Composite Building Panel with EPS Core and Fiberglass Mesh Coating
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Solution Overview
Problem
Existing building materials, such as foam blocks, lack the structural strength required for buildings to withstand high winds or earthquakes, and there is a need for a prefabricated panel system that minimizes construction time while using environmentally friendly materials and ensuring high structural integrity.
Innovation Solution
A composite building panel system comprising a core with a frame and insulating structural blocks, coated with multiple layers including an inner scratch layer and an outer main brown layer made of cement, aggregate, acrylic bonder, fiberglass strands, and fiberglass mesh, which provides structural strength and weather resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If foam blocks are used for building construction, then energy efficiency and environmental sustainability are improved, but structural strength is reduced
Solution Approach 1:
The patent applies composite materials by combining foam blocks with steel reinforcement elements (rebar, wire mesh) and concrete coating layers. The foam block provides thermal insulation while the steel and concrete components provide structural strength, creating a composite wall assembly that achieves both energy efficiency and structural integrity simultaneously.
2Ease of manufacture
If wood is used for building construction, then ease of manufacture is improved, but material waste and labor costs increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling wall panels in a controlled manufacturing environment before shipping to the construction site. The foam blocks, steel reinforcement, and concrete coatings are all prepared and integrated beforehand, eliminating on-site cutting and assembly operations that would otherwise generate significant wood waste and require extensive skilled labor.
3Strength
If traditional building materials are used, then structural strength is improved, but construction time and labor costs increase
Solution Approach 1:
The patent applies segmentation by dividing the building into modular wall panel units that can be manufactured independently and assembled quickly on-site. Each panel is a complete, self-contained unit with integrated insulation, reinforcement, and finishing layers, allowing parallel manufacturing of multiple panels while reducing on-site construction time compared to traditional stick-building methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite building panel system offers enhanced structural integrity, energy efficiency, and reduced construction time while using environmentally friendly materials, effectively addressing the need for stronger building panels.
Implementation Method 1
The outer main brown layer includes cement, aggregate, acrylic bonder, fiberglass strands, and fiberglass mesh
Implementation Method 2
The outer main brown layer includes cement, aggregate, acrylic bonder, fiberglass strands, and fiberglass mesh
Implementation Method 3
one or more than one insulating structural block coupled to the frame
Data Source
AI summary
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.