DOOR LOCK AND BALLISTIC DOOR SAFETY SYSTEM INCLUDING SAME

A door lock includes a base and a lock bar moveably coupled to the base. The base includes an angled top wall and a bottom wall, and has at least one channel defined therein. The lock bar includes at least one rod having a first end coupled to the lock bar and a second end that extends into the at least one channel. The lock bar further includes a top wall and an angled bottom wall that is oriented at substantially the same angle as the base top wall such that the base top wall and lock bar bottom wall are substantially parallel to one another. The lock bar is moveable relative to the base from a first position to a second, engaged position, in which the second end of the at least one rod protrudes from the base bottom wall.

BACKGROUND

The field of the disclosure relates generally to door locks, and more specifically, to foot-activated door locks and ballistic door safety systems including the same.

There are many situations in which it is desirable to securely lock a door, such as for safety reasons. Many doors include locks on or adjacent to their handles. However, in at least some cases, these locks can be broken (e.g., with an application of force on the handle) or otherwise bypassed, allowing the door to be opened about its hinges. Additionally, at least some known supplementary door locks are prone to failure and/or require multiple pieces or steps to activate the door lock.

BRIEF DESCRIPTION

A door lock includes a base configured to be coupled to a door and a lock bar moveably coupled to the base. The base includes an angled top wall and a bottom wall, and has at least one channel defined therein extending from the top wall to the bottom wall. The lock bar includes at least one rod having a first end coupled to the lock bar and a second end that extends into the at least one channel. The lock bar further includes a top wall and an angled bottom wall. The lock bar bottom wall is oriented at substantially the same angle as the base top wall such that the base top wall and lock bar bottom wall are substantially parallel to one another. The lock bar is moveable relative to the base from a first, disengaged position, in which the lock bar is spaced from the base, to a second, engaged position, in which the lock bar bottom wall engages the base top wall, and the second end of the at least one rod protrudes from the base bottom wall.

A ballistic door safety system includes a ballistic panel assembly and a door lock. The ballistic panel assembly includes a plurality of ballistic layers, and is configured to be coupled to a first surface of a door. The door lock includes a base configured to be coupled to the ballistic panel assembly and a lock bar moveably coupled to the base. The base includes an angled top wall and a bottom wall, and has at least one channel defined therein extending from the top wall to the bottom wall. The lock bar includes at least one rod having a first end coupled to the lock bar and a second end that extends into the at least one channel. The lock bar further includes a top wall and an angled bottom wall. The lock bar bottom wall is oriented at substantially the same angle as the base top wall such that the base top wall and lock bar bottom wall are substantially parallel to one another. The lock bar is moveable relative to the base from a first, disengaged position, in which the lock bar is spaced from the base, to a second, engaged position, in which the lock bar bottom wall engages the base top wall, and the second end of the at least one rod protrudes from the base bottom wall.

DETAILED DESCRIPTION

FIG. 1is a perspective view of an exemplary door lock102shown in a disengaged or unlocked position.FIG. 2is a perspective view of the door lock102shown in an engaged or locked position. As described in further detail herein, the door lock102is configured to be coupled to a door and, when activated, securely lock the door in place to prevent the door from being opened.

In the exemplary embodiment, the door lock102includes a mounting plate104for mounting the door lock102to a door (e.g., door242shown inFIG. 4B), a base108coupled to the mounting plate104, a lock bar128moveably coupled to the base108, and a floor plate168. The door lock102further includes at least one rod152fixed to the lock bar128and extending into the base108. As shown inFIGS. 1 and 2, when the door lock102is activated or moved from the disengaged position to the engaged position, the lock bar128and the at least one rod152move downward with respect to base108such that the at least one rod152protrudes from the bottom of the base108and extends through the floor plate168and into the floor172, thereby preventing the door to which the door lock102is mounted from being opened.

The mounting plate104is used to secure the base108to a door. Specifically, the mounting plate104has a plurality of fastener openings105defined therein for receiving a plurality of fasteners and securing the mounting plate104, and thereby the base108and remainder of door lock102, to a door. In the illustrated embodiment, the mounting plate104also includes two stop pins106for limiting or stopping upward movement of the lock bar128.

With additional reference toFIG. 3, the base108includes an angled top wall112, a bottom wall114, a front wall116, a back wall118, a first side wall120, and a second side wall122. The front wall116and the back wall118are substantially parallel to one another, and the first side wall120and the second side wall122are substantially parallel to one another. The top wall112extends from the back wall118to the front wall116at a first oblique angle α1relative to the front wall116. In the exemplary embodiment, two channels124are defined through the base108extending from the top wall112to the bottom wall114. One channel124is generally adjacent the first side wall120, and the other channel124is generally adjacent the second side wall122. In other embodiments, the base108may have more than or less than two channels defined therethrough. In some embodiments, for example, the base108has only one channel124defined therethrough. In other embodiments, the base108has more than two channels124defined therethrough. The base108also defines two pockets126, each extending inward from a respective side wall120,122, and to a respective one of the channels124.

The lock bar128includes a top wall130, an angled bottom wall132, a front wall134, a back wall136, a first side wall138, and a second side wall140. The front wall134and the back wall136are substantially parallel to one another, and the first side wall138and the second side wall140are substantially parallel to one another. The bottom wall132extends from the back wall136to the front wall134of the lock bar128at a second oblique angle α2relative to the back wall136. In the exemplary embodiment, the second angle α2of the lock bar128is the same as the first angle α1of the base108, such that the lock bar bottom wall132is parallel to the base top wall112and, when the lock bar128is engaged with the base108(as described further herein), the lock bar bottom wall132sits flush against the base top wall112. Additionally, in the exemplary embodiment, a foot plate extension142is coupled to the lock bar128. The foot plate extension142includes a top wall144, a front wall146, and a back wall148. In the exemplary embodiment, the back wall148of the foot plate extension142is coupled to the front wall134of the lock bar128with fasteners150. In other embodiments, the foot plate extension142is coupled to the top wall144of the lock bar128. In yet other embodiments, the foot plate extension142may be formed integrally with the lock bar128.

In the exemplary embodiment, the door lock102includes two rods152, each including a respective first end154and a respective second end156. Each of the first ends154includes a fastener opening158for receiving one of fasteners150therein. The first ends154of the rods152are coupled to the lock bar with the fasteners150. Specifically, the fasteners150extend through the front wall146of the foot plate extension142, through the front wall134of the lock bar128, and through the fastener openings158of the rods152to couple the foot plate extension142and the rods152to the lock bar128. In the exemplary embodiment, rods152are generally cylindrical in shape and are shaped complementary to the cylindrical channels124. Further, in the exemplary embodiment, the second ends156of the rods152are generally conical in shape and are configured to extend or pass through the channels124of the base108. In other embodiments, rods152and channels124may have any suitable complementary size and shape that enables door lock102to function as described herein.

The door lock102further includes two pins160, each extending through a respective one of the pockets126of the base108. Each of the pins160includes a first end162and a second end166. Each first end162is defined by a ball detent164. When the pins160are inserted into the pockets126of the base108, the ball detents164are engaged with the second ends156of the respective rods152, and the second ends166of the pins160are substantially flush with one of the respective side walls138,140of the base108.

The floor plate168is configured to be coupled to a surface170of a floor or ground172. The floor plate168has rod apertures174and fastener openings176defined therein. The rod apertures174are sized and shaped complementary to the rods152such that the rods152can extend through the rod apertures174, through the surface170, and into the ground172, as described in more detail below. The fastener openings176are configured to receive screws or other fasteners (not shown) that extend into the ground172to couple the floor plate168to the surface170.

In the exemplary embodiment, the door lock102further includes a conveyor mechanism178that enables the lock bar128to be moved relative to the base108, and to transition the door lock102from the engaged position (shown inFIG. 2) to the disengaged position (shown inFIG. 1). The conveyor mechanism178includes a toothed rack184having slots185defined therein, and a gear or pinion188that includes teeth189. A conveyor shaft channel180is defined in the base108and extends from the front wall116to the back wall118of the base108. A cavity182(shown inFIG. 4B) is defined in the back wall118of the base108and is configured to at least partially receive the gear188. A conveyor channel186is defined through the base108from the top wall112to the bottom wall114and is generally parallel to the channels124. The toothed rack184is coupled to the lock bar128via fastener187, and extends through the conveyor channel186of the base108. A conveyor shaft190extends through the conveyor shaft channel180and defines an axis of rotation for the gear188. A plate110encloses the toothed rack184and the conveyor shaft190within the base cavity182. The gear188is coupled to and co-axial with the conveyor shaft190and is rotatable with respect to the toothed rack184. The teeth189of the gear188are configured to mesh with the slots185of the toothed rack184and, upon rotation of the gear188, cause linear movement of the toothed rack184. The conveyor shaft190includes a knob192that abuts the front wall116of the base108.

In the exemplary embodiment, the door lock102further includes an unlock mechanism196that includes a key shaft198, a first end200, a second end202, and a removable key204. The key shaft198extends from the first end200to the second end202. The first end200of the key shaft198is positioned within an interior of the conveyor shaft190, intermediate the base front wall116and back wall118, and the second end202of the key shaft198is positioned on an opposite side of the mounting plate104and is configured to accept the key204. When the door lock102is mounted to the door242(seeFIG. 4B), the second end202of the key shaft198extends through the door242. The first end200is positioned on inner or interior side of the door242, and the second end202is outside of the door242(i.e., adjacent to the exterior surface244of the door242). The key shaft198is coupled to and co-axial with the conveyor shaft190. The key204is configured to operate the key shaft198such that rotation of the key204in the direction of arrow A causes rotation of key shaft198and corresponding rotation of the conveyor shaft190and the gear188, and corresponding movement of the toothed rack184.

In the disengaged position (shown inFIG. 1), the door lock102is configured such that the lock bar128is positioned above and separated or spaced from the base108by an open area or spacing222defined between the base108and the lock bar128. The rods152and the toothed rack184are visible or accessible within the spacing222. The orientation or angle of base top wall112and lock bar bottom wall132inhibits debris or other foreign objects from settling within the spacing222, which might otherwise prevent proper operation of the door lock102.

Further, in the disengaged position (shown inFIG. 1), the ball detent164of each pin160(shown inFIG. 3) engages the second end156of a respective rod152(shown inFIG. 3). The ball detents164keep the door lock102in the disengaged position by keeping the rods152in an elevated position. That is, each ball detent164is in contact with the second end156of a respective one of the rods152, and keeps the rods152from moving downward in a direction D.

To transition the door lock102from the disengaged position (shown inFIG. 1) to the engaged position (shown inFIG. 2), a force is exerted on the lock bar128and/or the foot plate extension142in a downward direction (i.e., in the direction D). The ball detents164of the pins160retract and allow the rods152to move in the direction D, thereby allowing the lock bar128to move downward in the direction D. As the lock bar128moves towards the engaged position, the second ends156of the rods152extend out of the base bottom wall114, and slide past the surface170and into the ground172through rod apertures174(shown inFIG. 3) of the floor plate168. The angled top wall112of the base108and the angled bottom wall132of the lock bar128engage one another in a flush fit. Notably, because the direction D is the same direction as the force of gravity, the door lock102is biased toward the engaged position by the weight of the lock bar128, rods152, and associated components. That is, in the absence or failure of the pins160, the door lock102would remain in the engaged or locked position.

FIG. 4Ais a front view of the door lock102ofFIG. 1, shown in the disengaged position.FIG. 4Bis a sectional view of the door lock102, taken along line A-A ofFIG. 4A, showing the door lock102coupled to a door242. The door242includes an exterior surface244and an interior surface246with respect to a room248, and the door lock102is coupled to the interior surface246of the door242. As shown inFIG. 4B, the conveyor mechanism178and the unlock mechanism196are coupled to one another via the conveyor shaft190and the key shaft198. Specifically, when the door lock102is mounted to the door242, the key shaft198extends from the door exterior244, through the door242, and is coupled to the conveyor shaft190of the conveyor mechanism178at the key shaft first end200.

FIG. 5is another sectional view of the door lock102taken along line A-A inFIG. 4A, showing activation of the door lock102by a user's foot250. Specifically, to transition the door lock102from the disengaged position to the engaged position, the foot250exerts an external downward force in the direction D on the door lock102. The foot250pushes downward on the top wall130of the lock bar128and the top wall144of the foot plate extension142. The top walls130and144of the lock bar128and the foot plate extension142, respectively, are substantially coplanar such that the foot250has a generally flat engagement or strike surface252to engage. That is, the foot plate extension142serves as an extension of the top wall130of the lock bar128. The foot250pushes down on the strike surface252, and the lock bar128translates downward in the direction D until the door lock102is in the engaged position (shown inFIG. 6B). As described above, in operation, as the foot250pushes down on the strike surface252, the rods152(shown inFIGS. 1 and 3) slide downward in the direction D causing the ball detents164of the pins160(shown inFIG. 1) to retract, allowing downward movement of the rods152. The rods152slide downward in the direction D through the respective channels124, through the bottom wall114of the base108, and through the rod apertures174of the floor plate168. Simultaneously, the toothed rack184of the conveyor mechanism178(shown inFIG. 1) translates downward, causing rotational movement of the gear188in the direction A.

FIG. 6Ais a front view of the door lock102, shown in the engaged position after the foot250pushes down on the strike surface252.FIG. 6Bis a sectional view of the door lock102, taken along line A-A ofFIG. 6A, showing the door lock102coupled to the door242. In the engaged position, the second ends156of the rods152protrude from the base bottom wall114, and extend into the ground172through the rod apertures174of the floor plate168. In the engaged position with the rods152secured in the ground172, the door lock102prevents the door242from being opened in an inward direction E or an outward direction F, depending on which direction the door242is configured to be opened. A force in either of the directions E or F on the exterior244of the door242would be counteracted by the rods152being coupled to the ground172, and the door242would not move.

Once the door lock102is in the engaged position, the door lock102must be transitioned back to the disengaged position in order to open the door242. From the interior surface246, the door lock102can be transitioned to the disengaged position by exerting an upward force in the direction G (i.e., opposite to the direction D) on the foot plate extension142and/or the lock bar128. Moving the foot plate extension142and/or the lock bar128in the direction G causes the toothed rack184(shown inFIG. 5) to move in the upward direction G, causing rotational movement of the gear188in a direction B. Further, moving the foot plate extension142in the direction G causes the rods152to translate upward. The rods152move through the rod apertures174of the floor plate168and through the bottom wall114of the base108until the conical second ends156of the rods152are engaged with the ball detents164of the pins160. With the second ends156of the rods152positioned within the base channels124, the door lock102is not coupled to the ground172and does not inhibit movement of the door242.

From the exterior surface244(i.e., outside the door242), the door lock102can be moved to the disengaged position only through use of the unlock mechanism196. The key204is inserted into the key shaft198and rotation of the key204in the direction B causes the key shaft198to rotate in the direction B, causing the gear188to rotate in the direction B, causing the toothed rack184to move upward in the direction G. Upward movement of the toothed rack184causes the lock bar128to move upward, causing the rods152to move upward out of the floor172and retract into the base channels124. In the exemplary embodiment, the key shaft198is configured to only accept a specific type of key that only certain entities (e.g., first responders) have access to. This configuration of the unlock mechanism196ensures that the door242is only opened from the exterior244by, for example, rescue workers.

Components of the door lock102, such as the mounting plate104, the base108, the lock bar128, the floor plate168, and the rod152, are constructed of structurally rigid materials and, in some embodiments, may provide protection from ballistic objects or projectiles. Suitable materials from which components of the door lock102, such as the mounting plate104, the base108, the lock bar128, the floor plate168, and the rod152, can be constructed include, for example and without limitation, steel (e.g., stainless steel), wood, and plastics. In some embodiments, the base108and the lock bar128are constructed of the same material. In other embodiments, the base108and the lock bar128are constructed of different materials.

FIG. 7is an exploded view of a ballistic door panel assembly302including a plurality of ballistic layers. The ballistic door panel assembly302is configured to be retrofitted to an existing door (e.g., door242, shown inFIG. 4B) to provide protection for occupants of a room from ballistic objects or projectiles. In the exemplary embodiment, the ballistic door panel assembly302has a generally rectangular shape, corresponding to the shape of a door (e.g., door242, shown inFIG. 4B). In other embodiments, the ballistic door panel assembly302can be suitably sized and shaped to fit the dimensions of any existing door, as desired.

The ballistic door panel assembly302includes a plurality of ballistic layers including a first ballistic panel303, a second ballistic panel304, and a plurality of ballistic films or sheets334interposed or sandwiched between the first ballistic panel303and the second ballistic panel304. As used herein, the term “ballistic layer” refers to a layer of material that is capable of absorbing and dissipating energy from a high-velocity impact, such as through spall formation, tensile fiber failure, fiber de-bonding, fiber pullout, and interlayer delamination.

The first and second ballistic panels303and304are constructed of suitably rigid materials such that they are self-supporting and provide a suitably rigid structure or substrate to support the plurality of ballistic sheets334. Suitable materials from which the first and second ballistic panels303and304can be constructed include, for example and without limitation, extruded ultra-high molecular weight polyethylene (UHMWPE), steel (e.g., stainless steel), and aluminum. The thickness of the ballistic panels303and304can vary depending on the type of material from which the ballistic panels303and304are constructed. In some embodiments, each of the ballistic panels303and304has a thickness of less than 2 inches. Particular embodiments of the ballistic door panel assembly302can have ballistic panels303and304with a thickness in the range of 0.125 inches to 1.5 inches, 0.125 inches to 1.0 inches, 0.125 inches to 0.75 inches, or 0.125 inches to 0.5 inches.

The ballistic sheets334are generally constructed of thin sheets or films having a thickness of less than 1/16 of an inch, and can be laminated together, together with or separately from the ballistic panels303and304. The ballistic sheets334can be made of, for example, glass fibers, carbon fibers, polymer fibers, polyethylene fibers, ceramic fibers, aramid fibers (e.g., KEVLAR), ultra-high molecular weight polyethylene (UHMWPE) fibers (e.g., DURAVAR), polymeric matrix composites, and/or any combination thereof. The number of ballistic sheets334interposed between the first and second ballistic panels303and304can vary depending on the type of material from which the ballistic sheets334are constructed, and the desired level of threat protection. In some embodiments, the number of ballistic sheets334interposed between the ballistic panels303and304is between 1 and 50. Particular embodiments of the ballistic door panel assembly302can include between 5 and 25 ballistic sheets334, between 7 and 20 ballistic sheets334, between 7 and 15 ballistic sheets334, between 10 and 20 ballistic sheets334, or between 10 and 15 ballistic sheets334.

The specific configuration of the ballistic door panel assembly302, such as the thickness of the ballistic panels303,304, the number of ballistic sheets334, and the types of materials used for the ballistic panels303,304and the ballistic sheets334may be selected to achieve a desired level of threat protection, such as a particular National Institute of Justice (NIJ) or UL level or rating. In some embodiments, for example, the ballistic door panel assembly302is configured such that it meets NIJ Level IIIA or UL Level 6. In the exemplary embodiment, the ballistic door panel assembly302is configured to meet NIJ Level IIIA, and includes first and second panels303and304made from extruded UHMWPE, each having a thickness of 0.25 inches, and 15 ballistic sheets334made of KEVLAR fibers.

FIG. 8is a sectional view of the ballistic door panel assembly302ofFIG. 7coupled to the door242(shown inFIG. 4B). A connection assembly404is configured to couple the ballistic door panel assembly302to the door242. In the illustrated embodiment, the connection assembly404couples the ballistic door panel assembly302to the interior surface246of the door242. In alternative embodiments, the connection assembly404is configured to couple the ballistic door panel assembly302to the exterior surface244of the door242. The connection assembly404extends from a front wall306of the first panel303, through the plurality of ballistic sheets334and the second panel304, to the exterior surface244of the door242. The connection assembly404includes a first connection device406and a second connection device408. The first connection device406includes a first end410and a second end411. The first end410includes an internally threaded opening412, and the second end includes a flange414. The second connection device408includes a first end416and a second end417. The first end416includes an externally threaded portion418, and the second end417includes a flange420. The threaded portion418of the second connection device408is configured to threadably engage the threaded opening412of the first connection device406, thereby securing the ballistic door panel assembly302to the door242. The flange414of the first connection device406engages the exterior surface244of the door242, and the flange420of the second connection device408engages the front wall306of the first panel303of the ballistic door panel assembly302when the first and second connection devices406and408are secured together.

FIG. 9is a front view of the ballistic door panel assembly302installed on the interior surface246of the door242. In the illustrated embodiment, the ballistic door panel assembly302includes a cutout502for a door handle504. The cutout502can be any shape that allows easy access to and accommodates the door handle504. In some embodiments, the door242may include a window506. When the door242includes the window506, the ballistic door panel assembly302can include a window cutout508to accommodate the window506. The window506and the window cutout508can be any shape and size. In other embodiments, the ballistic door panel assembly302does not include a window cutout508.

FIG. 10is a front view of a ballistic door safety system600installed on the interior surface246of the door242. The ballistic door safety system600includes the door lock102coupled to the ballistic door panel assembly302, which is coupled to the interior surface246of the door242. The door lock102is coupled to the ballistic door panel assembly302using fasteners (not shown) that extend through fastening holes105of the mounting plate104(shown inFIG. 1). The ballistic door panel assembly302is coupled to the door242with a plurality of the connection assemblies404. In the exemplary embodiment, when the door lock102is in the engaged position (shown inFIG. 2), the door242cannot be opened from the exterior surface244of the door242, and the ballistic door panel assembly302provides protection to occupants of a room from ballistic objects or projectiles.

The door lock described herein is configured to securely lock (i.e., prevent movement of) the door to which it is attached, and can be retrofitted to existing doors. The door lock can do coupled to, for example, but without limitation, interior and/or exterior doors in schools, office buildings, hotels, and homes. The door lock is usable generally as a “one-piece” assembly. That is, no external elements are needed to engage or activate the door lock. Moreover, the door lock is generally biased to the engaged position such that, if components of the door lock (e.g., pins) were to fail or become removed, the door lock would move to the engaged position, still keeping the door secured and any occupants of the room safe. The unlock mechanism of the door lock ensures that only people inside the locked room, or those who have access to the specific key, can transition the door lock from the engaged position to the disengaged position. This feature further protects the occupants of the room from external threats (e.g., intruders).

The systems and methods described herein are not limited to the specific embodiments described herein, but rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein.