Self-adhering roofing underlayment

Abstract

A self-adhering roofing underlayment system enables a length of self-adhering roof underlayment having an adhesive layer and barrier layer to be rolled into a roll without the adhesive bonding to the adjacent layers but enables the adhesive to bond to a roof when unspooled and applied to the roof. Pressure and / or heat may be required to bond the self-adhering roof underlayment to the roof surface and a tack adhesive may be included to provide an initial tack to the roof surface and allow repositioning before the application of pressure and / or heat.

Description

SELF-ADHERING ROOFING UNDERLAYMENTCross Reference To Related Applications

[0001] This application claims the benefit or priority to U.S. provisional patent application No. 63 / 662,095, filed on June 20, 2024; the entirety of which is hereby incorporated by reference herein.BACKGROUND OF THE INVENTIONField of the Invention

[0002] The invention relates to a self-adhering roofing underlayment system that enables a length of self-adhering roof underlayment having an adhesive layer and barrier layer to be rolled into a roll without the adhesive bonding the adjacent layers together but enables the adhesive to bond to a roof when unspooled and applied to the roof.Background

[0003] Roofing underlayment is used to provide a layer of additional resistance for moisture to pass through the roof into the building and may be non-breathable synthetic material. The roofing underlayment is applied over the plywood and shingles are mechanically attached to the roof, such as by roofing nails through the shingle, through the roofing underlayment and into the plywood. Roof underlayment may be configured with a surface adhesive strip that is configured to bond with the adhesive layer of another roof underlayment when overlapped on a roof. The surface adhesive strip may require a surface release liner over this strip to prevent adhesion when in a roll form.SUMMARY OF THE INVENTION

[0004] The invention is directed to a self-adhering roofing underlayment system that enables a length of self-adhering roof underlayment having an adhesive layer and barrier layer to be rolled into a roll without the adhesive bonding the adjacent layers together but enables the adhesive to bond to a roof when unspooled and applied to the roof. The adhesive of the self-adhering roofing underlayment may be a pressuresensitive adhesive requiring pressure above a threshold pressure level to bond the adhesive to the surface. The adhesive may be continuous or discontinuous. The adhesive may be recessed from a stand-off requiring the stand-off to be compressed for the adhesive to contact a surface for adhering thereto. Also, stand-offs on a surface side of the self-adhering roofing underlayment may prevent the adhesive from bonding to the surface side of an adjacent layer when the self-adhering roofing underlayment is configured in a roll. A portion of the adhesive may transfer onto the stand-offs when the roll of self-adhering roofing underlayment is unspooled leaving adhesive between the stand-offs for attachment to a roof surface.

[0005] An exemplary roll of self-adhering roof underlayment may include two layers of self-adhering roof underlayment, wherein the roll can be unspooled without the adhesive layer sticking to the adjacent layer. Each layer of the roll of self-adhering roof underlayment may include an adhesive layer and a barrier layer having a structural component and a water barrier component. Also, each layer of the selfadhering roof underlayment has a surface side and a roof side configured to bond to roof surface. The adhesive may be specifically designed to adhere to a roof, but not to adhere to an adjacent layer of self-adhering roof underlayment when in a roll form. The adhesive layer may be very thin, as described herein, and may provide an initial tack that enables the self-adhering roof underlayment to be repositioned for some time. The adhesive may be designed however to increase in adhesive strength over time, wherein the self-adhering roof underlayment is not repositionable after a threshold period of time.

[0006] The adhesive layer of a self-adhering roof underlayment may be configured not to bond to the water barrier component or layer of an adjacent layer of selfadhering roof underlayment when in a roll form. The barrier layer or the water barrier component may be a film of material that has surface energy that is low or below a threshold value and therefore prevents the adhesive of the adhesive layer from bonding to the water barrier component of the adjacent layer of self-adhering roof underlayment. A self-adhering roof underlayment may include a barrier layer or water barrier layer or component on the surface side of the self-adhering roof underlayment such that it is adjacent the roof side of the adjacent layer of the selfadhering roof underlayment when in a roll form.

[0007] The self-adhering roof underlayment system may be applied to a roof with the self-adhering roof underlayment applied to the roof with the adhesive layer contacting the roof. The self-adhering roof underlayment layer may be applied partially over a first layer of self-adhering roof underlayment and partially on the roof. The overlap width of the layers of self-adhering roof underlayment may be configured to provide a seal between along this interface.

[0008] The self-adhering roof underlayment has an adhesive layer on the roof side of the self-adhering roof underlayment. The adhesive layer or adhesive of the adhesive layer may be thin and have a thickness of about 50pm or less, about 25pm or less about 10pm or less, about 5pm or less, about 3pm or less, about 2pm or less, about 1 pm or less and any range between and including the thickness values provided. Put another way the adhesive may have an areal weight on the self-adhering roof underlayment of about 50 g / m2or less, about 35 g / m2or less, about 25 g / m2or less, about 10 g / m2or less, about 5 g / m2or less, about 2 g / m2or less, about 1 g / m2or more and any range between and including the weight values provided. The percentage of coverage of the adhesive may be low, such as about 10% or less, about 5% or less, about 1 % or less and any range between and including the percentages provided.

[0009] A self-adhering roof underlayment may include an adhesive activator that activates the adhesive to bond with the roof after unspooling the self-adhering roof underlayment from a roll of self-adhering roof underlayment and applying to the roof, and / or after applying pressure to the self-adhering roof underlayment when on the roof. An adhesive activator may be a pressure activator that requires a threshold pressure to activate. An exemplary pressure activator is an activator capsule that is configured to rupture, thereby releasing an adhesive activator chemical to cause the adhesive to bond to a roof surface. An activator chemical may chemically bond with the adhesive or bond to the roof and then bond with the adhesive or pre-adhesive material to form the adhesive. An activator chemical may be a cross-linker that causes the adhesive to cross-link.

[0010] A self-adhering roof underlayment may be applied to a roof and then rolled to secure the underlayment to the roof. Also, the pressure of walking on the underlayment when applied to a roof may activate the adhesive activator and cause the adhesive to bond to the roof. The self-adhering roof underlayment may be rolledwith a pressure roller to activate the adhesive, which may be a pressure sensitive adhesive or include an adhesive activator requiring pressure to cause the adhesive to activate and bond to the roof and / or to the underlayer of self-adhering roof underlayment.

[0011] A self-adhering roof underlayment may be applied to a roof and then heated to bond the underlayment to the roof. A heating device may be applied to heat the self-adhering roof underlayment, such as a heated roller or mat.

[0012] An exemplary roll of self-adhering roof underlayment may include two layers of self-adhering roof underlayment; wherein the roll can be unspooled without the adhesive layer sticking to the adjacent layer. The self-adhering roof underlayment may include an integral release layer that may be coupled to the adhesive layer or coupled to the barrier layer of an adjacent layer of self-adhering roof underlayment. An integral release liner is a material that prevents the adhesive layer from bonding to the adjacent layer of self-adhering roof underlayment and may have a texture or surface energy that prevents the adhesive from bonding.

[0013] When an integral release liner is coupled to the adhesive, it may be configured to allow the adhesive to wick through pores or opening in the integral release liner when an effective amount of pressure is applied, such as from a pressure roller. The integral release liner may be a woven or non-woven material have pores or openings therethrough.

[0014] When the integral release liner is coupled to the barrier layer, it may be configured to split in the thickness direction, thereby leaving a bit of integral release liner on the adhesive that does not impede the bonding of the adhesive to the roof and / or may have a surface energy that prevent the adhesive layer from bonding to the integral release liner.

[0015] An exemplary self-adhering roof underlayment may have an adhesive layer comprising an adhesive that is recessed from stand-offs to form a press-and-seal roof underlayment. The stand-offs may extend a stand-off offset distance from the adhesive layer and the stand-off are compressible, wherein compressing the standoffs enables the adhesive to contact a surface to adhere to said surface.

[0016] An exemplary self-adhering roof underlayment may have discrete stand-offs or stand-offs that form a grid pattern wherein the stand-offs are interconnected. The discrete stand-offs may be circular in shape having a diameter. The specificcoverage area of a stand-off layer may be about 25% or more, about 35% or more, about 50% or less, about 25% or less, about 15% or less and any range between and including the percentages provided. The adhesive layer may be configured between the stand-offs and may require compression of the stand-offs to cause the self-adhering roof underlayment to bond to a roof surface. Again, this pressure may be applied by a roller.

[0017] A self-adhering roof underlayment may have elongated stand-offs with a length that is more than double the width. The adhesive layer may be configured between the stand-offs and require compression of the stand-offs to cause the selfadhering roof underlayment to bond to a roof surface.

[0018] An exemplary self-adhering roof underlayment may be configured with an adhesive on the roof surface that is released by the stand-offs on the surface side, when unrolled from the roll of self-adhering roof underlayment. A roll of self-adhering roof underlayment may have a plurality of layers. The stand-offs of the second layer of self-adhering roof underlayment may be in contact with the adhesive of the first layer of self-adhering roof underlayment. The stand-offs may prevent or reduce the adhesive from the first layer of self-adhering roof underlayment from contacting the second layer of self-adhering roof underlayment. When a layer of self-adhering roof underlayment is unspooled from the roll of self-adhering roof underlayment and peeled off from the second layer of self-adhering roof underlayment, adhesive deposits may be left on the stand-offs from the adhesive layer of the adjacent layer of self-adhering roof underlayment and / or stand-off deposits may be configured on the adhesive from the unspooled layer of self-adhering roof underlayment. The stand-offs may effectively prevent permanent adhesion of the adhesive layer to the adjacent layer of self-adhering roof underlayment and may be configured to fracture to leave a stand-off deposit and / or the adhesive may be configured to fracture and leave an adhesive deposit on the stand-off. The adhesive may be configured with an exposed adhesive area, area without the stand-off deposits and this area may be effectively large enough to enable the self-adhering roof underlayment to be adhered to roof surface and may be at least 25% or more and more preferably at least 50% or more or even 75% or more. The more exposed adhesive area, the better the adhesion to the roof surface.

[0019] The adhesive may be a hot-melt type of adhesive (an adhesive that is not an adhesive at ambient temperature and requires elevated temperature to melt the adhesive to form an adhesive bond), a pressure sensitive adhesive and may be an adhesive that is cross-linked. An adhesive may be butyl adhesive, require an activator, and may be water based. An adhesive may be extrudable or co-extruded with a barrier layer or barrier layer component such the moisture resistant layer.

[0020] A standard for measuring peel strength of adhesion of roofing materials is ASTM D903-98 and some jurisdictions have a minimum peel strength requirement of 1 lb per inch for roofing underlayment. The self-adhering roof underlayment of the present invention may have a peel strength according to this test that is 11b / in or more and may be less than 11b / in.

[0021] A pressure required to bond the adhesive to a roofing surface may be about be applied by a pressure roller that is about 25cm in diameter, has a width of about 25cm or more, and weigh about 18kg to about 70kg. The pounds per linear inch produced by a roller may be about 2pli or more, about 4pli or more, about 5pli or more, about 8pli or more, about 10pli or more and any range between and including the pli values provided.

[0022] Moisture vapor transmission rate through the self-adhering roof underlayment may be measured using ASTM E96-00 (Last Updated: Aug 16, 2017), Water Vapor Transmission. ASTM E96 tests and evaluates the water vapor transfer through semi-permeable and permeable samples.

[0023] The self-adhering roof underlayment may have a moisture vapor transmission rate (MVTR) that meets industrial standards for housewrap material, or roofing underlayment material such as greater than about 5 US perm to meet code, about 10 US perm or more, about 20 US perm or more, about 50 US perm or more, and may be as much as 100 US perm, or any range between and including the MVTR values provided. For roofing underlayment, the MVTR may be from about 0.1 US perm to 100 US perm.

[0024] The summary of the invention is provided as a general introduction to some of the embodiments of the invention, and is not intended to be limiting. Additional example embodiments including variations and alternative configurations of the invention are provided herein.BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0025] The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of the invention.

[0026] Figure 1 shows a cross-sectional view of layers of roof underlayment of the prior art including a release liner over the adhesive layer and a second surface adhesive liner over a surface adhesive strip configured to bond to the adhesive layer when configured on a roof.

[0027] Figure 2 shows a perspective view of the prior art roof underlayment with both release liners removed and being attached to a roof with the surface adhesive strip bonding to the adhesive layer on the roof side of the roof underlayment.

[0028] Figure 3 shows a cross-sectional view of layers of a roll of exemplary selfadhering roof underlayment that includes two layers of self-adhering roof underlayment, each having an adhesive layer and a barrier layer having a structural component and a water barrier component.

[0029] Figure 4 shows a cross-sectional side view of two pieces of exemplary selfadhering roof underlayment being bonded to each other and to a roof surface of a roof.

[0030] Figure 5 shows a cross-sectional view of one layer of self-adhering underlayment having an adhesive layer with an adhesive and adhesive activator and a barrier layer including a structural component and a water barrier component.

[0031] Figure 6 shows a perspective view of layers of self-adhering underlayment being attached or bonded to a roof by use of a pressure roller to activate the adhesive to bond to the roof surface and / or the underlayer of the self-adhering underlayment.

[0032] Figure 7 shows a cross-sectional view of layers of an exemplary self-adhering roof underlayment that includes an adhesive layer and an integral release layer that prevents the adhesive layer from bonding to the adjacent self-adhering underlayment layer when in a roll form.

[0033] Figure 8 shows a cross-sectional side view of two pieces of exemplary selfadhering roof underlayment having an integral release layer being bonded together and to a roof.

[0034] Figure 9 shows a cross-sectional side view of a piece of exemplary selfadhering roof underlayment having a discontinuous adhesive layer on the roof side and a water barrier component on the surface side.

[0035] Figure 10 shows a roof side of the exemplary self-adhering roof underlayment shown in FIG. 9 with a discontinuous adhesive layer.

[0036] Figure 11 shows a cross-sectional side view of a piece of exemplary selfadhering roof underlayment having an adhesive recessed from stand-offs, a press- and-seal roof underlayment.

[0037] Figure 12 shows micrograph picture of a roof side of the exemplary selfadhering roof underlayment shown represented by FIG. 11 , with a discontinuous adhesive layer recessed from stand-offs.

[0038] Figure 13 shows a roof side view of an exemplary self-adhering roof underlayment having discrete circular stand-offs.

[0039] Figure 14 shows a roof side view of an exemplary self-adhering roof underlayment having elongated stand-offs.

[0040] Figure 15 shows a side view of a roll of self-adhering roof underlayment.

[0041] Figure 16 shows an enlarged cross-sectional view of layers of the roll of selfadhering roof underlayment with an adhesive layer on the interior surface of a first layer of self-adhering roof underlayment contacting the stand-offs of a second layer of self-adhering roof underlayment.

[0042] Figure 17 shows a cross-sectional view of the layers of self-adhering roof underlayment shown in FIG. 16, with the first layer of self-adhering roof underlayment being unrolled from the second layer of self-adhering roof underlayment.

[0043] Figure 18 shows an enlarged view of self-adhering roof underlayment with adhesive deposits configured on the stand-offs and stand-off deposits configured on the adhesive after being unspooled from a roll of self-adhering roof underlayment.

[0044] Corresponding reference characters indicate corresponding parts throughout the several views of the figures. The figures represent an illustration of some of the embodiments of the present invention and are not to be construed as limiting thescope of the invention in any manner. Some of the figures may not show all of the features and components of the invention for ease of illustration, but it is to be understood that where possible, features and components from one figure may be included in the other figures. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0045] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, use of "a" or "an" are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

[0046] Certain exemplary embodiments of the present invention are described herein and are illustrated in the accompanying figures. The embodiments described are only for purposes of illustrating the present invention and should not be interpreted as limiting the scope of the invention. Other embodiments of the invention, and certain modifications, combinations and improvements of the described embodiments, will occur to those skilled in the art and all such alternate embodiments, combinations, modifications, improvements are within the scope of the present invention.

[0047] Figure 1 shows a cross-sectional view of layers of roof underlayment 312, 312’ of the prior art including a barrier layer 317 and an adhesive release liner 319 over the adhesive layer 318 and a second surface adhesive liner 314 over a surfaceadhesive strip 316 configured on the surface side 304 to bond to the adhesive layer 318 when configured on a roof.

[0048] Figure 2 shows a perspective view of the prior art roof underlayment with both release liners removed and being attached to a roof 310 with the surface adhesive strip 316 bonding to the adhesive layer 318 on the roof side 306 of the roof underlayment.

[0049] As shown in FIG. 3, an exemplary roll of self-adhering roof underlayment 303 includes two layers of self-adhering roof underlayment 302, 302’; wherein the roll can be unspooled without the adhesive layer 330 sticking to the adjacent layer. As shown, two layers of the roll of self-adhering roof underlayment 303 of the selfadhering roof underlayment system 300, each include an adhesive layer 330, 330’ and a barrier layer 322, 322’ having a structural component 324, 324’ and a water barrier component 326, 326’. Also, each layer has a surface side 304 and a roof side 306. The adhesive layers 330, 330’ have respective adhesive 331 , 33T that may be specifically designed to adhere to a roof, but not to adhere with an adjacent layer of self-adhering roof underlayment when in a roll form. The adhesive layer may be very thin, as described herein, and may provide an initial tack that enables the self-adhering roof underlayment to be repositioned for some time. The adhesive may be designed however to increase in adhesive strength over time, wherein the self-adhering roof underlayment is not repositionable after a threshold period of time. A tack adhesives is configured to allow temporary repositioning of the roof underlayment and therefore the peel strength of the roof underlayment over time may increase, such as having about a 50% or more after one hour or an increase of about 100% or even 200% or more after 24 hours.

[0050] The adhesive layer 330 of a self-adhering roof underlayment 302 may be configured not to bond to the water barrier component 326’ of an adjacent layer of self-adhering roof underlayment 302’ when in a roll form. The water barrier component 326’ may be a film of material that has surface energy that is low or below a threshold value and therefore prevents the adhesive 331 of the adhesive layer from bonding to the water barrier component 326’ of the adjacent layer of selfadhering roof underlayment 302’.

[0051] As shown in FIG. 4, the self-adhering roof underlayment system 300 is being applied to a roof with the self-adhering roof underlayment 302’ applied to the roof310 with the adhesive layer 330’ contacting the roof. The self-adhering roof underlayment 302 layer is being applied partially over the first layer of self-adhering roof underlayment 302’ and partially on the roof 310. The overlap area 344 has an overlap width 345 of the layers of self-adhering roof underlayment 330, 330’ may be configured to provide a seal between along this interface.

[0052] As shown in FIG. 5, the self-adhering roof underlayment 302 has an adhesive layer 330 on the roof side 306 of the self-adhering roof underlayment 302. The adhesive layer has a thickness 335 that may be very thin, as described herein. The adhesive layer 330 includes an adhesive 331 and may also include an adhesive activator 336 that activates the adhesive to bond with the roof after unspooling the self-adhering roof underlayment from a roll of self-adhering roof underlayment and applying to the roof, and / or after applying pressure to the self-adhering roof underlayment when on the roof. An adhesive activator may be a pressure activator that requires a threshold pressure to activate. An exemplary pressure activator is an activator capsule 338 that is configured to rupture, thereby releasing an adhesive activator chemical 334 to cause the adhesive to bond to a roof surface.

[0053] A self-adhering roof underlayment 302 may be applied to a roof and then rolled to secure the underlayment to the roof. Also, the pressure of walking on the underlayment when applied to a roof may activate the adhesive activator and cause the adhesive to bond to the roof.

[0054] As shown in FIG. 6, a self-adhering roof underlayment 302 is being rolled with a pressure roller 400 to activate the adhesive, which may be a pressure sensitive adhesive or include an adhesive activator 336 requiring pressure to cause the adhesive 331 to activate and bond to the roof 310 and / or to the underlayer of selfadhering roof underlayment 302’. An exemplary self-adhering roof underlayment 302 may include an activator layer, or an activator capsule 338, that includes an adhesive activator 336 that activates the adhesive and / or increases the bond of the adhesive with a substrate, such as a roof surface or roof 310. The activator capsule 338 may be pressure activated, wherein a pressure above a threshold pressure will release the adhesive activator 336. The adhesive activator may be configured in the activator capsule and when pressure is applied, such as with a pressure roller 400, as shown in FIG. 6, the activator capsule may be ruptured to release the adhesive activator.

[0055] Referring now to FIGS. 7 to 8, an exemplary roll of self-adhering roof underlayment 303 (shown in FIG. 7) includes two layers of self-adhering roof underlayment 302, 302’; wherein the roll can be unspooled without the adhesive layer 330 sticking to the adjacent layer. As shown, two layers of the roll of selfadhering roof underlayment 303 of the self-adhering roof underlayment system 300 each include an adhesive layer 330, 330’ and a barrier layer 322, 322’ having a structural component 324, 324’ and a water barrier component 326, 326’ and an integral release layer 339. The integral release layer 339 may be coupled to the adhesive layer 330 or coupled to the barrier layer 322’ of an adjacent layer of selfadhering roof underlayment 302’. An integral release liner 339 is a material that prevents the adhesive layer from bonding to the adjacent layer of self-adhering roof underlayment 302’ and may have a texture or surface energy that prevents the adhesive from bonding.

[0056] When the integral release liner 339 is coupled to the adhesive, it may be configured to allow the adhesive to wick through pores or opening in the integral release liner when an effective amount of pressure is applied, such as from a pressure roller. The integral release liner may be a woven or non-woven material have pores or openings therethrough.

[0057] When the integral release liner 339 is coupled to the barrier layer, it may be configured to split in the thickness direction, thereby leaving a bit of integral release liner on the adhesive that does not impede the bonding of the adhesive to the roof and / or may have a surface energy that prevent the adhesive layer from bonding to the integral release liner.

[0058] Referring now to FIGS. 9 and 10, an exemplary self-adhering roof underlayment 302 having a discontinuous adhesive layer 330 on the roof side 306 and a water barrier component 326 on the surface side 304. The discontinuous adhesive 331 is discrete adhesive, wherein the adhesive is not interconnected, but rather individual adhesive portions as shown in FIG. 10.

[0059] Referring now to FIGS. 11 and 12, an exemplary self-adhering roof underlayment 302 has an adhesive layer 330 comprising an adhesive 331 that is recessed from roof-side stand-offs 333 to form a press-and-seal roof underlayment. The roof-side stand-offs 333 extend a stand-off offset distance 347 from theadhesive layer 330 and the stand-off are compressible, wherein compressing the stand-offs enables the adhesive 331 to contact a surface to adhere to said surface. The exemplary self-adhering roof underlayment 302 also has a structural component 324 which may include a barrier layer 322 such as a water barrier component 326 or layer. The roof-side stand-offs 333 may also comprise a tack adhesive 332 of different intrinsic adhesion than adhesive 331 thereby providing enough initial but repositionable adhesion to secure the underlayment 302 in place before weighted rolling to contact adhesive 331 to said surface.

[0060] Figure 12 shows micrograph picture of a roof side 306 of the exemplary selfadhering roof underlayment 302 with a adhesive layer 330 that is a discontinuous adhesive layer 329 that is recessed from the roof-side stand-offs 333 having a tack adhesive 332 thereon.

[0061] Figure 13 shows a roof side 306 or surface, of an exemplary self-adhering roof underlayment 302 having discrete circular roof-side stand-offs 37. The discrete roof-side stand-offs are circular in shape having a diameter 39. The specific coverage area is about 35%. The adhesive layer 331 is configured between the stand-offs and requires compression of the stand-offs to cause the self-adhering roof underlayment 303 to bond to a roof surface.

[0062] Figure 14 shows a roof side 306 of a self-adhering roof underlayment 302 having elongated roof side stand-offs 333 with a length 34 that is more than double the width 33. The adhesive 331 of the adhesive layer 331 is configured between the roof-side stand-offs and requires compression of the roof-side stand-offs to cause the self-adhering roof underlayment 302 to bond to a roof surface.

[0063] Referring now to FIGS. 15 to 18, an exemplary self-adhering roof underlayment 302 may be configured with an adhesive 331 on the roof side 306 that is released by the stand-offs 30 of the stand-off layer 308 on the surface side 304 when unrolled from the roll of self-adhering roof underlayment 81 , as best shown in FIG. 17. The stand-off layer 308 includes a plurality of stand-offs 30, such as discrete stand-offs 37, on the surface side 304. Discrete stand-offs have a defined outer perimeter as described herein. The roll of self-adhering roof underlayment 81 has a plurality of layers. The discrete stand-offs 37’ of the second layer of selfadhering roof underlayment 302’ are in contact with the adhesive 331 of the first layer of self-adhering roof underlayment 302. The stand-offs 30’ prevent theadhesive 331 from the first layer of self-adhering roof underlayment 302 from contacting the structural component 324’ of the second layer of self-adhering roof underlayment 302. Stand-offs 30, 30’ may also provide slip resistance to installers walking on the underlayment after installation. When a layer of self-adhering roof underlayment 302 is unspooled from the roll of self-adhering roof underlayment 81 and peeled off from the second layer of self-adhering roof underlayment 302’, adhesive deposits 35’ may be left on the stand-offs 30’ from the adhesive layer of the adjacent layer of self-adhering roof underlayment 302, and / or stand-off deposits 53 may be configured on the adhesive 331 from the unspooled layer of self-adhering roof underlayment 302’. The stand-offs may effectively prevent permanent adhesion of the adhesive layer to the adjacent layer of self-adhering roof underlayment and may be configured to fracture to leave a stand-off deposit and / or the adhesive may be configured to fracture and leave an adhesive deposit on the stand-off. The adhesive may be configured with an exposed adhesive area 55, area without the stand-off deposits and this area may be effectively large enough to enable the selfadhering roof underlayment 302 to be adhered to roof surface and may be at least 25% or more and more preferably at least 50% or more or even 75% or more. The more exposed adhesive area, the better the adhesion to the exterior wall surface.

[0064] The adhesive layer 330 may include a tack adhesive 332 that may provide an initial tack and then increase in strength over time, wherein the peel strength increases by about 50% or more within an hour and about 100% or even 200% after 24 hours at standard temperature a pressure (21 °C and 1 atmosphere or pressure). The tack adhesive may be configured on a stand-off 30, such as on a roof-side stand-off 333, which may be a discrete stand-off 37. The roof side 306 may include a roof-side stand-off layer 309 that includes a plurality of roof-side stand-offs 333, which may be discrete having a defined outer perimeter. The tack adhesive 332 may aid in the release of one layer of the self-adhering roof underlayment 302 from an adjacent layer of self-adhering roof underlayment 302’, wherein a stand-off 37 on the surface side 304 does not bond as much to the tack adhesive 332 as to the adhesive 331 of the adhesive layer 330. The combination of abutting stand-offs, the roof side stand-offs 333 abutting with the stand-offs 37 on the surface side 304 of the self-adhering roof underlayment 302 may further prevent contact of the adhesive 331 with the surface side 304 of the abutting layer. The tack adhesive 332 may only beconfigured on or form roof-side stand-offs 333 and the rest of the roof side 306 may be adhesive 331 of the adhesive layer 330 configured to bond to the roof. Also, a roof-side stand-off 333 may include an adhesive activator 336 and this roof-side stand-off 333 may be or include an activator capsule 338 having the adhesive activator 336 therein. The activator capsule may extend out from the adhesive layer 330 to produce a roof-side stand-off having a stand-off offset 347 that may prevent contact of the adhesive layer 330 with the surface side 304 of the self-adhering roof underlayment 302. As described herein, the adhesive activator may require a threshold pressure to rupture the activator capsule 338 to release the adhesive activator such as an adhesive activator chemical.

[0065] It will be apparent to those skilled in the art that various modifications, combinations and variations can be made in the present invention without departing from the scope of the invention. Specific embodiments, features and elements described herein may be modified, and / or combined in any suitable manner. Thus, it is intended that the present invention cover the modifications, combinations and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:1 . A self-adhering roof underlayment system comprising: a) a roll of self-adhering roof underlayment having a plurality of layers of selfadhering roof underlayment configured on said roll of self-adhering roof underlayment, wherein each layer of said plurality of layers of selfadhering roof underlayment comprises: i) a roof side; ii) a surface side opposite the roof side; iii) a barrier layer; iv) an adhesive layer comprising an adhesive on said roof side of the self-adhering roof underlayment; wherein the adhesive layer is in direct contact with said surface side of an adjacent layer of self-adhering roof underlayment when configured in said roll of self-adhering roof underlayment, and wherein the adhesive layer is configured to bond to a roof surface when unspooled from said roll and applied to a roof surface.

2. The self-adhering roof underlayment system of claim 1 , wherein the adhesive layer comprises a pressure sensitive adhesive.

3. The self-adhering roof underlayment system of claim 1 , wherein the adhesive layer has a thickness of 50 micrometer or less.

4. The self-adhering roof underlayment system of claim 1 , wherein the adhesive layer has a thickness of 10 micrometer or less.

5. The self-adhering roof underlayment system of claim 1 , wherein the adhesive layer further comprises an adhesive activator.

6. The self-adhering roof underlayment system of claim 5, wherein the adhesive activator requires application of pressure above a pressure threshold to activate the adhesive to bond.

7. The self-adhering roof underlayment system of claim 6, wherein the adhesive activator is configured in an activator capsule that is configured to rupture when said pressure above a pressure threshold is applied to the adhesive layer.

8. The self-adhering roof underlayment system of claim 7, wherein the adhesive activator includes an adhesive activator chemical that is released when theactivator capsule is ruptured and wherein the adhesive activator chemical causes the adhesive to bond to said roof surface.

9. The self-adhering roof underlayment system of claim 7, wherein the self-adhering roof underlayment further comprises a roof-side stand-off layer comprising roofside stand-offs having a roof-side stand-off offset from the adhesive layer and wherein the adhesive activator is configured on said stand-off.

10. The self-adhering roof underlayment system of claim 9, wherein the activator capsule forms said roof-side stand-off.11 .The self-adhering roof underlayment system of claim 5, wherein the self-adhering roof underlayment further comprises a roof-side stand-off and wherein the adhesive activator is configured on said stand-off.

12. The self-adhering roof underlayment system of claim 1 , wherein the adhesive layer comprises a pressure sensitive adhesive.

13. The self-adhering roof underlayment system of any one of claims 1 to 12, wherein the self-adhering roof underlayment further comprises a tack adhesive on the roof side and wherein the tack adhesive is configured to tack the selfadhering roof underlayment to a roof surface, and wherein the tack adhesive is configured to allow the self-adhering roof underlayment to be repositioned prior to bonding the adhesive layer to the roof surface.

14. The self-adhering roof underlayment system of claim 13, wherein the tack adhesive is configured in the adhesive layer and wherein the adhesive of the adhesive layer has an increasing peel strength over time.

15. The self-adhering roof underlayment system of claim 13, wherein the selfadhering roof underlayment further comprises a roof-side stand-off layer comprising roof-side stand-offs having a roof-side stand-off offset from the adhesive layer and wherein the tack adhesive is configured on said roof-side stand-offs.

16. The self-adhering roof underlayment system of any one of claims 1 to 12, further comprising a stand-off layer comprising stand-offs having a stand-off offset from the surface side of the self-adhering roof underlayment.

17. The self-adhering roof underlayment system of claim 16, wherein the stand-offs produce a stand-off offset of 2mm or more from the adhesive of the adhesive layer.

18. The self-adhering roof underlayment system of claim 16, wherein the stand-offs produce a stand-off offset of 4mm or more from the adhesive of the adhesive layer.

19. The self-adhering roof underlayment system of claim 16, wherein the stand-offs comprise unbonded nonwoven fibers.

20. The self-adhering roof underlayment system of claim 16, wherein the stand-offs comprise a film or material.21 .The self-adhering roof underlayment system of claim 1 , wherein the self-adhering roof underlayment further comprises a roof-side stand-off layer comprising roofside stand-offs having a roof-side stand-off offset from the adhesive layer.

22. The self-adhering roof underlayment system of claim 21 , wherein the roof-side stand-off offset is 2mm or more.

23. The self-adhering roof underlayment system of claim 21 , wherein the roof-side stand-off offset is 2mm or more24. The self-adhering roof underlayment system of claim 21 , wherein the roof-side stand-offs are compressible.

25. The self-adhering roof underlayment system of claim 21 , wherein the roof-side stand-offs are a fabric.

26. The self-adhering roof underlayment system of claim 21 , wherein the roof-side stand-offs comprise a film layer.

27. A method of unspooling and bonding a self-adhering roof underlayment to a roof surface comprising: a) providing the self-adhering roof underlayment system of claim 1 ; b) unspooling the roll of self-adhering roof underlayment onto a roof surface; c) wherein the adhesive of the adhesive layer effectively bonds to said roof surface, having a peel strength of at least 0.5N per 25mm (0.1 Ib / in).

28. The method of claim 27, wherein the adhesive layer comprises a pressure sensitive adhesive.

29. The method of claim 27, wherein the adhesive layer has a thickness of 50 micrometer or less.

30. The method of claim 27, wherein the adhesive layer has a thickness of 10 micrometer or less.31 . The method of claim 27 wherein the adhesive layer further comprises an adhesive activator.

32. The method of claim 31 , wherein the adhesive activator requires application of pressure above a pressure threshold to activate the adhesive to bond.

33. The method of claim 32, wherein the adhesive activator is configured in an activator capsule that is configured to rupture when said pressure above a pressure threshold is applied to the adhesive layer.

34. The method of claim 33, wherein the adhesive activator includes an adhesive activator chemical that is released when the activator capsule is ruptured and wherein the adhesive activator chemical causes the adhesive to bond to said roof surface.

35. The method of claim 33, wherein the self-adhering roof underlayment further comprises a roof-side stand-off layer comprising roof-side stand-offs having a roof-side stand-off offset from the adhesive layer and wherein the adhesive activator is configured on said stand-off.

36. The method of claim 35, wherein the activator capsule forms said roof -side standoff.

37. The method of claim 31 , wherein the self-adhering roof underlayment further comprises a roof-side stand-off and wherein the adhesive activator is configured on said stand-off.

38. The method of claim 27, wherein the adhesive layer comprises a pressure sensitive adhesive.

39. The method of claim 38, further comprising repositioning the self-adhering roof underlayment on said roof surface and then applying pressure to the selfadhering roof underlayment after unspooling the roll of self-adhering roof underlayment onto a roof surface to bond the unspooling the roll of self-adhering roof underlayment onto a roof surface to said roof surface to produce said peel strength of peel strength of at least 0.5N per 25mm (0.1 Ib / in).

40. The method of claim 38, further comprising applying pressure to the self-adhering roof underlayment after unspooling the roll of self-adhering roof underlayment onto a roof surface to bond the unspooling the roll of self-adhering roof underlayment onto a roof surface to said roof surface to produce said peel strength of peel strength of at least 0.5N per 25mm (0.1 Ib / in).41 . The method of any one of claims 27 to 40, wherein the self-adhering roof underlayment further comprises a tack adhesive on the roof side and wherein the tack adhesive is configured to tack the self-adhering roof underlayment to a roof surface, and wherein the tack adhesive is configured to allow the self-adhering roof underlayment to be repositioned prior to bonding the adhesive layer to the roof surface.

42. The method of claim 41 , wherein the tack adhesive is configured in the adhesive layer and wherein the adhesive of the adhesive layer has an increasing peel strength over time.

43. The method of claim 41 , wherein the self-adhering roof underlayment further comprises a roof-side stand-off layer comprising roof-side stand-offs having a roof-side stand-off offset from the adhesive layer and wherein the tack adhesive is configured on said roof-side stand-offs.

44. The method of claim 41 , further comprising repositioning the self-adhering roof underlayment on said roof surface and then applying pressure to the selfadhering roof underlayment after unspooling the roll of self-adhering roof underlayment onto a roof surface to bond the unspooling the roll of self-adhering roof underlayment onto a roof surface to said roof surface to produce said peel strength of peel strength of at least 0.5N per 25mm (0.1 Ib / in).

45. The method of claim 41 , further comprising applying pressure to the self-adhering roof underlayment after unspooling the roll of self-adhering roof underlayment onto a roof surface to bond the unspooling the roll of self-adhering roof underlayment onto a roof surface to said roof surface to produce said peel strength of peel strength of at least 0.5N per 25mm (0.1 Ib / in).

46. The method of any one of claims 27 to 40, further comprising a stand-off layer comprising stand-offs having a stand-off offset from the surface side of the selfadhering roof underlayment.

47. The method of claim 46, wherein the stand-offs produce a stand-off offset of 2mm or more from the adhesive of the adhesive layer.

48. The method of claim 46, wherein the stand-offs produce a stand-off offset of 4mm or more from the adhesive of the adhesive layer.

49. The method of claim 46, wherein the stand-offs comprise unbonded nonwoven fibers.

50. The method of claim 46, wherein the stand-offs comprise a film or material.51 . The method of claim 27, wherein the self-adhering roof underlayment further comprises a roof-side stand-off layer comprising roof-side stand-offs having a roof-side stand-off offset from the adhesive layer.

52. The method of claim 51 , wherein the roof-side stand-off offset is 2mm or more.

53. The method of claim 51 , wherein the roof-side stand-off offset is 2mm or more54. The method of claim 51 , wherein the roof-side stand-offs are compressible.

55. The method of claim 51 , wherein the roof-side stand-offs are a fabric.

56. The method of claim 51 , wherein the roof-side stand-offs comprise a film layer.

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