Note: Descriptions are shown in the official language in which they were submitted.
File No. P29410A01
EMBOSSED SLIP RESISTANT SHEET MATERIAL FOR ROOFING
BACKGROUND
(a) Field
[0001] This application claims priority of US patent application
16/104,614,
filed on August 17, 2018 and US patent application 15/810,109, filed on
November
12, 2017.
[0002] The subject matter disclosed generally relates to slip
resistant sheet
materials for roofing and to methods for manufacturing slip resistant sheet
materials for roofing. More particularly, the subject matter disclosed relates
to a
weather-resistive barrier for a roofing structure, and especially to a
reinforced roof
underlayment having a slip resistant feature.
(b) Related Prior Art
[0003] Roofing structures for buildings typically include an
underlayment
positioned between a roof support deck and an overlaynnent. The overlaynnent,
such as asphalt shingles, tiles, wooden shakes, slate tiles metal roofing, or
the like
is intended to provide protection from external weather conditions like wind,
rainwater, and snowmelt. In order to further protect against moisture and
other
elements which may pass under the overlayment, the underlayment is installed
over the roof deck and under the underlayment to provide an added waterproof
barrier. The additional moisture protection provided by the underlayment is
particularly necessary with tile roofs, where gaps often exist between the
tiles
where moisture can pass through. The underlayment also serves the function of
providing a seal around roofing fasteners used to affix the tiles to the roof
support
deck.
[0004] Typically, underlayment may include a polymeric material that
is
affixed and/or coated to a base sheet for providing a barrier to weather
conditions.
A limitation of such underlayment is that these polymeric materials can be
very
slippery in both wet and dry conditions. Installation of the underlayment and
the
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subsequent roofing material can therefore be problematic as workers may need
to
walk across or work upon the polymeric material coated or affixed to the base
sheet. This decreases the commercial attractiveness of such underlayment for
high pitch roof applications or in climates characterized by wet or humid
conditions.
[0005] Accordingly, there is a need for a roofing underlayment
having an
improved resistance to deterioration from exposure to external elements which
prevents a person from slipping while moving about on the roofing underlayment
and for an improved method of manufacturing the same.
SUMMARY
[0006] According to an embodiment, there is provided a slip
resistant sheet
material for roofing having an upper side, the slip resistant sheet material
comprising:
- a closed-weave woven base layer having a top surface facing towards the
upper side; and
- a thermoplastic layer affixed to the top surface, wherein the thermoplastic
layer comprises, on the upper side, slip-resistant surface texture and further
wherein the slip-resistant surface texture are present in the thermoplastic
layer and absent from the closed-weave woven base layer.
[0007] According to the above embodiment, there is no surface
texture or
embossing in the closed-weave woven base; i.e., the closed-weave woven base
is free from surface texture or embossing.
[0008] According an embodiment, the slip-resistant surface texture
is only
present in the thermoplastic layer.
[0009] According to an aspect, the thermoplastic layer has a
thickness and
wherein the surface texture are defined transversely to the thickness of the
slip
resistant sheet material.
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[0010] According to an aspect, the surface texture has a height
smaller than
the thickness of the thermoplastic layer.
[0011] According to an aspect, the surface texture is spread,
scattered,
dispersed or punctuated over the upper side.
[0012] According to an aspect, the slip resistant sheet material
further
comprises inter-embossment depressions, wherein the inter-embossment
depressions define paths for rain falling on the upper side to flow downward
between the surface texture when the slip resistant sheet material is
installed on a
sloped structure.
[0013] According to an aspect, the slip resistant sheet material is
adapted
for a worker to walk thereon in his footwear and whereby, when the worker
walks
or stands on the slip resistant sheet material, there exists friction between
the
footwear and the surface texture on the thermoplastic layer thereby providing
slip
resistance.
[0014] According to an aspect, the closed-weave woven base layer
further
comprises a bottom surface opposite the top surface and the slip resistant
sheet
material further comprises an additional thermoplastic layer affixed to the
bottom
surface.
[0015] According to an aspect, at least one of the thermoplastic
layer and
the additional thermoplastic layer is directly affixed to one of the top
surface and
the bottom surface without use of an adhesive or another intermediate layer.
[0016] According to an aspect, at least one of the thermoplastic
layer and
the additional thermoplastic layer is vapor impermeable.
[0017] According to an aspect, at least one the thermoplastic layer
and the
additional thermoplastic layer is a film-forming polymer.
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[0018] According to an aspect, at least one the thermoplastic layer
and the
additional thermoplastic layer comprises at least one of: polyethylene and
polypropylene.
[0019] According to an aspect, the closed-weave woven comprises
cross-
laminated polyethylene tape.
[0020] According to an embodiment, there is provided a method of
manufacturing a slip resistant sheet material for roofing having an upper
side. The
method comprises the steps of:
- providing a closed-weave woven base layer having a top surface;
- affixing a thermoplastic layer to the top surface of the closed-weave
woven
base layer; and
- embossing the thermoplastic layer with an embossed roller comprising a
pattern of depressions, the embossing transferring the pattern depressions
to the upper side of thermoplastic layer into a pattern of slip-resistant
surface texture, wherein the slip-resistant surface texture is present on the
thermoplastic layer and absent from the closed-weave woven base layer.
[0021] According to an aspect, the embossing step is performed
before
cooling down the thermoplastic layer.
[0022] According to an aspect, the embossing step comprises passing
the
slip resistant sheet material between two rollers, wherein one of the two
rollers
comprises the embossing roller.
[0023] According to an aspect, the closed-weave woven base layer
further
comprises a bottom surface opposite the top surface and the method further
comprises affixing an additional thermoplastic layer to the bottom surface.
[0024] According to an aspect, at least one of the affixing the
thermoplastic
layer step and the affixing the additional thermoplastic layer step comprises
directly
affixing the respective one of the thermoplastic layer and the additional
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thermoplastic layer to the respective one of the top surface and to the bottom
surface without use of an adhesive or another intermediate layer.
[0025] According to an aspect, at least one of the affixing the
thermoplastic
layer step and the affixing the additional thermoplastic layer step comprises
respectively extruding a film-forming polymer thereby producing the
thermoplastic
layer and the additional thermoplastic layer.
[0026] According to an aspect, the extruding a film-forming polymer
step
comprises extruding at least one of: polyethylene and polypropylene.
[0027] According to a further embodiment, there is provided a slip
resistant
non-woven sheet material for roofing. The slip resistant non-woven sheet
material
for roofing has an upper side and a lower side. The slip resistant non-woven
sheet
material for roofing is .typically made of a single layer which defines a top
surface
and a bottom surface, with the top surface facing in a same direction as the
upper
side. The single non-woven layer defines a weather-resistant barrier between
the
upper side and the lower side, and the slip-resistant surface texture provide
slip
resistance on the upper side of the sheet material for roofing.
[0028] According to an aspect, the slip-resistant texture surface of
the slip
resistant non-woven sheet material for roofing comprises rigid projections.
[0029] According to an aspect, the rigid projections are one of
filled with
material or resulting from a variable thickness of the non-woven sheet
material
according to projections and depressions present in slip-resistant texture
surface.
[0030] According to an aspect, the slip resistant non-woven sheet
material
for roofing features one or a plurality of characteristics, alone or in
combination,
similar to one(s) of the slip resistant sheet material comprising a close-
weave base
layer.
[0031] According to a further embodiment, there is provided a non-
woven
slip resistant sheet material comprising a thermoplastic layer affixed to the
top
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surface of a non- woven base layer, wherein the thermoplastic layer comprises,
on
the upper side, slip-resistant surface texture and further wherein the slip-
resistant
surface texture are present in the thermoplastic layer and absent from the non-
woven base layer.
[0032] According to an aspect, the non-woven slip resistant non-
woven
sheet material for roofing features one or a plurality of characteristics,
alone or in
combination, similar to one(s) of the slip resistant sheet material comprising
a
close-weave base layer.
[0033] According to a further embodiment, there is provided a closed-
weave
woven slip resistant sheet material comprising a thermoplastic layer affixed
to the
top surface of a closed-weave woven base layer, wherein the thermoplastic
layer
comprises, on the upper side, slip-resistant surface texture and further
wherein the
slip-resistant surface texture are present in the thermoplastic layer and
absent from
the non-woven base layer.
[0034] According to an aspect, the non-woven slip resistant non-
woven
sheet material for roofing features one or a plurality of characteristics,
alone or in
combination, similar to one(s) of the slip resistant sheet materials
comprising a
thermoplastic layer.
[0035] The following terms are defined below.
[0036] The term "slip resistant sheet material" is intended to mean
a sheet
material provided with an additional means for increasing the slip resistance
and
thereby increasing safety of those walking on roofs, or on any surfaces, on
which
the slip resistance sheet material is installed before installation of an
overlayment.
[0037] The terms and expression "surface texture", "embossing",
"embossment", "embossed" material and results from a process of embossing are
intended to refer to the result of an impression produced by pressure or
printing
and the process of making that impression over a receiving material or
surface,
and are thus intended to be interchangeable.
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[0038] The term "closed-weave woven" is intended to mean yarns or
threads that are normally tightly interlaced at a right angle to form a fabric
or a
sheet material. The method in which these yarns or threads are interwoven
affects
the characteristics of the fabric or of the sheet material. The yarns or
threads that
are tightly interlaced may also be at an angle different than the right angle.
[0039] The expression "non-woven material" is intended be broadly
defined
as sheet or web structures bonded together by entangling fiber or filament
(and by
perforating films) mechanically, thermally or chemically. The non-woven
material
is therefore not made by weaving or knitting and do not require converting
fibers
into yarns.
[0040] The term "thermoplastic layer" is intended to mean an elastic
and
flexible layer, made of a thermoplastic material, to be affixed to at least
one of the
top surface and bottom surface of a closed-weave woven. The "thermoplastic
layer" may provide a weather-resistant barrier which prevents moisture and
other
external elements from passing through the slip resistant sheet material.
[0041] Features and advantages of the subject matter hereof will
become
more apparent in light of the following detailed description of selected
embodiments, as illustrated in the accompanying figures. As will be realized,
the
subject matter disclosed and claimed is capable of modifications in various
respects, all without departing from the scope of the claims. Accordingly, the
drawings and the description are to be regarded as illustrative in nature and
not as
restrictive and the full scope of the subject matter is set forth in the
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Further features and advantages of the present disclosure
will
become apparent from the following detailed description, taken in combination
with
the appended drawings, in which:
[0043] Fig. 1 is an elevation view of a slip resistant sheet
material for roofing
in accordance with an embodiment;
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[0044] Fig. 2 is an enlarged, fragmentary, cross-sectional view of
the slip
resistant sheet material for roofing of Fig.1;
[0045] Fig. 2a is another enlarged, fragmentary, cross-sectional
view of the
slip resistant sheet material for roofing of Fig.1;
[0046] Fig. 2b is yet another enlarged, fragmentary, cross-sectional
schematic view of the slip resistant sheet material for roofing of Fig.1;
[0047] Fig. 2c is an enlarged, fragmentary, cross-sectional
schematic view
of the slip resistant sheet material for roofing where only the base layer and
the
first thermoplastic layer are present;
[0048] Fig. 3 is an exploded, perspective view of the slip resistant
sheet
material for roofing of Fig. 1;
[0049] Fig. 4 is an elevation view of a slip resistant sheet
material for roofing
in accordance with another embodiment;
[0050] Fig. 5 illustrates a method for manufacturing a slip
resistant sheet
material for roofing in accordance with another embodiment;
[0051] Fig. 6 is a perspective view of slip resistant sheet
materials for roofing
being installed on an exemplary roof structure in accordance with another
embodiment;
[0052] Fig. 7 is a perspective view showing the slip resistant sheet
materials
for roofing of Fig. 6 in a later stage of the installation process;
[0053] Fig. 8 illustrates a process for manufacturing a slip
resistant sheet
material for roofing in accordance with another embodiment;
[0054] Fig. 9 is an elevation view of a slip resistant sheet
material for roofing
in accordance with another embodiment;
[0055] Fig. 10 is an enlarged, fragmentary, cross-sectional view of
the slip
resistant sheet material for roofing of Fig. 9;
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[0056] Fig. 11 is an exploded, perspective view of the slip
resistant sheet
material for roofing of Fig. 9;
[0057] Fig. 12 illustrates a method for manufacturing a slip
resistant sheet
material for roofing of Fig. 9;
[0058] Fig. 13 is a perspective view of the slip resistant sheet
materials for
roofing of Fig. 9 being installed on an exemplary roof structure in accordance
with
an embodiment;
[0059] Fig. 14 is a perspective view of the slip resistant sheet
materials for
roofing of Fig. 9 being installed on an alternative roof structure in
accordance with
an embodiment;
[0060] Fig. 15 is a perspective view showing the slip resistant
sheet
materials for roofing of Fig. 9 in a later stage of the installation process
on the roof
structure of Fig. 13;
[0061] Fig. 16 is a perspective view showing the slip resistant
sheet
materials for roofing of Fig. 9 in a later stage of the installation process
on the roof
structure of Fig. 14;
[0062] Fig. 17 illustrates a process for manufacturing a slip
resistant sheet
material for roofing or Fig. 9 in accordance with an embodiment;
[0063] Fig. 18 is an elevation view of an embodiment of a textured
roller for
manufacturing an embodiment of the slip resistant sheet material for roofing
in
accordance with another embodiment;
[0064] Fig. 19 is an elevation view of the embodiments of the slip
resistant
sheet material for roofing manufactured using the roller of Fig. 18;
[0065] Fig. 20 is an elevation view of a slip resistant non-woven
sheet
material for roofing in accordance with another embodiment;
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[0066] Fig. 21 is a perspective view of the slip resistant non-woven
sheet
materials for roofing of Fig. 20 being installed on an exemplary roof
structure in
accordance with an embodiment;
[0067] Fig. 22 is a partially cut-out top view of a non-slip
resistant sheet
material for roofing in accordance with another embodiment;
[0068] Fig. 23 is an enlarged, fragmentary, cross-sectional view of
the slip
resistant sheet material for roofing of Fig. 22; and
[0069] Fig. 24 is an exploded, perspective view of the slip
resistant sheet
material for roofing of Fig. 22;
[0070] Fig. 25 is picture of the upper side of another embodiment of
a slip
resistant sheet material for roofing;
[0071] Fig. 26 is an enlarged view of the picture of the upper side
of the slip
resistant sheet material for roofing of Fig. 25;
[0072] Fig. 27 is a picture view of the lower side of the embodiment
of a slip
resistant sheet material for roofing of Figs. 25 and 26;
[0073] Fig. 28 is an enlarged view of the picture view of the lower
side of the
slip resistant sheet material for roofing of Fig. 27.
[0074] It will be noted that throughout the appended drawings, like
features
are identified by like reference numerals.
DETAILED DESCRIPTION
[0075] There is disclosed herein various embodiments of a slip
resistant
sheet material for roofing and of a method for manufacturing a slip resistant
sheet
material for roofing.
[0076] Referring now to the drawings, and more particularly to Fig.
1, there
is shown an elevation view of a slip resistant sheet material 10 for roofing
in
accordance with an embodiment. The slip resistant sheet material 10 for
roofing
has an upper side 15 and a lower side 17. The slip resistant sheet material 10
for
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roofing further includes a base layer 12 which defines a top surface 14 and a
bottom surface 16 (Fig. 2). The top surface 14 faces in a same direction as
the
upper side 15.
[0077] According to an embodiment, base layer 12 comprises a closed-
weave woven which is referred herein to as a closed-weave woven base layer 12.
According to another embodiment, the base layer 12 comprises a non-woven
fibrous material such as a spunbond polyester substrate.
[0078] According to an embodiment, the closed-weave woven base layer
12 includes yarns of a first direction 18 and yarns of a second direction 20
that are
interspersed with the yarns of the first direction 18. As better shown in Fig.
2, which
is a, cross-sectional view of the slip resistant sheet material 10 for roofing
of Fig.1,
and in Fig. 3, which is an exploded, perspective view of the slip resistant
sheet
material 10 for roofing of Fig. 1, the slip resistant sheet material 10 for
roofing
further includes thermoplastic first and second layers 22A, 22B respectively
affixed
to the top surface side 14 and the bottom surface 16 of the closed-weave woven
base layer 12 for providing a weather-resistant barrier. Still referring to
Figs. 2 and
3, there is shown that a first thermoplastic layer 22A is affixed to the top
surface
14 of the closed-weave woven and a second thermoplastic layer 22B (optional)
is
affixed to the bottom surface 16 of the closed-weave woven base layer 12.
[0079] As shown in Figs. 1-3, the closed-weave woven base layer 12
and
the first and second thermoplastic layers 22A, 22B are embossed to form an
embossed pattern 24. The embossed pattern 24 has a plurality of projections 26
that outwardly extends from the first thermoplastic layer 22A and a plurality
of
corresponding depressions 28 that inwardly extends from the second
thermoplastic layer 22B for providing slip resistance. The projections 26 of
the
embossed pattern 24 along with the first thermoplastic layer 22A provide an
anti-
skid surface / enhanced friction surface / slip resistant surface.
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[0080] The embossed pattern 24 increases the slip resistance and
thereby
increasing safety of those walking on roofs on which the slip resistant sheet
material 10 is installed before installation of an overlayment 36 (Fig. 7).
[0081] According to Figs 1-3, there is shown that the plurality of
projections
26 and the plurality of corresponding depressions 28 are regularly spaced
within
the embossed pattern 24 such as to define a specific mosaic or pattern, such
as
pattern 25. However, it is to be noted that the plurality of projections 26
and the
plurality of corresponding depressions 28 may be irregularly spaced within the
embossed pattern 24 as long as it increases the slip resistance and thereby
increases safety of those walking on roofs on which the slip resistant sheet
material
is installed before installation of the overlayment 36.
[0082] The embossed pattern 24 includes a texture formed by a
plurality of
features that are raised and or sunken with respect to the closed-weave woven
base layer 12 and the first and second thermoplastic layers 22A, 22B. For
example, the texture can include a plurality of protrusions or projections 26
and a
plurality of corresponding depressions 28 (i.e., cavities, voids) in the
closed-weave
woven base layer 12 and the first and second thermoplastic layers 22A, 22B.
The
texture of the embossed pattern 24 may be of varying heights or depths or can
be
substantially the same height or depth. Example of heights and depths of the
texture include between about 0.01 mm to 10 mm. The texture can be disposed
randomly or can be configured as a uniform or repeated pattern, such as
pattern
25. Where the texture is disposed as an array of uniform or repeating
configurations, examples may include straight lines, a cross-hatch pattern, a
chevron pattern, a checked pattern, a company logo, dots, and the like. The
texture
can include raised and/or sunken features that are adjacent to each other or
spaced apart from each other providing various densities. Examples include
where
the texture includes between 1 feature to 100 features per cm2 of the slip
resistant
sheet material 10. Additionally, the features of the texture can have the same
shape or can have varying shapes such as square, triangular, circular, ovular,
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obround, rectangular, random, or any other suitable shape configured to form
the
anti-skid surface.
[0083] In accordance with embodiments, the slip resistant sheet
material 10
may include only one thermoplastic layer, a first and a second thermoplastic
layers,
or a plurality of different thermoplastic layers, some providing weather-
resistant
barrier, some other providing UV-resistant barrier, microbial properties, heat
resistant properties and the like. It is to be noted that all the
thermoplastic layers
and the closed-weave woven base layer 12 need to be embossed to form the
embossed pattern 24. This configuration will provide the safety of those
walking
on roofs.
[0084] In accordance with an embodiment, the thermoplastic layer or
the
plurality of thermoplastic layers 22A, 22B may include a film-forming polymer.
[0085] In accordance with an embodiment, the thermoplastic layer or
the
plurality of thermoplastic layers 22A, 22B comprise(s) polyethylene,
polypropylene
or a mixture of polyethylene and polypropylene.
[0086] In accordance with an embodiment, the yarns of the first
direction 18
and the yarns of the second direction 20 are substantially flat, but can adopt
any
other cross-sectional configurations.
[0087] The thermoplastic layers 22A, 22B (first thermoplastic layer
22A and
second thermoplastic layer 22B) are normally affixed to both the upper and the
top
surface 14 and the bottom surface 16 of the closed-weave woven base layer 12,
as shown in the slip resistant sheet material 10 for roofing of Figs. 2 and 3.
[0088] Now referring to Fig. 4 and in accordance with another
embodiment,
the closed-weave woven base layer 12 may be formed of yarns of a first gauge
30
of material having a tensile strength sufficient to resist tearing when
exposed to
tensile loads from various directions. The yarns of the first gauge 30 are
normally
the yarns of the first direction 18 and the yarns of the second direction 20.
More
specifically, the slip resistant sheet material 10 for roofing includes the
closed-
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weave woven base layer 12, which includes yarns of the first direction 18 and
yarns
of the second direction 20. The closed-weave woven base layer 12 may further
includes yarns of a second gauge 32, interspersed within the closed-weave
woven
base layer 12 with the yarns of the first direction 18 (as shown in Fig. 4)
and/or
with the yarns of the second direction 20. The yarns of the second gauge 32
include a gauge that is greater than the first gauge. As better shown in Fig.
4, the
yarns of the second gauge 32 are interspersed in the closed-weave woven base
layer 12 at a given interval with the yarns of the first direction 18.
[0089] In accordance with an embodiment, the yarns of the second
gauge
32 of the closed-weave woven base layer 12 are parallel to each other. In the
closed-weave woven base layer 12, the spacing between the parallel yarns of
the
second gauge is substantially equal. The yarns of the second gauge 32 of the
closed-weave woven base layer 12 may also be perpendicular to each other.
[0090] Still referring to Fig. 4, there is shown an elevation view
of the closed-
weave woven base layer 12 of the slip resistant sheet material 10 for roofing
in
accordance with an embodiment. In Fig. 4, a first group of yarns of the first
gauge
are in a first direction (yarns of the first direction 18), a second group of
yarns of
the first gauge are in a second direction (yarns of the second direction 20)
perpendicular to the first direction and a third group of yarns of the second
gauge
32 are in the direction parallel to the yarns of the first direction 18. Also,
the yarns
of the second gauge 32 may be interspersed at the given interval in at least
one of
the first and second directions for providing an additional slipping
resistance in
addition to the embossed pattern 24 for preventing a person from slipping
while
moving on the slip resistant sheet material 10 for roofing. It is to be noted
that the
given interval is a multiple of 18 yarns in an embodiment, as shown in Fig. 4
and
referred to as X1 . In other embodiments the multiple may be 6 yarns, 9 yarns,
12
yarns, 15 yarns, 36 yarns, 72 yarns, 90 yarns, or any given interval of yarns
(not
shown) such as to further prevent slipping from a worker. Thus, according to
different embodiments, the given interval may be a multiple of any suitable
number.
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[0091] In accordance with an embodiment, the given interval may be a
mix
of at least two given intervals. For instance, for allowing a worker to walk
on a
roofing structure without sliding, the slip resistant sheet material 10 for
roofing may
include a first group of three yarns of the second gauge 32 interspersed at a
given
interval of 6 yarns of the yarns of the first direction 18 in the closed-weave
woven
base layer 12 and another yarn of the second gauge 32, distant from the first
group
of three yarns of the second gauge 32, at another given interval of 72 yarns
of the
yarns of the first direction 18.
[0092] According to another embodiment, the given interval is one
of: a
regular given interval and an irregular given interval. As another example, a
first
group of three yarns of the second gauge 32 may intersperse the closed-weave
woven base layer 12 at a first quarter of the closed-weave woven base layer
12, a
second group of three yarns of the second gauge 32 may intersperse the closed-
weave woven base layer 12 at a first half of the closed-weave woven base layer
12 and a third group of three yarns of the second gauge 32 may intersperse the
closed-weave woven base layer 12 at a second quarter of the closed-weave woven
base layer 12.
[0093] It is also to be noted that the yarns of the first direction
18 and the
yarns of the second direction 20 are tightly interwoven. The yarns of the
first
direction 18 and the yarns of the second direction 20 of the closed-weave
woven
base layer 12 may be formed of a thermoplastic polymer, such as polypropylene,
polyethylene, polyester, nylon or other similar materials. However, it is to
be noted
that the yarns of the first direction 18 and the yarns of the second direction
20 of
the closed-weave woven base layer 12 may be of any suitable material that has
strength sufficient to resist tearing when exposed to tensile loads from
various
directions.
[0094] The yarns of the first direction 18 and the yarns of the
second
direction 20 are interwoven as shown in Figs. 1-4, by way of example, to
provide
a closed-weave woven base layer 12 having an improved tensile strength not
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achievable with solid film of material. The orientation of the yarns of the
first
direction 18 and the yarns of the second direction 20 may also be selected to
optimize their tensile strength.
[0095] The yarns of the first gauge 30 (i.e., the yarns of the first
direction 18
and the yarns of the second direction 20) and the yarns of the second gauge 32
may comprise any cross-sectional shape and size, depending upon the desired
tensile characteristics of the closed-weave woven base layer 12. For example,
the
yarns of the first gauge 30 may be interwoven fibers as shown in Fig. 2, may
be
cross-laminated polyethylene tape, or may include any other interwoven
configuration. The size of the yarn of the first gauge 30 may be approximately
between 800 Denier to 1,000 Denier. The size of the yarn of the second gauge
32
may be approximately between 1,000 Denier and 12,000 Denier. However, the
size of the yarns of the first gauge 30 and the size of the yarns of the
second gauge
32 may be of any suitable size allowing the formation of a tight closed-weave
woven base layer 12.
[0096] Referring to Figs. 2 and 3, the first and second
thermoplastic layers
22A, 22B affixed to both the top surface 14 and the bottom surface 16 of the
closed-weave woven base layer 12 provide a weather-resistant barrier which
prevents moisture and other external elements from passing through the slip
resistant sheet material 10 for roofing. An exemplary embodiment for the first
and
second thermoplastic layers 22A, 22B includes a layer of thermoplastic film
which
is extruded over each side of the closed-weave woven base layer 12, so that
the
closed-weave woven base layer 12 is sandwiched between the first and the
second thermoplastic layers 22A, 22B.
[0097] The slip resistant sheet material 10 for roofing is shown as
haying a
thermoplastic layer 22A or 22B positioned over each side of the closed-weave
woven base layer 12. However, it is understood that certain applications may
allow
the closed-weave woven base layer 12 to have only one side coated with a
thermoplastic layer. The thermoplastic layer(s) (such as first and second
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thermoplastic layers 22A, 22B) may include polyethylene, polypropylene, or
other
similar thermoplastic polymers.
[0098] The slip resistant sheet material 10 for roofing is formed by
extruding
layers of thermoplastic polymer over the closed-weave woven base layer 12.
According to an embodiment, the first and the second thermoplastic layers 22A,
22B are directly affixed to the base layer without use of an adhesive or
another
intermediate layer.
[0099] According to another embodiment, the thermoplastic layers may
be
affixed to the closed-weave woven base layer 12 using an adhesive or any other
manner of attachment.
[00100] The thermoplastic layers (i.e., such as first and second
thermoplastic
layers 22A, 22B) may be variably pigmented to allow the color of the
thermoplastic
layers to be selected based upon particular requirements. The thickness of the
thermoplastic layers is selected such that the slip resistant sheet material
10 for
roofing is flexible, whereby the flexible nature of the slip resistant sheet
material
for roofing allows it to be formed into rolls and easily installed by simply
unrolling
the slip resistant sheet material 10 for roofing over a roof support structure
or the
like.
[00101] The slip resistant sheet material 10 for roofing may be
installed
between a roof support structure 34 (Fig. 6) and an overlayment 36 (Fig. 7) in
order
to provide a waterproof barrier for the roof structure. The slip resistant
sheet
material 10 for roofing may be mechanically fastened to the roof rafters 38
(Fig. 6)
using nails or screws, but it is understood that the slip resistant sheet
material 10
for roofing may be affixed to the roof rafters 38 using adhesives or other
possible
attachment methods.
[00102] The slip-resistant sheet material 10 for roofing may be
formed from
a plurality of thermoplastic layers having an improved resistance to
deterioration
from exposure to external elements, such as moisture and dirt, so that the
slip
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resistant sheet material 10 for roofing has an improved durability and
longevity.
Moreover, employing closed-weave woven base layer 12 including yarns of a
second gauge 32 in the slip resistant sheet material 10 for roofing provides
an
improved tensile strength capable of being walked upon without tearing when
being installed on the roof. The closed-weave woven base layer 12 further
provides
improved strength to resist tearing when exposed to external forces, such as
collected moisture, wind, and other external forces.
[00103] As shown, the improved resistance to deterioration and
tearing
provided by the slip resistant sheet material 10 for roofing improves the
integrity
and effectiveness of the weather-resistant barrier provided by the slip
resistant
sheet material 10 for roofing. By improving the longevity of the waterproof
integrity
of the slip resistant sheet material 10 for roofing to more closely match the
integrity
of the entire roof structure, the longevity of the integrity of the entire
roof structure
is improved.
[00104] According to an embodiment, and referring now to Fig. 6,
there is
shown a perspective view of the slip resistant sheet material 10 for roofing
being
installed on an exemplary roof structure. The slip resistant sheet material 10
for
roofing is to be installed between a roof support structure 34 and an
overlayment
36 in order to provide a waterproof barrier and a slip resistant material for
the roof
structure. As shown, the slip resistant sheet material 10 for roofing may be
formed
into rolls 40 which can be simply unrolled over the roof support structure 34
to
allow for easy installation. In this exemplary roof structure, the sarking
method is
utilized where the slip resistant sheet material 10 for roofing is fastened to
the top
side of the roof rafters 38 and allowed to drape between the open rafter bays
42.
The slip resistant sheet material 10 for roofing is preferably mechanically
fastened
to the roof rafters 38 using nails or screws, but it is understood that the
slip resistant
sheet material 10 for roofing may be affixed to the roof rafters 38 using
another
adhesives or other possible attachment methods.
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[00105]
Battens 44 are then fastened over the slip resistant sheet material
for roofing and into the top side of the roof rafters 38, where the
overlayment
36 is then attached to the battens 44, as shown in Fig. 7. The sarking method
is
merely one possible manner of installing a roof structure using the slip
resistant
sheet material 10 for roofing. For instance, the roof support structure 34 on
which
the slip resistant sheet material 10 for roofing is attached may include solid
sheathing or spaced sheathing. Further, any type of batten structure may be
attached to the slip resistant sheet material 10 for roofing for supporting
the
overlayment 36, such as wood battens, steel battens, plastic battens, counter-
battens made from any of these materials, or the overlayment 36 may be
attached
directly to the roof support structure 34 through the slip resistant sheet
material 10
for roofing.
[00106]
According to another embodiment and referring to Fig. 5, there is
provided a method 100 for manufacturing a slip resistant sheet material 10 for
roofing having an upper side and a lower side.
[00107] The
method 100 comprises providing a closed-weave woven base
layer having a top surface facing in a same direction as the upper side (step
102).
The method 100 further comprises affixing a first thermoplastic layer to the
top
surface (step 104). After affixing first thermoplastic layer to the top
surface, the
next step is embossing the base layer and the first thermoplastic layer to
form
projections in the same direction as the upper side at corresponding locations
in
the base layer and the first thermoplastic layer (step 106) thereby providing
slip
resistance on the upper side.
[00108]
According to an embodiment, the embossing (step 106) is performed
at ambient temperature.
[00109]
According to an embodiment, the embossing (step 106) comprises
embossing the base layer and the first thermoplastic layer with an engraved
roller.
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[00110] According to an embodiment, the closed-weave woven base layer
further comprises a bottom surface opposite the top surface and the method 100
further comprises affixing a second thermoplastic layer to the bottom surface
(step
108).
[00111] According to an embodiment, the affixing the first
thermoplastic layer
and the second thermoplastic layer (steps 104 and 108) comprises respectively
directly affixing the first thermoplastic layer and the second thermoplastic
layer to
the top surface and to the bottom surface without use of an adhesive or
another
intermediate layer.
[00112] According to an embodiment, the affixing the first
thermoplastic layer
and the second thermoplastic layer (steps 104 and 108) comprises respectively
extruding a film-forming polymer (not shown) thereby producing the first
thermoplastic layer and the second thermoplastic layer.
[00113] According to an embodiment, further comprising respectively
bonding the first thermoplastic layer and the second thermoplastic layer to
the top
surface and to the bottom surface (not shown).
[00114] According to an embodiment, the extruding a film-forming
polymer
(not shown) comprises extruding at least one of: polyethylene and
polypropylene.
[00115] In accordance with another embodiment, there is provided a
process
200 for manufacturing the slip resistant sheet material 10 for roofing. The
process
200 for manufacturing the slip resistant sheet material 10 for roofing is
shown in
Fig. 8. First, the closed-weave woven base layer 12 is unwound into an
unwinding
machine for showing upwardly the top surface 14 of the closed-weave woven base
layer 12. Next, a polymer film 204 is extruded through a heated die 202 to
form a
first thermoplastic layer 22A. The first thermoplastic layer 22A bonds to the
top
surface 14 of the closed-weave woven base layer 12 at the nip point 206 where
at
least one of rollers 212, 214 is cooled for cooling the temperature of the
closed-
weave woven base layer 12 which is being bonded with the first thermoplastic
layer
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22A. Optionally (not shown), the closed-weave woven base layer 12 is wounded
and again unwound into the unwinding machine for showing upwardly the bottom
surface 16 of the closed-weave woven base layer 12. Another polymer film 204
is
then extruded through the heated die 202 to form the second plastic layer 22B
covering the bottom surface 16 of the closed-weave woven base layer 12. The
second thermoplastic layer 22B then bonds to the bottom surface 16 of the
closed-
weave woven base layer 12 at the nip point 206, where at least one of rollers
212,
214 is cooled for cooling the temperature of the closed-weave woven base layer
12 which is being bonded with the second thermoplastic layer 22B. Finally, at
ambient temperature, the closed-weave woven base layer 12 that is now extruded
with first and/or second thermoplastic layers 22A, 22B passes through an
engraved roller 208 and a backer roller 210. Using this process 200, the
embossed -
pattern 24 is respectively cast into the first thermoplastic layer 22A, the
closed-
weave woven base layer 12 and alternatively, the second thermoplastic layer
22B.
Since the step of passing the closed-weave woven base layer 12 through the
engraved roller 208 and the backer roller 210 is performed once the closed-
weave
woven base layer 12 is extruded with first and second thermoplastic layers
22A,
22B, there is no need for one or both roller(s) 212,214 to be temperature
controlled
to cool the polymer film extrusion and engraved to provide the embossed
pattern
24.
[00116] Alternatively, instead of passing between the engraved roller
208
engraved with bump patterns 216 and the backer roller 210, the closed-weave
woven base layer 12 that is extruded with or sandwiched between the first
and/or
second thermoplastic layers 22A, 22B, may pass under a press plate engraved
with bump patterns (not shown).
[00117] The engraved roller 208 is substantially cylindrical and
includes a
surface configured for embossing the slip resistant sheet material 10 to form
the
anti-skid surface. The surface of the engraved roller 208 includes a texture
formed
by a plurality of features that are raised and or sunken with respect to
remainder
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of the surface of the engraved roller 208. For example, the surface can
include a
plurality of protrusions from the surface of the engraved roller, a plurality
of
depressions in the surface of the engraved roller or both. The texture for
forming
the embossment on the closed-weave woven base layer 12 and on the
thermoplastic layer(s) 22A and/or 22B may be of varying heights or depths or
can
be substantially the same height or depth. Example of heights and depths of
the
texture include between 0.01 mm to 10 mm. The texture can be disposed on the
surface of the engraved roller 208 randomly or can be configured as a uniform
or
repeated pattern. Where the texture is disposed as an array of uniform or
repeating
configurations, examples may include straight lines, a cross-hatch pattern, a
chevron pattern, a checked pattern, a company logo, dots, and the like. The
texture
can include raised and/or sunken features that are adjacent to each other or
spaced apart from each other providing various densities. Examples include
where
the texture includes between 1 feature and 100 features per cm2 of the surface
of
the engraved roller 208. Additionally, the features of the texture can have
the same
shape or can have varying shapes such as square, triangular, circular, ovular,
obround, rectangular, random, or any other suitable shape configured to form
the
anti-skid surface.
[00118] Various additives may be included or applied to the slip
resistant
sheet material 10. Examples may include various colorants, heat stabilizers,
waterproofing treatments, strengthening laminates, antimicrobials, UV blockers
and light stabilizers. The slip resistant sheet material 10 may also be
printed with
signage, such as logos, installation instructions, and/or orientation indicia.
[00119] According to another embodiment in relation with particularly
Figs. 9
to 19, there is shown another slip resistant sheet material 110 for roofing.
The slip
resistant sheet material 110 for roofing has an upper side 115 and a lower
side
117. The slip resistant sheet material 110 for roofing further includes a base
layer
112 which defines a top surface 114 and a bottom surface 116 (Fig. 10). The
top
surface 114 faces in a same direction as the upper side 115.
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[00120] According to an embodiment, base layer 112 comprises a closed-
weave woven which is referred herein to as a closed-weave woven base layer
112.
According to another embodiment, the base layer 112 comprises a non-woven
fibrous material such as a spunbond polyester substrate.
[00121] According to an embodiment, the closed-weave woven base layer
112 comprises yarns of a first direction 118 and yarns of a second direction
120
and is manufactured in a similar fashion as base layer 12. Accordingly, the
slip
resistant sheet material 110 for roofing comprises a first thermoplastic layer
122A
and (according to another embodiment) additionally a second thermoplastic
layer
122B respectively affixed to the top surface 114 and the bottom surface 116 of
the
closed-weave woven base layer 112 for providing a weather-resistant barrier
[00122] As shown in Figs. 9-11, the first thermoplastic layer 122A is
embossed to form an embossed pattern 124 comprising surface texture 126.
[00123] One must note that the terms "embossing", "embossment",
"embossed" material and the result from a process of embossing are intended to
refer to the result of an impression produced by pressure or printing and the
process of making that impression over a receiving material or surface.
[00124] The embossed pattern 124 comprises a plurality of surface
texture
126 or define reliefs that outwardly extend from the first thermoplastic layer
122A
for providing slip resistance on the upper side 115. The surface texture 126
of the
embossed pattern 124 in the first thermoplastic layer 1224 provide an anti-
skid
surface / enhanced friction surface / slip resistant surface.
[00125] The embossed pattern 124 increases the slip resistance and
thereby
increases safety of those walking on roofs on which the slip resistant sheet
material
110 is installed before installation of an overlayment 136 (Figs. 13-16).
[00126] The embossed pattern 124 comprise surface texture 126 spread,
scattered, dispersed or punctuated over the upper side 115 providing through
the
inter-embossment depressions paths for rain falling on the upper side 115 for
the
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rain to flow downward between the surface texture 126 when the slip resistant
sheet material 110 is installed on a sloped structure, leaving the surface
texture
126 free of water and thereby enhancing friction surface. Furthermore, the
embossed pattern 124 comprise surface texture 126 spread, scattered, dispersed
or punctuated at an embossment density insuring the footstep of those walking
on
roofs on which the slip resistant sheet material 110 is installed to always
step over
a plurality of surface texture 126.
[00127] According to Figs 9-11, there is shown that the surface
texture 126
are regularly spaced within the embossed pattern 124 such as to define a
specific
mosaic or pattern, such as pattern 125. However, it is to be noted that the
surface
texture 126 may be irregularly spaced within the embossed pattern 124 as long
as
it is designed to increase the slip resistance and thereby increases safety of
those
walking on roofs on which the slip resistant sheet material 10 is installed
before
installation of the overlayment 136.
[00128] According to Figs. 9-11, there is shown that the plurality
of surface
texture 126 are dimensioned, in size and height, as a preferred proportion of
the
whole thickness of the slip resistant sheet material 110. However, it is to be
noted
that in alternative embodiments the plurality of surface texture 126 are
differently
dimensioned, the selected alternative dimensions being based in part on the
thickness of the first thermoplastic layer 122A. In further alternative
embodiments,
the dimensions of the surface texture 125 of a same slip resistant sheet
material
110 vary in size and/or in height. According to embodiments, the height of the
surface texture is selected between 580RA and 620RA of the first thermoplastic
layer 122A, where RA is a measure of surface roughness
(https://en.wikipedia.org/wiki/Surface_roughness).
[00129] The embossed pattern 124 includes a texture formed by a
plurality
of features that are raised and or sunken with respect to the first
thermoplastic
layer 122A. For example, the texture can include a plurality of protrusions,
surface
texture or projections 126 in the first thermoplastic layer 122k The texture
of the
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embossed pattern 124 may be of varying heights or depths or can be
substantially
the same height or depth. Example of heights and depths of the texture include
between about 0.01 mm to 10 mm. The texture can be disposed randomly or can
be configured as a uniform or repeated pattern, such as pattern 125. When the
texture is disposed as an array of uniform or repeating configurations,
examples
may include straight lines, a cross-hatch pattern, a chevron pattern, a
checked
pattern, a company logo, dots, and the like. The texture can include raised
and/or
sunken features that are adjacent to each other or spaced apart from each
other
providing various densities. Examples include where the texture includes
between
1 feature to 100 features per cm2 of the slip resistant sheet material 110.
Additionally, the features of the texture can have the same shape or can have
varying shapes such as square, triangular, circular, ovular, obround,
rectangular,
random, or any other suitable shape configured to form the anti-skid surface.
[00130] According to an embodiment, the shape(s) is (are) selected
based
on enhanced friction characteristics and water flow characteristics.
[00131] In accordance with embodiments, the slip resistant sheet
material
110 may include only one thermoplastic layer, a first and a second
thermoplastic
layers, or a plurality of different thermoplastic layers, some providing
weather-
resistant barrier, some other providing UltraViolet (UV)-resistant barrier,
microbial
properties, heat resistant properties and the like. This configuration will
provide the
characteristics sought-after for durability requirements and by those walking
on
roofs.
[00132] In accordance with an embodiment, the thermoplastic layer or
the
plurality of thermoplastic layers 122A, 122B may include a film-forming
polymer.
[00133] In accordance with an embodiment, the thermoplastic layer or
the
plurality of thermoplastic layers 122A, 122B comprise(s) polyethylene,
polypropylene or a mixture of polyethylene and polypropylene.
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[00134] The slip resistant sheet material 110 for roofing is shown as
having
a thermoplastic layer 122A or 122B positioned over each side of the closed-
weave
woven base layer 112. However, it is understood that certain applications may
allow the closed-weave woven base layer 112 to have only its upper side 115
coated with a thermoplastic layer. The thermoplastic layer(s) (such as first
and
second thermoplastic layers 122A, 122B) may include polyethylene,
polypropylene, or other similar thermoplastic polymers.
[00135] The slip resistant sheet material 110 for roofing is formed
by
extruding at least one layer of thermoplastic polymer over the closed-weave
woven
base layer 112. According to embodiments, the first or the first and second
thermoplastic layers 122A, 122B are directly affixed to the base layer without
use
of an adhesive or another intermediate layer.
[00136] According to another embodiment, the thermoplastic layer, or
at least
one thermoplastic layer may be affixed to the closed-weave woven base layer
112
using an adhesive or any other manner of attachment.
[00137] The thermoplastic layers (i.e., such as first and second
thermoplastic
layers 122A, 122B) may be variably pigmented to allow the color of the
thermoplastic layers to be selected based upon particular requirements. The
thickness of the thermoplastic layers is selected such that the slip resistant
sheet
material 110 for roofing is flexible, whereby the flexible nature of the slip
resistant
sheet material 110 for roofing allows it to be formed into rolls and easily
installed
by simply unrolling the slip resistant sheet material 110 for roofing over a
roof
support structure or the like.
[00138] The slip resistant sheet material 110 for roofing may be
installed
between a roof support structure 134 (Figs. 13, 14) and an overlayment 136
(Figs.
15, 16) in order to provide a waterproof barrier for the roof structure. The
slip
resistant sheet material 110 for roofing may be mechanically fastened to the
roof
rafters 138 (Fig. 13) or to the panels 163 (a.k.a. paneling, e.g. plywood,
presswood,
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etc.) (Fig. 14) using nails or screws, but it is understood that the slip
resistant sheet
material 10 for roofing may be affixed to the roof rafters 138 or to the
panels 163
using adhesives or other possible attachment methods.
[00139] According to an embodiment, the rolls 140 are of a length
allowing
the whole width of the roof to be covered with the sheet material 110 for
roofing
without any interruption lengthwise. According strips of the slip resistant
sheet
material 110 for roofing are installed bottom up, a bottom edge portion of the
top
strip 154 of slip resistant sheet material 110 for roofing covering a top edge
portion
of the bottom strip 152.
[00140] The slip resistant sheet material 110 for roofing may be
formed from
a plurality of thermoplastic layers having an improved resistance to
deterioration
from exposure to external elements, such as moisture and dirt, so that the
slip
resistant sheet material 110 for roofing has an improved durability and
longevity.
Moreover, employing closed-weave woven base layer 112 including yarns of a
second gauge 132 in the slip resistant sheet material 110 for roofing provides
an
improved tensile strength capable of being walked upon without tearing when
being installed on the roof. The closed-weave woven base layer 112 further
provides improved strength to resist tearing when exposed to external forces,
such
as collected moisture, wind, and other external forces.
[00141] As shown, the improved resistance to deterioration and
tearing
provided by the slip resistant sheet material 110 for roofing improves the
integrity
and effectiveness of the weather-resistant barrier provided by the slip
resistant
sheet material 110 for roofing. By improving the longevity of the waterproof
integrity
of the slip resistant sheet material 110 for roofing to more closely match the
integrity of the entire roof structure, the longevity of the integrity of the
entire roof
structure is improved.
[00142] According to an embodiment, and referring now to Figs. 13-16,
there
is shown a perspective view of the slip resistant sheet material 110 for
roofing
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being installed on an exemplary roof structure. The slip resistant sheet
material
110 for roofing is to be installed between a roof support structure 134 and an
overlayment 136 in order to provide a waterproof barrier and a slip resistant
material for the roof structure. As shown, the slip resistant sheet material
110 for
roofing may be formed into rolls 140 which can be simply unrolled over the
roof
support structure 134 to allow for easy installation. In this exemplary roof
structure,
a method is utilized where the slip resistant sheet material 110 for roofing
is
fastened to the top side of the panels 163. According to another exemplary
roof
structure (not shown), a sarking method is utilized where the slip resistant
sheet
material 110 for roofing is fastened to the top side of the roof rafters 138,
thus
allowed to drape between the open rafter bays 142. The slip resistant sheet
material 110 for roofing is preferably mechanically fastened to the roof
rafters 138
using nails or screws, but it is understood that the slip resistant sheet
material 110
for roofing may be affixed to the roof rafters 138 using other adhesives or
other
possible attachment methods.
[00143] Battens 144 are then fastened over the slip resistant sheet
material
110 for roofing and into the top side of the roof rafters 138, where the
overlayment
136 is then attached to the battens 144, as shown in Figs. 13 and 15.
[00144] The sarking method is merely one possible manner of
installing a
roof structure using the slip resistant sheet material 110 for roofing. For
instance,
the roof support structure 134 on which the slip resistant sheet material 110
for
roofing is attached may include solid sheathing or spaced sheathing. Further,
any
type of batten structure may be attached to the slip resistant sheet material
110 for
roofing for supporting the overlayment 136, such as wood battens, steel
battens,
plastic battens, counter-battens made from any of these materials, or the
overlayment 136 may be attached directly to the roof support structure 134
through
the slip resistant sheet material 110 for roofing.
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[00145]
According to another embodiment and referring to Figs. 12 and 17,
there is provided a method 300 for manufacturing a slip resistant sheet
material
110 for roofing having an upper side and a lower side.
[00146] The
method 300 comprises providing a closed-weave woven base
layer 112 having a top surface 114 facing in a same direction as the upper
side
(step 302).
[00147] The
method 300 further comprises extruding a polymer film 404,
forming a curtain of polymer film 404, through a heated die 402 to form a
first
thermoplastic layer 122A to the top surface 114 (step 304).
[00148] The
next step comprises embossing the first thermoplastic layer
122A to form surface texture in the first thermoplastic layer 122A in its top
surface
114 (step 306) thereby providing slip resistance on the upper side.
[00149]
According to an embodiment, the embossing (step 306) is performed
at a temperature allowing the first thermoplastic layer 122A to be easily
shaped
while having the deformations, namely the surface texture, remaining
permanently
imprinted in the first thermoplastic layer 122A when the first thermoplastic
layer
122A is cooling down.
[00150]
According to an embodiment, the embossing temperature is between
about 550F to 600F allowing the molten polymer to be formed and set by the
textured pattern.
[00151]
According to an embodiment, the embossing (step 306) comprises
embossing the first thermoplastic layer with engraved means, and according to
this
embodiment an engraved roller 412.
[00152]
According to an embodiment, the embossing (step 306) comprises
compelling movement to the slip resistant sheet material on the side opposite
the
first thermoplastic layer 122A with a plain roller 414.
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[00153] According to an embodiment, the affixing the first
thermoplastic layer
122A (step 304) and optionally affixing the second thermoplastic layer 122B
(step
not shown) comprises respectively directly affixing the first thermoplastic
layer
122A and optionally the second thermoplastic layer 122B to the top surface 114
and to the bottom surface 116 without use of an adhesive or another
intermediate
layer.
[00154] According to an embodiment, the affixing the first
thermoplastic layer
122A (step 304) and optionally the second thermoplastic layer 122B (step not
shown) comprises respectively extruding a film-forming polymer thereby
producing
the first thermoplastic layer and optionally the second thermoplastic layer.
[00155] According to an embodiment, further comprising respectively
bonding the first thermoplastic layer 122A and optionally the second
thermoplastic
layer 122B to the top surface 114 and to the bottom surface 116 (not shown).
[00156] According to an embodiment, the extruding a film-forming
polymer
comprises extruding at least one of: polyethylene and polypropylene.
[00157] In accordance with another embodiment, there is provided a
process
400 for manufacturing the slip resistant sheet material 110 for roofing. The
process
400 for manufacturing the slip resistant sheet material 110 for roofing is
more
specifically shown in Fig. 17. First, the closed-weave woven base layer 112 is
unwound into an unwinding machine and exposes upwardly the top surface 114 of
the closed-weave woven base layer 112. Next, a polymer film 404 is extruded
through a heated die 402 to form a first thermoplastic layer 122A. The first
thermoplastic layer 122A bonds to the top surface 114 of the closed-weave
woven
base layer 112 at the nip point 406 where at least one of rollers 412, 414 is
cooled
for cooling the temperature of the closed-weave woven base layer 112 which is
being bonded with the first thermoplastic layer 122A. Furthermore, at this
step, the
embossing roller 412 embosses permanently the hot first thermoplastic layer
122A. Optionally (not shown), afterwards the closed-weave woven base layer 112
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is wounded and again unwound into the unwinding machine for showing upwardly
the bottom surface 116 of the closed-weave woven base layer 112. Another
polymer film 404 is then extruded through the heated die 402 to form the
second
thermoplastic layer 122B covering the bottom surface 116 of the closed-weave
woven base layer 112. The second thermoplastic layer 122B then bonds to the
bottom surface 116 of the closed-weave woven base layer 112 at the nip point
406, where at least one of rollers 412, 414 is cooled for cooling the
temperature of
the closed-weave woven base layer 112 which is being bonded with the second
thermoplastic layer 122B. It must be noted that this step of affixing the
second
thermoplastic layer 122B may use the same rollers 412, 414 or a set of
different
rollers based on the desire or not to obtain the embossing on the bottom
surface
116. Finally, the slip resistant sheet material 110 is cooled down and formed
into
rolls 140 for storage.
[00158] The
embossing roller 412 is substantially cylindrical and includes a
surface configured for embossing the slip resistant sheet material 110 to form
the
anti-skid surface. For example, the surface can include a plurality of
protrusions
from the surface of the embossing roller 412, a plurality of depressions in
the
surface of the engraved roller 412 or both. The texture for forming the
embossment
on the closed-weave woven base layer 112 and on the thermoplastic layer(s)
122A
and/or 122B may be of varying heights or depths or can be substantially the
same
height or depth. Example of heights and depths of the texture include between
0.01 mm to 10 mm. The texture can be disposed on the surface of the embossing
roller 412 randomly or can be configured as a uniform or repeated pattern.
Where
the texture is disposed as an array of uniform or repeating configurations,
examples may include straight lines, a cross-hatch pattern, a chevron pattern,
a
checked pattern, a company logo, dots, and the like. The texture can include
raised
and/or sunken features that are adjacent to each other or spaced apart from
each
other providing various densities. Examples include where the texture includes
between 1 feature and 100 features per cm2 of the surface of the embossing
roller
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412. Additionally, the features of the texture can have the same shape or can
have
varying shapes such as square, triangular, circular, ovular, obround,
rectangular,
random, or any other suitable shape configured to form the anti-skid surface.
[00159] According to an embodiment illustrated through Figs. 18 and
19, a
roller 500 having a substantially porous surface is used to manufacture the
slip
resistant sheet material 110 for roofing. The manufactured slip resistant
sheet
material 110 for roofing therefore have a sandpaper-like texture 502
comprising a
random pattern of small reliefs providing the slip-resistant characteristics.
[00160] Various additives may be included or applied to the slip
resistant
sheet material 110. Examples may include various colorants, heat stabilizers,
waterproofing treatments, strengthening laminates, antimicrobials, UV blockers
and light stabilizers. The slip resistant sheet material 110 may also be
printed with
signage, such as logos, installation instructions, and/or orientation indicia.
Such a
printing process would normally take place after the embossing process and
before
the process of forming the slip resistant sheet material 110 into rolls 140.
[00161] In accordance with another embodiment illustrated through
Figs. 20-
21, there is provided a non-woven sheet material 310 for roofing. The slip
resistant
non-woven sheet material 310 for roofing has an upper side 15 and a lower side
17 similar to embodiment of Fig. 2. The slip resistant non-woven sheet
material
310 for roofing is typically made of a single layer 312 which defines a top
surface
14 and a bottom surface 16 (still similar to Fig. 2). The top surface 14 faces
in a
same direction as the upper side 15.
[00162] As shown, the slip resistant non-woven sheet material 310 is
embossed on the top surface 14 to form an embossed pattern 324 comprising
surface texture 326.
[00163] The embossed pattern 324 comprises a plurality of surface
texture
326 or define reliefs that upwardly extend for providing slip resistance on
the upper
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side 15. The surface texture 326 of the embossed pattern 324 provide an anti-
skid
surface / enhanced friction surface / slip resistant surface.
[00164] The embossed pattern 324 increases the slip resistance and
thereby
increases safety of those walking on roofs on which the slip resistant non-
woven
sheet material 310 is installed before installation of an overlayment 136 (see
Fig.
15).
[00165] The embossed pattern 324 comprise surface texture 326 spread,
scattered, dispersed or punctuated over the upper side 15 providing through
the
inter-embossment depressions paths for rain falling on the upper side 15 for
the
rain to flow downward between the surface texture 326 when the slip resistant
non-
woven sheet material 310 is installed on a sloped structure, leaving the
surface
texture 326 free of water and thereby enhancing friction surface. Furthermore,
the
embossed pattern 324 comprise surface texture 326 spread, scattered, dispersed
or punctuated at an embossment density insuring the footstep of those walking
on
roofs on which the slip resistant non-woven sheet material 310 is installed to
always step over a plurality of surface texture 326.
[00166] Even though there is shown that the surface texture 326 are
regularly
spaced within the embossed pattern 324 such as to define a specific mosaic or
pattern, such as pattern 325. However, it is to be noted that the surface
texture
326 may be irregularly spaced within the embossed pattern 324 as long as the
selected pattern and the nature of the surface texture 326 increase the slip
resistance and thereby increases safety of those walking on roofs on which the
slip resistant non-woven sheet material 310 is installed before installation
of the
overlayment 136.
[00167] According to an embodiment, the surface texture 326 comprises
rigid
surface irregularities and is thus adapted to not collapse under pressure.
According
to an embodiment, the surface texture 326 comprises projections (similar to
projections 26, figs. 1 to 3) that include solid material (i.e., have no
internal voids)
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or alternatively resulting from the non-woven sheet material 310 being of
variable
thickness following the projections and depressions present in the non-woven
sheet material 310.
[00168] According to an embodiment, the single layer 312 comprises a
non-
woven fibrous material such as a spunbond polyester substrate. According to an
embodiment, the single layer 312 defines a weather-resistant barrier
preventing
water from rain and snow to reach the roof structure.
[00169] According to an embodiment, the lower side 17 of the slip
resistant
non-woven sheet material 310 comprises lower-side surface texture (not shown)
providing slip resistance on the lower side 17. According to an embodiment,
the
upper-side surface texture 126 and the lower-side surface texture are not
complementary, the raises of the upper-side surface texture 126 do not
corresponding to depressions between lower-side surface texture 126B.
[00170] According to an embodiment, the slip resistant non-woven sheet
material 310 has a thickness of at least about 5 mil. According to an
embodiment,
the thickness is about between 5 mil and 7.5 mil. The maximum thickness of the
slip resistant material 310 is in a range of about between1 mil and 1.5 mil.
[00171] The height of the upper-side surface texture 126 or lower-side
surface texture are further in a range of about between 350 RA and 750 RA
(Roughness Average, see http://www.rubert.co.uk/faqs/roughness-parameters/),
with the height of the upper-side surface texture 126 or lower-side surface
texture
measured from the level of the depressions between upper-side surface texture
126 / lower-side surface texture and the top or the apex of the corresponding
upper-side surface texture 126 / lower-side surface texture. The height of the
upper-side surface texture 126 / lower-side surface texture is in a range of
about
between 350 RA and 800 RA percent of the thickness of the slip resistant non-
woven sheet material 310, and/or in a range of about between 5 mils and 7.5
mils.
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[00172] According to an embodiment, the single slip resistant non-
woven
sheet material 310 is made of a material from the group comprising spunbond
polyester substrate and textured thermoplastics. The fibers of the slip
resistant
non-woven sheet material 310 are bound together by entangling the fibers
mechanically, thermally or chemically, with the surface texture 326 being
generated on the slip resistant non-woven sheet material 310 either
mechanically
or thermally at the time of manufacture of the slip resistant non-woven sheet
material 310 or afterwards. According to an embodiment, the fibers are a mix
of
thermoplastics having a surface texture within a range around 350 RA.
[00173] According to an embodiment, the single slip resistant non-
woven
sheet material 310 is Ultraviolet resistant (UV resistant). According to one
embodiment, the material used to manufacture the single slip resistant non-
woven
sheet material 310 is UV resistant. According to another embodiment, a
compound
is applied to the single slip resistant non-woven sheet material 310 on the
upper
side 15 to provide resistance against UV to the single slip resistant non-
woven
sheet material 310.
[00174] According to an embodiment, the density of the slip resistant
non-
woven sheet material 310 is in a range of about between 0.917 and 0.970. The
density of the slip resistant non-woven sheet material 310 participates in
providing
desired characteristics to the slip resistant non-woven sheet material 310
namely:
- acting as a weather-resistant barrier, or in other words a permeability
according to ESTM E96 of about 0.05 Perms or below;
- having a breaking strength according to ASTM D 226 MD of about a
minimum of 61 and a maximum of 66 lbs./inch;
- having a breaking strength according to ASTM D 226 CD of about a
minimum of 57 and a maximum of 61 lbs./inch;
- having a tear strength according to ASTM D226 MD of about a minimum of
69 and a maximum of 82 lbs./inch;
CA 3023751 2018-11-09
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-
having a tear strength according to ASTM D226 CD of about a minimum of
63 and a maximum of 79 lbs./inch;
- having a resistance according to a Mullen Burst test of about 158 psi;
- having a resistance to environmental temperatures and variations of the
environmental temperature varying within a range of about between 240 F
and -40 F.
[00175] In
accordance with another embodiment illustrated through Figs. 22-
24, there is provided a non-woven slip resistant sheet material 410 comprising
a
thermoplastic layer 122A affixed to the top surface of the non-woven base
layer
432, wherein the thermoplastic layer 122A comprises, on the upper side 15,
slip-
resistant surface texture 426 and further wherein the slip-resistant surface
texture
426 are present in the thermoplastic layer 122A and absent from the non-woven
base layer 432.
[00176]
According to a non-limiting embodiment, the thermoplastic layer
122A is the only thermoplastic layer affixed to the non-woven base layer 432.
[00177] As
shown, the thermoplastic layer 122A of the non-woven slip
resistant sheet material 410 is embossed on the top surface 114 to form an
embossed pattern 424 comprising surface texture 426 defining a specific mosaic
or pattern, such as pattern 425.
[00178] The
embossed pattern 424 comprises a plurality of surface texture
426 or define reliefs that upwardly extend for providing slip resistance on
the upper
side 15. The surface texture 426 of the embossed pattern 424 provide an anti-
skid
surface / enhanced friction surface / slip resistant surface.
[00179] The
closed-weave woven base layer 432 comprises no woven yarn
and is manufactured in a somewhat similar fashion as the slip resistant non-
woven
sheet material 310 to feature some characteristics similar to the slip
resistant non-
woven sheet material 310. Accordingly, the slip resistant sheet material 410
for
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roofing comprises a single first thermoplastic layer 122A affixed to the top
surface
114 of the non-woven base layer 432 for providing both a weather-resistant
barrier
and slip resistance.
[00180] In accordance with another embodiment illustrated through
Figs. 25-
28, there is provided a non-woven sheet material 510 for roofing. The slip
resistant
non-woven sheet material 510 for roofing has an upper side 515 and a lower
side
517. The slip resistant non-woven sheet material 510 for roofing comprises a
close-weave woven base layer 512 having a top surface facing towards the upper
side. The slip resistant non-woven sheet material 510 for roofing further
comprises
a thermoplastic layer 522 affixed to the top surface of the close-weave woven
base
layer 512. The thermoplastic layer 522 comprises, on the upper side, slip-
resistant
surface texture 526. The slip-resistant surface texture 526 are present in the
thermoplastic layer 522 and absent from the non-woven base layer 512.
[00181] According to an embodiment, the surface texture 526 comprises
rigid
surface irregularities and is thus adapted to not collapse under pressure.
According
to an embodiment, the surface texture 526 comprises projections (similar to
projections 26, figs. 1 to 3) that are filled by material or alternatively
resulting from
the non-woven sheet material 510 being of variable thickness following the
projections and depressions present in the non-woven sheet material 510 and
causing the upper side slip-resistant surface texture 526.
[00182] While preferred embodiments have been described above and
illustrated in the accompanying drawings, it will be evident to those skilled
in the
art that modifications may be made without departing from this disclosure.
Such
modifications are considered as possible variants comprised in the scope of
the
disclosure.
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