BACKGROUND OF THE INVENTION Certain enclosures must be protected by a door against attack by vandals, terrorists and the like. For example, embassies must have a door which can withstand violent break-in attempts, such as by means of sledge hammers, axes, crowbars, battering rams, ballistics and the like. Prior art door assemblies designed to withstand such brutal force attacks generally comprise very heavy, reinforced steel doors.

However, one disadvantage of such doors is their massive weight, sometimes exceeding 4000 kg, which makes transportation, handling and installation cumbersome and difficult. Another disadvantage is that despite the large weight, the door still has weak points. such as latch bolts and hinges. which can sometimes be pried open, sheared or torn loose from their moorings by violent, brute force.

SUMMARY OF THE INVENTION The present invention seeks to provide a vandalism-resistant door assembly which solves the abovementioned problems of the prior art.

There is thus provided in accordance with a preferred embodiment of the present invention a door assembly including a door post, a first door plate and a second door plate secured together to form a door body having a hinge end mountable by a hinge to the door post, a door lock mounted in the door body, and a door post locking assembly, mounted in an inner volume of the door post, selectively actuable by the door lock to be brought into locking engagement with the first door plate.

In accordance with a preferred embodiment of the present invention the first door plate includes at least one lug attached thereto. the at least one lug being formed with an aperture. and the door post locking assembly includes at least one locking element, wherein when the door lock is locked, the door lock moves the at least one locking element into locked engagement with the aperture. Preferably the at least one locking element is mounted generally perpendicular to the at least one lug.

Further in accordance with a preferred embodiment of the present invention a biasing device is provided operatively connected to the at least one locking element, which urges the at least one locking element out of locked engagement with the at least one lug when the door lock is unlocked.

Still further in accordance with a preferred embodiment of the present invention the first door plate includes a bent portion at an edge thereof.

Additionally in accordance with a preferred embodiment of the present invention an elongate bracket is secured to the second door plate near the hinge end, the elongate bracket including an extension arranged to be nominally spaced a distance from an inner surface of a second door post opposite the first-mentioned door post, wherein a prying force applied at the hinge end causes the extension of the elongate bracket to abut against a portion of the second door post, thereby substantially preventing unauthorized opening of the door body. Preferably the elongate bracket abuts against the second door post along most of a length of the door body.

In accordance with a preferred embodiment of the present invention a plurality of hinge housings are secured to the first door plate and the second door post.

Further in accordance with a preferred embodiment of the present invention each of the hinge housings includes a hinge-pin receiving member adjustably attached to a hinge base.

Still further in accordance with a preferred embodiment of the present invention the hinge-pin receiving member includes a block with a pair of pockets formed therein adapted to receive therein a bolt, the block having a pair of holes formed therein extending from one end of the block into the pockets, and a threaded hole extending from the end through to an opposite end of the hinge-pin receiving member, and a hinge base formed with a recess for receiving therein the hinge-pin receiving member.

Additionally in accordance with a preferred embodiment of the present invention the hinge-pin receiving member is secured to the hinge base by means of a pair of bolts placed into the pockets, heads of the bolts resting in the pockets, the bolts being screwed into a pair of threaded holes formed in the hinge base, the position of the hinge-pin receiving member relative to the hinge base being adjusted by means of an adjustment screw threaded through the threaded hole, which protrudes from the opposite end and abuts against the recess of the hinge base.

In accordance with a preferred embodiment of the present invention a hinge guard is attached to the first door plate near the hinge housings which substantially prevents access to the hinge housings. Preferably the hinge guard is also attached to the elongate bracket.

Further in accordance with a preferred embodiment of the present invention a reinforcing plate is placed inwards and generally parallel to the first door plate and secured to the door body. Preferably the reinforcing plate is constructed of a ballistics-resistant material.

Still further in accordance with a preferred embodiment of the present invention the first-mentioned door post is formed with an aperture. and an anti-wedging pin. having a head, is attached to an edge of the door body. the anti-wedging pin being arranged to pass through the aperture when the door assembly is closed with respect to the first-mentioned door post, the head of the anti-wedging pin being arranged to abut against the first-mentioned door post if a wedging force is applied to the door assembly near the anti-wedging pin.

Additionally in accordance with a preferred embodiment of the present invention the anti-wedging pin is formed with a threaded shank threadedly attached to the door edge. so that an amount that the anti-wedging pin protrudes out of the door edge can be adjusted.

In accordance with a preferred embodiment of the present invention including a pair of side-by-side brackets secured to the first-mentioned door post and protruding into spaces defined by another pair of brackets secured to a flanged extension of the first door plate.

Further in accordance with a preferred embodiment of the present invention the door lock includes a locking mechanism assembly mounted in the door body, the locking mechanism assembly including a lock and a plurality of locking bolts actuable by the lock.

Still further in accordance with a preferred embodiment of the present invention the plurality of locking bolts includes a plurality of dead bolts welded to a portion of the lock.

Additionally in accordance with a preferred embodiment of the present invention at least one of the plurality of locking bolts is adapted to slide generally linearly out of a door edge.

Further in accordance with a preferred embodiment of the present invention at least one of the plurality of locking bolts includes a locking hook adapted to move arcuately out of a door edge.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which : Fig. I A is a simplified pictorial illustration of a door assembly constructed and operative in accordance with a preferred embodiment of the present invention ; Fig. 1B is a simplified sectional illustration of the door assembly of Fig.

1 A. showing a hinged end of the door assembly in greater detail; Fig. 1 C is a simplified sectional illustration of the door assembly of Fig.

1 A « showing an edge of the door assembly near a door lock in greater detail; Figs. 2A, 2B and 2C are simplified back-view perspective, front-view perspective and sectional illustrations, respectively. of a hinge-pin receiving member useful in the door assembly of Fig. 1A, constructed and operative in accordance with a preferred embodiment of the present invention, Fig. 2C being taken along lines 2C-2C in Fig. 2A; Figs. 3A and 3B are simplified pictorial and sectional illustrations, respectively, of a hinge housing, comprising the hinge-pin receiving member attached to a hinge base. in accordance with a preferred embodiment of the present invention, Fig.

3B being taken along lines 3B-3B in Fig. 3A ; Fig. 4 is a simplified pictorial illustration of an assembly of the hinge housing ; Figs. 5A, 5B and 5C are simplified front-view perspective, back-view perspective and sectional illustrations, respectively, of a hinge guard useful in the door assembly of Fig. I A. constructed and operative in accordance with a preferred embodiment of the present invention, Fig. 5C being taken along lines 5C-5C in Fig. 5A ; Fig. 6 is a simplified pictorial illustration of an elongate bracket useful in the door assembly of Fig. 1 A, constructed and operative in accordance with a preferred embodiment of the present invention; Fig. 7 is a simplified pictorial illustration of an anti-wedging pin useful in the door assembly of Fig. 1A, constructed and operative in accordance with a preferred embodiment of the present invention ; Figs. 8 and 9 are simplified sectional and side-view illustrations, respectively. of the door assembly of Fig. 1A, showing an edge of the door assembly near a door lock and door post in greater detail, the door assembly and doorframe being constructed and operative in accordance with another preferred embodiment ci the present invention; and Fig. 10 is a simplified pictorial illustration of an apertured lug used in the door assembly of Figs. 8 and 9, constructed and operative in accordance with another preferred embodiment of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT Reference is now made to Fig. I A which illustrates a door assembly 10 constructed and operative in accordance with a preferred embodiment of the present invention.

Door assembly 10 preferably includes an outer door plate 12 and an inner door plate 14. Either one of the inner and outer door plates 12 and 14 has a peripheral door edge 16 extending theref-or i around a perimeter thereof (in the illustrated embodiment door edge 16 extends from inner door plate 12). Inner and outer door plates 12 and 14 are secured together to form a door body 18 with an inner volume 20 bounded by inner and outer door plates 12 and 14 and door edge 16.

Door assembly 10 preferably includes a locking mechanism assembly 170 mounted in the inner volume 20 of door body 18. Locking mechanism assembly 170 preferably includes a mortise lock 172 and a plurality of locking bolts actuable by lock 172. In accordance with a preferred embodiment of the present invention, the plurality of locking bolts includes a plurality of dead bolts 174 welded to a portion of lock 172. In the prior art, such dead bolts are normally riveted or screwed to the lock.

The welded construction of the present invention provides a much stronger defense against violent attacks.

The plurality of locking bolts also preferably includes locking bolts 176 which are adapted to slide generally linearly out of door edge 16. Additionally or alternatively. the plurality of locking bolts includes a locking hook 178 adapted to move arcuately out of door edge 16. Such locking bolts 176 and 178 are readily available from such manufacturers as Mul-T-Lock Ltd.. Yavne, Israel. Locking mechanism assembly 170 also preferably includes various linkage elements 180 and stiffeners 182, as is known in the art.

Preferably further reinforcing structure is provided to increase the ability of door assembly 10 to withstand violent attacks. A reinforcing plate 62 is preferably placed inwards and generally parallel to door plates 12 and 14 and secured to door body 18. Reinforcing plate 62 is preferably constructed of a ballistics-resistant material.

A plurality of hinge housings 22 are preferably secured to an outer surface of door edge 16. Hinge housings 22 are spaced from each other along the height of door body 18.

Referring now to Figs. 3A and 3B. it is seen that each hinge housing 22 preferably includes a hinge-pin receiving member 24 adjustably attached to a hinge base 26. Referring additionally to Figs. 2A. 2B and 2C. it is seen that hinge-pin receiving member 24 is preferably constructed of a generally prismatic block of a strong and durable material, such as steel, with a rounded end 27. A bore 28 is preferably formed in member 24 near end 27 for receiving therein a hinge pin 25 (Fig. 4). Opposite to end 27 is a generally flat end 29. Extending from flat end 29 are upper and lower faces 30 and 31, which are generally flat. A pair of pockets 32 and 33 are preferably formed in faces 30 and 31, respectively. each extending into flat end 29. The purpose of pockets 32 and is 1$ to receive therein bolts as will be explained hereinbelow. A pair of holes 34 and 35 are preferable formed in member 24, extending from end 27 into pockets 32 and 33, respectively. A threaded hole 36 is preferably formed in member 24, extending from end 27 through to flat end 29.

Referring again to Figs. 3A and 3B, it is seen that hinge base 26 is preferably constructed of a generally prismatic block of a strong and durable material, such as steel. with a generally prismatic recess 38 formed therein. Hinge-pin receiving member 24 can be placed into recess 38 (at the flat end 29). Member 24 is secured to hinge base 26 by placing a pair of bolts 40 and 41, such as Allen head bolts, into pockets 32 and 33. respectively. As seen in Fig. 3B, the heads of the bolts 40 and 41 rest in pockets 32 and 33, respectively, and the bolts are screwed into a pair of threaded holes 42 and 43. respectively. formed in hinge base 26. A pair of washers 44 and 45 may be placed under the heads of the bolts 40 and 41, respectively. Access to the heads of the bolts may be gained by placing a tool. such as a screwdriver or Allen-key (not shown) through holes 34 and 35. Before tightening bolts 40 and 41 to hinge base 26, the position of member 24 relative to hinge base 26 may be adjusted by means of an adjustment screw 46 threaded through hole 36, which protrudes from flat end 29 and abuts against recess 38. By suitable tightening or loosening of adjustment screw 46, the position of member 24 relative to hinge base 26, generally along an axis 48, may be adjusted.

Reference is now made to Figs. 1 B and 4 which illustrate the assembly of hinge housings 22 to door body 18. Hinge base 26 is secured to door edge 16. A pair of hinge bases 52 are placed above and below hinge base 26 and are secured to a relatively massive bar 51 in a door post 50. Hinge base 52 preferably has essentially the same recess 38 as hinge base 26. except that the outer dimensions of hinge base 52 may be different than those of hinge base 26. Hinge pin 25 is placed in holes 28 of hinge-pin receiving members 24. A hinge guard 54 is preferably attached to outer door plate 14 near hinge housings 22. and substantially prevents access to hinge housings 22. Any number of hinge guards 54 may be attached to outer door plate 14.

Hinge guard 54 is shown in more detail in Figs. SA, 5B and 5C. Hinge guard 54 preferably includes a recess 56 in which is received a portion of hinge housing 22. such as hinge base 26. Hinge guard 54 preferably includes a protruding member 58, illustrated as having a somewhat C-shape, although any arbitrary shape is also possible.

Protruding member 58 is received in a correspondingly-formed recess 60 in outer door plate 14. Hinge guard 54 is preferably secured to outer door plate 14 by means of a plurality of screws 53 (shown in Fig. 1B) which mate with threaded holes 61 formed in hinge guard 54 (five such holes being illustrated, although any other number of holes is also possible). The fact that protruding member 58 is received in recess 60 makes it extremely difficult to pry hinge guard 54 with a crow bar or other violent implement.

The massive hinge housing 22 substantially prevents a prying force from being applied on a concentrated portion of the hinge, such as the hinge pin 25. Instead, hinge housing 22 itself absorbs the prying force and spreads it out over a relatively large area, thus significantly increasing the structural integrity of the door assembly 10 and its ability to withstand violent attacks.

Referring again to Fig. 1 B. structure is preferably provided for substantially preventing prying door assembly with a crow bar or other violent implement at the hinge end of door assembly 10. In accordance with a preferred embodiment of the present invention, a bracket 64 is secured to door post 50 and protrudes into a space defined by another bracket 66 secured to outer door plate 14. The arrangement of the brackets 64 and 66 forms a labyrinth that helps to prevent access to the area near the hinges.

An elongate bracket 68 is preferably secured to inner door plate 12, supported thereat by a bracket 72. Elongate bracket 68 has a far extension 74 which is nominally spaced a distance from a bar 76 secured to an inner surface of door post 50. A prying force applied at the hinge end of door assembly 10, generally in the direction of arrows 78, will not succeed in forcing open the door at the hinge end. because extension 74 of elongate bracket 68 will abut against bar 76 and prevent further movement of the door. It is important to note that elongate bracket 68 abuts against bar 76 along most of the length of door body 18, making prying extremely difficult if not impossible.

Elongate bracket 68 does not interfere with authorized opening of the door.

Reference is now additionally made to Fig. 6 which illustrates elongate bracket 68. In accordance with a preferred embodiment of the present invention, hinge guard 54 is not only secured to outer door plate 14. but is also attached to elongate bracket 68. Screws 53 preferably pass through holes 80 formed on elongate bracket 68.

Elongate bracket 68 hides screws 53 from view as viewed from the inner side of the door. Elongate bracket 68 and hinge guards 54 are generally assembled to door assembly 10 at an installation site.

Referring again to Fig. 1 C, and additionally to Fig. 7, structure is preferably provided for substantially preventing prying door assembly with a crow bar or other violent implement at the lock end of door assembly 10. In accordance with a preferred embodiment of the present invention, an anti-wedging pin 82 is attached to door edge 16. Anti-wedging pin 82 preferably has a threaded shank 83, so that the amount that it protrudes out of door edge 16 can be adjusted. Anti-wedging pin 82 preferably has a relatively large head 84. When the door is closed, head 84 of anti-wedging pin 82 passes through an aperture 86 formed in a front surface 87 of a door post 88. and shank 83 is received in an extension 89 of aperture 86 in an inner side surface 90 of door post 88. In this position, if a wedging force is applied to the lock end of door assembly 10, generally in the direction of an arrow 92 (Fig. 1 C). head 84 abuts against surface 90 of door post 88 and substantially prevents further movement of the door. Any number of anti-wedging pins 82 may be assembled on door assembly 10, such as above and below a door lock (not shown), and near top and bottom portions of door body 18. Anti-wedging pins 82 do not interfere with authorized opening of the door.

In accordance with a preferred embodiment of the present invention, a pair of side-by-side brackets 94 are secured to door post 88 and protrude into spaces defined by another pair of brackets 96 secured to a flanged extension 98 of outer door plate 14. The arrangement of the brackets 94 and 96 forms a labyrinth that helps to prevent access to the area near the lock, and also helps prevents prying or wedging movement at the area near the lock.

Reference is now made to Figs. 8-10 which illustrates another preferred embodiment of door assembly 10, showing an edge of the door assembly near mortise lock 172 and door post 88 in greater detail. In this embodiment, a relatively thick outer door plate 202 is employed that extends the entire width of door assembly close to a bulkhead 204 that is part of the overall structure of door post 88. A plurality of apertured lugs 206 are preferably secured to outer door plate 202, such as by welding thereto. Lugs 206 are preferably formed with an elongate aperture 208, as seen in Fig. 10. Door post 88 is preferably formed with openings 210, through which lugs 206 can pass when door assembly 10 is closed. It is noted that door post 88 may be reinforced with various reinforcing members, such as a reinforcing bar 212 welded thereto.

In accordance with a preferred embodiment of the present invention, a door post locking assembly 214 is provided that can be brought into locking engagement with lugs 206 of outer door plate 202. Door post locking assembly 214 preferably includes one or more locking elements 216 actuable by mortise lock 172 and arranged to slide into and out of locking engagement with lugs 206. Locking element 216 is preferably mounted in an inner volume 217 of door post 88 generally perpendicular to lug 206. Locking element 216 is preferably provided with one or more ears 215. A biasing device 218. such as a coil spring, may be operatively connected to locking element 216 by means of a link 220. Biasing device 218 normally urges locking element 216 in the direction of an arrow 221, away from and out of locked engagement with lug 206 (when lock 172 is unlocked).

Lock 172 includes one or more locking bolts 222. When door assembly 10 is closed and lock 172 is locked. locking bolts 222 move against locking element 216 and push locking element 216 generally in the direction of an arrow 223, opposite to arrow 221. This causes locking element 216 to push against biasing device 218, and brings ears 215 into apertures 208 of lugs 206. In this position, locking element 216 is in locked engagement with lugs 206 and it is difficult, if not impossible, to pry outer door plate 202 away from door post 88. Outer door plate 202 is preferably fashioned with a bent portion 224 at an edge thereof, in order to increase the difficulty of gaining access to the inner volume 217 of door post 88.

It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove.

Rather the scope of the present invention includes both combinations and subcombinations of the features described hereinabove as well as modifications and variations thereof which would occur to a person of skill in the art upon reading the foregoing description and which are not in the prior art.