Building panels and method of forming building panels

Abstract

A building panel structure is disclosed, in which building panels are used to form a structure. Roof panels and roof panel tiles are disclosed, which can be used to form the roof of the structure. The roof panels and the building panels include a core and a coating covering a portion of the core. In some embodiments the core consists of a frame and at least one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes ceramic material. In some embodiments the coating includes a first layer and a second layer. In some embodiments the coating is used to retrofit existing wall structures. The roof panel and the roof tile can be shaped, formed, and colored to look like traditional roof tiles such as shake roof tiles or Spanish roof tiles.

1 . A building panel comprising:
 a building panel core, wherein the building panel core comprises:
 a front surface; 
 a rear surface; 
 a top edge; 
 a bottom edge; 
 a first side edge; 
 a second side edge; 
 a frame, wherein the frame comprises:
 a first frame member, wherein the first frame member extends horizontally from the first side edge to the second side edge; 
 a second frame member, wherein the second frame member extends horizontally from the first side edge to the second side edge; 
 and 
 a flange protruding from the first side edge, wherein the flange is coupled to the second frame member; 
 
 and 
 an insulating structural block coupled to the frame; 
   and   a coating covering a portion of the building panel core, wherein the coating comprises a cementitious mixture.   
     
     
         2 . The building panel of  claim 1 , wherein the first frame member is a first distance from the bottom edge, wherein the first distance is between 12 and 16 inches. 
     
     
         3 . The building panel of  claim 2 , wherein the second frame member is a second distance from the bottom edge, wherein the second distance is between 42 and 54 inches. 
     
     
         4 . The building panel of  claim 3 , further comprising a third frame member extending horizontally from the first side edge to the second side edge. 
     
     
         5 . The building panel of  claim 4 , wherein the third frame member is a third distance from the bottom edge, wherein the third distance is between 78 and 90 inches. 
     
     
         6 . The building panel of  claim 5 , wherein the coating comprises:
 a first coating layer covering a portion of the building panel core, wherein the first coating layer comprises cement, aggregate and acrylic bonder;   and   a second coating layer covering a portion of the first coating layer, wherein the second coating layer comprises cement, aggregate and acrylic bonder.   
     
     
         7 . The building panel of  claim 6 , wherein:
 the first coating layer comprises a plurality of crests and valleys;   the second coating layer covers the plurality of crests and valleys; and   the plurality of crests have an average half-width of between 1/16 inch and ½ inch.   
     
     
         8 . The building panel of  claim 7 , wherein the plurality of crests have an average height of between ⅛ inch and ¾ inch. 
     
     
         9 . A method of retrofitting an outer surface of an existing wall structure of a building, the method comprising:
 coupling a first piece of expanded polystyrene (EPS) foam to the outer surface of the existing wall structure of the building;   applying a first coating layer to a portion of the first piece of EPS foam, wherein the first coating layer comprises cement, aggregate and acrylic bonder;   and   applying a second coating layer to a portion of the first coating layer, wherein the second coating layer comprises cement, aggregate and acrylic bonder.   
     
     
         10 . The method of  claim 9 , wherein the existing wall structure of the building comprises a cement block. 
     
     
         11 . The method of  claim 9 , wherein the existing wall structure comprises:
 a cement block;   a second piece of EPS foam covering a portion of the cement block;   and   a cementitious adhesive coating covering a portion of the second piece of EPS foam.   
     
     
         12 . The method of  claim 9 , wherein the existing wall structure of the building comprises:
 a wood frame;   a wallboard coupled to the wood frame;   a metal lath coupled to the wallboard;   and   a stucco coating coupled to the metal lath.   
     
     
         13 . The method of  claim 9 , wherein the existing wall structure of the building comprises:
 a steel frame;   a wallboard coupled to the steel frame;   a second piece of EPS foam covering a portion of the wall board;   and   a cementitious adhesive coating covering a portion of the second piece of EPS foam.   
     
     
         14 . The method of  claim 9 , further comprising embedding a fluid channel in the first coating layer. 
     
     
         15 . The method of  claim 9 , further comprising covering a portion of the first coating layer with a fire barrier material before applying the second coating layer. 
     
     
         16 . A method of forming a building panel, the method comprising:
 expanding a portion of polystyrene foam beads;   placing a metal frame into a building panel mold;   placing the portion of expanded polystyrene foam beads into the building panel mold;   and   molding the portion of expanded polystyrene foam beads into a predetermined shape around the metal frame.   
     
     
         17 . The method of  claim 16 , further comprising aging the portion of expanded polystyrene foam beads after the portion of expanded polystyrene foam beads is expanded, and before the portion of expanded polystyrene foam beads is placed in the mold. 
     
     
         18 . The method of  claim 17 , wherein aging the portion of expanded polystyrene foam beads extends for a time less than or equal to 30 hours. 
     
     
         19 . The method of  claim 16 , wherein expanding a portion of polystyrene foam beads comprises applying steam to the portion of expanded polystyrene foam beads. 
     
     
         20 . The method of  claim 16 , wherein molding the portion of expanded polystyrene foam beads into a predetermined shape around the metal frame comprises applying steam and pressure to the portion of expanded polystyrene foam beads.