Flexible Composite Enclosure Material With Waterproof Acoustic Layering

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Solution Overview

Problem

Conventional outdoor enclosures, such as hunting blinds, lack improved composite materials that provide effective waterproofing, flexibility, and durability to withstand outdoor elements while maintaining acoustic insulation and aesthetics.

Innovation Solution

A composite material comprising a carpet layer with a pile and backing, bonded with a fiber-reinforced resin layer that includes randomly dispersed fibers, offering a thickness of 25-30 mils for enhanced waterproofing and flexibility, allowing the material to be self-supporting and adaptable for forming seamless enclosures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional sheet metal or foam core materials are used for blind structures, then waterproofing and structural strength are provided, but flexibility and resistance to deformation are reduced

Engineering Contradiction:

Improvestructural strengthVSAvoidflexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent applies composite materials by combining a carpet layer (providing flexibility and acoustic insulation) with a fiber-reinforced resin layer (providing waterproofing and structural strength). This composite structure resolves the contradiction by integrating materials with complementary properties, allowing the enclosure to be both strong and flexible without deformation.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional composite materials are used, then waterproofing is achieved, but acoustic insulation and aesthetics are compromised

Engineering Contradiction:

ImprovewaterproofingVSAvoidacoustic insulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The carpet layer in the composite material provides acoustic insulation by absorbing sound waves, while the fiber-reinforced resin layer ensures waterproofing. This multi-layer composite approach allows both functions to coexist without compromising either acoustic insulation or waterproofing performance.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If multiple separate components are used for enclosure walls, then manufacturing precision is improved, but device complexity and assembly difficulty increase

Engineering Contradiction:

Improveassembly precisionVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple functions (waterproofing, acoustic insulation, structural support, and aesthetics) into a single integrated composite material panel. This eliminates the need for multiple separate components and complex assembly procedures, reducing device complexity while maintaining manufacturing precision through the unified composite structure.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If thick material layers are used for durability, then resistance to outdoor elements is improved, but flexibility and ease of assembly are reduced

Engineering Contradiction:

ImprovedurabilityVSAvoidease of assembly

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The composite material achieves durability through the fiber-reinforced resin layer which provides resistance to outdoor elements, while the carpet layer maintains flexibility. The optimized thickness and composition of the composite allow the material to be both durable and easy to assemble without requiring excessive thickness.

Inventive Principle:

Principle #40Composite materials

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 material effectively withstands outdoor elements, provides acoustic insulation, and maintains structural integrity, making it suitable for outdoor enclosures by being waterproof, flexible, and resistant to deformation, while simplifying manufacturing and assembly processes.

Implementation Method 1

The second layer can include fiber, resin, and catalyst, and can be bonded or otherwise coupled to the first layer

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Implementation Method 2

The second layer can include a fiber-reinforced resin. The fiber-reinforced resin can include randomly dispersed fibers of random lengths

Methodology Applied

Scientific EffectPolymer matrix binding:

Data Source

PatentUS9909313B1Composite materials, methods of making composite materials, and enclosures constructed from composite materials

Publication Date: 2018.03.06 GRUBBS AUSTIN M

AI summary

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.