ROOFING UNDERLAYMENT AND PREPARATION METHOD THEREOF

Abstract

A roofing mat and a preparation method thereof are disclosed. A composite device includes a first roller, a second roller and a third roller. A die is located at the first roller. The preparation method comprises the following steps: step 1: laminating a first non-woven fabric to form a waterproof film; step 2: conveying asphalt to the die; step 3: rolling the first non-woven fabric by means of the first roller, rolling a woven fabric/a second non-woven fabric by means of the second roller, applying the asphalt to the waterproof film of the first non-woven fabric by means of the die, the first roller and the second roller being rolled and pressed against each other, the first non-woven fabric rolled by the first roller and the woven fabric/the second non-woven fabric rolled by the second roller being compressed together and then conveyed to a third roller for cooling, outputting, trimming, and winding.

Claims

1. A roofing underlayment, comprising a four-layer structure having a first non-woven fabric, a waterproof film, an asphalt layer and a woven fabric/a second non-woven fabric arranged in order from top to bottom, wherein the waterproof film is applied to an inner side of the first non-woven fabric, the asphalt layer is applied between the waterproof film and an inner side of the woven fabric/an inner side of the second non-woven fabric.

2. The roofing underlayment as claimed in claim 1, wherein the first non-woven fabric and the second non-woven fabric is made of a non-woven fabric having a weight of between 10 g and 100 g per square meter, and the non-woven fabric is a spunbonded, meltblown, needled or spunlace non-woven fabric.

3. The roofing underlayment as claimed in claim 2, wherein the waterproof film is a polyolefin-based extruded casting film or an elastomer-based extruded casting film or a hot-rolled composite film or an adhesive composite film.

4. The roofing underlayment as claimed in claim 1, wherein the asphalt layer includes 30-70 wt % asphalt, 1-15 wt % SBS, 20-60 wt % filler and 0.1-2 wt % tackifier, and the asphalt layer has a thickness of not greater than 10 mils.

5. The roofing underlayment as claimed in claim 1, wherein the woven fabric is made of a circular-knitting, plain-knitting, spunlace or warp-knitting woven fabric having a weight of between 20 g and 300 g per square meter, and its material is polypropylene (PP) or polyethylene (PE) or polyethylene terephthalate (PET) or polyamide nylon.

6. The roofing underlayment as claimed in claim 1, wherein an anti-slip film is applied to an outer side of the woven fabric/the second non-woven fabric.

7. The roofing underlayment as claimed in claim 6, wherein the anti-slip film is a polyolefin-based extruded casting anti-slip film or an elastomer-based extruded casting anti-slip film or a rolled coating anti-slip film.

8. A preparation method of a roofing underlayment, using a composite device for preparation, the composite device including a first roller, a second roller and a third roller arranged from left to right, a die being located at a left side of the first roller; the preparation method comprising the following steps: step 1: laminating an inner side of a first non-woven fabric to form a waterproof film on the inner side; step 2: conveying asphalt to the die; step 3: rolling the first non-woven fabric having the waterproof film by means of the first roller, rolling a woven fabric/a second non-woven fabric by means of the second roller, applying the asphalt to the inner side having the waterproof film of the first non-woven fabric by means of the die, the first roller and the second roller being rolled and pressed against each other, the inner side having the waterproof film of the first non-woven fabric rolled by the first roller and an inner side of the woven fabric/the second non-woven fabric rolled by the second roller being compressed together and then conveyed to a third roller for cooling, outputting, trimming, and winding.

9. The preparation method as claimed in claim 8, wherein a heating medium is provided in the first roller and the second roller, and a cooling medium is provided in the third roller.

10. The preparation method as claimed in claim 8, in the step 1, further comprising performing an anti-slip coating treatment on an outer side of the woven fabric/the second non-woven fabric to form an anti-slip film on the outer side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The FIGURE is a structural schematic view of a roofing underlayment in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings.

First Embodiment

[0026] As shown in the FIGURE, a roofing underlayment in accordance with a preferred embodiment of the present invention comprises a five-layer structure having a non-woven fabric 1, a waterproof film 2, an asphalt layer 3, a woven fabric 4, and an anti-slip film 5 arranged in order from top to bottom.

[0027] The non-woven fabric 1 is made of a non-woven fabric having a weight of between 10 g and 100 g per square meter. The non-woven fabric may be a spunbonded, meltblown, needled or spunlace non-woven fabric made of polypropylene (PP), polyester (polyethylene terephthalate, PET), nylon PA or other composite materials.

[0028] The waterproof film 2 is applied to the contact surfaces between the non-woven fabric 1 and the asphalt layer 3. Specifically, the waterproof film 2 may be a polyolefin-based extruded casting film or an elastomer-based extruded casting film or a hot-rolled composite film or an adhesive composite film.

[0029] The asphalt layer 3 is uniformly applied between the waterproof film 2 and the woven fabric 4. The asphalt layer includes 30-70 wt % asphalt, 1-15 wt % SBS, 20-60 wt % filler, and 0.1-2 wt % tackifier. The asphalt layer has a thickness of not greater than 10 mils (0.25 mm). In this embodiment, the thickness is 1 mil.

[0030] The woven fabric 4 is made of a circular-knitting, plain-knitting, spunlace or warp-knitting woven fabric having a weight of between 20 g and 300 g per square meter, and its material may be polypropylene (PP) or polyethylene (PE) or polyethylene terephthalate (PET) or polyamide nylon.

[0031] The anti-slip film 5 is applied to the outer side of the woven fabric 4. The anti-slip film 5 is a polyolefin-based extruded casting anti-slip film or an elastomer-based extruded casting anti-slip film or a rolled coating anti-slip film.

[0032] The present invention also provides a preparation method of a roofing underlayment by using a composite device including a first roller, a second roller, and a third roller arranged from left to right. A die is located at the left side of the first roller. A heating medium is provided in the first roller and the second roller. A cooling medium is provided in the third roller to ensure that the finished product is flat and perfect. The preparation method comprises the following steps:

[0033] step 1: laminating one side of a non-woven fabric to form a waterproof film on the side; and performing an anti-slip coating treatment on one side of a woven fabric to form an anti-slip film on the side of the woven fabric;

[0034] step 2: measuring, heating, stirring asphalt in a tank, and conveying the stirred asphalt to the die with a high pressure pump;

[0035] Step 3: rolling the non-woven fabric having the waterproof film by means of the first roller, rolling the woven fabric having the anti-slip film by means of the second roller, uniformly applying the asphalt on the side having waterproof film of the non-woven fabric by means of the die, the first roller and the second roller being rolled and pressed against each other, the laminating surface (that is, the waterproof film) of the non-woven fabric rolled by the first roller and a woven fabric surface (that is, another side of the anti-slip film) of the woven fabric rolled by the second roller being compressed together and then conveyed to a third roller for cooling, outputting, trimming, and winding.

Second Embodiment

[0036] The difference between the second embodiment and the first embodiment is the fourth layer from top to bottom. The woven fabric 4 is replaced with the same structure as the first layer. The non-woven fabric is made of a non-woven fabric having a weight of between 10 g and 100 g per square meter. The non-woven fabric may be a spunbonded, meltblown, needled or spunlace nonwoven made of polypropylene (PP), polyester (polyethylene terephthalate, PET), nylon PA or other composite materials.

Third Embodiment

[0037] The difference between the third embodiment and the second embodiment is that the fifth layer from top to bottom, namely, the anti-slip film 5, is not provided.

[0038] Although particular embodiments of the present invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the present invention. Accordingly, the present invention is not to be limited except as by the appended claims.