Shock insulating door system and method

Abstract

A door system includes a door having a frame forming at least a portion of a perimeter of the door and a sleeve configured to encase at least a portion of the frame. The frame is constructed from a first material and the sleeve is constructed from a different second material. The first material may be electrically conductive and the second material may be electrically insulating. Alternatively or additionally, the first material may be susceptible to wear and tear and the sleeve may be resilient and replaceable.

Claims

1. A door system comprising: a sliding door panel including a frame forming at least a portion of a perimeter of the door panel, wherein the frame comprises a first material and includes a first frame member having a leading edge, a trailing edge, and opposing sides connecting the leading edge to the trailing edge, wherein at least one side of the opposing sides includes a ridge protruding outward and extending along a length of the first frame member, wherein the frame of the door panel comprises a plurality of frame members including the first frame member, wherein the first frame member comprises a second ridge on the other side of the opposing sides; and a cover configured to encase at least a portion of the leading edge and at least a portion of the trailing edge, wherein the cover comprises a second material and includes a groove formed into an interior surface of the cover and extending along a length of the cover, the groove configured to receive the ridge to retain the cover on the first frame member, wherein the cover is a sleeve having a cross-sectional shape configured to conform to at least a majority of a cross-sectional shape of at least the first frame member of the plurality of frame members, wherein the sleeve comprises a corresponding second groove, wherein the second groove is configured to receive at least a portion of the second ridge to secure the sleeve on the first frame member.

2. A door system comprising: a sliding door panel including a frame forming at least a portion of a perimeter of the door panel, wherein the frame comprises a first material and includes a first frame member having a leading edge, a trailing edge, and opposing sides connecting the leading edge to the trailing edge, wherein at least one side of the opposing sides includes a ridge protruding outward and extending along a length of the first frame member, wherein the frame of the door panel comprises a plurality of frame members including the first frame member, wherein the first frame member has a generally rectangular cross-sectional shape comprising an internal wall configured to face an opposing second frame member of the frame, an external wall opposite the internal wall and configured to face outward from the door panel, and two lateral walls extending between the internal wall and the external wall; and a cover configured to encase at least a portion of the leading edge and at least a portion of the trailing edge, wherein the cover comprises a second material and includes a groove formed into an interior surface of the cover and extending along a length of the cover, the groove configured to receive the ridge to retain the cover on the first frame member, wherein the cover is a sleeve having a cross-sectional shape configured to conform to at least a majority of the cross-sectional shape of the first frame member, wherein the cross-sectional shape of the sleeve comprises: a first wall of the sleeve configured to contact an external surface of the external wall of the first frame member; a second wall and a third wall of the sleeve extending perpendicularly from the first wall, each of the second and third walls configured to contact a respective one of the lateral walls of the first frame member; and an open side opposite the first wall, wherein the open side of the sleeve comprises at least one lateral projection extending inward to a space defined between the second and third walls of the sleeve.

3. The door system of claim 2, wherein the at least one lateral projection comprises opposing lateral projections configured to at least partially conceal an external surface of the internal wall of the first frame member.

4. The door system of claim 3, further comprising a retaining structure configured to support an insert of the door panel extending across an opening defined by the plurality of frame members, wherein the opposing lateral projections are configured to cover at least a portion of the retaining structure.

5. A door system comprising: a sliding door panel including a frame forming at least a portion of a perimeter of the door panel, wherein the frame comprises a first material and includes a first frame member having a leading edge, a trailing edge, and opposing sides connecting the leading edge to the trailing edge, wherein at least one side of the opposing sides includes a ridge protruding outward and extending along a length of the first frame member, wherein the frame of the door panel comprises a plurality of frame members including the first frame member, wherein the first frame member has a generally rectangular cross-sectional shape comprising an internal wall configured to face an opposing second frame member of the frame, an external wall opposite the internal wall and configured to face outward from the door panel, and two lateral walls extending between the internal wall and the external wall; and a cover configured to encase at least a portion of the leading edge and at least a portion of the trailing edge, wherein the cover comprises a second material and includes a groove formed into an interior surface of the cover and extending along a length of the cover, the groove configured to receive the ridge to retain the cover on the first frame member, wherein the cover is a sleeve having a cross-sectional shape configured to conform to at least a majority of the cross-sectional shape of the first frame member, wherein the cross-sectional shape of the sleeve comprises: a first wall of the sleeve configured to contact an external surface of the external wall of the first frame member; a second wall and a third wall of the sleeve extending perpendicularly from the first wall, each of the second and third walls configured to contact a respective one of the lateral walls of the first frame member, wherein the second wall has a length exceeding a length of a respective one of the two lateral walls of the first frame member such that the second wall extends a distance past the internal wall of the first frame member; and an open side opposite the first wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are included to provide a further understanding of the disclosure, are incorporated in and constitute a part of this specification, illustrate aspects of the disclosure and together with the detailed description serve to explain the principles of the disclosure. No attempt is made to show structural details of the disclosure in more detail than may be necessary for a fundamental understanding of the disclosure and the various ways in which it may be practiced. In the drawings:

(2) FIG. 1 is a perspective view of a door system in accordance with the present disclosure.

(3) FIG. 2A is a perspective view of a train at a boarding platform with the platform doors and train doors closed.

(4) FIG. 2B is a perspective view of a train at a boarding platform with the platform doors opened and train doors closed.

(5) FIG. 3 is a front view of a door such as one used on a train.

(6) FIG. 4 is a cross-sectional view of a portion of the door taken along line 4-4 in FIG. 3.

(7) FIG. 5 is a cross-sectional view of a portion of the door taken along line 4-4 of FIG. 3 on which a cover is installed.

(8) FIG. 6 is a partial perspective view of a frame member of the door of FIG. 4.

(9) FIG. 7 is a partial perspective view of the cover of FIG. 5.

(10) FIG. 8 is a flowchart of a method of according to the present disclosure.

DETAILED DESCRIPTION

(11) The aspects of the disclosure and the various features and advantageous details thereof are explained more fully with reference to the non-limiting aspects and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one aspect may be employed with other aspects as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the aspects of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the aspects of the disclosure. Accordingly, the examples and aspects herein should not be construed as limiting the scope of the disclosure, which is defined solely by the appended claims and applicable law. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.

(12) FIG. 1 shows a door system 10 in accordance with an embodiment of the present disclosure. The door system 10 is installed in a wall 12. The floor 14 is also shown. The door system 10 includes a door 18 which may optionally be equipped with a handle 20. In other embodiments, other hardware may be mounted on the door 18 such as a push plate and/or kick plate. The door may be mounted with hinges such that the door pivots open and closed or may be mounted to slide such as in one or more tracks and/or on one or more roller assemblies.

(13) The door 18 may be made of a frame 26 which may be made of a plurality of portions or members which, in some embodiments, are extrusions which may be aluminum, steel, or other suitable material. The door 18 often contains an insert 24 such as a window that spans across an opening 23 formed within the frame 26. The insert 24 may be made of glass, plexiglass, or other suitable material. The frame 26 of the door 18 surrounds and may support the window or other insert 24. The door 18 is mounted in a door frame 22. The door frame 22 is mounted in the wall 12.

(14) In other embodiments, the door system 10 may be used in transit systems. For example, FIGS. 2A and 2B show a train platform 30. Some platforms 30 such as the ones shown in FIGS. 2A and 2B include platform door systems 10 which include platform doors 32. Other platforms 30 may be open platforms and not include platform doors 32. FIG. 2B shows the platform doors 32 slid to an open position exposing the train 28 and train door system 10 with train doors 36. The train doors 36 may slide to open or closed positions.

(15) FIG. 3 shows an example door 18, which may be similar to door 18 of FIG. 1 but mounted to slide rather than pivot, in accordance with the present disclosure. The door 18 has a frame 26 comprising a plurality of frame members including, but not limited to, a top frame member 27a, a bottom frame member 27b, a first side frame member 27c, and an opposing second side frame member 27d. It should be appreciated that any number of frame members may be assembled together to form a frame. The top frame member 27a may be secured to a hanger assembly 29 to facilitate sliding of the door 18. One or more bottom guides 31 may be secured to the bottom frame member 27b to maintain alignment of the door 18 as it slides. For example, the bottom guides 31 may extend into a slot in a floor, a door frame, or platform.

(16) The door 18 includes an insert 24. The insert 24 may be transparent, translucent, or opaque. For example, the insert 24 may be a window made of glass, plexiglass, plastic or other suitable material. The door 18 has a frame 26 that surrounds and supports the insert 24. Optionally, the door 18 has a handle 20 or other hardware such as put not limited to push plates, kick plates and the like. Any suitable type of handle 20 such as a lever, knob, gripping recess, etc. may be used.

(17) FIGS. 4 and 5 illustrate cross-sections of a portion of a frame member of a door, for example, along the line 4-4 through the first side frame member 27c of the door 18 of FIG. 3. However, it should be appreciated that the views of FIGS. 4 and 5 may be similarly applicable to the door 18 of FIG. 1, the platform doors 32 of FIG. 2A, the train doors 36 of FIG. 2B, or any other suitable door such as a hospital door in an oxygen-rich medical environment.

(18) FIGS. 4 and 5 show the cross-sectional view of the first side frame member 27c of an embodiment of a door 18. As illustrated, the first side frame member 27c has a generally rectangular cross-sectional shape. The term “generally rectangular” as used herein with reference to a cross-section may refer to any shape which resembles a rectangle, including a square, even though various recesses, pockets, openings, or protrusions may extend into or from the primary surfaces of such a shape. The illustrated embodiment of the first side frame member 27c includes an internal wall 55a, an external wall 55b, and two lateral walls 55c, 55d extending between the internal wall and the external wall, thereby forming a generally rectangular cross-section. Although the implementation shown is generally rectangular, other implementations of the first side frame member may be any metallic shaped member. In some implementations, it is a hollow metallic shaped member which may be tubular, cylindrical, arced, triangular, or any other suitable shape.

(19) A frame member 27 may include an insert retaining structure 40. The insert retaining structure 40 serves to attach the insert 24 to the frame 26 of the door and retains the insert 24 in the door. In the example cross-section shown in FIGS. 4 and 5, the insert retaining structure 40 includes a first seal 42 and second seal 44 and an insert stop 46. The first seal 42 is attached to a first retaining bracket 48 and the second seal 44 is attached to a second retaining bracket 50. The insert stop 46 may limit movement of the insert 24 toward the frame member and may also provide a mating feature such as one or more channels 61 to mate with or otherwise receive a portion of the first and second retaining brackets 48, 50. In the illustrated embodiment, the frame 26 forms two channels 61 for receiving a portion of the first and second retaining brackets 48, 50, respectively, for securing the retaining brackets to the frame 26. The retaining brackets 48, 50 may slide into the channel 61 and be captured by the channels or may be snap-fit into the channels. It should be appreciated that any suitable means for securing the retaining brackets 48, 50 to the frame 26 may be used such as, for example, an adhesive or a fastener. Further, in some embodiments the first and second retaining brackets 48, 50 may be formed as a single retaining bracket or one or both retaining brackets may be omitted altogether.

(20) A nosing assembly 52 may be attached to the frame 26 on an opposing side from the retaining brackets 48, 50, for example, by at least one fastener 54 and a nosing assembly retaining plate 56. The nosing assembly 52 may provide a relatively soft surface that is configured to contact a corresponding surface of a door frame 22, as may be the case in medical environments, or of an opposing sliding door 32, 36, as may be the case in transit applications. The nosing assembly 52 may include a resilient member 53 and a rigid nosing assembly retaining plate 56 may aid in connecting the nosing assembly 52 to the frame 26, where use of one or more fasteners 54 alone may result in tearing or deterioration of the nosing assembly 52. In other embodiments, the nosing assembly 52 may attach to the frame 26 in another suitable way. For example, but not limiting, the nosing assembly 52 may attach to the frame 26 by an adhesive or slide in a track in the frame 26 and be captured by the track.

(21) The resilient member 53 of the nosing assembly 52 may itself be electrically insulating such that the nosing assembly 52 may be disposed outside of the sleeve 58 without increasing the risk of electric shock or sparking. In this regard, as shown in FIGS. 4 and 5, components of the nosing assembly 52 which may be metallic in some embodiments, such as the fasteners 54 and nosing assembly retaining plate 56, may be disposed inside a hollow chamber of the resilient member of the nosing assembly 52 to insulate those components. A hole 60 may extend through an outer wall of the resilient member of the nosing assembly 52 to permit fasteners to be inserted into the hollow chamber for securing the nosing assembly 52 to a frame 26. Alternatively, one or both of the nosing assembly retaining plate 56 and fasteners 54 may be constructed of materials which are electrically insulating.

(22) In operation, the nosing assembly 52 may be slid into contact with an adjacent and corresponding surface of a door frame 22 or opposing door. The resilient member of the nosing assembly 52 may deform to absorb the impact when closing the door and/or to form a seal between the frame 26 and the adjacent surface.

(23) FIG. 5 shows an electrically insulating and/or protective sleeve 58 (hereinafter “sleeve”) fitted over the frame member 27c. It will be appreciated that the embodiment of a cover illustrated in the figures is a sleeve which wraps around a plurality of surfaces of a door, but the disclosure herein is applicable to any cover applied to a door system having the features described herein. For example, several distinct members may be applied to a door to form a cover, such as applying a first member to a front side of the door, a second member to the back side of the door, and a third member to the leading edge of the door generally spanning between the first and second members. In this regard, the term ‘sleeve’ used herein includes a one-piece member covering at least a portion of plurality of faces of a door but may also generally be considered as including any cover, including but not limited to a cover covering one face (or portion thereof) of a door or a cover comprising a plurality of separate protective and/or insulating members. FIG. 6 is a perspective view of the frame 26 of FIG. 5 and FIG. 7 is a perspective view of the sleeve 58 of FIG. 5. The sleeve 58 may be rubber, plastic, polymer, or any other suitable material. The sleeve 58 is generally shaped to correspond to the shape of the frame member to fully or partially encase, encapsulate, conceal, surround, insulate, or otherwise cover the frame member around its cross-sectional shape. However, the sleeve 58 may not need to exactly conform to the shape of the frame member as shown by the open side 66 that may not exactly conform to the insert retaining structure 40. Additionally, the sleeve 58 may only cover a portion or all of one side (or face) of a frame member 27, two sides, three sides, four sides, all sides, etc. For example, in some embodiments, the sleeve 58 may primarily only cover the outermost surface of the frame which is most susceptible to contact with users or other surfaces. In the illustrated embodiment, the sleeve 58 includes a first wall 57a which is configured to conform to the external wall 55b of the frame member 27c, and second and third walls 57b, 57c which are configured to conform to the lateral walls 55c, 55d of the frame member 27c. Additionally, the sleeve 58 may include one or more lateral projections 59a, 59b which extend inwardly toward a space defined by the second and third walls 57b, 57c of the sleeve 58. The lateral projections 59a, 59b may be oriented perpendicular to their respective wall of the sleeve or may extend at any suitable angle with respect thereto. In some embodiments, one or both lateral projections 59a, 59b may conform to at least a portion of the retaining structure 40 to electrically insulate the retaining structure and/or to aid in securing the sleeve 58 to the frame 26. In this regard, one or both lateral projections 59a, 59b may grip the frame 26 in a manner which prevents the sleeve 58 from sliding off the frame laterally.

(24) It should be appreciated that some or all frame members (e.g., top, sides, bottom) may receive a sleeve 58. For example, in some applications, only those frame members 27 most susceptible to contact may receive a sleeve such as the leading member supporting a handle 20, e.g., the first side frame member 27c. Similarly, all or only a portion of a frame member may receive a sleeve 58. For example, in a transit application, portions of a platform door 32 or train door 36 nearest patrons' arms and shoulders may receive a sleeve 58 while portions of the door near the platform 30 or door header may remain uncovered.

(25) In some embodiments, the sleeve 58 is made of a resilient material. In instances where a frame member is made from an extruded material or otherwise has a generally consistent cross section, the sleeve 58 can be slid over the frame member. The fastener 54 may extend through a hole 60 in the sleeve 58. If a door is equipped with a handle 20 or other hardware, the handle 20 or other hardware may be installed after the sleeve 58 is installed and attached to the frame 26 in a non-conducting manner (such as with non-conducting fasteners or concealed structural fasteners).

(26) In some embodiments, the frame 26 may include one or more retaining structures 62 that fit in one or more corresponding locking structures 64 in the sleeve 58. A retaining structure 62 and corresponding locking structure 64 cooperate to aid in retaining the sleeve 58 on the frame 27. An example of a retaining structure 62 may include a hook, a barb, a ridge, or similar protrusion extending from a surface of the frame 26. An example of a locking structure 64 may include a recess, a channel, a slot, or similar structure formed into the sleeve 58. The retaining structure 62 and locking structure 64 may each be formed of a plurality of discrete protrusions and recesses. However, in embodiments in which the sleeve 58 and/or corresponding frame 26 are formed from extrusions, the retaining structure 62 and locking structure 64 may extend the entire length of the respective sleeve 58 and frame member 27. It should be appreciated that, in some embodiments, the retaining structure 62 may be disposed on the sleeve 58 and the locking structure 64 may be disposed on the frame 26.

(27) As shown in FIGS. 5-7, the retaining structure 62 and corresponding locking structure 64 are shaped so that the sleeve 58 can slide over the frame member 27, but the retaining structure 62 and corresponding locking structure 64 will resist rotation of the sleeve 58 with respect to the frame 26 and/or translational movement of the sleeve 58 away from the frame 26 similar to how a dovetail joint and/or tongue and groove system works. In some embodiments, the sleeve 58 may be slid onto a frame member longitudinally with the retaining structure 62 and locking structure 64 aligned. In other embodiments, the sleeve 58 may be slid onto a frame member transverse to a longitudinal axis of the sleeve 58 through the open side 66 until one or more locking structures 64 receive one or more retaining structures 62. In some embodiments, a sleeve 58 may be flexible and/or resilient to allow the opening of the open side 66 to expand to receive the frame member. This arrangement may be more suitable for embodiments in which a sleeve 58 is attached after the door has been assembled or for retrofit installations of a sleeve 58.

(28) It should be appreciated that a sleeve 58 may not always be pre-formed and then applied to a frame member 27. Rather, in some embodiments, a sleeve 58 may be formed directly on a frame member 27. For example, a sleeve may be applied to a frame member 27 by spraying a protective or insulating material onto the frame, or dipping the frame member 27 into the material, and then curing the material.

(29) It will be understood that the shape of a frame member 27 and corresponding insulating sleeve 58 will vary from one door system 10 to another. Further, each frame member 27 (e.g., top, bottom, left side, and right side members) may require different sleeves having different geometries to ensure a suitably conforming fit. In some embodiments, a sleeve 58 may generally conform to a majority (e.g., contact over at least 51% of the surface area) of a corresponding shape of a member of a frame 26. In some embodiments, a door system 10 may comprise four frame members 27 having four distinct cross-sectional shapes and may further comprise four sleeves 58 each having cross-sectional shapes corresponding to the frame members.

(30) By fitting a sleeve 58 over all or part of the frame 26 of the door, a user is less likely to be shocked and a spark is less likely to occur when the user or an object contacts or nears the door. Further, it will be understood that the sleeve 58 may be damage resistant by nature of its resiliency, however, in the event of a damaged sleeve 58, the damaged sleeve 58 can be replaced with a new sleeve 58 if needed. All or a portion of a damaged sleeve may be slid off of the frame 26 and a new sleeve may be slid into place.

(31) In some embodiments, the sleeve 58 can be a cover to help protect the frame members 27 from damage and may or may not have insulating properties. In such instances, the sleeve 58 will receive the wear from contact and weathering rather than the frame 26 and the sleeve 58 can be replaced when needed or worn.

(32) In some embodiments, some disassembly of the door system 10 may be needed to install a new sleeve 58. Further, existing frame members 27 which may not initially have sleeves 58 may be fitted with insulating and/or protective sleeves 58. Such a retrofit may allow a formerly non-insulated door system 10 to become insulated or an unprotected door system 10 to become protected. In such embodiments, existing frame members 27 may lack a retaining structure 62, such as illustrated in FIG. 4, and a sleeve 58 may be secured to such frame members using fasteners, an adhesive, or any other suitable means. For example, a sleeve 58 may have a snug conforming shape such that the sleeve 58 itself grips onto a frame member 27. Additionally or alternatively, a frame member 27 may be modified to receive a sleeve 58. For example, a channel or recess may be cut into a member of a frame so that a corresponding protrusion or ridge on a sleeve 58 may be mated to the frame. Where a nosing assembly 52 is present, such a nosing assembly may be removed to allow a sleeve 58 to be installed after which the nosing assembly may be replaced.

(33) FIG. 8 illustrates a method 70 for reducing electrical discharge or preventing damage in a door system. The method may include a process 72 forming an insulative and/or protective sleeve comprising a first material that is different than a second material from which a door frame onto which the sleeve is to be installed is constructed. In some embodiments, the door frame may be formed from an electrically conductive material and the sleeve may be formed from an electrically insulating material. In some embodiments, the door frame may be susceptible to damage and wear and tear from contact with objects which may pass through the door and the sleeve may be formed from a material that protects the door frame from damage and may or may not be replaceable. Process 72 may include any method of manufacturing a sleeve made from a rubber, plastic, thermoplastic, polymer, etc. in accordance with the present disclosure such as extruding, injection molding, directly spraying, or dipping. Process 74 may include encasing at least a portion of at least one frame member of a door with the sleeve. Encasing the frame member may include a process 76 of sliding the sleeve onto the frame member and a process 78 of securing the sleeve to the frame member. The sleeve may be secured to the frame member by any suitable means such as, but not limited to, engagement of corresponding mating features of the sleeve and the frame member (e.g., a ridge and a channel), an adhesive, one or more fasteners, gripping the frame member with lateral protrusions of the sleeve, etc.

(34) Some embodiments of the method 70, particularly when used for retrofitting an existing door, may include removing hardware such as door handles or nosing assemblies prior to the process 74 of encasing the frame member and may include reinstalling the hardware after process 74. Reinstalling the hardware may include cutting, drilling, or otherwise forming openings through the sleeve to allow the hardware components to be reinstalled in their original locations.

(35) It should be appreciated that the various processes of the method 70 discussed above may be optional as not all of the described processes are required for implementing the method. Unless expressly stated as being required, each process should be considered optional.

(36) While the disclosure has been described in terms of exemplary aspects, those skilled in the art will recognize that the disclosure can be practiced with modifications in the spirit and scope of the appended claims. These examples given above are merely illustrative and are not meant to be an exhaustive list of all possible designs, aspects, applications or modifications of the disclosure. It should be appreciated that the geometry and features shown in this disclosure are non-limiting examples.