Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
  • E04D12/002—Sheets of flexible material, e.g. roofing tile underlay
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips

Definitions

• the invention pertains to roofing underlayments, and in particular to a system for preventing water leakage around fasteners that are used to secure roofing underlayment to a roof deck.
• the basic structure of a typical roofing underlayment is a woven scrim layer (or a non-woven layer) with a waterproof coating on both sides.
• nails are driven through the roofing underlayment to attach it to a roof deck.
• This makes holes through the underlayment and there is a susceptibility to water leakage around the nails.
• It is known in the art to include in a multilayer roofing underlayment a layer that is adapted to seal around nails, e.g. Thai et al, US 2010/0178827; Binkley et al., US 2007/0077838; Zickell et al., US 2007/0071946; and Sandrasegaran et al., WO 2010/070466.
• these systems require use of a full layer of the sealant, including across areas of the sheet where nailing will not occur.
• the invention provides nailing sealant areas or strips inside the layers of a sheet of underlayment that provide a seal around the fasteners passing through the sheet.
• a sheet of roofing underlayment comprising a base layer, a water-impermeable coating layer laminated to a first side of the base layer, and a plurality of spaced-apart sealant areas between the coating layer and the base layer, comprising a sealant adapted to form a seal around a fastener penetrating the sheet.
• Figure 1 is a cross-sectional view through one embodiment of the roofing underlayment.
• Figure 2 is a cross-sectional view through the underlayment of Fig. 1 nailed to a roof deck.
• Figure 3 is a cross-sectional view through a second embodiment of the underlayment.
• Figure 4 is a cross-sectional view through a third embodiment of the underlayment. Detailed Description of the Preferred Embodiments
• the roofing underlayment 10 comprises a base layer, namely a woven scrim layer 12, laminated to a first coating layer 14 on one side and to a second coating layer 16 on the opposite side.
• the scrim comprises woven tapes which may be made of various resins, including polyolefins such as polyethylene and polypropylene, polyesters, polystyrene, nylon, and ethylene acrylic copolymers.
• the base layer may be a woven, non-woven or film layer.
• the coating layers are water impermeable and may comprise any of the same resins as the scrim.
• the scrim may have a weight of about 75 grams per square meter,
• the coatings may have a thickness of about 1.5 mil, alternatively a thickness in the range of 0.3-3.5 mil.
• the sealant areas 18 are spaced-apart strips positioned between the scrim 12 and the first coating layer 14, which in use is the upper layer of the sheet. In the view of Fig. 1, the strips 18 extend into the plane of the paper.
• the sealant material may be any of various seal-forming adhesives, including hot melt adhesive, silicone, glue, modified bitumen and rubberized asphalt.
• the sealant areas 18 may be black or dark- colored to be visible through the coating 14. During the manufacture of the underlayment, the strips of sealant are applied between the first coating layer 14 and the scrim layer 12.
• the strips are placed in nailing areas such as along the longitudinal edges of the sheet, and, alternatively also across the middle of the sheet.
• nailing areas such as along the longitudinal edges of the sheet, and, alternatively also across the middle of the sheet.
• the strips may be intermittent rather than
• a sealant is employed that does not cure during the process of manufacturing the roofing underlayment. It remains liquid until a fastener, e.g. a nail, passes through the coating, exposing the sealant to air or humidity and causing the sealant to cure and form a rubbery gasket around the nail.
• the sealant cures during the process of manufacturing the roofing underlayment.
• the thickness of the top coating layer 14 or of the scrim layer 12, or both, may be reduced in the area of the sealant strips 18, as shown in Figure 1, so that the sheet 10 has a substantially uniform thickness. This facilitates winding up of the sheet evenly into a roll, avoiding build-up in the roll in the areas of the strips.
• roll buildup can be managed by making the strips intermittent, or having intermittent spots of sealant.
• roll buildup can be managed by osculation of the sealant strips.
• the osculation of the strips is done by means of the mechanism of delivering the stops being slightly moved left and right traversing across the web, preventing the sealant strips from stacking upon themselves layer after layer.
• the build-up is distributed over a space of
• Figure 2 shows the sheet of roofing underlayment 10 laid in place on a roof deck 22, with the second coating layer 16 being the bottom layer in direct contact with the deck, and the first coating layer 14 being the upper layer.
• Nails 20 are driven through the sheet along the strips 18, forming holes 24 through the sheet.
• the sealant forms a seal around the nails, preventing water infiltration to the deck.
• staples or screws can be used in place of nails.
• a further embodiment of the roofing underlayment 30 has additional sealant areas.
• Sealant areas or strips 32 are provided on the underside of the sheet, laminated to the outside of the second coating layer 16, aligned with the sealant areas 18 between the first coating layer 14 and the scrim layer 12.
• Additional sealant areas or strips 34 are provided on the upper side of the sheet, laminated to the first coating layer 14 and aligned with the sealant areas 18 and 32. This arrangement enhances the sealing around fasteners driven through the sealing areas 34, 18, 32.
• the roofing underlayment 30 may have only the internal sealant areas 18 and the top sealant areas 34, or only the internal sealant areas 18 and the bottom sealant areas 32.
• FIG 4 shows a further embodiment of the roofing underlayment 40.
• the sealant area 18 is positioned between the scrim layer 12 and the second coating layer 16 (in use, the layer in contact with the roof deck), rather than between the scrim layer 12 and the first coating layer 14 (in use, the top layer).
• the roofing underlayment 40 is otherwise the same as the roofing underlayment 10 as described above.

Landscapes

• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Laminated Bodies (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Publications (1)

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Citations (6)

Family Cites Families (5)

• 2013
  • 2013-05-02 US US14/398,656 patent/US20150093551A1/en not_active Abandoned
  • 2013-05-02 CA CA2872323A patent/CA2872323A1/fr not_active Abandoned
  • 2013-05-02 WO PCT/CA2013/050344 patent/WO2013163764A1/fr not_active Ceased

Patent Citations (6)

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