Method for making a high solids low volatile organic compounds content ethylene propylene diene terpolymer rubber coating

A method for making a high solids low volatile organic compounds durable curable waterproof liquid rubber formulation with a solids content of at least 60 percent solids by volume of the total formulation, comprising:

• a. creating an ethylene propylene diene terpolymer component by:
• (i) blending in a closed vessel;
• 1. a first portion of ethylene propylene diene terpolymer (EPDM), wherein the ethylene propylene diene terpolymer (EPDM) is 50 weight percent to 99 weight percent of a total amount of the ethylene propylene diene terpolymer (EPDM) used in the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation;
• and
• 2. a first portion of solvent wherein the first portion of solvent is 33 weight percent to 67 weight percent of a total amount of solvent used in the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation using a high shear mixer for at least 10 minutes to 24 hours at a temperature from 20 degrees Celsius to 50 degrees Celsius forming a high viscosity solution;
• (ii) adding a second portion of ethylene propylene diene terpolymer (EPDM) to the high viscosity solution, wherein the second portion of ethylene propylene diene terpolymer (EPDM) is 0.1 weight percent to 50 weight percent of the total amount of ethylene propylene diene terpolymer (EPDM) in the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation;
• (iii) adding a second portion of solvent to the high viscosity solution and blending for 10 minutes to 12 hours at a temperature from 20 degrees Celsius to 50 degrees Celsius forming a low viscosity liquid intermediate rubber formulation, wherein the second portion of solvent is 33 weight percent to 67 weight percent of the total amount of solvent in the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation;
• (iv) adding 0.01 weight percent to 10 weight percent based on a total weight of the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation of a co-agent, to the a low viscosity liquid intermediate rubber formulation, wherein the co-agent comprises at least one of:
• an acrylate, a triallyl cyanurate, a polybutadiene, and a phenylenedimaleimide;
• and
• (v) adding 0.1 weight percent to 15 weight percent based on a total weight of the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation of a peroxide to the low viscosity liquid intermediate rubber formulation, wherein the peroxide comprises at least one of:
• a peroxyketal, a peroxyester, a dialkyl peroxide, a peroxy carbonate, and an azo initiator;
• and
• b. continuing to blend the low viscosity liquid intermediate rubber formulation at a low shear for 10 minutes to 12 hours at a temperature from 20 degrees Celsius to 50 degrees Celsius forming the ethylene propylene diene terpolymer component;
• c. forming a catalyst component by blending in a closed vessel:
• (i) 0.1 weight percent to 10 weight percent of a metal drier based on the total weight of the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation, and wherein the metal drier comprises at least one of:
• a metal carboxylate, and a metal alkoxide;
• and
• (ii) 1 weight percent to 5 weight percent of a solvent based on the total weight of the of the solvent in the high solids low volatile organic compounds durable curable waterproof liquid rubber formulation, and wherein the solvent comprises at least one of:
• an aliphatic solvent, an aromatic solvent, and a plant-based solvent;
• and
• wherein the ethylene propylene diene terpolymer component and catalyst component are blended together forming a blend, prior to application on a substrate, using a weight ratio from 250:1 to 10:1 of the ethylene propylene diene terpolymer component to the catalyst component, the blend curing on the substrate without addition of another curative, resulting in a high solids low volatile organic compounds durable curable waterproof liquid rubber coating with a solids content of at least 60 percent solids by volume with a tensile strength greater than 250 psi, an elongation greater than 50 percent, and a Shore A hardness from 40 to 70.