Rubberized roof underlayment

Abstract

An underlayment product comprises a fibrous mat having an upper surface and a lower surface. A rubberized asphalt coating is applied to the lower surface of the fibrous mat and extends at least partially into the fibrous mat. An oxidized asphalt coating is applied to the upper and lower surfaces of the fibrous mat generally encapsulating the fibrous mat including the rubberized asphalt coating provided on the lower surface of the fibrous mat. The oxidized asphalt layers may be coated with a release layer such as talc, granules or a polymer.

1 . An underlayment membrane comprising: 
 a fibrous mat having an upper surface and a lower surface;    a rubberized asphalt coating applied to the lower surface of the fibrous mat and extending at least partially into said fibrous mat; and    an oxidized asphalt coating applied to said upper and lower surfaces of said fibrous mat generally encapsulating said upper and lower surfaces of said mat including said rubberized asphalt coating applied to the lower surface of the fibrous mat.    
   
   
       2 . The underlayment membrane of  claim 1  further including a release coating applied to said oxidized asphalt coating proximate said upper and lower surfaces of said fibrous mat.  
   
   
       3 . The underlayment membrane of  claim 2  wherein said release coating includes a talc coating.  
   
   
       4 . The underlayment membrane of  claim 2  wherein said release coating includes granule particles applied proximate at least said oxidized asphalt coating proximate said upper surface of said fibrous mat.  
   
   
       5 . The underlayment membrane of  claim 2  wherein said release coating includes a polymeric coating disposed on at least said oxidized asphalt coating proximate said upper surface of said fibrous mat.  
   
   
       6 . The underlayment membrane of  claim 5  wherein said polymeric coating is provided with a coating of finally-ground mineral.  
   
   
       7 . The underlayment membrane of  claim 6  wherein said finally-ground mineral includes talc.  
   
   
       8 . The underlayment membrane of  claim 6  wherein said finally-ground mineral includes granules.  
   
   
       9 . The underlayment membrane of  claim 1  wherein said rubberized asphalt coating includes approximately 46% flux asphalt, 4% rubber and 50% filler material.  
   
   
       10 . The underlayment membrane of  claim 1  wherein the fibrous mat includes fibers selected from the group consisting of polyesters, polypropylenes and fiberglass.  
   
   
       11 . An underlayment membrane comprising: 
 a fibrous mat having an upper surface and a lower surface;    a rubberized asphalt coating applied to the lower surface of the fibrous mat and extending at least partially into said fibrous mat;    an oxidized asphalt coating applied to said upper and lower surfaces of said fibrous mat generally encapsulating said upper and lower surfaces of said mat including said rubberized asphalt coating applied to the lower surface of the fibrous mat; and    a release coating applied to said oxidized asphalt coating proximate said upper and lower surfaces of said fibrous mat.    
   
   
       12 . An underlayment membrane comprising: 
 a fibrous mat having an upper surface and a lower surface;    a rubberized asphalt coating applied to the lower surface of the fibrous mat and extending only partially into said fibrous mat; and    an oxidized asphalt coating applied to said upper and lower surfaces of said fibrous mat generally encapsulating said upper and lower surfaces of said mat including said rubberized asphalt coating applied to the lower surface of the fibrous mat.