Patent ID: 8429854

Claim:
A hurricane-storm resistant door assembly comprising: a. a door comprising: (i) a first horizontal edge substantially parallel to a second horizontal edge; (ii) a first vertical edge substantially parallel to a second vertical edge, wherein the horizontal edges are connected to the vertical edges forming a space therebetween; (iii) a closed cell foam disposed within the space; (iv) a front skin disposed over both of the horizontal edges, both of the vertical edges, and the closed cell foam, wherein the front skin is a fiber reinforced polymer substrate substantially between 2 mm and 3.5 mm thick; (v) a back skin disposed over the edges and the closed cell foam opposite the front skin, wherein the back skin is a fiber reinforced polymer substrate between 2 mm and 3.5 mm and thick; (vi) a port opening formed through the closed cell foam, front skin, and back skin; and (vii) a port door configured to transition the opening from a closed state to an open state; b. a double welded impact resistant grill capable of withstanding at least 37 mph impacts, secured to the door over at least the port opening, wherein the double welded impact resistant grill comprises: (i) a first rod intersecting with a second rod forming an intersecting center grid that has a plurality of zones; wherein each zone of the plurality of zones has a support barrier connection disposed therein, and wherein each support barrier connection engages the first and second rods of the intersecting center grid; and (ii) a plurality of legs on the intersecting grid, wherein each leg has an integral one piece foot formed thereon, and wherein each foot has a central fastening hole formed therethrough; and (iii) a plurality of double welded securing rings, wherein each securing ring encircles the intersecting center grid and two different support barrier connections, simultaneously; c. a plurality of connection holes formed through the front skin, the back skin and the closed cell foam, wherein each connection hole is aligned with a respective fastening hole; and d. a plurality of fasteners, wherein each fastener is installed through respective connection holes and through one of the aligned fastening holes thereby securing the double welded impact resistant grill to a front skin side of the door forming the hurricane storm resistant door assembly able to sustain 37 mph flying debris impacts without deforming while producing a sound reducing barrier.