Patent ID: 8206539

Claim:
A method of manufacturing a panel of roofing shingles having a capstock layer of polymeric material and a base layer of polymeric foam material, comprising: extruding the polymeric foam material separate from a precursor of the capstock layer by extruding a separate polymeric foam material; extruding the precursor of the capstock layer separate from the polymeric foam material, by extruding a separate precursor with a nailing edge and an L-shaped cross section in which a short side of the L-shaped cross section forms the separate precursor having butt edges of the shingles, and a long side of the L-shaped cross section forms the separate precursor having multiple roofing shingles of different lengths and different heights to simulate randomly arranged shingles of different lengths and height, wherein each of the shingles is formed with substantially the same volume of the capstock layer to receive and fill with adequate polymeric material to avoid voids in the polymeric material caused by inadequate filling, followed by; combining the separate precursor with the separate polymeric foam material within a belt mold; transporting the precursor and the polymeric foam material within the belt mold, while one half of the belt mold forms and shapes the precursor to form the capstock layer with a shape and surface topography of multiple roofing shingles; and heating the polymeric foam material within the belt mold, while foaming and shaping the polymeric foam material within the belt mold in situ against the capstock layer, and while bonding together the polymeric foam material and the capstock layer within the belt mold to form the panel of roofing shingles.