# US 7,745,353 B2 · Anti-slip roofing underlayment

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- Number: US 7,745,353 B2
- Document ID: US7745353B2
- Status: Granted
- Kind: B2
- Application number: 11/954,347
- Filed: 2007-12-12
- Published: 2008-08-14
- Granted: 2010-06-29
- Earliest claimed: 2006-12-15
- Assignees: Intertape Polymer Corp.
- Inventors: Trevor Arthurs; Kathleen English
- Web page: https://patentgrep.com/patent/US7745353B2

## CPC

- E04D 12/002: {Sheets of flexible material, e.g. roofing tile underlay}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 27/12: next to a fibrous or filamentary layer
- D06N 3/045: {with polyolefin or polystyrene (co-)polymers}
- D06N 3/10: with styrene-butadiene copolymerisation products {or other synthetic rubbers or elastomers except polyurethanes}
- D06N 3/183: {the layers are one next to the other}
- D06N 3/186: {one of the layers is on one surface of the fibrous web and the other layer is on the other surface of the fibrous web}
- D10B 2505/02: Reinforcing materials; Prepregs
- Y10T 428/24355: Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T 442/102: Woven scrim
- Y10T 442/172: Coated or impregnated
- Y10T 442/176: Three or more layers
- Y10T 442/178: Synthetic polymeric fiber
- Y10T 442/183: Synthetic polymeric fiber
- Y10T 442/184: Nonwoven scrim
- Y10T 442/198: Coated or impregnated
- E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A roofing underlayment comprises a reinforcing layer, which is extrusion coated on at least one side with an anti-slip coating layer. The reinforcing layer comprises a woven polyethylene or polypropylene scrim. The anti-slip coating layer comprises a compound based on a styrene and ethylene/butylene-styrene, S-E/B-S, block copolymer, such as the compound sold under the trademark KRATON® MD6649. The anti-slip coating layer may also be embossed. The anti-slip coating layer is low in cost and helps prevent water from penetrating the primary roofing material. In addition, the anti-slip coating layer provides an improved anti-skid surface upon which an individual may safely walk. Embossment improves the wet slip resistance of the roofing underlayment.

## Claims

### Claim 1

A roofing underlayment comprising:
a reinforcing layer comprising:
an upper surface anti-slip coating layer comprising:
a core layer comprising 2% UV stabilizer, 10% Beige pigment, 4% anti-block, 20% low density polyethylene, and 64% h-homopolymer polypropylene; and
a skin layer comprising 2% UV stabilizer, 10% Beige pigment, 8% anti-block, 15% low density polyethylene, and 65% S-E/B-S block copolymer compound comprising about 30%-75% by weight styrene-ethylene/butylene-styrene, about 0%-50% by weight resin, and about 0.1-2% by weight antioxidant/stabilizer/dusting agent; and
a lower surface anti-slip coating layer;
wherein the anti-slip coating comprises a styrene and ethylene/butylene-styrene (S-E/B-S) block copolymer, wherein the upper surface anti-slip coating layer has a thickness of about 0.5 mils to 4 mils,
wherein the lower surface anti-slip coating layer has a thickness of about 0.5 mils to 4 mils, and
wherein the roofing underlayment is embossed with a pattern.

### Claim 2 (depends on 1)

The roofing underlayment according to claim 1, wherein the reinforcing layer comprises a woven polyethylene scrim.

### Claim 3 (depends on 1)

The roofing underlayment according to claim 1, wherein the reinforcing layer comprises a woven polypropylene scrim.

### Claim 4 (depends on 1)

The roofing underlayment according to claim 1, wherein the reinforcing layer comprises a nonwoven layer.

### Claim 5 (depends on 1)

The roofing underlayment according claim 1, wherein:
the reinforcing layer comprises a woven polypropylene scrim;
the lower coating layer comprises 73.5% thermoplastic olefin resin, 8.0% low density polyethylene, 2% U.V. stabilizer, 10.5% White MasterBatch, and 6% anti-block; and
wherein the core layer and the skin layer are coextruded onto the scrim; and wherein the core layer comprises 70% by weight of the upper coating layer and the skin layer comprises 30% by weight of the upper coating layer.

### Claim 6 (depends on 1)

The roofing underlayment according to claim 1, wherein the embossment is a diamond pattern.

### Claim 7 (depends on 6)

The roofing underlayment according to claim 6, wherein the diamond pattern comprises interlocking diamond shapes.

### Claim 8 (depends on 1)

The roofing underlayment according to claim 1, wherein embossment is provided by applying heat and pressure while the roofing underlayment is run through a nip assembly.

### Claim 9 (depends on 8)

The roofing underlayment according to claim 8, wherein the nip assembly contains a positive of a pattern to be embossed on the anti-slip coating layer.

### Claim 10 (depends on 1)

The roofing underlayment according to claim 1, wherein the embossment is applied by extrusion coating onto a patterned chill roll.

### Claim 11 (depends on 1)

The roofing underlayment according to claim 1, wherein the embossment is applied by direct embossment.

### Claim 12 (depends on 11)

The roofing underlayment according to claim 11, wherein the direct embossment is carried out after a smooth chill rolling.

### Claim 13

A roofing underlayment comprising:
a reinforcing layer comprising:
an upper surface anti-slip coating layer comprising:
a core layer; and
a skin layer; and
a lower surface anti-slip coating layer;
and wherein the reinforcing layer comprises a woven polypropylene scrim;
the core layer comprising 1% U.V. stabilizer, 10% Beige pigment, 8% low density polyethylene, and 81% homo-polymer polypropylene;
and wherein the skin coating layer comprises 2% UV stabilizer, 10% Beige pigment, 8% anti-block, 10% homo-polymer polypropylene, and 70% S-E/B-S block copolymer compound comprising about 30-75% by weight styrene-ethylene/butylene-styrene, about 0%-50% by weight resin, and about 0.1%-2% by weight antioxidant/stabilizer/dusting agent;
and wherein the lower coating layer comprises 73.5% thermoplastic olefin resin, 8.0% low density polyethylene, 2% UV stabilizer, 10.5% white masterbatch, and 6% anti-block;
wherein the core layer and the skin layer are coextruded onto the scrim, and wherein the core layer comprises 70% by weight of the upper coating layer and the skin layer comprises 30% by weight of the upper coating layer.