US-12624592-B2 - Door system with outer door frame pre-wired with AC electrical power for connection with DC power supply unit, and related methods of use, installation, and fabrication

Abstract

A door system comprises a door frame adapted to be mounted within an opening, a door pivotally attached to the door frame, an AC/DC converter configured to be electrically connected to an AC power unit operably associated with the door system, a slot in the door system, a pre-wired receptacle disposed in the slot, and an electric device removably disposed in the pre-wired receptacle and electrically connected to the AC/DC converter or the AC power unit through the electrical connector of the pre-wired receptacle.

Inventors

• Steven SWARTZMILLER

Assignees

• MASONITE CORPORATION

Dates

Publication Date

20260512

Application Date

20230515

Claims (9)

1. 1 . A door system, comprising: a door frame adapted to be mounted within an opening; a door pivotally attached to the door frame; an AC/DC converter configured to be electrically connected to an AC power unit operably associated with the door system; a slot in the door system; a pre-wired receptacle disposed in the slot, the pre-wired receptacle comprising an electrical connector electrically connected the AC/DC converter or the AC power unit; and an electric device removably disposed in the pre-wired receptacle and electrically connected to the AC/DC converter through the electrical connector of the pre-wired receptacle.
2. 2 . The door system of claim 1 , wherein the electrical connector comprises one of a plug connector and socket connector.
3. 3 . The door system of claim 2 wherein the slot is formed in the door.
4. 4 . The door system of claim 3 , wherein the door comprises an inner door frame including top and bottom rails and first and second stiles, and wherein the slot is formed in one of the stiles or rails.
5. 5 . The door system of claim 1 , wherein the slot is provided in the door frame.
6. 6 . The door system of claim 1 , wherein the electric device is a DC electric device comprising one of a powered lock, a sensor, a door state sensor, a LED, a video camera, a lighted key hole, and a video camera.
7. 7 . The door system of claim 1 , wherein: a plurality of pre-wired receptacles are formed in the door and/or door frame, each of the receptacles has a connector and is in electrical connection with the AC/DC converter, and a plurality of DC electric devices, each of the DC electric devices releasably mounted within one of the receptacles and in electrical connection with the AC/DC converter through the associated connector.
8. 8 . The door system of claim 7 , wherein at least one of the receptacles is formed in a peripheral edge of the door and at least one of the receptacles is formed in a surface of the door and/or door frame.
9. 9 . The door system of claim 8 , wherein the DC electric device comprises one of a powered lock, a sensor, a door state sensor, a LED, a video camera, a lighted key hole, and a video camera.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a National Stage application of International Application No. PCT/US2023/022252, filed May 15, 2023, which claims the benefit of U.S. Provisional Application No. 63/341,450 filed May 13, 2022, both of which are incorporated by reference in its entirety herein. BACKGROUND Field The present disclosure is directed to exterior or interior doors for residential or commercial buildings, such as for a home, apartment, condominium, hotel room or business. More particularly the present invention is directed to a power supply that is installed in the door frame or in the wall adjacent the door frame, so that the power connection to the door may be made sometime thereafter. Because power is initially installed proximate the door opening during initial construction, it is a relatively simple matter to then connect the power source to the door in order to provide a powered door suitable for smarthome use. The present disclosure is also directed to a door system comprising a prewired door provided with integrated electric devices plugged into or otherwise electrically connected to prewired receptacles, and sources of low- and/or high-voltage electrical power in order to provide power that may be used to operate the integrated electric devices. Description of Related Art Typical existing exterior or interior doors for residential or commercial buildings may have a number of electric devices (or components) mounted to the doors in order to provide desired functions, such as electronic access control, door state feedback, i.e., open/closed position vis-à-vis the jamb, an entry camera and/or audio communication, an electric powered door latch, an electric powered door lock, an auto open/close system, etc. Also, the market for exterior and interior doors has seen an increasing adoption of additional electric devices including video doorbells, smart locks, LED lighting, smart glass, fail safe electromechanical door closers, wireless connectivity electronics, etc. Each of these discrete electric and/or smart devices is typically an “add-on” to an existing installed door, functions within or on the existing door construction, and is usually powered separately with at least one battery that requires periodic replacement. Should the battery not be replaced, or charged regularly, then the electric device will not operate. In addition, current electric devices are mounted to exterior or interior doors in a manner that can be unattractive and unpleasant to look at owing to respective design styles that are not compatible with the home décor or one with the other. The electric devices typically each have either one or more rechargeable battery packs or at least one non-rechargeable battery that must periodically be recharged or changed and have some type of weatherable housing that also may not initially match the appearance of the door and may fade or degrade in appearance over time. While the commercial market, e.g., multi-tenant and mixed-use housing, hospitality, office, etc., has developed electrified door entry systems with electric strikes and door controller technologies, the adoption into the residential market has been limited. Existing residential door construction techniques focus on stile and rail construction and have not seen integration of power systems or integration of electric devices with an internal controller or “smart” door system. Experience has shown that supplying power to a door, such as a prehung door requires the coordination of several crafts, such as an electrician to bring power to the door, the carpenter to install the door, a painter to paint the area, etc. Should the homeowner wish to retrofit or install a powered door after initial construction, then the coordination becomes more cumbersome and the installation costs increased, particularly if a power line needs to be brought to the door for supplying power to the door. Therefore, the need exists for a door system, and method, designed for integration of electric and smart devices into the door system, pre or post-installation, post-installation serviceability of those devices, with power and data run to the door or around the door, or both, so that electric and data centric devices can be powered and data managed by a control system and the devices may be easily integrated into and powered/controlled from a central power supply and command controller without adversely impacting structural integrity, insulation and/or acoustic performance, energy efficiency, and aesthetics of the door system. Thus, improvements that may enhance performance and cost of door systems with electric and data driven devices are made possible. SUMMARY According to a first aspect of the present invention, there is provided a door system. A pre-wired receptacle may be provided in the door system, which includes the door or the door frame. As noted, the door system comprises a door frame adapted to be mounted within