Rubberized roof underlayment

Abstract

An underlayment product comprises a fibrous mat having an upper surface and a lower surface. A rubberized asphalt coating is applied to the lower surface of the fibrous mat and extends at least partially into the fibrous mat. An oxidized asphalt coating is applied to the upper and lower surfaces of the fibrous mat generally encapsulating the fibrous mat including the rubberized asphalt coating provided on the lower surface of the fibrous mat. The oxidized asphalt layers may be coated with a release layer such as talc, granules or a polymer.

Description

TECHNICAL FIELD [0001] The present invention relates to roof underlayments and more particularly, to a heavyweight, underlayment product which utilizes a rubberized asphalt layer. BACKGROUND INFORMATION [0002] An underlayment material is commonly used in a number of roofing applications as well as other underlayment situations. The typical product utilized in roofing underlayment is commonly referred to as “tar” of “felt” paper. The traditional “tar paper” is an asphalt impregnated paper product which is sold in a roll; unrolled on a roof; cut to length; and fastened to the roof utilizing staples or nails. Although tar paper is inexpensive, it does not seal nail holes through the paper and thus does not prevent water infiltration. In addition, once the felt is rolled out, it absorbs water and once wet, it wrinkles and expands, and must be allowed to dry out before covering with shingles. Other prior art shingle underlayment products also suffer from the same problems. [0003] Accordi...

AI Technical Summary

Benefits of technology

[0004] The present invention features a novel underlayment product which will be relatively inexpensive and replace prior art products such as “tar paper” or “felt paper”. The present invention provides an underlayment product with a top surface that can be walked on and will not slide under foot, and wherein the product will not stick to itself or the roof. In addition, the present invention has “cold” flow properties which allow it to “repair” or “heal” itself to thereby reseal around nail or puncture holes and also elongate and recover around punctures.

Problems solved by technology

Although tar paper is inexpensive, it does not seal nail holes through the paper and thus does not prevent water infiltration.

Other prior art shingle underlayment products also suffer from the same problems.

If the filler content is too low such that a higher asphalt percentage exists, the product would be sticky.

In addition, the filler also brings down the price of the finished product.

Loose talc is a slip problem.

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