fire rating according to a UL 790 flame-scatter test conducted by Underwriter Laboratories, Northbrook, IL.
23. 23. Method for covering an inclined roof, characterized in that it comprises: placing a plurality of tiles on the roof in a pre-selected installation pattern, each tile includes 100 parts by weight of at least one ethylene-propylene-diene terpolymer, - and 0 to about 120 parts by weight of at least one impact modifying polymer, per 100 parts by weight of the ethylene-propylene-diene terpolymer; the tile has a Shore "A" hardness without aging at about 23 ° C of at least 70.
24. 24. - The method according to claim 23, characterized in that at least one ethylene-propylene-diene terpolymer includes from about 80 to 100 parts by weight of at least one EPDM containing up to about 2% crystallinity and from 0 to about 20 parts by weight of at least one EPDM containing more than 2% by weight crystallinity.
25. 25. - The method according to claim 24, characterized in that at least one ethylene-propylene-diene terpolymer includes from about 95 to 100 parts by weight of at least one EPDM containing up to about 1.1% crystallinity and from 0 to about 5 parts by weight of at least one EPDM containing more than 1.1% by weight of crystallinity.
26. 26. - The method according to claim 23, characterized in that the impact modifying polymer is at least one polyolefin resin selected from the group consisting of polyethylene, polypropylene, copolymers of ethylene and propylene, copolymers of ethylene and butene and copolymers of ethylene and octene.
27. 27. The method according to claim 23, characterized in that the tile contains from 0 to about 50 parts by weight of at least one impact modifying polymer, per 100 parts by weight of the ethylene-propylene-diene terpolymer.
28. 28. The method according to claim 23, characterized in that the tile has a limiting oxygen index of at least 30 when tested in accordance with ASTM D2863-91.
29. 29. The method according to claim 28, characterized in that the tile has a "class A" fire rating according to the UL 790 flame-dispersion test performed by Underwriter Laboratories, Northbrook, IL. The method according to claim 23, characterized in that it also comprises from approximately 50 to approximately 600 parts by weight of at least one filler selected from the group consisting of combustible and non-combustible materials and their mixtures, per 100 parts by weight of the ethylene-propylene-diene terpolymer; and from about 30 to about 105 parts by weight of a processing material per 100 parts by weight of the ethylene-propylene-diene terpolymer. 31. The method according to claim 30, characterized in that at least one filler includes at least one combustible organic material selected from the group consisting of carbon black and ground mineral coal. 32. - The method according to claim 30, characterized in that at least one filler includes at least one non-combustible material selected from the group consisting of cryogenic or environmentally ground rubber; and mineral fillers. 33. - The method according to claim 32, characterized in that the mineral fillers are selected from the group consisting of clay, mica, talc, alumina trihydrate, antimony trioxide, calcium carbonate, titanium dioxide, silica, hydroxide, magnesium, calcium borate ore and its mixtures. 34. The method according to claim 30, characterized in that at least one processing material includes at least one processing oil or paraffin selected from the group consisting of paraffinic oils, naphthenic oils and liquid halogenated paraffins. The method according to claim 8, characterized in that at least one processing aid includes an additive selected from the group consisting of at least one aromatic hydrocarbon resin and a phenolic resin. 36. The method according to claim 30, characterized in that the filling at least includes a flame retardant package containing antimony trioxide and an ethylene-propylene-diene terpolymer. 37. The method according to claim 30, characterized in that it further comprises: from about 1.5 to about 10 parts by weight of a curing package, per 100 parts by weight of the ethylene-propylene-diene terpolymer.