# US 2020/0399904 A1 · Roofing underlayment with hydrophobic nonwoven core

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- Number: US 2020/0399904 A1
- Document ID: US20200399904A1
- Status: Published application
- Kind: A1
- Application number: 16/909,046
- Filed: 2020-06-23
- Published: 2020-12-24
- Earliest claimed: 2019-06-24
- Assignees: Owens Corning Intellectual Capital, LLC
- Applicants: Owens Corning Intellectual Capital, LLC
- Inventors: Martin Vido
- Web page: https://patentgrep.com/patent/US20200399904A1

## CPC

- B32B 5/022: {Non-woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/265: {characterised by one fibrous or filamentary layer being a non-woven fabric layer}
- B32B 5/266: {next to one or more non-woven fabric layers}
- B32B 5/271: {characterised by separate non-woven fabric layers that comprise chemically different strands or fibre material}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 27/02: in the form of fibres or filaments {(not used)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/40: comprising polyurethanes
- E04D 12/002: {Sheets of flexible material, e.g. roofing tile underlay}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 27/08: of synthetic resin
- B32B 27/18: characterised by the use of special additives
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2250/05: 5 or more layers
- B32B 2250/24: All layers being polymeric
- B32B 2250/242: All polymers belonging to those covered by group B32B27/32
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/26: Polymeric coating
- B32B 2262/023: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2262/0246: Acrylic resin fibres
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0292: Polyurethane fibres
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2305/20: in the form of a non-woven mat
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/73: Hydrophobic
- B32B 2307/744: Non-slip, anti-slip
- B32B 2419/06: Roofs, roof membranes
- D06N 5/00: {Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch (compositions of bituminous materials C08L95/00, roof covering E04D5/00, roofing underlays E04D12/002)}
- Y10T 428/24942: including components having same physical characteristic in differing degree
- Y10T 428/2495: Thickness [relative or absolute]
- Y10T 428/27: Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
- Y10T 428/273: of coating
- Y10T 442/602: Nonwoven fabric comprises an elastic strand or fiber material
- Y10T 442/66: Additional nonwoven fabric is a spun-bonded fabric
- Y10T 442/678: Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
- Y10T 442/681: Spun-bonded nonwoven fabric
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00)
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

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

## Claims

### Claim 1

A roofing underlayment comprising:
a hydrophobic nonwoven core layer having a basis weight of 100 g/m2 to 250 g/m2;
a first coating layer adhered to a first surface of the hydrophobic nonwoven core layer; and
a first exterior surface layer adhered to the first coating layer.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

The roofing underlayment according to claim 1, wherein the hydrophobic nonwoven core layer has a basis weight of 105 g/m2 to 150 g/m2.

### Claim 5 (depends on 1)

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

### Claim 6 (depends on 1)

The roofing underlayment o according to claim 1, wherein the first coating layer has a basis weight of 15 g/m2 to 35 g/m2.

### Claim 7 (depends on 1)

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

### Claim 8 (depends on 1)

The roofing underlayment according to claim 1, wherein the first exterior surface layer has a basis weight of 10 g/m2 to 120 g/m2.

### Claim 9 (depends on 1)

The roofing underlayment according to claim 1, wherein the first exterior surface layer is a bicomponent spunbond nonwoven material having a total basis weight of 30 g/m2 to 60 g/m2 and comprising a polyolefin layer bonded to a thermoplastic elastomer layer, and wherein the polyolefin layer is adhered to the first coating layer.

### Claim 10 (depends on 9)

The roofing underlayment according to claim 9, wherein the polyolefin layer has a basis weight of 15 g/m2 to 30 g/m2 and comprises 84% to 98% by weight virgin polypropylene, 1% to 8% by weight U.V. stabilizer, and 1% to 8% by weight colorant, based on the total weight of the polyolefin layer; and the thermoplastic elastomer layer has a basis weight of 15 g/m2 to 30 g/m2 and comprises 70% to 80% by weight virgin polypropylene, 15% to 25% thermoplastic elastomer, 1% to 8% by weight U.V. stabilizer, and 1% to 8% by weight colorant, based on the total weight of the thermoplastic elastomer layer.

### Claim 11 (depends on 9)

The roofing underlayment according to claim 9, wherein the polyolefin layer has a basis weight of 20 g/m2 to 30 g/m2 and comprises 45% to 55% by weight virgin polypropylene, 40% to 50% by weight recycled/reprocessed polypropylene, and 1% to 5% by weight colorant, based on the total weight of the polyolefin layer; and the thermoplastic elastomer layer has a basis weight of 20 g/m2 to 30 g/m2 and comprises 70% to 80% by weight virgin polypropylene, 15% to 25% thermoplastic elastomer, and 1% to 5% by weight colorant (e.g., color masterbatch), based on the total weight of the thermoplastic elastomer layer.

### Claim 12 (depends on 1)

The roofing underlayment according to claim 1, wherein the first exterior surface layer is a melt-blown nonwoven material comprising a polyolefin and having a basis weight of 10 g/m2 to 80 g/m2.

### Claim 13 (depends on 1)

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

### Claim 14 (depends on 13)

The roofing underlayment according to claim 13, wherein the second exterior surface layer is a co-extruded layer comprising a thermoplastic elastomer layer and a polyolefin layer and has a basis weight of 10 g/m2 to 120 g/m2.

### Claim 15 (depends on 14)

The roofing underlayment according to claim 14, wherein the polyolefin layer has a basis weight of 15 g/m2 to 25 g/m2 and comprises 40% to 50% by weight recycled/reprocessed polypropylene, 30% to 40% by weight virgin polypropylene, 10% to 20% by weight low density polyethylene, and 2% to 6% by weight colorant, based on the total weight of the polyolefin layer; and
wherein the thermoplastic elastomer layer has a basis weight of 2 g/m2 to 10 g/m2 and comprises 40% to 55% by weight thermoplastic elastomer, 25% to 45% by weight virgin polypropylene, 10% to 20% by weight low density polyethylene, and 2% to 6% by weight colorant, based on the total weight of the thermoplastic elastomer layer.

### Claim 16 (depends on 1)

The roofing underlayment according to claim 1, wherein the roofing underlayment has a total basis weight of 190 g/m2 to 265 g/m2.

### Claim 17 (depends on 1)

The roofing underlayment according to claim 1, wherein the roofing underlayment has a total basis weight of 225 g/m2 to 250 g/m2.

### Claim 18 (depends on 1)

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

### Claim 19 (depends on 1)

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

### Claim 20

A roofing underlayment comprising:
a hydrophobic nonwoven core layer having a basis weight of 110 g/m2 to 155 g/m2;
a first coating layer adhered to a first surface of the hydrophobic nonwoven core layer, wherein the first coating layer has a basis weight of 10 g/m2 to 40 g/m2;
a first exterior surface layer adhered to the first coating layer, wherein the first exterior surface layer has a basis weight of 20 g/m2 to 60 g/m2; and
a second exterior surface layer adhered to a second surface of the hydrophobic nonwoven core layer opposite the first surface, wherein the second exterior surface layer is a co-extruded layer comprising a thermoplastic elastomer layer having a basis weight of 2 g/m2 to 10 g/m2 and a polyolefin layer having a basis weight of 15 g/m2 to 25 g/m2,
wherein the hydrophobic nonwoven core layer comprises from 50% to 80% of a total basis weight of the roofing underlayment.