US 9,850,701 B1Granted

Door with impact resistant light

AssigneeSchlage Lock Company LLC

InventorsDavid L. Arway, Karen Bishop, David J. Wells, Lance W. Graff

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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.

Claims23

Dependent claims

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, the pane comprising a plurality of layers adhered to one another, wherein the plurality of layers comprises an impact side outer layer adhered to the inner frame of the impact side trim, a secure side outer layer adhered to the door body, and at least one intermediate layer located between the first outer layer and the second outer layer;
and
a plurality of fasteners coupling the impact side trim and the secure side trim to the door body.

10 more elements

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 opening 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, the pane comprising a plurality of layers adhered to one another, 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, 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;
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 first outer layer of the pane to the door body with a first adhesive device;
and
adhering the second outer layer of 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.

9 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/342,688Filed 3 Nov 2016
Granted: 26 Dec 2017
Term ends: Not estimatedThe source records don’t support an estimate.

Classification4 codes

E06B 3/827
Flush doors, i.e. with completely flat surface: of metal without an internal frame, e.g. with exterior panels substantially of metal
E06B 3/5892
By means of borders, cleats, or the like: fixing of window panes in openings in door leaves
E06B 5/10
Doors, windows, or like closures for special purposes ; Border constructions therefor: for protection against air-raid or other war-like action;…
E06B
Fixed or movable closures for openings in buildings, vehicles, fences or like