Preheat oven to 400F (reduce heat by 25F if using convection oven). Brush rimmed baking sheet with a thin coat of olive oil.
Spread the carrots, squash, tomatoes, onion, and garlic on sheet.
Drizzle all with more olive oil.
Sprinkle with salt and (to taste) and toss all item to ensure they are coated.
Roast vegetables until they are brown and tender, stiring occasionally, for about 15 minutes.
Cut squash and carrots into ½ inch pieces; set aside. Peel garlic cloves; place food in processor. Add tomatoes and onions; puree until almost smooth.
Pour ½ cup broth onto baking sheet; scrape up any browned bits.
Transfer broth and vegetable puree to large pot.
Add 5 ½ cups broth, kale, thyme and bay leaf to pot. Bring to boil. Reduce heat. Simmer uncovered until kale is tender, about 30 minutes.
Add carrots, beans, and squash to soup. Simmer 8 minutes to blend flavors, adding more broth to thin soup if neccessary. Season with salt and peper. Discard thyme sprigs and bay leaf.