Tamper resistant door

Abstract

A cavity is defined between stiles (101, 102, fig 1) and rails (111, 112, 113, fig 1) of a door. A panel 114 is located within this cavity, presenting an inner face and an outer face. Beads are locate

Description

The present invention relates to a method of fabricating a tamperresistant door. The present invention also relates to an apparatus for the construction of a tamper-resistant door. Secure doors with glass panels are well known and it is also known for these panels to be retained in place by the provision of a wedge gasket. However, if an unauthorised removal of this wedge gasket is made, it is possible that the wedge gasket could be put to other uses of an undesirable nature. However, problems also arise, particularly in terms of fit and presentation, if the gasket of this type is not deployed. According to a first aspect of the present invention, there is provided a method of fabricating a tamper resistant door as set out in claim 1. Thus, in this way, the wedge gasket ensures that the panel is securely held in place, thereby facilitating accurate alignment. However, by forcing the wedge gasket beyond the first leg and then deploying an anti-stick mastic, difficulties are created for anyone attempting to remove the wedge gasket; given that significant time and effort would be required to remove a sufficient quantity of the anti-pick mastic before it becomes possible to deploy force directly upon the wedge gasket. In an embodiment, an upper cavity is defined along with a lower cavity separated by an intermediate rail and a glass panel may be arranged within the upper cavity. The locating step may comprise receiving an extending flange of the bead within a stile or rail and engaging an inwardly extending tooth within a restraining channel of the extending flange. According to a second aspect of the present invention, there is provided an apparatus for the construction of a tamper resistant door, As set out in claim 11. Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings. The detailed embodiments show the best mode known to the inventor and provide support for the invention as claimed. However, they are only exemplary and should not be used to interpret or limit the scope of the claims. Their purpose is to provide a teaching to those skilled in the art. Components and processes distinguished by ordinal phrases such as “first” and “second” do not necessarily define an order or ranking of any sort. In the drawings: Figure 1 shows a conventional aluminium door; Figure 2 shows the removal of a wedge gasket from a door of the type shown in Figure 1; Figure 3 shows an embodiment of the present invention; Figure 4 details part of the embodiment shown in Figure 3; Figure 5 provides further details of the bead identified in Figure 4; and Figure 6 shows an attempt to remove the gasket from the embodiment of Figure 3. Figure 1 A conventional aluminium door is illustrated in Figure 1 of a type where it is possible to remove a wedge gasket. The door is constructed from a first stile 101 and a second stile 102, with the second stile 102 supporting a lock 103, such that it may be referred to as the lock stile. An upper rail 111, a lower rail 112 and an intermediate rail 113 define a first cavity between the upper rail 111 and the intermediate rail 113, along with a second cavity between the intermediate rail 113 and the lower rail 112. A respective panel is arranged within each of these cavities and in this example, a glass panel 114 is arranged within the first cavity with a solid panel 115 being located within the second cavity. Referring to the glass panel 114, this panel presents an inner face (as presented in Figure 1) along with an outer face, being the opposite side to that shown in Figure 1. To restrain the glass panel in place, beads are located between the stiles 101, 102 and rails 111, 113 and the inner face, wherein these beads include a first leg and a second leg to create a gripping section. The wedge gasket is then inserted between the beads and the inner face. As illustrated in Figure 1, it may be possible for an unauthorised person to apply force to the wedge gasket using an implement 116 such as a knife. Figure 2 Having deployed a knife or similar implement, as described with reference to Figure 1, it is possible for conventional wedge gaskets, such as a wedge gasket 201, to be removed from the rail 113. To overcome this problem, it is known to use resins and mastics that may be deployed in liquid form and thereafter allowed to set. Materials of this type may be configured such that they retain panels in place but crumble into pieces when abused in the way described with reference to Figure 1. However, this approach creates further problems, in that the panels must be restrained firmly in place while the material is allowed to set. Further action is then required to maintain the overall look of the bead after these restraining devices have been removed. Theoretically, such an approach is possible but experiments suggest that, in a manufacturing facility, such an approach is time-consuming and often leads to the production of units that are considered to be below the required level of quality. Figure 3 An embodiment of the present invention is shown in Figure 3. A panel 301 presents an inner face 302 and an outer face 303. A bead 304 for the outer face is extruded with a rail 305, substantially similar to rail 113 described with reference to Figure 1. This may be of a conventional design with a first leg 311 and a second leg 312 for receiving a wedge gasket. In this example, the tamper resistant functionality is not required on the outside surface. After the panel 301 has been arranged within the cavity, a bead 320 is located between the rail 305 and the inner face 302 of the panel. This bead also includes a first leg 311 and a second leg 312 to create a first gripping section. However, in addition, there is provided a third leg 313 to create a second gripping section. Figure 4 Inner surface 302 of the glass panel is shown in Figure 4. The first leg 311 is shown, along with the second leg 312 and the third leg 313. The first leg 311 and the second leg 312 create a first gripping section 401. In addition, the second leg 312 and the third leg 313 further create a second gripping section 402. A wedge gasket 411, substantially similar to that described with reference to Figure 2, has been inserted between the bead 320 and the inner face 302. However, this would result in a construction substantially similar to that described with respect to Figure 1. In order to make this tamper resistant, the wedge gasket is forced beyond the first leg 311, such that the wedge gasket is restrained within the second gripping section to apply compressive force against the panel. Thereafter, an anti-pick mastic 412 is deployed over the wedge gasket at the position of the first gripping section. The mastic is deployed in liquid form and subsequently sets. An example of a mastic of this type is available from Ideal Chemical Products Limited of Warrington GB and identified by the commercial designation Ideal Seal MS 290 MS polymer. It is further identified as an anti-pick silicone-free sealant and adhesive. The inventor has found that this composite solution creates a tight compressive seal to ensure that fit quality is maintained. The mastic does not need to perform this primary function of the bead. The mastic is deployed fundamentally for its anti-pick properties, with the panel held firmly in place by the wedge gasket. Figure 5 The bead 320 is detailed in Figure 5. This shows the first leg 311, the second leg 312 and the third leg 313. These in turn define the first gripping section 401 and the second gripping section 402. In this embodiment, the bead also includes an extending flange 501 for engagement within the rail (or stile). In addition, the rail or stile includes an inwardly extending tooth which is restrained within a channel 502. In an embodiment, the bead is produced by extruding aluminium. This extruding process may shape a first foot 511 that extends from the first leg towards the first gripping section. The extruding step may also shape a second foot 512 that extends from the second leg towards the second gripping section. Furthermore, the extruding step may shape a third foot 513 that extends from the third leg in the direction of the second gripping section. Figure 6 As shown in Figure 6, a knife 601 has been deployed in an unauthorised 5 way in an attempt to remove the wedge gasket in a way described with respect to Figure 1. However, by deploying the present invention, it is not in any way easy to remove the wedge gasket, due to the presence of the non-pick mastic 412. As shown in Figure 6, when force is applied, the mastic tends to break up into small pieces, such as piece 602. 10 The invention therefore provides for an apparatus for the construction of a tamper resistant door, in which a bead 320 is locatable between a stile 102 or a rail 113 of a door, and an inner face 302 of a panel 301 to secure the panel within a cavity. The apparatus includes a wedge gasket 411 and an antipick mastic 412. The bead 320 is configured to compress an inserted wedge 15 gasket 411 against the panel to restrain the panel in place. Furthermore, additional space is provided for the application of the anti-pick mastic 412.

Claims

1. A method of fabricating a tamper-resistant door, comprising the steps of:defining a cavity between stiles and rails of a door;arranging a panel within said cavity, wherein said panel presents an inner face and an outer face;locating beads between said stiles and rails and said inner face, wherein said beads include a first leg and a second leg to create a first gripping section, and a third leg to further create a second gripping section;inserting a wedge gasket between said beads and said inner face;forcing said wedge gasket beyond said first leg, such that said wedge gasket is restrained by said second gripping section to apply compressive force against said panel; anddeploying an anti-pick mastic over said wedge gasket substantially at the position of said first leg, to thereby inhibit any unauthorised attempt to remove the wedge gasket located by said inserting step.

2. The method of claim 1, wherein an upper cavity is defined along with a lower cavity separated by an intermediate rail.

3. The method of claim 2, wherein a glass panel is arranged within said upper cavity.

4. The method of any of claims 1 to 3, wherein said locating step comprises receiving an extending flange of said bead within a stile or rail and engaging an inwardly extending tooth within a restraining channel of said extending flange.

5. The method of any of claims 1 to 4, further comprising the step of extruding aluminium to produce said bead.

6. The method of claim 5, wherein said extruding step shapes a first foot that extends from said first leg towards said first gripping section.

7. The method of claim 5 or claim 6, wherein said extruding step shapes a second foot that extends from said second leg towards said second gripping section.

8. The method of any of claims 5 to 7, wherein said extruding step shapes a third foot that extends from said third leg in the direction of said second gripping section.

9. The method of any of claims 1 to 5, further comprising the step of further locating additional beads between said stiles and rails and said outer face.

10. The method of claim 6, further comprising the step of inserting a further wedge gasket between said additional beads and said outer face.

11. An apparatus for the construction of a tamper-resistant door, comprising:a bead locatable between a stile or a rail of a door and an inner face of a panel to secure said panel within a cavity, wherein said bead includes a first leg and a second leg to create a first gripping section, and a third leg to create a second gripping section;a wedge gasket; andan anti-pick mastic, wherein said bead is configured to compress an inserted wedge gasket against said panel to retrain said panel in place andprovide additional space for the application of said anti-pick mastic for inhibiting attempts to remove the wedge gasket, wherein the wedge gasket is forced beyond said first leg such that said wedge gasket is restrained by saidsecond gripping section to apply compressive force against said panel, and said anti-pick mastic is deployed over said wedge gasket substantially at the position of said first leg.

12. The apparatus of claim 11, wherein an intermediate rail defines an upper cavity.

13. The apparatus of claim 12, wherein a glass panel is arranged within said upper cavity.

14. The apparatus of any of claims 11 to 13, wherein:said bead includes an extending flange for reception with a stile or a rail; andsaid stile or rail includes an inwardly extending tooth for engagement within a restraining channel of said extending flange.

15. The apparatus of any of claims 11 to 14, wherein said bead is formed as an aluminium extrusion.

16. The apparatus of claim 15, wherein said extrusion has a first foot that extends from a first leg towards a first gripping section.

17. The apparatus of claim 15 or claim 16, wherein said extrusion has a second foot that extends from a second leg towards said first gripping section.

18. The apparatus of any of claims 15 to 17, wherein said extrusion has a third foot that extends from a third leg in the direction of a second gripping section.

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