Roofing underlayment

Abstract

A roofing underlayment includes a first layer of synthetic woven or nonwoven material; a second layer of woven or nonwoven material; a third layer of elastic recoverable material; and a fourth layer of fire resistant material. The third layer may have a weight of 50 gsm to 300 gsm. The elastic recoverable material includes an elastomer. The roofing underlayment can be configured to be secured to a roof such that the roofing underlayment meets (a) ASTM D4869 water shower exposure test, (b) UL790 burning brand rating, and (c) ASTM D1970 nail sealability.

What is claimed is: 
     
         1 . A roofing underlayment, comprising:
 a first layer of synthetic woven or nonwoven material;   a second layer of woven or nonwoven material;   a third layer of elastic recoverable material;
 wherein the third layer has a weight of 50 gsm to 300 gsm; 
 wherein the elastic recoverable material comprises an elastomer; and 
   a fourth layer of fire resistant material;
 wherein the roofing underlayment, when secured to a roof, meets:
 a) ASTM D4869 water shower exposure test; 
 b) UL790 burning brand rating; and 
 
   c) ASTM D1970 nail sealability.   
     
     
         2 . The roofing underlayment of  claim 1 , wherein the elastomer comprises a rubber-like elastomer, a thermoplastic elastomer (TPE), or any combination thereof. 
     
     
         3 . The roofing underlayment of  claim 1 , wherein the elastomer is not an adhesive. 
     
     
         4 . The roofing underlayment of  claim 1 , wherein the first layer, the second layer, the third layer, and the fourth layer are laminated with extrusion materials. 
     
     
         5 . The roofing underlayment of  claim 1 , wherein the first layer is a synthetic nonwoven material and includes a spunbond polypropylene. 
     
     
         6 . The roofing underlayment of  claim 1 , wherein the second layer is a woven material and includes a scrim of synthetic woven fabric including polypropylene. 
     
     
         7 . The roofing underlayment of  claim 1 , wherein the first layer or the second layer includes a weatherable layer including a UV-resistant material arranged to be an outermost first or second layer of the roofing underlayment. 
     
     
         8 . The roofing underlayment of  claim 1 , further comprising an adhesive layer arranged to be an innermost layer. 
     
     
         9 . The roofing underlayment of  claim 8 , wherein the adhesive layer includes a cover sheet. 
     
     
         10 . The roofing underlayment of  claim 1 , wherein a total weight of the roofing underlayment is from 170 gsm to 600 gsm. 
     
     
         11 . The roofing underlayment of  claim 1 , wherein a total weight of the roofing underlayment is from 200 gsm to 560 gsm. 
     
     
         12 . The roofing underlayment of  claim 1 , wherein the roofing underlayment has a topside coefficient of friction of 0.3 to 1.5. 
     
     
         13 . The roofing underlayment of  claim 1 , wherein the roofing underlayment has a backside coefficient of friction of 0.3 to 1.5. 
     
     
         14 . The roofing underlayment of  claim 1 , wherein the roofing underlayment meets Class A of UL790 burning brand rating. 
     
     
         15 . A method, comprising:
 obtaining a first layer of synthetic woven material;   obtaining a second layer of nonwoven material;   obtaining a third layer of elastic recoverable material;
 wherein the third layer has a weight of 50 gsm to 300 gsm; 
 wherein the elastic recoverable material comprises an elastomer; 
   obtaining a fourth layer of fire resistant material; and   laminating the first layer, the second layer, the third layer, and the fourth layer, so as to result in a roofing underlayment;
 wherein the roofing underlayment, when secured to a roof, meets:
 a) ASTM D4869 water shower exposure test; 
 b) UL790 burning brand rating; and 
 c) ASTM D1970 nail sealability. 
 
   
     
     
         16 . A method, comprising:
 obtaining a roofing underlayment comprising:
 a first layer of synthetic woven material; 
 a second layer of nonwoven material; 
 a third layer of elastic recoverable material; and
 wherein the third layer has a weight of 50 gsm to 300 gsm; 
 wherein the elastic recoverable material comprises an elastomer; and 
 
 a fourth layer of fire resistant material; 
   applying the roofing underlayment to a steep slope roof substrate; and   securing the roofing underlayment to the steep slope roof substrate to form a secured roofing underlayment;   wherein the secured roofing underlayment meets:
 a) ASTM D4869 water shower exposure test; 
 b) UL790 burning brand rating; and 
 c) ASTM D1970 nail sealability. 
   
     
     
         17 . The method of  claim 16 , wherein applying the roofing underlayment to the steep slope roof substrate comprises:
 peeling a sheet from the roofing underlayment;   exposing an adhesive of the roofing underlayment; and   adhering the roofing underlayment to the steep slope roof substrate.   
     
     
         18 . The method of  claim 16 , wherein securing the roofing underlayment includes fastening the roofing underlayment using fasteners that do not include capped roofing nails. 
     
     
         19 . The method of  claim 16 , wherein securing the roofing underlayment comprises stapling the roofing underlayment to the steep slope roof substrate. 
     
     
         20 . The method of  claim 16 , wherein securing the roofing underlayment comprises nailing the roofing underlayment to the steep slope roof substrate using capless roofing nails.