Composite building and panel systems

Abstract

A building panel structure is disclosed, where the building panel structure includes composite building panels. A composite building panel includes a core and a coating applied over the core. In some embodiments the core consists of a frame and one or more than one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes an inner scratch layer and an outer main brown layer. The inner scratch layer can be formed of at least two layers. The outer main brown layer can include a fiberglass mesh embedded into the outer main brown layer. A method of forming a building panel structure is disclosed which includes forming a core using a frame and one or more than block, applying an inner scratch layer to the core, and applying an outer main brown layer over the inner scratch layer.

1 . A building panel structure comprising:
 a core, comprising at least one insulating structural block and a frame, wherein the frame is embedded in the at least one insulating structural block;   an inner scratch layer, wherein the inner scratch layer comprises cement and aggregate; and   an outer main brown layer, the outer main brown layer comprising cement, aggregate, acrylic bonder, fiberglass strands, and fiberglass mesh.   
     
     
         2 . The building panel structure of  claim 1 , wherein the inner scratch layer covers a portion of the core. 
     
     
         3 . The building panel structure of  claim 1 , wherein the inner scratch layer mixture covers a surface of the at least one insulating structural block. 
     
     
         4 . The building panel structure of  claim 1 , wherein the frame is metal. 
     
     
         5 . A building panel structure comprising:
 a building panel core, wherein the building panel core comprises at least one foam block and a frame, wherein the frame is embedded in the at least one foam block;   an inner scratch layer covering a portion of the core, wherein the inner scratch layer comprises cement, aggregate, and acrylic bonder; and   an outer main brown layer covering a portion of the inner scratch layer, wherein the outer main brown layer comprises a mixture of Portland cement and aggregate.   
     
     
         6 . The building panel structure of  claim 5 , wherein the outer main brown layer further comprises fiberglass mesh. 
     
     
         7 . The building panel structure of  claim 6 , wherein the inner scratch layer further comprises fiberglass mesh. 
     
     
         8 . The building panel structure of  claim 5 , wherein the inner scratch layer further comprise fiberglass mesh. 
     
     
         9 . The building panel structure of  claim 5 , wherein the outer main brown layer further comprises acrylic bonder. 
     
     
         10 . The building panel structure of  claim 5 , wherein the outer main brown layer further comprises acrylic bonder and fiberglass strands. 
     
     
         11 . The building panel structure of  claim 5 , wherein the outer main brown layer further comprises acrylic bonder, fiberglass strands, and fiberglass mesh. 
     
     
         12 . The building panel structure of  claim 5 , wherein the inner scratch layer further comprises wire mesh. 
     
     
         13 . The building panel structure of  claim 5 , wherein the outer main brown layer further comprises wire mesh. 
     
     
         14 . A building comprising:
 a building panel core, wherein the building panel core comprises at least one foam block and a frame, wherein the frame is completely embedded in the at least one foam block;   an inner scratch layer covering a portion of the core, wherein the inner scratch layer comprises cement, aggregate and acrylic bonder; and   an outer main brown layer covering a portion of the inner scratch layer, wherein the outer main brown layer comprises a mixture of Portland cement and aggregate.   
     
     
         15 . The building of  claim 14 , wherein the inner scratch layer covers a portion of the at least one foam block. 
     
     
         16 . The building of  claim 14 , wherein the outer main brown layer further comprises acrylic bonder. 
     
     
         17 . The building of  claim 14 , wherein the outer main brown layer further comprises acrylic bonder and fiberglass strands. 
     
     
         18 . The building of  claim 14 , wherein the outer main brown layer further comprises acrylic bonder, fiberglass strands, and fiberglass mesh. 
     
     
         19 . The building of  claim 14 , wherein the outer main brown layer further comprises acrylic bonder and fiberglass mesh. 
     
     
         20 . The building of  claim 14 , wherein the outer main brown layer further comprises fiberglass mesh.