Plugless glazing system

Abstract

The present invention involves an entry door having a window glass situated in a door slab and a space between the window glass and the door slab. A plugless locking system is configured to fit in the space between the window glass and the door slab. The plugless locking system has a first plugless lock is configured to receive an external trim and is configured to mate with a second plugless lock. The second plugless lock is configured to receive an interior trim. The combination of the mated first and second plugless lock fit within the space between the window glass and door slab and secure interior and exterior trim to the entry door. Also disclosed is a method for using the plugless locking system in an entry door.

Claims

1. An entry door comprising: a door slab; a glass portion positioned within the door slab; and a plugless locking system positioned between the glass portion and the door slab, the plugless locking system comprising: a first plugless lock receiving an exterior trim; a first fastener attaching the first plugless lock to the exterior trim; a second plugless lock receiving an interior trim; and a second fastener attaching the second plugless lock to the interior trim, wherein the first and second fasteners are concealed by the first and second plugless lock and the first and second fasteners are contained within the first and second plugless locks.

2. The entry door of claim 1, wherein the first plugless lock further comprises: a base having an exterior side and an opposite interior side, the exterior side of the base is attached to the exterior trim; first and second members extending from the interior side of the base; a cavity defined by the base and the first and second members; a first arm extending from the first member, the first arm engages the interior trim; a second arm extending from the second member, the second arm engages a surface of the exterior trim; and at least one aperture within the first plugless lock.

3. The entry door of claim 2, wherein the second plugless lock comprises: a branch at least partially received within the cavity of the first plugless lock; and at least one flange member extending from the branch, the at least one flange member engages the aperture to attach the second plugless lock with the first plugless lock.

4. The entry door of claim 3, wherein grooves are configured to abut against a mating profile of the interior trim to support the second plugless lock relative to the interior trim.

5. The entry door of claim 4, wherein the mating profile includes a space defined by a first rib and a second rib.

6. The entry door of claim 4, wherein the mating profile includes a ridge that extends along the underside of the interior trim.

7. The entry door of claim 1, wherein the first and second plugless locks are removable from the door slab to selectively remove the glass portion.

8. The entry door of claim 1, wherein the glass portion is selectively removable from the door slab by removal of the first and second plugless locks.

9. An entry door comprising: a door slab; a glass portion positioned within a door slab; and a plugless locking system positioned between the door slab and the glass portion, the plugless locking system comprising: a first plugless lock; a first fastener attaching the first plugless lock to an exterior trim; a second plugless lock; and a second fastener attaching the second plugless lock to an interior trim, wherein the first and second fasteners are concealed by the first and second plugless lock and the first and second fasteners are contained within the first and second plugless locks.

10. The entry door of claim 6, wherein the first plugless lock further comprises: a base having an exterior side and an opposite interior side, the exterior side of the base is attached to the exterior trim; first and second members extending from the interior side of the base; a cavity defined by the base and the first and second members; a first arm extending from the first member, the first arm engages the interior trim; a second arm extending from the second member, the second arm engages a surface of the exterior trim; and at least one aperture within the first plugless lock.

11. The entry door of claim 10, wherein the second plugless lock comprises: a branch at least partially received within the cavity of the first plugless lock; and at least one flange member extending from the branch, the at least one flange member engages the aperture to attach the second plugless lock with the first plugless lock.

12. The entry door of claim 10, wherein the first and second plugless locks are formed from a UV resistant injection molded plastic composite.

13. The entry door of claim 10, wherein the first and second plugless locks are formed from at least one of acrylonitrile butadiene styrene and polycarbonate.

14. An entry door comprising: a door slab; a glass portion positioned within a door slab; and a plugless locking system operatively positioned between the door slab and the glass portion, the plugless locking system attached to an exterior trim by a first fastener and attached to an interior trim by a second fastener, wherein the first and second fasteners are concealed by the plugless locking system and the first and second fasteners are contained within the plugless locking system.

15. The entry door of claim 14, wherein the plugless locking system comprises first and second plugless locks.

16. The entry door of claim 15, wherein the first plugless lock comprises: a base having an exterior side and an opposite interior side, the exterior side of the base is attached to the exterior trim; first and second members extending from the interior side of the base; a cavity defined by the base and the first and second members; a first arm extending from the first member, the first arm engages the interior trim; a second arm extending from the second member, the second arm engages a surface of the exterior trim; and at least one aperture within the first plugless lock.

17. The entry door of claim 16, wherein the second plugless lock comprises: a branch at least partially received within the cavity of the first plugless lock; and at least one flange member extending from the branch, the at least one flange member engages the aperture to attach the second plugless lock with the first plugless lock.

18. The entry door of claim 14, wherein the plugless locking system is removably attached to the door slab.

19. The entry door of claim 18, wherein removing the plugless locking system allows removal of the glass portion from the slab.

20. The entry door of claim 14, wherein the plugless locking system is formed from a UV resistant molded plastic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations, wherein:

(2) FIG. 1A is an exterior view of an entry door;

(3) FIG. 1B is an interior view of the entry door;

(4) FIG. 2 is a cross-sectional view of an entry door with a window glass with a plugless locking system;

(5) FIGS. 3A, 3B, 3C, and 3D are perspective views of various first plugless locks;

(6) FIG. 4 is a bottom view of a first plugless lock;

(7) FIGS. 5A, 5B, and 5C are side views of various first plugless locks;

(8) FIGS. 6A, 6B, and 6C are perspective views of various second plugless locks;

(9) FIGS. 7A and 7B are bottom views of various second plugless locks;

(10) FIGS. 8A and 8B are side views of various second plugless locks;

(11) FIGS. 9A, 9B, and 9C are perspective views of a first plugless lock mating with an exterior trim;

(12) FIGS. 10A and 10B are perspective views of a first plugless lock mated with an exterior trim;

(13) FIGS. 11A, 11B, and 11C are perspective views a second plugless lock mating with an interior trim;

(14) FIGS. 12A and 12B are perspective views of a second plugless lock mated with an interior trim;

(15) FIG. 13 is a side view of a plugless locking system being installed in an entry door;

(16) FIGS. 14A and 14B are perspective views of a plugless locking system mated without an entry door; and

(17) FIGS. 15A, 15B, 15C and 15D are exploded views of embodiments of the plugless locking system.

DETAILED DESCRIPTION

(18) Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention.

(19) An entry door 10 capable of being attached to a building structure, the entry door 10 having a window glass 12, is shown in FIG. 1A. The entry door 10 may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the entry door 10 shown and described herein. The window glass 12 may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the window glass 12 shown and described herein. Further, the window glass 12 is not limited to glass; it may also be plastic or any other suitable material. The window glass 12 may be clear, colored, opaque, or any combination of such. Further, the window glass 12 may be comprised of multiple pieces, e.g., a stained glass window design. These, however, are merely exemplary embodiments of the entry door 10 and window glass 12any appropriate door or window glass may be used with the present teachings. While the entry door 10 is shown and described as being a door to enter a structure, it may also be an internal door, closet door, or any other type of door; the present teachings are not limited to the use and type of door shown and described.

(20) When terms such as interior, exterior, inner, outer, lower, upper, horizontal, and vertical are used herein, reference is made to the entry door 10 of the present teachings when oriented as shown, for example, in FIGS. 1A and 1B. It should be understood that such terms are used in their relative senses and are intended to be and are merely exemplary and not all-inclusive nor exclusive.

(21) As shown in FIGS. 1A and 1B, the entry door 10 may have a door slab 14, which may be formed from a variety of materials, including, but not limited to, wood, plastic, steel, fiberglass, aluminum or any other appropriate materialor it may be a combination of any such material. The entry door 10 may have an exterior surface 16 and an interior surface 18. When the entry door 10 is used as an entry door to a building, for example, the exterior surface of the door 16 is the side of the door exposed to the outside of the building. In this situation, the interior surface of the door 18 is exposed to the interior of the building.

(22) The window glass 12 may also have an exterior surface 20 and an interior surface 22. The exterior surface of the window glass 20 may be exposed to the outside of the building in the example above. The interior surface of the window glass 22 may be exposed to the interior of the building.

(23) The window glass 12 may have both an exterior trim 24 contacting the exterior surface of the door 16 and the exterior surface of the window glass 20 and an interior trim 26 contacting the interior surface of the door 18 and the interior surface of the window glass 22. The exterior and interior trims 24, 26 may be of any appropriate configuration. The exterior and interior trims 24, 26 may provide an aesthetically pleasing finish to the entry door 10. The exterior and interior trims, 24, 26 may be formed of any appropriate material, including, without limitation, wood, plastic, fiberglass, steel, aluminum, or any other materialor a combination of such materials.

(24) The window glass 12 may be secured to the door slab 14 by a plugless locking system 30 as shown in FIG. 2. The plugless locking system 30 may include a first plugless lock 32 and a second plugless lock 34.

(25) As shown in FIGS. 3A-D, 4, and 5A-C, the first plugless lock 32 may be generally rectangular in shape with a base 36 having a width smaller than the distance between the door slab 14 and the window glass 12 in the entry door 10. The base 36 may have a first base end 38 having at least one aperture 40A and a second base end 42 opposite from the first base end 38 having at least one aperture 40B. The base 36 may have additional apertures 85 that may mate with the exterior trim 24 allowing for repeatable installation of the plugless locking system 30.

(26) The first plugless lock 32 may also include a first side 44 of any appropriate configuration. The first side 44 may include a relief aperture 46 and a first side end 97 attached generally perpendicularly to the base 36 at a first base side 47. The first side 44 may also include a second side end 99 attached generally perpendicularly to a first ledge or arm 48. The first plugless lock 32 may further include a second side 50 having a relief aperture 52 and a first side end 95, which may be attached perpendicularly to the base 36 at the second base side 53. The second side 50 may also include a second side end 93 attached generally perpendicularly to a second ledge or arm 54. The first side 44 and the second side 50 may be generally parallel to one other, but are not limited to this configuration.

(27) A cavity 56 may be formed between the first side 44 and the second side 50, the cavity 56 having a width generally equivalent to that of the base 36. Further, the first side 44 may be shorter than the second side 50 and accordingly, the first arm 48 and the second arm 54 may be at different elevations. However, the first plugless lock 32 may be of any appropriate configuration and is not limited to that shown and described herein.

(28) As shown in FIGS. 6A-C, 7A-B, and 8A-b, the second plugless lock 34 may include a branch 58. The branch 58 may include a first flange member 60 positioned at one end of the branch 58 and a second flange member 62 position at an opposing end of the branch 58. The first flange member 60 may be spaced from the second flange member 62. A channel 64 may be defined by the space between the first flange member 60 and the second flange member 62 and bordered by the branch 58. The first flange member 60 may include a first end 66 having a first clip 68 and a second end 70 having a first groove 72. The first end 66 of the first flange member 60 and the first clip 68 may be configured to be received by the at least one aperture 40A of the base 36 of the first plugless lock 32.

(29) The second flange member 62 of the second plugless lock 34 may include a first end 74 having a second clip 76 and a second end 78 having a second groove 80. The first flange member 60 and the second flange member 62 may be generally parallel to one other, and both may extend at a substantially right angle from branch 58. In one embodiment, the first clip 68 may be opposite from the second clip 76 such that each clip may be biased relative to the other to be received within apertures as illustrated by FIGS. 6A and 6B. Both the first plugless lock 32 and the second plugless lock 34 of the plugless locking system 30 may be formed from a variety of materials, including, but not limited to, plastic, steel, fiberglass, aluminum or any other appropriate material or any combination of such. By way of a non-limiting example, the plugless locking system 30 may be formed from a strong UV resistant injection molded plastic or composite, such as acrylonitrile butadiene styrene (ABS) or polycarbonate (PC).

(30) The exterior trim 24 may be attached to the base 36 of the first plugless lock 32 through the use of a fastener 82 operatively inserted through a central hole 83, as shown in FIGS. 4, 9A, 9B, 9C, 10A and 10B. The present teachings of the fastener 82 are not limited to the screw shown. Any appropriate fastener 82 may be used without departing from the present teachings. The exterior trim 24 may be formed from a variety of materials, including, but not limited to, plastic, metal, wood, or any other suitable material or combination of such. The fastener 82 may be any type of fastener, including, but not limited to, a screw, nail, nut, bolt, lag, or any other appropriate fastener. The fastener 82 may be inserted through aperture 83 as illustrated by FIGS. 2 and 15A, and is to be concealed from view once the interior trim 26 and the exterior trim 24 of the system are installed in place.

(31) Similarly, as shown in FIGS. 11A, 11B, 11C, 12A, and 12B, the interior trim 26 may be attached to the second plugless lock 34 through the engagement with a mating profile 90 along an underside 92 of the interior trim 26 with the first groove 72 and the second groove 80 of the second plugless lock 34. In this embodiment, the mating profile 90 includes a ridge 122 that extends along the underside 92 of the interior trim 26 and is shaped to fit within the first and second grooves 72, 80. This configuration may prevent unwanted rotation between the interior trim 26 and the second plugless lock 34 as they are being attached. A fastener 82 may be operatively inserted through a central hole 84 of the second plugless lock 34. In one embodiment, the underside 92 of the interior trim 26 includes an extension portion 94 configured to receive the fastener 82 as it extends through the aperture 84 along the branch 58 of the second plugless lock 34. The extension portion 94 may extend from the underside 92 of the interior trim 26 and abut against the branch 58 as the fastener 82 is installed. The extension portion 94 may extend radially passed the edges of the branch 58 to form an overlap portion 96. The interior trim 26 may be formed from a variety of materials, including, but not limited to, plastic, metal, wood, or any other suitable material. The fastener 82 may be any type of fastener, including, but not limited to, a screw, nail, nut, bolt, lag, or any other appropriate fastener.

(32) The first plugless lock 32 may be configured to be received in a space 100 between the door slab 14 and the window glass 12 as shown in FIGS. 2, 9A and 13. The combination of the first plugless lock 32 and the attached exterior trim 24 may be inserted into the space 100, with the base 36 of the first plugless lock 32 leading. When fully inserted, the first plugless lock 32 may fit snugly between the window glass 12 and the door slab 14. The exterior trim 24 may rest on the exterior surface 16 of the door 14 and the exterior surface 20 of the glass 12. In one embodiment, a sealer material may be positioned between the exterior trim 24 and the exterior surfaces 16, 20. The sealer material may be a foam material or tape material applied to the trim 24 before installation. Additionally, the sealer material may be a silicone or other type of water based sealing material. The exterior trim 24 may bridge the space 100 between the door slab 14 and the window glass 12, creating a watertight seal on the entry door 10.

(33) After insertion into the space 100, the first arm 48 of the first plugless lock 32 may abut the interior surface 22 of the window glass 12 and the second arm 54 of the first plugless lock 32 may abut the interior surface 16 of the door slab 18.

(34) The second plugless lock 34 may also be configured to be received by the space 100 between the door slab 14 and the window glass 12. The second plugless lock 34 and the attached interior trim 26 may be inserted into the space 100, with the first clip 68 of the first flange member 60 and the second clip 76 of the second flange member 62 of the second plugless lock 34 leading. When fully inserted, the second plugless lock 34 may fit snugly between the window glass 12 and the door slab 14 with the interior trim 26 resting against the interior surface 18 of the door 14 and the interior surface 22 of the window glass 12. In one embodiment, a sealer material may be positioned between the interior trim 26 and the interior surfaces 18, 22. The sealer material may be a foam material or tape material applied to the trim 26 before installation. Additionally, the sealer material may be a silicone, polyurethane or other type of water based sealing material. This sealer material may be useful to reduce raddling of the trim.

(35) The second plugless lock 34 may be inserted inside the cavity 56 of the first plugless lock 32. The first end 66 of the first flange member 60 of the second plugless lock 34 may be inserted through the at least one aperture 40A of the first plugless lock 32. The first end 74 of the second flange member 62 of the second plugless lock 34 may be inserted through the at least one aperture 40B of the first plugless lock 32. First and second clips 68, 76 along the first ends 66, 74 respectively, may be flexible so that they may compress to pass through the at least one apertures 40A, 40B and expand upon exiting the at least one apertures 40A, 40B to generally resist opposing movement of the second plugless lock 34. The resulting mating combination of the first and second plugless locks 32, 34 may create a removable connection that allows for the replacement of the window glass 12, exterior trim 24, and/or interior trim 26. FIGS. 14A and 14B show this connection without the entry door 10, to show the mating of the first and second plugless locks 32, 34. Further, the second plugless lock 32 illustrated by FIGS. 6C, 8A, 8B, may be attached to interior trim 26 as illustrated by FIGS. 11A, 11B, 11C, 12A and 12B. This embodiment, is configured to be attached to the first plugless lock 32 that includes a relief apertures 46, 52 for receiving the extension portion 94 of the interior trim 26. In this embodiment, the overlap portion 96 of the extension portion 94 may extend within relief apertures 46 and 52 for a snug fit connection.

(36) Additionally, in another embodiment, the first plugless lock 32 illustrated by FIGS. 3B, 3C, 15A, 15B and 15C include apertures 102A, 102B positioned along sidewalls 104A, 104B that extend from the base 36 and between the first side 44 and the second side 50. These side apertures 102A, 102B are configured to receive the first and second clips of the second plugless lock 36 illustrated by FIGS. 6A and 6B.

(37) Further, as illustrated by FIGS. 15A, 15B, 15C, and 15D, a locating feature is provided wherein the second ends 70, 78 of the first flange 60 and second flange 62, respectively, may be inserted into the mating profile 90 along an underside 92 of the interior trim 26. In this embodiment, the matting profile 90 includes a first rib 110 and a second rib 112. The first and second ribs 110, 112 extend along the underside 92 and are spaced from one another along the underside 92 of the interior trim 26. The ribs 110, 112 may define a space that includes at least one slot 114 and a shoulder 116 therein. The first groove 72 may be configured to be received within the slot 114 while the remaining portion of the second ends 70, 78 may abut against the shoulder 116. This embodiment allows a user to quickly locate the proper position of the second plugless lock 34 relative to the interior trim 26 without risk of unwanted relative rotation.

(38) Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.