US-12618286-B2 - Induction coil embedded in laminate layer

Abstract

A door including a laminated member, an energy receiver, and an electrical device. The laminated member has a plurality of layers are bonded to one another. The energy receiver is configured to inductively receive electrical energy from an energy transmitter. The energy receiver includes a receiver coil forming a portion of at least one layer of the plurality of layers of the laminated member. The electrical device is disposed substantially or entirely within the door and is electrically coupled to the energy receiver.

Inventors

• Adam Kendall
• Bruce Procton

Assignees

• ENDURA PRODUCTS, LLC

Dates

Publication Date

20260505

Application Date

20230620

Claims (20)

1. 1 . A door comprising: a laminated member of a rail or stile having a plurality of layers bonded to one another; an energy receiver configured to inductively receive electrical energy from an energy transmitter disposed in a door frame, the energy receiver comprising a receiver coil forming a portion of at least one layer of the plurality of layers of the laminated member; the receiver coil partially or completely hidden within the laminated member of the rail or stile; and an electrical device disposed substantially or entirely within the door and electrically coupled to the energy receiver, wherein the receiver coil comprises a single layer element disposed between two adjacent layers of the plurality of layers of the laminated member.
2. 2 . The door according to claim 1 , wherein the electrical device is a powered lock.
3. 3 . The door according to claim 1 , wherein the electrical device is an energy storage unit configured to store electrical energy.
4. 4 . The door according to claim 3 , further comprising a second electrical device disposed substantially or entirely within the door, the energy storage unit electrically coupled to the second electrical device and configured to provide electrical energy to the second electrical device.
5. 5 . The door according to claim 1 , wherein the laminated member is a stile of the door, the stile defining a lock edge or a hinged edge of the door.
6. 6 . The door according to claim 1 , wherein the laminated member is a rail of the door, the rail defining a top edge or a bottom edge of the door.
7. 7 . The door according to claim 1 , wherein the laminated member is of unitary construction and includes the receiver coil therewithin.
8. 8 . The door according to claim 1 , wherein the plurality of layers comprise an outermost layer, an innermost layer, and one or more central layers disposed between the outermost layer and the innermost layer, the receiver coil forming a portion of at least one layer of the one or more central layers.
9. 9 . The door according to claim 8 , wherein each layer of the one or more central layers has a thickness, the thickness of each layer of the one or more central layers being substantially the same.
10. 10 . A door system comprising: a door frame; an energy transmitter disposed within the door frame; and a door having an exterior surface and an interior surface opposite the exterior surface, the door pivotally coupled to the door frame such that the door is capable of pivoting between an open position and a closed position, the door comprising: a laminated member having a plurality of layers bonded to one another to form a solid piece of material; an energy receiver configured to inductively receive electrical energy from the energy transmitter, the energy receiver comprising a receiver coil disposed within the plurality of layers of the laminated member such that the receiver coil is partially or completely hidden within a rail or stile; and an electrical device disposed substantially within the door, between the exterior surface and the interior surface, the electrical device electrically coupled to the energy receiver, wherein the receiver coil comprises a single layer element disposed between two adjacent layers of the plurality of layers of the laminated member.
11. 11 . The door system according to claim 10 , wherein the energy receiver is decoupled from the energy transmitter in response to the door pivoting from the closed position.
12. 12 . The door system according to claim 10 , wherein the electrical device is an energy storage unit configured to store electrical energy transmitted to the energy receiver.
13. 13 . The door system according to claim 12 , wherein the energy storage unit is a battery.
14. 14 . The door system according to claim 12 , further comprising a second electrical device, the energy storage unit electrically coupled to the second electrical device, the energy storage unit configured to provide electrical energy to the second electrical device.
15. 15 . The door system according to claim 10 , wherein the door frame comprises a header, a jamb, and a sill, the energy transmitter disposed within the header, the jamb, or the sill such that the energy transmitter is adjacent to the receiver coil when the door in the closed position.
16. 16 . A method of manufacturing the laminated member for the door as recited in claim 1 , the method comprising: layering the plurality of layers of a material; positioning the receiver coil of the energy receiver within the portion of the at least one layer of the plurality of layers; and bonding the plurality of layers with one another to form the laminated member such that the receiver coil is capable of inductively coupling the energy receiver to the energy transmitter while disposed within the laminated member.
17. 17 . The method according to claim 16 , wherein bonding the plurality of layers bonds the receiver coil within the plurality of layers such that the laminated member is of unitary construction with the receiver coil disposed therein.
18. 18 . The method according to claim 16 , further comprising electrically coupling the receiver coil to the electrical device of the door.
19. 19 . The method according to claim 16 , wherein layering the plurality of layers includes disposing the receiver coil between an outermost layer of the plurality of layers and an innermost layer of the plurality of layers such that the receiver coil is entirely disposed within the plurality of layers.
20. 20 . The method according to claim 19 , wherein layering the plurality of layers includes disposing the receiver coil closer to the outermost layer than the innermost layer.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of, and priority to, U.S. Provisional Patent Application Ser. No. 63/353,972, filed Jun. 21, 2022, the entire contents of which are hereby incorporated herein by reference. BACKGROUND 1. Technical Field The present disclosure relates to door panels and frames and, more specifically, to transmitting electrical energy from a door frame to a door panel. 2. Discussion of Related Art Energy transmission into doors is a challenge due to the motion of the door relative to the frame. For example, pivotally mounted doors may separate from contact with the frame. In addition, the narrow edge of the door provides little space for wires or contacts. Further, the presence of a hinge provides potentially damaging pinch points for wires passing between the frame and the door. Solutions to transferring electrical energy between the frame to the door panel include placing wires in an articulating arm. Another solution is using a hinge constructed with small holes or openings to permit wires to pass through the hinge. Both of these methods allow electrical energy to be passed between the frame and the door panel continuously whether the door panel is in an open or in a closed position. However, both of these methods can be complicated mechanically and are often visually unpleasing. SUMMARY In an embodiment of the present disclosure, a door includes a laminated member, an energy receiver, and an electrical device. The laminated member has a plurality of layers bonded to one another. The energy receiver is configured to inductively receive electrical energy from an energy transmitter. The energy receiver includes a receiver coil which forms a portion of at least one layer of the plurality of layers of the laminated member. The electrical device is disposed substantially or entirely within the door and is electrically coupled to the energy receiver. In embodiments, the electrical device of the door is a powered lock. The electrical device may be an energy storage unit configured to store electrical energy. The door may include a second electrical device disposed substantially or entirely within the door. The energy storage unit may be electrically coupled to the second electrical device and be configured to provide electrical energy to the second electrical device. In some embodiments, the laminated member is a stile of the door. The stile may define a lock edge or a hinged edge of the door. The laminated member may be a rail of the door. The rail of the door may define a top edge or a bottom edge of the door. The laminated member may be of unitary construction and may include the receiver coil therewithin. In certain embodiments, the plurality of layers of the laminated member includes an outermost layer, and innermost layer, and one or more central layers disposed between the outermost layer and the innermost layer. The receiver coil may form a portion of at least one layer of the one or more central layers. Each layer of the one or more central layers has thickness. The thickness of each layer of the one or more central layers may be substantially the same. In another embodiment of the present disclosure, a door system includes a door frame, an energy transmitter, and a door. The energy transmitter is disposed within the door frame. The door has an exterior surface and an interior surface opposite the exterior surface. The door is pivotally coupled to the door frame such that the door is capable of pivoting between an open position and a closed position. The door includes a laminated member, an energy receiver, and an electrical device. The laminated member has a plurality of layers bonded to one another to form a solid piece of material. The energy receiver is configured to inductively receive electrical energy from the energy transmitter. The energy receiver includes a receiver coil disposed within at least one layer of the plurality of layers of the laminated member. The electrical device is disposed substantially within the door between the exterior surface and the interior surface. The electrical device is electrically coupled to the energy receiver. In embodiments, the energy receiver is decoupled from the energy transmitter in response to the door pivoting from the closed position. The electrical device may be an energy storage unit configured to store electrical energy transmitted to the energy receiver. The energy storage unit may be a battery. The door system may include a second electrical device. The energy story unit may be electrically coupled to the second electrical device. The energy storage unit may be configured to provide electrical energy to the second electrical device. In some embodiments, the door frame includes a header, a jamb, and a sill. The energy transmitter may be disposed within the header, the jamb, or the sill such that the energy transmitter is adjacent to the receiver coil when the door is in the closed position. In