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

Abstract

A flexible, water-resistant composite material that can be used for the construction of outdoor enclosures. A material can include a combination of fiber, resin and catalyst upon a backing of a textile such as carpet, hook and loop material, or felt. After cure, the material can be cut to suit for assembly. The material can allow for a single piece to serve as two side walls and the roof or floor of an enclosure. The textile side of the material can be utilized for the interior of an enclosure and the composite side can be used for the exterior of the enclosure. An optional decorative or functional layer can be added to the material.

What is claimed is: 
     
         1 . An enclosure, comprising:
 four walls comprising a front wall, a rear wall opposite the front wall, and first and second side walls extending from the front wall to the rear wall; and   a roof covering an interior area of the enclosure circumscribed by the four walls;   wherein one or more of the four walls is formed from a composite material, the composite material comprising:   a first layer comprising carpet having a pile and a backing; and   a second layer comprising fiber, resin and catalyst;   wherein the second layer is coupled to the carpet backing;   wherein the second layer of the composite material is fiberglass and comprises a fabric sheet at least partially embedded therein;   wherein the second layer has an at least substantially uniform thickness of from about 25 mils to about 30 mils;   wherein at least two of the four walls and the roof are formed from a single, continuous sheet of the composite material; and   wherein the single sheet of composite material is coupled to a frame disposed at least partially within an interior of the enclosure so that the carpet pile faces the interior of the enclosure and the second layer of the composite material faces outwardly; and   wherein the single sheet of composite material comprises at least one opening there through that is bounded on at least one side by an integral flap of the composite material.   
     
     
         2 . The enclosure of  claim 1 , further comprising wherein the at least two walls formed from a single sheet of the composite material are disposed opposite one another. 
     
     
         3 . The enclosure of  claim 1 , further comprising wherein the roof comprises a gable with an arcuate profile on two sides of the enclosure. 
     
     
         4 . The enclosure of  claim 1 , further comprising:
 wherein at least one wall formed from the composite material includes an opening there through;   wherein the opening is bounded by a flap of composite material on at least one side;   a window unit coupled to the at least one wall, wherein the window unit is disposed at least partially within the opening; and   wherein the flap of composite material overlaps at least a portion of the window unit.   
     
     
         5 . The enclosure of  claim 1 , wherein the single sheet of composite material comprises at least one opening there through that is bounded on at least one side by a flap of the composite material. 
     
     
         6 . The enclosure of  claim 1 , further comprising wherein the second layer of the composite material comprises randomly dispersed fibers of random lengths. 
     
     
         7 . The enclosure of  claim 1 , further comprising wherein the second layer of the composite material is at least substantially waterproof. 
     
     
         8 . The enclosure of  claim 1 , further comprising wherein the resin is directly coupled to the carpet backing. 
     
     
         9 . The enclosure of  claim 1 , further comprising wherein the composite material is flexible enough that substantially no plastic deformation occurs when two ends of a piece of the composite material having a length of approximately eighteen inches and a thickness of approximately thirty mils are touched together. 
     
     
         10 . An enclosure, comprising:
 four walls comprising a front wall, a rear wall opposite the front wall, and first and second side walls extending from the front wall to the rear wall; and   a roof covering an interior area of the enclosure circumscribed by the four walls;   wherein one or more of the four walls is formed from a composite material, the composite material comprising:   a first layer comprising carpet having a pile and a backing; and   a second layer comprising fiber, resin and catalyst;   wherein the second layer is coupled to the carpet backing;   wherein the second layer of the composite material is fiberglass and comprises a fabric sheet at least partially embedded therein;   wherein the second layer has an at least substantially uniform thickness of from about 25 mils to about 30 mils;   wherein at least two of the four walls and the roof are formed from a single, continuous sheet of the composite material;   wherein the single sheet of composite material is coupled to a frame disposed at least partially within an interior of the enclosure so that the carpet pile faces the interior of the enclosure and the second layer of the composite material faces outwardly; and   wherein the single sheet of composite material comprises at least one opening there through that is bounded on at least one side by a flap of the composite material.   
     
     
         11 . The enclosure of  claim 10 , further comprising wherein the at least two walls formed from a single sheet of the composite material are disposed opposite one another. 
     
     
         12 . The enclosure of  claim 10 , further comprising wherein the roof comprises a gable with an arcuate profile on two sides of the enclosure. 
     
     
         13 . The enclosure of  claim 10 , further comprising:
 wherein at least one wall formed from the composite material includes an opening there through;   wherein the opening is bounded by a flap of composite material on at least one side;   a window unit coupled to the at least one wall, wherein the window unit is disposed at least partially within the opening; and   wherein the flap of composite material overlaps at least a portion of the window unit.   
     
     
         14 . The enclosure of  claim 10 , further comprising wherein the second layer of the composite material comprises randomly dispersed fibers of random lengths. 
     
     
         15 . The enclosure of  claim 10 , further comprising wherein the second layer of the composite material is at least substantially waterproof. 
     
     
         16 . The enclosure of  claim 10 , further comprising wherein the resin is directly coupled to the carpet backing. 
     
     
         17 . The enclosure of  claim 10 , further comprising wherein the composite material is flexible enough that substantially no plastic deformation occurs when two ends of a piece of the composite material having a length of approximately eighteen inches and a thickness of approximately thirty mils are touched together. 
     
     
       18. A method of making an enclosure having a front wall, a rear wall opposite the front wall, first and second side walls extending from the front wall to the rear wall, and a roof, the method comprising:
 coupling a composite material to a frame such that a carpet pile of the composite material is facing inwardly and a fiber-reinforced resin layer of the composite material is facing outwardly of the enclosure;   forming at least two of the four walls from a single, continuous sheet of the composite material;   forming an opening through at least one wall of the composite material;   forming a flap of the composite material that is integral with the single, continuous sheet of the composite material; and   bounding the opening with the flap of the composite material on at least one side;   wherein the fiber-reinforced resin layer of the composite material is fiberglass and comprises a fabric sheet at least partially embedded therein; and wherein the fiber-reinforced resin layer has an at least substantially uniform thickness of from about 25 mils to about 30 mils.   
     
     
       19. The method of  claim 18 , further comprising coupling a window unit to the at least one wall at least partially within the opening, such that the flap of composite material overlaps at least a portion of the window unit. 
     
     
       20. The enclosure of  claim 10 , wherein the flap is integral with the single sheet of composite material.