Patent Publication Number: US-2023151675-A1

Title: Composite door systems

Description:
CROSS REFERENCE AND PRIORITY CLAIM UNDER 35 U.S.C. § 119 
     The present Application for a Patent claims priority to U.S. patent application Ser. No. 16/999,472 entitled “Composite Door Systems,” filed on Aug. 21, 2020 and issued into U.S. Pat. No. 11,560,750 issued on Jan. 24, 2023, which claims priority to U.S. Provisional Patent Application Ser. No. 62/890,980 entitled “Composite Door Systems,” filed on Aug. 23, 2019, both of which are assigned to the assignees hereof and hereby expressly incorporated by reference herein. 
    
    
     FIELD 
     Embodiments of the present disclosure generally relate to barrier structures, in particular, embodiments of the disclosure relate to a composite door system comprising a shell and a core. 
     BACKGROUND 
     Dwellings, buildings, or other like barrier structures, typically comprise doors, walls, floors, roofs, partitions, etc. Moreover, in many instances, it is desirable that the barrier structures provide safety, security, resistance from the elements, such as but not limited to providing protection from extreme weather conditions, unauthorized access by users, or the like. Hence, barrier structures are designed to withstand and resist a variety of physical impacts. There is a need for improved barrier structures, and in particular, improved door systems. 
     SUMMARY 
     As will be described herein, the one or more composite door systems of the present disclosure may be utilized within a barrier structure, and may provide resistance to, and protection from, physical impacts, such as penetration from projectiles, as well as protection from fire, physical attacks, explosions, noise, medium and radio frequency radiation, etc. The composite door systems can be utilized in a variety of applications for barrier structures. The composite door systems may comprise a shell formed from a structural material, such as steel, other metals, composites, plastics, or any other material. The composite door systems may further comprise a core, which in some embodiments may be made of a composite material. The shell may be formed having a first face, a second face and a first side, as second side, and a bottom side operatively coupling the first face to the second face. The faces and sides may form a cavity in which a fill material may be provided. The shell may be manufactured and shipped to the installer or customer (e.g., to reduce costs during shipping), and the cavity of the shell may be filled on site with a liquid material that hardens into a solid material to form the core. As such, the top of the composite door system may be open to allow liquid material to fill the cavity within the shell. Alternatively, in some embodiments a top side may be provided that has one or more openings. The top side with the one or more openings may provide structural support to the shell (e.g., during shipping and filling of the cavity) while still allowing for liquid material to pass through the shell into the cavity. In some embodiments, the top side may comprise a plurality of openings. It should be understood that the first face, the second face, the first side, the second side, the bottom side, and/or the top side may be individual members (e.g., operatively coupled together, such as through a weld, or the like), or may be formed from one or more members (e.g., bent into the desired orientations and/or operatively coupled together, such as through a weld, or the like). 
     One embodiment of the invention comprises a composite door system. The composite door system comprises a shell comprising a first face, a second face, a first side member, a second side member, and a bottom side member. The first face, the second face, the first side member, the second side member, and the bottom side member form a cavity. The shell has one or more openings. The shell further has a fill material, wherein the fill material is provided through the one or more openings of the shell in a liquid material form and hardens to a solid form within the cavity. 
     In further accord with embodiments of the invention, the composite door system is a door. 
     In other embodiments of the invention, the shell further comprises one or more hardware housings operatively coupled to the shell. The one or more hardware housings are configured to resist flow of the liquid material. The one or more hardware housings are configured to receive hardware for the door. 
     In yet other embodiments of the invention, the one or more hardware housings is a solid hardware housing. The solid hardware housing is machined in order to receive the hardware. 
     In still other embodiments of the invention, the one or more hardware housings is a channel hardware housing. The channel hardware housing is formed from at least one side member of the shell. 
     In other embodiments of the invention, the one or more hardware housings is a cased hardware housing. The cased hardware housing is configured to receive the hardware. 
     In further accord with embodiments of the invention, the one or more hardware housings is a tubular hardware housing. The tubular hardware housing is configured to receive the hardware. 
     In other embodiments of the invention, the one or more hardware housings is a plate operatively coupled the first face or the second face at a hardware location. 
     In yet other embodiments of the invention, the one or more hardware housings further comprise one or more layers of projectile resistant material to provide additional projectile resistance where the hardware is located. 
     In still other embodiments of the invention, the hardware comprises mechanical hardware, electrified hardware, a lock, a handle, a hinge, a locking rod, a door closer, a door operator, an exit device, a mag lock, a camera, radar, a sensor, a detection device, a security device, a surveillance device, a knob, or a soft closing device. 
     In other embodiments, the invention, further comprises a top side member having a plurality of openings. The plurality of openings are configured to receive the liquid material and allow the liquid material to pass into the cavity. 
     In further accord with embodiments of the invention, the top side member comprises a channel with the plurality of openings. The channel is located between edges of the first face and the second face. 
     In other embodiments of the invention, the channel comprises a u-shaped channel formed form a web, a first flange, and a second flange, wherein the first flange the second flange are operatively coupled to the first face and the second face. 
     Another embodiment of the invention comprises a shell for a composite door system. The shell comprises a first face, a second face, a first side member, a second side member, and a bottom side member. The first face, the second face, the first side member, the second side member, and the bottom side member form a cavity. The shell has one or more openings, and the shell is configured to receive a liquid fill material through the one or more openings to form the composite door system when the liquid fill material hardens. 
     In further accord with embodiments, the invention further comprises one or more hardware housings operatively coupled to the shell. The one or more hardware housings are configured to resist flow of the liquid fill material. The one or more hardware housings are configured to receive hardware for the composite door system. 
     In other embodiments of the invention, the one or more hardware housings comprise a solid hardware housing, wherein the solid hardware housing is machined in order to receive the hardware. The one or more hardware housings comprise a channel hardware housing, wherein the channel hardware housing is formed from at least one side member of the shell. The one or more hardware housings comprise a cased hardware housing, and wherein the cased hardware housing is configured to receive the hardware. The one or more hardware housings comprise a tubular hardware housing, and wherein the tubular hardware housing is configured to receive the hardware. The one or more hardware housings comprise a plate operatively coupled the first face or the second face at a hardware location. 
     Another embodiment of the invention comprises a method of forming a composite door system. The method comprises forming a shell. The shell comprises a first face, a second face, a first side member, a second side member, and a bottom side member. The first face, the second face, the first side member, the second side member, and the bottom side member form a cavity. The shell has one or more openings. The method further comprises filling the cavity with a liquid material. The liquid material is provided through the one or more openings of the shell and hardens into a solid form within the cavity. 
     In further accord with embodiments of the invention, the method comprises shipping the shell after forming the shell to a site, and wherein the filling of the cavity occurs after the shell is received at the site. 
     In other embodiments, the filling of the cavity occurs at a facility that forms the shell, a distribution facility that ships the shell or the composite door system, or at an installation site. 
     In yet other embodiments, the method further comprises operatively coupling one or more hardware housings to the shell. The one or more hardware housings are configured to resist flow of the liquid material. The one or more hardware housings are configured to receive hardware for a door. 
     To the accomplishment the foregoing and the related ends, the one or more embodiments comprise the features hereinafter described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings. 
         FIG.  1   a    is perspective view of a composite door system, in accordance with some embodiments of the disclosure. 
         FIG.  1   b    is a front view of a composite door system, in accordance with some embodiments of the disclosure. 
         FIG.  1   c    is a cross-sectional view of a portion of the bottom side of the composite door system of  FIG.  1   a   , in accordance with some embodiments of the disclosure. 
         FIG.  2   a    is a cross-sectional view of a portion of the top side of the composite door system of  FIG.  1   a   , in accordance with some embodiments of the disclosure. 
         FIG.  2   b    is a top view of the composite door system of  FIG.  1   a   , in accordance with some embodiments of the disclosure. 
         FIG.  3    is a front view of a composite door system with a solid hardware housing mounted to the composite door system, in accordance with some embodiments of the disclosure. 
         FIG.  4    is a front view of a composite door system with cased hardware housings mounted to the composite door system, in accordance with some embodiments of the disclosure. 
         FIG.  5    is a perspective view of a composite door system with a tubular hardware housing mounted to the composite door system, in accordance with some embodiments of the disclosure. 
         FIG.  6    is a front view of a barrier structure using a composite door system, in accordance with some embodiments of the disclosure. 
         FIG.  7    is a process flow related to forming a composite door system by forming a shell, shipping the shell, and filling the shell, in accordance with some embodiments of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description teaches specific example embodiments of the invention; however, other embodiments of the invention do not depart from the scope of the present invention. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including” when used herein, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. 
     As illustrated in  FIG.  1   a   , the composite door system  100  may comprise a first face  102  (e.g., a front face), a second face  104  (e.g., a rear face), a first side  106  (e.g., a right side), a second side  108  (e.g., left side  108 ), a bottom side  110  (e.g., a lower side), and/or a top side  112  (e.g., an upper side). It should be understood that the first face  102 , the second face  104 , the first side  106 , the second side  108 , the bottom side  110 , and/or the top side  112  may be members that are operatively coupled together (e.g., separate members that are coupled together, members that are integrally formed together, and/or the like). 
     The sides and faces when operatively coupled together form a shell  80  having a cavity  114 , and the cavity may be filled to create a core  90 , such as filled using a fill material  140 . The shell  80  may be made of any type of material (e.g., steel, plastic, composite, fiberglass, or the like). However, in some embodiments the shell  80  may be 24, 22, 20, 18, 16, 14, 12, 10, 8, or any other gage steel ranging between, overlapping, or falling outside of these values. In some embodiments, the fill material  140  may be a homogenous cementitious material (e.g., concrete, or the like), a composite cementitious material (e.g., including a mixture of cementitious material and/or other materials, such as fibers, foam, or the like). It should be understood that cementitious means any type of cement or other like material, such as traditional cement, fly ash, blast-furnace slag, limestone fines, aggregate, and/or other types of cementitious materials, alone or in combination with each other. The fill material  140 , such as the composite cementitious material, may be much lighter than traditional homogenous cementitious material. For example, the fill material  140  may be 10, 20, 30, 40, 50, 60, 70, or the like percent lighter than traditional cementitious material, or range between, overlap, and/or fall outside of any of these values. It should be understood that the cementitious material may be inserted into (e.g., poured, or the like) into the cavity  114  in the form of a liquid fill material (e.g., completely liquid, liquid having particulates, and/or the like) which then hardens into a solid core  90 . 
     The first side  106 , second side  108 , and/or bottom side  110  may be formed from members, which may have any type of shape, such as but not limited to a planer shape, a v-shape, u-shape, convex, concave, irregular, or any other type of shape. Moreover, it should be understood that regardless of the shape of the member, when the member is installed it may sit within the edges of the first face  102  and/or second face  104 . As such, the members may form a channel  116  in any of the one or more of the sides  106 ,  108 ,  110 ,  112  of the shell  80 . As illustrated in  FIG.  1   b   , the bottom side  110  of the composite door system  100  may have a bottom u-channel member  120  having a web  122  and a first flange  124  and/or second flange  126  operatively coupled to the web  122 . It should be understood that the first flange  124  and/or second flange  126  may be operatively coupled to the first face  102  and/or second face  104  by any type of connector (e.g., fasteners—bolts, rivets, screws, or the like, welds, or other like connectors). Moreover, while  FIG.  1   c    illustrates that the bottom side  110  has a channel  116 , it should be understood that the first side  106  and/or second side  108  may also have a similar channel configuration of any shape (e.g., planer, u-shaped, v-shaped, concave, convex, and/or any other type of shape). As such, any of the sides  106 ,  108 ,  110 ,  112  of the composite door system  100  may have any type of member used to operatively coupled the first face  102  to the second face  104 . In some embodiments of the invention, the channels  116  on the sides  106 ,  108 ,  110 ,  112  which sits at least partially within the edges of the first face  102  and/or the second face  104  may provide a location for attaching hardware (e.g., mechanical and/or electrified hardware, including but not limited to locks, handles, hinges, locking rods, door closers, door operators, exit device, mag locks, cameras, radar, sensors, detection devices, security devices, surveillance devices, knobs, soft closing devices, deadbolts, and/or other hardware), as will be described in further detail herein. 
     Moreover, as discussed with respect to the bottom side  110 , first side  106 , and/or second side  108 , the top side  112  may have any type of member of any shape, including any type of channel  116 . For example, as illustrated by the cross-section view of the top side  112  of the composite door system  100  in  FIG.  2   a   , and the top view of the top side  112  of the composite door system  100  in  FIG.  2   b   , a top member may have one or more openings. For example, the top member may form a channel  130  within the top side  112  of composite door system  100 , such as a u-shaped channel  130  having a web  132 , a first flange  134  and/or a second flange  136 . However, as previously discussed, the top member may have any shape, such as planer, u-shaped, v-shaped, convex, concave, and/or other shape that may or may not provide a channel in the top side  112 . The u-shaped channel member  130  may comprise a web  132  and a first flange  134  and/or a second flange  136  that are operatively coupled to the web  132 . It should be further understood that the web  132  of the u-shaped channel member  130  may comprise one or more openings  131  that allow for filling the cavity  114  of the composite door system  100  with a liquid material that later hardens, as will be described in further detail herein. 
     It should be further understood that in some embodiments the shell  80  may further comprises one or more support members to form a reinforced core (e.g., reinforced concreate core). The one or more support members may be vertical support members (as shown), horizontal support members (not illustrated), angled support members (not illustrated), or the like. The one or more support member may provide additional structural support for the composite door system  100 . In some embodiments the one or more support members may be operatively coupled to the first face  102  and/or the second face  104  to provide additional support to the composite door systems  100 . The one or more support members may be any type of shape, including, but not limited to z-shaped, c-shaped, L-shaped, truss shaped, corrugated shaped, tubular shaped (e.g., circular, oval, square, rectangular, or the like), non-uniform shape, or any other like shape. In some embodiments, the support members may be 22 gage z-shaped stamped steel members  232 ; however, it should be understood that any gage steel may be utilized (e.g., 10, 12, 14, 16, 18, 20, 22, 24, or the like, or otherwise range between, overlap, and/or fall outside of any of the forgoing values). In some embodiments, the support members may be placed no more than 6 inches apart; however, in some embodiments, the support members may be placed 1, 2, 3, 4, 5, 6, 8, 10, 12, 16, 20, 24, or the like inches apart, or otherwise range between, overlap, and/or fall outside of any of the forgoing values. The one or more support members may be operatively coupled to the first face  102  and/or second face  104  through the use of a coupling, such as welds, fasteners (e.g., bolts, rivets, screws, or the like), adhesive, tape, epoxy, or other like couplings. 
     As illustrated in  FIG.  2   b   , the one or more openings  131  may be located in series along the top member (e.g., two, three, four, or the like openings). However, it should be understood that the one or more openings  131  may be located in series, be alternated, in parallel, uniform, non-uniform, and/or be formed with any pattern. It should be further understood that while the one or more openings  131  are illustrated as being rectangular in  FIG.  2   b   , the one or more openings  131  may be any shape, such as but not limited to square, circular, oval, triangular, trapezoidal, pentagonal, octagonal, hexagonal, any polygonal shape, and/or other like shape. Moreover, while the openings  131  are illustrated as being located within the top member  130 , it should be understood that openings may be located in any side and/or face (e.g., first face  102 , second face  104 , first side  106 , second side  108 , bottom side  110 , or the like). The one or more openings  131  may be 1.5 inches wide by 8 inches long, however, it should be understood that the one or more openings  131  may be any width (e.g., 0.25, 0.5, 0.75, 1, 1.25, 1.5, 1.75, 2.0, 2.25, 2.5, 2.75, 3.0, or the like), length (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, or the like), and/or thickness (e.g., the thickness of the member). It should be understood that the width and/or length may range between, overlap, or fall outside of any of these values. Regardless of the location and/or size of the one or more openings  131 , the openings allow for the passage of liquid fill material into the cavity  114 , which then hardens in the door to form a core  90  of the composite door system  100  that is damage resistant (e.g., projectile resistant, attack resistant, blast resistant, fire resistant, etc.). 
     It should be understood that the channels  116 , such as the u-shaped members  120  may be described herein as a hardware housing  150 . As such, the members, such as the u-shaped channel members  120  or the like, may provide locations in which to assemble hardware. The members provide a “mix guard” (e.g., “fill material guard”) to prevent cavity fill materials  140  from entering the locations designated for hardware installation. Furthermore, the members may provide structure to the composite door system  100  in order to allow for shipping of the hollow shell  80  without damaging the shell  80 . In particular, using a top member at the top side  112 , as opposed to an open top side  112  may provide improved structural support to the top side  112  of the shell  80 . It should be further understood that the shell  80  may further have one or members operatively coupled between the first face  102  and/or the second face  104 , which provides additional structural support to the shell  80  before the cavity  114  within the shell  80  is filled with fill material  140 . The hardware housings  150  (e.g., the channels  116 , or other hardware housings  150  described below in further detail) may be manufactured using FE (forced entry) and/or BR (Bullet Resistant) (collectively otherwise described herein as FEBR) resistant materials, composites, or the like to protect the hardware from projectiles, explosions, physical attack, or the like as described herein. 
     In other embodiments of the composite door system  100 , other hardware housings  150  may be used to secure door hardware instead of using a channel, as described above. For example, the hardware housings  150  may comprise a solid hardware housing  160  as illustrated in  FIG.  3   , a cased hardware housing  170  as illustrated in  FIG.  4   , a tubular hardware housing  180 , and/or other type of hardware housings  150  and/or combinations thereof. 
     For example, as illustrated in  FIG.  3    the shell  80  of the composite door system  100  may be operatively coupled to a solid hardware housing  160 , such as solid damage resistant material (e.g., projectile resistant material, or the like). The damage resistant material (e.g., projectile resistant material, or the like) may be, but is not limited to fiberglass, Kevlar, steel armor, polycarbonate, aluminum or other metals, laminate, carbon fiber, polyurethane, acrylic, other like material, or combinations thereof. The damage resistant material (e.g., the projectile resistant material, or the like) may be machined in order to create apertures for receiving door hardware. Alternatively, or additionally, the damage resistant material (e.g., projectile resistant material, or the like) may be formed into the desired shape to receive the desired hardware without machining or with minimal machining. As such, as illustrated in  FIG.  3   , the projectile resistant material may be machined for receiving hardware before and/or after the projectile resistant material is operatively coupled to the shell  80 . It should be understood that the projectile resistant material (or other damage resistant material) may also provide a fill material guard that prevents the fill material  140  from flowing in the hardware apertures where the hardware may be located, while still providing resistance to projectiles, or other impacts, from damaging the hardware. It should be understood that the solid hardware housing may be 12 inches wide (or other sizes, such as 6, 7, 8, 9, 10, 11, 13, 14, 15, 16, 17, 18, 20, 24, or the like or range between, overlap, or fall outside of these values). 
     As illustrated in  FIG.  4   , the cased hardware housing  170  may comprise a box, or a portion thereof, that is operatively coupled to the first face  102  and/or the second face  104 . The cased hardware housing  170  may comprise a housing having five sides with an open side, four sides with two open sides, three sides with three open sides, and/or two sides (L-shaped member) with four open sides, and/or in some embodiments may comprise a plate (e.g.., a planer member that is operatively coupled to the first face  102  and/or the second face  106 ). In some embodiments the cased hardware housing  170  may be made of steel, a fiberglass material, or the like. Moreover, the cased hardware housing  170  may be any size, such has having a thickness of 1/16″, ⅛″, ¼″, ½″, ⅔″, ¾″, 1″ or other like size, or range between, overlap, and/or fall outside of these values. In some embodiment, steel of at least ¼″ may be utilized in order to provide level 7 or 8 resistance to projectiles, as will be discussed in further detail herein. It should be understood that the cased hardware housing  170  (or the channel housings previously described, or other hardware housings) may have a 0.5″, 1″, 1.5″, 2″, 2.5″, 3″, 4″, 5″ or the like opening in the cased hardware housing to allow for assembly of the hardware (e.g., for a 1″ mortise lock, or the like). 
     As illustrated in  FIG.  5   , the hardware housings  150  may comprise a tubular hardware housing  180  that is operatively coupled to the first face  102  and/or the second face  104 . The tubular hardware housing  180  may be of any shape, such as a cylindrical tube, a square tube, a circular tube, oval tube, a rectangular tube, any polygonal tube, an irregular tube, and/or any other type of tube to which hardware may be operatively coupled. The core may surround all or at least a portion of the tubular hardware housing  180 . 
     It should be understood that any type of hardware housing  150  may be located within any location of the composite door system  100  depending on the type of hardware and/or the location of such hardware. It should be understood, for example, as illustrated in  FIGS.  3  and  5    that the hardware housings  150  may run adjacent the entirety, or a portion thereof, of a side of the composite door system  100 , such as along the first side  106 . This location may allow for locating a locking mechanism (e.g., a mortise lock, elongated bar lock, door knob, door lever, deadbolt lock, or the like). Moreover, as illustrated in  FIG.  4    the hardware housings  150  may be located along different positions adjacent the first side  106 , second side, and/or the top side  112 . These locations may allow for locating a locking mechanism in different locations along the edges (e.g., first side  106 , second side  108 , or the like) and/or allow for the attachment of different types of handles (e.g., panic exit handles and locking mechanisms, such as L-shaped pivoting handles, or the like). Moreover, as illustrated in  FIGS.  4  and  5   , including a hardware housing  150  adjacent the top side  112  of the composite door system  100  may allow for operative coupling of a door closer or door operator (e.g., collectively door control system). It should be further understood that the hardware housings  150  may be located adjacent any side of the composite door system  100  and/or within the composite door system  100  (e.g., in the interior away from the edges, or the like) in order to protect the hardware from projectiles or provide other damage resistance. The hardened fill material  140  is what typically provides protection from projectiles or other damage, and the hardware may be located within the composite door system  100  at locations that may not be thick enough to provide the desired protection using the fill material  140 . As such, the hardware housings  150  may be utilized to provide the desired protection at these locations. Therefore, regardless of the type of hardware housing  150 , it may be made of a material and/or have a thickness that provides different levels of damage resistance (e.g., projectile resistance, attack resistance, or the like). For example, the hardware housings  150  may provide UL level 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or the like protection from projectiles, as will be described in further detail herein. 
     While the first face  102 , second face  104 , first side  106 , second side  108 , bottom side  110 , and/or top side  112  may have surfaces that are smooth (or generally smooth, or substantially smooth, or the like), the faces and/or sides may have structural elements in the exterior surfaces (surfaces that can be seen) and/or interior surfaces (surfaces facing the cavity  114 ), such as corrugations, or the like, which provide structural support to the shell  80  before the cavity is filled with fill material  140 . 
     It should be further understood, that depending on the desired application of the composite door system  100 , there may be one or more additional layers that comprise of other materials, such as but not limited to water resistant or proofing layers, concreate layers, coatings, or the like depending on the operation and/or installation requirements for the composite door systems  100  and/or the barrier structures in which they may be used. 
     In some embodiments of the disclosure, the composite door systems  100  may include a window portion. The window portion may be transparent, semi-transparent, or non-transparent. The window portion may be described as a sidelight, transom, borrowed light, door light, sash window, roller window, louver, or any other like window. The window portion may be damage resistant (e.g., projectile resistant, element resistant—wind, attack resistant, fire resistant, blast resistant, or the like). The window portion may be made from any type of material such as glass, acrylic, polycarbonate, laminate, other type of material, or combinations thereof in one or more layers. The window portion may itself be damage resistant or the window portion may have a glazed layer that is damage resistant. As such, the window may have a UL level 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or the like rating. The window portion may be installed in the shell  80  of the composite door system  100  before shipping to the installer, or it may be installed on site by the installer. As such, the window may be installed within a window housing that is similar to, or the same as the hardware housings  150  previously described herein. The liquid fill material  140  may be poured into the cavity  114  of the shell  80  with the window installed or before the window is installed, and the liquid fill material  140  will flow around the window and/or the window housing in order to fill the cavity  114  of the shell  80 . As such, one or more members may be located within the cavity  114  in order direct the flow of the liquid flow material  140  within the cavity  114 . Alternatively, the shell  80  filled with the hardened fill material  140  may be retrofitted with a window portion, that is, after the fill material  140  hardens in the cavity  114  on-site, or within an installed composite door system  100  that is retrofitted after installation. Moreover, any window portions already installed within a composite door system  100  may be retrofitted with a glaze to improve the damage resistance of the window portion of the composite door system  100 . The glaze may be made from a material that is the same as or similar to the materials of the window portion described above. Moreover, the glaze may be applied using any method, such as painted, heat sealed, applied as a sticker, or the like. 
       FIG.  6    illustrates one embodiment of a barrier structure  10  that utilizes one or more composite door systems  100 , in accordance with some embodiments of the disclosure. It should be understood that one or more composite door systems  100  may be utilized in a number of different barrier structures  10 , such as in temporary structures, permanent structures, walls, partitions, or the like. 
     Regardless of how the composite door systems  100  are utilized, it should be understood that the composite door systems  100  are created and installed in accordance with the composite door system manufacturing and assembly process  400 , as illustrated in  FIG.  7   . As illustrated by block  410  in  FIG.  7   , the members for the shell  80  of the composite door system are created, for example, by cutting (e.g., using a shears, lasers, water, or the like cutting devices), stamping (e.g., stamping, cold forming, pressing, or the like), or other like method of creating the desired members. 
     Block  420  of  FIG.  7    further illustrates that the shell  80  of the composite door system  100  is formed. For example, the members are operatively coupled together, such as by bending portions of the members (e.g., bending the portions to create one or more of the sides and/or faces from a single member) and/or using a connector (e.g., welding, using a fastener—bolt, rivet, screw, clamp, bracket, shearing of lapped portions of the shell, or the like) to operatively coupled two or more members together. 
       FIG.  7    further illustrates in block  430  that the one or more hardware housings  150  and the shell  80  are operatively coupled together in one or more locations. As previously discussed herein, the hardware housings  150 , may comprise the members (e.g., channels) of the sides of the shell  80 , a solid hardware housing  160 , a cased hardware housing  170 , a tubular hardware housing  180 , and/or the like that are operatively coupled to (e.g., within, butted against, or the like) the shell  80 . As previously described herein, the hardware housings  150  are used to secure the hardware for the composite door system  50 . Moreover, once the hardware housings  150  are operatively coupled to the shell  80 , the hardware may be operatively coupled to the composite door system  10 . For example, channel members (e.g., channel hardware housing), the solid hardware housings  160  (e.g., which may be machined to receive the hardware), the case hardware housings  170 , and/or the tubular hardware housings  180 , may be prepared to receive the hardware assembled to the composite door system  10 . It should be understood that the hardware may be operatively coupled to the hardware housings  150  at this point before the fill material  140  is provided to the composite door system  100 , or alternatively, the hardware may be assembled on-site (e.g., before or after the fill material  140  is provided to the composite door system  100 ). 
     Block  440  of  FIG.  7    further illustrates that the one or more shells  80  are shipped to the location at which the barrier structure  10  is to be assembled and/or installed using the composite door systems  100 . Since the composite door systems  100  only comprise the shells  80 , the shipping weight is much less than conventional doors for barrier systems  10  (e.g., commercial FEBR doors, doors made of fiberglass, Kevlar, or other types of projectile doors, or the like). In this way, manufacturing and shipping costs are greatly reduced. Furthermore, the locally sourced fill material  140  may be utilized and/or formed onsite at the assembly location. Sourcing the fill material  150  locally may further reduce shipping and/or installation costs. 
       FIG.  7    further illustrates in block  450  that the fill material  140  may be created and/or formed on site, such as for example, at the assembly location of the building structure  10 . For example, powered material may be formed and/or created at the assembly location, and thereafter, mixed with a liquid (e.g., water) in order to create the fill material  140  (e.g., cementitious, composite cementitious, or the like fill material in liquid form). Block  460  further illustrates that the liquid fill material  140  formed may then be inserted into the shell  80 . For example, the liquid fill material  140  may be poured into the channel (e.g., top u-channel  130 ) at the top side  112  of the composite door system  10 . In this way, the channel may provide a feeding location for the fill material  140  for the composite door system  100 . As such, the liquid fill material  140  may at least partially fill the channel, and the one or more openings  131  in the channel or other member at the top side  112  may allow the liquid fill material  140  to flow into the cavity  114 , and thus, at least partially fill the cavity  114 . It should be understood that a pre-determined amount of liquid fill material  140  may be provided to the cavity  114  based on the size and shape of the composite door system  100 ; however, it should be understood that the u-channel provides a fill gage, such that when the u-channel begins to fill with a liquid fill material  140  it should be understood that the cavity  114  may be filled because no additional liquid fill material is passing through the one or more openings  131  of the member on the top side  112  of the composite door system  100 . While it is generally described herein that the liquid fill material  140  is poured into the shell  80  through one or more openings  131  in the top side  112  of the composite door system  100 , it should be understood that the one or more openings  131  may be additionally and/or alternatively located in a portion of the first face  102 , second face  104 , first side  106 , second side  108  and/or bottom side  110 . For example, it may be beneficial to fill the composite door system  100  in the orientation in which it is going to be installed. As such, the one or more barrier systems  10  may be positioned in any orientation and filled with liquid fill material and allowed to harden before orienting the composite door system  100  for installation in a barrier structure  10 . 
     Block  470  of  FIG.  7    further illustrates that the liquid fill material  150  is allowed to cure within the cavity  114  into a solid core  90  in order to create the composite door system  100 . 
       FIG.  7    further illustrates in block  480  that the composite door systems  100  and/or other components (e.g., structural members, panels, or the like) are assembled together in order to create a barrier structure  10 . Any of the embodiments of the composite door systems  100  discussed herein may be utilized to construct a barrier structure  10  having one or more walls  12 , one or more doors  14 , one or more roofs, one or more partitions, and/or any other structural components of any type of barrier structure  10 . Moreover, the composite door systems  100  may be combined with other types of doors and/or walls as desired to form the desired barrier structure  10 . 
     Barrier structures  10 , such as dwellings, buildings, partitions, and the like, typically comprise doors  14 , walls  12  (e.g., panels), or the like, and in many instances, it is desirable that the barrier structures  10  provide resistance to and protection from physical impacts from projectiles. The projectiles may occur due to debris from extreme weather (e.g., hurricanes, tornados, severe thunderstorms, typhoons, or the like). Alternatively, the projectiles may be ballistics from firearms, ordnance, explosive devices, or the like. In still other embodiments, the projectiles may be a result of explosions that could occur due to gas, chemicals, or other like explosive materials. In still other embodiments the projectiles may be a result of destructive testing of products (e.g., crash testing of cars, blade out turbine testing, or performance testing of other products). Additionally, it may be desirable to have improved fire resistance, sound proofing, radiation protection, electromagnetic shielding, or the like. 
     Conventional FE (forced entry) and/or BR (Bullet Resistant) doors, otherwise described herein as FEBR door openings, use ballistic resistant materials such as steel armor, composite BR fiberglass, Kevlar, BR composites, or other like materials as part of the core components, all of which add weight to door. FEBR door openings utilizing these conventional materials can weigh 450-750 pounds depending on the size, core type and steel gauges used. This extreme weight increases the wear on the door opening hardware, increases the freight costs, installation and user handling risks and cost of ownership. 
     The conventional FEBR doors described above are not only extremely heavy, costly to transport, undesirably bulky and dangerous during shipping or should they fail during operation, but they also are potentially unable to provide the desired projectile resistance within the desired door sizes. The weight of conventional FEBR doors not only makes manufacturing, shipping, and installing the doors difficult and dangerous, but it also causes problems when operating the doors. For example, the doors are difficult for a user to move, and they cause detrimental wear and tear to the hardware components of the door, such as the hinges, door opening mechanisms, etc. degrading the operation of the doors and/or requiring replacement of the hardware components. The weight of these doors makes the freight and shipping costs for transportation extremely high, in particular, when these doors are shipped long distances (e.g., thousand(s) of miles), and moreover, this makes it difficult to quickly build temporary structures in dangerous locations that provide protection from projectiles. As such, conventional door products for FEBR and enhanced protection openings are approaching their performance limits. 
     The composite door systems  100  (for use in door openings) of the present disclosure alleviate the foregoing deficiencies with conventional doors, and also provide additional advantages. For example, the composite door systems  100  of the present invention provide improved security, enhanced threat protection, and use of more sustainable materials to reduce weight, waste, lower the cost of ownership and the impact on the environment. 
     First, the composite door systems  100  of the present disclosure provide outstanding resistance to and protection from a variety of physical impacts by projectiles. In particular, the composite door systems  100  are structured to provide various UL level protection from ballistic projectiles (e.g., firearm, or the like) and also protection from other projectiles such as debris or shrapnel. As such, the composite door systems  100  described herein may provide the desired FE (forced entry) and/or BR (Bullet Resistant) properties while providing reduced weights and/or improved shipping and/or installation processes. For example, the composite door systems  100  may have UL752 Level 1 (9 mm handgun) to UL 752 Level 10 (.50 Caliber Rifle) protection, and in particular embodiments UL752 level 1 (9 mm), UL752 level 2 (0.357 Magnum), UL752 level 3 (0.44 Magnum), UL752 level 4 (.30 Caliber Rife), UL752 level 6 (9 mm rifle), UL752 level 7 (5.56 mm), UL752 level 8 (7.62 mm), UL752 level 9 (0.30-06 rifle), UL752 level 10 (.50 caliber rifle), or the like protection, or have protection that ranges between, overlaps, or falls outside of these levels of protection. Furthermore, the composite door systems  100  may also be rated to withstand 5, 10, 15, 20, 25, 30, 40, 50, 60, or the like minutes of simulated “mob” attack, or range between, overlap, or fall outside of these levels of protection. As such, it should be understood that the barrier structures  10  described herein may be shipped and/or assembled on site in the desired location quickly and cost effectively, while providing the desired levels of projectile protection. 
     As an example, a door made from conventional projectile-resistive materials, such as armor steel or BR fiberglass core, weighs about 450-750 lbs. However, a door made from a composite cementious fill material may be 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, or the like percent lighter. As such, because the shells  80  of the composite door system  100  are extremely light weight, they may be shipped in greater quantities due to the reduced weight, and may be installed and/or replaced (should a door need replacing) using smaller equipment (e.g., trucks, smaller cranes, or the like) than would be required with comparable conventional steel armor, BR fiberglass, or other like conventional door material. Moreover, the composite door systems  100  can be retrofit in existing buildings. Furthermore, it should be understood that the shells  80  may be installed in the barrier structure  10  (e.g., the door shells may be installed first) for ease of installation before the fill material  140  is added to the shells  80 . Consequently, regardless of the installation methods, the weight reductions of the present disclosure reduce freight costs (e.g., due to reduced fuel needs), lowers cost of ownership, and reduces operator risk, wear and tear on hardware and installation and/or maintenance. 
     Moreover, the composite door systems  100  of the present disclosure are also about 20% stronger than conventional projectile-resistive materials (e.g., concrete, or other like materials). As such, all things being equal (e.g., the size of the door, thickness thereof, or the like) the composite door systems  100  of the present disclosure may be 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, or the like percent stronger than a corresponding concreate system. 
     The composite door systems  100 , as disclosed herein, utilize construction materials and alternate core materials, and are formed in a way that is environmentally friendly. For example, the materials of the shell  80  and/or core  90  may be made from recyclable and/or repurposed materials (e.g., 10, 20, 30, 40, 50, 60, 70, or the like percent recyclable and/or repurposed). Moreover, the steel used in the shell (otherwise described as a skin) may be made from recycled and/or repurposed materials (e.g., 10, 20, 30, 40, 50, 60, 70, 80, 90 or the like percent recycled and/or repurposed). Furthermore, the composite door systems  100  may replace conventional FEBR core materials and/or adhesives that are petroleum based or produced from materials that are less environmentally friendly. In some embodiments, the composite door systems  100  may meet UL Environmental/Sustainable Solutions for GREENGUARD and GREENGUARD Gold certification. Additionally, the composite door systems  100  may meet compliance and third party validation for Environmental Product Declarations (EPD), DECLARE labels, Living Building Challenge requirements, and/or compliance to California Prop65. 
     The composite door systems  100  described herein reduce the cost of the end product and manufacturing methodology, and moreover, the composite door systems  100  reduce the environmental and resource costs when compared to conventional FEBR doors. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “distal,” “proximal,” “upper,” “top,” “bottom,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upper,” and “lower”, or other like terminology merely describe the configuration shown in the figures. The referenced components may be oriented in an orientation other than that shown in the drawings and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. It will be understood that when an element is referred to as “operatively coupled” to another element, the elements can be formed integrally with each other, or may be formed separately and put together. Furthermore, “operatively coupled” to can mean the element is directly coupled to the other element, or intervening elements may be present between the elements. Furthermore, “operatively coupled” may mean that the elements are detachable from each other, or that they are permanently operatively coupled together. 
     Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.