Abstract: The present invention generally encompasses a starter block for use in the starter course of a roofing project to facilitate the subsequent positioning of shingles upon a hip roof without causing said shingles to substantially bend. The starter block has a tapered thickness, that is, the height of the front surface is greater than the height of the back surface. In one embodiment, the height of the front surface is about twice the height of the back surface. Otherwise, the starter block is generally rectangular. In one embodiment, the starter block is formed from a composite material, such as a combination of at least a polymer component (e.g. polyethylene) and a filler component (e.g., glass, stone, limestone), and includes at least one nib extending from each of its side surfaces and at least one nailing zone on its top surface.

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.

Abstract: A molding apparatus is configured with a distribution channel configured to deliver a blended feed composition directly into an article molding region such that a molded article is formed with gating on the bottom surface of the article. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. Additionally, the body of each article molding region of the “A” surface mold tool is adapted for molding a bottom surface for the composite article, and the body of the article molding region of the “B” surface mold tool is adapted for molding a top surface for the composite article.

Abstract: A roofing member provides improved thermal expansion relief characteristics when mounted adjacent to other roofing members in laterally extending courses on a roof surface. According to one arrangement, the roofing member has a main body with top and bottom surfaces, and side regions, as well as one or more spacer tabs extending outwardly from one or more of the side regions. Each spacer tab extends outwardly from a location on one of the side regions that is adjacent to one of a set of depressions formed into the bottom surface of the main body. In this way, when thermal expansion of adjacently mounted roofing members occurs causing a compressive force to be applied against particular spacer tabs, the spacer tabs fail in a way that at least partially displaces the respective tabs into the adjacently positioned depressions, thereby reducing the stress loads that adjacent shingles apply to one another.

Abstract: A molding apparatus is configured with a distribution channel configured to deliver a blended feed composition directly into an article molding region such that a molded article is formed with gating on the bottom surface of the article. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. Additionally, the body of each article molding region of the “A” surface mold tool is adapted for molding a bottom surface for the composite article, and the body of the article molding region of the “B” surface mold tool is adapted for molding a top surface for the composite article.

Abstract: A molding apparatus is configured with article molding regions that receive a direct flow of a molding material feed such that external flow channels are not needed. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. With at least the “A” surface mold tool, a port is coupled with the body of each article molding region to establish a direct pathway is through which the molding material feed flows to enter the article molding regions, and thus the closed molding cavity, without having to flow along the tool front sides outside of the article molding regions.

Abstract: A roofing shingle with a laying line that facilitates the alignment of an overlying course of shingles with respect an underlying course of shingles is provided. The laying line is located on a front surface of the shingle and has a width such that the laying line is exposed when an edge of another shingle is placed in contacting proximity with the laying line. The shingle may also have a scale and one or more nibs that protrude from the sides of the shingle that assist in aligning the shingles in the second course with the shingles in the underlying course. The shingle may also include nailing zones located on the front surface of the shingles provide a location for fastening the shingles to the roof. A method of laying the shingles of the present invention on a roof is also provided.

Abstract: A variegated building product solution includes a process for creating variegated building products through the introduction of color infused pellets with base pellets to create an aggregate, non-uniformly mixed pellet mixture as feed material for a molding process. In one aspect, the process involves the introduction of a set of color infused pellets into the stream of feed material pellets at preselected intervals. The feed material pellets includes color of a first hue, and the set of color infused pellets possess at least a second hue at variance from the first hue, such that the combined pellets form the aggregate, non-uniformly mixed pellet mixture. According to the process, the aggregate pellet mixture is moved into a molding chamber for molding of the aggregate pellet mixture into a variegated building product.

Abstract: A roofing shingle with a laying line that facilitates the alignment of an overlying course of shingles with respect an underlying course of shingles is provided. The laying line is located on a front surface of the shingle and has a width such that the laying line is exposed when an edge of another shingle is placed in contacting proximity with the laying line. The shingle may also have a scale and one or more nibs that protrude from the sides of the shingle that assist in aligning the shingles in the second course with the shingles in the underlying course. The shingle may also include nailing zones located on the front surface of the shingles provide a location for fastening the shingles to the roof. A method of laying the shingles of the present invention on a roof is also provided.

Abstract: Useful composites and methods of using such composites are provided. The composites include an outer layer containing a first polymeric material, an intermediate layer circumscribed by the outer layer and containing a second polymeric material, and an inner layer circumscribed by the intermediate layer and containing a third polymeric material. The inner layer, in combination with the intermediate layer, is structured and effective to reinforce the composite relative to a substantially identical composite without the inner layer. The present composites can be produced using co-extrusion processing.

Abstract: A roofing member provides improved thermal expansion relief characteristics when mounted adjacent to other roofing members in laterally extending courses on a roof surface. According to one arrangement, the roofing member has a main body with top and bottom surfaces, and side regions, as well as one or more spacer tabs extending outwardly from one or more of the side regions. Each spacer tab extends outwardly from a location on one of the side regions that is adjacent to one of a set of depressions formed into the bottom surface of the main body. In this way, when thermal expansion of adjacently mounted roofing members occurs causing a compressive force to be applied against particular spacer tabs, the spacer tabs fail in a way that at least partially displaces the respective tabs into the adjacently positioned depressions, thereby reducing the stress loads that adjacent shingles apply to one another.

Abstract: A molding apparatus is configured with article molding regions that receive a direct flow of a molding material feed such that external flow channels are not needed. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. With at least the “A” surface mold tool, a port is coupled with the body of each article molding region to establish a direct pathway is through which the molding material feed flows to enter the article molding regions, and thus the closed molding cavity, without having to flow along the tool front sides outside of the article molding regions.

Abstract: A molding apparatus is configured with a distribution channel configured to deliver a blended feed composition directly into an article molding region such that a molded article is formed with gating on the bottom surface of the article. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. Additionally, the body of each article molding region of the “A” surface mold tool is adapted for molding a bottom surface for the composite article, and the body of the article molding region of the “B” surface mold tool is adapted for molding a top surface for the composite article.

Abstract: The present invention generally encompasses a ridge cap roofing product that is formed from a composite material. The ridge cap has a cross section that is generally in the shape of an inverted V with a rounded apex and includes a front section and a back section. The front section has a straight lower edge. The back section has a lowered edge that tapers both upward and inward. The tapered shape of the ridge cap's back section insures that installed ridge caps lie flat and that a covered ridge or hip does not have a saw tooth appearance. The ridge cap of the present invention is somewhat flexible so that it can be used with roofs that have a range of pitches. In one embodiment, the top surface of the ridge cap's front section is textured or contoured so that it simulates certain conventional shingles.

Abstract: A method and apparatus are provided for forming embossed simulated boards through a combination of extrusion molding process and separate embossing step. During embossing, the extrudate from the extruder is pressure formed forming a texturized surface on at least one face of the board with the board being captured on all sides of the board during the embossing step. After embossing, the extrudate is cooled to a temperature sufficient to rigidify the thus cooled extrudate. The cooled extrudate may then be cut into the appropriate lengths.

Abstract: A starter block and a shingle are utilized to form courses that may be positioned in overlapping fashion on a roof to form a roofing covering system. The particular design of the starter block and shingle result in a roofing product that provides increased durability over previous designs. The starter block may be formed with top and bottom surfaces, opposite side surfaces with tapering heights, and a front surface having a greater height than a back surface of the starter block. When the starter block is coupled to a roof deck, a semi-rigid shingle having a generally planar bottom surface may be placed upon the starter block so that a portion of the shingle extends off of the starter block over the back surface thereof and onto the roof deck to facilitate contact between the shingle and the roof deck at a location more proximal to the starter block back surface than if the same back surface had the same height as the front surface.

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.

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.