US2011314762A1PendingUtilityA1

Impact resistant door and method of manufacturing

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Individually held — no corporate assignee on recordPriority: Jun 28, 2010Filed: Jun 28, 2010Published: Dec 29, 2011
Est. expiryJun 28, 2030(~3.9 yrs left)· nominal 20-yr term from priority
Inventors:Scott WidmerWilliam Mullet
E06B 2003/7023E06B 3/825E06B 2003/7049E06B 3/7015
40
PatentIndex Score
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Cited by
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References
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Claims

Abstract

A door comprising a frame having a hinge stile, a lock stile, a top rail, and a bottom rail defining an internal cavity, an interlayer secured within the internal cavity, a front skin further defining the internal cavity, and a rear skin opposite the front skin and further defining the internal cavity. A method of manufacturing a door including the steps of securing a hinge stile, a strike stile, a top rail, a bottom rail, and a first skin defining a frame and an internal cavity within the frame, inserting an interlayer within the internal cavity, securing the interlayer within the internal cavity to an inner surface of the frame with a plurality of fasteners, and securing a second skin opposite the first skin and further defining the internal cavity.

Claims

exact text as granted — not AI-modified
1 . A door comprising:
 a frame having a hinge stile, a lock stile, a top rail, and a bottom rail defining an internal cavity;   an interlayer secured within the internal cavity;   a front skin further defining the internal cavity; and,   a rear skin opposite the front skin and further defining the internal cavity.   
     
     
         2 . The door of  claim 1  wherein the interlayer is a woven swath of cloth. 
     
     
         3 . The door of  claim 1  wherein the interlayer is one of a carbon fiber cloth, a Kevlar cloth, and a fiberglass cloth. 
     
     
         4 . The door of  claim 1  wherein the interlayer is secured within the internal cavity with a plurality of fasteners. 
     
     
         5 . The door of  claim 4  wherein the fasteners are staples. 
     
     
         6 . The door of  claim 4  wherein the fasteners are spaced approximately two inches apart. 
     
     
         7 . The door of  claim 4  wherein a perimeter of the interlayer is folded approximately parallel to an inner surface of the frame and the fasteners secure the perimeter to the inner surface of the frame. 
     
     
         8 . The door of  claim 1  wherein the interlayer is secured at an equal distance between the front skin and the rear skin. 
     
     
         9 . The door of  claim 1  wherein the interlayer is of sufficient strength to prevent penetration of a nine pound two inch by four inch piece of lumber impacting the door at 34 miles-per-hour. 
     
     
         10 . The door of  claim 1  wherein the interlayer is secured proximate an inner surface of the front skin. 
     
     
         11 . The door of  claim 1  wherein the interlayer is secured proximate an inner surface of the rear skin. 
     
     
         12 . The door of  claim 1  further comprising a foam within the internal cavity and on at least one side of the interlayer. 
     
     
         13 . The door of  claim 12  wherein the bottom rail further comprises a through hole and a plug, wherein the plug is removed to permit installation of the foam via the through hole, and the plug seals the internal cavity after installation of the foam. 
     
     
         14 . A method of manufacturing a door comprising the steps of:
 assembling a hinge stile, a strike stile, a top rail, a bottom rail, and a first skin defining a frame and an internal cavity within the frame;   inserting an interlayer within the internal cavity;   securing the interlayer within the internal cavity to an inner surface of the frame with a plurality of fasteners; and,   securing a second skin opposite the first skin and further defining the internal cavity.   
     
     
         15 . The method of  claim 14  further comprising the step of inserting a foam within the internal cavity. 
     
     
         16 . The method of  claim 15  further comprising the step of inserting a plug within a through hole. 
     
     
         17 . The method of  claim 14  further comprising the step of trimming a perimeter of the interlayer. 
     
     
         18 . The method of  claim 14  further comprising the step of locating an adhesive on an inner surface of the first skin and the second skin. 
     
     
         19 . The method of  claim 14  wherein the step of securing the interlayer includes the step of mounting the interlayer at an equal distance between the first skin and the second skin.

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