Underlayment with thermal insulation
An underlayment that meets underlayment requirements and provides thermal insulation is disclosed. The underlayment includes a core material and an upper emittance layer having an exterior surface. An upper reinforcement layer is positioned between the upper emittance layer and the core material. A first encapsulation layer is positioned between the upper emittance layer and the upper reinforcement layer. A second encapsulation layer is positioned between the upper reinforcement layer and the core material. The underlayment includes a lower emittance layer having an exterior surface. A lower reinforcement layer is positioned between the lower emittance layer and the core material. A third encapsulation layer is positioned between the lower emittance layer and the lower reinforcement layer. A fourth encapsulation layer is positioned between the lower reinforcement layer and the core material.
1. An underlayment configured to insulate and protect a roofing assembly, the underlayment comprising:
an insulating layer including closed-cell foam core material;
an upper low-emittance reflective layer having an exterior surface, the exterior surface of the upper low-emittance reflective layer being configured to be positioned either (i) directly adjacent to and in contact with an underside of a roof covering (ii) adjacent to the underside of the roof covering and separated from the underside of the roof covering by only an airspace;
an upper scrim layer between the upper low-emittance reflective layer and the foam core material, the upper scrim layer being encapsulated on a first side by a first heat-sealed encapsulation layer fused to the upper low-emittance reflective layer and the upper scrim layer via flame lamination, and being encapsulated on a second opposing side by a second heat-sealed encapsulation layer fused to the upper scrim layer and the foam core material via flame lamination, both the first and second heat-sealed encapsulation layers being non-permeable;
a lower low-emittance reflective layer having an exterior surface, the exterior surface of the lower low-emittance reflective layer being configured to at least partially contact a roof deck of the roofing assembly;
a lower scrim layer between the lower low-emittance reflective layer and the foam core material, the lower scrim layer being encapsulated on a first side by a third heat-sealed encapsulation layer fused to the lower low-emittance reflective layer and the lower scrim layer via flame lamination, and being encapsulated on a second opposing side by a fourth heat-sealed encapsulation layer fused to the lower scrim layer and the foam core material via flame lamination, both the third and fourth heat-sealed encapsulation layer being non-permeable,
wherein the underlayment has a total thickness ranging from about ⅛ inches to about 7/32 inches, and
wherein the underlayment has an R-value of between about 0.5 and 1.
2. The underlayment of claim 1 , wherein the insulating layer comprises closed cell polyethylene foam.
3. The underlayment of claim 1 , wherein the insulating layer comprises polyolefin.
4. The underlayment of claim 1 , wherein the upper scrim layer and the lower scrim layer are made of fiberglass or plastic material.
5. The underlayment of claim 4 , wherein the upper scrim layer and the lower scrim layer are in one of a 2×2, 5×5, 8×8, tri D or Diamond pattern.
6. The underlayment of claim 1 , wherein each of the heat-sealed encapsulation layers is polyethylene.
7. The underlayment of claim 1 , wherein the upper low-emittance reflective layer and the lower low-emittance reflective layer include aluminum.
8. The underlayment of claim 1 , wherein the underlayment has a thickness of 0.125 inches.
9. The underlayment of claim 8 in combination with a roofing assembly having a 0.5 inch reflective airspace, the combination having an R-value of 3.
10. The underlayment of claim 8 in combination with a roofing assembly having a 0.75 inch reflective airspace, the combination having an R-value of 4.
11. The underlayment of claim 8 in combination with a roofing assembly having a 1.5 inch reflective airspace, the combination having an R-value of 6.1.
12. The underlayment of claim 8 in combination with a roofing assembly having a 3.5 inch reflective airspace, the combination having an R-value of 8.7.
13. The underlayment of claim 1 , wherein the underlayment has a thickness of 0.218 inches.
14. The underlayment of claim 8 in combination with a roofing assembly having a 0.5 inch reflective airspace, the combination having an R-value of 3.5.
15. The underlayment of claim 8 in combination with a roofing assembly having a 0.75 inch reflective airspace, the combination having an R-value of 4.5.
16. The underlayment of claim 8 in combination with a roofing assembly having a 1.5 inch reflective airspace, the combination having an R-value of 6.6.
17. The underlayment of claim 8 in combination with a roofing assembly having a 3.5 inch reflective airspace, the combination having an R-value of 9.2.
18. The underlayment of claim 1 , wherein the exterior surface of the upper low-emittance reflective layer forms an upper outermost exterior surface of the underlayment, and the exterior surface of the lower low-emittance reflective layer forms a lower outermost exterior surface of the underlayment.
19. The underlayment of claim 1 , wherein one of the upper scrim layer or the lower scrim layer has a 2×2 pattern, and where another of the upper scrim layer or the lower scrim layer has a 5×5 pattern.
20. The underlayment of claim 1 , wherein the upper low-emittance reflective layer and the lower low-emittance reflective layer each have an emissivity rating of at least about 85%.