Composite materials, methods of making composite materials, and enclosures constructed from composite materials

Not applicable.This application is a broadening reissue of U.S. Pat. No. 9,909,313 issued on Mar. 6, 2013.

Not applicable.

Not applicable.

The present disclosure is generally related to composite materials, and more particularly to composite materials for outdoor enclosures such as hunting blinds.

Outdoor structures are commonly used to provide shelter from the elements in outdoor settings. Blind structures, for example, can be temporarily or otherwise installed or placed in outdoor environments to provide shelter. They may also provide concealment for the occupant such that wildlife, e.g., birds, deer, etc., can be observed with a lessened chance of the flight response that recognition of the occupant's presence could otherwise provoke. Such outdoor structures can provide varying degrees of shelter to an occupant from the environment, which can be adverse depending upon location, weather, season, etc.

Some conventional blind structures are typically moved to a desired location or assembled in situ at the desired location from modules or parts fabricated remotely from the assembly location. The walls of such blind structures can have a core made from wood, foam, etc., which is faced with a sheet metal or other exterior. The exterior can be painted or have graphics incorporated to make the blind structure more difficult to discern in the desired environment or to improve aesthetics, and the interior may include insulation or other structure supported by the core, such as to provide a degree of comfort and acoustic dampening for the occupant.

Some of such outdoor structures may be considered satisfactory for their intended purposes under some circumstances. However, there remains a need for improved composite materials, methods of making composite materials, and enclosures constructed from such composite materials. The present disclosure provides a solution to these needs.

A composite material can include a first layer and a second layer. The first layer can include a carpet having a pile and a backing. The second layer can include fiber, resin, and catalyst, and can be bonded or otherwise coupled to the first layer. The second layer can be coupled to the first layer on a side of the carpet backing opposite the pile. The carpet pile can define or be a first surface of the composite material, such as an exterior surface. The second layer can define or be a second surface of the composite material, such as another exterior surface, which can include an opposite exterior surface. At least once surface can be adapted to withstand outdoor elements.

In at least one embodiment, the second layer can include fiberglass. The second layer can include a fiber-reinforced resin. The fiber-reinforced resin can include randomly dispersed fibers of random lengths. The second layer can have a thickness that is between about 25 mils (0.635 mm) and about 30 mils (0.762 mm). Fabric, such as a sheet of fabric, can be at least partially embedded in the resin.

In at least one embodiment, the second layer can be at least substantially waterproof. The first layer can, but need not, be waterproof. The resin can be directly coupled to the carpet backing. In at least one embodiment, the composite material can have flexibility such that at least substantially no plastic deformation occurs when two ends of the composite material having a length of approximately 18 inches (0.4572 m) and a thickness of approximately 30 mils (0.762 mm) are touched together.

In at least one embodiment, an enclosure can include a plurality of walls, such as a front wall, a rear wall opposite the front wall, and first and second side walls extending at least partially between the front wall and the rear wall. A roof can at least partially cover an interior of the enclosure and can be at least partially circumscribed by the four walls. One or more of the walls can be formed from a composite material as disclosed herein.

In at least one embodiment, at least two walls of an enclosure can be formed from a single sheet of a composite material disclosed herein. For example, a first side wall and a second side wall can be formed from a single sheet of composite material, or two or more other walls can be formed from a single sheet of composite material. In at least one embodiment, two or more walls, such as a first side wall and a second side wall, and a roof can be formed from a single sheet of composite material.

In at least one embodiment, an enclosure can be a hunting blind. One or more apertures can be disposed in or through one or more walls. A window unit can be coupled with an aperture. A door unit can be coupled with an aperture.

A method of making a composite material can include providing a first layer including a carpet with a pile and a backing. A second layer can be coupled to the first layer, such as to the carpet backing, pile, or a combination thereof. A second layer can include fiber, resin, and catalyst. The second layer can be rolled, such as with a roller, or otherwise formed, such as until a thickness of the second layer is at least substantially uniform over an area, which can be an area. The resin can be allowed to cure, and one or more steps can take place before, at one or more pints in time during, or after curing.

In at least one embodiment, applying one or more layers, such as a second layer, can include spraying at least a portion of a second layer on to a carpet backing. In at least one embodiment, spraying can be done using a chop gun system. A method can include randomly dispersing fibers of random lengths on to a carpet backing. A method can include building up a layer, such as a second layer, until a desired thickness is achieved for a particular application, such as a thickness of between about 25 mils (0.635 mm) and about 30 mils (0.762 mm), or another thickness, separately or in combination, in whole or in part.

These and other features of the systems and methods of the present disclosure will become more readily apparent to those skilled in the art from the following detailed description of one or more embodiments in conjunction with the drawings.

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of an enclosure in accordance with the disclosure is shown inand is designated generally by reference character. Other exemplary embodiments of enclosures, composite materials, and methods of making composite materials in accordance with the disclosure, or aspects thereof, are provided in the remaining figures, as will be described. The systems and methods of the present disclosure relate to enclosures for outdoor environments, such as hunting blinds, though the present disclosure is not limited to hunting blinds or outdoor enclosures, as will be understood by a person of ordinary skill in the art having the benefits of the present disclosure.

The Figures briefly described above and the written description of specific structures and functions below are not presented to limit the scope of what Applicant has invented or the scope of the appended claims. Rather, the Figures and written description are provided to teach any person skilled in the art to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in the art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present disclosure will require numerous implementation-specific decisions to achieve the developer's ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and likely are not limited to, compliance with system-related, business-related, government-related and other constraints, which may vary by specific implementation, location and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art having benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms. The use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. Also, the use of relational terms, such as, but not limited to, “front”, “rear”, “side”, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” and the like are used in the written description for clarity and convenience in specific reference to the Figures and are not intended to limit the scope of the invention or the appended claims. The terms “couple,” “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and can include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, operably, directly or indirectly with intermediate elements, one or more pieces of members together and can further include without limitation integrally forming one functional member with another in a unity fashion. The coupling can occur in any direction, including rotationally.

is a perspective view of one of many embodiments of an enclosure according to the present disclosure.is schematic cross-sectional view of one of many embodiments of a composite material according to the present disclosure.is a schematic cross-sectional view of another of many embodiments of a composite material according to the present disclosure.is a schematic view of a method of making a composite material according to the present disclosure.is a schematic exploded view of one of many embodiments of an enclosure according to the present disclosure.is a partial front perspective view of one of many embodiments of an enclosure according to the present disclosure.is an exterior detail view of a portion of the enclosure of.is an interior detail view of a portion of the enclosure of.is a partial interior perspective view of one of many embodiments of an enclosure according to the present disclosure.is another partial interior perspective view of one of many embodiments of an enclosure according to the present disclosure.are described in conjunction with one another.

Referring to the figures, some of many illustrative embodiments of an enclosurefor at least partially enclosing a space are shown. Enclosurecan be or include a hunting blind as shown for exemplary purposes, but need not, and can be or include another type of enclosure, such as a portable, permanent or semi-permanent housing or shell for at least partially separating its contents from an environment surrounding the enclosure, whether indoors, outdoors, or otherwise. In at least one embodiment, enclosurecan include a roof, such as a top or cover, a floor, such as a bottom or surface for supporting from the bottom, and one or more sides or walls, such as a front wall, a rear wall, a first side wall, and a second side wall. It will be understood that the aforementioned sides are referred to as front, rear, first and second for purposes of reference and convenience in describing the same, and can alternatively be referred to in other ways, such as first, second, third, fourth, etc., walls or sides, sides 1, 2, 3, 4, etc., sides a, b, c, d, etc., and so on. Unless otherwise indicated, the same is true for other components or portions of the systems and methods of the present disclosure. In at least one embodiment, a front wallcan be arranged opposite or otherwise spaced relative to a rear wall. A first side wallcan extend between or otherwise be coupled to or span front walland rear wall. A second side wallcan be disposed from front wallto rear wall, such as at least partially or generally opposite first side wall. Enclosurecan include an interior, such as an inside space or volume, bounded by or within front wall, rear wall, first side walland second side wall. While enclosureofis shown to have four sides for illustrative purposes, this need not be the case, and other embodiments of the disclosure can include any number of sides according to a particular application, such as 1, 2, 3, 4, 5, up to 20, or more. Similarly, while the exemplary embodiment ofis shown to include a floorthat is generally rectangular or square, this need not be the case, and other embodiments of the disclosure can be or include a floor (if present) of any shape according to a particular application, such as, triangular, circular, oblong, pentagonal, or another shape.

In at least one embodiment, roofcan at least partially cover at least a portion of interiorof enclosure, which can, but need not, include overlaying at least a portion of one or more sides of enclosure. As other examples, roofcan extend past the exterior of one or more sides or be disposed within one or more sides, separately or in combination, in whole or in part. Roofcan comprise one or more portions, and can have any shape according to a particular application at hand, which can include being curved, angled, flat, arched, or another configuration, separately or in combination, in whole or in part. Roofcan be coupled to one or more sides directly or indirectly, including being formed integrally with one or more sides or a portion thereof. Interiorcan be at least partially surrounded or circumscribed by one or more of front wall, rear wall, first side wall, and second side wall. Floorcan be disposed at least partially within or below interior, such as opposite roof. In at least one embodiment, floorcan bound a lower portion of interiorand one or more sides or walls, such as front wall, rear wall, first side walland second side wall. An optional tower, such as a stand, base, feet, legs, and/or other structure(s) for elevating enclosureabove the ground or another surface, can be at least partially coupled or arranged on a side of flooropposite interior, such as for improving a user's field of view of the surroundings of enclosure.

In at least one embodiment, enclosurecan include one or more portions or components formed from a composite material according to the present disclosure, such as composite material(described in further detail below). For example, one or more of front wall, rear wall, and side walls,can be formed from composite material, in whole or in part. As shown in the exemplary embodiment of, roofand floorcan also (or individually) be formed from composite material, separately or in combination with one or more other materials (e.g., wood, metal, plastic, etc.), in whole or in part. In at least one embodiment, floorcan be formed partially of composite materialand partially of another material, such as wood, and can be configured for allowing replacement of at least a portion of the floor from time to time. For example, in an embodiment of enclosurehaving a floorcomprised of composite materialand, e.g., a wooden panel, or of a panel otherwise coupled to the remainder of the enclosure, which are but some embodiments of many, floorcan be configured for allowing a user to optionally replace the panel, such as when exposure to wear, or moisture, or other elements has resulted in deterioration of the panel over time. In at least one embodiment, one or more walls can be turned inwardly at the bottom and a floor panel can be coupled to the inwardly turned portion(s), such as above such portions, below such portions, or a combination thereof. This need not be the case, however, and a floor panel(s) can alternatively (or collectively) be coupled to a support structure(if present) of enclosure, such as a frame, skeleton or other structure for supporting enclosure, such as in an upright or other position (see, e.g.,).

In at least one embodiment, two or more sides of enclosure, such as first side walland second side wall, can be formed from a single sheet of composite material, separately or in combination with one or more other portions of enclosure. As illustrated in, in at least one embodiment, enclosurecan include a first side wall, second side walland roofformed from a single sheet of composite material(see also, for example). As another example, enclosurecan include a front wall, rear walland roofformed from a single sheet of composite material. As another example, enclosurecan include two sides and a floor(and/or a roof) formed from a single sheet of composite material. As another example, enclosurecan include two or more adjacent sides, which can include all sides (which can be any number of sides) formed from a single sheet of composite material. Such a single sheet of composite materialcan be at least partially continuous. In an embodiment such as the one shown in, for example, enclosurecan include sides and a roof (and/or floor, if present) comprising a single sheet of composite materialin a seamless fashion, for example, so that no seam or joint exists at a transition between roofand one or more sides, such as first side wallor second side wall. As will be appreciated by those of skill in the art having the benefits of the present disclosure, an absence of seams at such locations can simplify manufacture of enclosure, such as by reducing the number of parts (e.g., panels, couplers, seals, etc.), steps, or costs for constructing enclosure. As will also be appreciated by those of skill in the art having the benefits of the present disclosure, absence of seams at one or more locations along roofor the top of a side can at least partially improve air tightness of enclosure, which can reduce moisture infiltration avenues, or exfiltration avenues for scent or noise from within enclosure interior. In at least one embodiment, however, one or more seams can exist at one or more of such locations and/or couplers may be used at such locations, such as for coupling one portion of the enclosure to another or for coupling one or more sides of the enclosure to a support structure, such as an interior or exterior frame made from tubing, bar stock, angle iron, or another material for constructing a support structure(if present) for the portion(s) of enclosurecomprising composite material. The couplers can, but need not, pass at least partially through composite materialin one or more locations. In at least one embodiment, one or more couplers, such as screws, bolts, rivets and the like, can couple composite materialto one or more support members, which can include passing through the support member into composite material, or vice versa.

In at least one embodiment, one or more of front wall, rear wall, first side wall, and second side wallcan include one or more aperturesfrom the interior of enclosureto the exterior of enclosure, such as a hole, opening, slit or other space. In at least one embodiment, one or more aperturescan be configured to seat or otherwise couple with a module, such as a door unit, window unit, or other structure, such as a selectively or optionally openable opening for viewing, venting, or cooperating with a user-operated device, such as a camera or hunting apparatus (e.g., firearm, bow, crossbow, game call, etc.). Door unitcan be moveably coupled (indicated with a movement arrowin) with enclosure, such as for selectively covering or filling at least a portion of apertureand allowing access to interiorof enclosure. Window unitcan be moveably coupled (indicated with a movement arrowin) with enclosure, such as for selectively covering or filling at least a portion of aperture, and ca be arranged for providing a user with a field of view of the environment surrounding enclosurefrom within interiorof enclosure. Door unitand window unit(or portions thereof) can each be configured to move, in whole or in part, in any manner according to a particular application, such as pivotally, slideably or otherwise, and can include unitary structures (e.g., a door and a window, respectively) or multi-component structures, such as frames, seals, hinges, door or window panels, locks, and other components for coupling or operating a door or window. As illustrated in, for example, a door unitor window unitcan include a stationary portiona,a (e.g., a door frame or window frame) coupled to a movable portionb,b (e.g., a door panel or window panel), and a stationary portion can be coupled to composite material. As another example, a movable portionb,b (e.g., a door or window, if present) can be coupled directly to composite material, such as with hinges or other devices for movement and a stationary portiona,a can comprise a side or other portion of enclosure(i.e., the frames can be absent), in whole or in part.

The shapes, number, types and locations of door unitand window unitshown inare for illustration purposes only, and enclosurecan include any shape, number, type and location of door unitand window unitaccording to a particular application. Enclosurecan include one or more door unitsand/or window unitsin any side or other portion of the enclosure, including in roofor floor, if desired. In at least one embodiment, one or more door unitsand/or window unitscan be at least partially formed of composite material. In at least one embodiment, one or more aperturescan comprise an opening comprising composite materialcut and rolled or otherwise moved outwardly from the center or another portion of the aperture. In at least one embodiment, composite materialcan be configured to form a seal along at least a portion of a perimeter or border of aperture, which can include being shaped and disposed to provide an at least partially airtight or watertight coupling between at least a portion of an apertureand a door unitor window unitcoupled to the aperture. In at least one embodiment, composite materialcan be configured to form one or more other structures along a perimeter or border of an aperture, such as a sill, rest, debris barrier, or the like, which can be located along the top, bottom, side or other portion of aperture. A door unitor window unitcan be coupled to an aperture in any manner according to a particular application, which can include coupling a door or window frame (which can include additional structures, such as an overhang, gutter, canopy, or the like for displacing rain water) to a wall of enclosureusing couplers (e.g., rivets), such as along a perimeter or other portion thereof.

With continuing reference to the figures, and specific reference to, in at least one embodiment, enclosurecan include one or more window units(or, e.g., door units), such as in a wall or side, and composite materialcan be adapted for coupling with window unit. For example, enclosurecan include an aperturethat is smaller in at least one dimension (e.g., height or width) than at least a portion of window unit, such as at least a portion of a stationary componenta. In such an embodiment, which is but one of many, enclosurecan include one or more flaps, such as a flange, tab, or extension, for coupling window unitto composite material. In at least one embodiment, flapcan be an integral portion of composite material, such as of a wall,,,, formed by way of one or more slits, such as cuts, slots, or other openings, for forming flapfrom a portion of composite material. Flapcan be adapted for coupling with window unitor a portion thereof with one or more couplers, such as fasteners, adhesives, or other connectors, separately or in combination, in whole or in part. Flapcan be adapted for sealingly coupling with window unitor a portion thereof, which can, but need not, include the use of a sealant(s). In at least one embodiment, one or more flapscan be adapted for inserting or otherwise disposing window unit(or, e.g., door unit) at least partially through a wall, side or other portion of enclosure, such as by way of accepting at least a portion of window unitthrough a slit.

With continuing reference to the figures, and specific reference to, composite materialwill now be described in further detail. Composite materialcan include one or more materials coupled together to form a composite, such as a first layerand a second layer. First layercan be or include carpet, which can include a pileand a backing(which can include one or more sublayers). Second layercan be or include fiber material, such as fiber glass, and can include fiber, resin, and catalyst. In at least one embodiment, second layercan be coupled to first layerfor forming a composite sheet according to the disclosure having a structure of sufficient characteristics for forming a wall of a hunting blind or similar enclosure. Such characteristics can include, but are not limited to, being at least substantially waterproof or nonporous, flexible enough to form an enclosure as described herein yet rigid enough to support the weight and application of such enclosure, abrasion resistant, and environment (e.g., temperature) resistant.

First layercan have a pile surfaceand an opposed backing face. Carpet pile surfacecan be defined by carpet pileand can bound interiorof enclosure(see). As will be appreciated by those of skill in the art in view of the present disclosure, bounding interiorwith carpet pile surfacecan provide acoustic separation or insulation of interiorof enclosurefrom an environment external to enclosure. In at least one embodiment, interior surfaces of roof, floor, front wall, rear wall, and first side walland second side wallbound interiorof enclosure. As will also be appreciated by those of skill in the art in view of the present disclosure, bounding substantially the entirety of the interiorof enclosurewith carpet pile surfaceof composite materialcan provide acoustic isolation of interiorfrom an external environment. This can be desirable in certain embodiments, such as hunting blinds, where interiormay otherwise be within earshot of wildlife that are within the proximity of enclosure. In at least one embodiment, composite materialcan bound less than the entirety of interiorof enclosure, and can be used for any one or more of the sides, roof and floor of enclosure.

Backing facecan be at least partially comprised of carpet backing. As shown in the illustrative embodiment of, carpet backingcan include a flexible, mesh-like grating for providing carpetwith longitudinal rigidity and lateral rigidity (i.e., resistance to stretch), albeit with flexibility sufficient to allow carpetto flex and/or be rolled. Carpet backingcan include a plurality of layers of various materials (e.g., a primary backing layer and one or more secondary backing layers). Carpetcan be or include action backed carpet, unitary backed carpet, or another type of carpet, separately or in combination, in whole or in part.

Second layercan be coupled to first layeron a side of carpet backingopposite carpet pile surface. In this respect, second layercan have a carpet faceand an opposite exterior surface. Carpet facecan be coupled to backing faceof carpet, and carpet backingcan have contour, texture or other structure suitable for coupling with second layer. Exterior surfacecan be disposed on a side of carpet backingopposite carpet pile surfaceand carpet face, and can comprise at least a portion of an exterior surface of enclosure(shown in). In at least one embodiment, exterior surfacecan comprise at least substantially the entire exterior surface(s) of one or more of the roof, floor, front wall, rear wall, first side walland second side wallof enclosure(see). In at least one embodiment, composite materialcan include no intervening layers between first layerand second layer, which can simplify manufacture of composite material. In at least one embodiment, carpetcan form a core of composite material. In at least one embodiment, carpetor a portion thereof can form a core of composite materialwithout any intervening structure disposed between carpet pile surfaceand exterior surface, such as wood, polyisocyanate, foam, plastic, or the like.

In at least one embodiment, second layercan include a fiberglass material, which can include any type of fiber-based material or fiber material. The fiberglass materialcan include a fiber-reinforced resin, e.g., respective fibers of fiber(which can be any type of fiber, such as glass, plastic, etc., whether now known or future developed) fixed relative to one another by resinin a cured state, and optionally including residual catalyst. In at least one embodiment, fibers of fibercan be randomly dispersed throughout second layer, which can simplify application of second layerand/or reduce the cost of composite material. In at least one embodiment, fibers of fibercan be of random lengths, which can simplify manufacture of second layerand/or reduce the cost of composite material. In at least one embodiment, second layercan be applied or otherwise coupled to first layer, such as to backing, by spraying, which can include use of a chop gun system. Other application techniques include rolling, brushing, pouring, troweling, or other manners of applying fiberglass and similar materials.

Second layercan have a thickness(shown in), such as from carpet faceof first layerto exterior surfaceof second layer, which can include at least a portion of second layerembedded or otherwise protruding at least partially into first layer. In at least one embodiment, thicknesscan be between about 25 mils and about 30 mils, which can include thicknesses from 20 to 35 mils. Thicknesscan, but need not, be at least substantially uniform across one or more portions of composite materialaccording to a particular application at hand. In at least one embodiment, thicknesscan be less than about 25 mils, more than about 30 mils, or a combination thereof. In at least one embodiment, thicknesses between about 25 mils and about 30 mils can render second layerat least substantially impermeable to water, which can render enclosure(shown in) suitable for some outdoor installations. In at least one embodiment, thicknesses between about 25 mils and about 30 mils can enable second layerto provide sufficient rigidity to first layersuch that composite materialcan be self-supporting but sufficiently flexible to form arcuate structures, such as an arcuate gable of a roof(shown in). For example, as illustrated in, composite materialcan have a flexibility such that at least substantially no plastic deformation occurs when two ends of the composite material having a length of approximately eighteen inches and a thickness of approximately 30 mils are touched together. In at least one embodiment, the composite materials of the present disclosure can include or exhibit a bend radius having a greater degree of curvature than traditional molding (pre-cure) and after a sheet or other form of composite material, etc., has at least partially cured. In at least one embodiment, the composite materials of the present disclosure can be cut, sheared, or worked with machines or tools predominately utilized for metal fabrication, such as, for example, rollers, shearers, notchers, iron workers, etc., which can be uncharacteristic of at least some traditional composites.

With reference to, a composite materialis shown, which is another of many embodiments of a composite material according to the disclosure. Composite materialis similar to composite material(shown in), and additionally can include a second layerhaving a fabric sheetat least partially embedded within second layer. In this respect, second layercan include an at least partially intermediate layer, which can include fiber, resin, catalyst, and fabric sheet, and an outer layercontaining fiber, resin, and catalyst, and optionally at least a portion of fabric sheet. Fabric sheetcan be or include any type of fabric or similar material according to a particular application, which can, but need not, provide added strength, rigidity or toughness to composite material. In at least one embodiment, fabric sheetcan include a decorative, cosmetic, or other pattern, which can be at least partially viewable through outer layer. In at least one embodiment, fabric sheetcan be or include a nexus material. In at least one embodiment, fabric sheetcan be or include one or more other materials, such as cloth, cheesecloth, burlap, screen, netting, or the like, separately or in combination with one another or one or more other materials discussed herein and/or for providing a pattern or color to enclosure, in whole or in part. In an embodiment wherein enclosureis a hunting blind, which is but one of many, sheetcan include a camouflage pattern. In an embodiment wherein enclosureis adapted for use in an urban or other setting, sheetcan include a pattern or coloration adapted to blend enclosurein with its surroundings, such as for cosmetic purposes in a residential setting. Sheetcan be included in one or more portions of an enclosure(e.g., sides, roof, floor, etc.), in whole or in part, or it can be absent.

With reference to, a methodof making a composite material according to the disclosure, e.g., composite material, is illustrated. Methodcan include providinga first layer, e.g., first layer, which can include a carpet, e.g., carpet, with a pile, e.g., pile, and backing, e.g., carpet backing. In at least one embodiment, the carpet can be provided in a roll, such as a roll with a standard or commercially common dimension, e.g., 12 feet wide×160 feet long. Working with carpet in roll form having standard dimensions can allow for advantageous fabrication, which can include limiting the slitting or cutting necessary to form one or more portions (e.g., the front, rear, and side walls) of enclosure(shown in). In at least one embodiment, a roll of carpet can be split into two approximately six foot long strips or three approximately four foot strips according to a particular application, and each strip can be formed into a composite material according to the present disclosure. Of course, other dimensions for sections of composite material or carpet during manufacture of composite material are possible, which can include any dimension according to a particular application, which can depend at least in part on availability of materials or, as another example, the type or size of an enclosureaccording to a particular application.

Methodcan include applyinga second layer, which can include fiber, e.g., fiber, resin, e.g., resin, and catalyst, e.g., catalyst, to the carpet backing, e.g., of carpet. In at least one embodiment, carpetcan be laid pile side down, or hung pile side away, and second layercan be applied to carpetby spraying. The second layercan be rolled, e.g., with a roller, such as until thickness of the second layer reaches a desired thickness, which can be any thickness, or, for example, until a thickness of second layerreaches an at least substantially uniform thickness. The resin can be allowed to at least partially cure, as indicated with reference numeral. As will be appreciated by those of skill in the art having the benefits of the present disclosure, curing can result in removal of at least some, but not necessarily all, of a catalyst of second layer. In at least one embodiment, a cure time can be about thirty minutes, which can facilitate movement of a composite material through a composite material fabrication workstation. In at least one embodiment, a cure time, which can be a partial or complete cure time, can be less than thirty minutes or more than thirty minutes, which can depend, for example, on any number of factors, such as the particular materials being used, the environmental conditions, and other factors that can effect cure time, such as material ratios.

In at least one embodiment, applyinga second layerto a first layercan include distributing fiberonto first layerwith random orientations, which can impart anisotropic or other reinforcement to first layer. Applyingthe second layercan include sprayingthe second layeronto the carpet backing, in whole or in parts. In this respect, second layercan be applied to the first layerby sprayinga mixture of fiber, resin, and catalystdirectly onto the first layer. Methodcan include building up the second layeruntil thicknessof the second layerreaches a desired thickness for a particular application at hand, which can be any thickness, including between about 25 mils and about 30 mils in one or more applications.

Sprayingcan be accomplished using a spray applicator, e.g., a chop gun system. Use of spray applicator like chop gun systemcan simplify manufacture of composite materialas the second layercan be applied rapidly, and with relatively high first-pass thickness and uniformity, to the first layer. In at least one embodiment, spray application of second layeronto first layercan allow for reduction (or elimination) of any need to roll second layer, such as over first layer, during manufacture of composite material.

In at least one embodiment, one or more additional layers or sublayers, such as an optional decorative layer, can be applied to composite material, such as to, in or through exterior surfaceof composite material. For example, a fabric, cheesecloth or other material, such as with a decorative or other design, e.g., a camouflage pattern, can be deposited over (and/or at least partially within or through) second layer. Once positioned with the applied second layer, additional fiber, resin, and catalystcan be applied to the material and allowed to cure. In at least one embodiment, such material can be added or otherwise coupled to or within composite materialafter second layeris at least partially cured, and the addition of additional fiber, resin, and catalystcan be optional, such as depending on a particular application of composite materialor enclosure. In at least one embodiment, the additional fiber, resin, and catalyst(if present) applied onto or over the decorative layer or other material can have a thickness of between about 2 mils and about 3 mils (inclusive), which can include a thickness of between about 1 mil and about 4 mils, and which can provide suitable protection to or coupling of the decorative or other layer for a particular application. In at least one embodiment, a thickness of additional fiber, resin and catalyst can be sufficiently transparent such that an underlying material, such as a decorative layer, is at least partially viewable through the added material from the exterior of an enclosure(shown in). Alternatively, or collectively, one or more pigments, e.g., olive-drab green or another color, which can be any color or combination of colors, can be intermixed with fiber, resin, and catalystsuch that second layercan have suitable pigmentation for a contemplated environment, whether with or without a decorative layer being incorporated in second layer, separately or in combination, in whole or in part.

Once at least partially cured, composite materialcan be sizedto front wall, rear wall, roof, and first side walland second side wallof enclosure(shown in), separately or in combination, in whole or in part. Sizingcan include defining a height of the front wall, rear wall, or another portion of enclosure. Sizingcan include defining a single, continuous length of composite material, such as that of one or more walls and/or one or more of a roof or floor, such as a first side wall, roof, and second side wall, or can include defining multiple continuous or discontinuous lengths or other dimensions of composite materialor of one or more components thereof. In at least one embodiment, the upper edges of front walland rear wall(or one or more other sides) can be arcuate such that roofcan span the upper portions of front walland rear wall(or one or more other sides) with an arcuate gable profile, which can simplify assembly of enclosure.

With reference to, one of many embodiments of an enclosureis shown in an exploded view. As shown in, a single continuous pieceof composite materialcan form first side wall, roof, and second side wallof enclosure. In at least one embodiment, a single continuous piece of composite materialcan form two or more other portions of enclosure, as described elsewhere in this disclosure. Roofcan be defined with an arcuate gable, which can be disposed over or otherwise relative to an arcuate edgeof, e.g., front walland rear wall, such as for at least partially enclosing interiorwith composite material. A frame, shown schematically, or other support structure, can provide support for one or more portions of enclosure, such as front wall, rear wall, and continuous piece(and/or other components or portions), and can support each relative to floorand/or floor(if present). Couplerscan be received within or otherwise coupled to composite materialfor coupling continuous pieceor another portion of composite materialor enclosureto frame. In at least one embodiment, composite materialcan be readily cut or otherwise manipulated in the field, which can allow, for example, apertures to be cut to seat additional window units or other customization or modification of enclosureto suit an intended application.

In at least one embodiment, at locations, such as seams, e.g., where front and rear walls meet the side walls and roof, e.g., seam, a strip, e.g., of mesh fiber or other coupling material, such as a strip of approximately three inches in width (or more, or less), which can be impregnated with resin (and design material or pigment, if present), can be fitted over or otherwise coupled to the seams or joints, such as for additional sealing of the seams, which can improve separation (or isolation) of interiorof enclosurefrom an environment external to enclosure, rain water, snow, etc. In at least one embodiment, the composite materials of the present disclosure can be used for one or more other aspects of an enclosure, including, but not limited to, stripor, as another example, one or more shelvesor other structures disposed on the interior or exterior of an enclosure.

In at least one embodiment, some of the benefits and characteristics of a composite material according to the disclosure when utilized as the walls or other portions of an outdoor enclosure can include the following: (i) the exterior of the enclosure can be at least partially water-resistant or waterproof; (ii) the interior of the enclosure can be at least partially carpeted, such as on walls, floor and ceiling, which can be favorable for acoustics and aesthetics; (iii) the exterior of the enclosure can be resistant to abrasion, deformation, and degradation; (iv) the exterior or composite material structures of the enclosure can functionally accept fasteners and other couplers, such as screws and rivets; and (v) in the event of a cut, tear or puncture of the exterior surface, the cut, tear or puncture can be easily and efficiently remedied, which can include utilizing a method for covering the seams of an enclosure described herein.

Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the spirit of Applicant's invention. Further, the various methods and embodiments of the invention can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice-versa.

The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.

The inventions have been described in the context of preferred and other embodiments and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments are available to those of ordinary skill in the art having the benefits of the present disclosure. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicant, but rather, in conformity with the patent laws, Applicant intends to fully protect all such modifications and improvements that come within the scope or range of equivalents of the following claims.