Method for manufacturing roofing products

Abstract

A method of making a roofing product such as a shingle is provided. One such method includes creating a mixture having at least a polymer and a filler, forming a sheet from the mixture, cooling the sheet, embossing the sheet, forming multiple roofing products from the sheet and bundling at least some of the roofing products together. This method is performed using an automated procedure. Another method of the present invention involves creating a composite roofing product using mold cavities, using a robot to transfer some of the roofing products from some of the mold cavities to a conveying system, and stacking together at least two of the roofing products that have different colors of different surface configurations.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This Application is a divisional of and claims priority to U.S. application Ser. No. 10 / 457,728 filed Jun. 9, 2003 entitled “Method for Manufacturing Roofing Products,” currently pending, which is a continuation-in-part of U.S. Pat. No. 6,935,089 issued Aug. 30, 2005, which documents are hereby incorporated by reference to the extent permitted by law.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT[0002]None.BACKGROUND OF THE INVENTION[0003]The present invention relates to a method of manufacturing roofing products. In particular, the invention relates to an automated manufacturing process for producing shingles.[0004]Traditional roofing products such as asphalt shingles, wood shake shingles, slate shingles and metal panels have both benefits and detriments. For instance, wood shake and slate roofs are aesthetically pleasing to many homeowners. However, wood shake shingles are considered a fire hazard while slate shingles a...

AI Technical Summary

Benefits of technology

The present invention provides a method for creating shingles using a partially automated system. The method includes steps of creating a mixture of filler and polymer, forming a sheet from the mixture, cooling the sheet, embossing the sheet, foaming multiple roofing products from the sheet, and associating at least some of the roofing products with one another. The invention also includes a method of making shingles by creating composite shingles using at least one mold cavity, using a robot to transfer some of the shingles from some of the mold cavities to a conveying system, and stacking together at least two of the shingles wherein the shingles have different colors or different surface configurations. The technical effects of the invention include increased efficiency in the production of shingles and improved quality of the finished product.

Problems solved by technology

However, wood shake shingles are considered a fire hazard while slate shingles are very expensive and subject to cracking.

These asphalt products, however, typically do not have the structural rigidity of slate or wood.

These products, however, are subject to denting and breakage.

Although some of these patents promote economics of scale in aspects of their manufacturing, the references do not disclose a manufacturing solution that takes advantage of economics of scale and that may be automated from virtually beginning to end.

Images