Building Panel System With Interdigitated Coating Layers
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Solution Overview
Problem
Existing building materials, such as foam blocks, lack the structural strength required for buildings in areas prone to high winds or earthquakes, while also being environmentally friendly and energy-efficient.
Innovation Solution
A composite building panel system comprising a core made of insulating structural blocks, such as EPS foam, combined with a coating that includes a scratch layer and a main brown layer, providing structural reinforcement and protection while maintaining energy efficiency and environmental sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foam blocks are used for building construction, then energy efficiency and environmental sustainability are improved, but structural strength deteriorates
Solution Approach 1:
The patent applies composite materials by combining foam blocks with cementitious coating layers containing reinforcing mesh. The core foam block provides insulation while the cementitious layers with embedded mesh provide structural strength, creating a composite building panel that achieves both energy efficiency and structural integrity.
Solution Approach 2:
The patent merges foam blocks with cementitious coating systems into a unified building panel structure. The foam block is combined with multiple cementitious layers and reinforcing mesh to create a composite system that integrates the insulating properties of foam with the structural properties of cement and metal reinforcement.
2Object-generated harmful factors
If foam blocks are used for building construction, then environmental sustainability is improved, but structural strength deteriorates
Solution Approach 1:
The patent uses composite materials to combine environmentally friendly foam blocks with cementitious coating layers and reinforcing mesh. This composite structure maintains the environmental benefits of foam while adding the structural strength needed for earthquake and wind resistance through the cement and metal reinforcement components.
3Strength
If reinforcing mesh is embedded in coating layers, then structural strength is improved, but device complexity increases
Solution Approach 1:
The patent segments the coating system into distinct functional layers: a first cementitious coating layer with embedded reinforcing mesh for structural strength, and a second cementitious coating layer for protection and finish. This segmentation allows each layer to perform its specific function while maintaining overall system manageability.
Solution Approach 2:
The patent applies local quality by placing reinforcing mesh specifically within the first cementitious coating layer where structural strength is most needed, rather than uniformly throughout the entire coating system. The mesh is embedded at the optimal location to maximize structural reinforcement while minimizing unnecessary complexity.
Data Source
AI summary
A building panel structure is disclosed, in which building panels are used to form a structure. The building panel includes 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 scratch layer and a main brown layer. In some embodiments the scratch layer and the main brown layer are interdigitated to increase the strength and durability of the coating and the building panel. In some embodiments the building panel includes a construction board formed separate from the core. The construction board is formed of coating mixtures and applied to the core after the coating mixtures have cured.