Impact resistant door and method of manufacturing

Abstract

A door comprising a frame having a hinge stile, a lock stile, a top rail, and a bottom rail defining an internal cavity, an interlayer secured within the internal cavity, a front skin further defining the internal cavity, and a rear skin opposite the front skin and further defining the internal cavity. A method of manufacturing a door including the steps of securing a hinge stile, a strike stile, a top rail, a bottom rail, and a first skin defining a frame and an internal cavity within the frame, inserting an interlayer within the internal cavity, securing the interlayer within the internal cavity to an inner surface of the frame with a plurality of fasteners, and securing a second skin opposite the first skin and further defining the internal cavity.

Description

BACKGROUND OF THE INVENTION[0001]1. Technical Field[0002]The invention relates generally to an improved door and method of manufacturing. More particularly, the invention relates to an impact resistant door having an interlayer capable of withstanding flying debris. Specifically, the invention relates to a door with an interlayer having a woven structure disposed within an internal cavity.[0003]2. Background Information[0004]Doors provide homes with the ability to access the interior while providing security and restricting access as necessary. In hurricane prone areas of the world, doors must meet certain requirements in order to meet local safety standards. One of the more difficult standards to meet is the impact resistance requirement for flying debris that could be encountered. One of the common tests for flying debris is the typical large missile test. This test consists of firing a nine pound 2×4 piece of lumber with the end impacting the door at approximately 34 miles-per-ho...

AI Technical Summary

Benefits of technology

[0008]The present invention broadly comprises a door including a frame having a hinge stile, a lock stile, a top rail, and a bottom rail defining an internal cavity, an inter

Problems solved by technology

One of the more difficult standards to meet is the impact resistance requirement for flying debris that could be encountered.

Solid doors provide a great deal of impact resistance but suffer from a number or setbacks.

First, solid doors are substantially more expensive than hollow doors because of the shear amount of material necessary.

Second, solid doors are substantially heavier and more difficult to transport and mount in a doorway.

Third, solid doors manufactured out of wood warp more easily and can require maintenance.

While hollow doors provide reduced costs and easier transportation and mounting, the hollow doors can be unsafe in areas where flying debris is a risk.

Metal skins provide the necessary structure and impact resistance, but are generally unsatisfactory to consumers because of the fit and finish of metal.

Specifically, metal is difficult to manipulate into a wood-like finish that most consumers desire in a door.

Further, metal doors are subject to rusting and denting.

However, the is relative thinness of the skins leaves the home prone to flying debris.

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