Abstract:
The present invention involves an entry door having a window glass situated in a door slab and a space between the window glass and the door slab. A plugless locking system is configured to fit in the space between the window glass and the door slab. The plugless locking system has a first plugless lock is configured to receive an external trim and is configured to mate with a second plugless lock. The second plugless lock is configured to receive an interior trim. The combination of the mated first and second plugless lock fit within the space between the window glass and door slab and secure interior and exterior trim to the entry door. Also disclosed is a method for using the plugless locking system in an entry door.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims benefit from U.S. Provisional Patent Application No. 61/914,187, entitled “Plugless Glazing System,” filed on Dec. 10, 2013, which is hereby incorporated in its entirety by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates generally to a glazing system for door, and more particularly, to a plugless glazing system for a door. 
       BACKGROUND 
       [0003]    Entry doors for residences, business, and industrial facilities utilize entry doors of various designs. One popular design is a door designed with a window inset in the door. An entry door with a window often utilizes window trim in addition to the glass panel. In standard designs, two mating parts attach to oppose pieces of window trim. The first mating part attaches to the exterior window trim, holding the glass, trim, and the door slab together. The second mating part attaches to the interior window trim and locates and mates with the part attached to the exterior window trim. 
         [0004]    Standard designs require external screws or other fasteners to secure the interior trim to the exterior trim. The use of external screws requires the use of trim plugs or other means to improve the aesthetic appearance of the interior trim. As trim plugs are painted and stained separately from the trim, this can lead to differences between the shade, hues, and glosses of the trim and trim plugs. Additionally, it is time consuming to prepare individual trim plugs for painting and staining. 
         [0005]    It is also time consuming to install trim plugs during the door assembly process as one door may require up to 26 trim plugs. The trim plugs need to be installed carefully so that they properly cover the screw heads and that they attach to and blend in with the interior trim. Improperly fitted trim plugs can cause paint and/or stain chipping, marring or hazing, which leads to a potentially inferior finish to the door. 
         [0006]    Therefore, there is a need for a more efficient connection system for entry door window trim. Specifically, there is a need for a plugless trim system that provides a better finish and is more aesthetically pleasing. 
       SUMMARY 
       [0007]    Provided is a plugless locking system for attaching trim over a space between a glazing member and a framing member, the plugless locking system includes a first plugless lock that is configured to attach to an exterior trim. The first plugless lock may include a base having an exterior side and an opposite interior side, the exterior trim may be configured to attach to the exterior side of the base. A first member may extend from the interior side of said base and a second member may extend from the interior side of said base and be generally parallel to said first member. A cavity may be defined by the base, the first member and the second member. A first arm may extend from said first member, said first arm configured to operatively engage a surface of the glazing member and a second arm may extend from said second member, said second arm configured to operatively engage a surface of the framing member. At least one aperture may be provided within the first plugless lock. 
         [0008]    A second plugless lock may be configured to attach to an interior trim, wherein the second plugless lock attaches with said first plugless lock, the second plugless lock includes a branch configured to be at least partially received within said cavity of the first plugless lock. At least one flange member may extend from said branch, the flange member may be configured to operatively engage said aperture to attach said second plugless lock with said first plugless lock. The interior trim and the exterior trim may be positioned over the space between the glazing member and the framing member. 
         [0009]    The second plugless lock includes a first flange member and second flange member wherein each flange member includes a first end having a clip and a second end including a groove. The grooves of the first and second flange members may be positioned opposite from the clips along the branch. The groove may be configured to abut against a mating profile of said interior trim to support the second plugless lock relative to the interior trim. 
         [0010]    A fastener may attaches the first plugless lock to the exterior trim and another fastener may attach the second plugless lock to the interior trim wherein the fasteners may be concealed by the plugless locking system once the plugless locking system is installed within the space between the glazing member and the framing member. The first plugless lock and the second plugless lock may not be viewable once the plugless locking system is installed within the space between the glazing member and the framing member. 
         [0011]    The branch includes a first flange member spaced from a second flange member, the first flange member includes a first clip configured to operatively engage a first aperture of the first plugless lock and the second flange member includes a second clip configured to operatively engage a second aperture of the first plugless lock. The first flange member may include a first groove extending from the branch opposite from the first clip and the second flange member may include a second groove extending from the branch opposite from the second clip. The grooves may be configured to abut against a mating profile of said interior trim to support the second plugless lock relative to the interior trim. 
         [0012]    The first clip and second clip may be configured to bias relative to one another to operatively attach to the first and second apertures, respectively. The mating profile may include a space defined by a first rib and a second rib or may include a ridge that extends along the underside of the interior trim. 
         [0013]    Provided by this disclosure is an entry door that includes a window glass positioned within a door slab, wherein there is a space between the window glass and the door slab. A plugless locking system is configured to fit in the space between the window glass and the door slab. The plugless locking system having a first plugless lock configured to receive an exterior trim, the first plugless lock includes a base having at least one aperture. A first member may extend generally perpendicularly from said base and a second member may extend generally perpendicularly from said base and generally parallel to said first member. A cavity may be positioned generally between said first and second members. A first ledge and a second ledge may extend from said first and second members, respectively. Said first and second ledges may be configured to operatively engage said window glass and door slab. A second plugless lock may be configured to receive an interior trim, wherein the second plugless lock attaches with said first plugless lock, the second plugless lock includes a branch configured to be received within said cavity. At least one clip may extend from said branch, the clip may be configured to operatively engage said aperture to attach said second plugless lock with said first plugless lock. At least one groove may extend from said branch and be positioned opposite said clip. The groove may be configured to abut against said interior trim. 
         [0014]    The grooves may be configured to abut against a mating profile of said interior trim to support the second plugless lock relative to the interior trim. The mating profile may include a space defined by a first rib and a second rib. The mating profile may include a ridge that extends along the underside of the interior trim. 
         [0015]    A fastener may attach the first plugless lock to the exterior trim and another fastener may attach the second plugless lock to the interior trim wherein the fasteners are concealed by the interior trim and the exterior trim when the plugless locking system is installed within the space. The first plugless lock and the second plugless lock may not be viewable once the plugless locking system is installed within the space between the glass window and the door slab. 
         [0016]    Also provided is a method for attaching an interior trim and an exterior trim to an entry door having a window glass, the method includes the steps attaching an exterior trim to a first plugless lock configured to receive the exterior trim through the use of at least one fastener. The combination of the exterior trim and the first plugless lock may be inserted into a space between a door slab and window glass on an exterior surface of the entry door, with the first plugless lock end being inserted first and upon complete insertion, the exterior trim resting on the exterior surface of the entry door and an exterior surface of the window glass. An interior trim may be attached to a second plugless lock configured to receive the interior trim through the use of at least one fastener. The combination of the interior trim and the second plugless lock may be inserted into a space between the door slab and window glass on an interior surface of the entry door, with the second plugless lock end being inserted first and, upon complete insertion, the interior trim resting on the interior surface of the entry door and an interior surface of the window glass. The first plugless lock may be mated with the second plugless lock in the space between the door slab and window glass of the entry door. 
         [0017]    In one embodiment, a groove of the second plugless lock is inserted within a mating profile of the interior trim and the second plugless lock may be attached to the interior trim with a fastener. 
         [0018]    In another embodiment, a ridge of a mating profile of the interior trim is mated with a groove of the second plugless lock and the second plugless lock may be attached to the interior trim with a fastener. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations, wherein: 
           [0020]      FIG. 1A  is an exterior view of an entry door; 
           [0021]      FIG. 1B  is an interior view of the entry door; 
           [0022]      FIG. 2  is a cross-sectional view of an entry door with a window glass with a plugless locking system; 
           [0023]      FIGS. 3A ,  3 B,  3 C, and  3 D are perspective views of various first plugless locks; 
           [0024]      FIG. 4  is a bottom view of a first plugless lock; 
           [0025]      FIGS. 5A ,  5 B, and  5 C are side views of various first plugless locks; 
           [0026]      FIGS. 6A ,  6 B, and  6 C are perspective views of various second plugless locks; 
           [0027]      FIGS. 7A and 7B  are bottom views of various second plugless locks; 
           [0028]      FIGS. 8A and 8B  are side views of various second plugless locks; 
           [0029]      FIGS. 9A ,  9 B, and  9 C are perspective views of a first plugless lock mating with an exterior trim; 
           [0030]      FIGS. 10A and 10B  are perspective views of a first plugless lock mated with an exterior trim; 
           [0031]      FIGS. 11A ,  11 B, and  11 C are perspective views a second plugless lock mating with an interior trim; 
           [0032]      FIGS. 12A and 12B  are perspective views of a second plugless lock mated with an interior trim; 
           [0033]      FIG. 13  is a side view of a plugless locking system being installed in an entry door; 
           [0034]      FIGS. 14A and 14B  are perspective views of a plugless locking system mated without an entry door; and 
           [0035]      FIGS. 15A ,  15 B,  15 C and  15 D are exploded views of embodiments of the plugless locking system. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention. 
         [0037]    An entry door  10  capable of being attached to a building structure, the entry door  10  having a window glass  12 , is shown in  FIG. 1A . The entry door  10  may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the entry door  10  shown and described herein. The window glass  12  may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the window glass  12  shown and described herein. Further, the window glass  12  is not limited to glass; it may also be plastic or any other suitable material. The window glass  12  may be clear, colored, opaque, or any combination of such. Further, the window glass  12  may be comprised of multiple pieces, e.g., a stained glass window design. These, however, are merely exemplary embodiments of the entry door  10  and window glass  12 —any appropriate door or window glass may be used with the present teachings. While the entry door  10  is shown and described as being a door to enter a structure, it may also be an internal door, closet door, or any other type of door; the present teachings are not limited to the use and type of door shown and described. 
         [0038]    When terms such as “interior,” “exterior,” “inner,” “outer,” “lower,” “upper,” “horizontal,” and “vertical” are used herein, reference is made to the entry door  10  of the present teachings when oriented as shown, for example, in  FIGS. 1A and 1B . It should be understood that such terms are used in their relative senses and are intended to be and are merely exemplary and not all-inclusive nor exclusive. 
         [0039]    As shown in  FIGS. 1A and 1B , the entry door  10  may have a door slab  14 , which may be formed from a variety of materials, including, but not limited to, wood, plastic, steel, fiberglass, aluminum or any other appropriate material—or it may be a combination of any such material. The entry door  10  may have an exterior surface  16  and an interior surface  18 . When the entry door  10  is used as an entry door to a building, for example, the exterior surface of the door  16  is the side of the door exposed to the outside of the building. In this situation, the interior surface of the door  18  is exposed to the interior of the building. 
         [0040]    The window glass  12  may also have an exterior surface  20  and an interior surface  22 . The exterior surface of the window glass  20  may be exposed to the outside of the building in the example above. The interior surface of the window glass  22  may be exposed to the interior of the building. 
         [0041]    The window glass  12  may have both an exterior trim  24  contacting the exterior surface of the door  16  and the exterior surface of the window glass  20  and an interior trim  26  contacting the interior surface of the door  18  and the interior surface of the window glass  22 . The exterior and interior trims  24 ,  26  may be of any appropriate configuration. The exterior and interior trims  24 ,  26  may provide an aesthetically pleasing finish to the entry door  10 . The exterior and interior trims,  24 ,  26  may be formed of any appropriate material, including, without limitation, wood, plastic, fiberglass, steel, aluminum, or any other material—or a combination of such materials. 
         [0042]    The window glass  12  may be secured to the door slab  14  by a plugless locking system  30  as shown in  FIG. 2 . The plugless locking system  30  may include a first plugless lock  32  and a second plugless lock  34 . 
         [0043]    As shown in  FIGS. 3A-D ,  4 , and  5 A-C, the first plugless lock  32  may be generally rectangular in shape with a base  36  having a width smaller than the distance between the door slab  14  and the window glass  12  in the entry door  10 . The base  36  may have a first base end  38  having at least one aperture  40 A and a second base end  42  opposite from the first base end  38  having at least one aperture  40 B. The base  36  may have additional apertures  85  that may mate with the exterior trim  24  allowing for repeatable installation of the plugless locking system  30 . 
         [0044]    The first plugless lock  32  may also include a first side  44  of any appropriate configuration. The first side  44  may include a relief aperture  46  and a first side end  97  attached generally perpendicularly to the base  36  at a first base side  47 . The first side  44  may also include a second side end  99  attached generally perpendicularly to a first ledge or arm  48 . The first plugless lock  32  may further include a second side  50  having a relief aperture  52  and a first side end  95 , which may be attached perpendicularly to the base  36  at the second base side  53 . The second side  50  may also include a second side end  93  attached generally perpendicularly to a second ledge or arm  54 . The first side  44  and the second side  50  may be generally parallel to one other, but are not limited to this configuration. 
         [0045]    A cavity  56  may be formed between the first side  44  and the second side  50 , the cavity  56  having a width generally equivalent to that of the base  36 . Further, the first side  44  may be shorter than the second side  50  and accordingly, the first arm  48  and the second arm  54  may be at different elevations. However, the first plugless lock  32  may be of any appropriate configuration and is not limited to that shown and described herein. 
         [0046]    As shown in  FIGS. 6A-C ,  7 A-B, and  8 A-b, the second plugless lock  34  may include a branch  58 . The branch  58  may include a first flange member  60  positioned at one end of the branch  58  and a second flange member  62  position at an opposing end of the branch  58 . The first flange member  60  may be spaced from the second flange member  62 . A channel  64  may be defined by the space between the first flange member  60  and the second flange member  62  and bordered by the branch  58 . The first flange member  60  may include a first end  66  having a first clip  68  and a second end  70  having a first groove  72 . The first end  66  of the first flange member  60  and the first clip  68  may be configured to be received by the at least one aperture  40 A of the base  36  of the first plugless lock  32 . 
         [0047]    The second flange member  62  of the second plugless lock  34  may include a first end  74  having a second clip  76  and a second end  78  having a second groove  80 . The first flange member  60  and the second flange member  62  may be generally parallel to one other, and both may extend at a substantially right angle from branch  58 . In one embodiment, the first clip  68  may be opposite from the second clip  76  such that each clip may be biased relative to the other to be received within apertures as illustrated by  FIGS. 6A and 6B . Both the first plugless lock  32  and the second plugless lock  34  of the plugless locking system  30  may be formed from a variety of materials, including, but not limited to, plastic, steel, fiberglass, aluminum or any other appropriate material or any combination of such. By way of a non-limiting example, the plugless locking system  30  may be formed from a strong UV resistant injection molded plastic or composite, such as acrylonitrile butadiene styrene (ABS) or polycarbonate (PC). 
         [0048]    The exterior trim  24  may be attached to the base  36  of the first plugless lock  32  through the use of a fastener  82  operatively inserted through a central hole  83 , as shown in  FIGS. 4 ,  9 A,  9 B,  9 C,  10 A and  10 B. The present teachings of the fastener  82  are not limited to the screw shown. Any appropriate fastener  82  may be used without departing from the present teachings. The exterior trim  24  may be formed from a variety of materials, including, but not limited to, plastic, metal, wood, or any other suitable material or combination of such. The fastener  82  may be any type of fastener, including, but not limited to, a screw, nail, nut, bolt, lag, or any other appropriate fastener. The fastener  82  may be inserted through aperture  83  as illustrated by  FIGS. 2 and 15A . and is to be concealed from view once the interior trim  26  and the exterior trim  24  of the system are installed in place. 
         [0049]    Similarly, as shown in  FIGS. 11A ,  11 B,  11 C,  12 A, and  12 B, the interior trim  26  may be attached to the second plugless lock  34  through the engagement with a mating profile  90  along an underside  92  of the interior trim  26  with the first groove  72  and the second groove  80  of the second plugless lock  34 . In this embodiment, the mating profile  90  includes a ridge  122  that extends along the underside  92  of the interior trim  26  and is shaped to fit within the first and second grooves  72 ,  80 . This configuration may prevent unwanted rotation between the interior trim  26  and the second plugless lock  34  as they are being attached. A fastener  82  may be operatively inserted through a central hole  84  of the second plugless lock  34 . In one embodiment, the underside  92  of the interior trim  26  includes an extension portion  94  configured to receive the fastener  82  as it extends through the aperture  84  along the branch  58  of the second plugless lock  34 . The extension portion  94  may extend from the underside  92  of the interior trim  26  and abut against the branch  58  as the fastener  82  is installed. The extension portion  94  may extend radially passed the edges of the branch  58  to form an overlap portion  96 . The interior trim  26  may be formed from a variety of materials, including, but not limited to, plastic, metal, wood, or any other suitable material. The fastener  82  may be any type of fastener, including, but not limited to, a screw, nail, nut, bolt, lag, or any other appropriate fastener. 
         [0050]    The first plugless lock  32  may be configured to be received in a space  100  between the door slab  14  and the window glass  12  as shown in  FIGS. 2 ,  9 A and  13 . The combination of the first plugless lock  32  and the attached exterior trim  24  may be inserted into the space  100 , with the base  36  of the first plugless lock  32  leading. When fully inserted, the first plugless lock  32  may fit snugly between the window glass  12  and the door slab  14 . The exterior trim  24  may rest on the exterior surface  16  of the door  14  and the exterior surface  20  of the glass  12 . In one embodiment, a sealer material may be positioned between the exterior trim  24  and the exterior surfaces  16 ,  20 . The sealer material may be a foam material or tape material applied to the trim  24  before installation. Additionally, the sealer material may be a silicone or other type of water based sealing material. The exterior trim  24  may bridge the space  100  between the door slab  14  and the window glass  12 , creating a water tight seal on the entry door  10 . 
         [0051]    After insertion into the space  100 , the first arm  48  of the first plugless lock  32  may abut the interior surface  22  of the window glass  12  and the second arm  54  of the first plugless lock  32  may abut the interior surface  16  of the door slab  18 . 
         [0052]    The second plugless lock  34  may also be configured to be received by the space  100  between the door slab  14  and the window glass  12 . The second plugless lock  34  and the attached interior trim  26  may be inserted into the space  100 , with the first clip  68  of the first flange member  60  and the second clip  76  of the second flange member  62  of the second plugless lock  34  leading. When fully inserted, the second plugless lock  34  may fit snugly between the window glass  12  and the door slab  14  with the interior trim  26  resting against the interior surface  18  of the door  14  and the interior surface  22  of the window glass  12 . In one embodiment, a sealer material may be positioned between the interior trim  26  and the interior surfaces  18 ,  22 . The sealer material may be a foam material or tape material applied to the trim  26  before installation. Additionally, the sealer material may be a silicone, polyurethane or other type of water based sealing material. This sealer material may be useful to reduce raddling of the trim. 
         [0053]    The second plugless lock  34  may be inserted inside the cavity  56  of the first plugless lock  32 . The first end  66  of the first flange member  60  of the second plugless lock  34  may be inserted through the at least one aperture  40 A of the first plugless lock  32 . The first end  74  of the second flange member  62  of the second plugless lock  34  may be inserted through the at least one aperture  40 B of the first plugless lock  32 . First and second clips  68 ,  76  along the first ends  66 ,  74  respectively, may be flexible so that they may compress to pass through the at least one apertures  40 A,  40 B and expand upon exiting the at least one apertures  40 A,  40 B to generally resist opposing movement of the second plugless lock  34 . The resulting mating combination of the first and second plugless locks  32 ,  34  may create a removable connection that allows for the replacement of the window glass  12 , exterior trim  24 , and/or interior trim  26 .  FIGS. 14A and 14B  show this connection without the entry door  10 , to show the mating of the first and second plugless locks  32 ,  34 . Further, the second plugless lock  32  illustrated by  FIGS. 6C ,  8 A,  8 B, may be attached to interior trim  26  as illustrated by  FIGS. 11A ,  11 B,  11 C,  12 A and  12 B. This embodiment, is configured to be attached to the first plugless lock  32  that includes a relief apertures  46 ,  52  for receiving the extension portion  94  of the interior trim  26 . In this embodiment, the overlap portion  96  of the extension portion  94  may extend within relief apertures  46  and  52  for a snug fit connection. 
         [0054]    Additionally, in another embodiment, the first plugless lock  32  illustrated by  FIGS. 3B ,  3 C,  15 A,  15 B and  15 C include apertures  102 A,  102 B positioned along sidewalls  104 A,  104 B that extend from the base  36  and between the first side  44  and the second side  50 . These side apertures  102 A,  102 B are configured to receive the first and second clips of the second plugless lock  36  illustrated by  FIGS. 6A and 6B . 
         [0055]    Further, as illustrated by  FIGS. 15A ,  15 B,  15 C, and  15 D, a locating feature is provided wherein the second ends  70 ,  78  of the first flange  60  and second flange  62 , respectively, may be inserted into the mating profile  90  along an underside  92  of the interior trim  26 . In this embodiment, the matting profile  90  includes a first rib  110  and a second rib  112 . The first and second ribs  110 ,  112  extend along the underside  92  and are spaced from one another along the underside  92  of the interior trim  26 . The ribs  110 ,  112  may define a space that includes at least one slot  114  and a shoulder  116  therein. The first groove  72  may be configured to be received within the slot  114  while the remaining portion of the second ends  70 ,  78  may abut against the shoulder  116 . This embodiment allows a user to quickly locate the proper position of the second plugless lock  34  relative to the interior trim  26  without risk of unwanted relative rotation. 
         [0056]    Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.