Exterior Insulated Finish System and Method

Abstract

An EIFS panel may include a foam body. An EIFS panel may include a penetration through the foam body. An EIFS panel may include a molded structural member coupled with the foam body, wherein the molded structural member finishes the penetration such that no additional field work is required to prepare the EIFS panel for installation. An EIFS panel may include a pre-drilled fastener hole extending through the foam body, the pre-drilled fastener hole configured to align a fastener with a support structure of a building, wherein, when the fastener is inserted through the pre-drilled fastener hole, the EIFS panel is secured to the support structure of the building.

What is claimed is: 
     
         1 . An EIFS panel comprising:
 a foam body;   a penetration through the foam body;   a molded structural member coupled with the foam body, wherein the molded structural member finishes the penetration such that no additional field work is required to prepare the EIFS panel for installation; and   a pre-drilled fastener hole extending through the foam body, the pre-drilled fastener hole configured to align a fastener with a support structure of a building, wherein, when the fastener is inserted through the pre-drilled fastener hole, the EIFS panel is secured to the support structure of the building.   
     
     
         2 . The EIFS panel of  claim 1 , wherein the molded structural member comprises:
 a window assembly; and   flashing and other water management components for finishing a window penetration.   
     
     
         3 . The EIFS panel of  claim 2 , wherein the window assembly comprises:
 a window cassette; and   a removably attached window unit.   
     
     
         4 . The EIFS panel of  claim 3 , wherein the window cassette comprises:
 an inner cassette body, the inner cassette body defining an opening configured to receive a window unit;   a stop positioned around an interior surface of the inner cassette body on a building side of the window cassette, the stop configured to abut an interior surface of the window unit placed in the inner cassette body from an exterior side; and   an outer cassette body coupled with a front side of the inner cassette body, the outer cassette body configured to receive a retaining clip, the retaining clip configured to hold the window unit in the inner cassette body against the stop.   
     
     
         5 . The EIFS panel of  claim 4 , wherein the window cassette further comprises:
 a retaining clip seating channel defined by a protrusion from the front side of the inner cassette body and an interior surface of the outer cassette body; and   a retaining clip securing channel on an interior surface of the outer cassette body.   
     
     
         6 . The EIFS panel of  claim 5 , wherein the retaining clip further comprises:
 a bottom plate, the bottom plate configured to fit in the interior surface of the outer cassette body having a securing ridge configured to couple with the retaining clip securing channel;   a window retention member protruding from a top side of the bottom plate and configured to extend beyond the interior surface of the inner cassette body to retain the window unit in the window cassette; and   a seating ridge protruding from the bottom plate and configured to couple with the retaining clip seating channel.   
     
     
         7 . The EIFS panel of  claim 6 , wherein the retaining clip further comprises:
 a drip edge coupled with the window retention member, the drip edge configured to direct water away from the window unit.   
     
     
         8 . The EIFS panel of  claim 4 , wherein the inner cassette body and the outer cassette body are filled with insulating foam. 
     
     
         9 . The EIFS panel of  claim 1 , further comprising:
 a first recess in a building facing surface of the foam body, the first recess configured to couple with a locating node affixed to an exterior wall of a building, wherein coupling the first recess and the locating node aligns the pre-drilled fastener hole with the support structure of the building and supports the foam body while the fastener is attached to the support structure of the building.   
     
     
         10 . The EIFS panel of  claim 9 , further comprising:
 a second recess in the building facing surface of the foam body, the second recess configured to align with a feature on the exterior wall of the building, such that the foam body sits flush with the exterior wall of the building.   
     
     
         11 . The EIFS panel of  claim 9 , further comprising:
 a drainage groove in the building facing surface of the foam body.   
     
     
         12 . The EIFS panel of  claim 1 , further comprising:
 a foam attachment anchor secured in the pre-drilled fastener hole, the foam attachment anchor configured to couple the fastener with the foam body.   
     
     
         13 . The EIFS panel of  claim 1 , wherein the foam body comprises a graphite enhanced polystyrene insulation board. 
     
     
         14 . A method comprising:
 performing, by a data capture device, a first scan of an exterior wall of a building;   processing, by a panel builder module, first scan data from the data capture device to generate a first panel layout, wherein the first panel layout includes a window penetration;   performing, by the data capture device, a second scan of the exterior wall of the building, the second scan performed to capture data reflecting modifications made to the exterior wall of the building based on analysis of the first scan;   creating, by the panel builder module, a second panel layout, the second panel layout including a second plurality of negative volumes based on the first scan and the second scan; and   fabricating, by a panel shaping tool, an integrated window penetration EIFS panel based on the second panel layout.   
     
     
         15 . The method of  claim 14 , wherein processing the first scan data further comprises:
 creating, by the panel builder module, a three-dimensional point cloud of the exterior wall of the building using the first scan data;   rendering, by the panel builder module, a model of the exterior wall of the building using the three-dimensional point cloud;   creating, by the panel builder module, a master volume for creating the first panel layout;   creating, by the panel builder module, a first plurality of negative volumes in the master volume corresponding to features of the exterior wall of the building; and   generating, by the panel builder module, the first panel layout on the master volume.   
     
     
         16 . The method of  claim 15 , wherein creating the second panel layout comprises:
 identifying, by the panel builder module, a location of a locating pin installed on the exterior wall of the building; and   creating, by the panel builder module, the second plurality of negative volumes corresponding to the location of the locating pin.   
     
     
         17 . The method of  claim 14 , wherein fabricating the EIFS panel comprises:
 cutting, by the panel shaping tool, the EIFS panel from a foam billet;   cutting, by the panel shaping tool, a plurality of voids and a plurality of recesses in the EIFS panel based on the first plurality of negative volumes and the second plurality of negative volumes, wherein the plurality of voids includes the window penetration; and   coupling a molded structural member with window penetration, wherein the molded structural member finishes the window penetration such that no additional field work is required to prepare the EIFS panel for installation.   
     
     
         18 . The method of  claim 16 , further comprising:
 fastening the EIFS panel to the exterior wall of the building by:
 aligning a recess corresponding to the locating pin with the locating pin; 
 drilling a hole in the exterior wall of the building through a pre-drilled fastener hole in the EIFS panel; and 
 securing the EIFS panel to the exterior wall of the building with a fastener inserted through the pre-drilled fastener hole. 
   
     
     
         19 . The method of  claim 17 , wherein the molded structural member comprises:
 a window assembly; and   flashing and other water management components for finishing a window penetration.   
     
     
         20 . The method of  claim 19 , wherein the window assembly comprises:
 a window cassette; and   a removably attached window unit.