AU2023219803B2

AU2023219803B2 - Improved security door assembly

Info

Publication number: AU2023219803B2
Application number: AU2023219803A
Authority: AU
Inventors: Warren Lewis
Original assignee: Fmi Building Innovation Ltd
Current assignee: Fmi Building Innovation Ltd
Priority date: 2023-08-21
Filing date: 2023-08-21
Publication date: 2025-11-20
Anticipated expiration: 2043-08-21
Also published as: AU2023219803A1

Abstract

- 17 A security door assembly is provided comprising retaining members, each engaging between the door frame and a security mesh screen. The retaining members have a lengthwise slot for receiving the mesh screen, and a plurality of pins, each inserted through the retaining members and mesh such that the pin punctures the mesh screen and deforms it into a pin aperture, thus securely retaining the mesh screen within the slots. - 17 -

Description

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2023219803 21

IMPROVED SECURITY DOOR ASSEMBLY 23 Sep 2025

FIELD OF THE INVENTION The present invention relates to an improved security door assembly. More particularly, but not exclusively, it relates to a security door assembly having a mesh screen, and a method of securing the mesh screen in the security door assembly.

BACKGROUND OF THE INVENTION 2023219803

Security doors are a common addition to the entrance doorways of both residential and commercial buildings. Typically, they are fitted in front of a regular entrance door and have a separate locking mechanism, as well as a mesh screen which is intended to be resistant to both impact forces attacks with weapons and/or attempts to pry or breach the door. Typically, a security door will include a multi-point locking mechanism, for example at least 2 points of locking, and often at least 3 points of locking, to ensure adequate performance, particularly against attempts to pry the frame. They may also have a frame and hinges that are reinforced and/or tamper resistant. An occupant of the building can have the regular door open but leave the security door closed and locked for safety, which may be useful to allow air circulation through the mesh screen in hot weather, or to check who is at the door from behind the safety of the mesh screen. The security door may also provide some additional protection against break-ins. However, the effectiveness of security doors is often limited by the strength with which they retain the mesh screen in the security door frame. Regardless of the strength of the frame, the hinges, and the mesh screen itself, if the mesh retention is too weak then it may be relatively easy to rip the edges of the mesh screen out from the door frame via impact or prying forces. Although some retention designs exist to mitigate this weakness, they are typically bulky and/or involve a complex assembly of numerous and/or expensive parts. This can make them undesirable for certain doorways or otherwise unappealing or aesthetically compromised. It is thus desirable to find security door assembly designs that can better retain the mesh screen in the door frame, without being excessively bulky or complex.

In this specification, where reference has been made to external sources of information, including patent specifications and other documents, this is generally for the purpose of providing a context for discussing the features of the present invention. Unless stated otherwise, reference to such sources of information is not to be construed, in any 23 Sep 2025 jurisdiction, as an admission that such sources of information are prior art or form part of the common general knowledge in the art. For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be chronologically ordered in that sequence, unless there is no other logical manner of interpreting the sequence. 2023219803

It is an object of the present invention to provide an improved security door assembly which overcomes or at least partially ameliorates some of the abovementioned disadvantages or which at least provides the public with a useful choice.

BRIEF DESCRIPTION OF THE INVENTION According to a first aspect, the invention broadly comprises a security door assembly comprising: a plurality of retaining members, each retaining member comprising a lengthwise slot with a first wall and a second wall, wherein the first wall has one or more first pin apertures and the second wall has one or more second pin apertures which each correspond to one of the first pin apertures; a mesh screen about which the retaining members are arranged such that edges of the mesh screen are retained within the slots of the retaining members; a plurality of pins, each inserted through one of the first apertures and through the corresponding second pin aperture such that the pin punctures the mesh screen and deforms it into the corresponding second pin aperture, thus securely retaining the mesh screen within the slots; and a door frame comprising a plurality of framing members within which the retaining members are secured, such that the mesh screen spans the door frame. According to another aspect each first pin aperture is smaller in diameter than the corresponding second pin aperture. According to another aspect each first pin aperture has a slip fit with the pin. According to another aspect each first pin aperture has a press fit with the pin. According to another aspect the retaining members are secured within the framing members by closures which clip into the framing members.

According to another aspect each retaining member further comprises flanges which 23 Sep 2025

facilitate securement within the door frame. According to another aspect the flanges of each retaining member extend orthogonally from the first wall and from the second wall. According to another aspect each of the retaining members has a group of at least two of the first pin apertures and at least two of the corresponding second pin apertures. According to another aspect the pins are regularly spaced on each edge of the mesh 2023219803

screen. According to another aspect the pins are regularly spaced around a perimeter of the mesh screen. According to another aspect the pins are regularly spaced by not more than approximately 500mm on each edge of the mesh screen. According to another aspect the retaining members are regularly spaced on each edge of the mesh screen. According to another aspect at least ten of the retaining members are arranged about the mesh screen and retain it. According to another aspect more of the retaining members are arranged on each vertical edge of the mesh screen than on each horizontal edge of the mesh screen. According to another aspect five of the retaining members are arranged on each vertical edge of the mesh screen and three of the retaining members are arranged on each vertical edge of the mesh screen. According to another aspect the retaining members are extrusions. According to another aspect the framing members are extrusions. According to another aspect the mesh screen is stainless steel. According to another aspect the invention broadly comprises a mesh screen retention arrangement comprising: a retaining member comprising a lengthwise slot with a first wall and a second wall, wherein the first wall has one or more first pin apertures and the second wall has one or more second pin apertures which each correspond to one of the first pin apertures; a mesh screen retained within the lengthwise slot of the retaining member; and a plurality of pins, each inserted through one of the first pin apertures and 23 Sep 2025 through the corresponding second pin aperture such that the pin punctures the mesh screen and deforms it into the corresponding second pin aperture, thus securely retaining the mesh screen within the lengthwise slot, and wherein the retaining members are secured on a door frame comprising a plurality of framing members, such that the mesh screen spans the door frame. According to another aspect the invention comprises a method of securing a mesh 2023219803 screen in a security door assembly, the method comprising: providing a plurality of retaining members, each retaining member comprising a lengthwise slot with a first wall and a second wall, wherein the first wall has one or more first pin apertures and the second wall has one or more second pin apertures which each correspond to one of the first pin apertures; arranging the retaining members about a mesh screen such that edges of the mesh screen are within the slots of the retaining members; and inserting a pin through each first pin aperture and then forcibly driving it through the corresponding second pin aperture such that the pin punctures the mesh screen and deforms the mesh screen into the corresponding second pin aperture, thus securely retaining the mesh screen within the slots, and securing the mesh screen in a door frame comprising a plurality of framing members via said plurality of retaining members, such that the mesh screen spans the door frame. According to another aspect the method further comprises securing the retaining members within a plurality of framing members, thereby forming a door frame spanned by the mesh screen. According to another aspect the pin is forcibly driven through the second pin aperture by hammering. According to another aspect the pin is forcibly driven through the second pin aperture by hydraulic press.

Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term “and/or” means “and” or “or”, or both. 23 Sep 2025

As used herein “(s)” following a noun means the plural and/or singular forms of the noun.

The term “comprising” as used in this specification and claims means “consisting at least in part of”. When interpreting statements in this specification and claims which include that term, the features, prefaced by that term in each statement, all need to be present but 2023219803

other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described by way of example only and with reference to the drawings in which:

Figure 1A shows a front view of a security door assembly; Figure 1B shows a detail of the retaining member in front view and side cross-section; Figure 2A shows a perspective view of a retaining member and an example mesh screen prior to insertion of the retaining pins; Figure 2B shows a perspective view of the retaining member and mesh screen of Figure 2A, after insertion of the pins; Figure 3A shows an enlarged cross-sectional side view of a retaining member; Figure 3B shows an enlarged cross-sectional side view of a retaining member and mesh screen after insertion of the pin; Figure 4A shows a cross-sectional side view of the retaining members and mesh screen; Figure 4B shows a cross-sectional side view of the retaining members placed on the mesh screen prior to insertion of the pins; Figure 4C shows a cross-sectional side view of the retaining members placed on the mesh screen after insertion of the pins; Figure 5A shows a cross-sectional side view of the retaining members, mesh screen, and framing members prior to attachment of the closures; and Figure 5B shows a cross-sectional side view of the retaining members, mesh screen, and framing members after attachment of the closures.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 23 Sep 2025

According to various aspects of the various embodiments of the present invention as illustrated in figures 1A-6B, there is provided a security door assembly 10 which will now be described.

As shown in Figure 1A, the security door assembly 10 comprises a door frame 12, a mesh screen 14, and a plurality of retaining members 16 arranged about the mesh screen 14 2023219803

to securely retain the edges of the mesh screen 14. The door frame 12 comprises framing members 18 which secure the retaining members 16, and which may incorporate other features of a door including hinges 20 and a handle 22, for example. The mesh screen 14 spans the door frame 12, and the retaining members 16 anchor the mesh screen 14 securely to the door frame 12 to prevent the mesh screen 14 from breaking free upon impact or other attempt to enter.

As shown in Figure 1B, each of the retaining members 16 comprises a lengthwise slot 24, within which a portion of the edge of the mesh screen 14 can be securely retained. The retention arrangement between each retaining member 16 and the mesh screen 14 will herein be described in more detail.

As shown in Figure 2A-2B, the retention arrangement involves the use of pins 26 which pass through the mesh screen 14 to securely retain it in the lengthwise slot 24. As can be seen, the mesh screen 14 has no pre-formed holes to allow passage of the pins 26, and rather the pins 26 are forcibly driven through the mesh screen 14 and puncture it.

As shown in Figure 3A, the lengthwise slot 24 has a first wall 28 and a second wall 29, the first wall 28 having one or more first pin apertures 30 and the second wall having one or more second pin apertures 31 which each correspond to one of the first apertures 30, and are generally aligned.

As shown in Figure 3B, the pin 26 passes through both the first aperture 30 and the corresponding second aperture 31, puncturing the mesh screen 14 which sits between them in the lengthwise slot 24. The mesh screen 14 is deformed into the second aperture 31, thus 23 Sep 2025 improving retention. This deformation occurs in a localised region about the pin 26.

Although Figures 1B-2B depict retaining members 16 with two sets of pin apertures (a set being a first pin aperture 30 and a corresponding second pin aperture 31), the retaining members 16 could have only one set, or more than two. The number of sets may depend on the length of the retaining members 16, and how many retaining members 2023219803

16 are used to retain the mesh screen 14, according to the security performance characteristics desired.

In some preferred configurations , the retaining members 16 are regularly spaced on each edge of the mesh screen 14. However, the spacing may be different for the vertical edges than for the horizontal edges. For example, it has been found that a spacing of between around 300mm to 500mm (measured centre to centre), provides sufficient performance. Further, it is preferred that each retainer includes at least 2 spaced pins as shown in Figure 1A. Preferably, more of the retaining members are arranged on each vertical edge of the mesh screen 14 (typically being longer) than on each horizontal edge, to maintain an approximately similar spacing. Figure 1A shows, for example, five retaining members 16 on each vertical edge and three retaining members 16 on each horizontal edge.

It will be appreciated that many other configurations of the retaining members 16 are possible, including many variations in the number of retaining members 16, spacing of the retaining members, and the number of pins provided in each retaining member, in order to achieve the desired performance. Overall, it is expected that the pin spacing (e.g. maximum) will be more important for performance than the number of retainers. Therefore, to achieve a desired performance an approximately even pin spacing around the mesh perimeter is likely desired.

Preferably the retaining members 16 are all identical to allow for low cost of manufacturing and ease of assembly, but alternatively some could be of different lengths. For example, the retaining members 16 could extend along an entire edge, with the vertical members thus being longer than the horizontal members. In this configuration, it will be appreciated that the overall number of pins employed, and/or the pin spacing may be the 23 Sep 2025 same, or different, compared to a configuration having a plurality of shorter retainers. For overall consistent performance of the security door, a maximum pin spacing should not be exceeded. For example as illustrated in Figure 2A & 1A, the spacing between adjacent pins on the same retainer (Figure 2A) may be different to the spacing between adjacent pins on a different retainer member (Figure 1A). It has been found that good performance is achieved with maximum pin spacing not exceeding around 500mm, and preferably not exceeding 2023219803 approximately 400mm.

In the most preferred example configurations including multiple retainers, it is preferable to use at least ten retaining members 16, (being at least 2 retainers across the width of the door, and at least 3 retainers along the height of the door) each retainer having a length of between approximately 7 to 15cm, and a pair of spaced pins on each retainer having a spacing between approximately 4 to 12 cm.

Figures 4A-4C show the process of connecting the retaining members 16 to the mesh screen 14. The steps can be considered part of a method of securing the mesh screen 14 in a security door assembly 10. Firstly, the retaining members 16 are arranged about edges of the mesh screen 14 such that the edges sit within the lengthwise slots 24. Then, the pins 26 are inserted through the first pin apertures 30 and forcibly driven through the corresponding second pin apertures 31 such that the pin 26 punctures the mesh screen 14 and deforms the mesh screen 14 into the corresponding second pin aperture 31. This arrangement has been found to result in a very tight and robust joint.

In some configurations, each first pin aperture 30 may be smaller in diameter than the corresponding second pin aperture 31. Thus, the first pin aperture 30 has a tighter fit about the pin 26, while the clearance in the second pin aperture 31 provides a space into which the mesh screen 14 can deform as the pin is driven through. The difference in diameter may therefore be selected based on the thickness and/or gauge of the mesh screen 14 intended for use. The pin 26 may have a slip fit with the first pin aperture 30 for easy insertion, or alternatively it may have a press fit to better secure the pin 26.

In the most preferred embodiments, the relative sizes of the pin apertures 30,31 23 Sep 2025

are approximately equal. For example, a tight fit between the pin 26 and aperture 30 can be formed as the pin is driven through. Accordingly, an extremely secure coupling between the mesh screen 14 and the retaining members is achieved as the pin 26 and mesh is forced through the aperture 31, and causes the aperture to become enlarged as the mesh is effective swaged into the retainer member 16. Various techniques may be used to forcibly drive the pins 26 through the second 2023219803

pin aperture 31 thereby puncturing the mesh screen 14 and/or deforming the aperture 31 to swage the mesh into the retainer. One technique may be hammering of the pins 26, or punching the pins with a punch, but any suitable technique could be used. For example a press (such as a hydraulic press or other type), may be used.

Typically, the mesh 14 is a stainless steel mesh having suitable performance properties for a security door. Similarly, the pins 26 are also preferably stainless steel, or at least sufficiently hard to deform and/or puncture the mesh during the fastening process.

In contrast, it is preferred that the retainer(s) 16 are of a softer material, such as aluminium or a suitable aluminium alloy, so that the pin(s) and mesh are able to deform the respective apertures 31, during the above described swaging process.

It is to be appreciated that the mesh 14 typically comprises a number of filaments or strands arranged in a grid pattern. Alternatively, an expanded mesh could potentially be used. In all cases the mesh has a nominal strand dimension and nominal hole dimensions. In order for the pins 26 to adequately engage the mesh (within the retainer(s)), it is necessary for the pins to be set back from the very edge of the mesh sheet an adequate amount, and that will be dependent on the mesh structure and properties. Accordingly, the present system allows for easily achievable variations to accommodate various mesh dimensions, mesh properties, and desired performance. For example: • the dimensions of the pins 26 may be chosen and/or varied to accommodate different mesh gauges and configurations,

• the size and/or width of the retaining members 16 (or the location of the 23 Sep 2025

pin apertures) may be varied to change the amount of mesh engaged by the pins, and/or • the dimensions of the cavity 32 and closure 34 may be varied to accommodate different mesh sizes and/or properties. • the pin spacing can be varied, although a maximum pin spacing of not more than around 500mm is preferred 2023219803

• the number of pins per retaining member can be varied • The pins are preferably arranged in a regular pattern, for example not a random arrangement. The regular pattern may be approximately uniform pin spacing between adjacent pins around the entire perimeter, or groups of pins per retainer member, arranged regularly around the perimeter as schematically illustrated in Figure 1A.

It has been found that a 316 stainless steel mesh having a woven strand configuration of strands up to approximately 1mm in diameter, gives excellent performance. It will be appreciated that there are many woven configurations that may be suitable.

Figures 5A-5B show the process of securing the retaining members 16 within the framing members 18, which occurs after insertion of pins 26 through the mesh screen 14. Each framing member 18 may comprise a cavity 32 within which retaining members 16 can be secured. The cavity 32 is preferably closed by a closure 34 which clips into the framing member 18, leaving a gap for the mesh screen 14 to extend out of the cavity 32. It will be appreciated that the lip 37 of the frame 18, and the closure 34 are responsible for resisting the primary forces experienced when the mesh is impacted or otherwise attacked.

To ensure that the retaining members 16 are secure within the framing members 18, the retaining members 16 preferably comprise flanges 36 extending orthogonally from the first wall 28 and the second wall 29. The flanges 36 may span the cavity 28 and bear on its walls and/or the closure 34, thus locating the retaining member 16 and distributing loads applied via the mesh screen 14. The pin 26 may also in some configurations span the cavity

28 and bear on its walls and/or the closure 34, providing additional points of contact for such 23 Sep 2025

purposes.

It is also envisioned that additional and optional fastening may be employed. For example, additional fastening may be provided to improve retention performance, and/or to simply prevent vibrations or rattles from developing between the mesh and frame. For example, the additional fastening may be provided by screws or bolts through 2023219803

the mesh (and/or retainer(s)) and into the frame. Another example, is additional fastening provided by a suitable double sided tape adhesive between the mesh and/or retainer(s), and the frame. Yet another example, is a suitable adhesive and/or silicone sealant applied between the mesh and/or retainer(s), and the frame. In all of the above cases, it is preferred, but not essential, that the additional fastening is not visible in the finished security door frame (e.g. concealed by the frame and closure 34).

To facilitate convenient manufacture, the retaining members 16 are preferably extrusions, as are the framing members 18. The material for each may be aluminium, or another suitable material such as steel. Preferably the mesh screen 14 is stainless steel.

The security door assembly 10 of the present invention has various advantages over alternative assemblies, such as those which clamp the mesh screen between two plates using a bolt. Firstly, using pins 26 to deform the mesh screen 14 into the second apertures 31 can provide superior retention compared to reliance on clamping force or other retention means such as bolts, rivets or screws. Secondly, the necessary width of the retaining members 16 and hence the framing members 18 is low compared to alternative assemblies. Thus, the security door assembly 10 is less bulky. Thirdly, pins 26 are preferably completely concealed within the framing members 18 when the closures 34 are attached, whereas other methods may result in exposed screw heads for example.

Although the previous description refers to mesh 14, it is possible, although not 23 Sep 2025

typically preferred, the panel 14 may not be a mesh but rather a solid sheet. To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. This invention may also be said broadly to consist in the parts, elements and features 2023219803

referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

Claims

CLAIMS 23 Sep 2025

1. A security door assembly comprising: a plurality of retaining members, each retaining member comprising a lengthwise slot with a first wall and a second wall, wherein the first wall has one or more first pin apertures and the second wall has one or more second pin apertures which each correspond to one of the first pin apertures; 2023219803

a mesh screen about which the retaining members are arranged such that edges of the mesh screen are retained within the slots of the retaining members; a plurality of pins, each inserted through one of the first apertures and through the corresponding second pin aperture such that the pin punctures the mesh screen and deforms it into the corresponding second pin aperture, thus securely retaining the mesh screen within the slots; and a door frame comprising a plurality of framing members within which the retaining members are secured, such that the mesh screen spans the door frame.

2. The security door assembly of claim 1, wherein each first pin aperture is smaller in diameter than the corresponding second pin aperture.

3. The security door assembly of claim 1 or 2, wherein each first pin aperture has a slip fit with the pin.

4. The security door assembly of claim 1 or 2, wherein each first pin aperture has a press fit with the pin.

5. The security door assembly of any one of the preceding claims, wherein the retaining members are secured within the framing members by closures which clip into the framing members.

6. The security door assembly of any one of the preceding claims, wherein each retaining member further comprises flanges which facilitate securement within the door frame.

7. The security door assembly of claim 6, wherein the flanges of each retaining member 23 Sep 2025

extend orthogonally from the first wall and from the second wall.

8. The security door assembly of any one of the preceding claims, wherein each of the retaining members has a group of at least two of the first pin apertures and at least two of the corresponding second pin apertures. 2023219803

9. The security door assembly of any one of the preceding claims, wherein the pins are regularly spaced on each edge of the mesh screen.

10. The security door assembly of any one of the preceding claims, wherein the pins are regularly spaced around a perimeter of the mesh screen.

11. The security door assembly of the previous claim, wherein the pins are regularly spaced by not more than approximately 500mm on each edge of the mesh screen.

12. The security door assembly of any one of the preceding claims, wherein the retaining members are regularly spaced on each edge of the mesh screen.

13. The security door assembly of any one of the preceding claims, wherein at least ten of the retaining members are arranged about the mesh screen and retain it.

14. The security door assembly of any one of the preceding claims, wherein more of the retaining members are arranged on each vertical edge of the mesh screen than on each horizontal edge of the mesh screen.

15. The security door assembly of claim 11, wherein five of the retaining members are arranged on each vertical edge of the mesh screen and three of the retaining members are arranged on each vertical edge of the mesh screen.

16. The security door assembly of any one of the preceding claims, wherein the retaining members are extrusions.

17. The security door assembly of any one of the preceding claims, wherein the framing 23 Sep 2025

members are extrusions.

18. The security door assembly of any one of the preceding claims, wherein the mesh screen is stainless steel.

19. A mesh screen retention arrangement comprising: 2023219803

a retaining member comprising a lengthwise slot with a first wall and a second wall, wherein the first wall has one or more first pin apertures and the second wall has one or more second pin apertures which each correspond to one of the first pin apertures; a mesh screen retained within the lengthwise slot of the retaining member; and a plurality of pins, each inserted through one of the first pin apertures and through the corresponding second pin aperture such that the pin punctures the mesh screen and deforms it into the corresponding second pin aperture, thus securely retaining the mesh screen within the lengthwise slot, and wherein the retaining members are secured on a door frame comprising a plurality of framing members, such that the mesh screen spans the door frame.

20. A method of securing a mesh screen in a security door assembly, the method comprising: providing a plurality of retaining members, each retaining member comprising a lengthwise slot with a first wall and a second wall, wherein the first wall has one or more first pin apertures and the second wall has one or more second pin apertures which each correspond to one of the first pin apertures; arranging the retaining members about a mesh screen such that edges of the mesh screen are within the slots of the retaining members; and inserting a pin through each first pin aperture and then forcibly driving it through the corresponding second pin aperture such that the pin punctures the mesh screen and deforms the mesh screen into the corresponding second pin aperture, thus securely retaining the mesh screen within the slots, and securing the mesh screen in a door frame comprising a plurality of framing 23 Sep 2025 members via said plurality of retaining members, such that the mesh screen spans the door frame.

21. The method of claim 20, further comprising securing the retaining members within a plurality of framing members, thereby forming a door frame spanned by the mesh screen. 2023219803

22. The method of claim 20 or 21, wherein the pin is forcibly driven through the second pin aperture by hammering.

23. The method of claim 20 or 21, wherein the pin is forcibly driven through the second pin aperture by hydraulic press.