Multilayer structure with enhanced walkability

Patent metadata

Field	Value
Publication number	US-2025188742-A1
Application number	US-202519057167-A
Country	US
Kind code	A1
Filing date	Feb 19, 2025
Priority date	Dec 5, 2022
Publication date	Jun 12, 2025
Grant date	—

Abstract

A roofing underlayment with enhanced walkability is provided. The roofing underlayment has a reinforcement, a film, and a plurality of gripping structures. The gripping structures are disposed on at least a portion of a first film surface of the film. The roofing underlayment has at least one of a coefficient of friction of between about 1.2 and about 1.8 when tested in dry condition using COF method 1, a coefficient of friction of between about 0.8 and about 1.5 when tested in wet condition using COF method 1, and a coefficient of friction of between about 0.5 and about 1.2 using COF method 1.

First claim

What is claimed is:

1 . A roofing underlayment comprising:
a reinforcement having a first reinforcement surface and a second reinforcement surface; a first coating on the first reinforcement surface; and a plurality of gripping structures formed in the first coating, wherein each gripping structure has a height in the range of about 50 μm to about 400 μm and a maximum cross-sectional dimension greater than or equal to 300 μm.

2 . The roofing underlayment of claim 1 , wherein the first coating comprises a thermoplastic material.

3 . The roofing underlayment of claim 1 , wherein the first coating has a thickness in the range of about 20 μm to about 1,200 μm.

4 . The roofing underlayment of claim 1 , wherein the first coating has a basis weight in the range of about 10 g/m 2 to about 200 g/m 2 , and
wherein the first coating comprises at least one of a polypropylene and a polyethylene.

5 . The roofing underlayment of claim 1 , wherein the roofing underlayment has a coefficient of friction of between about 1.2 and about 1.8 when tested in dry conditions using a COF method 1.

6 . The roofing underlayment of claim 1 , wherein the roofing underlayment has a coefficient of friction of between about 0.8 and about 1.5 when tested in wet conditions using the COF method 1.

7 . The roofing underlayment of claim 1 , wherein the roofing underlayment has a coefficient of friction of between about 0.5 and about 1.2 when tested in sawdust conditions using the COF method 1.

8 . The roofing underlayment of claim 1 , wherein the plurality of gripping structures have a pitch in the range of about 600 μm to about 1,200 μm.

9 . The roofing underlayment of claim 1 , wherein each gripping structure has a maximum cross-sectional dimension in the range of about 350 μm to about 550 μm.

10 . The roofing underlayment of claim 1 , further comprising a second coating on the second reinforcement surface.

11 . The roofing underlayment of claim 1 , further comprising:
an adhesive coating; and an optional release liner, wherein the adhesive coating is adhered to the second reinforcement surface, and wherein the optional release liner is adhered to a surface of the adhesive coating opposite the reinforcement.

12 . The roofing underlayment of claim 11 , wherein the reinforcement is at least partially impregnated with the adhesive coating.

13 . The roofing underlayment of claim 1 , wherein the reinforcement comprises a glass mat.

14 . A roofing underlayment comprising:
a reinforcement having a first reinforcement surface and a second reinforcement surface; a coating on the first reinforcement surface; and a plurality of gripping structures formed in the coating, wherein the roofing underlayment has a coefficient of friction of between about 0.8 and about 1.5 when tested in wet conditions using the COF method 1, and wherein the roofing underlayment has a retention rate of greater than or equal to 90% in wet conditions when tested using COF method 1.

15 . The roofing underlayment of claim 14 , wherein the coating comprises a thermoplastic material.

16 . The roofing underlayment of claim 14 , wherein the coating has a thickness in the range of about 20 μm to about 1,200 μm.

17 . The roofing underlayment of claim 14 , wherein the coating has a basis weight in the range of about 10 g/m 2 to about 200 g/m 2 , and
wherein the coating comprises at least one of a polypropylene and a polyethylene.

18 . The roofing underlayment of claim 14 , wherein each gripping structure has a height in the range of about 50 μm to about 400 μm and a maximum cross-sectional dimension in the range of about 350 μm to about 550 μm.

19 . The roofing underlayment of claim 14 , wherein the coating and the plurality of gripping structures have a Shore D hardness of 40 to 100.

20 . The roofing underlayment of claim 14 , further comprising:
an adhesive coating; and an optional release liner, wherein the adhesive coating is adhered to the second reinforcement surface, and wherein the optional release liner is adhered to a surface of the adhesive coating opposite the reinforcement.

21 . The roofing underlayment of claim 20 , wherein the reinforcement is at least partially impregnated with the adhesive coating.

22 . The roofing underlayment of claim 14 , wherein the roofing underlayment has a width in the range of about 0.6 μm to about 2 μm, a length in the range of about 9 μm to about 100 μm, and a thickness in the range of about 125 μm to about 2,500 μm.

23 . A roofing underlayment comprising:
a carrier layer having a first carrier surface and a second carrier surface; a first coating positioned above the first carrier surface, a plurality of gripping structures formed in the first coating, a first adhesive coating positioned below the second carrier surface; a reinforcement having a first reinforcement surface and a second reinforcement surface, the reinforcement positioned below the first adhesive coating with the first reinforcement surface facing the first adhesive coating; and a second adhesive coating positioned below the second reinforcement surface, wherein each gripping structure has a height in the range of about 50 μm to about 400 μm and a maximum cross-sectional dimension greater than or equal to 300 μm.

24 . The roofing underlayment of claim 23 , further comprising a release liner positioned below the second adhesive coating.

25 . The roofing underlayment of claim 23 , wherein the carrier layer comprises a second reinforcement.

26 . The roofing underlayment of claim 23 , wherein the reinforcement is at least partially impregnated with at least one of the first adhesive coating and the second adhesive coating.

27 . The roofing underlayment of claim 23 , wherein the first adhesive coating and the second adhesive coating are the same material.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Pruzinsky Stephanie
• Vido Martin
• Newsome Toni
• Shaeffer Brian
• Cortes-Medina Marcos
• Nogaj Melissa
• Maxson Stephanie
• Pham Dinh Chi
• Shinde Tathya Amar
• Shumaker Matthew C

Classifications

• B32B2419/06

  Roofs, roof membranes · CPC title

• B32B2307/536

  Hardness · CPC title

• B32B2250/03

  3 layers · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title