Patent Publication Number: US-2016222720-A1

Title: Apparatus and method for an armor door

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to doors and in particular to doors with enhanced security that accommodate the flow of air. 
     2. Description of the Related Art 
     Doors are commonly constructed with enhanced security aspects that can include additional bolts, reinforcing and sophisticated locking mechanisms. Doors, however, do not readily address the need to be able to convert between an enhanced security door and a door that can provide a secure source of external air into a commercial space. 
     SUMMARY OF THE INVENTION 
     A door with enhanced security is described that comprises a first elongate side that is opposed to a second elongate side and a third side that is opposed to a fourth side. The first side and second side connect to the third and fourth side to define a rectangular perimeter of the door. The door has an interior face and an opposed exterior face that connect to sides. The door defines an aperture that extends through the door from the exterior face to the interior face. 
     A gate is connected to the door. The gate is selectively movable in the aperture of the door between a first position with the gate at least partially positioned in the aperture and the aperture is at least partially open and a second position with the aperture closed by the gate. The gate includes a plurality of interconnected slats. A locking mechanism secures the gate in at least one position in the door. A screen is positioned in the aperture of and connected to the door. The gate is stored in a hood connected to the interior face of the door. The gate is preferably retracted in a roll and stored in the hood. 
     The door includes a track and the track receives and guides the movement of the gate. A space is defined in the door between the track and an inside surface of the exterior face of the door. The space can be configured to receive and securely retain the screen in position in the door. The screen is positioned in the aperture of the door. The screen can also be an insert that is a protective sheet or layer with perforations. The insert is suitable to act as a protective layer for an external door. The insert can also be a separate assembly from the screen that is connected to the door to limit access through the aperture. The insert is preferably perforated sheet metal. In an alternative arrangement of the door, the gate is movable and positionable in a space between an inside of the exterior face of the door and the track. In this arrangement, the track is configured to receive and securely position the screen in the aperture. 
     An actuation mechanism can assist in or provide the movement of the gate between the first position and the second position. The locking mechanism of the door can secure the gate in the second position. The locking mechanism can also secure the gate in a plurality of positions between the first position and the second position. The locking mechanism can be manually actuated, mechanically actuated and/or electrically actuated. 
     The fourth side of the door defines a second aperture that provides access to the space defined in the door. The second aperture has a door that provides access to and secures the second aperture in a closed position. The second aperture can provide access to the screen in the space. 
     The door with enhanced security is preferably an external door that provides a weatherproof interface against external weather conditions. Weatherproof as defined herein includes an air tight and waterproof sealing of the aperture as well as the interface between the door and the doorframe and/or any other interfacing external structure. Various forms of weatherproofing and/or insulation provide air and water tight seals that make the door weatherproof. For example, the hinged connection between the slats and the interface between the gate and the tracks can include insulation that provides a weatherproof interface. The gate in the second position preferably includes the secure closing of the aperture in the door that further includes a weatherproof closure of the aperture. 
     While many doors have provided apertures that have movable glass and/or screens that are alternately positionable, these doors lack the ability to simultaneous provide a high security enclosure and the free flow of air. Heretofore there has never been a door with a selectively movable gate that provides a high security closure for an aperture in the door in combination with an enhanced security screen for the free flow of air through the aperture of the door. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a rear, first side and top perspective view of an apparatus and method for an armor door that includes a gate in an aperture of the door; 
         FIG. 2  is a front, second side and top perspective view of the armor door of  FIG. 1  without the gate; 
         FIG. 3  is a partial cross-sectional view of  FIG. 1  taken along lines  3 - 3  showing the screen and gate extended from the hood of the door; 
         FIG. 4  is a rear view of the armor door of  FIG. 1 , with the gate in the closed position; and 
         FIG. 5  is a partial cross-sectional view of a second arrangement of the gate and screen of the apparatus and method for an armor door of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to  FIG. 1 , an apparatus and method for an armor door  10  includes a door  12 , an aperture  14  that is defined in door  12 , a screen  16  and a gate  18 . Door  12  includes a first side  20 , a second side  22  opposed to first side  20 , a third side  24  and a fourth side  26  opposed to third side  24 . First side  20  and second side  22  are elongate sides connected by the third or bottom side  24  and fourth or top side  26 . Sides  20 ,  22 ,  24  and  26  have a depth that is the thickness of door  12 . First side  20 , second side  22 , third side  24  and fourth side  26  define a perimeter for door  12  that includes the width, height and thickness of door  12 . Door  12  in this preferred embodiment has standard exterior door dimensions for width, height and thickness, but door  12  can be fabricated in any size or as any type of door to include sliding and double doors arrangements. 
     As shown in  FIGS. 1 and 2 , door  12  includes an interior face  28  and an exterior face  30 . Interior face  28  and exterior face  30  connect to opposing sides of sides  20 ,  22 ,  24  and  26 . A hinge  21  is preferably connected to side  20  and can be any type of hinge to include a continuous hinge that securely connects door  12  to at least the adjoining door frame of door  12 . A first door handle  32  is connected to interior face  28  and includes the associated latching mechanism and a latch plate that connects to a door frame. Armor door  10  can optionally further include a door frame that can be connected into a wall structure with door  12 . 
     Aperture  14  is preferably located between handle  32  and fourth side  26 , but can extend below handle  32  towards third side  24 . Aperture  14  of door  12  extends between the interior face  28  and exterior face  30 . Aperture  14  is defined in exterior face  30  by a rim  36 . In this preferred embodiment, rim  36  includes a first edge  38  in proximity and approximately parallel to first side  20 , an opposed second edge  40  in proximity and approximately parallel to second side  22 , a third edge  42  positioned in fixed spaced separation and approximately parallel to third side  24  and a fourth edge  44  in proximity and approximately parallel to side  26 . Third edge  42  and fourth edge  44  connect to opposing edges  38  and  40  to form continuous rim  36  and define aperture  14  in exterior face  30 . Edges  38 ,  40 ,  42  and  44  preferably define a rectangular shape rim  36 . 
     Door  12  includes a plurality of interior walls between faces  28  and  30 . A first interior wall  46  is in proximity and approximately parallel to first side  20 , a second interior wall  48  is in proximity and approximately parallel to second side  22  and a third interior wall  50  is approximately parallel and in fixed spaced separation to third side  24 . Walls  46 ,  48  and  50  define a U-shape that is open towards fourth side  26 . Walls  46 ,  48  and  50  are recessed in fixed spaced separation from edges  54 ,  56  and  58  of rim  52  defined in exterior face  30 . Walls  46 ,  48  and  50  preferably extend between and are connected to faces  28  and  30 . 
     Aperture  14  is defined in interior face  28  by a rim  52 . In this preferred embodiment, rim  52  includes a first edge  54  in proximity and approximately parallel to first side  20 , an opposed second edge  56  in proximity and approximately parallel to second side  22 , a third edge  58  that is positioned in fixed spaced separation to and approximately parallel to third side  24  and a fourth edge  60  in proximity and approximately parallel to fourth side  26 . Third edge  58  and fourth edge  60  connect to opposing edges  54  and  56  to form rim  52  and define aperture  14  in interior face  30 . First interior wall  46 , second interior wall  48  and third interior wall  50  connect to first edge  38 , second edge  40  and third edge  42 , respectively. Edges  54 ,  56 ,  58  and  60  preferably define an approximately rectangular shape rim  52 . 
     Aperture  14  of door  12  in this preferred embodiment is defined by rims  36 ,  52 , interior walls  46 ,  48 ,  50  and fourth side  26 . Interior walls  46 ,  48  and  50  are recessed from rim  36  of exterior face  30 . Interior walls  46 ,  48  and  50  define edges  54 ,  56  and  58 , respectively with interior face  28 . In this preferred embodiment, third interior wall  50  defines a ledge between first interior wall  46  and opposing second interior wall  48 . Wall  50  connects to third side  58  of rim  52  of interior face  28 . Rims  36  and  52  define aperture  14  as having a quadrangular shape in door  12 , but it is understood that rims  36  and  52  can define any shape or size of aperture  14  in door  12 . 
     Referring now to  FIGS. 1-3 , a pair of tracks  62  are aligned and positioned in opposition on first interior wall  46  and second interior wall  48 . Tracks  62  are preferably U-shaped channels positioned in fixed space separation from the inside of exterior face  30 . Tracks  62  preferably extend from or are in proximity to third interior wall  50  along each respective first interior wall  46  and second interior wall  48  for a predefined distance towards opposing fourth side  26 . Tracks  62  receive and accommodate the movement of gate  18  between a first open position and a second closed position. 
     A space  63  is defined in door  12  between the inside of exterior face  30 , wall  46 , wall  48 , wall  50 , side  26  and tracks  62 . Space  63  is defined to receive screen  16 . Screen  16  is selectively removable and replaceable within space  63 . Screen  16  has a frame that can have a tight and secure fitting relationship in space  63  of door  12 . This can include a tight fit between side  30 , tracks  62 , wall  46 , wall  48 , wall  50  and side  26 . The secure fitting of screen  16  can be the frame of screen  16  connecting to wall  50 , tracks  62  and/or walls  46 ,  48  and  50 . Screen  16  is preferably slidably positioned in space  63 . Alternatively, screen  16  can be received in a second channel connected to tracks  62  or in a separate channel or track  62  positioned in space  63 . 
     Screen  16  is preferably a high security screen. In the preferred embodiment, screen  16  is positioned in a frame and is resistant to puncture and cutting by sharp objects such as knives. The frame of screen  16  is preferably metal, but it can be alternative materials such as but not limited to composite materials. Screen  16  can further include bars and/or other forms of enhanced security measures to provide additional levels of protection against intrusion through aperture  14 . Armor door  10  can include sensors to detect the movement of screen  16  in door  12  and/or penetrations of screen  16 . Screen  16  can also provide limited or no visibility from exterior face  30  of door  12  to the interior face  28  of door  12  while accommodating visibility through screen  16  from the interior face  28  of door  12 . 
     Screen  16  of door  12  can alternatively be an insert  17  that includes a plurality of apertures. Insert  17  can be a grid, series of bars, lattice or any other structure that acts as a security barrier, but accommodates a free flow of air. In one preferred embodiment, insert  17  is an alloy type  1008  carbon steel perforated sheet. Insert  17  provides an enhanced level of security above that of screen  16 . Insert  17  is located over or in aperture  14  door  12 . Insert  17  is preferably located in space  63  separately, with and/or as an integrated assembly with screen  16 , in exterior rim  36  or connected to the external face of external side  30 . Insert  17  can have a fixed connection to door  12  or be a removable and replaceable assembly. The quantity and dimensions of the perforations defined in insert  17  can vary depending upon the desired application. Insert  17  can also replace screen  16  in door  12 . 
     Referring now to  FIGS. 1-4 , gate  18  can be selectively moved to open and close aperture  14 . Gate  18  includes a plurality of slats  64  that are interconnected to form a continuous, preferably solid, wall or gate. Gate  18  is movable between a first position and a second position as shown by arrows A. In the first position of gate  18 , aperture  14  is at least partially open and in the second position gate  18  closes aperture  14 . 
     Hood  66  is connected to door  12 . In this preferred embodiment, hood  66  is connected to interior side  28  of door  12  in proximity to fourth side  26 . Hood  66  includes a mechanism that winds and unwinds gate  18  for the movement of gate  18  between the first position and second position. The mechanism can be mechanical, electro-mechanical, hydraulic, pneumatic or electronic device that drives the movement of gate  18  between the first position and the second position. The winding of gate  18  into hood  66  can include gate  18  being partially recessed between the interior face  28  and exterior face  30  of door  12  or retracted into hood  66  and external to door  12 . Hood  66  provides for the storage of gate  18 . At least a portion of gate  18  can be retained in hood  66  when gate  18  is in the first position. Gate  18  can be moved between the first position and the second position by any means to include manually pulling down on gate  18  within door  12 , by one or more handles/actuators positioned on the outside of or connected to hood  66  or electrically. 
     Moving from the first position to the second position of gate  18 , tracks  62  interface with and receive gate  18  from hood  66 . Gate  18  is extended to be in direct contact with wall  50  to securely block aperture  14 . Gate  18  is received by and has a secure sliding engagement with tracks  62  that extend at least partially into aperture  14 . Gate  18  preferably provides a solid air-tight weatherproof external interface to weather conditions. In addition, tracks  62  can provide an air tight sealing interface with slats  64  of gate  18 . Slats  64 , are flexibly connected together via a preferably hinged interface to accommodate the winding and storage of gate  18  in hood  66  and the movement of gate  18  between the first position and the second position. In the preferred embodiment, slats  64  are connected together by hinges that allow the required movement of slats  64  between the first position and the second position. The hinges between slats  64  can be flexible hinges that provide a continuous gate  18  structure and/or gate  18  can be provided with a weatherproofing layer. Slats  64  are preferably solid elements with a sealing interface between slats  64 . Door  12  includes weather proofing, insulation, seals and/or weather stripping materials such as, but not limited to cross linked polyethylene foam, sponge rubber, neoprene and vinyl materials. 
     Door  12  includes a locking mechanism  68  that securely connects gate  18  in a position relative to aperture  14 . In one preferred embodiment, slats  64  include one or more locking mechanisms  68  that engage and fix gate  18  in position in door  12 . Preferably, a distal slat  65  includes locking mechanism  68  that engages gate  18  with apertures  67  in first interior wall  46 , second interior wall  48  and/or third interior wall  50  to secure gate  18  in the second position. The term slats  64 , as defined herein, includes slat  65  and the interface or hinge between slat  64  and slat  65 . The locking mechanism  68  in distal slat  65  can include, for example, an actuator  69  in distal slat  65  that moves at least one bolt  73  to extend from within distal slat  65  into at least one of apertures  67  in interior walls  46 ,  48  and/or  50  of door  12 . Preferably, locking mechanism  68  includes one or more actuators  69  that move opposing bolts  73  from distal slat  65  into the opposing apertures  67  defined in opposing interior walls  46  and  48  to secure gate  18  at a desired location in door  12 . The desired location can define a desired size of opening of aperture  14  and/or the closure of aperture  14 . Additional apertures  67  can be located along opposing interior walls  46  and  48  to define secure positions for slat  65  of gate  18  so as to accommodate a range of different sizes of openings of aperture  14 . Locking mechanism  68  can be opened and closed by any means to include by the direct hand movement of the bolts in distal slat  65 , a separate mechanical actuator  69  for locking mechanism  68 , an electrically actuated locking mechanism  68 . It is understood that locking mechanism  68  can also connect gate  18  to third interior wall  50  in the closed position of gate  18 . 
     Locking mechanism  68  can also be located in door  12  and connect to gate  18 . In this preferred embodiment, locking mechanism  68  is positioned in door  12  and engages gate  18  through or with first interior wall  46 , second interior wall  48  and/or third interior wall  50  to secure gate  18  in the second position covering aperture  14 . Locking mechanism  68  in door  12  includes one or more actuators  69  positioned on interior face  28 . For example, one actuator  69  can have multiple settings for different positions of gate  18  in aperture  14  or multiple actuators  69  can be positioned on interior face  28  to provide for the desired position of gate  18  and size of opening of aperture  14 . Alternatively, a powered locking mechanism  68  can secure gate  18  in position at any location along tracks  62  and block any additional movements of gate  18  along tracks  62 . 
     First door handle  32  on interior face  28  can have any shape or structure, but is preferably a safety bar type door handle. Door  12  can optionally include a second door handle  34  that is approximately opposed to first door handle  32 . Second door handle  34  can be omitted and door  12  opened solely by a key from the exterior face  30 . When present second door handle  34  can have any shape to perform the opening function to include a bent plate or traditional handle. Armor door  10  preferably includes a door locking mechanism that is connected to first door handle  32 . 
     Door  12  interior face  28  and exterior face  30  are preferably metal, but could be any material suitable for the use in a security type door. Additional materials of construction of door sides  20 ,  22 ,  24  and  26  as well as faces  28  and  30  can include, but are not limited to composite materials and natural materials such as wood or other materials that are at least fire resistant and can be reinforced as required. Door  12  sides  20 ,  22 ,  24  and  26  as well as faces  28  and  30  are preferably connected by standard means that can include one or more of welding, mechanical connections and bonding using heat and/or adhesives. Door  12  can have a solid core and/or include an interior frame structure. 
     In one exemplary preferred embodiment, door  12  has standard sized dimensions for a commercial entry door that includes an approximate width of thirty-six (36) inches, an approximate thickness of one and three-quarter (1¾) inches and an approximate height of eighty-four (84) inches. Aperture  14  of door  12  is defined by a rim  36  in exterior side  30 . In this exemplary preferred embodiment aperture  14  rim  36  has lateral dimensions between first edge  38  and second edge  40  of approximately twenty-seven and three quarters (27¾) inches and dimensions between third edge  42  and fourth edge  44  of approximately thirty-two and one-half (32½) inches. In one preferred embodiment, aperture  14  in exterior face  30  has lateral dimensions between first edge  54  and second edge  56  of approximately twenty-seven and three quarters (27¾) inches and dimensions between third side  58  and fourth side  60  of approximately thirty-three and a half (33½) inches. 
     Armor door  10  has advantages that include a high security door that can selectively move gate  18  to open aperture  14  covered by an insert  17  and/or screen  16  for the free exchange of air. The position of gate  18  inside screen  16  also accommodates a simplified direct manual movement of gate  18 . The dimensional differences between rim  52  and walls  46 ,  48  and  50  and external position of screen  16  provide a reduce access to gate  18  that also enhances the security of door  12 . 
     As shown in  FIGS. 2 and 5 , door  12  can have an alternative structural arrangement in which gate  18  is positioned external to screen  16  in space  63  and tracks  62  receive screen  16 . The inside of exterior face  30  and tracks  62  or another set of tracks can assist in the guiding of gate  18  into and from space  63 . 
     In this alternative structural arrangement, hood  66  can be connected to the inside of exterior face  30  and/or interior face  28  and the winding of the plurality of slats  64  of gate  18  is positioned at least partially in door  12 . As described previously, gate  18  in the second position is in apposition with and/or interfaces with third interior wall  50  and can be secured to first interior wall  46 , second interior wall  48  and/or third interior wall  50 . 
     Continuing with the alternative structural arrangement, when locking mechanism  68  is positioned in distal slat  65  and the manual engagement of the locking mechanism  68  for gate  18  is desired, a pedestal wall  72  can extend from third interior wall  50  that is aligned with screen  16  that provides access to gate  18  distal slat  65  and locking mechanism  68 . Pedestal wall  72  securely engages the frame of screen  16  and provides one or more apertures  74  with secure covers that can be opened and closed to provide manual access to space  63  and to actuate locking mechanisms  68  located in distal slat  65 . Locking mechanism  68  can also secure gate  18  to first interior wall  46 , second interior wall  48  and/or third interior wall  50  remotely via mechanical or electrical locking mechanisms  68  with or without pedestal wall  72  such as described previously with actuator  69  located on the interior face  28  of door  12 . Screen  16  can be removed and replaced in this embodiment through side  22  and wall  48  or through rim  36 . 
     The alternative structural arrangement provides advantages that include a high security door that accommodates the selective movement gate  18  to vary the size of the aperture  14  and screen  16  opening for the free exchange of air. This arrangement also has the advantage that by gate  18  being positioned external to screen  16  it reduces the likelihood of external damage to screen  16 . Further, by hood  66  being connected to exterior face  30 , the length of hood  66  that extends outward from interior face  28  can be reduced. 
     Referring now to  FIGS. 1-5 , in operation the apparatus and method for an armor door  10  provides a door  12  that can remain secure while selectively providing fresh air ventilation through screen  16  in aperture  14 . 
     Screen  16  is preferably removed and replaced through an aperture  70  in door  12 . In the preferred embodiment aperture  70  is defined in second side  22  and/or fourth side  26 . Aperture  70  preferably includes a cover  71  that can be fastened and unfastened to provide access to and securely close aperture  70 . The connection between the cover for aperture  70  and door  12  can be of any type to include friction, fasteners, hinged, electrically actuated or biased for example. To remove and replace screen  16 , door  12  is opened sufficiently to open cover  71  and then access to is provided through aperture  70  and into space  63 . Screen  16  can then be readily removed and a replacement screen  16  positioned in space  63 . Similarly, insert  17 , when positioned in space  63  or in exterior rim  36 , can be accessed and/or removed separately or as an integrated assembly of screen  16  and insert  17  from space  63 . 
     In the first position of gate  18 , aperture  14  is at least partially open and gate  18  is at least partially withdrawn into hood  66 . Gate  18  slat  65  can be securely positioned in a plurality of locations along first interior wall and second interior wall  48  to provide varying sizes of aperture  14  in door  12 . When gate  18  is fully retracted into hood  66 , aperture  14  is at the maximum opening. 
     As described previously, gate  18  can be moved between the first position and second position manually, by a mechanical device and/or by an electrically powered device. Mechanical devices can include for example a crank or a chain to actuate the winding or unwinding of gate  18  that can be positioned on or connected to hood  66  of door  12  or directly on face  28  of door  12 . Mechanical assistance can also include a bias to a preferred position of gate  18 . Electrically powered devices include drive motors to wind and/or unwind gate  18  that can be selectively actuated from a nearby electrical switch or remotely. To securely close gate  18  in door  12 , distal slat  65  of gate  18  is moved to a position in apposition with third interior wall  50  and secured using locking mechanism  68 . Locking mechanism  68  can be similarly actuated by direct manual activation, through mechanically actuated devices, electrically actuated through local switches or remotely. It is understood that one electromechanical device is capable of moving gate  18  and actuating locking device  68 . 
     In the preceding specification, the present disclosure has been described with reference to specific exemplary embodiments thereof. It will be evident, however, that various modifications, combinations and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the claims that follow. While the present disclosure is described in terms of a series of embodiments and/or arrangements, the present disclosure can combine one or more novel features of the different embodiments. The specification and drawings are accordingly to be regarded in an illustrative manner rather than a restrictive sense.