U.S. patent application number 16/893322 was filed with the patent office on 2020-12-17 for roofing underlayment.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to William E. Smith.
Application Number | 20200392734 16/893322 |
Document ID | / |
Family ID | 1000004917469 |
Filed Date | 2020-12-17 |
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United States Patent
Application |
20200392734 |
Kind Code |
A1 |
Smith; William E. |
December 17, 2020 |
ROOFING UNDERLAYMENT
Abstract
A roofing underlayment that resists water ingress around
fasteners that are used to secure the underlayment to a substrate,
such as a roof deck, is provided. The roofing underlayment includes
a base layer, a coating layer applied to the base layer, and a
water-swellable composition. An upper surface of the roofing
underlayment may have a water contact angle of at least
120.degree..
Inventors: |
Smith; William E.;
(Pataskala, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Family ID: |
1000004917469 |
Appl. No.: |
16/893322 |
Filed: |
June 4, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62861509 |
Jun 14, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 2101/32 20130101;
D06M 15/248 20130101; D06M 2101/20 20130101; D06M 15/227 20130101;
D06M 15/233 20130101; D06M 2101/34 20130101; D06M 15/59 20130101;
E04D 12/002 20130101; D06M 15/507 20130101 |
International
Class: |
E04D 12/00 20060101
E04D012/00; D06M 15/233 20060101 D06M015/233; D06M 15/507 20060101
D06M015/507; D06M 15/59 20060101 D06M015/59; D06M 15/248 20060101
D06M015/248; D06M 15/227 20060101 D06M015/227 |
Claims
1. A roofing underlayment comprising: a base layer; and a coating
layer applied to the base layer, wherein at least one of the base
layer and the coating layer includes a water-swellable
composition.
2. A roofing underlayment comprising: a baser layer; a coating
layer applied to the base layer; and a layer comprising a
water-swellable composition.
3. The roofing underlayment according to claim 2, wherein the layer
comprising the water-swellable composition is applied to the base
layer.
4. The roofing underlayment according to claim 2, wherein the layer
comprising the water-swellable composition is applied to the
coating layer.
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.
6. The roofing underlayment according to claim 1, wherein the base
layer comprises at least one of a polyolefin, a polyester, a
polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, and an ionomer
resin.
7. The roofing underlayment according to claim 1, wherein the
coating layer is a film material.
8. The roofing underlayment according to claim 1, wherein the
coating layer comprises at least one of a polyolefin, a polyester,
a polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, and an ionomer
resin.
9. The roofing underlayment according to claim 1, wherein the
water-swellable composition comprises at least one of a bentonite,
a polyacrylic acid or a salt thereof, a polyethylene oxide, a
polyacrylamide, a crosslinked polyacrylate, a crosslinked
polyacrylamide, a polyacrylamide copolymer, an ethylene maleic
anhydride copolymer, a cross-linked carboxymethylcellulose, a
polyvinyl alcohol copolymer, a starch grafted copolymer of
polyacrylonitrile, a hydrolyzed cellulose-polyacrylonitrile, a
polyurethane, and a hydrophilic swelling rubber.
10. The roofing underlayment according to claims 1, wherein an
upper surface of the roofing underlayment has a water contact angle
of 120.degree. to 180.degree..
11. A roofing underlayment comprising: a base layer; and a coating
layer applied to the base layer; wherein an upper surface of the
roofing underlayment has a water contact angle of at least
120.degree..
12. The roofing underlayment according to claim 11, wherein the
upper surface of the roofing underlayment comprises a surfactant
layer comprising at least one surfactant selected from a silane, a
stearic acid compound, and a fluoropolymer.
13. The roofing underlayment according to claim 11, wherein the
upper surface of the roofing underlayment comprises at least one of
nanostructures and microstructures.
14. The roofing underlayment according to claim 13, wherein the
nanostructures are formed by at least one of inorganic
nanoparticles, carbon nanoparticles, and etching the upper surface
of the roofing underlayment; and wherein the microstructures are
formed by at least one of inorganic microparticles, carbon
microparticles, and etching the upper surface of the roofing
underlayment.
15. The roofing underlayment according to claim 13, wherein the
upper surface of the roofing underlayment comprises nanostructures
formed by inorganic nanoparticles, wherein the inorganic
nanoparticles comprise at least one of silica, alumina, titania,
zirconia, ceria, zinc oxide, iron oxide, vanadia, antimony oxide,
and tin oxide.
16. The roofing underlayment according to claim 11, wherein the
base layer is selected from a woven material, a nonwoven material,
and a film material.
17. The roofing underlayment according to claim 11, wherein the
base layer comprises at least one of a polyolefin, a polyester, a
polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, and an ionomer
resin.
18. The roofing underlayment according to claim 11, wherein the
coating layer is a film material.
19. The roofing underlayment according to claim 11, wherein the
coating layer comprises at least one of a polyolefin, a polyester,
a polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, and an ionomer
resin.
20. The roofing underlayment according to claim 11, wherein the
upper surface of the roofing underlayment has a water contact angle
of 120.degree. to 180.degree..
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Application No. 62/861,509, filed Jun. 14, 2019, the
entire content of which is incorporated by reference herein.
FIELD
[0002] The general inventive concepts relate to underlayments and,
more particularly, to a roofing underlayment that resists water
ingress around fasteners that are used to secure the roofing
underlayment to a substrate, such as a roof deck.
BACKGROUND
[0003] Underlayments are commonly used in roofing applications
along with an overlayment roofing material, such as asphalt
shingles, slate tiles, wooden shakes, metal roofing, and so forth.
The underlayment is generally secured to the roof deck using
fasteners such as nails or staples, and the overlayment roofing
material is installed over the underlayment using fasteners
(typically nails) that penetrate the underlayment and the roof
deck. The fasteners that penetrate the underlayment create holes
through the underlayment that are susceptible to water ingress.
SUMMARY
[0004] The general inventive concepts relate to a roofing
underlayment that resists water ingress around fasteners that are
used to secure the roofing underlayment to a substrate, such as a
roof deck. To illustrate various aspects of the general inventive
concepts, several exemplary embodiments of the roofing underlayment
are disclosed.
[0005] In one exemplary embodiment, a roofing underlayment includes
a base layer and a coating layer applied to the base layer. At
least one of the base layer and the coating layer include a
water-swellable composition. When the roofing underlayment is
punctured by a fastener used to secure the underlayment to a
substrate, the water-swellable composition expands upon coming into
contact with water to form a seal around a portion of the
fastener.
[0006] In one exemplary embodiment, a roofing underlayment includes
a base layer, a coating layer applied to the base layer, and a
layer comprising a water-swellable composition. The layer
comprising the water-swellable composition may be applied to the
base layer, the coating layer, or both the base layer and the
coating layer. When the roofing underlayment is punctured by a
fastener used to secure the underlayment to a substrate, the
water-swellable composition expands upon coming into contact with
water to form a seal around a portion of the fastener.
[0007] In one exemplary embodiment, a roofing underlayment includes
a base layer and a coating layer applied to the base layer. An
upper surface of the roofing underlayment has a water contact angle
of at least 120.degree.. Such a water contact angle renders the
upper surface of the roofing underlayment resistant to wetting such
that water coming into contact with the upper surface of the
roofing underlayment will bead up, making it more difficult for
water to infiltrate around fasteners that are used to secure the
roofing underlayment.
[0008] Other aspects, advantages, and features of the general
inventive concepts will become apparent to those skilled in the art
from the following detailed description, when read in light of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The general inventive concepts, as well as embodiments and
advantages thereof, are described below in greater detail, by way
of example, with reference to the drawings in which:
[0010] FIG. 1 is a cross-sectional view of an embodiment of a
roofing underlayment according to the present disclosure;
[0011] FIG. 2 is a cross-sectional view of an embodiment of a
roofing underlayment according to the present disclosure;
[0012] FIG. 3 is a cross-sectional view of an embodiment of a
roofing underlayment according to the present disclosure;
[0013] FIG. 4 is a cross-sectional view of an embodiment of a
roofing underlayment according to the present disclosure; and
[0014] FIG. 5 is a cross-sectional view of an embodiment of a
roofing underlayment according to the present disclosure.
DETAILED DESCRIPTION
[0015] While the general inventive concepts are susceptible of
embodiment in many different forms, there are shown in the
drawings, and will be described herein in detail, specific
embodiments thereof with the understanding that the present
disclosure is to be considered as an exemplification of the
principles of the general inventive concepts. Accordingly, the
general inventive concepts are not intended to be limited to the
specific embodiments illustrated herein.
[0016] The general inventive concepts relate to roofing
underlayments configured to resist water ingress around fasteners
that are used to secure the roofing underlayment to a substrate,
such as a roof deck. As will be described in further detail below,
the resistance to water ingress may be accomplished by
incorporating a water-swellable composition into the roofing
underlayment and/or by providing a roofing underlayment with an
upper surface that has a water contact angle of at least
120.degree..
[0017] In one exemplary embodiment, a roofing underlayment 100 is
provided. Referring to FIG. 1, the roofing underlayment 100
comprises a base layer 10 and a coating layer 20 applied to a top
side of the base layer 10 (i.e., a side intended to be furthest
from the roof deck). Although FIG. 1 illustrates the roofing
underlayment 100 having the coating layer 20 applied to the top
side of the base layer 10, it is contemplated that the coating
layer 20 may be applied to the bottom side of the base layer 10
instead. In another embodiment, as seen in FIG. 2, the roofing
underlayment 100 comprises a base layer 10, a first coating layer
20 applied to a top side of the base layer 10, and a second coating
layer 30 applied to a bottom side of the base layer 10.
[0018] In accordance with the present disclosure, the roofing
underlayment 100 also comprises a water-swellable composition. The
water-swellable composition may be included in one layer or
multiple (e.g., two, three, four) layers of the roofing
underlayment 100. By including a water-swellable composition, the
roofing underlayment 100 resists water ingress through holes
created by fasteners used to secure the roofing underlayment 100 to
a substrate, such as a roof deck. For example, when the roofing
underlayment 100 is punctured by fasteners (e.g., nails, staples),
the water-swellable composition expands upon coming into contact
with water to form a seal around a portion of the fastener and
thereby resists water from passing through the holes created by the
fasteners.
[0019] In certain embodiments, the roofing underlayment is a
self-adhered underlayment. In such embodiments, a layer of adhesive
material (not shown) (e.g., an asphalt-based adhesive) is applied
to a bottom surface of the roofing underlayment, and the layer of
adhesive material adheres the roofing underlayment to a substrate,
such as a roof deck. The layer of adhesive material may be covered
with a conventional release material. Fasteners are not required to
secure the self-adhered roofing underlayment to the substrate.
However, the water-swellable composition in the self-adhered
roofing underlayment will function to resist water ingress through
holes created by fasteners used to secure an overlayment roofing
material (e.g., shingles, tiles, shakes) to the substrate. In other
words, when the self-adhered roofing underlayment is punctured by
fasteners (e.g., nails, staples) used to secure an overlayment
roofing material to a roof deck, the water-swellable composition in
the self-adhered roofing underlayment will expand upon coming into
contact with water/moisture to form a seal around a portion of the
fastener and thereby resist water from passing through the holes
created by the fasteners.
[0020] The water-swellable composition of the present disclosure
may comprise a variety of materials. Exemplary materials suitable
for use as the water-swellable composition of the present
disclosure include, but are not limited to, a bentonite, a
polyacrylic acid or a salt thereof, a polyethylene oxide, a
polyacrylamide, a crosslinked polyacrylate, a crosslinked
polyacrylamide, a polyacrylamide copolymer, an ethylene maleic
anhydride copolymer, a cross-linked carboxymethylcellulose, a
polyvinyl alcohol copolymer, a starch grafted copolymer of
polyacrylonitrile, a hydrolyzed cellulose-polyacrylonitrile, a
polyurethane, a hydrophilic swelling rubber, and combinations
thereof. In certain embodiments, the water-swellable composition of
the present disclosure is at least one of sodium bentonite, sodium
polyacrylate, and polyethylene oxide. In certain embodiments, the
water-swellable composition of the present disclosure is sodium
bentonite.
[0021] In certain embodiments, the base layer 10 comprises a
water-swellable composition. The base layer 10 of the present
disclosure may be formed from a variety of materials, most
typically a polymeric material. Exemplary materials suitable for
forming the base layer 10 of the present disclosure include, but
are not limited to, a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof. In certain
embodiments, the base layer 10 comprises a polyolefin and a
water-swellable composition. In certain embodiments, the base layer
10 comprises polypropylene, polyethylene, and combinations thereof,
and a water-swellable composition comprising sodium bentonite,
sodium polyacrylate, and combinations thereof.
[0022] In certain embodiments, the base layer 10 comprises up to
20% by weight of a water-swellable composition. In certain
embodiments, the base layer 10 comprises from 0.1% by weight to 20%
by weight of a water-swellable composition, including from 0.1% by
weight to 15% by weight, from 0.1% by weight to 10% by weight, from
0.1% by weight to 5% by weight, and also including from 0.5% by
weight to 2% by weight of a water-swellable composition. In certain
embodiments, the base layer 10 comprises from 80% by weight to
99.9% by weight of a polymeric material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 0.1% by weight to 20% by weight of a
water-swellable composition. In certain other embodiments, the base
layer 10 comprises from 85% by weight to 99.9% by weight of a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and from 0.1%
by weight to 15% by weight of a water-swellable composition. In yet
other embodiments, the base layer 10 comprises from 90% by weight
to 99.9% by weight of a polymeric material selected from a
polyolefin (e.g., polyethylene, polypropylene), a polyester, a
polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, an ionomer resin,
and combinations thereof; and from 0.1% by weight to 10% by weight
of a water-swellable composition. In still other embodiments, the
base layer 10 comprises from 95% by weight to 99.9% by weight of a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and from 0.1%
by weight to 5% by weight of a water-swellable composition. In yet
other embodiments, the base layer 10 comprises a polymeric material
selected from a polyolefin (e.g., polyethylene, polypropylene), a
polyester, a polystyrene, a polyamide, an ethylene-acrylic
copolymer, a polyvinyl chloride, a polyvinylidene chloride, an
ionomer resin, and combinations thereof; and does not include a
water-swellable composition. In any of the foregoing embodiments,
the polymeric material may comprise polypropylene, polyethylene,
and combinations thereof; and the water-swellable composition may
comprise sodium bentonite, sodium polyacrylate, and combinations
thereof.
[0023] The base layer 10 may be structured in a variety of ways.
For example, the base layer 10 may be a woven material, a nonwoven
material, or a film material. In general, and regardless of form,
the base layer 10 has a basis weight of 50 g/m.sup.2 to 150
g/m.sup.2, including a basis weight of 75 g/m.sup.2 to 125
g/m.sup.2, and also including a basis weight of 80 g/m.sup.2 to 105
g/m.sup.2.
[0024] In certain embodiments, the base layer 10 is a woven
material. In certain embodiments, the base layer 10 is a woven
material comprising a polymeric material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and a water-swellable composition. In certain other
embodiments, the base layer 10 is a woven material comprising a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and does not
include a water-swellable composition. In any of the foregoing
embodiments, the polymeric material may comprise polypropylene,
polyethylene, and combinations thereof; and the water-swellable
composition may comprise sodium bentonite, sodium polyacrylate, and
combinations thereof.
[0025] In certain embodiments, the base layer 10 is a nonwoven
material. In certain embodiments, the base layer 10 is a nonwoven
material comprising a polymeric material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and a water-swellable composition. In certain other
embodiments, the base layer 10 is a nonwoven material comprising a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and does not
include a water-swellable composition. In any of the foregoing
embodiments, the polymeric material may comprise polypropylene,
polyethylene, and combinations thereof; and the water-swellable
composition may comprise sodium bentonite, sodium polyacrylate, and
combinations thereof.
[0026] In certain embodiments, the base layer 10 is a film
material. In certain embodiments, the base layer 10 is a film
material comprising a polymeric material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and a water-swellable composition. In certain other
embodiments, the base layer 10 is a film material comprising a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and does not
include a water-swellable composition. In any of the foregoing
embodiments, the polymeric material may comprise polypropylene,
polyethylene, and combinations thereof; and the water-swellable
composition may comprise sodium bentonite, sodium polyacrylate, and
combinations thereof.
[0027] In certain embodiments, at least one coating layer (e.g.,
the first coating layer 20, the second coating layer 30, or both)
comprises a water-swellable composition. The at least one coating
layer 20, 30 of the present disclosure is generally water
impermeable and may be formed from a variety of materials, most
typically a polymeric material. Exemplary materials suitable for
forming the coating layer 20, 30 of the present disclosure include,
but are not limited to, a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof. In certain
embodiments, the at least one coating layer 20, 30 comprises a
polyolefin and a water-swellable composition. In certain
embodiments, the at least one coating layer 20, 30 comprises
polypropylene, polyethylene, and combinations thereof; and a
water-swellable composition comprising sodium bentonite, sodium
polyacrylate, and combinations thereof.
[0028] In certain embodiments, the at least one coating layer 20,
30 comprises up to 20% by weight of a water-swellable composition.
In certain embodiments, the at least one coating layer 20, 30
comprises from 0.1% by weight to 20% by weight of a water-swellable
composition, including from 0.1% by weight to 15% by weight, from
0.1% by weight to 10% by weight, from 0.1% by weight to 5% by
weight, and also including from 0.5% by weight to 2% by weight of a
water-swellable composition. In certain embodiments, the at least
one coating layer 20, 30 comprises from 80% by weight to 99.9% by
weight of a polymeric material selected from a polyolefin (e.g.,
polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 0.1% by weight to 20% by weight of a
water-swellable composition. In certain other embodiments, the at
least one coating layer 20, 30 comprises from 85% by weight to
99.9% by weight of a polymeric material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 0.1% by weight to 15% by weight of a
water-swellable composition. In yet other embodiments, the at least
one coating layer 20, 30 comprises from 90% by weight to 99.9% by
weight of a polymeric material selected from a polyolefin (e.g.,
polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 0.1% by weight to 10% by weight of a
water-swellable composition. In still other embodiments, the at
least one coating layer 20, 30 comprises from 95% by weight to
99.9% by weight of a polymeric material selected from a polyolefin,
a polystyrene, a polyamide, an ethylene-acrylic copolymer, and
combinations thereof; and from 0.1% by weight to 5% by weight of a
water-swellable composition. In yet other embodiments, the at least
one coating layer 20, 30 comprises a polymeric material selected
from a polyolefin (e.g., polyethylene, polypropylene), a polyester,
a polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, an ionomer resin,
and combinations thereof; and does not include a water-swellable
composition. In any of the foregoing embodiments, the polymeric
material may comprise polypropylene, polyethylene, and combinations
thereof; and the water-swellable composition may comprise sodium
bentonite, sodium polyacrylate, and combinations thereof.
[0029] The at least one coating layer 20, 30 is preferably
structured as a film material. In general, the at least one coating
layer 20, 30 has a basis weight of 15 g/m.sup.2 to 50 g/m.sup.2,
including a basis weight of 15 g/m.sup.2 to 40 g/m.sup.2, and also
including a basis weight of 20 g/m.sup.2 to 30 g/m.sup.2. In
certain embodiments, when the roofing underlayment 100 includes a
first coating layer 20 and a second coating layer 30, as seen in
FIG. 2, the basis weight and the material used to form the first
coating layer 20 and the second coating layer 30 may be the same.
In certain embodiments, when the roofing underlayment 100 includes
a first coating layer 20 and a second coating layer 30, as seen in
FIG. 2, the basis weight and the material used to form the first
coating layer 20 and the second coating layer 30 may be
different.
[0030] In certain embodiments, the at least one coating layer 20,
30 is a film material. In certain embodiments, the at least one
coating layer 20, 30 is a film material comprising a polymeric
material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and a
water-swellable composition. In certain other embodiments, the at
least one coating layer 20, 30 is a film material comprising a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and does not
include a water-swellable composition. In any of the foregoing
embodiments, the polymeric material may comprise polypropylene,
polyethylene, and combinations thereof; and the water-swellable
composition may comprise sodium bentonite, sodium polyacrylate, and
combinations thereof.
[0031] With reference now to FIG. 3, an exemplary embodiment of a
roofing underlayment 100a according to the present disclosure is
illustrated. As seen in FIG. 3, the roofing underlayment 100a
comprises a base layer 10a, a water-swellable layer 40a applied to
a top side of the base layer 10a, a first coating layer 20a applied
to the water-swellable layer 40a, and a second coating layer 30a
applied to a bottom side of the base layer 10a. Alternatively, the
water-swellable layer 40a may be applied to a bottom side of the
base layer 10a, or both the top side and the bottom side of the
base layer 10a. Although, FIG. 3 illustrates the roofing
underlayment 100a including a first coating layer 20a and a second
coating layer 30a,it is contemplated that either the first coating
layer 20a or the second coating layer 30a may be omitted.
[0032] The base layer 10a of the roofing underlayment 100a may
comprise any of the previously described structures, materials, and
properties disclosed herein with respect to the base layer 10 of
the roofing underlayment 100 shown in FIGS. 1 and 2. In certain
embodiments, the base layer 10a is a woven material comprising a
polymeric material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof. In certain
embodiments, the base layer 10a is a woven material comprising
polypropylene, polyethylene, and combinations thereof. In certain
embodiments, the base layer 10a is a woven material consisting
essentially of polypropylene, polyethylene, and combinations
thereof. In certain embodiments, the base layer 10a has a basis
weight of 50 g/m.sup.2 to 150 g/m.sup.2, including a basis weight
of 75 g/m.sup.2 to 125 g/m.sup.2, and also including a basis weight
of 80 g/m.sup.2 to 105 g/m.sup.2.
[0033] The first and second coating layers 20a, 30a may comprise
any of the previously described structures, materials, and
properties disclosed herein with respect to the coating layers 20,
30 of the roofing underlayment 100 shown in FIGS. 1 and 2. In
certain embodiments, the first and second coating layers 20a, 30a
are a film material comprising a polymeric material selected from a
polyolefin (e.g., polyethylene, polypropylene), a polyester, a
polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, an ionomer resin,
and combinations thereof. In certain embodiments, the first and
second coating layers 20a, 30a are a film material comprising
polypropylene, polyethylene, and combinations thereof. In certain
embodiments, the first and second coating layers 20a, 30a are a
film material consisting essentially of polypropylene,
polyethylene, and combinations thereof. In certain embodiments, the
first and second coating layers 20a, 30a may have a basis weight of
15 g/m.sup.2 to 50 g/m.sup.2, including a basis weight of 15
g/m.sup.2 to 40 g/m.sup.2, and also including a basis weight of 20
g/m.sup.2 to 30 g/m.sup.2. In certain embodiments, when the roofing
underlayment 100a includes a first coating layer 20a and a second
coating layer 30a, as seen in FIG. 3, the basis weight and the
material used to form the first coating layer 20a and the second
coating layer 30a may be the same. In certain other embodiments,
when the roofing underlayment 100a includes a first coating layer
20a and a second coating layer 30a, as seen in FIG. 3, the basis
weight and the material used to form the first coating layer 20a
and the second coating layer 30a may be different.
[0034] As mentioned above, the exemplary roofing underlayment 100a
illustrated in FIG. 3 includes a water-swellable layer 40a. In
general, the water-swellable layer 40a comprises a water-swellable
composition. The water-swellable layer 40a may have a basis weight
of 15 g/m.sup.2 to 40 g/m.sup.2, including a basis weight of 20
g/m.sup.2 to 35 g/m.sup.2, and also including a basis weight of 25
g/m.sup.2 to 30 g/m.sup.2. By including a water-swellable layer
40a,the roofing underlayment 100a is able to resist water ingress
through holes created by fasteners used to secure the roofing
underlayment 100a to a substrate, such as a roof deck. For example,
when the roofing underlayment 100a,including the water-swellable
layer 40a,is punctured by fasteners (e.g., nails, staples), the
water-swellable composition in the water-swellable layer 40a
expands upon coming into contact with water to form a seal around a
portion of the fastener and thereby resists water from passing
through the holes created by the fasteners.
[0035] In certain embodiments, the water-swellable layer 40a
consists essentially of a water-swellable composition. In certain
embodiments, the water-swellable layer 40a comprises a
water-swellable composition and a polymeric carrier material. Any
of the previously described water-swellable compositions may be
used to form the water-swellable layer 40a. Exemplary polymeric
carrier materials suitable for use in the water-swellable layer 40a
include, but are not limited to, a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof. In certain
embodiments, the water-swellable layer 40a comprises sodium
bentonite, sodium polyacrylate, and combinations thereof as the
water-swellable composition; and polypropylene, polyethylene, and
combinations thereof as the polymeric carrier material.
[0036] In certain embodiments, the water-swellable layer 40a
comprises from 20% by weight to 80% by weight of a polymeric
carrier material selected from a polyolefin (e.g., polyethylene,
polypropylene), a polyester, a polystyrene, a polyamide, an
ethylene-acrylic copolymer, a polyvinyl chloride, a polyvinylidene
chloride, an ionomer resin, and combinations thereof; and from 20%
by weight to 80% by weight of a water-swellable composition. In
certain other embodiments, the water-swellable layer 40a comprises
from 20% by weight to 75% by weight of a polymeric material
selected from a polyolefin (e.g., polyethylene, polypropylene), a
polyester, a polystyrene, a polyamide, an ethylene-acrylic
copolymer, a polyvinyl chloride, a polyvinylidene chloride, an
ionomer resin, and combinations thereof; and from 25% by weight to
80% by weight of a water-swellable composition. In yet other
embodiments, the water-swellable layer 40a comprises from 25% by
weight to 70% by weight of a polymeric carrier material selected
from a polyolefin (e.g., polyethylene, polypropylene), a polyester,
a polystyrene, a polyamide, an ethylene-acrylic copolymer, a
polyvinyl chloride, a polyvinylidene chloride, an ionomer resin,
and combinations thereof; and from 30% by weight to 75% by weight
of a water-swellable composition. In still other embodiments, the
water-swellable layer 40a comprises from 35% by weight to 60% by
weight of a polymeric carrier material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 40% by weight to 65% by weight of a
water-swellable composition. In yet other embodiments, the
water-swellable layer 40a comprises from 45% by weight to 55% by
weight of a polymeric carrier material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 45% by weight to 55% by weight of a
water-swellable composition. In still other embodiments, the
water-swellable layer 40a comprises from 20% by weight to 30% by
weight of a polymeric carrier material selected from a polyolefin
(e.g., polyethylene, polypropylene), a polyester, a polystyrene, a
polyamide, an ethylene-acrylic copolymer, a polyvinyl chloride, a
polyvinylidene chloride, an ionomer resin, and combinations
thereof; and from 70% by weight to 80% by weight of a
water-swellable composition. In any of the foregoing embodiments,
the polymeric carrier material may comprise polypropylene,
polyethylene, and combinations thereof; and the water-swellable
composition may comprise sodium bentonite, sodium polyacrylate, and
combinations thereof.
[0037] With reference now to FIG. 4, an exemplary embodiment of a
roofing underlayment 100b according to the present disclosure is
illustrated. As seen in FIG. 4, the roofing underlayment 100b
comprises a base layer 10b, a first coating layer 20b applied to a
top side of the base layer 10b, a second coating layer 30b applied
to a bottom side of the base layer 10b, and a water-swellable layer
40b applied to the first coating layer 20b, thus forming an upper
surface of the roofing underlayment 100b. Alternatively, or
additionally, the water-swellable layer 40b may be applied to the
second coating layer 30b, thus forming a lower surface of the
roofing underlayment 100b. In contrast to the exemplary embodiment
of the roofing underlayment 100a illustrated in FIG. 3, the
exemplary embodiment of the roofing underlayment 100b of FIG. 4
includes the water-swellable layer 40b as an exterior layer of the
roofing underlayment 100b as opposed to an interior layer as seen
in FIG. 3. However, it is contemplated that the roofing
underlayment 100b may include a water-swellable layer 40b as an
exterior layer of the roofing underlayment 100b; and a
water-swellable layer 40b as an interior layer of the roofing
underlayment 100b. Furthermore, it is contemplated that the
exterior water-swellable layer 40b and the interior water-swellable
layer 40b may each be the same or different.
[0038] In one exemplary embodiment, a roofing underlayment 100c is
provided. Referring to FIG. 5, the roofing underlayment 100c
comprises a base layer 10c and a coating layer 20c applied to a top
side of the base layer 10c. An upper surface 50c of the roofing
underlayment 100c is structured to have a water contact angle of at
least 120.degree.. By structuring the upper surface 50c to have a
water contact angle of at least 120.degree., the upper surface 50c
of the roofing underlayment 100c resists wetting such that water
coming into contact with the upper surface 50c of the roofing
underlayment 100c will bead up, making it more difficult for water
to infiltrate around fasteners that are used to either secure the
roofing underlayment 100c to a substrate or to secure an
overlayment roofing material to a substrate, such as a roof deck.
It should be understood that any of the previously described
embodiments of the roofing underlayment may have an upper surface
that is structured to have a water contact angle of at least
120.degree..
[0039] Achieving a water contact angle of at least 120.degree. may
be accomplished by reducing the surface energy through the use of a
surfactant layer on the upper surface 50c of the roofing
underlayment 100c and/or imparting nanoscale and/or microscale
surface roughness or texture to the upper surface 50c of the
roofing underlayment 100c. Suitable surfactants for forming the
surfactant layer include, but are not limited to, silanes (e.g.,
fluoroalkylsilanes, polysilazanes), stearic acid compounds, and
fluoropolymers. The nanoscale and/or microscale roughness or
texture may be attained by applying or otherwise providing
nanostructures and/or microstructures on the upper surface 50c of
the roofing underlayment 100c. Accordingly, in certain embodiments,
the upper surface 50c of the roofing underlayment 100c comprises a
surfactant layer and/or nanostructures, microstructures, and
combinations thereof.
[0040] In certain embodiments, the upper surface 50c of the roofing
underlayment 100c comprises nanostructures. The nanostructures may
be formed on the upper surface 50c of the roofing underlayment 100c
in a variety of ways. In certain embodiments, the nanostructures
are formed on the upper surface 50c of the roofing underlayment
100c by at least one of inorganic nanoparticles, carbon
nanoparticles, and etching the upper surface 50c of the roofing
underlayment 100c.
[0041] In certain embodiments, the upper surface 50c of the roofing
underlayment 100c comprises nanostructures formed by inorganic
nanoparticles. A variety of inorganic nanoparticles may be used to
form the nanostructures on the upper surface 50c of the roofing
underlayment 100c. Exemplary inorganic nanoparticles suitable for
forming the nanostructures include, but are not limited to, silica,
alumina, titania, zirconia, ceria, zinc oxide, iron oxide, vanadia,
antimony oxide, and tin oxide. The inorganic nanoparticles
generally have an average particle size of 10 nm to 900 nm. In
certain embodiments, the inorganic nanoparticles have an average
particle size of 25 nm to 750 nm, including from 30 nm to 700 nm,
from 40 nm to 650 nm, from 50 nm to 600 nm, from 75 nm to 500 nm,
and also including from 25 nm to 150 nm.
[0042] In certain embodiments, an inorganic nanoparticle suspension
is utilized to form the nanostructures on the upper surface 50c of
the roofing underlayment 100c. The inorganic nanoparticle
suspension may comprise any one or more of the inorganic
nanoparticles described herein. In addition, the inorganic
nanoparticle suspension may comprise various carrier mediums to
suspend the inorganic nanoparticles. Exemplary carrier mediums
include, but are not limited to, water, acetone, alcohol (e.g.,
methanol, ethanol), hydrocarbons (e.g., pentane, hexane),
fluoropolymers (e.g., polyvinylidene fluoride), polysiloxanes
(e.g., polydimethylsiloxane), silanes (e.g.,
1H,1H,2H,2H-perfluorooctyltriethoxysilane), and combinations
thereof. In certain embodiments, the nanostructures may be formed
on the upper surface 50c of the roofing underlayment 100c by
applying the inorganic nanoparticles using a blade coating process,
a squeeze coating process, a brush coating process, a spin coating
process, a dip coating process, or a spray coating process.
[0043] In certain embodiments, the upper surface 50c of the roofing
underlayment 100c comprises nanostructures formed by carbon
nanoparticles (e.g., carbon black, carbon nanotubes, carbon
nanofibers, carbon nanocarpets). The carbon nanoparticles generally
have an average particle size of 10 nm to 900 nm. In certain
embodiments, the carbon nanoparticles have an average particle size
of 25 nm to 750 nm, including from 30 nm to 700 nm, from 40 nm to
650 nm, from 50 nm to 600 nm, from 75 nm to 500 nm, and also
including from 25 nm to 150 nm.
[0044] In certain embodiments, a carbon nanoparticle suspension is
utilized to form the nanostructures on the upper surface 50c of the
roofing underlayment 100c. The carbon nanoparticle suspension
generally comprises carbon nanoparticles and a carrier medium to
suspend the carbon nanoparticles. Exemplary carrier mediums
include, but are not limited to, water, acetone, alcohol (e.g.,
methanol, ethanol), hydrocarbons (e.g., pentane, hexane),
fluoropolymers (e.g., polyvinylidene fluoride), polysiloxanes
(e.g., polydimethylsiloxane), silanes (e.g.,
1H,1H,2H,2H-perfluorooctyltriethoxysilane), and combinations
thereof. In certain embodiments, the nanostructures may be formed
on the upper surface 50c of the roofing underlayment 100c by
applying the carbon nanoparticles using a blade coating process, a
squeeze coating process, a brush coating process, a spin coating
process, a dip coating process, or a spray coating process.
[0045] In certain embodiments, the nanostructures are formed on the
upper surface 50c of the roofing underlayment 100c by etching the
upper surface 50c of the roofing underlayment 100c. In certain
embodiments, the etching of the upper surface 50c of the roofing
underlayment 100c to form the nanostructures is carried out using
acid etching, plasma etching, reactive ion etching, and
combinations thereof.
[0046] In certain embodiments, the upper surface 50c of the roofing
underlayment 100c comprises microstructures. The microstructures
may be formed on the upper surface 50c of the roofing underlayment
100c in a variety of ways. In certain embodiments, the
microstructures are formed on the upper surface 50c of the roofing
underlayment 100c by at least one of inorganic microparticles,
carbon microparticles, and etching the upper surface 50c of the
roofing underlayment 100c.
[0047] In certain embodiments, the upper surface 50c of the roofing
underlayment 100c comprises microstructures formed by inorganic
microparticles. A variety of inorganic microparticles may be used
to form the microstructures on the upper surface 50c of the roofing
underlayment 100c. Exemplary inorganic microparticles suitable for
forming the microstructures include, but are not limited to,
silica, alumina, titania, zirconia, ceria, zinc oxide, iron oxide,
vanadia, antimony oxide, and tin oxide. The inorganic
microparticles generally have an average particle size of 1 .mu.m
to 900 .mu.m. In certain embodiments, the inorganic microparticles
have an average particle size of 25 .mu.m to 750 .mu.m, including
from 30 .mu.m to 700 .mu.m, from 40 .mu.m to 650 .mu.m, from 50
.mu.m to 600 .mu.m, from 75 .mu.m to 500 .mu.m, and also including
from 25 .mu.m to 150 .mu.m.
[0048] In certain embodiments, an inorganic microparticle
suspension is utilized to form the microstructures on the upper
surface 50c of the roofing underlayment 100c. The inorganic
microparticle suspension may comprise any one or more of the
inorganic microparticles described herein. In addition, the
inorganic microparticle suspension may comprise various carrier
mediums to suspend the inorganic microparticles. Exemplary carrier
mediums include, but are not limited to, water, acetone, alcohol
(e.g., methanol, ethanol), hydrocarbons (e.g., pentane, hexane),
fluoropolymers (e.g., polyvinylidene fluoride), polysiloxanes
(e.g., polydimethylsiloxane), silanes (e.g.,
1H,1H,2H,2H-perfluorooctyltriethoxysilane), and combinations
thereof. In certain embodiments, the microstructures may be formed
on the upper surface 50c of the roofing underlayment 100c by
applying the inorganic microparticles using a blade coating
process, a squeeze coating process, a brush coating process, a spin
coating process, a dip coating process, or a spray coating
process.
[0049] In certain embodiments, the upper surface 50c of the roofing
underlayment 100c comprises microstructures formed by carbon
microparticles. The carbon microparticles generally have an average
particle size of 10 .mu.m to 900 .mu.m. In certain embodiments, the
carbon microparticles have an average particle size of 25 .mu.m to
750 .mu.m, including from 30 .mu.m to 700 .mu.m, from 40 .mu.m to
650 .mu.m, from 50 .mu.m to 600 .mu.m, from 75 .mu.m to 500 .mu.m,
and also including from 25 .mu.m to 150 .mu.m.
[0050] In certain embodiments, a carbon microparticle suspension is
utilized to form the microstructures on the upper surface 50c of
the roofing underlayment 100c. The carbon microparticle suspension
generally comprises carbon microparticles and a carrier medium to
suspend the carbon microparticles. Exemplary carrier mediums
include, but are not limited to, water, acetone, alcohol (e.g.,
methanol, ethanol), hydrocarbons (e.g., pentane, hexane),
fluoropolymers (e.g., polyvinylidene fluoride), polysiloxanes
(e.g., polydimethylsiloxane), silanes (e.g.,
1H,1H,2H,2H-perfluorooctyltriethoxysilane), and combinations
thereof. In certain embodiments, the microstructures may be formed
on the upper surface 50c of the roofing underlayment 100c by
applying the carbon microparticles using a blade coating process, a
squeeze coating process, a brush coating process, a spin coating
process, a dip coating process, or a spray coating process.
[0051] In certain embodiments, the microstructures are formed on
the upper surface 50c of the roofing underlayment 100c by etching
the upper surface 50c of the roofing underlayment 100c. In certain
embodiments, the etching of the upper surface 50c of the roofing
underlayment 100c to form the microstructures is carried out using
acid etching, plasma etching, reactive ion etching, and
combinations thereof.
[0052] As mentioned above, the upper surface 50c of the roofing
underlayment 100c may have a water contact angle of at least
120.degree. by the use of a surfactant and/or the formation of at
least one of nanostructures and microstructures on the upper
surface 50c. In certain embodiments, the upper surface 50c of the
roofing underlayment 100c has a water contact angle of 120.degree.
to 180.degree., including a water contact angle of 130.degree. to
180.degree., a water contact angle of 140.degree. to 180.degree., a
water contact angle of 150.degree. to 180.degree., a water contact
angle of 160.degree. to 180.degree., and also including a water
contact angle of 120.degree. to 160.degree..
[0053] All references to singular characteristics or limitations of
the present disclosure shall include the corresponding plural
characteristic or limitation, and vice versa, unless otherwise
specified or clearly implied to the contrary by the context in
which the reference is made.
[0054] All combinations of method or process steps as used herein
can be performed in any order, unless otherwise specified or
clearly implied to the contrary by the context in which the
referenced combination is made.
[0055] All ranges and parameters, including but not limited to
percentages, parts, and ratios, disclosed herein are understood to
encompass any and all sub-ranges assumed and subsumed therein, and
every number between the endpoints. For example, a stated range of
"1 to 10" should be considered to include any and all subranges
between (and inclusive of) the minimum value of 1 and the maximum
value of 10; that is, all subranges beginning with a minimum value
of 1 or more (e.g., 1 to 6.1), and ending with a maximum value of
10 or less (e.g., 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each
number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the
range.
[0056] The underlayments of the present disclosure can comprise,
consist of, or consist essentially of the essential elements and
limitations of the disclosure as described herein, as well as any
additional or optional components or limitations described herein
or otherwise known to be useful in underlayment applications.
[0057] To the extent that the terms "include," "includes," or
"including" are used in the specification or the claims, they are
intended to be inclusive in a manner similar to the term
"comprising" as that term is interpreted when employed as a
transitional word in a claim. Furthermore, to the extent that the
term "or" is employed (e.g., A or B), it is intended to mean "A or
B or both A and B." When the Applicant intends to indicate "only A
or B but not both," then the term "only A or B but not both" will
be employed. Thus, use of the term "or" herein is the inclusive,
and not the exclusive use. Furthermore, the phrase "at least one of
A, B, and C" should be interpreted as "only A or only B or only C
or any combinations thereof." In the present disclosure, the words
"a" or "an" are to be taken to include both the singular and the
plural. Conversely, any reference to plural items shall, where
appropriate, include the singular.
[0058] In some embodiments, it may be possible to utilize the
various inventive concepts in combination with one another.
Additionally, any particular element recited as relating to a
particularly disclosed embodiment should be interpreted as
available for use with all disclosed embodiments, unless
incorporation of the particular element would be contradictory to
the express terms of the embodiment. Additional advantages and
modifications will be readily apparent to those skilled in the art.
Therefore, the disclosure, in its broader aspects, is not limited
to the specific details presented therein, the representative
apparatus, or the illustrative examples shown and described.
Accordingly, departures may be made from such details without
departing from the spirit or scope of the general inventive
concepts.
[0059] The scope of the general inventive concepts presented herein
are not intended to be limited to the particular exemplary
embodiments shown and described herein. From the disclosure given,
those skilled in the art will not only understand the general
inventive concepts and their attendant advantages, but will also
find apparent various changes and modifications to the devices,
systems, and methods disclosed. It is sought, therefore, to cover
all such changes and modifications as fall within the spirit and
scope of the general inventive concepts, as described and/or
claimed herein, and any equivalents thereof.
* * * * *