SYSTEMS AND METHODS FOR MANUFACTURING AND INSTALLING EIFS PANELS

Abstract

A method of manufacturing and installing an EIFS panel on a building is provided. The method includes assembling the EIFS panel at a location that is different than a site of the building. Assembling the EIFS panel includes assembling a frame of the EIFS panel, attaching the sheathing onto the frame, attaching insulation to the sheathing, rasping the insulation, and installing a leveling and attachment system on the EIFS panel. The method also includes attaching and leveling the EIFS panel on the building.

Claims

1. A method of manufacturing an exterior insulated finish systems (EIFS) panel and installing the EIFS panel on a building, the method comprising: assembling the EIFS panel at a location that is different than a site of the building, wherein assembling the EIFS panel comprises: assembling a frame of the EIFS panel; attaching the sheathing onto the frame; attaching insulation to the sheathing; rasping the insulation; and installing a leveling and attachment system on the EIFS panel; and attaching and leveling the EIFS panel on the building.

2. The method of claim 1, wherein attaching and leveling the EIFS panel on the building comprises leveling the EIFS panel on the building relative to other EIFS panels on the building adjacent to the EIFS panel.

3. The method of claim 1, wherein the leveling and attachment system includes at least one bracket including a nut positioned in the bracket for receiving a fastener or a picking eye.

4. The method of claim 3, further comprising attaching the at least one bracket to a top of the EIFS panel and inserting the picking eye into the nut.

5. The method of claim 3, further comprising attaching the at least one bracket to a bottom of the EIFS panel and inserting the fastener into the nut.

6. A method of manufacturing an exterior insulated finish systems (EIFS) panel, the method comprising: assembling a frame of the EIFS panel; attaching the sheathing onto the frame; attaching insulation to the sheathing; rasping the insulation; and installing a leveling and attachment system on the EIFS panel, wherein the EIFS panel is entirely manufactured at a location that is different than a site of the building.

7. The method of claim 6, wherein the leveling and attachment system includes at least one bracket including a nut positioned in the bracket for receiving a fastener or a picking eye.

8. The method of claim 6, further comprising custom designing the EIFS panel based on a thermal design of the building.

9. The method of claim 6, wherein the frame comprises at least one stud and wherein the method further comprises steel rolling the at least one stud.

10. The method of claim 6, further comprising applying a protective covering to an outer surface of the insulation.

11. A method of installing an exterior insulated finish systems (EIFS) panel on a building, the method comprising: providing the EIFS panel including a leveling and attachment system; leveling the EIFS panel on the building relative to other EIFS panels on the building adjacent to the EIFS panel; and attaching the EIFS panel to the building.

12. The method of claim 11, wherein leveling the EIFS panel on the building relative to other EIFS panels on the building adjacent to the EIFS panel comprises leveling the EIFS panel on the building relative to other EIFS panels on the building adjacent to the EIFS panel using a laser level.

13. The method of claim 11, wherein attaching the EIFS panel to the building comprises attaching the EIFS panel to the building using an impact wrench.

14. The method of claim 13, wherein attaching the EIFS panel to the building using an impact wrench comprises inserting a fastener into the nut and the building using the impact wrench.

15. The method of claim 14, wherein inserting a fastener into the nut and the building using the impact wrench comprises inserting the fastener into the building only until the EIFS panel is level with EIFS panels adjacent to the EIFS panel.

16. A system for manufacturing an exterior insulated finish systems (EIFS) panel, the system comprising: a frame assembly station configured to assemble a frame of the EIFS panel, wherein a leveling and attachment system is attached to the frame at the framing assembly station, and wherein the leveling and attachment system is configured to level and attach the EIFS panel on a building after the EIFS panel has been completely manufactured using the system; a sheathing station configured to attach sheathing to the frame; an insulation attachment station configured to attach insulation to the sheathing; a rasping station configured to rasp the insulation; and a finishing station configured to prime and paint the EIFS panel.

17. The system of claim 16, further comprising a steel roller configured to form at least one stud, wherein the frame assembly station is configured to assemble the at least one stud into the frame.

18. The system of claim 16, further comprising a weatherproofing station configured to apply an elastomer to a portion of the sheathing.

19. The system of claim 16, further comprising a protective covering application station configured to apply a protective covering to the insulation.

20. The system of claim 16, wherein the leveling and attachment system includes at least one bracket including a nut positioned in the bracket for receiving a fastener or a picking eye.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A further understanding of the nature and advantages of the embodiments may be realized by reference to the following drawings. In the appended figures, similar components or features may have the same reference label.

[0013] FIG. 1 illustrates a perspective, partial cutaway view of an example exterior insulation finishing system (EIFS) panel in accordance with aspects of the present disclosure.

[0014] FIG. 2 illustrates an example of a bracket of a leveling and attachment system in accordance with aspects of the present disclosure.

[0015] FIG. 3 illustrates an example system for manufacturing the EIFS panel illustrated in FIG. 1 in accordance with aspects of the present disclosure.

[0016] FIG. 4 illustrates three perspective views of an example of the steel roller illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0017] FIG. 5 illustrates a perspective view of an example of the sheathing station illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0018] FIG. 6 illustrates a perspective view of an example of the frame assembly station and the sheathing station illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0019] FIG. 7 illustrates a perspective view of an example of the weatherproofing station illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0020] FIG. 8 illustrates a perspective view of an example of the rasping station illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0021] FIG. 9 illustrates a perspective view of an example of the rasping station illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0022] FIG. 10 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0023] FIG. 11 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0024] FIG. 12 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0025] FIG. 13 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0026] FIG. 14 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0027] FIG. 15 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0028] FIG. 16 illustrates another perspective view of the rasping station illustrated in FIG. 9 in accordance with aspects of the present disclosure.

[0029] FIG. 17 illustrates a perspective view of an example of the finishing station illustrated in FIG. 3 in accordance with aspects of the present disclosure.

[0030] FIG. 18 illustrates a flow diagram of a method of manufacturing and installing the EIFS panel illustrated in FIG. 1 in accordance with aspects of the present disclosure.

[0031] While the embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the instant disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION

[0032] The systems and methods disclosed herein relate to, among other things, a method of manufacturing and installing EIFS panels and systems for manufacturing and installing EIFS panels. As discussed above, the manufacturing and installation process for EIFS panels is labor intensive, expensive, and may lead to unwanted discharge of material from the construction site. The system and methods described herein include manufacturing the EIFS panels in an at least partially automated facility and installing the EIFS panels using a leveling and attachment system. The EIFS panels are completely manufactured and assembled in the facility, reducing costs and eliminating construction steps at the construction site. Additionally, the leveling and attachment system enables the completely constructed EIFS panels to be attached and leveled without any assembly of the EIFS panels onsite. Accordingly, the systems and methods described herein reduce costs, decrease construction times, and decrease the environmental impact of manufacturing and installing EIFS panels.

[0033] Specifically, the EIFS panels described herein include the leveling and attachment system that enables the fully assembled EIFS panels to be attached to a building and leveled without manufacturing or constructing the EIFS panels on site. The leveling and attachment system includes brackets including a nut positioned in the bracket for receiving a fastener or a picking eye. The brackets are attached to the top and bottom of the completed EIFS panels. The brackets mounted to the top of the EIFS panel are each configured to include a picking eye in the nut such that a crane or other lifting equipment can lift and position the EIFS panel on the side of the building. The brackets mounted to the bottom of the EIFS panel are each configured to include a fastener in the nut and, when the EIFS panel has been positioned on the side of the building, the fastener is attached to the side of the building. In the illustrated embodiments, the faster includes a screw and the screw is inserted into the side of the building using an impact wrench. Furthermore, the operator of the impact wrench also positions a laser level that indicates when the EIFS panel is level with the EIFS panels adjacent to it. The operator of the impact wrench inserts the screw into the building only until the EIFS panel is level with the EIFS panels adjacent to it. The leveling and attachment system enables the EIFS panel to be installed quickly and efficient while also enabling the EIFS panel to be level with other EIFS panels on the building. Furthermore, the leveling and attachment system also enables the EIFS panels to be attached to the side of the building without at least partially constructing the EIFS panel on the side of the building. Thus, the leveling and attachment system enables the EIFS panels to be manufactured off site, reducing costs and construction times.

[0034] Additionally, the process includes an automated steel roller that automatically centers a metal coil in the steel roller, automatically spaces or gaps the rollers within the steel roller for the metal coil that is being shaped, and automatically shapes a cutting die to accommodate the size and shape of the metal studs being formed in the steel roller. Specifically, as discussed herein, resetting the steel roller for a new size metal stud requires spacing or gapping each of the spaced rollers and replacing the shaped die. Thus, resetting the steel roller is a time consuming process that reduces production and decreases profits.

[0035] The automated steel roller described herein includes a tensioned spring that is precisely tensioned such that the rollers accommodate the new size metal coil by allowing the roller to move to receive the metal coil and holding the roller in place to form the stud profile. More specifically, the tensioned spring automatically tensions the roller against the coil such that as the coil passes beneath the roller, the tensioned spring holds the roller in place to form the stud profile. Thus, the tensioned spring enables the rollers to automatically space or gap themselves without the time consuming manual gapping process.

[0036] The automated steel roller described herein also includes an automatic shaped die that automatically changes shape based on the shape of the metal stud. As discussed herein, each size of metal stud requires a new shaped die, and the shaped die is bolted into place. As such, resetting the steel roller for a new size metal stud requires replacing the shaped die. The automatic shaped die described herein includes two movable vertical blocks that define the width of the metal stud and two automated flange and lip adjustment tools that move vertically to define the shape of a lip of the metal stud. When a new sized metal stud is being produced, the two movable vertical blocks automatically move horizontally within the shear of the steel roller to define the width of the metal stud, and the two automated flange and lip adjustment tools move vertically to define the height of the lip of the metal stud. Thus, the automatic shaped die enables the steel roller to be automatically reset for a new size of metal stud without a time consuming and costly manual reset.

[0037] FIG. 1 illustrates a perspective, partial, cutaway view of an example exterior insulation finishing system (EIFS) panel 100 manufactured using the methods described herein. The EIFS panel 100 may include a frame 102 form by at least one stud 104, a sheathing 106, an adhesive 108, insulation 110, a protective covering 112, an adhesive 114, and a finishing coat 116. The frame 102 is formed by the studs 104 and is attached to the sheathing 106. The elastomer 108 at least partially weatherproofs the sheathing 106. The insulation 110 is attached to the sheathing 106 by the adhesive 108 and the adhesive 114 attaches the protective covering 112 and the finishing coat 116 the insulation 110.

[0038] In the illustrated embodiment, the frame 102 and the studs 104 are formed of steel, such as a light gauge steel. In alternative embodiments, the frame 102 and the studs 104 may be formed of any material that enables EIFS panels 100 to operate as described herein. For example, in alternative embodiments, the frame 102 and the studs 104 may be formed of wood, metals other than steel, and/or any other material. The studs 104 may include any framing component that forms the frame 102 including, but not limited to, a stud, a track, a U-channel, a furring channel, an L-header, and/or a strap. The studs 104 are assembled as described herein to form the frame 102.

[0039] FIG. 2 illustrates an example of a bracket 202 of a leveling and attachment system 200. The leveling and attachment system 200 includes at least one bracket 202 including a nut 204 positioned in the bracket 202 for receiving a fastener 206 or a picking eye 208. The brackets 202 are attached to the top and bottom of the completed EIFS panels 100. The brackets 202 mounted to the top of the EIFS panel 100 are each configured to include the picking eye 208 in the nut 204 such that a crane or other lifting equipment (not shown) can lift and position the EIFS panel 100 on the side of the building (not shown). The brackets 202 mounted to the bottom of the EIFS panel 100 are each configured to include the fastener 206 in the nut 204 and, when the EIFS panel 100 has been positioned on the side of the building, the fastener 206 is attached to the side of the building. In the illustrated embodiments, the faster 206 includes a screw and the screw is inserted into the side of the building using an impact wrench. Furthermore, the operator of the impact wrench also positions a laser level (not shown) that indicates when the EIFS panel 100 is level with the EIFS panels adjacent to it. The operator of the impact wrench inserts the screw 206 into the building only until the EIFS panel 100 is level with the EIFS panels adjacent to it. The leveling and attachment system 200 enables the EIFS panel 100 to be installed quickly and efficient while also enabling the EIFS panel 100 to be level with other EIFS panels on the building. Furthermore, the leveling and attachment system 200 also enables the EIFS panels 100 to be attached to the side of the building without at least partially constructing the EIFS panels 100 on the side of the building. Thus, the leveling and attachment system 200 enables the EIFS panels 100 to be manufactured off site, reducing costs and construction times.

[0040] FIG. 3 illustrates an example system 300 for manufacturing the EIFS panel 100. The system 300 includes a steel roller 302, a frame assembly station 304, a sheathing station 306, a weatherproofing station 308, an insulation attachment station 310, a rasping station 312, a protective covering application station 314, a finishing station 316, and a panel loading station 318.

[0041] The steel roller 302 is configured to form coiled steel into the studs 104 and the studs 104 are configured to be assembled into the frame 102. In alternative embodiments, the steel roller 302 may be configured to form any type of steel into the studs 104. Additionally, in alternative embodiments, the steel roller 302 may be replaced with a system that is configured to form any material into the studs 104 including a system configured to form the studs 104 from wood, metals other than steel, and/or any other material.

[0042] FIG. 4 illustrates a perspective view of an example of the steel roller 302 illustrated in FIG. 3. The steel roller 302 includes a plurality of roller stations 402 each including a plurality of rollers 404 that are configured to form the coiled steeled into the studs 104 in a cold rolling shaping process. Specifically, each roller station 402 progressively bends the coiled steel into the studs 104. For example, the rollers 404 of each roller station 402 are progressively angled such that when the coiled steel is received in each roller station 402, the coiled steel progressively bends until the coiled steel has been cold formed into a predetermined stud shape as described herein.

[0043] Each roller station 402 includes at least one tensioned spring 406 that is precisely tensioned such that the rollers 404 accommodate the any size metal coil by allowing the roller 404 to move to receive the metal coil and holding the roller 404 in place to form the stud profile. More specifically, the tensioned spring 406 automatically tensions the roller 404 against the coil such that, as the coil passes beneath the roller 404, the tensioned spring 406 holds the roller 404 in place to form the stud profile. The steel roller 302 also includes a coil centering system 416 that includes a plurality of rollers that automatically centers the coil in the steel roller 302 as the coil is fed into the steel roller 302. As such, the coil centering system 416 eliminates another step in the manual gapping process. Thus, the tensioned spring 406 enables the rollers 404 to automatically space or gap themselves without the time consuming manual gapping process.

[0044] The steel roller 302 also includes a shear 408 including two vertical blocks 410, a cutting blade 412, and a flange and lip adjustment tool 414. The two vertical blocks 410 and the flange and lip adjustment tool 414 form an automatic shaped die that automatically changes shape based on the shape of the metal stud. As discussed herein, each size of metal stud requires a new shaped die, and the shaped die is bolted into place. As such, resetting the steel roller for a new size metal stud requires replacing the shaped die. The automatic shaped die enables the steel roller 302 to be reset without replacing the shaped die by automatically changing shape to the size of the new metal stud. Specifically, the automatic shaped die described herein includes the two movable vertical blocks 410 that define the width of the metal stud and the two automated flange and lip adjustment tools 414 that move vertically to define the shape of a lip of the metal stud. When a new sized metal stud is being produced, the two movable vertical blocks 410 automatically move horizontally within the shear 408 of the steel roller 302 to define the width of the metal stud, and the two automated flange and lip adjustment tools414 move vertically to define the height of the lip of the metal stud. Once the metal stud is a predetermined length, the cutting blade 412 cuts the metal stud and the automatic shaped die maintains the shape of the metal stud as the metal stud is being cut. Thus, the automatic shaped die enables the steel roller 302 to be automatically reset for a new size of metal stud without a time consuming and costly manual reset.

[0045] The steel roller 302 also includes a coil centering system 416 that includes a plurality of rollers that automatically center the coil in the steel roller 302 as the coil is fed into the steel roller 302. As such, the coil centering system 416 eliminates another step in the manual gapping process.

[0046] The steel roller 302 also includes a light safety curtain 418 including a plurality of towers 420 extending around the steel roller 302. In the illustrated embodiment, the light safety curtain 418 includes four towers 420. In alternative embodiments, the light safety curtain 418 may include any number of towers 420 that enable the steel roller 302 to operate as described herein. The at least one of the towers 420 emits a curtain of laser light in the direction of at least one of the other towers 420. At least one of the other towers 420 includes a light detector or sensor that continually detects the curtain of laser light. If the curtain of laser light is broken by an operator or an object, the steel roller 302 automatically shuts off for the protection of the operator and to protect equipment from damage. Additionally, the light safety curtain 418 enables the operator to quickly shut off the steel roller 302 if the process is malfunctioning by simply breaking the plane of the curtain of laser light without having to travel to a shut off button. Thus, the light safety curtain 418 enables quick operation and shut off of the steel roller 302 when required.

[0047] In the frame assembly station 304, an assembler manually assembles the studs 104 into the frame 102. More specifically, the assembler attaches the studs 104 together using fasteners such as, but not limited to, screws. In alternative embodiments, the frame assembly station 304 may be at least partially automated. For example, in some embodiments, the frame assembly station 304 may include a partially automated fastening machine that enables the assembler to quickly assemble the frame 102 by quickly attaching the studs 104.

[0048] The frame assembly station 304 includes a movable stand 502 (shown in FIG. 5) and the frame 102 is assembled on the movable stand 502 based on the custom plan for the EIFS panel 100. In alternative embodiments, the frame assembly station 304 may include any equipment that enables the frame assembly station 304 to operate as described herein. The movable stand 502 includes wheels and transports the EIFS panel 100 throughout the remainder to the system 300. The leveling and attachment system 200 may be attached to the frame 102 at the framing assembly station 304.

[0049] The sheathing 106 is attached to the frame 102 in the sheathing station 306. More specifically, the assembler attaches the sheathing 106 to the frame 102 using fasteners such as, but not limited to, screws. In alternative embodiments, the sheathing station 306 may be at least partially automated. For example, in some embodiments, the sheathing station 306 may include a partially automated fastening machine that enables the assembler to quickly attach the sheathing 106 by quickly attaching the sheathing 106 to the frame 102.

[0050] FIGS. 5 and 6 illustrate perspective views of an example of the frame assembly station 304 and the sheathing station 306 illustrated in FIG. 3. The sheathing station 306 includes a flexible router 602 and a screw station 604. The flexible router 602 is configured to cut excess portions of the sheathing 106 off during installation of the sheathing 106 on the frame 102. The flexible router 602 is configured to be flexible such that minor deviations or bumps during the cutting process do not damage either the flexible router 602 or the frame 102. The screw station 604 is configured to enable the assembler to quickly and efficiently screw the sheathing 106 to the frame 102. Specifically, the screw station 604 is configured to receive a box of screws that are randomly arranged in the box. The screw station 604 is then configured to automatically orient the screws in the correct direction, load each screw into a screw gun, and automatically screw each screw into either the frame 102 during frame assembly or into the sheathing 106 and the frame 102 during the sheathing process. The screw station is also configured to vary the torque of the screw gun during the screwing process based on the materials that the screw gun is screwing through.

[0051] FIG. 7 illustrates a perspective view of an example of the weatherproofing station 308 illustrated in FIG. 3. An elastomer is applied to portions of the sheathing 106 in the weatherproofing station 308 to weatherproof the EIFS panel 100. The elastomer is applied to the joints between pieces of sheathing 106 to weatherproof the sheathing of the EIFS panel 100 in case the exterior portions of the EIFS panels 100 are damaged or otherwise leak such that water penetrates to the sheathing 106. The elastomer mitigates the risk of further leakage by weatherproofing the seams between the individual pieces of sheathing 106 in the EIFS panel 100. In the illustrated embodiment, the elastomer includes an elastomeric flashing membrane, which is a one-component flexible liquid flashing membrane for use as a flexible flashing membrane. In alternative embodiments, the elastomer may be any type of substance that weatherproofs the sheathing 106.

[0052] In the illustrated embodiment, the elastomer is manually applied to the seams between the sheathing 106 by an operator using a trowel (not shown) to spread the elastomer on the seams between the sheathing 106. In alternative embodiments, the weatherproofing station 308 may be at least partially automated. For example, the weatherproofing station 308 may include an elastomer dispenser (not shown) including a nozzle system configured to dispense and spread the elastomer on the seams between the sheathing 106. Furthermore, in alternative embodiments, the weatherproofing station 308 may be incorporated into the sheathing station 306.

[0053] The insulation attachment station 310 is configured to attach insulation 110 to the sheathing 106 using the adhesive 108. In the illustrated embodiment, the insulation 100 includes EPS (expanded polystyrene) insulation and the adhesive 108 may include a single component polyurethane foam adhesive or a dry-mix polymer adhesive. In alternative embodiments, the insulation may include any type of insulation and/or the adhesive may be any type of adhesive. In the illustrated embodiment, the insulation 110 is manually cut to fit the shape of the sheathing 106, the adhesive 108 is manually applied to the sheathing 106 and/or the insulation 110, and the insulation 110 is manually positioned on the sheathing 106. In alternative embodiments, the insulation attachment station 310 may be at least partially automated. For example, the insulation attachment station 310 may include an automated cutting machine, an automated adhesive dispenser, and/or an automated insulation positioning device.

[0054] FIGS. 8 and 9 illustrate perspective views of an example of the rasping station 312 illustrated in FIG. 3 including an EPS leveling machine 950. FIG. 10 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. FIG. 11 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. FIG. 12 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. FIG. 13 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. FIG. 14 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. FIG. 15 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. FIG. 16 illustrates another perspective view of the rasping station 312 illustrated in FIG. 9. The levelling machine 950 includes a gantry assembly 952, a pair of spaced apart rail assemblies 954 and 955, a face mill assembly 956, an edging and reveal assembly 958. By way of reference the rail assemblies 954 and 955 define an x-axis and the gantry assembly defines a y-axis. A z-axis is perpendicular to an x-y plane defined by the x and y axes.

[0055] The gantry assembly 952 is moveably attached to the rail assemblies 954 and 955 such that the gantry assembly is moveable along the x-axis. The face mill assembly 956 is moveably attached to the gantry assembly such that it is moveable along the y axis. Similarly, the edging and reveal assembly 958 is moveably attached to the gantry assembly 952 such that it is moveable along the y-axis.

[0056] The gantry assembly 952 includes a gantry beam 960 and pair of gantry uprights 962 and 63 attached to either end of the gantry beam 960. The pair of gantry uprights 962 and 963 are moveably attached to the rail assemblies 954 and 955. The rail assembly 955 includes a chain link 964 which is attached to the respective gantry upright 963 and the chain link 964 is used to move the gantry assembly 952 along the rail assemblies 954 and 955.

[0057] The rail assemblies 954 and 955 include a rail portion 966 for receiving the gantry uprights 962 and 963. A plurality of spaced apart legs 968 extend downwardly from the rail portion 966. The rail assembly 955 further includes a chain link 964 operably attached to the gantry assembly 952 for moving the gantry assembly along the rail assemblies 954 and 955.

[0058] The face mill assembly 956 includes a mill portion 970, a hood portion 972, and a back support 974. A pair of upper and lower face mill rails 976 and 978 respectively are mounted on the gantry beam 960. The back support 974 is moveably attached to the upper and lower face mill rails 976, 978 attached to the gantry assembly 952. A face mill chain link 980 is operably attached to the back support 974 and is used to move the face mill assembly 956 along the gantry assembly 952 in the y axis. The mill and hood assembly 971 includes the mill portion 970 and the hood portion 972. The mill and hood assembly 971 are moveably attached to the back support 974. A mill chain link 982 is operably attached between the back support 974 and the mill and hood assembly 971 and moves the mill and hood assembly 971 upwardly and downwardly thus moving the mill and hood assembly 971 in the z axis. The hood portion 972 includes a plurality of saw blades 981. The saw blades 981 are generally in the x-y plane. The saw blades 981 have a plurality of teeth 983 that extend downwardly perpendicular to the hood portion or downwardly in the z axis. In use the saw blades 981 rotate in different directions. The saw blades are used to grind down or rasp the EPS layer of the EIFS panel. The hood portion 972 is part of an exhaust system that vacuums the rasped debris. The hood portion 972 has exit ports 984 which are attachable to hoses. The hoses are attached to a suction device 986. Suction device 986 includes removable and replaceable bags 988.

[0059] The edging and reveal assembly 958 include an edging assembly 990 and a reveal assembly 992. The edging assembly 990 is used to square the edges of the panel or to square the edges of holes in the panel such as window or door openings in the panel. The reveal assembly 992 is used to create different patterns into the panel. For example, a company name or logo might be etched into the panel. Alternatively, a pattern may be etched into the surface of the entire panel to provide texture or other visual interest in the panel. It will be appreciated by those skilled in the art that, in the embodiment shown herein, the edging assembly and the reveal assembly are combined in an edging and reveal assembly 958. However, it will be appreciated by those skilled in the art that the edging assembly and the reveal assembly could be separate and could separately be attached to the gantry assembly 952 and could move independently in the x, y, and z axes.

[0060] The edging and reveal assembly 958 include a support frame 994 which is moveably attachable to the gantry assembly 952 in a fashion similar to that described above with regard to the face mill assembly 956. An edging and reveal chain link 996 are operably attached to the support frame 994 and is used to move the edging and reveal assembly along the gantry assembly 952 in the y axis.

[0061] The edging assembly 990 includes a driver portion 998, a chuck 1000 operably attached to the driver portion and a drill bit 1002 inserted in the chuck. The drill bit 1002 extends downwardly in the z axis. The driver portion 998 is operably attached to a back plate 1004 which is moveably attached to the drill support frame 994. An edging chain link 1006 is operably connected to the back plate 1004 and the drill support frame 994 is configured to move the edging assembly 990 upwardly and downwardly in the z axis. The chuck 1000 may also be attached to a hose 984 which in turn is attached to the suction device 986. Preferably the drill bit 1002 is a gold drill bit.

[0062] The reveal assembly 992 includes a reveal motor assembly 1010 operably connected to a control assembly 1012 which is operably connected to a shape wire assembly 1014. The reveal motor assembly includes a reveal motor bracket 1016 and a reveal motor assembly 1018. The control assembly 1012 includes a casing 1020 and a limit switch assembly 1022. The shape wire assembly 1014 includes a wire loop 1024 operably connected to the limit switch assembly 1022. The wire loop 1024 is operably connected to the hotwire cutter 1026 through an insulator block 1028. A shield 1030 covers the wire loop 1024. Preferably the hotwire cutter 1026 is a 350 F hotwire. In the embodiment shown herein, the hotwire cutter 1026 has a general nib shape. It will be appreciated by those skilled in the art that different shape cutters could also be used. A reveal chain link 1029 is operably connected to the back plate 1004 and the reveal motor bracket 1016 is configured to move the reveal assembly 992 upwardly and downwardly in the z axis.

[0063] The levelling machine is operably connected to a control system (not shown). The control system is computer operated. The control system moves the face mill assembly 956 in the x, y, and z axes. Similarly, the control system moves the edging and reveals assembly 958 in the x and y axes and selectively moves the edging assembly 990 and the reveal assembly 992 in the z axis.

[0064] In some embodiments, the edging assembly 990 and/or the reveal assembly 992 may be configured to rotate in addition to moving in the x, y, and z axes. Specifically, in some embodiments, at least a portion of the edging assembly 990 and/or the reveal assembly 992 may be configured to rotate or swivel such that the edging assembly 990 and/or the reveal assembly 992 swivels or rotates 360 about the z axis and 180 about the y axis rather than maintaining the edging assembly 990 and/or the reveal assembly 992 upright in the z axis. More specifically, at least one of the edging and reveal chain link 996, the driver portion 998 of the edging assembly 990, the back plate 1004 of the edging assembly 990, the reveal motor assembly 1010 of the reveal assembly 992, the reveal motor bracket 1016 of the reveal assembly 992, and/or the reveal motor assembly 1018 of the reveal assembly 992 may be configured to rotate or swivel the edging assembly 990 and/or the reveal assembly 992360 about the z axis and 180 about the y axis. Rotation of the edging assembly 990 and/or the reveal assembly 992 enables the levelling machine 950 to edge or cut complex geometric shapes, complex facades, or complex or curved planes in the insulation 110.

[0065] In order to ensure that the EIFS panel 100 is perfectly level during the rasping process, rasping station 312 may include an adjustable sawhorse 1050 (shown in FIG. 8) that is configured to move the EIFS panel 100 up and down to ensure that the outer surface of the EIFS panel 100 is level after rasping. Specifically, the adjustable sawhorse 1050 includes a plurality of legs 1052 and a beam 1054 attached to the legs 1052. The legs 1052 each include a laser level system 1056 that precision level the beam 1054 and the EIFS panel 100 that sits on the beam 1054. The adjustable sawhorse 1050 moves the EIFS panel 100 up and down to ensure that the outer surface of the EIFS panel 100 is level after rasping. Additionally, the rasping station 312 may include a scanning system (not shown) configured to scan the EIFS panel 100 and control the rasping process.

[0066] The levelling machine shown herein provides a method to accurately level the exterior surface and place reveals in a layer of EPS preferably within 1/16- 1/32, wherein the EPS is ready to receive the base coat/mesh and fish coats. This levelling machine provides a means to ensure that each panel has a flat surface that can be easily matched with adjacent panels within a wall system. This method of providing accurately located exterior EPS surface enables one to align the exterior of the panels from the inside of the building. The latter is because the exterior surface is accurate relative to the steel frame, the contractor can set panels by referencing the back side of the panel system as the contractor can rely on where the exterior surface is located by virtue of this levelling machine. More specifically, during constructions the installers are able to install the panels with reference to interior layout line, then spot check the exterior visually and make minor adjustments to align the panels and finalize the installation. Because of the tight tolerance realized by the levelling machine and method described herein the installation is safer, faster, accurate, visually appealing, and more cost effective.

[0067] The protective covering 112 is applied to the insulation 110 at the protective covering application station 314. In the illustrated embodiment, the protective covering 112 includes a mesh and the adhesive 114 includes a cementitious product. The mesh and the cementitious product are both manually applied to the outer surface of the insulation 100. In alternative embodiments, at least a portion of the protective covering application station 314 may be automated.

[0068] FIG. 17 illustrates a perspective view of an example of the finishing station 316 illustrated in FIG. 3 The finishing station 316 is configured to prime and paint the EIFS panels 100. The finishing station 316 includes an automated painting and priming system 1702 including a container 1704 and a scanning system (not shown). The scanning system scans the EIFS panel 100 and controls the automated painting and priming system 1702 to ensure that the paint is evenly applied to the EIFS panel 100. More specifically, the paint is transported from the container 1704 to at least one nozzle (not shown) that evenly disperses the paint on the EIFS panel 100. Additionally, the scanning system controls the automated painting and priming system 1702 by speeding up or slowing down the nozzle as the paint is dispersed on the EIFS panel 100. Moreover, the scanning system controls the automated painting and priming system 1702 by controlling the pressure, the height, and the speed of the nozzle to produce a uniform paint layer every single time.

[0069] FIG. 18 illustrates a flow diagram of a method 1800 of manufacturing and installing the EIFS panel 100. The method 1800 includes a comprehensive process that includes designing, planning, assembling, transporting, and installing EIFS panels 100. The method 1800 is designed to minimize material, labor, transportation, and installation costs such that the cost to construct a building is substantially reduced.

[0070] The method 1800 begins with custom designing 1802 each EIFS panel 100 based on the design of the building. Custom designing 1802 includes modeling each EIFS panel 100 using a computer aided design program to develop a custom plan for each EIFS panel 100 and an overall model for the entire building. The custom plan for each EIFS panel 100 interfaces with the overall model for the entire building and the method 1800 is customized based on the custom plan for each EIFS panel 100. For example, the custom plan includes the schematics and design plans for the frame 102 including the positions of each stud 104 and where fasteners or screws are to be positioned and installed during assembly of the frame 102. The custom plan for each EIFS panel 100 may be at least partially based on a thermal plan of the entire building. For example, the thermal plan may at least partially determine the thickness of the insulation 110. The custom plan for each EIFS panel 100 and the overall model for the entire building is accessible by the entire assembly team to streamline manufacturing of each EIFS panel 100.

[0071] Additionally, on a larger scale, a transportation plan for the EIFS panels 100 is at least partially based on the overall model for the entire building. Specifically, the order of manufacture of each EIFS panel 100 may be based on the order of construction of the EIFS panels on the building. The EIFS panels 100 may be manufactured such that the EIFS panels 100 that are placed next to each other on the building are manufactured and transported in order of construction, reducing storage and labor costs. Accordingly, the overall model for the entire building may be developed in reverse, or by starting with the order of installation of each EIFS panel 100 on the building and working backward to determine the order of manufacturing of each component of each EIFS panel 100 to minimize stores space, labor costs, and overall costs of construction.

[0072] The custom plan for each EIFS panel 100 includes a QR code for every EIFS panel 100 for quick identification of each EIFS panel 100 during the construction and manufacturing process. The custom plan for each EIFS panel 100 also includes a frame plan including dimensions for the frame 102, a finished plan including an isometric drawing, a material cut list, and additional construction and transportation documents and information that may streamline the manufacturing and construction process. Each document or piece of information is hyperlinked within the custom plan for each EIFS panel 100 or the overall model for the entire building to streamline the manufacturing and construction process. During each step of the manufacturing and construction process, the QR code for each EIFS panel 100 is scanned such that the manufacturing and construction process for each EIFS panel 100 is tracked and logged through each point of the process.

[0073] The method 1800 includes steel rolling 1804 the studs 104 using the steel roller 302. Specifically, the steel roller 302 is fed coiled steel and rolls the coiled steel into the specific forms for the studs 104. Each stud 104 may be individually shaped for each panel 100 because each panel 100 may be individually designed to a specific portion of a building. The studs 104 include at least one of a stud, a track, a U-channel, a furring channel, an L-header, and/or a strap. The steel roller 302 rolls the coiled steel into one of a stud, a track, a U-channel, a furring channel, an L-header, and/or a strap.

[0074] A stud is cold-formed steel that has been formed into a C-shape with a lip return and are used as a vertical element in the EIFS panel 100. A track caps the bottom and top of the EIFS panel 100 and are U-shaped without a lip return to allow the stud to seat inside the track. However, tracks may have a C-shape with a lip similar to the studs in some areas. The U-channel is a smaller U-shaped component that extends through web knockouts in the studs for additional bracing within the EIFS panel 100. The furring channel is applied to the face of the EIFS panel 100 to provide a wedge or spacing element (otherwise known as furring) to the sheathing. The L-shaped header is L-shaped and is positioned on top of the EIFS panel 100 to act as a header. They span across openings to help transfer the load over a door or window onto jamb studs. Straps are thin sheets of steel used for tension loads within the EIFS panel 100. The steel roller 302 rolls the coiled steel into one of a stud, a track, a U-channel, a furring channel, an L-header, and/or a strap to form the components of the frame 102. Each stud 104 is labeled such that it can be easily identified and assembled.

[0075] The method 1800 also includes assembling 1806 the studs 104 into the frame 102 using the frame assembly station 304. In the illustrated embodiment, assembling 1806 the studs 104 into the frame 102 using the frame assembly station 304 includes assembling the frame 102 on the movable stand 402 based on the custom plan for the EIFS panel 100. The assembler identifies the studs 104 and assembles the frame 102 on the movable stand 402 based on the custom plane for the EIFS panel 100.

[0076] The method 1800 further includes attaching 1808 the sheathing 106 onto the frame 102 using the sheathing station 306. Specifically, attaching 1808 the sheathing 106 onto the frame 102 using the sheathing station 306 may include attaching the sheathing 106 to the frame 102 using a plurality of fasteners. In the illustrated embodiment, the plurality of fasteners may include a plurality of screws and the screws may be screwed into the sheathing 106 and the frame 102 using the screw station 504. Additionally, attaching 1808 the sheathing 106 onto the frame 102 using the sheathing station 306 may include cutting off excess portions of the sheathing 106 using the flexible router 502. In alternative embodiments, attaching 1808 the sheathing 106 onto the frame 102 using the sheathing station 306 may include any additional steps that enable the system 200 to operate as described herein.

[0077] The method 1800 also includes weatherproofing 1810 portions of the sheathing 106 using the weatherproofing station 308. In the illustrated embodiment, an elastomer is applied to the joints between pieces of sheathing 106 to weatherproof the sheathing of the EIFS panel 100 in case the exterior portions of the EIFS panels 100 are damaged or otherwise leak such that water penetrates to the sheathing 106. The elastomer is manually applied to the seams between the sheathing 106 by an operator using a trowel (not shown) to spread the elastomer on the seams between the sheathing 106. In alternative embodiments, the weatherproofing station 308 may include an elastomer dispenser (not shown) that automatically dispenses and spreads the elastomer on the seams between the sheathing 106.

[0078] The method 1800 also includes attaching 1812 the insulation 110 to the sheathing 106 using the adhesive 108 at the insulation attachment station 310. In the illustrated embodiment, the insulation 100 includes EPS (expanded polystyrene) insulation and the adhesive 108 may include a single component polyurethane foam adhesive or a dry-mix polymer adhesive. The insulation 110 is manually cut to fit the shape of the sheathing 106, the adhesive 108 is manually applied to the sheathing 106 and/or the insulation 110, and the insulation 110 is manually positioned on the sheathing 106. In alternative embodiments, an automated system may be used to cut the insulation 110, apply the adhesive 108, and/or position the insulation 110 on the adhesive 108 and the sheathing 106.

[0079] The method 1800 also includes rasping 1814 the insulation 110 to level the insulation 110 such that the outer surfaces of the EIFS panels 100 are level before application of further layers and installation on a building. Specifically, the insulation 110 is rasped using the rasping station 312 including the levelling machine 950. First, an EIFS panel 100 is positioned in a predetermined location underneath the levelling machine 950. The EIFS panel 100 is then leveled using the adjustable sawhorse 1050. The outer surface of the insulation 110 is rasped using the levelling machine 950 as described herein. The edges of the insulation 110 may be further cut and shaped. Reveals may be etched into the insulation 110 as described herein. For example, the hotwire cutter 1026 may be used to shape drip ledges of the EIFS panels 100 and the drill bit 1002 may be used to shape other architectural details.

[0080] As discussed above, the custom plan for each EIFS panel 100 may include details concerning the construction of the EIFS panel 100. Specifically, the custom plan for each EIFS panel 100 may include a program that directs rasping 1814, edging, or otherwise cutting of the insulation 110. More specifically, during the construction of each EIFS panel 100, an operator needed to program the levelling machine 950 to make the cuts for each EIFS panel 100. Programing the levelling machine 950 was time consuming, decreased throughput, and decreased profits. The custom plan for each EIFS panel 100 described herein includes a program that is automatically generated and uploaded to the levelling machine 950 by scanning the QR code for each EIFS panel 100. Thus, the programing step has been eliminated and the rasping 1814 process has been streamlined.

[0081] The method 1800 also includes applying 1816 the protective covering 112 to the outer surface of the insulation 110. The protective covering 112 is manually positioned on the outer surface of the insulation 110 and the adhesive 114 or cementitious product is manually applied to the protective covering 112. Additionally, excess adhesive 114 or cementitious product is skimmed off the outer surface of the EIFS panel 100 and vacuum sanders are used to control the level of the outer surface of the EIFS panel 100.

[0082] The method 1800 also includes priming and painting 1818 the EIFS panel 100. The EIFS panel 100 is primed and painted using the finishing station 316. Specifically, the finishing station 316 scans the EIFS panel 100 and automatically controls the automated painting and priming system 1702 to produce a uniform paint layer on the EIFS panel 100.

[0083] The method 1800 further includes panel loading 1820 the EIFS panel 100 onto a vehicle (such as a truck) for transport to the construction site. The EIFS panel is loaded onto the vehicle at the panel loading station 318.

[0084] The method 1800 further includes installing 1822 the leveling and attachment system 200 on the EIFS panel 100. More specifically, the brackets 202 are attached to the top and bottom of the completed EIFS panels 100. The brackets 202 mounted to the top of the EIFS panel 100 are each configured to include the picking eye 208 in the nut 204 such that a crane or other lifting equipment (not shown) can lift and position the EIFS panel 100 on the side of the building (not shown). The brackets 202 mounted to the bottom of the EIFS panel 100 are each configured to include the fastener 206 in the nut 204.

[0085] Steps 1802-1822 are all performed at a location that is different or away from the building site. More specifically, in the illustrated embodiment, the EIFS panels 100 are manufactured at a manufacturing facility that is different than the building site and that includes the system 300. Manufacturing the EIFS panels 100 in a separate facility decreases manufacturing times, increases the reproducibility and quality of the EIFS panels 100, and reduces the overall cost of manufacturing the EIFS panels 100.

[0086] The method 1800 further includes attaching and leveling 1824 the EIFS panel 100 on a building. The crane or other lifting equipment lifts and positions the EIFS panel 100 on the side of the building and, when the EIFS panel 100 has been positioned on the side of the building, the fastener 206 is attached to the side of the building. In the illustrated embodiments, the faster 206 includes a screw and the screw is inserted into the side of the building using an impact wrench. Furthermore, the operator of the impact wrench also positions a laser level (not shown) that indicates when the EIFS panel 100 is level with the EIFS panels adjacent to it. The operator of the impact wrench inserts the screw 206 into the building only until the EIFS panel 100 is level with the EIFS panels adjacent to it.

[0087] The systems and methods disclosed herein relate to, among other things, a method of manufacturing and installing EIFS panels and systems for manufacturing and installing EIFS panels. As discussed above, the manufacturing and installation process for EIFS panels is labor intensive, expensive, and may lead to unwanted discharge of material from the construction site. The system and methods described herein include manufacturing the EIFS panels in an at least partially automated facility and installing the EIFS panels using a leveling and attachment system. The EIFS panels are completely manufactured and assembled in the facility, reducing costs and eliminating construction steps at the construction site. Additionally, the leveling and attachment system enables the completely constructed EIFS panels to be attached and leveled without any assembly of the EIFS panels onsite. Accordingly, the systems and methods described herein reduce costs, decrease construction times, and decrease the environmental impact of manufacturing and installing EIFS panels.

[0088] Specifically, the EIFS panels described herein include the leveling and attachment system that enables the fully assembled EIFS panels to be attached to a building and leveled without manufacturing or constructing the EIFS panels on site. The leveling and attachment system includes brackets including a nut positioned in the bracket for receiving a fastener or a picking eye. The brackets are attached to the top and bottom of the completed EIFS panels. The brackets mounted to the top of the EIFS panel are each configured to include a picking eye in the nut such that a crane or other lifting equipment can lift and position the EIFS panel on the side of the building. The brackets mounted to the bottom of the EIFS panel are each configured to include a fastener in the nut and, when the EIFS panel has been positioned on the side of the building, the fastener is attached to the side of the building. In the illustrated embodiments, the faster includes a screw and the screw is inserted into the side of the building using an impact wrench. Furthermore, the operator of the impact wrench also positions a laser level that indicates when the EIFS panel is level with the EIFS panels adjacent to it. The operator of the impact wrench inserts the screw into the building only until the EIFS panel is level with the EIFS panels adjacent to it. The leveling and attachment system enables the EIFS panel to be installed quickly and efficient while also enabling the EIFS panel to be level with other EIFS panels on the building. Furthermore, the leveling and attachment system also enables the EIFS panels to be attached to the side of the building without at least partially constructing the EIFS panel on the side of the building. Thus, the leveling and attachment system enables the EIFS panels to be manufactured off site, reducing costs and construction times.

[0089] The description set forth herein, in connection with the appended drawings, describes example configurations and does not represent all the examples that may be implemented or that are within the scope of the claims. The term exemplary used herein means serving as an example, instance, or illustration, and not preferred or advantageous over other examples. The detailed description includes specific details for the purpose of providing an understanding of the described techniques. These techniques, however, may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the described examples.

[0090] In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If just the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0091] The description herein is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the scope of the disclosure. Thus, the disclosure is not limited to the examples and designs described herein, but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.

Terminology and Interpretative Conventions

[0092] Any methods described in the claims or specification should not be interpreted to require the steps to be performed in a specific order unless stated otherwise. Also, the methods should be interpreted to provide support to perform the recited steps in any order unless stated otherwise.

[0093] Spatial or directional terms, such as left, right, front, back, and the like, relate to the subject matter as it is shown in the drawings. However, it is to be understood that the described subject matter may assume various alternative orientations and, accordingly, such terms are not to be considered as limiting.

[0094] Articles such as the, a, and an can connote the singular or plural. Also, the word or when used without a preceding either (or other similar language indicating that or is unequivocally meant to be exclusive e.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., x or y means one or both x or y).

[0095] The term and/or shall also be interpreted to be inclusive (e.g., x and/or y means one or both x or y). In situations where and/or or or are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all the items together, or any combination or number of the items.

[0096] The terms have, having, include, and including should be interpreted to be synonymous with the terms comprise and comprising. The use of these terms should also be understood as disclosing and providing support for narrower alternative embodiments where these terms are replaced by consisting of or consisting essentially of.

[0097] Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, and the like, used in the specification (other than the claims) are understood to be modified in all instances by the term approximately. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term approximately should be construed in light of the number of recited significant digits and by applying ordinary rounding techniques.

[0098] All disclosed ranges are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed by each range. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).

[0099] All disclosed numerical values are to be understood as being variable from 0-100% in either direction and thus provide support for claims that recite such values or any and all ranges or subranges that can be formed by such values. For example, a stated numerical value of 8 should be understood to vary from 0 to 16 (100% in either direction) and provide support for claims that recite the range itself (e.g., 0 to 16), any subrange within the range (e.g., 2 to 12.5) or any individual value within that range (e.g., 15.2).

[0100] The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries in widely used general dictionaries and/or relevant technical dictionaries, commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used in a manner that is more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase as used in this document shall mean or similar language (e.g., this term means, this term is defined as, for the purposes of this disclosure this term shall mean, etc.). References to specific examples, use of i.e., use of the word invention, etc., are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained in this document should be considered a disclaimer or disavowal of claim scope.

[0101] The subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any embodiment, feature, or combination of features described or illustrated in this document. This is true even if only a single embodiment of the feature or combination of features is illustrated and described in this document.