Roofing underlayment with enhanced walkability and traction

Patent metadata

Field	Value
Publication number	US-2020399903-A1
Application number	US-202016909026-A
Country	US
Kind code	A1
Filing date	Jun 23, 2020
Priority date	Jun 24, 2019
Publication date	Dec 24, 2020
Grant date	—

Abstract

A roofing underlayment with enhanced walkability and/or traction is provided. The roofing underlayment includes a base layer, a first coating layer adhered to a first surface of the base layer, and a melt-blown nonwoven layer adhered to the first coating layer. The melt-blown nonwoven layer enhances walkability by providing a rough surface on which roofing installers may walk.

First claim

What is claimed is:

1 . A roofing underlayment comprising:
a base layer; a first coating layer adhered to a first surface of the base layer; and a melt-blown nonwoven layer adhered to the first coating layer.

2 . The roofing underlayment according to claim 1 , wherein the melt-blown nonwoven 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 melt-blown nonwoven layer has a basis weight of 10 g/m 2 to 120 g/m 2 and comprises a thermoplastic composition comprising a polyolefin, wherein the thermoplastic composition has a melt flow index of at least 100 g/10 minutes.

4 . The roofing underlayment according to claim 1 , wherein the melt-blown nonwoven layer has a basis weight of 25 g/m 2 to 50 g/m 2 and comprises a thermoplastic composition comprising at least one of a polypropylene and a polyethylene, and wherein the thermoplastic composition has a melt flow index of 800 g/10 minutes to 1,200 g/10 minutes.

5 . The roofing underlayment according to claim 1 , wherein the base layer is selected from a woven material, a nonwoven material, and a film material;
wherein the base layer comprises at least one of a polyolefin, a polyester, a polystyrene, a polyamide, a polyurethane, a polycarbonate, an ethylene acrylic copolymer, and a glass; and wherein the base layer has a basis weight of 25 g/m 2 to 250 g/m 2 .

6 . The roofing underlayment according to claim 5 , wherein the base layer is a woven material having a basis weight of 85 g/m 2 to 105 g/m 2 and comprises a polypropylene, a filler material, and a U.V. stabilizer.

7 . The roofing underlayment according to claim 5 , wherein the base layer comprises a spunbond nonwoven material having a basis weight of 135 g/m 2 to 145 g/m 2 and comprises a polypropylene.

8 . The roofing underlayment according to claim 1 , wherein the first coating layer is selected from a woven material, a nonwoven material, and a film material;
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, an ethylene acrylic copolymer, and a hot melt adhesive; and wherein the first coating layer has a basis weight of 5 g/m 2 to 50 g/m 2 .

9 . The roofing underlayment according to claim 8 , wherein the first coating layer is a film material having a basis weight of 20 g/m 2 to 50 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 4% to 8% by weight colorant, wherein the weight percentages are based on the total weight of the first coating layer.

10 . The roofing underlayment according to claim 8 , wherein the first coating layer is a film material having a basis weight of 20 g/m 2 to 30 g/m 2 and comprises 40% to 50% by weight recycled/reprocessed polypropylene, 25% to 35% by weight thermoplastic elastomer, 10% to 20% by weight low density polyethylene, 2% to 8% by weight colorant, and 1% to 7% by weight virgin polypropylene, wherein the weight percentages are based on the total weight of the first coating layer.

11 . The roofing underlayment according to claim 1 , further comprising a second coating layer adhered to a second surface of the base layer opposite the first surface.

12 . The roofing underlayment according to claim 11 , wherein the second coating 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 80 g/m 2 , and wherein the polyolefin layer is adhered to the second surface of the base layer.

13 . The roofing underlayment according to claim 12 , 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.

14 . The roofing underlayment according to claim 1 , wherein the roofing underlayment has a basis weight of 75 g/m 2 to 460 g/m 2 .

15 . A roofing underlayment comprising:
a base layer; a first coating layer adhered to a first surface of the base layer; a first melt-blown nonwoven layer adhered to the first coating layer; and a second melt-blown nonwoven layer adhered to a second surface of the base layer.

16 . The roofing underlayment according to claim 15 , wherein the first melt-blown nonwoven layer has a basis weight of 10 g/m 2 to 120 g/m 2 and comprises at least one of a polyolefin, a polyester, a polystyrene, a polyamide, a polyurethane, a polycarbonate, and an ethylene acrylic copolymer; and
wherein the second melt-blown nonwoven layer has a basis weight of 10 g/m 2 to 120 g/m 2 and comprises at least one of a polyolefin, a polyester, a polystyrene, a polyamide, a polyurethane, a polycarbonate, and an ethylene acrylic copolymer.

17 . The roofing underlayment according to claim 15 , wherein the first melt-blown nonwoven layer has a basis weight of 10 g/m 2 to 120 g/m 2 and comprises a first thermoplastic composition comprising a polyolefin, wherein the first thermoplastic composition has a melt flow index of at least 100 g/10 minutes; and
wherein the second melt-blown nonwoven layer has a basis weight of 10 g/m 2 to 120 g/m 2 and comprises a second thermoplastic composition comprising a polyolefin, wherein the second thermoplastic composition has a melt flow index of at least 100 g/10 minutes.

18 . The roofing underlayment according to claim 15 , wherein the first melt-blown nonwoven layer has a basis weight of 25 g/m 2 to 50 g/m 2 and comprises a first thermoplastic composition comprising at least one of a polypropylene and a polyethylene, and wherein the first thermoplastic composition has a melt flow index of 800 g/10 minutes to 1,200 g/10 minutes; and
wherein the second melt-blown nonwoven layer has a basis weight of 25 g/m 2 to 50 g/m 2 and comprises a second thermoplastic composition comprising at least one of a polypropylene and a polyethylene, and wherein the second thermoplastic composition has a melt flow index of 800 g/10 minutes to 1,200 g/10 minutes.

19 . The roofing underlayment according to claim 15 , wherein the base layer is a woven material having a basis weight of 85 g/m 2 to 105 g/m 2 and comprises a polypropylene, a filler material, and a U.V. stabilizer.

20 . The roofing underlayment according to claim 15 , wherein the base layer comprises a spunbond nonwoven material having a basis weight of 135 g/m 2 to 145 g/m 2 and comprises a polypropylene.

21 . The roofing underlayment according to claim 15 , wherein the first coating layer is selected from a woven material, a nonwoven material, and a film material;
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, an ethylene acrylic copolymer,

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Vido Martin
• Sun Zhenchao
• Woodall Jason
• Pruzinsky Stephanie
• Thaxton Steve
• Difilippo Sabrina
• Robinson Chris

Classifications

• B32B2419/06

  Roofs, roof membranes · CPC title

• B32B2262/0253

  Polyolefin fibres · CPC title

• B32B27/365

  comprising polycarbonates · CPC title

• B32B2262/0246

  Acrylic resin fibres · CPC title

• B32B27/36

  comprising polyesters · CPC title