AU2015201774B2 - An apparatus and method for the separation of stacked roof cladding elements - Google Patents

Abstract

The present invention relates to an apparatus and method for separating individual stacked roofing panels during their manufacture. The invention is 5 particularly useful where the roofing panels have been profiled and cut to size using an angled cutting machine in accordance with their position on a roof. Because adjacent panels in the resulting stack are typically of different shapes and sizes, scratching and damage may result through contact between the cut edge which may have burrs and the surface of a further panel stacked there above or there beneath. 10 The application of a hot melt material to a surface of the panel adjacent cut edges prevents such contact. 6371226 1 (GHMatters) P98984.AL.1 JASMINS ~ '4 r 'a In 4(4~

Description

1 2015201774 19 Jun2017

An apparatus and method for the separation of stacked roof cladding elements

The present invention relates to an apparatus and method for the separation of stacked roof cladding elements and, in particular, to the application of a separating material such as a quick freeze hot melt to a surface of each roof cladding element to 5 thereby separate the elements when stacked.

BACKGROUND OF THE INVENTION

The present invention is directed toward applying a separating material to corrugated elements for use in roofing, however, it is to be understood that this is by way of example only and the corrugated elements may equally well be used in other 10 applications, such as wall cladding for example.

Corrugated galvanised iron and steel elements, in the following also called panels and sheets, have been widely used in Australia for roofing since the late 1800’s. In earlier years, sheet metal was cut into rectangular sheets and then transported on-site where they were then cut by hand or by mobile apparatus into the 15 shapes and sizes required for a particular style roof. In more recent years, the process has become more efficient in that computer software is used in association with cutting machines to cut sheet metal to sizes which are predetermined by the computer software. The software allows a user to input a particular style of roof including roof dimensions, angles, etc, and this information is sent to a cutting 20 machine which performs the required cuts on sheet metal.

The present Applicant is the owner of various patent applications relating to apparatus and methods for the manufacture of roof cladding elements whereby such apparatus is capable of performing angle cuts as well as straight cuts of sheet metal in a way which allows for minimal wastage of metal and clean angle cuts even when 25 the metal is profiled in the longitudinal direction. Computer software is used to determine the optimum cuts to be made into a roll of strip steel and the cut pieces are typically stacked into a pile and packaged, ready for transportation to a site where they are then installed. These patent applications include AU2005205780 and AU2005204265. The contents of these applications are expressly incorporated by 30 reference herein. 9180172_1 (GHMatters) P98984.AU.1 2 2015201774 19 Jun2017

The use of bevelled blades in the abovementioned apparatus allows for angled cuts of corrugated roofing panels, however, there is always a possibility that edge corners of the panel will extend slightly upwards or downwards slightly, or that burrs will be present along the cut edge. Because the cut sheets are stacked one 5 above the other and adjacent stacked sheets mostly possess different shapes and sizes, there will always be a risk that such pointed corners and burrs will scratch and/or damage the roofing panel located there above or there beneath. This is particularly unfavourable when the scratched or damaged surface is that which is exposed on the roof after installation. 10 There is therefore a need in the industry for stacked roof panels to include a means of separation between individual panels to thereby prevent scratching or damaging due to burrs and other protrusions which may be present along their edges.

It is therefore an object of the present invention to provide an apparatus and 15 method for the separation of stacked roof cladding elements which overcome at least some of the aforementioned problems or provides the public with a useful alternative.

SUMMARY OF THE INVENTION

Therefore in one form of the invention there is proposed an apparatus for separating stacked longitudinal panels formed by feeding a longitudinal strip of 20 material through a cutting apparatus configured to cut the panels to a predetermined size and shape, said apparatus including: a means of applying a separating material to a surface of each panel adjacent a leading and/or trailing edge thereof, such that when each panel is stacked one above the other, the separating material maintains the edges in a spaced apart relationship 25 from adjacently stacked panels.

The longitudinal strip of material may be profiled in the longitudinal direction by a roll forming apparatus prior to cutting of the panels.

The means of applying the separating material may be in the form of one or more jets configured to eject a predetermined amount of said material at 30 predetermined positions along each panel edge. 9180172_1 (GHMatters) P98984.AU.1 3 2015201774 19 Jun2017

The apparatus may include a plurality of jets mounted perpendicularly to the direction of feed, each of said plurality of jets configured to be controllably fired at predetermined times.

Preferably when the edge of a panel is perpendicular to the direction of feed, 5 the mounted jets are fired at once when the panel is stopped at an appropriate position relative to the jets.

In preference when the edge of a panel is angled relative to the direction of feed, the mounted jets are fired sequentially from one side of the panel to the other while the panel is moving through, the timing of the jets being dependent upon the 10 angle of the edge.

The timing of said plurality of jets may be dependent on one or more parameters including the angle of the cut and the longitudinal profile of the material.

The timing of said plurality of jets may be controlled using a control device.

The cutting apparatus may be able to perform angled cuts on said longitudinal 15 strip of material by rotating about a central vertical axis, resulting in longitudinal panels having angled trailing and/or leading edges.

The one or more jets may be rotatable with said cutting apparatus and slideable along an axis parallel with cutting blades associated with said cutting apparatus to thereby apply said separating material along the edge of the panel. 20 Movement and timing of said one or more jets may be dependent on one or more parameters including the angle at which the cutting apparatus extends and the longitudinal profile of the material.

Movement and timing of said jets may be controlled using a control device.

The jets may be vertically moveable so that they move closer to the panel 25 before firing and move away from the panel after firing.

The separating material may be a pliable hot melt substance adapted to cool and solidify after it has been applied to the panel surface. 9180172_1 (GHMatters) P98984.AU.1 4 2015201774 19 Jun2017

The longitudinal profile may be in the form of corrugations having peaks and troughs.

The separating material may be adapted to be applied beneath the peaks of the corrugated panels. 5 The separating material may be adapted to be applied above the peaks of the corrugated panels.

The separating material may be adapted to be applied approximately 3mm from said leading and trailing edge of each panel.

In a further form of the invention there is proposed an apparatus for 10 separating stacked roof cladding elements, including: a support means adapted to support a cutting means in a position to receive a longitudinal strip of material, wherein said cutting means is adapted to cut said longitudinal strip of material into predetermined shapes and sized; and a plurality of nozzles adapted to controllably eject a small amount of soft hot melt 15 material to a surface of each roof cladding element adjacent leading and trailing edges of the elements to thereby separate the edges from elements stacked there above or there below.

The cutting means may be rotatable about a vertical axis of rotation relative to said support means to thereby cut said material at pre-determined angles. 20 The hot melt material may be applied before the longitudinal strip of material is cut.

The hot melt material may be applied after the longitudinal strip of material is cut.

In a still further form of the invention there is proposed an apparatus for 25 producing a plurality of cladding sheets for a structure, such as a roof, which apparatus includes: a roll-forming assembly for roll-forming a flat strip of metal into a roll-formed profile; a cutting assembly for cutting the roll-formed strip into a plurality of separate cladding sheets, said cutting assembly able to cut the strip through a range of angles; 30 at least one jet used to apply separating material dots to the sheet surface adjacent 9180172 1 (GHMatters) P98984.AU.1 5 2015201774 19 Jun2017 the longitudinal ends of each sheet; and a control means adapted to control operation of the roll-forming assembly, the cutting assembly and the at least one jet.

In a yet further form of the invention there is proposed a method of separating 5 at least two stacked, correspondingly profiled elements, said method including the step of applying a predetermined amount of separating material to a surface of one of said elements adjacent at least one longitudinal end thereof to separate said end from a surface of the other stacked element.

The at least two stacked, correspondingly profiled elements may be 10 corrugated elements having peaks and troughs.

The separating material may be in the form of a hot melt material adapted to be applied to a surface beneath at least one corrugation peak.

Alternatively said separating material is in the form of a hot melt material adapted to be applied to a surface above at least one corrugation peak. 15 Preferably said material is applied using one or more jets adapted to eject said hot melt material which subsequently cools and solidifies.

In a yet further form of the invention there is proposed a method of producing a plurality of stacked roll-formed cladding sheets for building a structure, such as a roof, from a roll-formed strip including the steps of: 20 inputting data related to the design of the structure into a computer program that calculates the number of sheets and their size and shape that when placed on an underlying frame together form the structure; arranging the calculated sheets into a linear order that satisfies a pre-determined criteria; 25 cutting the roll-formed strip using a cutting assembly in accordance with the calculated size and shape; applying a separating material adjacent each longitudinal end of the cladding sheet, including straight and angled ends, so that when the cladding sheets are stacked one above the other, said separating material separates said ends from the surfaces of 30 adjacently stacked sheets.

The separating material may be applied after the sheet is cut. 9180172 1 (GHMatters) P98984.AU.1 6 2015201774 19 Jun2017

Alternatively the separating material may be applied before the sheet it cut.

In a still further form of the invention there is proposed a roofing panel as manufactured using the apparatus and method defined above.

BRIEF DESCRIPTION OF THE DRAWINGS 5 The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings,

Figure 1 illustrates an exploded perspective view of a stack of corrugated roof 10 cladding elements which have been cut according to their designated position on a roof; Figure 2 illustrates a perspective view of the stack of roof cladding elements of Figure 1; Figure 3 15 illustrates a corrugated roof cladding element being fed into an angle cutting machine and a row of hot melt jets which are aligned with the peaks of the corrugated roof cladding element in accordance with the present invention; Figure 4 illustrates a side cross-sectional view of the angle cutting machine of Figure 3 including the hot melt jets, when the blades are angled 20 perpendicular to the direction of feed; Figure 5 illustrates an end view of the line of hot melt jets of Figure 3 and Figure 4; Figure 6 illustrates a perspective view of a straight cut corrugated roof cladding element having hot melt dots beneath each of its peaks, including an 25 enlarged view of the hot melt dots; Figure 7 illustrates a perspective view of an angle cut corrugated rood cladding element having hot melt dots beneath each of its peaks, including an enlarged view of the hot melt dots; 9180172 1 (GHMatters) P98984.AU.1 7 2015201774 19 Jun2017

Figure 8 illustrates a cross-sectional end view of a stack of corrugated roof cladding elements having hot melt dots beneath each peak which separate each element in the stack;

Figure 9 5 illustrates a perspective view of a straight cut corrugated roof cladding element having a hot melt dot above each of its peaks in accordance with a second aspect of the present invention; and

Figure 10 illustrates an end view of the corrugated rood cladding element of Figure 9.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 10 The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the 15 following description to refer to the same and like parts.

The present invention relates to the separation of stacked roof cladding elements of the same or different size in order to prevent scratching as a result of abrasive surfaces which may be present on the elements. The description herein refers to the use of an angle cutting machine (the machine forming the subject matter 20 of one of the applicant’s patent applications mentioned above) for cutting roofing elements having angled ends, however, it is to be understood that the invention need not necessarily involve angle cuts, it is related to the separation of stacked roof panelling regardless of their shape and size.

However, the present invention is particularly relevant to angle cut roof 25 sheeting because the likelihood of scratching and damage increases when adjacent, stacked roofing elements are stacked one above the other because the cut edges may include burrs and protrusions which may contact the surface of adjacent panels in the stack.

Shown firstly in Figure 1 and Figure 2 is a stack 10 of individual corrugated 30 roof cladding elements 12. This stack 10 is typical of one which would result from the angle cutting machine 14 shown in Figures 3 and 4 and it will be appreciated that 9180172 1 (GHMatters) P98984.AU.1 8 2015201774 19 Jun2017 each element 12 is shaped according to its position on a roof (not shown). As mentioned in the preamble the cutting machine 14 is run using computer software to determine the optimum cuts which are required along a length of strip steel according to their position on the roof, in order to minimise waste metal. As a result, one panel 5 in the resulting stack of panels may be intended for one roof portion, while the panel stacked there above may be intended for a completely different roof portion.

The stack 10 shown in Figures 1 and 2 is typical of one which is subsequently packaged and transported to a site ready for assembly. A problem which has been encountered is that because cut angled edges such as edge 16 contacts surface 18 10 of an adjacent panel, unsightly scratches may result on the surface 18. This not only occurs with angle cut edges but also with straight cut edges, and sometimes even through contact between two flat surfaces of adjacent elements 12 in a stack. For this reason, individual elements need to be separated.

The cutting machine 14 in Figures 3 and 4 includes a frame 20 and a rotating 15 blade mechanism 22 which will not be described in great detail herein. The rotating blade mechanism 22 is adapted to rotate about point 24 according to the angle of cut which is required, and typically includes two selectable sets of hydraulically driven bevelled blades 26 and 28 to accommodate different angle ranges when cutting corrugated strip steel 30. Rotation of the blade mechanism 22, motion of the feed 20 rollers (not shown) to feed the elements 20 into the machine 14 along direction 32, and operation of the blades 26 and 28 in both the angle cutting machine 14 and any associated straight edge cutting machine (not shown), are all controlled using a suitable control device (not shown). The control device operates in connection with the abovementioned computer software which transmits relevant information to the 25 control device according to a particular roof profile.

Figures 3-5 also illustrate the use of a row of hot melt jets 34 positioned perpendicularly to the direction 32 of feed of the profiled strip steel 30 above a support beam 36 associated with the frame 20 of the angle cutting machine 14. The jets 34 are positioned to eject a small amount of hot melt material 38 from a nozzle 30 40 thereof beneath each of the peaks 42 of the profiled strip steel 30 being fed through to the angle cutting machine 14. It is to be understood that the positioning of the jets is by way of example only. For example, as will become apparent in the 9180172_1 (GHMatters) P98984.AU.1 9 2015201774 19 Jun2017 second embodiment of the invention, the jets 34 could equally well be positioned above the corrugated sheeting and thereby fire downwardly.

In preference, the hot melt material 38 has properties which allow it to transform into a soft pliable material when heated, and then into a solid state material 5 when cooled. In other words, when activated, each jet 34 ejects a small volume of hot melt material which has just been heated to contact and stick to the underside of each peak 42 where it then quick freezes so that the resultant product is a small dot 38 fixed to the panel surface. It is to be understood that the present invention is not to be limited to the use of a hot melt material as described. Any suitable separating 10 medium could be applied.

When the jets are positioned beneath the roof panelling so that they fire upwardly, it is preferable that the separating medium be applied below the corrugation peaks, as opposed to the troughs, so that they are somewhat hidden and do not interfere with movement of the panel through the cutting apparatus or with 15 installation of the panels onto the roof frame.

Each dot measures approximately 10mm in diameter and 2-3mm in thickness, however, the exact dimensions of the dot are not overly important. The important factor is that they are of a size to adequately separate adjacently stacked panels. 20 The jets 34 are preferably controlled in correspondence with the other parameters of the cutting machine 14. For example, the same control device which is used to control operation of the roll forming and cutting apparatus could also be used to control operation of the hot melt jets. Parameters which are relevant to calculating when each jet should be fired include the angle of cut at the leading and trailing edge 25 of the panel, and also the length of the panel. The desired result is to create a line of hot melt dots 38 beneath each peak 42, and spaced approximately 3mm from the cut edge.

For example, if a straight edge cut is to be made, the fed strip of material will be stopped in the appropriate position and each of the jets 34 will be made to fire at 30 the same instance forming a row of dots 38 beneath each peak 42 in a line which extends perpendicular to the direction 32 in which the material is fed. Such a panel 44, having a straight trailing edge 46 and straight leading edge 48, is shown in Figure 9180172 1 (GHMatters) P98984.AU.1 10 2015201774 19 Jun2017 6. It can be seen that the roof panel 44 has hot melt dots 38 on the underside of each peak 42 adjacent the trailing 46 and leading 48 edges. Those skilled in the art would realise that if the cut forms a leading edge of a panel, the jets will be fired after the intended cut line passes over the jets 34 as it is fed through, whereas if the cut forms 5 the trailing edge of a panel, the jets will be fired before the intended cut line passes over.

If an angle cut is to be made, each jet 34 can be fired sequentially from one side to the other as the corrugated strip steel 30 is fed through, thereby forming a diagonal row of dots 38 aligned at substantially the same angle as the envisaged cut 10 edge. Obviously, different angles will require each jet to be fired at different times and the control device (not shown) is responsible for controlling the timing of the jets 34. For example, where the cutting angle is close to perpendicular to the direction 32 of feed, the time interval between each jet firing will be small, whereas if the cutting angle is large, then the time interval between sequential firings will also be larger. 15 Alternatively, the speed at which the corrugated strip steel 30 is fed could be altered so that the jets 34 fire sequentially from one side of the strip to the other at predetermined time intervals, and so the resultant angle of dots will depend on the feed speed. A corrugated roofing element 50 having an angled trailing edge 52 and a 20 straight leading edge 54 is shown in Figure 7 having hot melt dots 38 on the underside of each peak adjacent the trailing 54 and leading 52 edges.

In an alternate arrangement, a single jet (not shown) could be used which is slideably mounted to a bar mounted directly to the cutting apparatus so that it is rotatable therewith. The bar would extend along an axis substantially parallel to the 25 cutting blades. Therefore, if the jet is positioned before the cutting blades for example, once the feed material is stopped in a position ready to be cut, the jet can first be slideably moved and stopped in appropriate positioned where separating medium can be applied. Movement of the jet should be controlled so that it starts at one side of the panel and applies material along the edge in a stop-start motion until 30 it reached the other side of the panel. The jet could be positioned after the cutting apparatus also, so that hot melt material is applied along the edge after it is cut. Those skilled in the art would realise that the positions in which the jet is made to stop to apply the hot melt material would depend on the angle of cut. Such 9180172J (GHMatters) P98984.AU.1 11 2015201774 19 Jun2017 predetermined data could be stored in a computing device associated with the control means.

Figure 8 illustrates a cross-sectional view of a stack 56 of cut corrugated roofing panels 66 having hot melt dots 38 attached to the underside of each peak 42 5 of each panel. It can be appreciated in this drawing how the hot melt dots 38 serve to separate the surface 68 of one panel in the stack 56 from the otherwise adjoining surface 70 of an adjacent panel 66 located there above or there below. Such a stack 56 may then be transported to a site and the resulting corrugating roofing panels will be free of scratches and dents. 10 It is to be understood that hot melt dots need not necessarily be applied to every single peak and/or trough of the panel. There could equally well be jets positioned beneath (or above) the outer peaks only, to thereby apply a hot melt dot to either side of the panel only. Provided that there is sufficient material to separate adjoining sheets, then the exact firing sequence of the jets is not critical. 15 As mentioned, the jets 34 could also be positioned on the other side of the machine 14 so that the hot melt dots 38 are applied subsequent to cutting. It is to be further understood that the jets 34 could be made to automatically raise (or lower) to a position suitable for firing, in order to prevent contact between any dried up hot melt material which may be present on the nozzle 40 against strip being fed through. 20 As also mentioned above, the hot melt dots could equally well be applied to the top surface of the panels, as shown in Figures 9 and 10. The hot melt dots are easily removable and can be washed away post installation so the fact that they are located on the side of the panel that is visible is not important. For example, the hot melt could be of the type that dissolves in water and hence following installation 25 would disappear with the next rainfall, or alternatively, could be rinsed off. The jet(s) would therefore be positioned to be fired downwardly on top of the peaks (or other area of the panel), however, would function in substantially the same manner as previously described with regards to timing.

The present invention therefore provides a means of separating individual 30 stacked roofing panels during their manufacture. The invention is particularly useful where the roofing panels have been profiled and cut to size using an angled cutting machine according to their position on a roof. Because adjacent panels in the 9180172_1 (GHMatters) P98984.AU.1 12 2015201774 19 Jun2017 resulting stack are typically of different shapes and sizes, scratching and damage may result through contact between the cut edge which may have burrs and the surface of a further panel stacked there above or there beneath. The application of a hot melt material to a surface of the panel adjacent the cut edges prevents such 5 contact.

Finally, it is to be understood that the present invention could also be used for a number of other purposes, not just to separate the stacked panels. It may be useful for any purpose requiring some sort of visual indicator formed by the hot melt dots, for example, it is important to ensure that the corrugations run perpendicular to the 10 end of the roof structure. Skilled persons typically rely upon visual aligning of the sheets to ensure that the corrugations are perpendicular, however, this can result in unsightly misalignment. It is known to mark the edge of the roof sheets to assist in aligning them with the edge of the roof structure, such as a gutter. Such markings act as a guide to ensure that the sheets are accurately installed. The hot melt dots, or 15 other applied visual indicia, could be used for such purposes. If required, individual dots could also be made to be individually coloured by using dyed hot melt material.

Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred 20 embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus.

In the claims, except where the context requires otherwise due to express 25 language or necessary implication, the word “comprising” is used in the sense of “including”, i.e. the features specified may be associated with further features in various embodiments of the invention. 9180172_1 (GHMatters) P98984.AU.1

Claims (27)

1. An apparatus for separating stacked longitudinal panels formed by feeding a longitudinal strip of material through a cutting apparatus configured to cut the panels to a predetermined size and shape, said apparatus including: a means of applying a separating material to a surface of each panel adjacent a leading and/or trailing edge thereof, such that when each panel is stacked one above the other, the separating material maintains the edges in a spaced apart relationship from adjacently stacked panels.

2. An apparatus as in claim 1 wherein said means of applying the separating material is in the form of one or more jets configured to eject a predetermined amount of said material at predetermined positions along each panel edge.

3. An apparatus as in claim 2 wherein said apparatus includes a plurality of jets mounted perpendicularly to the direction of feed, each of said plurality of jets configured to be controllably fired at predetermined times.

4. An apparatus as in claim 3 wherein when the edge of a panel is perpendicular to the direction of feed, the mounted jets are fired at once when the panel is stopped at an appropriate position relative to the jets.

5. An apparatus as in claim 3 or claim 4 when the edge of a panel is angled relative to the direction of feed, the mounted jets are fired sequentially from one side of the panel to the other while the panel is moving through, the timing of the jets being dependent upon the angle of the edge.

6. An apparatus as in any one of claims 3-5 wherein timing of said plurality of jets is dependent on one or more parameters including the angle of the cut and the longitudinal profile of the material.

7. An apparatus as in any one of the above claims wherein said cutting apparatus is able to perform angled cuts on said longitudinal strip of material by rotating about a central vertical axis, resulting in longitudinal panels having angled trailing and/or leading edges.

8. An apparatus as in claim 7 wherein said one or more jets is rotatable with said cutting apparatus and slideable along an axis parallel with cutting blades associated with said cutting apparatus to thereby apply said separating material along the edge of the panel.

9. An apparatus as in claim 8 wherein movement and timing of said one or more jets is dependent on one or more parameters including the angle at which the cutting apparatus extends and the longitudinal profile of the material.

10. An apparatus as in any one of the above claims wherein said separating material is a pliable hot melt substance adapted to cool and solidify after it has been applied to the panel surface.

11. An apparatus as in any one of the above claims wherein said longitudinal strip of material has a longitudinal profile in the form of corrugations having peaks and troughs.

12. An apparatus as in claim 11 wherein said separating material is adapted to be applied beneath the peaks of the corrugated panels.

13. An apparatus as in claim 11 wherein said separating material is adapted to be applied above the peaks of the corrugated panels.

14. An apparatus as in any one of the above claims wherein said separating material is adapted to be applied approximately 3mm from said leading and trailing edge of each panel.

15. An apparatus for separating stacked roof cladding elements, including: a support means adapted to support a cutting means in a position to receive a longitudinal strip of material, wherein said cutting means is adapted to cut said longitudinal strip of material into predetermined shapes and sized; and a plurality of nozzles adapted to controllably eject a small amount of soft hot melt material to a surface of each roof cladding element adjacent leading and trailing edges of the elements to thereby separate the edges from elements stacked there above or there below.

16. An apparatus as in claim 15 wherein said cutting means is rotatable about a vertical axis of rotation relative to said support means to thereby cut said material at pre-determined angles.

17. An apparatus as in claim 15 or claim 16 wherein the hot melt material is applied before the longitudinal strip of material is cut.

18. An apparatus as in claim 15 or claim 16 wherein the hot melt material is applied after the longitudinal strip of material is cut.

19. An apparatus for producing a plurality of cladding sheets for a structure, such as a roof, which apparatus includes: a roll-forming assembly for roll-forming a flat strip of metal into a roll-formed profile; a cutting assembly for cutting the roll-formed strip into a plurality of separate cladding sheets, said cutting assembly able to cut the strip through a range of angles; at least one jet used to apply separating material dots to the sheet surface adjacent the longitudinal ends of each sheet; and a control means adapted to control operation of the roll-forming assembly, the cutting assembly and the at least one jet.

20. A method of separating at least two stacked, correspondingly profiled elements, said method including the step of applying a predetermined amount of separating material to a surface of one of said elements adjacent at least one longitudinal end thereof to separate said end from a surface of the other stacked element.

21. A method as in claim 20 wherein said at least two stacked, correspondingly profiled elements are corrugated elements having peaks and troughs.

22. A method as in claim 21 wherein said separating material is in the form of a hot melt material adapted to be applied to a surface beneath at least one corrugation peak.

23. A method as in claim 21 wherein said separating material is in the form of a hot melt material adapted to be applied to a surface above at least one corrugation peak.

24. A method of producing a plurality of stacked roll-formed cladding sheets for building a structure, such as a roof, from a roll-formed strip including the steps of: a. inputting data related to the design of the structure into a computer program that calculates the number of sheets and their size and shape that when placed on an underlying frame together form the structure; b. arranging the calculated sheets into a linear order that satisfies a predetermined criteria; c. cutting the roll-formed strip using a cutting assembly in accordance with the calculated size and shape; d. applying a separating material adjacent each longitudinal end of the cladding sheet, including straight and angled ends, so that when the cladding sheets are stacked one above the other, said separating material separates said ends from the surfaces of adjacently stacked sheets.

25. The method defined in claim 24 wherein separating material is applied after the sheet is cut.

26. The method defined in claim 24 wherein separating material is applied before the sheet it cut.

27. A roofing panel as manufactured using the apparatus and method claimed in any one of the above claims.