GB2496244A - Laminated non-woven fabric, comprising meltblown and spunbonded layers, for roofing underlay - Google Patents

Laminated non-woven fabric, comprising meltblown and spunbonded layers, for roofing underlay Download PDF

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Publication number
GB2496244A
GB2496244A GB1216251.7A GB201216251A GB2496244A GB 2496244 A GB2496244 A GB 2496244A GB 201216251 A GB201216251 A GB 201216251A GB 2496244 A GB2496244 A GB 2496244A
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United Kingdom
Prior art keywords
text
layer
laminated fabric
meltblown
laminated
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Granted
Application number
GB1216251.7A
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GB2496244B (en
GB201216251D0 (en
Inventor
David John Avril
George Murray Baxter
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Don and Low Ltd
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Don and Low Ltd
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Priority to GB1216251.7A priority Critical patent/GB2496244B/en
Publication of GB201216251D0 publication Critical patent/GB201216251D0/en
Publication of GB2496244A publication Critical patent/GB2496244A/en
Application granted granted Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/156—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is calendered and immediately laminated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
    • E04D12/002—Sheets of flexible material, e.g. roofing tile underlay
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B32B2250/242—All polymers belonging to those covered by group B32B27/32
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/22—Fibres of short length
    • B32B2305/28—Fibres of short length in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/71—Resistive to light or to UV
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/625—Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The fabric laminate comprises a calendered melt blown layer 22 and at least one spun bond layer 24, 26, preferably as an SMS sandwich. The laminated fabric has a hydrostatic head > 140 (190-300) cm. The preferred fabric has air permeability ² 60 lm2/s, but moisture vapour transmission rate (MVTR) > 1500 g/m2/day. Preferably the melt-blown and spun-bonded layers, comprising polyolefin, especially polypropylene fibres, have basis weight 10-60 and 15-150 g/m2 respectively. The preferred laminate contains hydrophobic melt additive, ultraviolet (UV) absorbing additive, flame retardant, pigment or plasticiser. Preferably, the in line or off line calendering uses flat or point bonding rolls at 10-170°C and 30-150 N/mm. The laminate is used with fully supported or sarked roves.

Description

IMPROVED LAMINATED FABRIC
FIELD OF INVENTION
The invention relates to a laminated fabric and a method of producing same.
The laminated fabric is suitable for a variety of applications. For example, laminated fabrics of the present invention may be comprised in building materials, such as roofing underlay. This invention relates to air and vapour permeable laminated fabrics with improved levels of water hold-out.
BACKGROUND TO INVENTION
Vapour permeable fabrics known in the art as possessing good barrier properties to water droplets and/or solid particles generally comprise co-extruded or monolayer films comprising a plurality of micropores or monolithic films. Such vapour permeable films are sometimes used as roofing underlays due to their ability to assist in evacuating unwanted moisture vapour from roof spaces. Generally these vapour permeable films that provide a barrier to the passage of liquid water droplets are air barrier materials known as vapour permeable/air barrier roofing underlays.
However, in the UK, it is increasingly acknowledged that roof tile underlays that are both vapour permeable and air permeable are very effective at evacuating large amounts of moisture vapour from the roof space beneath the underlay. Air permeable and vapour permeable underlays are breathable' in the true sense of the word and are acknowledged to form an effective alternative to traditional mechanical vents in cold' unoccupied pitched roof spaces.
That is to say that the underlay is sufficiently breathable such that any moisture entering the roofspace from the occupied living area underneath will evacuate the roofspace into the atmosphere through the underlay itself.
There are 2 typical roof constructions: warm' roofs -where the insulation is at rafter level with the roofspace itself being occupied, and cold' roof spaces -where the insulation is laid on the floor of the roofspace and it is unoccupied.
Unwanted moisture is conventionally evacuated from cold' roof spaces via the introduction of mechanical vents, typically at the eaves and the ridge. These mechanical vents allow atmospheric air to enter and leave the roofspace, which effectively transports unwanted moisture vapour to the outside atmosphere. The use of mechanical vents at the eaves and/or ridge of a cold' unoccupied roof space can increase the heat losses from a property by various mechanisms including (i) increasing the temperature gradient between the occupied and unoccupied spaces, and (ii) air entering the roof space via mechanical vents at the eaves can pass through the glass wool insulation laid on the floor of the roofspace, thus reducing the efficiency of the insulation. Thus, the use of an air and vapour permeable roofing underlay as an effective alternative to mechanical ventilation may reduce heat losses and improve the thermal efficiency of a property, whilst at the same time reducing the risk of condensation. The superior performance of air permeable fabrics to reduce condensation in energy efficient cold' (unoccupied) unventilated roofspaces has been acknowledged by the National House Building Council (NHBC) in the UK. This national body now insist that, for any new build domestic property that incorporates a non-ventilated cold' roof space, i.e. where traditional mechanical vents are eliminated from the roof construction, only roofing underlays that are both air and vapour permeable are used.
Typical air and vapour permeable underlay fabrics include nonwoven laminated materials comprising a meltblown layer, such as those described in ER 0742305 Al (Don & Low Limited). These materials are widely used in both supported and unsupported roofing applications. However we have identified that, when installed on a supported roof, in specific extreme weather conditions, referred to later as rain/freeze/thaw/rain' conditions, air and vapour permeable SMS underlays can be vulnerable to leakage.
It is an object of at least one embodiment of at least one aspect of the present invention to obviate or at least mitigate one or more problems or disadvantages in the
prior art.
SUMMARY OF INVENTION
According to a first aspect of the present invention there is provided a laminated fabric comprising: a first layer of calendered meltblown material laminated to a second layer of spunbond material; wherein the laminated fabric has a hydrostatic head of greater than 140 cm.
In use, a laminated fabric according to embodiments of the present invention may be used as or comprise a building material, for example, a roofing underlay, e.g. most advantageously for use in or on a fully supported or "sarked" roof.
Preferably the laminated fabric may comprise an air permeable laminate.
Preferably the laminated fabric may comprise a vapour permeable laminate, in particular a water vapour permeable laminate.
In certain embodiments of the present invention, the laminated fabric may comprise a third layer of spunbond material. The third layer of material may be laminated to one side of the first layer and the second layer may be laminated to a second side of the first layer. In certain embodiments, the first layer of calendered meltblown material may be sandwiched between the second and third layers of spun-bond material. In these and other embodiments, the second and/or third layers of spunbond material comprise outer layers of the laminated fabric and may provide support to the meltblown layer. The second and/or third layers of spunbond material may act as an abrasion resistant, durable and/or protective cover for the meltblown material. In these and other embodiments, where the meltblown sheet is processed to form the intermediate layer of a three-layer structure, the two outer layers being spun-bonded layers, the structure may conveniently be referred to an SMS (spunbonded/meltblown/spunbonded) structure.
In certain embodiments of the present invention, the first layer of meltbiown material is calendered to provide a meitblown layer having a film-like appearance and/or properties. The additional calendering step may be applied to the meltbiown layer to impart improved levels of watei hold-out.
The laminated fabric may have a hydrostatic head of greater than 140cm, greater than about 150cm, greater than about 160cm, greater than about 170cm, or even greater than about 190cm. The laminated fabric may have a hydrostatic head between 140cm and 1000cm, between 150cm and 800cm, between 160cm and 600 cm, between 170cm and 400cm or between 190cm and 300cm.
Prior to lamination, the first layer of calendered meltblown material may have a hydrostatic head of greater than 100cm, greater than 120cm, greater than 140cm or greater than 160cm. Prior to lamination, the first layer of calendered meltblown material may have a hydrostatic head between 100cm and 300cm, between 120cm and 280cm, between 140cm and 260cm or between 160cm and 240cm.
The laminated fabric may be air permeable. The laminated fabric may have an air permeability less than about 60 l/m2/s, less than about 40 l/m2/s, or less than about 20 l/m2/s. The laminated fabric may have an air permeability between 0.5 l/m2/s and 40 l/m2/s, for example between 1 l/m2/s and 20 l/m2/s.
Prior to lamination, the first layer of calendered meltblown material may be air permeable. Prior to lamination, the first layer of material may have an air permeability less than about 300 l/m2/s, less than about 200 l/m2/s, less than about 100 l/m2/s or even less than about 50 l/m2/s or 25 l/m2/s. The first layer of material may have an air permeability between about 0.5 l/m2/s and 50 l/m2/s, for example between 1 l/m2/s and 30 l/m2/s.
In these and other embodiments, the air permeability of the meltblown layer and/or of the laminated fabric may assist in allowing the passage of water vapour through the fabric. For example, the air permeability of the fabric may assist in evacuating moisture from a roof space.
The laminated fabric may be vapour permeable. The laminated fabric may have a moisture vapour transmission rate (MVTR) greater than 1500 g/m2/24h, greater than 1750 g/m2124h, greater than 2000 g/m2/24h, or greater than 2250 g/m2/24h. The laminated fabric may have a MVTR of about 2300 g/rn2/24h. In these and other embodiments, unexpectedly the additional calendering step of a meitblown layer prior to incorporation into a laminated fabric does not significantly affect the vapour permeability of the laminated fabric. The first layer of calendered meltblown material may have a basis weight between 10 g/m2 and 60 g/m2, or between 20 g/m2 and 50 g!m2 or between 30 gIm2 and 40 gIm2. For example, the first layer of calendered meltblown material may have a basis weight of approximately 35 g/m2. In these and other embodiments, a laminated fabric comprising a calendered meltblown layer advantageously provides an increased hydrostatic head and comparable levels of vapour permeability to a laminated fabric comprising a typical meltblown layer of the same basis weight.
The second and/or third layer of spunbond material may have a basis weight between 15 and 150 g/m2, or between 40 and 100 g/m2. The second and/or third layer of spunbond material may have a basis weight of approximately 50 g/m2 or approximately 90 g/m2. The second and third layers of spunbond material may have different basis weights. For example, when used as a roofing underlay, the layer of spunbond material comprising the underside (i.e. the layer facing the roofspace) may have a lower basis weight than the opposing layer of spunbond material facing outwards. In embodiments of the present invention, the first layer of meltblown material and the second and third layers of spunbond material may comprise polymers. Examples of polymers from which meltblown and spunbond materials may be made include polyolefinic polymers such as polyethylene and polypropylene homopolymers and co-polymers thereof and of mixtures of homopolymers and co-polymers. Preferably, the meltblown and spunbond materials comprise polypropylene. Other polymeric materials may also be found suitable as will be apparent to the skilled reader.
Meltblown and spunbond materials may be formed of single component fibres or bicomponent fibres. Bicomponent fibres may comprise at least two different polymeric materials wherein one polymeric material may soften at a lower temperature than the other(s). Bicomponent fibres may have a core-sheath, layered or matrix-type structure. Preferably, the meltblown and spunbond materials comprise fibres formed of a single polymer component, such as homopolymer fibres.
In embodiments, the laminated material may comprise additives. Additives may be present in the first, second and/or third layers of the laminated fabric.
Additives may include hydrophobic melt additives and the like, for example an organic fluorocarbon derivative. Such additives are known in the art and may be added to polymers from which meltblown materials are made to improve their hydrophobic and/or oleophobic barrier properties. Other additives, such as UV absorbing additives may be advantageously added to the melt polymer so as to inhibit the polymer degradation due to, for example, exposure to ultraviolet light.
Examples of other additives which may be comprised in the laminated material, and/or added to the meltblown material, include conventional additives such as flame retardants, pigments and plasticisers, and the like.
The fabrics of the invention may typically take the form of sheeting, strips, rolls and the like.
According to a second aspect of the present invention there is provided a roof which comprises a laminated fabric according to the first aspect of the present invention.
The roof may be a fully supported or sarked roof or a non-supported cold-pitched roof.
A fully supported or sarked roof may comprise boards or sheets placed onto rafters. In such embodiments, the laminated fabric may be placed directly on the rigid upper surface of the boards or sheets (hence the underlay is termed as being supported'). Such environments are known to be particularly challenging and the laminated fabrics of embodiments of the present invention may be particularly advantageous due to its improved water hold-out properties.
In an unsupported roof, the laminated fabric may be loosely draped across the rafters (with no other support) (hence the underlay is termed as being unsupported'). The laminated fabric may be secured to the rafters. Battens and/or counter battens may be placed over the laminated fabric to secure the slates.
According to a third aspect of the present invention there is provided a method of making a laminated fabric comprising: laminating a first layer of a calendered meltblown material to at least a second layer of spunbond material to provide a laminated fabric having a hydrostatic head of greater than 140cm.
In certain embodiments, the method may comprise laminating the first layer to a third layer of spunbond material.
The method may comprise providing a first layer of calendered meltblown material having a hydrostatic head of greater than 100cm, greater than 120cm, greater than 140cm or greater than 160cm. The method may comprise providing a first layer of calendered meltblown material having a hydrostatic head between 100cm and 300cm, between 120cm and 280cm, between 140cm and 260cm or between 160cm and 240cm.
Laminating may comprise passing the first, second and/or third layers of material through calender rollers, preferably through heated calender rollers and/or under pressure. Typically temperatures for laminating a polypropylene SMS may be between 120°C and 170 °C and pressures between 30 N/mm -150 N/mm may be employed in the laminating process. SMS fabrics produced with different polymers may require different lamination process conditions dependant on polymer melt temperature Laminating meltblown sheets to such supportive, open layers, such as the second and/or third layer of spunbond material, may be effected by passing the sheet materials simultaneously through, for example, a point bonding calendering process.
In this process, which is known in the art, a combination of heat and pressure is applied in an intermittent pattern known as point bonding. The area of such bond points is typically 5% to 40% of the total area of the bonded materials and may preferably be in the range 15% to 20%.
According to a fourth aspect of the present invention there is provided a method of making a laminated fabric comprising: calendering a first layer of a meltbiown material; and laminating the first layer of calendered meltblown material to at least a second layer of spunbond material to provide a laminated fabric having a hydrostatic head of greater than 140cm.
The method may further comprise laminating the first layer of meltblown material to a third layer of spunbond material.
The method may comprise calendering a first layer of polypropylene meltblown material at a temperature between 110 and 170 °C. The method may comprise calendering a first layer of meltblown material at a pressure between 30 and 150 N/mm. Meltblown fabrics produced with different polymers may require different calender process conditions dependant on polymer melt temperature. This meltblown calendering step may be carried out in line' i.e. the calendering step is integrated into the meltblown manufacturing process (immediately following extrusion), or off line' i.e. the meltblown may be subjected to a separate calendering step that is independent of the meltblown manufacturing process The method may comprise passing the meltblown sheet through a flat calendering process or a point bonding calendering process.
The method may further comprise calendering the first layer of meltblown material to provide a layer of calendered meltblown material having a hydrostatic head of at least 100cm, at least 120cm, at least 140cm or at least 160cm. The method may comprise calendering the first layer of meltblown material to provide a layer of calendered meltblown material having a hydrostatic head between 100cm and 300cm, between 120cm and 280cm, between 140cm and 260cm or between 160cm and 240cm.
The method may comprise providing a pre-compressed first layer of meltblown material. The method may comprise compressing a first layer of meltbiown material, preferably prior to a calendering step Compressing a material typically involves applying pressure, sometimes with gentle heating. However, as would be understood by the person skilled in the art, pressures and/or temperatures used in compressing step are not high enough to cause softening of fibres and/or filaments in the material.
According to a fifth aspect of the present invention there is provided a use of a laminated fabric as defined in the first, second, third or fourth aspects as a building material.
In certain embodiments the laminated material may be used as a roofing underlay. For example, the laminated material may be used on a fully supported or sarked roof.
The term meltblown" as used herein may refer to a non-woven material formed by meltblowing. Meltblown materials typically comprise short length fibres formed when molten polymer is extruded into a high velocity gas stream. These short length fibres may typically be laid out onto a moving belt and bond to one another to form a web. Meltblown fibres are typically 2 -4pm in diameter The term "spunbond" as used herein may refer to a non-woven material formed by spin laying. Spunbond materials may typically comprise continuous filaments formed when molten polymer is extruded through a spinneret. These continuous filaments may typically be laid out onto a moving screen and bond to one another to form a web. Spunbond filaments are typically 15 -25 pm in diameter.
The term "calendered" as used herein may refer to a material which has undergone a calendering step. For example, by passing the material through the nip of a pair of rollers, wherein one or both of the rollers are heated. The calender rollers typically impart heat and pressure onto the material causing at least the outer surface of the filaments or fibres to soften and allowing them to bond to one another. In this way, the calendering process increases the consolidation of the material. The rollers may be plain, smooth and/or patterned.
It is to be appreciated that the various embodiments may be applied to each of the aspects without departing from the scope of the invention. For example, any features of the first aspect may be equally applicable with the second, third, fourth, or fifth aspects. However, for the sake of brevity, these embodiments have not been repeated in relation to each aspect.
BRIEF DESCRIPTION OF DRAWINGS
These and other aspects of the present invention will now be described by way of example only, with reference to the accompanying drawings.
Figure 1 shows a schematic representation of a side view of a laminated fabric comprising a first layer of a calendered meltblown material laminated to a second layer of spunbond material according to an embodiment of the present invention; Figure 2 shows a schematic representation of a side view of a laminated fabric comprising a first layer of a calendered meltblown material laminated to a second and third layer of spunbond material according to an embodiment of the present invention; Figure 3 shows a schematic cross-sectional representation of an unsupported roof; Figure 4 shows a schematic cross-sectional representation of a fully supported or sarked roof; and Figure 5 shows a perspective view of a laminated fabric according to one embodiment of the present invention.
DETAILED DESCRIPTION OF DRAWINGS
Referring to Figure 1, there is shown a laminated fabric 10 according to a first embodiment of the present invention. The fabric 10 comprises a first layer of a calendered meltblown material 12 laminated to a second layer of spunbond material 14. The laminated fabric 10 has a hydrostatic head of greater than 140 cm.
A second embodiment of the present invention is shown in Figures 2 and 5. In this embodiment, the first layer of calendered meltblown material 22 is sandwiched between the second and third layers of spun-bond material (24, 26). The second and third layers of spunbond material (24, 26) act as an abrasion resistant, durable and protective cover for the calendered meltblown material 22.
In these and other embodiments of the present invention, the calendered meltblown material layer (12, 22) is laminated to the layer(s) of spunbond material (14, 24, 26) by passing the sheet materials simultaneously through, for example, a point bonding calendering process. In this process, which is known in the art, a combination of heat and pressure is applied in an intermittent pattern known as point bonding. An example pattern is illustrated most clearly in Figure 5. The area of such bond points is typically 5% to 40% of the total area of the bonded materials and may preferably be in the range 15% to 20%.
Laminated fabrics according to these and other embodiments of the present invention are air permeable and vapour permeable. Thus, air and vapour are able to pass through the membrane as illustrated by arrows B' in Figure 5. As is also illustrated on Figure 5, laminated fabrics according to embodiments of the present invention offer improved water hold-out properties meaning that the fabric resists the passage of water droplets (as shown by arrows A').
Laminated fabrics according to embodiments of the present invention may be used as building materials, for example, as roofing underlays. Typical roof constructions are shown in Figures 3 and 4. Figure 3 shows an unsupported roof, wherein the underlay, for example a laminated fabric 10,20) is draped between the rafters 30. Battens 42 are typically placed on top of the underlay and the tiles or slates 40 are secured onto these battens.
An alternative construction is a fully supported or sarked roof as is shown in Figure 4. In this type of construction, boards or sheets 44 are placed on the rafters 30. These boards or sheets 44 are commonly known in the art as sarking and are typically made out of timber or fibreboard, such as oriented strand board (OSB). An underlay, such as a laminated fabric 10,20, is laid directly onto the sarking 44. Tiles or slates 40 are secured directly through the underlay to the sarking (as shown in Figure 4). Alternatively battens may be laid on top of the underlay and secured to the sarking and the tiles or slates secured to these battens.
The use of air permeable, vapour permeable underlays in fully supported or sarked roofs is particularly demanding as these types of construction can be more likely to compromise the water hold-out performance. For example, the presence of chemical timber treatments in sarking can leach into the underlay structure, allowing water to more easily permeate the fabric. Additionally, when the fthric underlay is placed against a solid surface, e.g. sarking, water sitting on an upper surface of the underlay can have a tendency to migrate through the underlay in an effect known as tenting'. Particularly problematic to fibrous underlays directly supported on their underside by a solid surface such as sarking, is the rain/freeze/thaw/rain' effect.
When underlays in such environments are subjected to persistent and heavy rain, some of the water can penetrate its way into the upper surface of the underlay. If this rain is followed by a severe drop in temperature, the water can freeze and so expand, opening up the upper surface of the underlay. If, immediately after thawing, there is another period of prolonged rain, water can potentially penetrate its way further into the fabric. If this cycle of rain/freeze/thaw/rain is repeated, this can eventually result in water penetrating the underlay and reaching the sarking, which can lead to problems of damp in the roofspace. The phenomenon of rain/freeze/thaw/rain' is specific to supported roofs where the underlay is directly supported on rigid sarking.
Advantageously, laminated fabrics according to embodiments of the present invention are able to provide good water hold-out even when used in these demanding environments.
Examples falling within the scope of the invention will now be described.
ExamQle 1 A pre-compressed polypropylene meltblown layer was calendered at a temperature of 110 -170 t and a pressure of 30 -150 N/mm using a point/flat calendering process to provide a film-like' meltblown layer of basis weight 35 g/m2 and having an air permeability of 21 l/rn2/s.
The polypropylene meitblown layer was thermally laminated using a point-bonding calendering process at a temperature of 120170cc and a pressure of 30 -150 N/mm to a second polypropylene spunbond layer having a basis weight of 90 g/m2 and a third polypropylene spunbond layer having a basis weight of 50 g/m2.
The properties of the laminated fabric were tested and are set out in Table 2.
Comparative Example 1 A pre-compressed polypropylene meltblown layer having a basis weight of 35 g/m2 and an air permeability of 400 l/m2/s was thermally laminated using a point-bonding calendering process to a second polypropylene spunbond layer having a basis weight of 90 g/m2 and a third polypropylene spunbond layer having a basis weight of 50 g/m2 as described for Example 1.
The properties of the meltblown layers and the laminated fabric were tested in accordance with the following procedures and are set out in Tables 1 and 2.
Hydrostatic Head Hydrostatic head is a measurement of the ability of a fabric to resist water penetration. It is the pressure, measured in cm H20, required to force water through the fabric. The value quoted is the pressure reached when 3 drops of water have penetrated the fabric. Hydrostatic head was measured according to the test method as set out in BS EN 20811:1992 Textiles -Determination of resistance to water penetration -Hydrostatic pressure test.
Air Qermeability Air permeability may be quantified by measuring the quantity of air that passes through a fixed area of fabric at a set pressure drop across the fabric. The air permeability of the Example fabrics was measured using the test method EDANA14O.2-99 (developed by The European Disposables & Nonwovens Association (EDANAfl. In this test method, the quantity of air (measured in 11m2/s) passing through a 20cm2 of fabric is measured at a pressure drop of 200 Pa.
Moisture Vapour Transmission Rate (MVTR) The MVTR of the fabrics was determined using the test method as set out in BS 3177:1959 -Method for determining the permeability to water vapour of flexible sheet materials used for packaging.
Table 1 -Meltblown Properties Meltblown Property Units Comparative Example 1 Example 1 Typical' meltblown Film like' meltblown Meitblown Weight g/m2 35 35 Hydrostatic Head cm 70 165 Air Permeability l/m2Is 400 21 Table 2 -Laminate Properties Laminated fabric Comparative Example 1 Example 1 Property Units (comprising typical' (comprising film like' meltbiown) meltbiown) Laminate Weight g/m2 175 175 SMS Laminate 90 90 g/m2 Spunbond layer 1 polypropylene spunbond polypropylene spunbond SMS Laminate 35 35 g/m2 Meltblown layer 2 typical' meltblown film like' meltblown SMS Laminate 50 50 g/m2 Spunbond layer 3 polypropylene spunbond polypropylene spunbond Hydrostatic Head cm 94 200 Air Permeability l/m2/s 67 10 MVTR g/m2/day 2400 2335 The data illustrates that the laminated fabric of Example 1 showed an improved water hold-out (hydrostatic head) in comparison to the laminated fabric of Comparative Example 1. Surprisingly, the laminated fabric comprising the film-like' meltblown has maintained a relatively high moisture vapour transmission rate (MVTR), meaning that the increase in hydrostatic head has not led to a reduced vapour permeability.
The laminated fabric incorporating the heavily consolidated film-like' meltblown of Example 1 provides an improved level of water hold-out together with the benefits of an air and vapour permeable material.
To quantify the impact of improved hydrostatic head on the practical water hold-out performance of a laminated material roofing underlay in fully supported roofs, a rain/freeze/thaw/rain' test was conducted in the laboratory that simulates the extreme conditions that can occur on a fully supported roof. The test involved securing an underlay to a section of timber sarking and subjecting this underlay to a constant 6 hour water spray (rain). This wet underlay, secured to the sarking, was then immediately placed in a freezer overnight at -15°C. The underlay and sarking were then removed from the freezer and immediately subjected to a further 6 hours of water spray. On completion of this second water spray cycle the underlay was removed from the sarking and the sarking was inspected. If the sarking was found to be wet then this indicated that the underlay had leaked at some stage during the test.
If the sarking was found to be dry then this indicated that the underlay had not leaked during the test. Also, to quantify the water hold-out performance after the rain/freeze/thaw/rain' test, a section of the underlay that had been directly under the water spray was removed and its retained hydrostatic head measured. The results are set out in Table 3.
Table 3
Laminated fabric Property Units ______________________ ____________________ Comparative Example 1 Example 1 Condition of sarking / Wet patches Dry board after rain/freeze/thaw/rain' test Hydrostatic Head Before cm 94 200 Hydrostatic Head After cm 78 -42 206 The laminated material described in Example 1 did not result in wet sarking board after the test and it retained high levels of water hold-out with a final hydrostatic head of 206cm. By contrast a reduced hydrostatic head for the laminated material of Comparative Example 1, in the range 78cm to 42cm, was observed after the rain/freeze/thaw/rain' test and wet patches were observed on the underlying sarking board. The results indicate that laminated fabrics according to embodiments of the present invention are much better able to resist repeated rain/freeze/thaw/rain' cycles and so are more suited for use in demanding applications, such as fully supported or sarked roofs.

Claims (1)

  1. <claim-text>CLAIMS1. A laminated fabric comprising: a first layer of calendered meitbiown material laminated to a second layer of spunbond material; wherein the laminated fabric has a hydrostatic head of greater than 140 cm.</claim-text> <claim-text>2. A laminated fabric as claimed in claim 1, wherein the laminated fabric comprises a building material such as a roofing underlay, such as for use in a fully supported or "sarked" roof.</claim-text> <claim-text>3. A laminated fabric according to claim 1, wherein the laminated fabric is air permeable laminate, and/or vapour permeable, such as a water vapour permeable.</claim-text> <claim-text>4. A laminated fabric according to any preceding claim, wherein the laminated fabric comprises a third layer of spunbond material, optionally wherein the first layer of calendered meltblown material is sandwiched between the second and third layers of spun-bond material.</claim-text> <claim-text>5. A laminated fabric according to any preceding claim, wherein the laminated fabric has a hydrostatic head of greater than 140cm, greater than about 150cm, greater than about 160cm, greater than about 170cm, or even greater than about 190cm.</claim-text> <claim-text>6. A laminated fabric according to any preceding claim, wherein the laminated fabric has a hydrostatic head between 140cm and 1000cm, between 150cm and 800cm, between 160cm and 600cm, between 170cm and 400cm or between 190cm and 300cm.</claim-text> <claim-text>7. A laminated fabric according to any preceding claim, wherein prior to lamination, the first layer of calendered meitblown material has a hydrostatic head of greater than 100cm, greater than 120cm, greater than 140cm or greater than 160cm.</claim-text> <claim-text>8. A laminated fabric according to any preceding claim, wherein the laminated fabric has an air permeability less than about 60 l/m2/s, less than about 40 l/m2/s, or less than about 20 l/m2/s.</claim-text> <claim-text>9. A laminated fabric according to any preceding claim, wherein the laminated fabric has a moisture vapour transmission rate (MVTR) greater than 1500 g/m2/24h, greater than 1750 g/m2/24h, greater than 2000 gIm2/24h, or greater than 2250 g/m2/24h.</claim-text> <claim-text>10. A laminated fabric according to any preceding claim, wherein the first layer of calendered meltblown material has a basis weight between 10 g/m2 and 60 g/m2, or between 20 g/m2 and 50 g/m2 or between 30 g/m2 and 40 g/m2.</claim-text> <claim-text>11. A laminated fabric according to any preceding claim, wherein the second and/or third layer of spunbond material have a basis weight between 15 and 150 g/m2, or between 40 and 100 g/m2.</claim-text> <claim-text>12. A laminated fabric according to any preceding claim, wherein the first layer of meltblown material and the second and third layers of spunbond material comprise polymers selected from polyolefinic polymers such as polyethylene and polypropylene homopolymers and co-polymers thereof and of mixtures of homopolymers and co-polymers.</claim-text> <claim-text>13. A laminated fabric according to any preceding claim, wherein the first layer of meltblown material and the second and third layers of spunbond material comprise polypropylene.</claim-text> <claim-text>14. A laminated fabric according to any preceding claim, wherein the laminated material comprises additives selected from hydrophobic melt additives, UV absorbing additives, flame retardants, pigments, plasticisers and combinations thereof.</claim-text> <claim-text>15. A roof comprising a laminated fabric according to any preceding claim.</claim-text> <claim-text>16. A roof according to claim 15, wherein the roof is a fully supported roof.</claim-text> <claim-text>17. A method of making a laminated fabric comprising: calendering a first layer of a meltblown material; and laminating the first layer of calendered meltblown material to at least a second layer of spunbond material to provide a laminated fabric having a hydrostatic head of greater than 140cm.</claim-text> <claim-text>18. A method of making a laminated fabric according to claim 17, which comprises laminating the first layer of meltblown material to a third layer of spunbond material.</claim-text> <claim-text>19. A method of making a laminated fabric according to claims 17 and 18, wherein the method comprises calendering a first layer of polypropylene meltblown material at a temperature between 110 and 170 °C, and optionally at a pressure between 30 and 150 N/mm.</claim-text> <claim-text>20. A method of making a laminated fabric according to claims 17 to 19, wherein the step of calendering the meltblown layer is carried out in line' or off line'.</claim-text> <claim-text>21. A method of making a laminated fabric according to claims 17 to 20, wherein the method comprises passing the meltblown sheet through a flat calendering process or a point bonding calendering process.</claim-text> <claim-text>22. A method of making a laminated fabric according to claims 17 to 21, wherein the method comprises calendering the first layer of meltbiown material to provide a layer of calendered meltblown material having a hydrostatic head of at least 100cm, at least 120cm, at least 140cm or at least 160cm.</claim-text> <claim-text>23. A method of making a laminated fabric according to claims 17 to 22, wherein the method comprises compressing a first layer of meltblown material, optionally prior to a calendering step.</claim-text> <claim-text>24. A method of making a laminated fabric comprising: laminating a first layer of a calendered meltblown material to at least a second layer of spunbond material to provide a laminated fabric having a hydrostatic head of greater than 140cm.</claim-text> <claim-text>25. A method of making a laminated fabric according to claim 24, which comprises laminating the first layer to a third layer of spunbond material.</claim-text> <claim-text>26. A method of making a laminated fabric according to any of claims 24 to 25, which comprises providing a first layer of calendered meltblown material having a hydrostatic head of greater than 100cm, greater than 120cm, greater than 140cm or greater than 160cm.</claim-text> <claim-text>27. A method of making a laminated fabric according to any of claims 24 to 26, wherein the laminating is effected by passing the sheet materials simultaneously through, for example, a point bonding calendering process.</claim-text> <claim-text>28. A method of making a laminated fabric according to any of claims 24 to 27, wherein the laminating comprises applying a combination of heat and pressure in an intermittent pattern known as point bonding, optionally wherein the area of such bond points is in the range 5% to 40% or 15% to 20% of the total area of the bonded materials.</claim-text> <claim-text>29. Use of a laminated fabric according to any preceding claim as a building material.</claim-text> <claim-text>30. Use of a laminated fabric according to any preceding claim as a roofing underlay, such as on a fully supported or sarked roof.</claim-text> <claim-text>31. A laminated fabric substantially as described herein with reference to the accompanying drawings.</claim-text> <claim-text>32. A method of making a laminated fabric substantially as described herein with reference to the accompanying drawings.</claim-text> <claim-text>33. Use of a laminated fabric substantially as described herein with reference to the accompanying drawings.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS:CLAIMS1. A method of making a buding material comprising a laminated fabric, the method comprising: calendering a first layer of a meltbiown material prior to lamination; and then laminating the first ayer of calendeired meltblown riaterial to at least a second and a third layer of spunbond material by passing the materials simultaneously through a point bond calendering process to provide a spunbonded/meltblown/spunbonded (SMS) laminated fabric having a hydrostatic head of greater than 140cm; wherein the meithiown layer is formed of single component fibres; the spunbond layers are formed of single component fflaments; and the meltblown and spunbond ayers are formed of a polyolefinic polymer. r2. A method of making a building material according to claim 1, wherein the 0 method comprises calendering a first layer of polypropylene meltblown material prior to lamination at a temperature between 110 and 170 °c, and optionay at a pressure between 30 and 150 N/mm.3. A method of making a building material according to any of claims 1 to 2, wherein the step of calendaring the meitbiown layer prior to laminaton is carried out Lin line' or gaff line'.4. A method of making a building material according to any of claims I to 3, wherein the method comprises passing the meltblown sheet through a flat calendering process or a point bond calendering process prior to lamination, 5. A method of making a buding material according to any of claims 1 to 4.wherein the method comprises calendering the first layer of meltblown material prior to lamination to provide a layer of calendared meitbiown material having a hydrostatic head of at east 100cm. at least 120cm, at least 140cm or at least 160cm.6. A method of making a buding material according La any of claims 1 to 5, wherein the method comprises compressing a first layer of meitbiown material prior to a cendedrig step.A method of making a building material according to any of claims I to 6, wherein the laminating comprises applying a combination of heat and pressure in an intermittent pattern known as point bonding and wherein the area of such bond points is in the range 5% to 40% or 15% to 20% of the total area of the bonded materials. r8. A building material comprising a laminated fabric obtained by: 0 calendaring a first layer of a meltblown material prior to lamination; and laminating the first layer of calendared meitblown material to at least a second and a third layer of spunbond material by passing the materials simultaneously through a point bond calendaring process to provide a spunbonded/meltblcwn/spunbonded (SMS) laminated fabric having a hydrostatic head of greater than 140cm; wherein the meltblown layer is formed of single component fibres; the spunbond layers are formed of single component filaments; and the meitblown and spunbond layers are formed of a polyolefinic polymer.9. A building material comprising a laminated fabric, the material comprising: a first layer of calendered meltbiown material; 26 the first layer of calendared meltblown material being laminated to at least a second and a third layer of spunbond material by further point bond calendaring to provide the aminated fabric comprising a spunbonded/meitbown/spunbonded (SMS) laminated fabric having a hydrostatic head of greater than 140cm; the rn&tbown ayer being formed of singe component fibres; the spunbond ayers being fOrmed of singe component filaments; and the meltblown and spunbond layers being formed of a polyoiefinic poiyrner.10, A building material according to either of daims 8 or 9, wherein the building material is a roofing underlay, or a roofing underlay for use in a fuily supported or saiked roof.11. A building material according to any of cairns 8 to 10, wher&n the laminated 0') fabric is air permeable laminate and/or water vapour permeable. 0')0 12. A building material according to any of claims 8 to Ii, wherein the laminated fabric has a hydrostatic head of greater than 140cm, greater than about 150cm, greater than about 160cm, greater than about 170cm, or even greater than about 190cm.13. A building material according to any of claims 8 to 12, wherein the laminated fabric has a hydrostatic head between 140cm and 1000cm, between 150cm and 800cm. between 180cm and 600cm, between 170cm and 400cm or between 190cm and 300cm.14. A building material according to any of cairns B to 13, wherein prior to lamination, the first layer of calendered metblown material has a hydrostatic head of greater than 100cm, greater than 120cm, greater than 140cm or greater than 160cm.15. A building maLarial according to any of daims $ to 14, wherein the laminated fabric has an air permeability less than about 60 Vm2/s, less than about 40 Wm2/s, or less than about 20 11m21 a.16. A building material according to any of claims 8 to 15, wherein the iaminated fabric has a moisture vapour transmission rate (MVTR) greeter than 1500 g/m2/24h, greater than 1750 gim2/24h, greater than 2000 gIrn2I24h, or greater than 2250 gim2f24h.17. A building material according to any of claims 8 to 16, wherein the first layer of calendared meitbiown material has a basis weight between 10 g/m2 and 60 g/n,2, or C') between 20 g/m2 and 50 g/m2 or between 30 g/m2 and 40 g!m2.CO0 18. A building materiel according to any of claims 8 to 17, wherein the second and/or third layer of spunbond material have a basis weight between 15 and 150 g/m2, or between 40 and 100 g/m2.19. A building material according to any of claims 8 to 18, wherein the polyolefinic polymer is selected from polyethylene and polypropylene homopolymers and cx>-polymers thereof.20. A building material according to any ol claims 8 to 19, wherein the first layer of meltblown material and the second and third layers of spunbond material comprise polypropylene.21. A bullding materia' accorthng to any of Sims S to 20, wherein the laminated materi& cornpres additives selected from hydrophobic melt additives, UV absorbing additives, flame retardants, pigments, plasticisers and combinations thereof.22. A roof comprising a bullding material according to any of claims 8 to 21.23. A roof according to claim 22, wherein the roof is a fully supported roof.24, Use of a building material according to any of claims 8 to 21 as a roong underlay.C") 25. Use of a bullding material according to any of Sims 8 to 21 as a roofing C) underlay on a fully supported or sarkod roof.N-15 26. A bullding material substantially as described herein with reference to the accompanying drawings.27. A method of making a bullding material substantially as described herein with reference to the accompanying drawings.28, Use of a building material substantially as described herein with reference to the accompanying drawings.</claim-text>
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