Roofing underlayment with hydrophobic nonwoven core

Patent metadata

Field	Value
Publication number	US-11518137-B2
Application number	US-202016909046-A
Country	US
Kind code	B2
Filing date	Jun 23, 2020
Priority date	Jun 24, 2019
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

Abstract

A roofing underlayment includes a hydrophobic nonwoven core layer that provides enhanced resistance to water infiltration. In addition to the hydrophobic nonwoven core layer, the roofing underlayment includes a coating layer adhered to a surface of the hydrophobic nonwoven core layer, and an exterior surface layer adhered to the coating layer. A roofing system that includes the roofing underlayment is also provided.

First claim

What is claimed is:

1. A roofing underlayment comprising:
a hydrophobic nonwoven core layer having a basis weight of 100 g/m 2 to 250 g/m 2 ,
a first coating layer adhered to a first surface of the hydrophobic nonwoven core layer, and
a first exterior surface layer comprising a bicomponent spunbond nonwoven material having a total basis weight of 30 g/m 2 to 60 g/m 2 and comprising a polyolefin layer bonded to a thermoplastic elastomer layer, and wherein the polyolefin layer is adhered to the first coating layer.

2. The roofing underlayment according to claim 1 , wherein the hydrophobic nonwoven core layer comprises at least one of a polyolefin, a polyester, a polystyrene, a polyamide, a polyurethane, a polycarbonate, and an ethylene acrylic copolymer.

3. The roofing underlayment according to claim 1 , wherein the hydrophobic nonwoven core layer comprises a polypropylene.

4. The roofing underlayment according to claim 1 , wherein the hydrophobic nonwoven core layer has a basis weight of 105 g/m 2 to 150 g/m 2 .

5. The roofing underlayment according to claim 1 , wherein the first coating layer comprises at least one of a polyolefin, a thermoplastic elastomer, a polyester, a polystyrene, a polyamide, a polyurethane, a polycarbonate, and an ethylene acrylic copolymer.

6. The roofing underlayment according to claim 1 , wherein the first coating layer has a basis weight of 15 g/m 2 to 30 g/m 2 .

7. The roofing underlayment according to claim 1 , wherein the polyolefin layer has a basis weight of 15 g/m 2 to 30 g/m 2 and comprises 84% to 98% by weight virgin polypropylene, 1% to 8% by weight U.V. stabilizer, and 1% to 8% by weight colorant, based on the total weight of the polyolefin layer; and the thermoplastic elastomer layer has a basis weight of 15 g/m 2 to 30 g/m 2 and comprises 70% to 80% by weight virgin polypropylene, 15% to 25% thermoplastic elastomer, 1% to 8% by weight U.V. stabilizer, and 1% to 8% by weight colorant, based on the total weight of the thermoplastic elastomer layer.

8. The roofing underlayment according to claim 1 , wherein the polyolefin layer has a basis weight of 20 g/m 2 to 30 g/m 2 and comprises 45% to 55% by weight virgin polypropylene, 40% to 50% by weight recycled/reprocessed polypropylene, and 1% to 5% by weight colorant, based on the total weight of the polyolefin layer; and the thermoplastic elastomer layer has a basis weight of 20 g/m 2 to 30 g/m 2 and comprises 70% to 80% by weight virgin polypropylene, 15% to 25% thermoplastic elastomer, and 1% to 5% by weight colorant, based on the total weight of the thermoplastic elastomer layer.

9. The roofing underlayment according to claim 1 , further comprising a second exterior surface layer adhered to a second surface of the hydrophobic nonwoven core layer opposite the first surface.

10. The roofing underlayment according to claim 9 , wherein the second exterior surface layer is a co-extruded layer comprising a thermoplastic elastomer layer and a polyolefin layer and has a basis weight of 10 g/m 2 to 120 g/m 2 .

11. The roofing underlayment according to claim 10 , wherein the polyolefin layer has a basis weight of 15 g/m 2 to 25 g/m 2 and comprises 40% to 50% by weight recycled/reprocessed polypropylene, 30% to 40% by weight virgin polypropylene, 10% to 20% by weight low density polyethylene, and 2% to 6% by weight colorant, based on the total weight of the polyolefin layer; and
wherein the thermoplastic elastomer layer has a basis weight of 2 g/m 2 to 10 g/m 2 and comprises 40% to 55% by weight thermoplastic elastomer, 25% to 45% by weight virgin polypropylene, 10% to 20% by weight low density polyethylene, and 2% to 6% by weight colorant, based on the total weight of the thermoplastic elastomer layer.

12. The roofing underlayment according to claim 1 , wherein the roofing underlayment has a total basis weight of 190 g/m 2 to 265 g/m 2 .

13. The roofing underlayment according to claim 1 , wherein the roofing underlayment has a total basis weight of 225 g/m 2 to 250 g/m 2 .

14. The roofing underlayment according to claim 1 , wherein the hydrophobic nonwoven core layer comprises at least 50% of a total basis weight of the roofing underlayment.

15. The roofing underlayment according to claim 1 , wherein the hydrophobic nonwoven core layer comprises from 50% to 80% of the total basis weight of the roofing underlayment.

16. A roofing underlayment comprising:
a hydrophobic nonwoven core layer having a basis weight of 110 g/m 2 to 155 g/m 2 ;
a first coating layer adhered to a first surface of the hydrophobic nonwoven core layer, wherein the first coating layer has a basis weight of 10 g/m 2 to 40 g/m 2 ;
a first exterior surface layer adhered to the first coating layer, wherein the first exterior surface layer has a basis weight of 20 g/m 2 to 60 g/m 2 ; and
a second exterior surface layer adhered to a second surface of the hydrophobic nonwoven core layer opposite the first surface, wherein the second exterior surface layer is a co-extruded layer comprising a thermoplastic elastomer layer having a basis weight of 2 g/m 2 to 10 g/m 2 and a polyolefin layer having a basis weight of 15 g/m 2 to 25 g/m 2 ,
wherein the hydrophobic nonwoven core layer comprises from 50% to 80% of a total basis weight of the roofing underlayment.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Vido Martin

Classifications

• B32B2419/06

  Roofs, roof membranes · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title

• B32B5/022 Primary

  Non-woven fabric · CPC title

• B32B2255/26

  Polymeric coating · CPC title

• Y10T442/681

  Spun-bonded nonwoven fabric · CPC title