Apparatus and method of fabricating a door

A method for fabricating a door having a window, the door having a first door skin and a second door skin, the method including the following steps in the order named: forming a first door light opening perimeter having a first plurality of tabs arranged about the first door light opening perimeter, wherein the first door light opening perimeter defines a first door light portion; forming a second door light opening perimeter having a second plurality of tabs arranged about the second door light opening perimeter, wherein the second door light opening perimeter defines a second door light portion; positioning the first door skin on a first press; positioning an insert in aligned registration with the first plurality of tabs; positioning the second door skin over the insert, wherein the second plurality of tabs are in aligned registration with the insert, and the first door light opening perimeter is aligned with the second door light opening perimeter; applying pressure with the first press to secure the first and second door skins with the insert; injecting a foam into a first cavity formed between the first skin outside the first door light portion, the second door skin outside the second door light portion and the insert; and, removing the first and second door light portions.

FIELD OF THE INVENTION

The invention broadly relates to doors, more specifically to lights for doors, and even more particularly to lights for doors constructed from complimentary door skins. The invention also broadly relates to a method of fabricating a door with a door light perimeter defined within the door skins before assembly and arranged to accommodate a window. The invention also relates to an apparatus for carrying out the method of fabrication.

BACKGROUND OF THE INVENTION

Typically, doors constructed of steel or fiberglass comprise two molded door skins forming the front and back surfaces of the door. The door skins are joined together and filled with an expanding foam core which provides insulation, e.g., thermal and sound, and increases structural integrity. Reinforcing and mounting strips, made typically of wood, are sometimes used to provide additional structural and internal integrity when needed.

Each door skin generally has rolled edges to define a perimeter edge used to secure the door skins together when assembled. The door skins are aligned and positioned within a press which forces the perimeter edges together and locks them in place. After the door skins are secured together, synthetic insulation foam is injected between the skins filling the cavity formed therebetween.

For example, contemporary metallic doors are constructed of thin metallic door skins that form the exterior of the door. Door skins are formed from hot dipped galvanized deep drawn steel that is stamped into a desired door shape. The door skins form the exterior of the door and can be joined at the perimeter of the skins by flanges, as previously described, or the door skins can be joined to a frame, e.g., a wood frame, between the skins. Subsequently, a foam core is used to fill the internal cavity left between the door skins, as described supra.

If the door is intended to have a window opening, commonly known to those of ordinary skill in the art as a door light, an additional fabrication step is required. The opening must be cut out to remove the respective door skin areas, and includes the foam core therebetween. The cut out, including both the metal skins and foam, subsequently becomes a waste product that must be disposed of as there is no further use that can be made of the cut out. In fact, waste products of this type are typically considered hazardous waste due to the presence of the foam, and therefore, special waste disposal considerations must be taken into account.

Although the finished door does not include the above described waste material, the finished door cost does include the cost of these materials. Thus, end users must pay more for a door having less material, i.e., after the window opening is formed. In some instances, manufacturers of finished doors cut the window opening in their facility as opposed to having the raw door manufacturer perform this operation. Thus, an uncut door which includes all the additional waste material must be shipped to the finishing manufacturer. The uncut doors weigh more than cut doors and therefore shipping costs are also increased thereby raising the final cost to an end user.

As can be derived from the variety of devices and methods directed at forming doors and in particular forming doors having a light, many means have been contemplated to accomplish the desired end, i.e., constructing a low cost, high quality door with at least one light. Heretofore, tradeoffs between material waste generated during manufacture and cost were required. Thus, there is a long-felt need for a door constructed from door skins having a door light perimeter defined therein prior to filling the door with insulating foam. There is a further long-felt need for a door having a door light and a reduced overall weight. There is also a long-felt need for a door having a door light which generates a reduced amount of waste during assembly. There is yet also a long-felt need for a door having a door light which generates recyclable waste during assembly.

BRIEF SUMMARY OF THE INVENTION

The present invention broadly comprises a method for fabricating a door having a window, the door having a first door skin and a second door skin, the method including the following steps in the order named: a) forming a first door light opening perimeter and a second door light opening perimeter in the first and second door skins, respectively, wherein the first and second door light opening perimeters define a first portion and a second portion, respectively; b) positioning the first door skin on a first press; c) positioning an insert in aligned registration with the first door light opening perimeter of the first door skin; d) positioning the second door skin over the insert, wherein the second door light opening perimeter is in aligned registration with the insert and the first door light opening perimeter; e) applying pressure with the first press to secure the first and second door skins with the insert; f) injecting a foam into a first cavity formed between the first and second door skins and the insert; and, g) removing the first and second portions. In an embodiment, the method further includes the step of: h) inserting the window within a second cavity formed by the insert.

In an embodiment, the insert includes a pair of engagement flanges for aligned registration and engagement with the first and second door skins, each of the pair of engagement flanges includes a groove arranged for receipt of one of the first or second door light opening perimeters therein. In an embodiment, the insert further includes a secondary pair of flanges positioned substantially parallel and between the pair of engagement flanges, the secondary pair of flanges are encapsulated by the foam within the cavity during the injection step. In an embodiment, the secondary flanges are equal in length but shorter in length than either of the engagement flanges. In an embodiment, each of the grooves includes a V-shaped cross-section. In an embodiment, the insert is a molded plastic article. In an embodiment, the insert is a metal article formed by a second press, the insert including first and second bent portions. In an embodiment, the first and second bent portions of the insert are operatively arranged to matingly engage the first and second door light opening perimeters, respectively.

In an embodiment, the present invention broadly comprises a door fabricated according to the method including the following steps in the order named: a) forming a first door light opening perimeter and a second door light opening perimeter in the first and second door skins, respectively, wherein the first and second door light opening perimeters define a first portion and a second portion, respectively; b) positioning the first door skin on a first press; c) positioning an insert in aligned registration with the first door light opening perimeter of the first door skin; d) positioning the second door skin over the insert, wherein the second door light opening perimeter is in aligned registration with the insert and the first door light opening perimeter; e) applying pressure with the first press to secure the first and second door skins with the insert; f) injecting a foam into a first cavity formed between the first and second door skins and the insert; and, g) removing the first and second portions.

In an embodiment, the present invention broadly comprises a method for fabricating a door having a window, the door including a first door skin and a second door skin, the method including the following steps in the order named: a) forming a first door light opening perimeter having a first plurality of tabs arranged about the first door light opening perimeter, wherein the first door light opening perimeter defines a first door light portion; b) forming a second door light opening perimeter having a second plurality of tabs arranged about the second door light opening perimeter, wherein the second door light opening perimeter defines a second door light portion; c) positioning the first door skin on a first press; d) positioning an insert in aligned registration with the first plurality of tabs; e) positioning the second door skin over the insert, wherein the second plurality of tabs are in aligned registration with the insert, and the first door light opening perimeter is aligned with the second door light opening perimeter; f) applying pressure with the first press to secure the first and second door skins with the insert; g) injecting a foam into a first cavity formed between the first door skin outside the first door light portion, the second door skin outside the second door light portion and the insert; and, h) removing the first and second door light portions. In some embodiments, the present invention further includes the step of: i) inserting the window within a second cavity formed by the insert.

In some embodiments, the insert includes a pair of sealing flanges arranged to provide seals about the first and second door light opening perimeters, each of the pair of sealing flanges includes a substantially planar surface arranged for engagement with the first and second door skins. In other embodiments, the insert further includes a connection portion integral to and between the pair of sealing flanges, the connection portion engaged by the foam within the cavity during the injection step. In yet other embodiments, the connection portion is substantially V-shaped. In still yet other embodiments, the pair of sealing flanges and the connection portion are substantially W-shaped. In some embodiments, the insert is a molded plastic article, while in other embodiments, the insert is a metal article formed by a second press, the insert includes a pair of sealing flanges and a connection portion integral to and between the pair of sealing flanges. In some embodiments, the pair of sealing flanges are operatively arranged to provide seals about the first and second door light opening perimeters. The present invention broadly comprises a door fabricated according to the above method.

In an embodiment, the present invention broadly comprises a door including a first door skin having a first door light opening perimeter, the first door light opening perimeter includes a first plurality of tabs arranged about the first door light opening perimeter, a second door skin having a second door light opening perimeter, the second door light opening perimeter includes a second plurality of tabs arranged about the second door light opening perimeter, wherein the first and second door skins are oppositely disposed and arranged to form a first cavity therebetween. The first and second door light opening perimeters are in registered alignment. The present invention door further includes an insert having a pair of sealing flanges and a connection portion integral to and between the pair of sealing flanges, the sealing flanges arranged to provide seals about the first and second door light opening perimeters, each of the pair of sealing flanges includes a substantially planar surface arranged for engagement with the first and second door skins to close the first cavity between the first and second door skins to prevent an infill of a foam into a second cavity during fabrication of the door, wherein the second cavity is defined by the first and second door light opening perimeters and the insert. In some embodiments, the first door light opening perimeter further includes a first plurality of breakaway connectors arranged to permit the removal of a first door light portion of the first door skin within the first door light opening perimeter, and the second door light opening perimeter further includes a second plurality of breakaway connectors arranged to permit the removal of a second door light portion of the second door skin within the second door light opening perimeter.

It is a general object of the present invention to provide a door having a door light at a low cost which is easy to manufacture.

It is another general object of the present invention to minimize the labor and waste created by cutting out a door light from a door after door skins have been assembled and foam insulation has been injected into a cavity formed between the door skins, wherein the waste is a recyclable product.

It is yet another object of the present invention to minimize associated shipping costs for shipping a door from raw door manufacturers to finished door manufacturers by providing a door having a lower weight.

These and other objects and advantages of the present invention will be readily appreciable from the following description of preferred embodiments of the invention and from the accompanying drawings and claims.

DETAILED DESCRIPTION OF THE INVENTION

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. It should be appreciated that the term “light” is synonymous with terms such as “window”, “opening”, “portal”, “aperture”, “orifice”, “porthole”, etc., and such terms may be used interchangeably as appearing in the specification and claims. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.

Adverting now to the figures,FIG. 1shows a perspective view of an embodiment of present invention door light insert10, whileFIG. 2shows a perspective view of door light insert10during installation between first and second door skins12and14, respectively.FIG. 3shows a cross sectional view of door light insert10,FIG. 4shows a cross sectional view of completed door16including door light insert10after fabrication andFIG. 5shows a perspective view of completed door16including door light insert10. The following discussion is best understood in view ofFIGS. 1 through 5.

Door light insert10is used for fabrication of door light18in door16. Door16comprises a pair of interlocking and oppositely disposed door skins12and14which, when assembled, form cavity20therebetween. Door skins12and14further comprise door light openings22and24, respectively. During assembly of door16, door light opening22is registerably aligned with opposing door light opening24. In the embodiments shown inFIGS. 1 through 5, insert10comprises engagement flanges26and28for engagement with door skins12and14, respectively, within cavity20. Insert10is engageable within door light openings22and24, and closes cavity20, i.e., the volume formed between door skins12and14, and prevents infill of foam30into door light openings22and24, and hence door light18, during fabrication.

In some embodiments, insert10further comprises secondary flanges32and34positioned substantially parallel to and between engagement flanges26and28. Secondary flanges32and34are substantially encapsulated in foam30within cavity20during fabrication of door16. In some of these embodiments, secondary flanges32and34are equal in length but shorter in length than either of engagement flanges26or28. In other words, secondary flanges32and34have first lengths36, while engagement flanges26and28have second lengths38, and first lengths36are less than second lengths38. In yet other embodiments, engagement flanges26and28each comprise offset engagement surfaces40and42, respectively, so that outer interfaces44and46between first and second door skins12and14, respectively, and insert10are substantially flush. Outer interfaces44and46are created by the combination of outer surfaces48and50of door skins12and14, respectively, and steps52and54of insert10, respectively. In the embodiments shown inFIGS. 1 through 5, insert10is a molded plastic article. However, as one of ordinary skill in the art will recognize, other materials may also be used, e.g., wood, metal, ceramic or polymers, and such variations are within the spirit and scope of the claimed invention. A second embodiment of a present invention door light insert is discuss in detail infra, wherein the insert is constructed from metal.

FIG. 6shows a perspective view of an embodiment of the present invention, i.e., door light insert56, whileFIG. 7shows a perspective view of door light insert56during installation between first and second door skins58and60, respectively.FIG. 8shows a cross sectional view of door light insert56, whileFIG. 9shows a cross sectional view of completed door62including door light insert56after fabrication. The following discussion is best understood in view ofFIGS. 6 through 9.

In the embodiments shown inFIGS. 6 through 9, door skins58and60comprise beads64and66, respectively, arranged proximate door light openings68and70, respectively. Although beads64and66are primarily used for the alignment and securing of insert56, beads64and66also provide the added benefit of increasing the rigidity of first and second door skins58and60, respectively. This increased rigidity allows for easier handling of door skins during the assembly process. Although the embodiments shown inFIGS. 6 through 9comprise stamped metal door skins, one of ordinary skill in the art will recognize that other materials of construction for the door skins are also possible, e.g., molded fiberglass, molded polymer or wood, and such variations are within the spirit and scope of the claimed invention. Additionally, in these embodiments, insert56is a metal article formed by a press (not shown), for example, a roll press. Insert56comprises first and second bent portions72and74, respectively, operatively arranged to matingly engage beads64and66, respectively. After insert56exits the press, the areas where corners are required are cut or notched so that insert56may be bent to form the desired shape. For example, corners76a,76b,76cand76dare cut and subsequently bent to form approximately ninety degree angles. First and second ends78and80, respectively, are joined by means generally known in the art, e.g., welding, overlapping, dovetailing or bonding. In the embodiment shown inFIG. 6, first and second ends78and80, respectively, are joined with weld82. Although in the embodiments shown inFIGS. 6 through 9, bent portions72and74are arranged to matingly engage beads64and66, respectively, one of ordinary skill in the art will recognize that other means of interfacing insert56and door skins58and60are also possible, e.g., as described supra relative to insert10, and such variations are within the spirit and scope of the claimed invention. Similarly, although beads64and66and bent portions72and74are shown as generally curved shapes, other shapes are also possible, e.g., V-shaped or square shaped, and these variations are also within the spirit and scope of the claimed invention.

In some embodiments, bonding agents84and86are deposited on bent portions72and74, respectively, as insert56exits the press, or are subsequently deposited as secondary operations after forming insert56. Bonding agents84and86may for example be an adhesive, a pressure sensitive adhesive, a glue, an epoxy or a weld. Thus, during assembly, bent portion72having bonding agent84deposited thereon is pressed against bead64of first door skin58thereby securing insert56to first door skin58. Subsequently, bead66of second door skin60is pressed against bent portion74, having bonding agent86deposited thereon, thereby securing second door skin60to insert56. One of ordinary skill in the art recognizes that bonding agents84and86serve a variety of purposes which include but are not limited to: providing bonding strength to hold door skins58and60and insert56together during assembly and thereafter; and, providing a thermal break within the assembly to reduce heat transfer between door skins58and60and insert56. Subsequent to assembling door skins58and60and insert56, cavity88, i.e., the volume formed between first and second door skins58and60, respectively, and wall90of insert56, is filled with foam92. As can be seen in the figures, in these embodiments, wall90prevents any inflow of foam92within cavity94, i.e., the opening for a window.

One of ordinary skill in the art recognizes that although not described above, engagement flanges26and28of insert10may also have a bonding agent deposited thereon for purposes of assembly, and such variations are within the spirit and scope of the claimed invention. Additionally, one of ordinary skill in the art will recognize that all embodiments described herein may also be practiced without the presence of bonding agents, and such variations are also within the spirit and scope of the claimed invention.

FIG. 10shows a front plan view of door skin96including horizontal and vertical break away strips98and100, respectively. Due to the thickness of the door skins, bending and distortion may occur during the assembly process thereby decreasing the aesthetic quality of the assembled door. Therefore, in some embodiments, door skin96includes horizontal and vertical break away strips98and100, respectively, operatively arranged within door light opening102. Although in the embodiment shown inFIG. 10door skin96includes two horizontal break away strips98and one vertical break away strip100, one of ordinary skill in the art will recognize that other arrangements are also possible, e.g., one horizontal break away strip, one vertical break away strip, one diagonal break away strip, a plurality of horizontal break away strips, a plurality of vertical break away strips, a plurality of diagonal break away strips or combinations thereof, and such variations are within the spirit and scope of the invention as claimed. Subsequent to door assembly, the break away strips may be removed by bending weakened portions103until the break away strips separate from the door skin, or alternatively, the break away strips may be left in to provide further structural support during shipping of an assembled door to a manufacturer of finished doors, and in those instances, the break away strips are removed after shipping but prior to the final installation of a window.

The following discussion is best understood in view ofFIGS. 1 through 9, and in particularFIGS. 2 and 7. The present invention also broadly comprises a method for fabricating doors, for example doors16and62having door light insert10and56, respectively. As described supra, door16comprises first and second door skins12and14, respectively, having first and second door light openings22and24, respectively, while door62comprises first and second door skins58and60, respectively, having first and second door light openings68and70, respectively. A first door skin, e.g., first door skin12or58, is positioned on a press (not shown). Then, an insert, e.g., insert10or56, is positioned in aligned registration with a first door light opening of the first door skin, e.g., first door light opening22or68. Next, a second door skin, e.g., second door skin14or60, is positioned over the insert, wherein a second door light opening, e.g., second door light opening24or70, is in aligned registration with the insert and the first door skin. Then, pressure is applied in the direction of arrows104with the press to secure the first and second door skins with the insert. Subesequently, a foam, e.g., foam30or92, is injected into a cavity formed between the first and second door skins and the insert, e.g., cavity20or88.

Depending on the needs and/or requirements of the purchaser of a door assembled by the method described supra, in some embodiments, the method further comprises inserting a window (not shown) within a second cavity formed by the insert, e.g., cavity18or94.

FIG. 11shows a perspective view of an embodiment of the present invention, i.e., door light insert200, whileFIG. 12shows a perspective view of door light insert200during installation between first and second door skins202and204, respectively.FIG. 13shows a cross sectional view of door light insert200, andFIG. 14shows a cross sectional view of completed door206including door light insert200after fabrication.FIG. 15shows a perspective view of an embodiment of a present invention including door light insert208shown during installation between first and second door skins210and212, respectively.FIG. 16shows a cross sectional view of door light insert208, whileFIG. 17shows a cross sectional view of completed door214including door light insert208after fabrication. The following discussion is best understood in view ofFIGS. 11 through 17.

It has been found that a door may be manufactured using a modified present invention insert, e.g., inserts200or208, and a modified method of assembly as described herebelow. The modified method for fabricating a door having a window, begins with first and second door skins which do not include door light openings, e.g., first and second door skins202and204, respectively, or first and second door skins210and212, respectively. The method comprises the following steps in the order set forth herein. First, a door light opening perimeter is formed in each door skin, wherein each door light perimeter defines a portion. For example, first door skin202includes first door light opening perimeter216formed therein, and defining first portion218; first door skin210includes first door light opening perimeter220formed therein, and defining first portion222; second door skin204includes second door light opening perimeter224formed therein, and defining second portion226; and, second door skin212includes second door light opening perimeter228formed therein, and defining second portion230. Second, the first door skin, e.g., first door skin202or210, is positioned on a first press, e.g., first press231. Third, an insert, e.g., door light insert200or208, is positioned in aligned registration with the first door light opening perimeter, e.g., first door light opening perimeter216or220. Fourth, the second door skin, e.g., second door skin204or212, is positioned over the insert, e.g., door light insert200or208, wherein the second door light opening perimeter, e.g., second door light opening perimeter224or228, is in aligned registration with the insert and the first door light opening perimeter. Fifth, the first press applies pressure, as shown by unidirectional arrows232, to secure the first and second door skins with the insert. Sixth, a foam, e.g., foam233or234, is injected into a first cavity formed between the first and second door skins and the insert, e.g., first cavity236or238. Seventh, the first portion, e.g., first portion218or222, and the second portion, e.g., second portion226or230, are removed. In an embodiment, the method further comprises the eighth step of inserting a window, e.g., window240, within a second cavity, e.g., second cavity241or242, formed by the insert.

In the above described embodiment, the insert, e.g., insert200, comprises pair of engagement flanges243aand243bfor aligned registration and engagement with first and second door skins, e.g., door skins202and204, each of engagement flanges243aand243bcomprises a groove, e.g., groove244aand244b, respectively, arranged for receipt of one of first or second door light opening perimeters216and224therein. In an embodiment, the insert, e.g., insert200, further comprises secondary pair of flanges246aand246bpositioned substantially parallel and between pair of engagement flanges243aand243b. It should be appreciated that secondary pair of flanges246aand246bare encapsulated by foam, e.g., foam233, within the cavity, e.g., cavity236formed between the first and second door skins and the insert, during the above described injection step. In an embodiment, secondary flanges246aand246bare equal in length but shorter in length than either of engagement flanges243aand243b. In other words, secondary flanges246aand246bcomprise length248, while engagement flanges243aand243bcomprise length250, and length248is less than length250. It should be appreciated that other combinations of lengths and arrangements are also possible, e.g., the secondary flanges may be longer than the engagement flanges or the secondary flanges may be unequal in length relative to each other, and such variations are within the spirit and scope of the claimed invention.

In an embodiment, the grooves, e.g., grooves244aand244b, comprise a V-shaped cross-section, e.g., V-shaped sections252aand252b, respectively. Furthermore, in an embodiment, the insert, e.g., insert200, is a molded plastic article. Moreover, in an embodiment, the insert, e.g., insert208, is a metal article formed by a second press (not shown), e.g., a roll press, the insert comprises first and second bent portions, e.g., bent portions254aand254b, respectively. It should be appreciated that insert208is formed according to the method described above relative to insert56. In an embodiment, the first and second bent portions are operatively arranged to matingly engage first and second door light opening perimeters, respectively, e.g., door light opening perimeters220and228. Additionally, in an embodiment, the present invention broadly comprises a door, e.g., door206or214, fabricated according to the method described supra.

In an embodiment, bonding agents256aand256bare deposited on bent portions254aand254b, respectively, as insert208exits the press, or are subsequently deposited as secondary operations after forming insert208. Bonding agents256aand256bmay for example be an adhesive, a pressure sensitive adhesive, a glue, an epoxy or a weld. Thus, during assembly, bent portion254ahaving bonding agent256adeposited thereon is pressed against first door light opening perimeter220of first door skin210thereby securing insert208to first door skin210. Subsequently, second door light opening perimeter228of second door skin212is pressed against bent portion254b, having bonding agent256bdeposited thereon, thereby securing second door skin212to insert208. One of ordinary skill in the art recognizes that bonding agents256aand256bserve a variety of purposes which include but are not limited to: providing bonding strength to hold door skins210and212and insert208together during assembly and thereafter; and, providing a thermal break within the assembly to reduce heat transfer between door skins210and212and insert208. Subsequent to assembling door skins210and212and insert208, first cavity238, i.e., the volume formed between first and second door skins210and212, respectively, and wall258of insert208, is filled with foam234. As can be seen in the figures, wall258prevents any inflow of foam234within second cavity242, i.e., the opening for a window.

One of ordinary skill in the art recognizes that although not described above, engagement flanges243aand243bof insert200may also have a bonding agent deposited thereon for purposes of assembly, and such variations are within the spirit and scope of the claimed invention. Additionally, one of ordinary skill in the art will recognize that all embodiments described herein may also be practiced without the presence of bonding agents, and such variations are also within the spirit and scope of the claimed invention.

FIG. 18shows a perspective view of an embodiment of a present invention door light insert, i.e., insert300, whileFIG. 19shows a perspective view of door light insert300shown during installation between first and second door skins302and304, respectively.FIG. 20shows a front plan view of a door assembled according to the arrangement ofFIG. 19, i.e., door306, prior to removing first and second door light portions308and310, respectively, whileFIG. 21shows a front plan view of door306after removing first and second door light portions308and310, respectively.FIG. 22shows a cross sectional view taken generally along line22-22ofFIG. 20andFIG. 23shows a cross sectional view taken generally along line23-23ofFIG. 21.FIG. 24shows a cross sectional view of door306after removing first and second door light portions308and310, respectively, and inserting window311is inserted into door306. The following discussion is best understood in view ofFIGS. 18 through 24.

It has also been found that a door, e.g., door306, may be manufactured using a further modified present invention insert, e.g., insert300, and a further modified method of assembly, as described herebelow. The further modified method for fabricating a door having a window, begins with first door skin302and second door skin304. Again, this embodiment of the method begins with first door skin302including first door light portion308and second door skin304including second door light portion310and first and second door light portions308and310, respectively, have not been removed. The method comprises the following steps in the order set forth herein. First, a first door light opening perimeter is formed, e.g., first door light opening perimeter312. The first door light opening perimeter comprises a first plurality of tabs, e.g., tabs314, arranged about the first door light opening perimeter, wherein the first door light opening perimeter defines a first door light portion, e.g., first door light portion308. Next, a second door light opening perimeter is formed, e.g., second door light opening perimeter316. The second door light opening perimeter comprises a second plurality of tabs, e.g., tabs318, arranged about the second door light opening perimeter, wherein the second door light opening perimeter defines a second door light portion, e.g., second door light portion310. Then, the first door skin, e.g., first door skin302, is positioned on a first press, e.g., first press320. Next, an insert, e.g., insert300, is positioned in aligned registration with the first plurality of tabs, e.g., tabs314. It should be appreciated that by positioning insert300in aligned registration with the first plurality of tabs, insert300is also positioned in aligned registration with the first door light opening perimeter, e.g., first door light opening perimeter312. Next, the second door skin, e.g., second door skin304, is positioned over the insert, e.g., insert300, wherein the second plurality of tabs, e.g., tabs318, are in aligned registration with the insert, and thus the first and second door light opening perimeters are aligned. Additionally, it should be appreciated that by positioning the second plurality of tabs in aligned registration with insert300, insert300is also positioned in aligned registration with the second door light opening perimeter, e.g., second door light opening perimeter316. Then, the first press applies pressure, as shown by unidirectional arrows322, to secure the first and second door skins with the insert. Next, a foam, e.g., foam324, is injected into a first cavity formed between the first door skin outside the first door light portion, the second door skin outside the second door light portion and the insert, e.g., first cavity326. Lastly, the first and second door light portions, e.g., first and second door light portions308and310, respectively, are removed. In an embodiment, the modified method further comprises the additional step of inserting a window, e.g., window311, within a second cavity, e.g., second cavity330, formed by the insert.

In the above described method, the insert, e.g., insert300, comprises a pair of sealing flanges, e.g., sealing flanges332aand332b, arranged to provide seals about first and second door light opening perimeters312and316, respectively. Each of sealing flanges332aand332bcomprises a substantially planar surface, e.g., planar surfaces334aand334b, arranged for engagement with first and second door skins302and304. Insert300further comprises connection portion336. Connection portion336is integral to and between sealing flanges332aand332b. Connection portion336is engaged by foam324within first cavity326during the injection step. In the embodiment shown in the figures, connection portion336is substantially V-shaped. Thus, pair of sealing flanges332aand332bin combination with connection portion336is substantially W-shaped. One of ordinary skill in the art will recognize that although sealing flanges332aand332bare shown to be substantially planar surfaces, other configurations are also possible, e.g., curved surfaces or V-shaped grooves, and such variations are within the spirit and scope of the claimed inventions. It should be appreciated that with such variations complimentary mating features will also be present proximate the door light opening perimeters, e.g., curved surfaces or V-shaped grooves.

It should be appreciated that insert300may be constructed from a variety of materials. For example, insert300may be a molded plastic article, or insert300may be a metal article formed by a press, e.g., a roller press. As described above, such inserts comprise a pair of sealing flanges, e.g., sealing flanges332aand332b, and a connection portion, e.g., connection portion336, integral to and between the pair of sealing flanges. Similarly, the sealing flanges are operatively arranged to provide seals about the first and second door light opening perimeters, e.g., first and second door light opening perimeters312and316, respectively.

It should also be appreciated that the present invention broadly comprises a door, e.g., door306, fabricated according to the method described supra.

In view of the foregoing, a present invention door, i.e., door306, comprises a first door skin, e.g., first door skin302. The first door skin comprises a first door light opening perimeter, e.g., first door light opening perimeter312. The first door light opening perimeter comprises a first plurality of tabs arranged about the first door light opening perimeter, e.g., first plurality of tabs314. Additionally, the present invention door comprises a second door skin, e.g., second door skin304. The second door skin comprises a second door light opening perimeter, e.g., second door light opening perimeter316. The second door light opening perimeter comprises a second plurality of tabs arranged about the second door light opening perimeter, e.g., second plurality of tabs318. Thus, the present invention door comprises oppositely disposed first and second door skins which are arranged to form a first cavity therebetween, e.g., first cavity326. It should be appreciated that the above described arrangement results in the first and second door light opening perimeters being in registered alignment. The present invention door further comprises an insert, e.g., insert300. The insert comprises a pair of sealing flanges, e.g., sealing flanges332aand332b, and a connection portion integral to and between the pair of sealing flanges, e.g., connection portion336. The sealing flanges are arranged to provide seals about the first and second door light opening perimeters. Each of the pair of sealing flanges comprises a substantially planar surface, e.g., planar surfaces334aand334b, arranged for engagement with the first and second door skins to close the first cavity between the first and second door skins to prevent an infill of a foam, e.g., foam324, into a second cavity, e.g., second cavity330, during fabrication of the present invention door. The second cavity is defined by the first and second door light opening perimeters and said insert.

In the embodiment shown in the figures, the first door light opening perimeter further comprises a first plurality of breakaway connectors, e.g., first plurality of breakaway connectors338, arranged to permit the removal of a first area of said first door skin within said first door light opening perimeter, e.g., first door light portion308. Similarly, the second door light opening perimeter further comprises a second plurality of breakaway connectors, e.g., second plurality of breakaway connectors340, arranged to permit the removal of a second area of said second door skin within said second door light opening perimeter, e.g., second door light portion310. It should be appreciated that the side or sides of each tab314proximate first door light opening perimeter312is cut during the tab forming step, and then bent towards the cavity formed between the door skins. Contrarily, the portion of material which makes up each breakaway connector338remains connected to first door light opening perimeter312. Thus, subsequent to tab formation, first door light portion308is held to first door skin302by only breakaway connectors338. Similarly, the side or sides of each tab318proximate second door light opening perimeter316is cut during the tab forming step, and then bent towards the cavity formed between the door skins. Contrarily, the portion of material which makes up each breakaway connector340remains connected to second door light opening perimeter316. Thus, subsequent to tab formation, second door light portion310is held to second door skin304by only breakaway connectors340.

Quite unexpectedly, it has been found that doors constructed according to the present invention method, i.e., doors which include the present invention door light insert, attain improved strength and rigidity, e.g., during hurricane strength testing. Additionally, as there is no foam within the inner cavity created by the first and second door skins and the insert, as the first and second door light portions are removed, such portions may be recycled and used for the manufacture of more door skins. Contrarily, as described supra, if foam were allowed to enter the inner cavity, the removal of the first and second door light portions would produce a hazardous waste which must be disposed of according to the local laws where the door is manufactured. In other words, merely having the first and second door light portions bound together by foam therebetween converts the first and second door light portions to hazardous waste.

One of ordinary skill in the art will recognize several additional aspects of the present invention, which aspects are within the spirit and scope of the claimed invention. For example, the door skins may also include decorative portions, e.g., embossments, and these portions may be formed during the same stamping operation as the door light openings are formed, or as a prior or subsequent operation. Additionally, the door skins may have decorative portions secured thereto, e.g., raised decorative embellishments. It should also be appreciated that a present invention insert may be sold individually, in combination with door skins or as a part of a completed door having a door light opening and/or a window installed therein. In like fashion, it should be appreciated that, although the present invention inserts described supra have rectangular or square shaped openings, other shapes are also possible, e.g., circular, hemispherical, triangular, polygon or octagon, and such variations are within the spirit and scope of the claimed invention. Additionally, although in the embodiments shown in the figures and described above include grooves and bent portions having V-shaped or arcuate cross sections, other shapes are also possible, e.g., square, rectangular, polygon, etc., and such variations are within the spirit and scope of the claimed invention.