US 12,145,348 B2
System for forming a roofing membrane, and associated method
Caleb David Cheung, San Jose, CA (US)
Assigned to GAF Energy LLC, Parsippany, NJ (US)
Filed by GAF Energy LLC, Parsippany, NJ (US)
Filed on Aug. 24, 2023, as Appl. No. 18/455,129.
Claims priority of provisional application 63/400,646, filed on Aug. 24, 2022.
Prior Publication US 2024/0066853 A1, Feb. 29, 2024
Int. Cl. B32B 37/06 (2006.01); B32B 27/08 (2006.01); B32B 27/32 (2006.01); B32B 37/10 (2006.01); B32B 37/20 (2006.01); B32B 38/00 (2006.01); B32B 38/06 (2006.01); E04D 5/06 (2006.01); E04D 5/10 (2006.01)
CPC B32B 37/203 (2013.01) [B32B 27/08 (2013.01); B32B 27/32 (2013.01); B32B 37/06 (2013.01); B32B 37/10 (2013.01); B32B 38/0004 (2013.01); B32B 38/06 (2013.01); E04D 5/06 (2013.01); E04D 5/10 (2013.01); B32B 2250/02 (2013.01); B32B 2250/03 (2013.01); B32B 2250/242 (2013.01); B32B 2323/00 (2013.01); B32B 2419/06 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A method, comprising:
obtaining a first roll of a first sheet,
wherein the first sheet comprises thermoplastic polyolefin (TPO), and
wherein the first sheet has a width of at least 60 inches measured parallel to an axis of the first roll of the first sheet;
obtaining a second roll of a second sheet,
wherein the second sheet comprises thermoplastic polyolefin (TPO), and
wherein the second sheet has a width of at least 60 inches measured parallel to
an axis of the second roll of the second sheet;
heating at least a portion of a width of the first sheet with hot air from a hot air knife, thereby to form a heated first sheet;
compressing the heated first sheet and the second sheet with one another between two rollers, thereby to form a laminated roofing membrane,
wherein the heated first sheet and the second sheet directly contact one another without any intervening layer disposed between the heated first sheet and the second sheet
wherein the hot air knife is adjacent to the two rollers; and
cutting the laminated roofing membrane, thereby forming a separate first laminated roofing shingle.