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.

1 . A method of manufacturing roofing products, said method comprising the following steps:
 (a) creating a mixture having at least a filler and a polymer;   (h) forming a sheet from said mixture;   (c) cooling the sheet;   (d) embossing the sheet;   (e) forming multiple roofing products from the sheet; and   (f) associating at least some of the roofing products;   wherein steps (a) through (f) are performed using an automated procedure.   
     
     
         2 . The method of  claim 1  wherein said filler is limestone. 
     
     
         3 . The method of  claim 1  wherein said polymer is polyethylene. 
     
     
         4 . The method of  claim 1  wherein said mixture also contains a colorant. 
     
     
         5 . The method of  claim 1  wherein said mixture also contains a fire retardant. 
     
     
         6 . The method of  claim 1  wherein said mixture also contains a UV protector. 
     
     
         7 . The method of  claim 1  wherein said creating step is performed in an extruder machine. 
     
     
         8 . The method of  claim 1  wherein said step of forming a sheet from said mixture is performed by extruding said mixture from an extruder machine through a sheet die. 
     
     
         9 . The method of  claim 1  wherein said cooling step is performed at least in part by a cooling conveyor. 
     
     
         10 . The method of  claim 1  wherein said cooling step is performed at least in part by a mister. 
     
     
         11 . The method of  claim 1  wherein said step of forming multiple roofing products from the sheet includes cutting said sheet to create said multiple roofing products. 
     
     
         12 . The method of  claim 1  wherein said associating step comprises:
 stacking at least some of the roofing products thereby forming a stack;   placing said stack on a pallet; and   wrapping the stack.   
     
     
         13 . The method of  claim 12  wherein said associating step further includes placing a strap around said stack. 
     
     
         14 . The method of  claim 1  wherein said step of forming multiple roofing products from the sheet creates a number of roofing products and scrap and further comprising the step of:
 (g) recycling said scrap;
 wherein said steps (a) through (g) are performed in an automated procedure. 
   
     
     
         15 . A method for manufacturing roofing products, said method comprising the following steps:
 (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.   
     
     
         16 . The method of  claim 15  wherein said filler is limestone. 
     
     
         17 . The method of  claim 15  wherein said polymer is polyethylene. 
     
     
         18 . The method of  claim 15  wherein said mixture also contains a colorant. 
     
     
         19 . The method of  claim 15  wherein said mixture also contains a fire retardant. 
     
     
         20 . The method of  claim 15  wherein said mixture also contains a UV protector. 
     
     
         21 . The method of  claim 15  wherein said creating step is performed in an extruder machine. 
     
     
         22 . The method of  claim 15  wherein said first cooling station includes at least a cooling conveyor. 
     
     
         23 . The method of  claim 15  wherein said first cooling station includes at least a mister. 
     
     
         24 . The method of  claim 15  wherein said second cooling station includes at least a cooling conveyor. 
     
     
         25 . The method of  claim 15  wherein said second cooling station includes at least a mister. 
     
     
         26 . The method of  claim 15  wherein said bundling step comprises:
 stacking at least some of the roofing products to form a stack;   placing the stack on a pallet; and   wrapping the stack;   wherein said steps are performed using an automated procedure.   
     
     
         27 . The method of  claim 26  wherein said bundling step further comprises placing a strap around the stack wherein said step is performed in an automated procedure. 
     
     
         28 . The method of  claim 15  wherein said step of forming multiple roofing products by cutting the sheet creates scrap and further comprising the step of:
 (j) recycling said scrap.