DOOR ASSEMBLY WITH RECHARGEABLE ELECTRICAL POWER SUPPLY FOR INTEGRATED ELECTRIC DEVICES AND METHODS THEREOF
20250334001 ยท 2025-10-30
Inventors
- Satishkumar SIVASANKARAN (Aurora, IL, US)
- Alex BODURKA (Portage, MI, US)
- Navid ANDALIBI-ABADAN (Glen Ellyn, IL, US)
Cpc classification
E06B5/10
FIXED CONSTRUCTIONS
E05B2047/0082
FIXED CONSTRUCTIONS
H02J50/80
ELECTRICITY
E06B2003/7051
FIXED CONSTRUCTIONS
E05B47/0001
FIXED CONSTRUCTIONS
E06B3/7001
FIXED CONSTRUCTIONS
E06B7/28
FIXED CONSTRUCTIONS
International classification
E06B7/28
FIXED CONSTRUCTIONS
E06B5/10
FIXED CONSTRUCTIONS
E05B47/00
FIXED CONSTRUCTIONS
Abstract
Aspects of the present disclosure describe a rechargeable door that includes at least one internal rechargeable battery and at least one further DC component powered by such rechargeable battery, wherein the at least one internal rechargeable battery is configured to be recharged via a physical connection, such as wired connections, or other contacts such as magnetic contacts or pogo pins or spring contacts, in the door via a second rechargeable battery or via wireless recharging, for example magnetic inductive or resonance charging, via placement of the second rechargeable battery on or within the door.
Claims
1. A powered door system comprising: a door slab comprising an inner door frame; an exterior door skin secured to the inner door frame; an interior door skin secured to the inner door frame opposite the exterior door skin; a core comprising foam insulation disposed within the inner door frame between the exterior door skin and the interior door skin; smart glass mounted to or at least partially housed within the door slab; an electric device mounted to the door slab; an opening formed on a lock side edge of the door slab; a battery housing secured within the opening; a rechargeable battery slidingly disposed within the battery housing; a controller disposed within an interior of the door slab on a hinge side of the door slab and electronically coupled to the rechargeable battery, the controller configured to provide a respective operating voltage to the smart glass and the electric device; and a charging station configured for electrically connecting to an alternating power source and for charging the rechargeable battery.
2. The powered door system of claim 1, wherein the electric device is operated by low-voltage direct current (DC).
3. The powered door system of claim 1, wherein the rechargeable battery includes a user interface that comprises a low power indicator, the low power indicator configured to display a low power status of the rechargeable battery.
4. The powered door system of claim 3, wherein the low power indicator includes an LED light.
5. The powered door system of claim 1, further comprising a door handle mounted onto the door slab.
6. The powered door system of claim 1, wherein the exterior door skin and the interior door skin are fiberglass.
7. The powered door system of claim 1, wherein the charging station includes a user interface that includes at least one of an input power indicator and a charging status indicator.
8. The powered door system of claim 7, wherein the user interface of the charging station includes the input power indicator, and wherein the input power indicator includes an LED light.
9. The powered door system of claim 7, wherein the user interface of the charging station includes the charge status indicator, and wherein the charge status indicator includes an LED light.
10. The powered door system of claim 7, wherein the user interface of the charging station further includes an indicator showing a fault status of the rechargeable battery connected thereto.
11. The powered door system of claim 1, further comprising an internal battery disposed within an interior of the door slab.
12. The powered door system of claim 11, wherein the internal battery is configured for receiving power from the rechargeable battery via a charging circuit, and for powering at least one of the smart glass and the electric device when the rechargeable battery is removed from the door slab.
13. The powered door system of claim 12, wherein the charging circuit creates a wired or wireless connection between the rechargeable battery and interior battery.
14. The powered door system of claim 1, wherein at least one of the electric device and the smart glass are connected directly to the rechargeable battery.
15. The powered door system of claim 1, further comprising one or more additional electric devices mounted to or within the door slab.
16. The powered door system of claim 15, wherein the one or more additional electric devices comprise one or more of an electric powered door latch, a doorbell, a digital camera, a light, a motion sensor, an entry camera with video, heating and cooling thermostat controls, an alarm sensor or control, an audio communication device, and a proximity sensor.
17. The powered door system of claim 1, wherein the controller is further configured to receive wireless signals.
18. The powered door system of claim 17, wherein the controller is configured to receive data from a connected device.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0023]
[0024]
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DETAILED DESCRIPTION
[0036] Reference will now be made in detail to the exemplary embodiments and exemplary methods as illustrated in the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and exemplary methods.
[0037] This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as horizontal, vertical, front, rear, upper, lower, top and bottom as well as derivatives thereof (e.g., horizontally, vertically, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion and to the orientation relative to a vehicle body. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms concerning attachments, coupling and the like, such as connected and interconnected, refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term operatively connected is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. The term integral (or unitary) relates to a part made as a single part, or a part made of separate components fixed (i.e., non-moveable) and connected together. Additionally, the word a and an as used in the claims means at least one and the word two as used in the claims means at least two.
[0038]
[0039] The illustrated door frame 12 includes first and second parallel, spaced apart vertically extending jamb members 12.sub.1, 12.sub.2 and a horizontally extending upper jamb rail member or header 12c that connects upper ends of the first and second jamb members 12.sub.1, 12.sub.2. Those skilled in the art recognize that lower ends of the jamb members 12.sub.1, 12.sub.2 may be interconnected through a threshold 12.sub.t. The at least one hinge 16.sub.1 pivotally attaches the door 14 to the first jamb member 12.sub.1. Typically, at least two hinges 16.sub.1 and 16.sub.2 are provided to secure the door 14 to the first jamb member 12.sub.1. Preferably, as best shown in
[0040] The illustrated door 14 includes a rectangular inner door frame 20, an exterior door skin (or facing) 23, and an interior door skin (or facing) 24 secured to opposite sides of the inner door frame 20, as best shown in
[0041] The inner door frame 20 includes a pair of parallel, spaced apart horizontally extending top and bottom rails 21.sub.1 and 21.sub.2, respectively, and a pair of parallel, spaced apart vertically extending first (lock side) and second (hinge side) stiles 22.sub.1 and 22.sub.2, respectively, typically manufactured from wood or an engineered wood, such as a laminated veneer lumber (LVL). The top and bottom rails 21.sub.1 and 21.sub.2 horizontally extend between the first and second stiles 22.sub.1 and 22.sub.2. Moreover, the top and bottom rails 21.sub.1 and 21.sub.2 may be fixedly secured to the first and second stiles 22.sub.1 and 22.sub.2, such as through adhesive or mechanical fasteners. The inner door frame 20 further may include a mid-rail (not shown). The mid-rail extends horizontally and is spaced apart from the top and bottom rails 21.sub.1 and 21.sub.2, respectively, and is typically also manufactured from wood or an engineered wood, such as a laminated veneer lumber (LVL). Moreover, the mid-rail may be fixedly secured to the first and second stiles 22.sub.1 and 22.sub.2. The hinges 16 are secured to the first stile 22.sub.1, which define a hinge stile of the inner door frame 20.
[0042] The inner door frame 20 and the exterior and interior door skins 23, 24 of a typical door 14 surround an interior cavity, which may be hollow or may be filled with, for example, corrugated pads, foam insulation, or other core materials, if desired. Thus, the door 14 may include a core 15 disposed within the inner door frame 20 between the exterior and interior door skins 23 and 24. The core 15 may be formed from foam insulation, such as polyurethane foam material, cellulosic material and binder resin, corrugated pads, etc. While a door 14 is described in exemplary embodiments as having a frame 20 with skins 23, 24 and an interior cavity, exemplary embodiments of the present disclosure contemplate any door construction that includes at least one hollow interior space, as will be described in more detail below, at least partially housing plural interior DC components, including an internal rechargeable battery and at least one additional of a plurality of possible DC components described herein.
[0043] As shown in
[0044] In exemplary embodiments, the electrical devices 30 typically are low-voltage DC electric devices operated by low-voltage DC electrical power. Low voltage direct current (DC) is known in the art as 50 volts (V) or less. Common low voltages are 1.8 V, 3.3 V, 5 V, 12 V, 24 V, and 48 V. Low voltage is normally used for doorbells, video doorbells, garage door opener controls, heating and cooling thermostats, alarm system sensors and controls, outdoor ground lighting, household and automobile batteries. Many DC electric devices operate at 5 V DC. Low voltage (when the source is operating properly), such as 5 V DC, will not provide a shock from contact. However, a high current, low voltage short circuit (automobile battery) can cause an arc flash and possibly burns.
[0045] As illustrated in
[0046] In exemplary embodiments, the rechargeable power source 40 includes a rechargeable battery pack 120 and a removable rechargeable battery pack 100. In a first exemplary embodiment, as illustrated in
[0047]
[0048] In exemplary methods, the charged battery pack 100 may be inserted into the door to provide additional power to the power source 40. The exemplary power source 40, as shown in
[0049] In exemplary embodiments, the power source 40 also includes a low battery indicator 124 to monitor the power status of the battery pack 100 to warn the user that the battery pack 100 is low on power and needs to be replaced and recharged. When the battery pack 100 is indicated as being low, the user removes the battery pack 100 from the door 14 and replaces it with a freshly charged battery pack 100. The removed battery pack 100 is then recharged at the charging station 102 to be used at a later time to replace the battery pack 100 that is then being used in the door 14.
[0050] In exemplary embodiments where only one removable battery pack 100 is available, the exemplary door system 10 and associated electrical components 30 can be configured to be fully operational due to the presence of the internal battery 120, even in the absence of the removable battery pack 100 (e.g., while it is recharging).
[0051] As shown in
[0052] As shown in
[0053] In exemplary the battery pack 100 may charge the internal battery 120 wirelessly or by hard wired connection. For hard wired charging, the battery pack 100 may include electrical connectors that mate to corresponding connectors on the interior door skin 24. The battery pack 100 may be attached to the exterior of the door skin 24 magnetically (using on or plural possible sets of magnets) or by one or more latches, such as a push latch, magnetically touch latch, traditional latch, or combinations thereof, and positioned proximate to the internal battery 120. Magnetic attachment provides further advantage with regard to case of attachment and detachment of the battery pack 100 to and from the door skin 24 without requiring any tools or mechanical interfaces. In exemplary embodiments, magnetic contacts used to attach the battery pack 100 both hold the battery pack (e.g., configured as a puck) in place and act as charge terminal(s) for the battery. Battery pack 100 may be used for wireless charging, e.g., using magnetic induction or magnetic resonance, or for charging via physical connections, including wired or non-wired connections (e.g., without limitation, pogo pins or spring contacts). Additional advantages of a magnetic connection include water and dust resistance for the door and associated door system, as well as providing an overall fast mechanism for charging the internal battery.
[0054]
[0055] As has been noted with regard to various exemplary embodiments, the battery pack 100 may be used to charge the internal battery 120 by wired connection or wirelessly. When connected by wired connection, the battery pack 100 and the internal battery 120 perform as described above for the first embodiment, except for the difference in how the battery pack 100 is connected to the door 14. The charged battery pack 100 may be inserted into the door 14 to provide DC power to the power source 40. The preferred power source 40 of the second embodiment, as shown in
[0056] As noted above, the battery pack 100 of the second embodiment may charge the internal battery 120 wirelessly. Wireless charging is known in the art, e.g., in U.S. Pat. Nos. 9,143,000 and 8,193,764, the disclosures of which are incorporated by reference herein. Wireless charging for the present invention may be accomplished, e.g., using near field techniques, such as by inductive coupling. Wireless charging preferably involves a power transmitter (preferably in the battery pack 100) and a power receiver (preferably in the power source 40). The battery pack 100 may charge the internal battery 120 with inductive charge systems, such as through use of Qi Standard, Apple MagSafe, Magne Charge, SAE J2954 Standard, PMA Stadard, Rezence (A4WP), or the like. The power transmitter includes at least one transmitter coil and a controller for controlling the charging of the power receiver. The power receiver and the power transmitter (and thus, the battery pack 100 and the power source 40) are mounted within proximity of one another to provide effective power transmission. The proximity is generally provided by the charging standard used by the system. In exemplary embodiments, materials separating the power transmitter and the power receiver are made of electrically insulating material to minimize energy loss during wireless charging. The battery pack 100 and/or the power source 40 may also include hardware and/or software to monitor the status, to optimize/control the charge/discharging cycle, or to optimize/control the operation of the internal battery 120 and/or the battery pack 100. In exemplary embodiments, such magnetic induction is configured along with modulating data over the charging coils for a smart door system.
[0057] In other exemplary embodiments, wireless charging may be performed via magnetic resonance, which relies on the resonant frequency of the charging coils in order to create the electrical current. In exemplary embodiments, this advantageously permits multiple devices to be in the same resonant field, without relying on exact coil alignment. In further exemplary embodiments, such differing devices can have varying power requirements and varying placements along the transmission field. Further, such magnetic resonance can have longer range relative to induction, e.g., up to about 50 centimeters (cm) (versus, e.g., 15 cm for magnetic induction) and power transmission up to, e.g., 100 watts (W).
[0058]
[0059] It should be understood that various aspects disclosed herein may be combined in different combinations than the combinations specifically presented in the description and accompanying drawings. It should also be understood that, depending on the example, certain acts or events of any of the processes or methods described herein may be performed in a different sequence, may be added, merged, or left out altogether (e.g., all described acts or events may not be necessary to carry out the techniques). In addition, while certain aspects of this disclosure are described as being performed by a single module or unit for purposes of clarity, it should be understood that the techniques of this disclosure may be performed by a combination of units or modules associated with, for example, a smart door.