NON-SLIP ROOFING UNDERLAYMENT AND METHOD FOR MANUFACTURING SAME
Embodiments of the present invention generally relate to a non-slip roofing underlayment made using an extrusion lamination process with a desirable minimum substrate-to-substrate static coefficient of friction of at least 0.400, made using an extrusion lamination process. In one embodiment, a roofing underlayment is manufactured from the steps comprising providing a first layer of a woven thermoplastic material, extruding a second layer of thermoplastic material on the first layer, at a temperature between about 470 degrees and about 600 degrees Fahrenheit, and laminating a third layer of non-woven thermoplastic material on the second layer through a nip at a pressure between about 50 pounds per square inch and about 90 pounds per square inch.
1 . A method of manufacturing a roofing underlayment comprising the steps:
providing a first layer of a woven material;
extruding a second layer of thermoplastic material on the first layer, at a temperature between about 470 degrees and about 600 degrees Fahrenheit; and
laminating a third layer of non-woven material on the second layer through a nip at a pressure between about 50 pounds per square inch and about 90 pounds per square inch.
2 . The method of claim 1 , wherein the woven material is a polyolefin.
3 . The method of claim 2 , wherein the woven material is polypropylene.
4 . The method of claim 1 , wherein non-woven material is at least one from the group of polypropylene, polyethylene, cotton cloth, nylon, and polyester.
5 . The method of claim 1 , wherein the extruded thermoplastic material is at least one from the group of polypropylene, nylon, polyester, and polyethylene.
6 . The method of claim 1 , wherein the second layer of thermoplastic material is extruded on the first layer, at a temperature between about 500 degrees and 585 degrees Fahrenheit.
7 . The method of claim 6 , wherein the second layer of thermoplastic material is extruded on the first layer, at about 535 degrees Fahrenheit.
8 . The method of claim 1 , wherein the third layer of non-woven material is laminated on the second layer through a nip at a pressure between about 60 pounds per square inch and about 85 pounds per square inch.
9 . The method of claim 8 , wherein the third layer of non-woven material is laminated on the second layer through a nip at about 80 pounds per square inch.
10 . The method of claim 1 , further comprising:
extruding an additional layer of thermoplastic material on the third layer.
11 . The method of claim 10 , further comprising:
laminating an additional layer of non-woven material on the additional layer of thermoplastic material.
12 . A roofing underlayment manufactured from the steps comprising:
providing a first layer of a woven thermoplastic material;
extruding a second layer of thermoplastic material on the first layer, at a temperature between about 470 degrees and about 600 degrees Fahrenheit; and
laminating a third layer of non-woven thermoplastic material on the second layer through a nip at a pressure between about 50 pounds per square inch and about 90 pounds per square inch.
13 . The roofing underlayment of claim 12 , wherein the substrate-to-substrate static coefficient of friction is greater than about 0.400.
14 . The roofing underlayment of claim 12 , wherein the woven thermoplastic material is a polyolefin.
15 . The roofing underlayment of claim 14 , wherein the thermoplastic woven material is polypropylene.
16 . The roofing underlayment of claim 12 , wherein non-woven thermoplastic material is at least one from the group of polypropylene, polyethylene, nylon, and polyester.
17 . The roofing underlayment of claim 12 , wherein the extruded thermoplastic material is at least one from the group of polypropylene, nylon, polyester, and polyethylene.
18 . The roofing underlayment of claim 12 , wherein the second layer of thermoplastic material is extruded on the first layer, at a temperature between about 500 degrees and 585 degrees Fahrenheit.
19 . The roofing underlayment of claim 18 , wherein the second layer of thermoplastic material is extruded on the first layer, at about 535 degrees Fahrenheit.
20 . The roofing underlayment of claim 12 , wherein the third layer of non-woven thermoplastic material is laminated on the second layer through a nip at a pressure between about 60 pounds per square inch and about 85 pounds per square inch.
21 . The roofing underlayment of claim 20 , wherein the third layer of non-woven thermoplastic material is laminated on the second layer through a nip at about 80 pounds per square inch.