# US 2014/0150362 A1 · Building panels and method of forming building panels > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0150362 A1 - Document ID: US20140150362A1 - Status: Published application - Kind: A1 - Application number: 14/105,645 - Filed: 2013-12-13 - Published: 2014-06-05 - Earliest claimed: 2010-01-20 - Assignees: Propst Family Limited Partnership - Applicants: Propst Family Limited Partnership - Inventors: John Eugene Propst - Web page: https://patentgrep.com/patent/US20140150362A1 ## CPC - E04G 23/0296: {Repairing or restoring facades (covering or linings, e.g. for walls E04F13/00)} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 17/02: in the form of fibres or filaments - C04B 28/04: Portland cements - E04B 1/66: Sealings ({damp-proof courses E04B1/644; fire-proof sealings E04B1/948;} additions of anti-leak properties to plaster C04B; bituminous sealing masses C08L95/00; sealings for hydraulic engineering work in general E02B3/16; against ground humidity or ground water E02D31/02; coverings against rain or other precipitations of the atmosphere E04D) - E04B 1/941: {Building elements specially adapted therefor} - E04B 2/02: built-up from layers of building elements - E04B 7/22: the slabs having insulating properties, e.g. laminated with layers of insulating material - E04C 2/296: composed of insulating material and non-metallic or unspecified sheet-material (E04C2/288 takes precedence) - E04D 1/28: Roofing elements comprising two or more layers, e.g. for insulation - E04D 3/352: {at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets} - E04F 13/0866: {composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence)} - E04F 13/0869: {having conduits for fluids} - E04F 13/0885: {specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application} - E04F 13/14: stone or stone-like materials, e.g. ceramics {concrete,}; of glass {or with an outer layer of stone or stone-like materials or glass (E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00)} - B32B 2260/023: Two or more layers - B32B 2260/044: Water-setting substance, e.g. concrete, plaster - B32B 2262/101: Glass fibres - B32B 2419/06: Roofs, roof membranes - B32B 2607/00: Walls, panels - C04B 2111/00612: {as one or more layers of a layered structure} - C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures - C04B 2111/80: Optical properties, e.g. transparency or reflexibility - E04B 2002/0202: {Details of connections} - F24S 20/67: in the form of roof constructions (in the form of shingles or tiles F24S20/69) - F24S 20/69: in the form of shingles or tiles - Y02B 10/20: Solar thermal - E04G: SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00) - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - F24S: SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS (for producing mechanical power from solar energy F03G6/00) - Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS ## 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. ## Claims ### Claim 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. ### Claim 2 (depends on 1) 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. ### Claim 3 (depends on 2) 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. ### Claim 4 (depends on 3) The building panel of claim 3, further comprising a third frame member extending horizontally from the first side edge to the second side edge. ### Claim 5 (depends on 4) 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. ### Claim 6 (depends on 5) 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. ### Claim 7 (depends on 6) 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. ### Claim 8 (depends on 7) The building panel of claim 7, wherein the plurality of crests have an average height of between ⅛ inch and ¾ inch. ### Claim 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. ### Claim 10 (depends on 9) The method of claim 9, wherein the existing wall structure of the building comprises a cement block. ### Claim 11 (depends on 9) 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. ### Claim 12 (depends on 9) 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. ### Claim 13 (depends on 9) 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. ### Claim 14 (depends on 9) The method of claim 9, further comprising embedding a fluid channel in the first coating layer. ### Claim 15 (depends on 9) 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. ### Claim 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. ### Claim 17 (depends on 16) 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. ### Claim 18 (depends on 17) 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. ### Claim 19 (depends on 16) The method of claim 16, wherein expanding a portion of polystyrene foam beads comprises applying steam to the portion of expanded polystyrene foam beads. ### Claim 20 (depends on 16) 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.