Roofing products including coated facer

Abstract

Roofing underlayments include an asphalt batch layer and a coated facer having a thickness of from about 0.75 mm to about 1.25 mm disposed on the asphalt batch layer. The coated facer comprises an uncoated nonwoven mat comprising a plurality of fibers having a diameter of from about 10 microns to about 13 microns bound together by a binder and a coating on the nonwoven mat. The binder comprises less than about 25 wt. % of a total weight of the nonwoven mat. The roofing underlayment has a Gurley stiffness of less than 15,000 g when measured in accordance with ASTM D6125.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application No. 63 / 754,973, filed on Feb. 6, 2025, the entire disclosure of which is fully incorporated herein by reference.FIELD

[0002] The general inventive concepts relate to roofing products and, more particularly, to roofing products including coated nonwoven mats.BACKGROUND

[0003] In a typical roofing installation, an underlayment is applied to the plywood or OSB deck of a roof. An underlayment may be mechanically fastened or adhesively attached to the deck to provide waterproofing. One way to prepare an underlayment is to apply an asphalt batch composition to a glass mat and scrape the excess asphalt batch off the top side of the mat. However, at high temperatures, the asphalt batch may become sticky, which can be problematic for roofers and other persons walking on the roofing material. Additionally, the manufacturing process can result in saturation inconsistencies or buckling in addition to the sticking.

[0004] Accordingly, there is a need for alternative roofing materials that provide an improved walking surface and product consistency.SUMMARY

[0005] In a first aspect of the present disclosure, a roofing underlayment comprises an asphalt batch layer and a coated facer having a thickness of from about 0.75 mm to about 1.25 mm disposed on the asphalt batch layer. The coated facer comprises an uncoated nonwoven mat comprising a plurality of fibers having a diameter of from about 10 microns to about 13 microns bound together by a binder and a coating on the nonwoven mat. The binder comprises less than about 25 wt. % of a total weight of the nonwoven mat. The roofing underlayment has a Gurley stiffness of less than 15,000 g when measured in accordance with ASTM D6125.

[0006] In a second aspect, a roofing underlayment comprises the roofing underlayment of the previous aspect, wherein the roofing underlayment has a Gurley stiffness of from about 5,000 g to about 13,000 g.

[0007] In a third aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein a total weight of the uncoated nonwoven mat is less than or equal to about 100 g / m2.

[0008] In a fourth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the coating on the nonwoven mat is present on the coated facer at a dry weight of from about 100 g / m2 to about 200 g / m2.

[0009] In a fifth aspect, a roofing underlayment comprises the roofing underlayment of any of the first through fourth aspects, wherein the coating on the nonwoven mat is present on the coated facer at a dry weight of from about 200 g / m2 to about 300 g / m2.

[0010] In a sixth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the coating on the nonwoven mat comprises an emulsion copolymer having a Tg of less than about 25° C.

[0011] In a seventh aspect, a roofing underlayment comprises the roofing underlayment of the sixth aspect, wherein the emulsion copolymer has a Tg of less than about 0° C.

[0012] In an eighth aspect, a roofing underlayment comprises the roofing underlayment of the sixth or seventh aspects, wherein the emulsion copolymer has a Tg of less than about −15° C.

[0013] In a ninth aspect, a roofing underlayment comprises the roofing underlayment of any of the sixth through eighth aspects, wherein the emulsion copolymer comprises styrene acrylic.

[0014] In a tenth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the coating on the nonwoven mat comprises greater than about 75 wt. % of a mineral filler, based on a total dry weight of the coating.

[0015] In an eleventh aspect, a roofing underlayment comprises the roofing underlayment of the tenth aspect, wherein the mineral filler is selected from the group consisting of calcium carbonate, alumina trihydrate, and mixtures thereof.

[0016] In a twelfth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the nonwoven mat further comprises a plurality of PET fibers having a diameter of less than about 8 microns, wherein the plurality of PET fibers are present in an amount of from about 10 wt. % to about 50 wt. % based on a total weight of the fibers in the nonwoven mat and the plurality of glass fibers are present in an amount of from about 50 wt. % to about 90 wt. % based on the total weight of fibers in the nonwoven mat.

[0017] In a thirteenth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the binder comprises a hydrophilic binder.

[0018] In a fourteenth aspect, a roofing underlayment comprises the roofing underlayment of any of the first through twelfth aspects, wherein the binder comprises a crosslinked binder.

[0019] In a fifteenth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the plurality of glass fibers is a first plurality of glass fibers having a diameter of from about 10 microns to about 11 microns, the uncoated nonwoven mat further comprising a second plurality of glass fibers having a diameter of greater than or equal to about 13 microns; and wherein the first plurality of glass fibers are present in the nonwoven mat in an amount of less than or equal to about 50 wt. % based on a total weight of fibers in the nonwoven mat and the second plurality of glass fibers are present in the nonwoven mat in an amount of greater than or equal to about 50 wt. %.

[0020] In a sixteenth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the coating on the nonwoven mat is present on the coated facer at a dry weight of from about 50 g / m2 to about 150 g / m2.

[0021] In a seventeenth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the coating comprises a monolithic polymer film.

[0022] In an eighteenth aspect, a roofing underlayment comprises the roofing underlayment of the seventeenth aspect, wherein the monolithic polymer film comprises a film-forming polymer selected from the group consisting of one or more polyolefins, one or more polyesters, and combinations thereof.

[0023] In a nineteenth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the roofing underlayment is in the form of a rolled product.

[0024] In a twentieth aspect, a roofing underlayment comprises the roofing underlayment of any previous aspect, wherein the asphalt batch layer comprises a non-adhesive asphalt batch composition.

[0025] In a twenty-first aspect, a roofing underlayment comprises the roofing underlayment of any of the first through nineteenth aspects, wherein the asphalt batch layer comprises an adhesive asphalt batch composition.

[0026] According to a twenty-second aspect, a roofing underlayment comprises an asphalt batch layer and a coated facer having a thickness of from about 0.75 mm to about 1.25 mm disposed on the asphalt batch layer. The coated facer comprises an uncoated nonwoven mat comprising a plurality of glass fibers having a diameter of from about 10 microns to about 13 microns and a plurality of PET fibers having a diameter of less than about 8 microns, and a coating on the nonwoven mat. The plurality of glass fibers is present in an amount of from about 50 wt. % to about 90 wt. % based on the total weight of fibers in the nonwoven mat and the plurality of PET fibers is present in an amount of from about 10 wt. % to about 50 wt. % based on the total weight of fibers in the nonwoven mat. The plurality of glass fibers and the plurality of PET fibers are bound together by a hydrophilic binder. The hydrophilic binder comprises less than about 25 wt. % of a total weight of the nonwoven mat. The roofing underlayment has a Gurley stiffness of less than 15,000 g when measured in accordance with ASTM D6125.

[0027] In a twenty-third aspect, a roofing underlayment comprises the roofing underlayment of the twenty-second aspect, wherein the nonwoven mat is impregnated with the coating.

[0028] In a twenty-fourth aspect, a roofing underlayment comprises the roofing underlayment of any of the twenty-second or twenty-third aspects, wherein the coating comprises an emulsion copolymer having a Tg of less than or equal to about 20° C. and further includes at least about 75 wt. % of a mineral filler.

[0029] In a twenty-fifth aspect, a roofing underlayment comprises the roofing underlayment of any of the twenty-second through twenty-fourth aspects, wherein the coating is present on the coated facer at a dry weight of from about 100 g / m2 to about 200 g / m2.

[0030] In a twenty-sixth aspect, a roofing underlayment comprises the roofing underlayment of any of the twenty-second through twenty-fifth aspects, wherein the roofing underlayment is in the form of a rolled product.

[0031] In a twenty-seventh aspect, a roofing underlayment comprises the roofing underlayment of any of the twenty-second through twenty-sixth aspects, wherein the asphalt batch layer comprises a non-adhesive asphalt batch composition.

[0032] In a twenty-eighth aspect, a roofing underlayment comprises the roofing underlayment of any of the twenty-second through twenty-sixth aspects, wherein the asphalt batch layer comprises an adhesive asphalt batch composition.

[0033] In a twenty-ninth aspect, a roofing underlayment comprises the roofing underlayment of any of the twenty-second through twenty-eighth aspects, wherein the roofing underlayment has a Gurley stiffness of from about 5,000 g to about 13,000 g.

[0034] In a thirtieth aspect, a roofing underlayment comprises an asphalt batch layer and a coated facer having a thickness of from about 0.75 mm to about 1.25 mm disposed on the asphalt batch layer. The coated facer comprises an uncoated nonwoven mat comprising a first plurality of glass fibers having a diameter of from about 10 microns to about 11 microns and a second plurality of glass fibers having a diameter of greater than or equal to about 13 microns and a coating on the nonwoven mat. The first plurality of glass fibers is present in an amount of from about 0 wt. % to about 50 wt. % based on the total weight of fibers in the nonwoven mat and the second plurality of glass fibers is present in an amount of from about 50 wt. % to about 100 wt. % based on the total weight of fibers in the nonwoven mat. The first plurality of glass fibers and the second plurality of glass fibers are bound together by a crosslinked binder. The crosslinked binder comprises less than about 25 wt. % of a total weight of the nonwoven mat. The roofing underlayment has a Gurley stiffness of less than 15,000 g when measured in accordance with ASTM D6125.

[0035] In a thirty-first aspect, a roofing underlayment comprises the roofing underlayment of the thirtieth aspect, wherein the coating comprises an emulsion copolymer having a Tg of less than or equal to about 20° C. and further includes at least about 75 wt. % of a mineral filler.

[0036] In a thirty-second aspect, a roofing underlayment comprises the roofing underlayment of the thirtieth or thirty-first aspect, wherein the coating is present on the coated facer at a dry weight of from about 200 g / m2 to about 300 g / m2.

[0037] In a thirty-third aspect, a roofing underlayment comprises the roofing underlayment of any of the thirtieth through thirty-second aspects, wherein the roofing underlayment is in the form of a rolled product.

[0038] In a thirty-fourth aspect, a roofing underlayment comprises the roofing underlayment of any of the thirtieth through thirty-third aspects, wherein the asphalt batch layer comprises a non-adhesive asphalt batch composition.

[0039] In a thirty-fifth aspect, a roofing underlayment comprises the roofing underlayment of any of the thirtieth through thirty-third aspects, wherein the asphalt batch layer comprises an adhesive asphalt batch composition.

[0040] In a thirty-sixth aspect, a roofing underlayment comprises the roofing underlayment of any of the thirtieth through thirty-fifth aspects, wherein the roofing underlayment has a Gurley stiffness of from about 5,000 g to about 13,000 g.

[0041] According to a thirty-seventh aspect, a roofing underlayment comprises an asphalt batch layer and a coated facer having a thickness of from about 0.75 mm to about 1.25 mm disposed on the asphalt batch layer. The coated facer comprises an uncoated nonwoven mat comprising a plurality of glass fibers having a diameter of from about 10 microns to about 13 microns bound together by a crosslinked binder and a coating on the nonwoven mat. The crosslinked binder comprises less than about 25 wt. % of a total weight of the nonwoven mat. The roofing underlayment has a Gurley stiffness of less than 15,000 g when measured in accordance with ASTM D6125.

[0042] In a thirty-eighth aspect, a roofing underlayment comprises the roofing underlayment of the thirty-seventh aspect, wherein the coating comprises a monolithic polymer film layer.

[0043] In a thirty-ninth aspect, a roofing underlayment comprises the roofing underlayment of the thirty-seventh or thirty-eighth aspects, wherein the coating is present on the coated facer at a dry weight of from about 50 g / m2 to about 150 g / m2.

[0044] In a fortieth aspect, a roofing underlayment comprises the roofing underlayment of any of the thirty-seventh through thirty-ninth aspects, wherein the roofing underlayment is in the form of a rolled product.

[0045] In a forty-first aspect, a roofing underlayment comprises the roofing underlayment of any of the thirty-seventh through fortieth aspects, wherein the asphalt batch layer comprises a non-adhesive asphalt batch composition.

[0046] In a forty-second aspect, a roofing underlayment comprises the roofing underlayment of any of the thirty-seventh through fortieth aspects, wherein the asphalt batch layer comprises an adhesive asphalt batch composition.

[0047] In a forty-third aspect, a roofing underlayment comprises the roofing underlayment of any of the thirty-seventh through forty-second aspects, wherein the roofing underlayment has a Gurley stiffness of from about 5,000 g to about 13,000 g.BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The general inventive concepts, as well as illustrative embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the FIGURE in which:

[0049] FIG. 1 illustrates a cross-sectional view of an example coated nonwoven mat of the present disclosure.DETAILED DESCRIPTION

[0050] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. Although other methods and materials similar or equivalent to those described herein may be used in the practice or testing of various aspects, exemplary suitable methods and materials are described below. In case of conflict, the present specification including definitions will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting of the general inventive concepts.

[0051] The terminology as set forth herein is for description of various aspects only and should not be construed as limiting the application as a whole. Unless otherwise specified, “a,”“an,”“the,” and “at least one” are used interchangeably. Furthermore, as used in the description of the application and the appended claims, the singular forms “a,”“an,” and “the” are inclusive of their plural forms, unless contradicted by the context surrounding such.

[0052] Unless otherwise indicated, all numbers expressing quantities used in the specification and claims are to be understood as being modified in all instances by the term “about.” The term “about” means within + / −10% of a value, or in some instances, within + / −5% of a value, and in some instances within + / −1% of a value.

[0053] To the extent that the term “includes” or “including” is used in the description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” Thus, use of the term “or” herein is the inclusive, and not the exclusive use.

[0054] The compositions of the present disclosure can comprise, consist of, or consist essentially of the essential elements of the disclosure described herein, as well as any additional or optional elements described herein, or which are otherwise useful in such compositions.

[0055] All ranges and parameters, including but not limited to percentages, parts, and ratios, disclosed herein are understood to encompass any and all sub-ranges assumed and subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all sub-ranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 1 to 6.1, or 2.3 to 9.4), and to each integer (1, 2, 3, 4, 5, 6, 7, 8, 9, and 10) contained within the range.

[0056] Any combination of method or process steps as used herein may be performed in any order, unless otherwise specified or clearly implied to the contrary by the context in which the referenced combination is made.

[0057] The terms “binder,”“binder composition,” and “curable composition,” as used herein, are used interchangeably and refer to a material that holds one or more components of a nonwoven article together. Those of ordinary skill in the art will understand that a binder composition is often an aqueous mixture or solution of dissolved ingredients that cures to interconnect fibers together.

[0058] The terms “binder solids” or “binder components,” as used herein, are used interchangeably and refer to the functional ingredients of the binder composition prior to addition or mixing with water to form the ultimate binder for application to the inorganic fibers.

[0059] The terms “nonwoven,”“mat,”“veil,” and “facer” are used interchangeably herein and refer to a bound web of fibers.

[0060] While the general inventive concepts are susceptible of aspects in many different forms, there are shown in the drawings, and will be described herein in detail, specific aspects are presented with the understanding that the present disclosure is to be considered as an exemplification of the principles of the general inventive concepts. Accordingly, the general inventive concepts are not intended to be limited to the specific aspects illustrated herein.

[0061] The general inventive concepts relate to roofing products including an asphalt batch layer and a coated facer. When the coated facer is disposed on the asphalt batch layer, the coated facer can reduce or even prevent the asphalt batch layer from penetrating through the facer to the top surface of the roofing product. By reducing exposure of the asphalt on the surface of the roofing product, alternative batch compositions can be utilized in the roofing products without concern as to the stickiness of the asphalt batch at high temperatures. Such alternative batch compositions include both asphalt and non-asphalt batch compositions, which may include non-asphaltic adhesives such as butyl-based adhesives, acrylic-based adhesives, and the like. Although the present disclosure will refer to an asphalt batch composition, it should be appreciated that such non-asphalt-based batch compositions may be used in the alternative or in combination with the asphalt batch. Additionally, the roofing product may exhibit improved saturation consistency. Additional features and advantages may be provided in accordance with the various aspects disclosed herein.

[0062] An exemplary roofing product is illustrated in FIG. 1. In general, the roofing product may be, for example, a roofing underlayment 100 that includes an asphalt batch layer 20, and a coated facer 30 disposed on the asphalt batch layer.Asphalt Batch Layer

[0063] The asphalt batch layer 20 of the roofing underlayment 100 may be an adhesive or non-adhesive asphalt batch layer. As used herein the term “asphalt” is meant to include asphalts produced from petroleum refining, including residua from atmospheric distillation, from vacuum distillation, and from solvent de-asphalting units, recycled asphalt streams, such as re-refined motor oil bottoms. Mixtures of different asphalts can also be used. The asphalt may also comprise natural bitumen, such as the products extracted from the oil sands in Alberta or asphalts derived from oil sands by various refinery processes. In addition to asphalt, the asphalt batch layer can further include polymers, fillers, or other components suitable for modifying the properties of the asphalt batch layer.

[0064] The asphalt may comprise any type of asphalt known in the art, including, for example, virgin asphalt, recycled or reclaimed asphalt, paving grade asphalt, oxidized asphalt, partially oxidized asphalt, non-oxidized asphalt, polymer modified asphalt, or mixtures thereof. By “paving grade asphalt,” as used herein, is meant a performance grade asphalt according to AASH20 17320-17 that has a softening point within the range of about 60° F. to about 130° F. and a penetration value of at least about 25 dmm. Any suitable paving-grade asphalt(s) can be used, for example paving asphalts which meet the PG 64-22 specifications (AASHTO M320). PG 64-22 is the most common paving specification in the United States. Paving asphalts were previously graded by viscosity and a common asphalt that is similar to the PG 64-22 grade asphalt and also usable in this method, is the old AC20 grade asphalt (ASTM D 3381). Other examples of suitable paving-grade asphalts include PG 67-22, PG 70-22, PG 58-22, PG 58-28, PG 58-22, PG 70-16, PG 70-10, PG 67-10, pen grade 40 / 50, pen grade 60 / 70, pen grade 85 / 100, pen grade 120 / 150, AR4000, AR8000, and AC / 30 grade.

[0065] In some aspects, the asphalt comprises a polymer modified asphalt. The polymer modified asphalt may comprise any suitable asphalt and any suitable polymer, or any suitable mixture of different asphalts and / or different polymers. The polymer may include, for example, an elastomeric radial or linear polymer. In some aspects, the polymer additive comprises a copolymer such as a linear or radial copolymer. In some aspects, the polymer additive comprises a polyolefin, such as, for example, polypropylene, polyethylene, polybutene, and the like. Exemplary polymers include one or more of atactic polypropylene (APP), isotactic polypropylene (IPP), styrene-butadiene block copolymer (SBS), chloroprene rubber (CR), amorphous polyolefin, styrene butadiene rubber (SBR) latex, natural and reclaimed rubbers, butadiene rubber (BR), acrylonitrile-butadiene rubber (NBR), isoprene rubber (IR), styrene-polyisoprene (SI), butyl rubber, ethylene propylene rubber (EPR), ethylene propylene diene monomer rubber (EPDM), polyisobutylene (PIB), chlorinated polyethylene (CPE), styrene / isoprene copolymer, polyacrylate, epoxy modified acrylate copolymer, styrene ethylene-butylene-styrene (SEBS), hydrogenated SBS, polychloroprene. and vinylacetate / polyethylene (EVA). In other exemplary embodiments, the polymer additive comprises a radial polymer or a combination of linear and radial polymers.

[0066] In various aspects, the coated facer 30 reduces penetration of the asphalt batch layer 20 through the coated facer 30, thereby enabling a broader range of asphalt batch compositions to be utilized in the roofing underlayment 100 as compared to conventional underlayments.

[0067] In certain aspects, the asphalt batch layer 20 has a total thickness of 0.25 mm to 2.3 mm, including a total thickness of 0.35 mm to 2.1 mm, a total thickness of 0.50 mm to 1.95 mm, a total thickness of 0.55 mm to 1.85 mm, a total thickness of 0.60 mm to 1.75 mm, a total thickness of 0.40 mm to 2.3 mm, a total thickness of 0.40 mm to 2.1 mm, a total thickness of 0.40 mm to 1.75 mm, a total thickness of 0.40 mm to 1.50 mm, a total thickness of 0.40 mm to 1.25 mm, a total thickness of 0.40 mm to 1.00 mm, a total thickness of 0.40 mm to 0.74 mm, and a total thickness of 0.75 mm to 1.5 mm, including all subranges and endpoints therebetween.

[0068] The roofing product may include one or more asphalt batch layers. For example, the roofing product may include a single asphalt batch layer, as shown in FIG. 1, or two or more asphalt batch layers may be present in the roofing product. It should be appreciated that the various asphalt batch layers can be formed from the same asphalt batch compositions or different compositions. Moreover, in aspects in which the asphalt batch layer comprises an adhesive asphalt batch layer, the roofing product may further include a release liner. When included, the release liner may be removed prior to installation of the roofing product such that the roofing product can be adhered to a surface.Coated Facer

[0069] A coated facer 30 is disposed on the asphalt batch layer 20. When utilized in a roofing underlayment, the coated facer 30 may eliminate the need to include a separate reinforcement layer, as the coated facer may provide sufficient strength to the roofing underlayment, as will be discussed in greater detail hereinbelow. The coated facer may also form a walkable surface, enabling roofers to walk on the roofing underlayment without sticking to the roof. In various aspects disclosed herein, the coated facer forms an “upper surface” or an “exposed surface” when installed on a roof, while the asphalt batch layer forms a “lower surface.” For example, the roofing underlayment is positioned such the asphalt batch layer is between the coated facer and the roof deck.

[0070] In general, the coated facer 30 comprises an uncoated nonwoven mat, sometimes referred to herein as a nonwoven base layer or precursor layer, and a coating on the nonwoven mat. The uncoated nonwoven mat comprises a first surface and an opposing second surface. The uncoated nonwoven mat of the present disclosure may be formed by a variety of processes, including wet-laid processes and dry-laid processes. In certain aspects, the uncoated nonwoven mat is formed by a wet-laid process, which involves forming an aqueous slurry of discrete fibers in a mix tank filled with various components (sometimes referred to as white water), such as water, surfactants, viscosity modifiers, defoaming agents, lubricants, biocides, and / or other chemical agents. Agitation of the white water promotes dispersion of the fibers (e.g., chopped glass fibers) therein, to form a chopped glass fiber slurry. It is desirable that the slurry is agitated sufficiently to achieve a uniform or nearly uniform dispersion of the fibers.

[0071] The aqueous fiber dispersion or slurry may then be processed into a wet-laid mat according to any number of conventional methods known in the art. For example, the aqueous fiber slurry is deposited onto a moving screen or conveyor, on which the majority of the water drains through, leaving a randomly oriented fiber web. The fiber web may be further dried by a vacuum slot or other drying means. A binder composition may then be applied to the fiber web in a conventional manner, such as by curtain coating, spraying, twin wire dip bath, two roll padder, and the like. Water and excess binder composition may then be removed by a vacuum or other water removal means.

[0072] Finally, the fiber product may be dried and cured in one or more ovens. An exemplary temperature range for drying is from 350° F. (177° C.) to 600° F. (316° C.). The dried and cured product is the finished nonwoven base layer.

[0073] The nonwoven base layer of the present disclosure may be formed from a variety of materials. In general, the nonwoven base layer comprises a plurality of fibers and a binder composition that binds the fibers together. Exemplary fibers for forming the nonwoven base layer include, but are not limited to, glass fibers, synthetic fibers (e.g., polyester fibers, polyethylene fibers, polypropylene fibers, polyethylene terephthalate (PET) fibers, polyamide fibers, aramid fibers, polyaramid fibers), mineral fibers, carbon fibers, ceramic fibers, natural fibers (e.g., cellulose fibers, cotton fibers, jute fibers, bamboo fibers, ramie fibers, bagasse fibers, hemp fibers, coir fibers, linen fibers, kenaf fibers, sisal fibers, flax fibers, henequen fibers), or a blend of two or more different types of fibers. For example, the nonwoven base layer may comprise a blend of glass fibers and polymer fibers, such as PET fibers.

[0074] In aspects, the nonwoven base layer comprises glass fibers. The glass fibers can be made from any type of glass. Exemplary glass fibers include, but are not limited to, A-type glass fibers, C-type glass fibers, E-type glass fibers, S-type glass fibers, ECR-type glass fibers (e.g., Advantex® glass fibers commercially available from Owens Corning of Toledo, Ohio), Hiper-Tex® glass fibers, high-performance (i.e., high modulus and / or tensile strength, including H-glass and H2 glass commercially available from Owens Corning) glass fibers, wool glass fibers, and combinations thereof.

[0075] The fibers used to form the nonwoven base layer may have a variety of fiber diameters. In some aspects, the fibers used to form the nonwoven base layer have an average fiber diameter that is greater than or equal to about 13 microns. For example, the fibers may have an average fiber diameter of 13 microns to 20 microns, 13 microns to 18 microns, 13 microns to 16 microns, 13 microns to 15 microns, 14 microns to 20 microns, 14 microns to 18 microns, 14 microns to 16 microns, 14 microns to 15 microns, 15 microns to 20 microns, 15 microns to 18 microns, or even 15 microns to 16 microns, including any and all ranges and sub-ranges therein.

[0076] In aspects, the fibers used to form the nonwoven base layer have an average fiber diameter of less than or equal to about 13 microns or less than or equal to about 11 microns. For example, the fibers may have an average fiber diameter of 3 microns to 13 microns, 6 microns to 13 microns, 8 microns to 13 microns, 10 microns to 13 microns, 3 microns to 12 microns, 6 microns to 12 microns, 8 microns to 12 microns, 10 microns to 13 microns, 3 microns to 11 microns, 6 microns to 11 microns, 8 microns to 11 microns, 10 microns to 11 microns, 3 microns to 10 microns, 6 microns to 10 microns, or even 8 microns to 10 microns, including any and all ranges and sub-ranges therein. It is also contemplated that a blend of fibers having different fiber diameters, such as a blend of smaller diameter fibers (e.g., average fiber diameter of 5.5 microns to 9 microns) and larger diameter fibers (e.g., average fiber diameter of 10 microns to 13 microns), may be used to form the nonwoven base layer.

[0077] The fibers used to form the nonwoven base layer may also have a variety of fiber lengths. In aspects, the fibers used to form the nonwoven base layer have an average fiber length of 6.35 mm to 50.8 mm, 12.7 mm to 38.1 mm, or 17.05 mm to 23.4 mm, including any and all ranges and subranges therein. It is also contemplated that a blend of fibers having different fiber lengths, such as a blend of shorter fibers (e.g., average fiber length of 6.35 mm to 12.7 mm) and longer fibers (e.g., average fiber length of 17.05 mm to 23.4 mm), may be used to form the nonwoven base layer.

[0078] The nonwoven base layer may comprise a blend of different fiber types and sizes. For example, the nonwoven base layer may comprise a plurality of glass fibers having an average diameter of from about 10 microns to about 13 microns and a plurality of polymer fibers having an average diameter of less than about 8 microns. In aspects, the polymer fibers may be PET fibers. In such aspects, the plurality of glass fibers may be present in an amount of from about 50 wt. % to about 90 wt. %, based on a total weight of fibers in the nonwoven mat, and the PET fibers may be present in an amount of from about 10 wt. % to about 50 wt. %, based on the total weight of fibers in the nonwoven mat. In some such aspects, the PET fibers and the glass fibers are the only fibers in the nonwoven mat.

[0079] In some aspects, the nonwoven base layer may comprise a blend of different sizes. For example, the nonwoven base layer may comprise a first plurality of glass fibers having an average diameter of from about 10 microns to about 11 microns and a second plurality of glass fibers having an average diameter of greater than or equal to about 13 microns. In such aspects, the first plurality of glass fibers may be present in an amount of less than or equal to about 50 wt. %, based on a total weight of fibers in the nonwoven mat, and the second plurality of glass fibers may be present in an amount of greater than or equal to about 50 wt. %, based on the total weight of fibers in the nonwoven mat. In some such aspects, the glass fibers are the only fibers in the nonwoven mat.

[0080] As mentioned above, the nonwoven base layer also includes a binder composition to bind the fibers of the nonwoven base layer together. In various aspects, the binder composition generally comprises a binder resin material, a coupling agent, a wetting agent, and one or more optional additives. In any of the aspects disclosed herein, the binder may comprise a crosslinked binder. In aspects, the binder may comprise a hydrophilic binder.

[0081] The nonwoven base layer may comprise from 1% to 30% by weight binder composition, based on the total weight of the nonwoven base layer. For example, the nonwoven base layer may comprise less than about 30% by weight binder composition, less than about 25% by weight binder composition, or less than about 20% by weight binder composition. Thus, the nonwoven base layer may include from 5% to 27%, from 10% to 25%, or from 15% to 23% by weight binder composition, based on the total weight of the nonwoven base layer. As one of skill in the art will appreciate, the amount of binder composition used to form the nonwoven base layer may be determined by measuring loss on ignition.

[0082] The binder resin may be a thermoset material, a thermoplastic material, or a mixture of a thermoset material and a thermoplastic material. The thermoset material may comprise, for example, an acrylic material, a urea formaldehyde material, or a combination of the two materials. In some aspects, the acrylic material is polyacrylic acid, such as low molecular weight polyacrylic acid with a weight average molecular weight at or below 10,000 Daltons. The thermoset material, once cross-linked under proper curing conditions, provides good tensile performance and solvent resistance, helping maintain mat integrity in different applications. In aspects, the thermoplastic material may include any thermoplastic material having a low glass transition temperature (e.g., below −15° C.), for example, ethylene vinyl acetate.

[0083] In any of the aspects disclosed herein, the binder resin may be present in the binder composition in an amount of 90% to 99% based on the total weight of the binder composition. In aspects, the binder resin may be present in the binder composition in an amount of 97% to 99% based on the total weight of the binder composition.

[0084] The binder composition may further include a coupling agent. It is to be appreciated that the coupling agents described herein are exemplary in nature, and any suitable coupling agent known to those of ordinary skill in the art may be utilized in any of the exemplary aspects described or otherwise suggested herein. In aspects, the coupling agent, or coupling agents, may be present in the binder composition in an amount of 0.05% to 10%, 0.1% to 3%, or 0.15% to 0.5% based on the total weight of the binder composition.

[0085] In aspects, at least one of the coupling agents is a silane coupling agent. Suitable silane coupling agents may include silanes containing one or more nitrogen atoms that have one or more functional groups such as amine (primary, secondary, tertiary, and quaternary), amino, imino, amido, imido, ureido, or isocyanato. Suitable silane coupling agents may also include, but are not limited to, aminosilanes, silane esters, vinyl silanes, methacryloxy silanes, epoxy silanes, sulfur silanes, ureido silanes, and isocyanato silanes. Specific, non-limiting examples of silane coupling agents for use in the instant invention include γ-methacryloxypropyl-trimethoxysilane (A-174), γ-aminopropyltriethoxysilane (A-1100), n-phenyl-γ-aminopropyltrimethoxysilane (Y-9669), n-trimethoxy-silyl-propyl-ethylene-diamine (A-1120), methyl-trichlorosilane (A-154), γ-chloropropyl-trimethoxy-silane (A-143), vinyl-triacetoxysilane (A-188), and methyltrimethoxysilane (A-1630).

[0086] In various aspects, the binder composition may further include a wetting agent or surfactant. The wetting agent can improve the wetting behavior of the binder composition to allow quick wicking of the binder composition into the nonwoven base layer. According to various aspects, the wetting agent includes one or more ethoxylated groups. By way of example and not limitation, the wetting agent may be selected from the group consisting of ethoxylated fatty acids, such as ethoxylated polyethylene glycol (PEG), ethoxylated polyols with hydrophobic tails, and the like. Commercially available examples of wetting agents that may be well-suited for use in the binder compositions include PEG 400 MO (available from Pulcra), PEG 400 ML (available from Pulcra), DYNOL™ 607 (available from Evonik), and SURFYNOL® 465 (available from Evonik). Other wetting agents known and used in the art may be used.

[0087] The wetting agent may be included in the binder composition in an amount of from about 0.05 wt. % to about 2 wt. %, based on a total weight of the binder composition. For example, the wetting agent may be included in the binder composition in an amount of from about 0.05 wt. % to about 2 wt. %, from about 0.1 wt. % to about 2 wt. %, from about 0.5 wt. % to about 2 wt. %, from about 0.7 wt. % to about 2 wt. %, from about 1 wt. % to about 2 wt. %, from about 1.2 wt. % to about 2 wt. %, from about 1.5 wt. % to about 2 wt. %, from about 1.7 wt. % to about 2 wt. %, from about 0.05 wt. % to about 1.7 wt. %, from about 0.1 wt. % to about 1.7 wt. %, from about 0.5 wt. % to about 1.7 wt. %, from about 0.7 wt. % to about 1.7 wt. %, from about 1 wt. % to about 1.7 wt. %, from about 1.2 wt. % to about 1.7 wt. %, from about 1.5 wt. % to about 1.7 wt. %, from about 0.05 wt. % to about 1.5 wt. %, from about 0.1 wt. % to about 1.5 wt. %, from about 0.5 wt. % to about 1.5 wt. %, from about 0.7 wt. % to about 1.5 wt. %, from about 1 wt. % to about 1.5 wt. %, from about 1.2 wt. % to about 1.5 wt. %, from about 0.05 wt. % to about 1.2 wt. %, from about 0.1 wt. % to about 1.2 wt. %, from about 0.5 wt. % to about 1.2 wt. %, from about 0.7 wt. % to about 1.2 wt. %, from about 1 wt. % to about 1.2 wt. %, from about 0.05 wt. % to about 1 wt. %, from about 0.1 wt. % to about 1 wt. %, from about 0.5 wt. % to about 1 wt. %, or even from about 0.7 wt. % to about 1 wt. %, including any and all ranges and sub-ranges included therein.

[0088] The binder composition used to form the nonwoven base layer of the present disclosure may optionally include additional components such as, for example, dyes, oils, fillers, colorants, aqueous dispersions, UV stabilizers, lubricants, wetting agents, surfactants, viscosity modifiers, and / or antistatic agents. Such additives may be included in the binder composition in an amount of 0% percent to 10% based on the total weight of the binder composition.

[0089] In aspects, the binder composition used to form the nonwoven base layer of the present disclosure may include water to dissolve or disperse the functional components for application onto the fibers. Water may be added in an amount sufficient to dilute the aqueous binder composition to a viscosity that is suitable for its application to the fibers.

[0090] The nonwoven base layer of the present disclosure may have a wide range of basis weights (uncoated). In various aspects, the nonwoven base layer may have an uncoated basis weight of less than or equal to about 100 g / m2. For example, the nonwoven base layer may be an uncoated basis weight of 25 g / m2 to 100 g / m2, 30 g / m2 to 100 g / m2, 35 g / m2 to 100 g / m2, 40 g / m2 to 100 g / m2, 45 g / m2 to 100 g / m2, 50 g / m2 to 100 g / m2, 25 g / m2 to 75 g / m2, 30 g / m2 to 75 g / m2, 35 g / m2 to 75 g / m2, 40 g / m2 to 75 g / m2, 45 g / m2 to 75 g / m2, 50 g / m2 to 75 g / m2, 25 g / m2 to 60 g / m2, 30 g / m2 to 60 g / m2, 35 g / m2 to 60 g / m2, 40 g / m2 to 60 g / m2, 45 g / m2 to 60 g / m2, or 50 g / m2 to 60 g / m2, including any and all ranges and sub-ranges therein.

[0091] The nonwoven base layer of the present disclosure may also have a variety of thicknesses. In aspects, the nonwoven base layer has a thickness of 0.25 mm to 2 mm, 0.3 mm to 0.7 mm, 0.3 mm to 0.6 mm, 0.75 mm to 1.25 mm, 0.75 mm to 2 mm, 1 mm to 2 mm, 1.25 mm to 1.9 mm, or even 1.5 mm to 1.8 mm, including any and all ranges and sub-ranges therein.Coating Layer

[0092] As described above, the coated facer 30 includes a coating layer comprising a coating composition adhered to the first surface of the nonwoven base layer. The coating layer may be applied to the first surface of the nonwoven base layer using a coating process, as described in further detail below.

[0093] The coating layer extends at least partially into the nonwoven base layer (i.e., partially through a thickness of the nonwoven base layer measured from the first surface to the second surface). For example, the coating layer may extend into the nonwoven base layer in an amount of up to 50% of the thickness of nonwoven base layer, such as from 10% to 50% or from 5% to 25% of the thickness of nonwoven base layer (measured from the first surface to the second surface). When the coating layer only partially extends into the nonwoven base layer, he second surface of the nonwoven base layer is free of a coating composition. It should be appreciated that the thickness to which the coating layer extends into the nonwoven base layer may vary somewhat along the width and / or length of the nonwoven base layer.

[0094] Alternatively, the nonwoven base layer may be “impregnated” fully with the coating, such that the coating penetrates substantially through (e.g., greater than about 50% of the thickness of the mat, greater than about 60% of the thickness of the mat, greater than about 75% of the thickness of the mat, greater than about 80% of the thickness of the mat, greater than about 90% of the thickness of the mat, greater than about 95% of the thickness of the mat, or even greater than about 99% of the thickness of the mat) or even fully through (100%) the thickness of the mat.

[0095] The coating layer comprises a coating composition that includes a polymeric binder component and optionally a filler component (or “filler”). Suitable polymeric binders may include latex binders. Exemplary polymeric binders include one or more polymers selected from acrylic latex, styrene-butadiene-rubber (SBR), styrene-butadiene-styrene (SBS), ethylene-vinyl-chloride (EVCl), poly-vinylidene-chloride (PVdC), modified poly-vinyl-chloride (PVC), poly-vinyl-alcohol (PVOH), ethylene-vinyl-acetate (EVA), and poly-vinyl-acetate (PVA). In one or more aspects provided herein, the polymeric binder is a polymer or copolymer of acrylic acid, methacrylic acid, acrylates, methacrylates, acrylonitrile, vinyl versatate, styrene, and combinations thereof. In some aspects, the coating composition comprises an emulsion copolymer. In some aspects, the coating includes a styrene acrylic binder.

[0096] The polymeric binder component may be an emulsion copolymer having a Tg of less than about 25° C. For example, the emulsion copolymer may have a Tg of less than about 25° C., less than about 20° C., less than about 15° C., less than about 10° C., less than about 5° C., less than about 0° C., less than about −5° C., less than about −10° C., or even less than about −15° C.

[0097] The amount of polymeric binder in the coating composition may be described as a percent weight of coating binder based on the weight of the total solids (the non-water portion of the coating composition) in the coating composition. The coating composition may include, for example, about 2% to about 20% polymeric binder, about 4% to about 15% polymeric binder, about 5% to about 10% polymeric binder, or even about 5.5% to about 8.0% polymeric binder, based on the weight of the total solids in the coating composition.

[0098] Exemplary optional fillers suitable for making coated mats include, but are not limited to, ground limestone (calcium carbonate), clay (kaolin), sand, mica, talc, gypsum (calcium sulfate dihydrate), aluminum trihydrate (ATH), vermiculite, antimony oxide, micronized rubber, or a combination of any two or more of these substances. In aspects, the filler may be a mineral filler selected from the group consisting of calcium carbonate, alumina trihydrate, and mixtures thereof. The amount of filler in the coating composition may be described as a percent weight of filler based on the weight of the total solids (the non-water portion of the coating composition) in the coating composition. The coating composition may include, for example, about 65% to about 99% filler, about 75% to about 98% filler, about 80% to about 97% filler, or about 85% to about 95% filler, based on the weight of the total solids in the coating composition, including any and all ranges and sub-ranges therein. In some aspects, the coating composition may include greater than about 75 wt. % filler, based on a total dry weight of the coating. However, it should be noted that the use of filler is optional, and, accordingly, in any of the aspects disclosed herein, the coating composition may not include filler.

[0099] The coating composition may be an aqueous coating composition. Accordingly, the amount of water in the coating composition may be described as a percent weight of water based on the weight of the total solids (the non-water portion of the coating composition) in the coating composition. In aspects, the coating composition may include about 15% to about 60% water, about 20% to about 50% water, or about 30% to about 40% water, based on the weight of the total solids in the coating composition.

[0100] The coating may be a monolithic polymer film. The monolithic polymer film generally comprises at least one film-forming polymer. Film-forming polymers include, by way of example and not limitation, polyolefins, polyesters, and combinations thereof.

[0101] The coating composition may optionally include one or more additives. Exemplary additives include, but are not limited to, fire retardants, dyes, pigments, colorants, UV stabilizers, anti-static agents, film forming agents, dispersants, defoamers, biocides, viscosity modifiers, and so forth. Exemplary dispersants include sodium polyacrylate, ammonium polyacrylate, sodium salt of an acrylic copolymer, potassium salt of an acrylic copolymer, ammonium salt of an acrylic copolymer, polyalkoxylated copolymer, nonionic copolymers, and mixtures thereof. In any of the aspects disclosed herein, the dispersant may be present in the coating composition in an amount from 0.01% to about 2.0%, or from about 0.05% to about 1.5%, or from about 0.08% to about 1.0%, or from about 0.1% to about 0.8%, based on the weight of the total solids in the coating composition.

[0102] The coating composition may also have a variety of viscosities. For example, the coating composition may have a viscosity of 250 cP (centipoise) to 25,000 cP, including, for example, viscosities of 500 cP to 20,000 cP, 1000 cP to 15,000 cP, 5000 cP to 10,000 cP, and 7000 cP to 8,000 cP, including all ranges and sub-ranges therein.

[0103] The coating may be applied in a wide range of coat weights. The coating may have a coat weight of from about 25 g / m2 to about 400 g / m2, including, for example from about 30 g / m2 to about 400 g / m2, from about 30 g / m2 to about 300 g / m2, from about 30 g / m2 to about 200 g / m2, from about 30 g / m2 to about 150 g / m2, from about 30 g / m2 to about 100 g / m2, from about 40 g / m2 to about 400 g / m2, from about 40 g / m2 to about 300 g / m2, from about 40 g / m2 to about 200 g / m2, from about 40 g / m2 to about 150 g / m2, from about 40 g / m2 to about 100 g / m2, from about 50 g / m2 to about 400 g / m2, from about 50 g / m2 to about 300 g / m2, from about 50 g / m2 to about 200 g / m2, from about 50 g / m2 to about 150 g / m2, from about 50 g / m2 to about 100 g / m2, from about 50 g / m2 to about 80 g / m2, from about 65 g / m2 to about 400 g / m2, from about 65 g / m2 to about 300 g / m2, from about 65 g / m2 to about 200 g / m2, from about 65 g / m2 to about 150 g / m2, from about 65 g / m2 to about 100 g / m2, from about 100 g / m2 to about 400 g / m2, from about 100 g / m2 to about 300 g / m2, from about 100 g / m2 to about 200 g / m2, from about 200 g / m2 to about 400 g / m2, or from about 200 g / m2 to about 300 g / m2, including any and all ranges and sub-ranges therein. The coat weight is reported on a dry weight basis.

[0104] The coating layer may have a variety of thicknesses. In any of the aspects disclosed herein, the coating layer may have a thickness of 1 micron to 500 microns, including, for example, a thickness of 5 microns to 250 microns, 10 microns to 200 microns, and 50 microns to 100 microns, including any and all ranges and sub-ranges therein.

[0105] The coating composition may be deposited onto the nonwoven base layer. The coating composition may be deposited using a variety of methods. The coating composition may be deposited using methods including knife over plate via dipping bath or knife over roll via dipping bath. Other suitable methods include, but are not limited to, waterfall coating, curtain coating, fountain coating, immersion or impregnation coating, brush coating, and spray coating.

[0106] The amount of binder composition present in the coated nonwoven mats may be determined by measuring loss on ignition (LOI). The coated nonwoven mat may have a wide range of LOI and can vary depending on the LOI of the uncoated nonwoven mat as well as the LOI attributable to the coating. The uncoated nonwoven base layer may have an LOI of 5%-25%, such as, for example, 6%-20%, or 7%-15%. Accordingly, the coated nonwoven mat may have a total LOI of 10%-50%, including, for example, an LOI of 12%-30%, or 15%-20%.

[0107] It should be appreciated that the nonwoven mats and coatings can be combined in a variety of ways to achieve a coated nonwoven mat that is suitable for use in roofing products, and in particular, in roofing underlayments. For example, the nonwoven mat may be comprised of a blend of fibers in which 10-50 wt. % of the fibers are PET fibers that are less than 8 μm in diameter and 50-90 wt. % of the fibers are glass fibers having a diameter of from about 10 μm to about 13 μm. The nonwoven mat is bound by a hydrophilic binder that comprises less than about 25 wt. % of the mat weight, and the uncoated nonwoven mat has a basis weight of less than or equal to about 100 g / m2. The nonwoven mat is impregnated with a coating that contributes a dry weight of 100-200 g / m2. The coating is comprised of an emulsion copolymer (e.g., styrene acrylic) having a Tg of less than about 20° C. and further contains greater than or equal to about 75 wt. % of a mineral filler (e.g., calcium carbonate, alumina trihydrate, or a combination thereof). The coated nonwoven mat has a thickness of about 1 mm.

[0108] As another example, the nonwoven mat may be comprised of a blend of fibers in which 0-50 wt. % of the fibers are glass fibers that have a diameter of from about 10 μm to 11 μm and at least 50 wt. % of the fibers are glass fibers having a diameter of greater than or equal to about 13 μm. The nonwoven mat is bound by a crosslinked binder that comprises less than about 25 wt. % of the mat weight, and the uncoated nonwoven mat has a basis weight of less than or equal to about 100 g / m2. The nonwoven mat is coated with a coating that contributes a dry weight of 200-300 g / m2. The coating is comprised of an emulsion copolymer (e.g., styrene acrylic) having a Tg of less than about 20° C. and further contains greater than or equal to about 75 wt. % of a mineral filler (e.g., calcium carbonate, alumina trihydrate, or a combination thereof). The coated nonwoven mat has a thickness of about 1 mm.

[0109] As yet another example, the nonwoven mat may be comprised of a blend of glass fibers that have a diameter of from about 10 μm to 13 μm. The nonwoven mat is bound by a crosslinked binder that comprises less than about 25 wt. % of the mat weight, and the uncoated nonwoven mat has a basis weight of less than or equal to about 100 g / m2. The nonwoven mat is coated with a coating that contributes a dry weight of 50-150 g / m2. The coating is comprised of a monolithic polymer film (e.g., polyolefins or polyesters). The coated nonwoven mat has a thickness of about 1 mm.

[0110] The coated nonwoven mat can be prepared according to any suitable method known and used in the art. For example, the method may comprise: a) depositing an aqueous fiber slurry onto a processing line to form a wet laid mat having a first major surface and a second major surface; b) applying a binder composition to at least one of the first major surface and the second major surface of the wet laid mat; and c) heating the wet laid mat to cure the binder composition, thereby forming the nonwoven mat. In various aspects, the fibers are provided to a conveying apparatus such as a conveyor by a storage container for delivery to a mixing tank that contains various surfactants, viscosity modifiers, defoaming agents, and / or other chemical agents with agitation to disperse the fibers and to form an aqueous fiber slurry.

[0111] The fiber slurry is deposited onto a processing line to form a wet laid mat having a first major surface and a second major surface. The processing line may be any suitable formation apparatus capable of forming a wet laid mat including, but not limited to, a moving screen or forming wire on an inclined wire forming machine, wire cylinders, Fourdrinier machines, Stevens former, Roto former, Inver former, or Venti former machines. While on the processing line, a substantial portion of the water from the fiber slurry is removed to form a wet laid mat of enmeshed, randomly oriented fibers. The water may be removed from the wet laid mat by a conventional vacuum or air suction system.

[0112] The binder composition may be applied to the wet laid mat using a suitable application method including, but not limited to, a binder wire, a spray applicator, a curtain coater, and a Foulard applicator.

[0113] After the binder composition is applied to the wet laid mat, the wet laid mat is heated to remove any residual water and cure the binder composition, thereby forming the nonwoven mat. The step of heating the wet laid mat may be accomplished using any known heating or drying method. Suitable heating methods that may be used in the method of the present disclosure include, but are not limited to, a rotary / thru air dryer or oven, a heated drum dryer, an infrared heating source, a hot air blower, and a microwave emitting source. In aspects, the heating step comprises exposing the wet laid mat having the binder composition applied thereto to a temperature of 150° C. to 250° C. for a time period of up to 45 seconds.

[0114] In some aspects, the method of making the coated nonwoven mat includes applying a coating layer including a coating composition to at least one of the first surface or the second surface of the nonwoven base layer to form a coated nonwoven mat. The coating composition may be applied to the nonwoven mat by conventional coating techniques such as spray coating, Meyer rod coating, slot die coating, blade / knife coating, forward roll coating, reverse roll coating, gravure coating, or curtain coating. The method of making the coated nonwoven mat also includes heating the coated nonwoven mat, thereby forming a finished coated nonwoven mat. The step of heating the coated nonwoven mat can take place in one or more ovens. An exemplary temperature range for drying is from 350° F. (177° C.) to 600° F. (316° C.). The step of heating the coated nonwoven mat can also include melting the coating composition onto the nonwoven base layer, allowing the coating composition to flow and create a more tightly sealed coating with lower porosity.Roofing Materials

[0115] The coated nonwoven mat is disposed on an asphalt batch layer that may at least partially extend into the coated facer to form a roofing product, such as a roofing underlayment. In particular, the selection of coated nonwoven mats having specific properties provides the roofing underlayments with properties that are particularly desirable, including traction, flexibility, low asphalt bleed through / sticking, reduced cracking and increased strength. For example, flexibility is important in roofing underlayment applications because roofing installers need to apply the roofing underlayment in valleys and other tight corners, while traction (especially wet traction) is important because the installers walk on the roofing underlayment during installation of shingles and other roof coverings. However, it is also important that the roofing underlayment is not sticky or tacky, which enables the installers to walk on the underlayment in high temperatures and unroll the material without it sticking. In various aspects, the roofing underlayment does not include (e.g., is free of) granules on the exposed surface of the coated facer, which can come off and reduce traction over time. The coated facer also prevents the asphalt batch layer from becoming exposed, which can get hot and sticky in high temperatures. Moreover, the flexibility further enables the roofing product to be manufactured and transported as a rolled product.

[0116] The traction of the roofing underlayment may be characterized by the SATRA wet and dry tests, measured in accordance with a modified ASTM F2913 standard (samples were not prewashed and were adhered to an OSB substrate; testing was done in “flat” mode with 300 N normal force; average of the first 5 slips is reported; shoe was a men's size 11 commercially available “Authentic Shoe” from Vans). Under dry conditions, the roofing underlayment exhibits a coefficient of friction of greater than or equal to about 1.1. For example, the dry coefficient of friction may be greater than or equal to about 1.1, greater than or equal to about 1.2, greater than or equal to about 1.3, greater than or equal to about 1.4, greater than or equal to about 1.5, or even greater than or equal to about 1.6. Under wet conditions, the roofing underlayment exhibits a coefficient of friction of greater than or equal to about 0.7. For example, the wet coefficient of friction may be greater than or equal to about 0.7, greater than or equal to about 0.8, greater than or equal to about 0.9, or even greater than or equal to about 1.0.

[0117] The strength of the roofing underlayment may be characterized by tensile strength, notched tear strength, and low temperature flex, each measured in accordance with ASTM D1970 standard. In any of the aspects disclosed herein, the roofing underlayment passes the low temperature flex test set forth in ASTM D1970. In any of the aspects disclosed herein, the roofing underlayment exhibits a tensile strength of from about 40 lbf to about 70 lbf. For example, the roofing underlayment may exhibit a tensile strength of from about 40 lbf to about 70 lbf, from about 45 lbf to about 70 lbf, from about 50 lbf to about 70 lbf, from about 55 lbf to about 70 lbf, from about 60 lbf to about 70 lbf, from about 40 lbf to about 65 lbf, from about 45 lbf to about 65 lbf, from about 50 lbf to about 65 lbf, from about 55 lbf to about 65 lbf, from about 60 lbf to about 65 lbf, from about 40 lbf to about 60 lbf, from about 45 lbf to about 60 lbf, from about 50 lbf to about 60 lbf, from about 55 lbf to about 60 lbf, from about 40 lbf to about 55 lbf, from about 45 lbf to about 55 lbf, or from about 50 lbf to about 55 lbf, including any and all ranges and subranges including any of these endpoints.

[0118] The roofing underlayment may exhibit a notched tear strength of greater than or equal to about 55 lbf, greater than or equal to about 60 lbf, greater than or equal to about 65 lbf, or even greater than or equal to about 70 lbf. In any of the aspects disclosed herein, the roofing underlayment exhibits a notched tear strength of from about 55 lbf to about 100 lbf. For example, the roofing underlayment may exhibit a tensile strength of from about 55 lbf to about 100 lbf, from about 60 lbf to about 100 lbf, from about 65 lbf to about 100 lbf, from about 70 lbf to about 100 lbf, from about 75 lbf to about 100 lbf, from about 80 lbf to about 100 lbf, from about 85 lbf to about 100 lbf, from about 90 lbf to about 100 lbf, from about 55 lbf to about 95 lbf, from about 60 lbf to about 95 lbf, from about 65 lbf to about 95 lbf, from about 70 lbf to about 95 lbf, from about 75 lbf to about 95 lbf, from about 80 lbf to about 95 lbf, from about 85 lbf to about 95 lbf, from about 90 lbf to about 95 lbf, from about 55 lbf to about 90 lbf, from about 60 lbf to about 90 lbf, from about 65 lbf to about 90 lbf, from about 70 lbf to about 90 lbf, from about 75 lbf to about 90 lbf, from about 80 lbf to about 90 lbf, from about 85 lbf to about 90 lbf, from about 55 lbf to about 85 lbf, from about 60 lbf to about 85 lbf, from about 65 lbf to about 85 lbf, from about 70 lbf to about 85 lbf, from about 75 lbf to about 85 lbf, from about 80 lbf to about 85 lbf, from about 55 lbf to about 80 lbf, from about 60 lbf to about 80 lbf, from about 65 lbf to about 80 lbf, from about 70 lbf to about 80 lbf, or from about 75 lbf to about 80 lbf, including any and all ranges and subranges including any of these endpoints.

[0119] The flexibility of the roofing underlayment may be characterized according to the Gurley stiffness as measured in accordance with ASTM D6125 (50 g and 4.5 inch sample length). Masking tape was applied to samples for a consistent texture, level of tack, and roughness. The roofing underlayment may further exhibit a Gurley stiffness of greater than or equal to about 3,000 g or greater than or equal to about 5,000 g. The Gurley stiffness may further be less than or equal to about 15,000 g or less than or equal to about 11,000 g. For example, the roofing underlayment may have a Gurley stiffness of from about 3,000 g to about 15,000 g, from about 5,000 g to about 15,000 g, from about 7,000 g to about 15,000 g, from about 9,000 g to about 15,000 g, from about 3,000 g to about 13,000 g, from about 5,000 g to about 13,000 g, from about 7,000 g to about 13,000 g, from about 9,000 g to about 13,000 g, from about 3,000 g to about 11,000 g, from about 5,000 g to about 11,000 g, from about 7,000 g to about 11,000 g, from about 9,000 g to about 11,000 g, from about 3,000 g to about 9,000 g, from about 5,000 g to about 9,000 g, or even from about 7,000 g to about 9,000 g, including any and all ranges and subranges including any of these endpoints.

[0120] In various aspects, the roofing underlayment exhibits no asphalt bleed through upon visual inspection. The roofing underlayment may also have a uniform finish upon visual inspection.EXAMPLES

[0121] Roofing underlayments were prepared using one of five coated facers (Samples A-E). A control underlayment was also prepared using an uncoated facer that is conventionally used in underlayment applications (Control). The coatings were either impregnated or coated on the nonwoven mat, and included styrene acrylic, an aliphatic acrylic, or polypropylene (PP). The nonwoven mats included either a polyvinyl alcohol (PVOH) or urea formaldehyde (UF) binder. Fibers were glass fibers, with the exception of Sample A, which included a blend of PET and glass fibers. Fiber dimensions are reported as X-Y, where X is the average fiber diameter in microns (μm) and Y is the average fiber length in millimeters (mm). Properties of each of the facers is provided below in Table 1.TABLE 1Base veilCoatweightBinderFiber (diameterBinderCoating / weightSample(g / m2)(wt. %)(μm)-length (mm))TypeImpreg(g / m2)Coating ResinA88g / m218 wt. %0.5-5 (25%)(PET)PVOHImpreg150g / m2Styrene acrylic10-10 (75%)(glass)B86g / m218 wt. %10-6 PVOHImpreg194g / m2Styrene acrylicC73g / m223 wt. %11-19 (30%)UFCoated260g / m2Styrene acrylic13-19 (70%)D103g / m223 wt. %13-19UFCoated250g / m2Aliphatic acrylicE103g / m223 wt. %13-19UFCoated81g / m2PPControl88g / m223 wt. %13-19UFN / AN / AN / A

[0122] The facers in Table 1 were disposed on an asphalt batch layer that extended at least partially into a reinforcement layer to form the underlayment samples. Each of the underlayment samples was tested for various properties, including strength, stiffness, cracking, and traction. The % coupons tearing was measured using the ASTM D1970 Adhesion test and is reported as the number of samples that failed by tearing (versus becoming unadhered). The results are reported in Table 2 below, where the Sample refers to the nonwoven mat used to prepare the underlayment.TABLE 2Sample ASample BSample CSample DSample EControlThickness42.244.844.545.443.746.3(mil)StrengthTensile - MD58.829.562.663.367.547.2(lbf)Elongation -24.721.429.423.623.722.3MD (%)Notched65.364.358.897.791.781.5Tear - MD (lbf)Notched56.056.660.073.879.172.6Tear - CD (lbf)StiffnessGurley7,61011,5576,75616,3218,01911,095Stiffness (g)CrackingLow Temp100%100%100%40%100%100%Flex (% passing)Coupons 0% 80% 0%40% 0%N / ATearing (%)TractionSATRA Dry1.251.101.161.141.311.47(COF)SATRA Wet1.030.880.740.760.910.93(COF)

[0123] The underlayment prepared with nonwoven mat Sample B exhibited visible asphalt bleed through, and had a tensile strength of only 29.5 lbf. However, the data included a number of very low outliers, suggesting that there was possibly an unseen tear in the material. The underlayment prepared with nonwoven mat Sample D was very stiff and brittle, as demonstrated by the low temperature flex test and coupons tearing during adhesion test, although all of the other samples passed the test.

[0124] In general, the underlayments including nonwoven mats having finer fibers and / or PET fibers exhibited a lower tear strength as compared to the control. However, with the exception of Sample B, the Samples did not exhibit visible asphalt bleed through, suggesting that a wider variety of asphalt batch formulations could be utilized in underlayments including these nonwoven mats.

[0125] The method of the present disclosure may be used to make any of the various aspects described herein. All references to singular characteristics or limitations of the present disclosure shall include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made.

[0126] All combinations of method or process steps as used herein can be performed in any order, unless otherwise specified or clearly implied to the contrary by the context in which the referenced combination is made.

[0127] All ranges and parameters, including but not limited to percentages, parts, and ratios, disclosed herein are understood to encompass any and all sub-ranges assumed and subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more (e.g., 1 to 6.1), and ending with a maximum value of 10 or less (e.g., 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range.

[0128] The underlayments of the present disclosure can comprise, consist of, or consist essentially of the essential elements and limitations of the disclosure as described herein, as well as any additional or optional components or limitations described herein or otherwise useful in underlayments.

[0129] It may be possible to utilize the various inventive concepts in combination with one another. Additionally, any particular element recited as relating to a particularly disclosed aspect should be interpreted as available for use with all disclosed aspects, unless incorporation of the particular element would be contradictory to the express terms of the aspect. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the disclosure, in its broader aspects, is not limited to the specific details presented therein, the representative apparatus, or the illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concepts.

[0130] The scope of the general inventive concepts presented herein are not intended to be limited to the particular aspects shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices, systems, and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and / or claimed herein, and any equivalents thereof.

Claims

1. A roofing underlayment comprising:an asphalt batch layer; anda coated facer having a thickness of from about 0.75 mm to about 1.25 mm disposed on the asphalt batch layer, wherein the coated facer comprises:an uncoated nonwoven mat comprising a plurality of fibers having a diameter of from about 10 microns to about 13 microns bound together by a binder, wherein the binder comprises less than about 25 wt. % of a total weight of the nonwoven mat; anda coating on the nonwoven mat;wherein the roofing underlayment has a Gurley stiffness of less than 15,000 g when measured in accordance with ASTM D6125.

2. The roofing underlayment of claim 1, wherein the roofing underlayment has a Gurley stiffness of from about 5,000 g to about 13,000 g.

3. The roofing underlayment of claim 1, wherein a total weight of the uncoated nonwoven mat is less than or equal to about 100 g / m2.

4. The roofing underlayment of claim 1, wherein the coating on the nonwoven mat is present on the coated facer at a dry weight of from about 100 g / m2 to about 200 g / m2.

5. The roofing underlayment of claim 1, wherein the coating on the nonwoven mat is present on the coated facer at a dry weight of from about 200 g / m2 to about 300 g / m2.

6. The roofing underlayment of claim 1, wherein the coating on the nonwoven mat comprises an emulsion copolymer having a Tg of less than about 25° C.

7. The roofing underlayment of claim 6, wherein the emulsion copolymer has a Tg of less than about 0° C.

8. The roofing underlayment of claim 6, wherein the emulsion copolymer comprises styrene acrylic.

9. The roofing underlayment of claim 1, wherein the coating on the nonwoven mat comprises greater than about 75 wt. % of a mineral filler, based on a total dry weight of the coating.

10. The roofing underlayment of claim 9, wherein the mineral filler is selected from the group consisting of calcium carbonate, alumina trihydrate, and mixtures thereof.

11. The roofing underlayment of claim 1, wherein the nonwoven mat further comprises a plurality of PET fibers having a diameter of less than about 8 microns, wherein the plurality of PET fibers are present in an amount of from about 10 wt. % to about 50 wt. % based on a total weight of the fibers in the nonwoven mat and the plurality of glass fibers are present in an amount of from about 50 wt. % to about 90 wt. % based on the total weight of fibers in the nonwoven mat.

12. The roofing underlayment of claim 11, wherein the binder comprises a hydrophilic binder.

13. The roofing underlayment of claim 1, wherein the binder comprises a crosslinked binder.

14. The roofing underlayment of claim 13, wherein the plurality of glass fibers is a first plurality of glass fibers having a diameter of from about 10 microns to about 11 microns, the uncoated nonwoven mat further comprising a second plurality of glass fibers having a diameter of greater than or equal to about 13 microns; and wherein the first plurality of glass fibers are present in the nonwoven mat in an amount of less than or equal to about 50 wt. % based on a total weight of fibers in the nonwoven mat and the second plurality of glass fibers are present in the nonwoven mat in an amount of greater than or equal to about 50 wt. %.

15. The roofing underlayment of claim 1, wherein the coating on the nonwoven mat is present on the coated facer at a dry weight of from about 50 g / m2 to about 150 g / m2.

16. The roofing underlayment of claim 15, wherein the coating comprises a monolithic polymer film.

17. The roofing underlayment of claim 16, wherein the monolithic polymer film comprises a film-forming polymer selected from the group consisting of one or more polyolefins, one or more polyesters, and combinations thereof.

18. The roofing underlayment of claim 1, wherein the roofing underlayment is in the form of a rolled product.

19. The roofing underlayment of claim 1, wherein the asphalt batch layer comprises a non-adhesive asphalt batch composition.

20. The roofing underlayment of claim 1, wherein the asphalt batch layer comprises an adhesive asphalt batch composition.

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