Roofing Underlayment

Abstract

A roofing underlayment includes a first layer of synthetic woven or nonwoven material; a second layer of woven or nonwoven material; a third layer of elastic recoverable material; and a fourth layer of fire resistant material. The third layer may have a weight of 50 gsm to 300 gsm. The elastic recoverable material includes an elastomer. The roofing underlayment can be configured to be secured to a roof such that the roofing underlayment meets (a) ASTM D4869 water shower exposure test, (b) UL790 burning brand rating, and (c) ASTM D1970 nail sealability.

Description

RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63/161,144, filed on Mar. 15, 2021, and titled "ROOFING UNDERLAYMENT," the entire contents of which are hereby incorporated by reference.

FIELD

[0002] This disclosure relates generally to a roofing underlayment. More specifically, this disclosure relates to roofing underlayment having excellent nail sealability, water proofing, and fireproofing.

BACKGROUND

[0003] A roofing underlayment may be covered with different types of roofing materials including, but not limited to, asphalt shingles, metal shingles, concrete tiles, cedar shakes, polymeric shingles, and the like. The roofing underlayment should pass fire testing and water proofing testing.

[0004] Improved roofing underlayments are desirable.

SUMMARY

[0005] In some embodiments, a roofing underlayment includes a first layer of synthetic woven or nonwoven material; a second layer of woven or nonwoven material; a third layer of elastic recoverable material; and a fourth layer of fire resistant material. In some embodiments, the third layer has a weight of 50 gsm to 300 gsm. In some embodiments, the elastic recoverable material includes an elastomer. In some embodiments, the roofing underlayment, when secured to a roof, meets (a) ASTM D4869 water shower exposure test, (b) UL790 burning brand rating, and (c) ASTM D1970 nail sealability test.

[0006] In some embodiments, the first layer is a synthetic nonwoven material and includes a spunbond polypropylene.

[0007] In some embodiments, the second layer is a woven material and includes a scrim of synthetic woven fabric including polypropylene.

[0008] In some embodiments, the first layer or the second layer of the roofing underlayment includes a weatherable layer including a UV-resistant material arranged to be an outermost first or second layer of the roofing underlayment.

[0009] In some embodiments, the roofing underlayment includes an adhesive layer arranged to be an innermost layer of the roofing underlayment. In some embodiments, the adhesive layer includes a cover sheet.

[0010] In some embodiments, the elastomer comprises a rubber-like elastomer, a thermoplastic elastomer (TPE), or any combination thereof. In some embodiments, the TPE is selected from the group consisting of a thermoplastic olefin (TPO), a styrene, a copolyester, a polyamide, a polyurethane, a thermoplastic vulcanizate (TPV), or any combination thereof. In some embodiments, the TPV can be a vulcanized PP/EPDM compound.

[0011] In some embodiments, the elastomer is not an adhesive.

[0012] In some embodiments, the first layer, the second layer, the third layer, and the fourth layer are laminated with extrusion materials.

[0013] In some embodiments, a total weight of the roofing underlayment is from 170 gsm to 600 gsm. In some embodiments, the total weight of the roofing underlayment is from 200 gsm to 560 gsm.

[0014] In some embodiments, the roofing underlayment has a topside coefficient of friction of 0.3 to 1.5.

[0015] In some embodiments, the roofing underlayment has a backside coefficient of friction of 0.3 to 1.5.

[0016] In some embodiments, the roofing underlayment meets Class A of UL790 burning brand rating.

[0017] In some embodiments, a method includes obtaining a first layer of synthetic woven or nonwoven material; obtaining a second layer of woven or nonwoven material; obtaining a third layer of elastic recoverable material; and obtaining a fourth layer of fire resistant material. In some embodiments, the third layer has a weight of 50 gsm to 300 gsm. In some embodiments, the elastic recoverable material includes an elastomer. In some embodiments, the method includes laminating the first layer, the second layer, the third layer, and the fourth layer, so as to result in a roofing underlayment. In some embodiments, the roofing underlayment, when secured to a roof, meets (a) ASTM D4869 water shower exposure test, (b) UL790 burning brand rating, and (c) ASTM D1970 nail sealability test.

[0018] In some embodiments, a method includes obtaining a roofing underlayment including a first layer of synthetic woven or nonwoven material; a second layer of woven or nonwoven material; a third layer of elastic recoverable material; and a fourth layer of fire resistant material. In some embodiments, the third layer has a weight of 50 gsm to 300 gsm. In some embodiments, the elastic recoverable material includes an elastomer. In some embodiments, the method further includes applying the roofing underlayment to a steep slope roof substrate. In some embodiments, the method includes securing the roofing underlayment to the steep slope roof substrate to form a secured roofing underlayment. In some embodiments, the secured roofing underlayment meets (a) ASTM D4869 water shower exposure test, (b) UL790 burning brand rating, and (c) ASTM D1970 nail sealability test.

[0019] In some embodiments, securing the roofing underlayment to the steep slope roof substrate includes using fasteners that do not include capped roofing nails.

[0020] In some embodiments, securing the roofing underlayment to the steep slope roof includes stapling the roofing underlayment to the steep slope roof.

[0021] In some embodiments, securing the roofing underlayment to the steep slope roof includes nailing the roofing underlayment to the steep slope roof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Reference is made to the drawings that form a part of this disclosure, and which illustrate the embodiments in which the devices and methods described herein can be practiced.

[0023] FIG. 1 shows a roofing underlayment, according to some embodiments.

[0024] FIG. 2 shows an exploded view of the roofing underlayment of FIG. 1, according to some embodiments.

[0025] FIG. 3 shows an exploded view of the roofing underlayment of FIG. 1, according to some embodiments.

[0026] FIG. 4 shows a method, according to some embodiments.

[0027] FIG. 5 shows a method, according to some embodiments.

[0028] Like reference numbers represent the same or similar parts throughout.

DETAILED DESCRIPTION

[0029] Embodiments of this disclosure are directed to roofing underlayments having good waterproofing and nail sealability, and meeting fire rating standards. For example, the roofing underlayments described herein can meet ASTM D4869 water shower exposure test, UL790 burning brand rating, and ASTM D1970 nail sealability test.

[0030] In some embodiments, a roofing underlayment includes a fire resistant, nail sealable, and weatherable synthetic laminate composite material that is useful as a water resistant and skid-resistant roofing underlayment. In some embodiments, the roofing underlayment includes a plurality of layers. In some embodiments, the plurality of layers include a layer of elastic recoverable material, a fire barrier, and a weatherable coating which can be secured, for example with capless roofing nails or staples, to provide resistance to liquid water transmission using ASTM D4869 liquid-water transmission shower test, to meet Class A UL790 burning brand rating, and to meet ASTM D1970 nail sealability test.

[0031] UL790 burning brand rating includes testing procedures that can typically be performed on a roofing system including a roofing underlayment and roof coverings to meet different fire ratings including Class A, B, or C. Class A roof coverings are effective against severe fire exposure. Class B roof coverings are effective against moderate fire exposure. Class C roof coverings are effective against light fire exposure. In some embodiments, the presence of the elastic recoverable material can enable usage of nails without caps (e.g., nails other than capped roofing nails).

[0032] In some embodiments, a "steep slope roof" includes any roof substrate that is disposed on a roof having a pitch of Y/X, where Y and X are in a ratio of 4:12 to 12:12, where Y corresponds to the "rise" of the roof, and where X corresponds to the "run" of the roof

[0033] FIG. 1 shows a roofing underlayment 10, according to some embodiments.

[0034] In some embodiments, the roofing underlayment 10 can have a high strength to weight ratio, elasticity, UV resistance, water resistance, and fire resistance. For example, in some embodiments, the roofing underlayment 10 can be more than 10 times lighter, more than 10 times stronger, or any combination thereof, relative to an asphalt-saturated felt underlayment. In some embodiments, the roofing underlayment 10 can have a UV resistance that provides at least 10 years of outdoor exposure stability. In some embodiments, the roofing underlayment 10 can be secured to a roof. In some embodiments, the roof can be a steep slope roof. In some embodiments, the roofing underlayment 10 can be secured to the roof using nails, adhesive, or any combination thereof. In some embodiments, when secured to a roof, the roofing underlayment 10 can meet the ASTM D4869 water shower exposure test. In some embodiments, when secured to a roof, the roofing underlayment meets Class A fire rating of UL790 burning brand rating.

[0035] In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm or more. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 550 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 500 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 450 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 400 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 350 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 300 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 250 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 170 gsm to 200 gsm.

[0036] In some embodiments, the roofing underlayment 10 has a weight that is 200 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 250 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 300 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 350 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 400 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 450 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 500 gsm to 600 gsm. In some embodiments, the roofing underlayment 10 has a weight that is 550 gsm to 600 gsm.

[0037] In some embodiments, the roofing underlayment 10 has a weight that is 50% to 80% of a total weight of a peel-and-stick conventional roofing underlayment. In some embodiments, the roofing underlayment 10 has a weight that is 60% to 80% of a total weight of a peel-and-stick conventional roofing underlayment. In some embodiments, the roofing underlayment 10 has a weight that is 70% to 80% of a total weight of a peel-and-stick conventional roofing underlayment.

[0038] In some embodiments, the roofing underlayment 10 has a weight that is 50% to 70% of a total weight of a peel-and-stick conventional roofing underlayment. In some embodiments, the roofing underlayment 10 has a weight that is 50% to 60% of a total weight of a peel-and-stick conventional roofing underlayment.

[0039] In some embodiments, a peel-and-stick conventional roofing underlayment can have a weight of 400 gsm to 700 gsm.

[0040] In some embodiments, the roofing underlayment 10 can alternatively be used in other applications including, but not limited to, housewrap, vapor barriers, industrial packaging, geomembranes, flashing, and soundproofing underlayments.

[0041] In some embodiments, the roofing underlayment 10 can have a topside coefficient of friction of any amount, but in some embodiments can be from 0.3 to 1.5. In some embodiments, the topside coefficient of friction can be from 0.4 to 1.5. In some embodiments, the topside coefficient of friction can be from 0.5 to 1.5. In some embodiments, the topside coefficient of friction can be from 0.6 to 1.5. In some embodiments, the topside coefficient of friction can be from 0.7 to 1.5. In some embodiments, the topside coefficient of friction can be from 0.8 to 1.5. In some embodiments, the topside coefficient of friction can be from 0.9 to 1.5. In some embodiments, the topside coefficient of friction can be from 1 to 1.5. In some embodiments, the topside coefficient of friction can be from 1.1 to 1.5. In some embodiments, the topside coefficient of friction can be from 1.2 to 1.5. In some embodiments, the topside coefficient of friction can be from 1.3 to 1.5. In some embodiments, the topside coefficient of friction can be from 1.4 to 1.5.

[0042] In some embodiments, the topside coefficient of friction can be from 0.3 to 1.4. In some embodiments, the topside coefficient of friction can be from 0.3 to 1.3. In some embodiments, the topside coefficient of friction can be from 0.3 to 1.2. In some embodiments, the topside coefficient of friction can be from 0.3 to 1.1. In some embodiments, the topside coefficient of friction can be from 0.3 to 1. In some embodiments, the topside coefficient of friction can be from 0.3 to 0.9. In some embodiments, the topside coefficient of friction can be from 0.3 to 0.8. In some embodiments, the topside coefficient of friction can be from 0.3 to 0.7. In some embodiments, the topside coefficient of friction can be from 0.3 to 0.6. In some embodiments, the topside coefficient of friction can be from 0.3 to 0.5. In some embodiments, the topside coefficient of friction can be from 0.3 to 0.4.

[0043] In some embodiments, the roofing underlayment 10 can have a backside coefficient of friction of any amount, but in some embodiments can be from 0.3 to 1.5. In some embodiments, the backside coefficient of friction can be from 0.4. to 1.5. In some embodiments, the backside coefficient of friction can be from 0.5 to 1.5. In some embodiments, the backside coefficient of friction can be from 0.6 to 1.5. In some embodiments, the backside coefficient of friction can be from 0.7 to 1.5. In some embodiments, the backside coefficient of friction can be from 0.8 to 1.5. In some embodiments, the backside coefficient of friction can be from 0.9 to 1.5. In some embodiments, the backside coefficient of friction can be from 1 to 1.5. In some embodiments, the backside coefficient of friction can be from 1.1 to 1.5. In some embodiments, the backside coefficient of friction can be from 1.2 to 1.5. In some embodiments, the backside coefficient of friction can be from 1.3 to 1.5. In some embodiments, the backside coefficient of friction can be from 1.4. to 1.5.

[0044] In some embodiments, the backside coefficient of friction can be from 0.3 to 1.4. In some embodiments, the backside coefficient of friction can be from 0.3 to 1.3. In some embodiments, the backside coefficient of friction can be from 0.3 to 1.2. In some embodiments, the backside coefficient of friction can be from 0.3 to 1.1. In some embodiments, the backside coefficient of friction can be from 0.3 to 1. In some embodiments, the backside coefficient of friction can be from 0.3 to 0.9. In some embodiments, the backside coefficient of friction can be from 0.3 to 0.8. In some embodiments, the backside coefficient of friction can be from 0.3 to 0.7. In some embodiments, the backside coefficient of friction can be from 0.3 to 0.6. In some embodiments, the backside coefficient of friction can be from 0.3 to 0.5. In some embodiments, the backside coefficient of friction can be from 0.3 to 0.4.

[0045] FIG. 2 shows an exploded view of the roofing underlayment 10 of FIG. 1, according to some embodiments. In FIG. 2, layers of the roofing underlayment 10 are visible.

[0046] In some embodiments, the roofing underlayment 10 includes a first layer 15, a second layer 20, a third layer 25, and a fourth layer 30.

[0047] In some embodiments, the first layer 15 can include a synthetic woven or nonwoven material. In some embodiments, a synthetic woven material can include a woven fabric. In some embodiments, examples of woven fabrics that can be used can include, but are not limited to, open weave leno scrim (1.times.1, 2.times.2, 3.times.3 or 4.times.4) or woven fabric with coverage ranging from 50% to 100% with pic count of 5.times.5 to 24.times.24. In some embodiments, examples of synthetic woven materials include any polyolefin, including, but not limited to, polyethylene, polypropylene, polyester (PET), fiberglass, nylon, rayon, and blends thereof. In some embodiments, a synthetic nonwoven material can include a spunbond polypropylene.

[0048] In some embodiments, the second layer 20 can include a woven or a nonwoven material. In some embodiments, the nonwoven material can include melt blown nonwovens, needlepunch nonwovens, spunlace nonwovens, polyester nonwovens, polymeric films, glass mats, and combinations thereof. In some embodiments, the nonwoven material may be calendared or embossed with different types of patterns. In some embodiments, the nonwoven material may be a single layer and/or bi-component nonwoven. In some embodiments, the nonwoven material can be used either alone or laminated with other substrates. In some embodiments, the woven material can be a scrim of woven fabric.

[0049] In some embodiments, the third layer 25 can include an elastic recoverable material. In some embodiments, a suitable elastic recoverable material can include an elastomer with good elastic recovery or resilience, which is a measure of the ability of a material to return to its original shape when a compression load is removed. Examples of an elastic recoverable material includes, but is not limited to, adhesive, a rubber-like elastomer, a TPE, or any combination thereof. In some embodiments, the TPE can be a TPO, a styrene, a copolyester, a polyamide, a polyurethane, a TPV, or any combination thereof. In some embodiments, the TPV can be a vulcanized PP/EPDM compound.

[0050] ASTM D1970 includes the following test procedure. A material to be tested ("test material") is cut to make test specimens sized 12''.times.12''. At least two specimens are to be tested. The test specimens are installed on 12''.times.12'' (3/8'' thick--APA Grade, Exposure 1) plywood by mechanically securing (staple gun) each of the four corners. Two roofing nails (1.25'') are hammered 1'' to 2'' apart near the center of the plywood so that the nail heads are flush with the surface of the test specimens. The nails are placed on different grains of plywood so if one fails, it does not flow into the other nail. The nails are backed out about 0.25'' from the coated surface by tapping the pointed ends of the nails. The assemblies are placed on a tray. The bottom is removed from a 1 gallon tin can. The can is then placed in the center of the surface having the nails. A bead of silicone sealant is applied around the outside and inside of the rim of the can. The silicone bead is pushed into the gap between the tin can and the coated surface, and the sealant is allowed to cure for about 24 hours. After waiting about 24 hours, deionized water is mixed with food coloring (as an indicator for water penetration) to produce a dyed water, which is used to fill the can to a depth of 5''. The entire assemblies, along with the bottom tray, are placed in a refrigeration unit maintained at 4.degree. C..+-.2.degree. C. for three days. On the third day ahead of water exposure, the dyed water is poured out, the inside of the can is blotted dry, and the can is removed. The assemblies are inspected for any signs of dyed water on the underside of the plywood, around the nail shanks, and between the plywood and test material. The nails are removed, and the test material is removed from around the nail holes to examine the plywood for any dye stains. Any signs of dyed water result in a failure. If dry, the specimen meets the nail sealability ASTM D1970.

[0051] In some embodiments, the third layer 25 has a weight of 50 grams per square meter ("gsm") to 300 gsm. In some embodiments, the third layer 25 has a weight of 60 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 70 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 80 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 90 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 100 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 110 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 120 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 130 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 140 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 150 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 160 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 170 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 180 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 190 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 200 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 210 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 220 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 230 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 240 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 250 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 260 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 270 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 280 gsm to 300 gsm. In some embodiments, the third layer 25 has a weight of 290 gsm to 300 gsm.

[0052] In some embodiments, the third layer 25 has a weight of 50 gsm to 290 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 280 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 270 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 260 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 250 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 240 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 230 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 220 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 210 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 200 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 190 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 180 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 170 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 160 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 150 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 140 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 130 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 120 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 110 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 100 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 90 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 80 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 70 gsm. In some embodiments, the third layer 25 has a weight of 50 gsm to 60 gsm.

[0053] In some embodiments, the fourth layer 30 can include a fire resistant material. Any fire resistant material may be suitable such as, but not limited to, aluminum foil, a fire resistant coating including fire retardants such as sodium borate, aluminum trihydrate, halogen flame retardants, halogen-free flame retardants (e.g., phosphorus-nitrogen flame retardant, intumescent compound, expanded graphite, metal hydroxide such aluminum trihydrate and magnesium hydroxide), or any combination thereof

[0054] In some embodiments, the first layer 15, second layer 20, third layer 25, and fourth layer 30 can be arranged in a different order. An example of a different ordering is shown in FIG. 3 and described below.

[0055] In some embodiments, the roofing underlayment 10 can include one or more additional layers. In the illustrated embodiment of FIG. 2, these additional layers are illustrated in dashed lines. For example, in some embodiments, the roofing underlayment 10 can include a UV resistant layer 35. In some embodiments, the UV resistant layer 35 is an outermost layer of the roofing underlayment 10. In some embodiments, the UV resistant layer 35 can be laminated to the first layer 15 or the second layer 20. Thus, the UV resistant layer 35 can be arranged to be one of the first or second outermost layers of the roofing underlayment. In some embodiments, the roofing underlayment 10 can include an adhesive layer 40. In some embodiments, the adhesive layer 40 is an innermost layer of the roofing underlayment 10. In some embodiments, the adhesive layer 40 can include a sheet 45 to cover the adhesive layer 40. In such embodiments, the sheet 45 can be removed to expose the adhesive layer 40. Such an adhesive layer 40 and sheet 45 combination may be referred to as a peel-and-stick application.

[0056] In some embodiments, the adhesive layer 40 can include bitumen or a PSA coating.

[0057] FIG. 3 shows an exploded view of the roofing underlayment 10 of FIG. 1, according to some embodiments. In FIG. 3, layers of the roofing underlayment 10 are visible.

[0058] In some embodiments, the roofing underlayment 10 includes an arrangement in which the second layer 20 and the first layer 15 are reversed from FIG. 2. That is, the arrangement of the layers includes the second layer 20, the first layer 15, the third layer 25, and the fourth layer 30. For simplicity of this Specification, aspects of the roofing underlayment 10 in FIG. 3 will not be described in further detail.

[0059] FIG. 4 is a flowchart of a method 100, according to some embodiments.

[0060] In some embodiments, at block 105 the method 100 includes obtaining a first layer of synthetic woven material. At block 110 the method 100 includes obtaining a second layer of nonwoven material. At block 115 the method 100 includes obtaining a third layer of elastic recoverable material. At block 120 the method 100 includes obtaining a fourth layer of fire resistant material.

[0061] In some embodiments, at block 125 the method 100 includes laminating the first layer, the second layer, the third layer, and the fourth layer, so as to result in a roofing underlayment. In some embodiments, laminating the layers can include extrusion lamination, adhesive lamination, or any combination thereof In some embodiments, laminating the layers can include laminating the first layer and the second layer to form a first laminate, then laminating the first laminate to the third layer to form a second laminate, then laminating the second laminate to the fourth layer, so as to result in a roofing underlayment. In some embodiments, the laminating can include laminating the different layers in a different order than the preceding example. In some embodiments, more than one lamination method can be used (e.g., both extrusion lamination and adhesive lamination). In some embodiments, the resulting roofing underlayment corresponds to the roofing underlayment 10 described in accordance with FIGS. 1 and 2 above. In some embodiments, the roofing underlayment is configured to be secured to a roof such that the roofing underlayment meets (a) ASTM D4869 water shower exposure test, and (b) UL790 burning brand rating. In some embodiments, the third layer has a weight of 50 gsm to 300 gsm.

[0062] FIG. 5 is a flowchart of a method 150, according to some embodiments.

[0063] In some embodiments, at block 155, the method 150 includes obtaining a roofing underlayment (e.g., the roofing underlayment 10 of FIGS. 1-2). In some embodiments, the roofing underlayment includes a first layer of synthetic woven material; a second layer of nonwoven material; a third layer of elastic recoverable material; and a fourth layer of fire resistant material. In some embodiments, the third layer has a weight of 50 gsm to 300 gsm.

[0064] In some embodiments, at block 160 the method 150 further includes applying the roofing underlayment to a steep slope roof substrate. In some embodiments, applying the roofing underlayment to the steep slope roof substrate includes peeling a sheet from the roofing underlayment; exposing an adhesive of the roofing underlayment; and adhering the roofing underlayment to the steep slope roof substrate. In some embodiments, at block 165 the method 150 includes securing the roofing underlayment to the steep slope roof substrate to form a secured roofing underlayment. In some embodiments, securing the roofing underlayment to the steep slope roof substrate includes fastening the roofing underlayment to the steep slope roof substrate. In some embodiments, fastening the roofing underlayment to the steep slope roof substrate includes stapling, nailing, or any combination thereof. In some embodiments, nailing the roofing underlayment includes using fasteners that do not include capped roofing nails. A "capped roofing nail" as used herein generally includes a roofing nail (such as, but not limited to, a galvanized roofing nail) having a cap for disbursing a hold of the roofing nail to a larger surface area than the head of the nail by itself. The cap can generally be disk-shaped and may have a diameter in the range of 3/4'' to 1-1/4''. The cap can be, for example, plastic or the like. In some embodiments, the secured roofing underlayment meets (a) ASTM D4869 water shower exposure test, and (b) UL790 burning brand rating.

[0065] Among those benefits and improvements that have been disclosed, other objects and advantages of this disclosure will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present disclosure are disclosed herein; however, the disclosed embodiments are merely illustrative of the disclosure that may be embodied in various forms. In addition, each of the examples given regarding the various embodiments of the disclosure are intended to be illustrative, and not restrictive.

[0066] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases "in one embodiment," "in an embodiment," and "in some embodiments" as used herein do not necessarily refer to the same embodiment(s), though it may. Furthermore, the phrases "in another embodiment" and "in some other embodiments" as used herein do not necessarily refer to a different embodiment, although it may. All embodiments of the disclosure are intended to be combinable without departing from the scope or spirit of the disclosure.

[0067] All prior patents, publications, and test methods referenced herein are incorporated by reference in their entireties.

[0068] The terminology used herein is intended to describe embodiments and is not intended to be limiting. The terms "a," "an," and "the" include the plural forms as well, unless clearly indicated otherwise. The terms "comprises" and/or "comprising," when used in this Specification, specify the presence of the stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or components.

[0069] It is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the shape, size, and arrangement of parts without departing from the scope of the present disclosure. This Specification and the embodiments described are examples, with the true scope and spirit of the disclosure being indicated by the claims that follow.

Claims

1. A roofing underlayment, comprising: a first layer of synthetic woven or nonwoven material; a second layer of woven or nonwoven material; a third layer of elastic recoverable material; wherein the third layer has a weight of 50 gsm to 300 gsm; wherein the elastic recoverable material comprises an elastomer; and a fourth layer of fire resistant material; wherein the roofing underlayment, when secured to a roof, meets: a) ASTM D4869 water shower exposure test; b) UL790 burning brand rating; and c) ASTM D1970 nail sealability.

2. The roofing underlayment of claim 1, wherein the elastomer comprises a rubber-like elastomer, a thermoplastic elastomer (TPE), or any combination thereof.

3. The roofing underlayment of claim 1, wherein the elastomer is not an adhesive.

4. The roofing underlayment of claim 1, wherein the first layer, the second layer, the third layer, and the fourth layer are laminated with extrusion materials.

5. The roofing underlayment of claim 1, wherein the first layer is a synthetic nonwoven material and includes a spunbond polypropylene.

6. The roofing underlayment of claim 1, wherein the second layer is a woven material and includes a scrim of synthetic woven fabric including polypropylene.

7. The roofing underlayment of claim 1, wherein the first layer or the second layer includes a weatherable layer including a UV-resistant material arranged to be an outermost first or second layer of the roofing underlayment.

8. The roofing underlayment of claim 1, further comprising an adhesive layer arranged to be an innermost layer.

9. The roofing underlayment of claim 8, wherein the adhesive layer includes a cover sheet.

10. The roofing underlayment of claim 1, wherein a total weight of the roofing underlayment is from 170 gsm to 600 gsm.

11. The roofing underlayment of claim 1, wherein a total weight of the roofing underlayment is from 200 gsm to 560 gsm.

12. The roofing underlayment of claim 1, wherein the roofing underlayment has a topside coefficient of friction of 0.3 to 1.5.

13. The roofing underlayment of claim 1, wherein the roofing underlayment has a backside coefficient of friction of 0.3 to 1.5.

14. The roofing underlayment of claim 1, wherein the roofing underlayment meets Class A of UL790 burning brand rating.

15. A method, comprising: obtaining a first layer of synthetic woven material; obtaining a second layer of nonwoven material; obtaining a third layer of elastic recoverable material; wherein the third layer has a weight of 50 gsm to 300 gsm; wherein the elastic recoverable material comprises an elastomer; obtaining a fourth layer of fire resistant material; and laminating the first layer, the second layer, the third layer, and the fourth layer, so as to result in a roofing underlayment; wherein the roofing underlayment, when secured to a roof, meets: a) ASTM D4869 water shower exposure test; b) UL790 burning brand rating; and c) ASTM D1970 nail sealability.

16. A method, comprising: obtaining a roofing underlayment comprising: a first layer of synthetic woven material; a second layer of nonwoven material; a third layer of elastic recoverable material; and wherein the third layer has a weight of 50 gsm to 300 gsm; wherein the elastic recoverable material comprises an elastomer; and a fourth layer of fire resistant material; applying the roofing underlayment to a steep slope roof substrate; and securing the roofing underlayment to the steep slope roof substrate to form a secured roofing underlayment; wherein the secured roofing underlayment meets: a) ASTM D4869 water shower exposure test; b) UL790 burning brand rating; and c) ASTM D1970 nail sealability.

17. The method of claim 16, wherein applying the roofing underlayment to the steep slope roof substrate comprises: peeling a sheet from the roofing underlayment; exposing an adhesive of the roofing underlayment; and adhering the roofing underlayment to the steep slope roof substrate.

18. The method of claim 16, wherein securing the roofing underlayment includes fastening the roofing underlayment using fasteners that do not include capped roofing nails.

19. The method of claim 16, wherein securing the roofing underlayment comprises stapling the roofing underlayment to the steep slope roof substrate.

20. The method of claim 16, wherein securing the roofing underlayment comprises nailing the roofing underlayment to the steep slope roof substrate using capless roofing nails.