Antislip sheet material with twisted tapes

Abstract

A sheet of material suitable for roofing or industrial wrapping applications has an anti-skid surface formed by ridges of twisted tapes. The sheet comprises a woven scrim of warp tapes and weft tapes. Some of the tapes are twisted about their longitudinal axis, for example about (25) to (400) revolutions per meter, to form ridges having a height substantially greater than the thickness of the tapes. The ridges impart an anti-skid surface to the sheet. The scrim is bonded to a coating or film to make the sheet waterproof.

Claims

1. A roofing underlayment having an anti-skid surface, the roofing underlayment comprising: a first set of tapes generally parallel to each other; and a second set of tapes generally parallel to each other and perpendicular to the first set of tapes; wherein tapes of the first set and tapes of the second set are plastic and have a width greater than their thickness; wherein the tapes of the first set are interwoven with the tapes of the second set to form a scrim; wherein every fourth tape of the first set is twisted between about 250 revolutions per meter and about 400 revolutions per meter about its longitudinal axis to form a first plurality of spaced apart parallel ridges; wherein every third tape of the second set is twisted between about 250 revolutions per meter and about 400 revolutions per meter about its longitudinal axis to form a second plurality of spaced apart parallel ridges; wherein the first plurality of spaced apart parallel ridges and the second plurality of spaced apart parallel ridges form an anti-skid contour of the anti-skid surface of the sheet.

2. The roofing underlayment of claim 1, further comprising a waterproof film on the scrim.

3. The roofing underlayment of claim 1, further comprising a film bonded to the scrim by lamination, wherein said film comprises a high coefficient of friction elastomer.

4. The roofing underlayment of claim 1, further comprising a first extrusion coating on a first side of the scrim and a second extrusion coating on a second side of the scrim.

5. The roofing underlayment of claim 1, wherein twisted tapes of the first set have the same width as other tapes of the first set.

6. The roofing underlayment of claim 1, wherein twisted tapes of the second set have different widths than other tapes of the second set.

7. The roofing underlayment of claim 1, wherein the tapes of the first set and the tapes of the second set have a tape width of between about 1.5 mm and about 6 mm.

8. The roofing underlayment of claim 1, wherein each of the first set of tapes and the second set of tapes have between about 1 tape per inch and about 25 tapes per inch.

9. The roofing underlayment of claim 1, wherein ridges of the first plurality of spaced apart parallel ridges and ridges of the second plurality of spaced apart parallel ridges have a height at least five times greater than a thickness of untwisted tapes of the first set and untwisted tapes of the second set.

10. The roofing underlayment of claim 1, wherein ridges of the first plurality of spaced apart parallel ridges have a height of between about ten mils and about twenty mils.

11. The roofing underlayment of claim 1, wherein each twisted tape of the first set are laid on top of and follow a same weaving path of an untwisted tape of the first set.

12. A roofing underlayment having an anti-skid surface, the roofing underlayment comprising: a first repeating pattern of tapes comprising flat tapes and twisted tapes, wherein the tapes of the first repeating pattern are generally parallel to each other, wherein the twisted tapes of the first repeating pattern are twisted between about 250 revolutions per meter and about 400 revolutions per meter; a second repeating pattern of tapes comprising flat tapes and twisted tapes, wherein the tapes of the second repeating pattern are generally parallel to each other, wherein the twisted tapes of the second repeating pattern are twisted between about 250 revolutions per meter and about 400 revolutions per meter; wherein the tapes of the first repeating pattern are interwoven with the tapes of the second repeating pattern to form a scrim, wherein the tapes of the first repeating pattern are generally perpendicular to the tapes of the second repeating pattern; wherein the twisted tapes of the first repeating pattern and the twisted tapes of the second repeating pattern form an anti-skid contour of the anti-skid surface of the sheet.

13. The roofing underlayment of claim 12, wherein each of the twisted tapes of the first repeating pattern and the second repeating pattern are twisted into a circular cross-section.

14. The roofing underlayment of claim 12, further comprising an extrusion coating on the scrim.

15. The roofing underlayment of claim 12, wherein the twisted tapes of the first repeating pattern have the same width as the flat tapes of the first repeating pattern.

16. The roofing underlayment of claim 12, wherein the twisted tapes of the second repeating pattern have different widths than the flat tapes of the second repeating pattern.

17. The roofing underlayment of claim 12, wherein the tapes of the first repeating pattern and the tapes of the second repeating pattern have a tape width between about 1.5 mm and about 6 mm.

18. The roofing underlayment of claim 12, wherein each of the first repeating pattern and the second repeating pattern have between about 1 tape per inch and about 25 tapes per inch.

19. The roofing underlayment of claim 12, wherein the twisted tapes of the first repeating pattern and the twisted tapes of the second repeating pattern form ridges having a height at least five times greater than a thickness of the flat tapes of the first repeating pattern and the flat tapes of the second repeating pattern.

20. The roofing underlayment of claim 12, wherein the twisted tapes of the first repeating pattern and the twisted tapes of the second repeating pattern form ridges having a height between about ten mils and about twenty mils.

21. The roofing underlayment of claim 12, wherein the twisted tapes of the first repeating pattern are laid on top of and follow a same weaving path of the flat tapes of the first repeating pattern, and wherein the twisted tapes of the second repeating pattern are laid on top of and follow a same weaving path of the flat tapes of the second repeating pattern.

22. The roofing underlayment of claim 1, wherein each of the twisted tapes of the first set and the second set are twisted into a circular cross-section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a plan view of a sheet according to a first embodiment of the invention.

(2) FIG. 2 is a cross-sectional view on the line 2-2 of FIG. 1.

(3) FIG. 3 a cross-sectional view of a second embodiment of the invention.

(4) FIG. 4 is a cross-sectional view of a third embodiment of the invention.

(5) FIG. 5 is a plan view of a fourth embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(6) Exemplary embodiments are illustrated in the referenced figures of the drawings. It is intended that the embodiments are to be considered illustrative rather than restrictive.

(7) Referring to FIGS. 1 and 2, the sheet material 10 has a scrim 12 coated on one side by a coating layer 14. The scrim 12 is woven in a plain weave of warp tapes 16 and weft tapes 18. The weft tapes 18 are laid flat in the weave, in the conventional manner. The warp tapes 16 are twisted, such that they describe full revolutions about their longitudinal axis along the length of the weave. The frequency of the twisting is about one revolution every centimeter. Preferred frequencies of such twisting are in the range of 25 to 400 revolutions per meter. Some of the twisted tapes can have different frequencies of twisting from others.

(8) The thickness of the tapes comprising the scrim is about 1 to 2 mils (0.025 to 0.05 mm). However, when twisted, the effective thickness of the warp tapes 16 is about 10 to 20 mils (0.25 to 0.5 mm). The warp tapes 16 accordingly form ridges, having a height of about 10 to 20 mils, running along the warp direction of the sheet 10, which provide an increased coefficient of friction to the surface of the sheet. To form an effective anti-skid surface, the height of the ridges should be at least about five times greater than the thickness of the tapes, alternatively at least about ten times greater.

(9) The scrim 12 and the coating 14 are made of plastic, poly olefin resins, for example polyethylene or polypropylene. They may alternatively be made of various other plastics, including polyesters, polystyrene, nylon and ethylene acrylic copolymers. Alternatively, the scrim and/or the coating 14 may comprise a high coefficient-of-friction material, for example ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), rubber or elastomer. The scrim provides a structural layer having high tensile and tear strength.

(10) The tapes 16, 18 are conventional extruded plastic tapes having a flat profile and a width greater than their thickness. The tape width is preferably about 1.5 to 6 mm. The number of tapes per inch in the machine direction and in the cross direction is in the range of 1 to 25. Tapes that are to be twisted may be the same width and thickness as tapes that are not to be twisted, or they may have a greater width and/or thickness.

(11) The frequency of twisting of the warp tape 16, and the thickness and denier of the tapes 16, 18 can be selected to achieve the desired coefficient of friction of the anti-skid surface of the sheet 10.

(12) The coating layer 14 is a waterproof film bonded to the scrim. It may be permeable to water vapor to allow the escape of moisture from buildings when the sheet is used as a roofing underlayment or for similar applications. The coating layer 14 is manufactured in-situ using a co-extrusion process and is laminated to the scrim 12, or it can comprise a film that is bonded to the scrim, for example by thermal bonding, lamination or adhesive. Optionally, a second coating layer is bonded to the opposite side of the scrim.

(13) FIG. 3 illustrates an embodiment of the invention in which twisted warp tapes are added to a scrim woven with conventional untwisted warp and weft tapes. The sheet material 20 comprises a scrim 22 with a coating layer 14 laminated thereto. The scrim 22 is woven of untwisted warp tapes 21 and untwisted weft tapes 23 in a plain weave. Twisted warp tapes 25 are woven into this scrim, the twisted warp tapes 25 being laid on top of and following the same weaving path as the untwisted warp tapes 21, interweaving with the weft tapes 23 of the scrim. The twisted warp tapes 25 form a twisted warp layer 24. This layer 24 comprises ridges formed by the twisted warp tapes 25, imparting an enhanced coefficient of friction to the upper surface of the sheet 20.

(14) FIG. 4 illustrates a further embodiment of the invention in which both twisted warp tapes and twisted weft tapes are added to a scrim woven with conventional untwisted warp and weft tapes. The sheet material 30 comprises a scrim 22 with a coating layer 14 laminated thereto. The scrim 22 is woven of untwisted warp tapes 21 and untwisted weft tapes 23 in a plain weave. Twisted warp tapes 25 and twisted weft tapes 27 are woven into this, the twisted warp tapes being laid on top of and following the same path as the untwisted warp tapes 21, and the twisted weft tapes 27 being laid on top of and following the same weaving path as the untwisted weft tapes 23. The twisted warp tapes 25 and twisted weft tapes 27 form a layer 26 which comprises ridges formed by the twisted warp tapes and twisted weft tapes, imparting an enhanced coefficient of friction to the upper surface of the sheet 30.

(15) FIG. 5 illustrates a further embodiment of the invention in which the sheet material 40 comprises a scrim 50 with a coating layer 14 (not shown) laminated thereto. The scrim 50 includes twisted warp tapes 42 and twisted weft tapes 44, and untwisted warp tapes 46 and untwisted weft tapes 48. The twisted warp tapes replace every fourth untwisted warp tape, and the twisted weft tapes replace every third untwisted weft tape, in the example shown. Alternatively, the twisted tapes may be placed at different intervals, for example replacing every wrap and/or weft tape, or every second or every fifth, etc. warp and/or weft tape.

(16) In the sheet materials of the invention, either or both of the warp and weft tapes can be twisted; and the sheet material can be uncoated, coated on one side or on both sides; and it can include additional layers, depending on the properties desired for a particular application.

(17) Some further features and embodiments of the invention include the following:

(18) (a) The weft tapes are twisted and the warp tapes are untwisted;

(19) (b) Both the warp tapes and the weft tapes are twisted;

(20) (c) Each warp (and/or weft) tape is twisted, or every second or third etc. warp (and/or weft) tape is twisted and the others are untwisted;

(21) (d) Where twisted tapes are added to a scrim made of untwisted tapes (as in FIGS. 3 and 4) the added twisted tapes may be in the machine direction or in the cross direction or both;

(22) (e) The scrim is uncoated, or coated on one side, or coated on both sides, or includes additional layers;

(23) (f) The weave of the scrim is plain, twill or other weaves;

(24) (g) The color of the twisted tapes is the same as the surrounding fabric to blend in with it; or it is different to make the antislip grid more visible;

(25) (h) The twisted tapes are applied to the whole of a sheet or to only a part of it;

(26) (i) Adjacent twisted tapes have different frequencies of turning, for example some have relatively more and some have relatively fewer revolutions per meter, creating a rougher surface with ridges of different heights;

(27) (j) The twisted tapes or the coating, or both, are treated with or comprise a tacky or high coefficient-of-friction coating or additive. For example, they may incorporate ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), rubber or elastomer; and/or

(28) (k) The sheet material includes additives or is treated to provide UV-resistance.

(29) Although the invention has been described in terms of various embodiments, it is not intended that the invention be limited to these embodiments. Various modifications within the scope of the invention will be apparent to those skilled in the art. The scope of the invention is defined by the claims that follow.