Door with impact resistant light

Patent metadata

Field	Value
Publication number	US-10125539-B2
Application number	US-201715854412-A
Country	US
Kind code	B2
Filing date	Dec 26, 2017
Priority date	Nov 3, 2016
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

An exemplary door includes a door body and a light assembly. The door body includes a first door panel defining a first panel opening, a second door panel defining a second panel opening, and an internal cavity. The area of the first panel is greater than the area of the second panel opening. The light assembly includes a first trim, a second trim, and an impact-resistant pane positioned in the door cavity. The first trim includes an outer frame coupled to the first door panel and an inner frame positioned in the internal cavity. The pane has an area greater than the area of the second panel opening area, and includes an first outer layer adhered to the inner frame of the first trim, a second outer layer adhered to the door body, and at least one intermediate layer.

First claim

What is claimed is:

1. A door, comprising:
a door body defining an impact side, a secure side, a plurality of edges, and an internal cavity, the door body having a longitudinal height, a lateral width, and a transverse thickness, the door body comprising:
an impact side door panel defining the impact side of the door body, the impact side door panel defining an impact side panel opening having an impact side panel opening area;
a secure side door panel defining the secure side of the door body, the secure side door panel defining a secure side panel opening having a secure side panel opening area less than the impact side panel opening area;
wherein the impact side door panel is transversely offset from the secure side door panel and the internal cavity is formed therebetween; and
wherein the impact side panel opening is aligned with the secure side panel opening; and

a light assembly mounted to the door body, the light assembly comprising:
an impact side trim mounted to the impact side door panel, the impact side trim including an outer frame coupled to the impact side door panel, an intermediate frame extending transversely through the impact side panel opening, and an inner frame positioned in the internal cavity, wherein the inner frame defines an impact side trim opening aligned with the secure side panel opening;
a secure side trim mounted to the secure side door panel, the secure side trim including a secure side trim opening aligned with the secure side panel opening;
an impact-resistant pane positioned in the door cavity, the pane having a pane area greater than the secure side panel opening area; and
a plurality of fasteners coupling the impact side trim and the secure side trim to the door body.

2. The door of claim 1 , wherein the pane comprising a plurality of layers.

3. The door of claim 2 , wherein the plurality of layers comprises at least three layers adhered to one another.

4. The door of claim 2 , wherein the plurality of layers comprises at least an impact side outer layer adhered to the inner frame of the impact side trim, and a secure side outer layer adhered to the door body.

5. The door of claim 4 , further comprising at least one additional layer located between the impact side outer layer and the secure side outer layer.

6. The door of claim 5 , wherein each of the impact side outer layer and the secure side outer layer comprises a glass layer, and wherein the at least one additional layer comprises a polycarbonate layer.

7. The door of claim 4 , wherein the impact side outer layer is adhered to the inner frame of the impact side trim by a first adhesive device, and the secure side outer layer is adhered to the door body by a second adhesive device different from the first adhesive device.

8. The door of claim 7 , wherein the first adhesive device comprises at least one strip of a double-sided adhesive tape, and wherein the second adhesive device comprises at least one bead of a glazing material.

9. The door of claim 8 , wherein the double-sided adhesive tape comprises a foam having a first adhesive side and a second adhesive side.

10. The door of claim 8 , further comprising at least one second strip of the double-sided adhesive tape adhering the impact side trim to the impact side panel, and at least one third strip of the double-sided adhesive tape adhering the secure side trim to the secure side panel.

11. The door of claim 1 , further comprising at least one bead of the glazing material forming a seal between an inner edge of the impact side trim opening and the pane.

12. The door of claim 8 , wherein the secure side outer layer further comprises an anti-spall film formed on the glass layer of the secure side outer layer, and wherein the at least one bead of glazing material is adhered to the anti-spall film.

13. The door of claim 1 , wherein the door body further comprises a bracket assembly including a plurality of brackets;
wherein each bracket comprises a base portion, a first flange extending from the base portion by a first distance, and a second flange extending from the base portion by a second distance greater than the first distance;
wherein the first flanges are coupled to the impact side door panel and at least partially surround the impact side panel opening; and
wherein the second flanges are coupled to the secure side door panel and at least partially surround the secure side panel opening.

14. The door of claim 13 , wherein the secure side outer layer is adhered to the second flanges.

15. The door of claim 13 , wherein the bracket assembly further comprises a plurality of slots, wherein each of the slots is formed in one of the base portions, and wherein a corresponding one of the fasteners extends through each of the slots.

16. The door of claim 1 , wherein the pane area is less than the impact side panel opening area.

17. A method, comprising:
preparing a door body including a first door panel, a second door panel, and an internal cavity formed between the first door panel and the second door panel, wherein the first door panel includes a first panel opening having a first panel opening area, wherein the second panel includes a second panel having a second panel opening area greater than the first panel opening area, and wherein the second panel opening is aligned with the first panel opening;
preparing a light assembly, wherein preparing the light assembly includes:
preparing a first trim including a first trim opening having a first trim opening area corresponding to the first panel opening area;
preparing a second trim including a second trim opening area corresponding to the first trim opening area, wherein the second trim includes an outer frame, an inner frame defining the second trim opening, and an intermediate frame sized and configured to be received in the second panel opening;
preparing an impact-resistant pane having a pane area greater than the first panel opening area;

mounting the light assembly to the door body, wherein mounting the light assembly to the door body comprises:
inserting the pane into the door cavity through the second panel opening;
adhering the pane to the door body with a first adhesive device; and
adhering the pane to the inner frame of the second trim with a second adhesive device; and

securing the mounted light assembly to the door body, wherein securing the light assembly to the door body comprises securing the first trim and the second trim to the door body with a plurality of fasteners.

18. The method of claim 17 , wherein the pane comprising a plurality of layers.

19. The method of claim 18 , wherein the plurality of layers comprises a first outer layer, a second outer layer, and at least one intermediate layer located between the first outer layer and the second outer layer.

20. The method of claim 19 , wherein each of the first outer layer and the second outer layer comprises a glass layer, and wherein each of the at least one intermediate layers comprises a polycarbonate layer.

Assignees

• Schlage Lock Co Llc

Inventors

• Arway David L
• Bishop Karen
• Wells David J
• Graff Lance W

Classifications

• E06B3/827 Primary

  of metal without an internal frame, e.g. with exterior panels substantially of metal · CPC title

• E06B3/5892

  Fixing of window panes in openings in door leaves · CPC title

• E06B5/10

  for protection against air-raid or other war-like action; for other protective purposes · CPC title