Method of manufacturing roofing products

Abstract

Methods of making roofing products. One such method includes (a) creating a mixture having a filler and a polymer; (b) forming a sheet from the mixture; (c) cooling the sheet; (d) embossing the sheet; (e) forming multiple roofing products from the sheet; and (f) bundling at least some of the roofing products. Steps (a)-(f) are performed using an automated procedure. Another of the methods involves (a) creating composite roofing products using mold cavities; (b) using a robot to transfer some of the roofing products from some of the mold cavities to a conveying system; and (c) stacking together at least two of the roofing products that have different colors or different surface configurations.

1 . (canceled)  
   
   
       2 . (canceled)  
   
   
       3 . (canceled)  
   
   
       4 . (canceled)  
   
   
       5 . A method of making roofing products comprising: 
 (a) creating a mixture having a filler and a polymer;    (b) forming a sheet by extruding the mixture through a die;    (c) smoothing the sheet;    (d) cooling the sheet using a first cooling station;    (e) embossing the sheet;    (f) cooling the sheet using a second cooling station;    (g) forming multiple roofing products by cutting the sheet;    (h) cooling at least some of the roofing products; and    (i) bundling at least some of the roofing products.    
   
   
       6 . The method of  claim 5 , where (i) comprises: 
 (j) stacking at least some of the roofing products to form a stack;    (k) placing the stack on a pallet; and    (l) wrapping the stack;    where (j)-(l) are performed using an automated procedure.    
   
   
       7 . The method of  claim 6 , where (i) further includes: 
 (m) placing a strap around the stack;    and where (j)-(m) are performed using an automated procedure.    
   
   
       8 . The method of  claim 5 , further comprising: 
 (j) recycling scrap from the cutting.    
   
   
       9 . A method of making roofing products comprising: 
 (a) creating composite roofing products using mold cavities;    (b) using a robot to transfer some of the roofing products from some of the mold cavities to a conveying system; and    (c) stacking together at least two of the roofing products that have different colors or different surface configurations.    
   
   
       10 . The method of  claim 9 , where (c) forms a stack, and the method further comprises: 
 (d) placing the stack on a pallet.    
   
   
       11 . The method of  claim 10 , further comprising: 
 (e) wrapping the stack;    where (c)-(e) are performed using an automated procedure.    
   
   
       12 . The method of  claim 11 , further comprising: 
 (f) placing a strap around the stack;    where (c)-(f) are performed using an automated procedure.    
   
   
       13 . The method of  claim 9 , where at least one of the mold cavities has a surface formed using digitized modeling.  
   
   
       14 . The method of  claim 5 , wherein steps (a)-(h) are performed using an automated procedure.  
   
   
       15 . A method of making roofing products comprising: 
 (a) creating a mixture having a filler and a polymer;    (b) forming a sheet by extruding the mixture through a die;    (c) smoothing the sheet;    (d) cooling the sheet using a first cooling station;    (e) embossing the sheet;    (f) cooling the sheet using a second cooling station;    (g) forming multiple roofing products by cutting the sheet;    (h) cooling at least some of the roofing products; and    (i) bundling at least two of the roofing products that have different colors or different surface configurations.    
   
   
       16 . The method of  claim 15 , where (i) comprises: 
 (j) stacking at least some of the roofing products to form a stack;    (k) placing the stack on a pallet; and    (l) wrapping the stack;    where (j)-(i) are performed using an automated procedure.    
   
   
       17 . The method of  claim 16 , where (i) further includes: 
 (n) placing a strap around the stack;    and where (j)-(m) are performed using an automated procedure.    
   
   
       18 . The method of  claim 15 , further comprising: 
 (j) recycling scrap from the cutting.