Patent Publication Number: US-7721501-B2

Title: Door with glass insert and method for assembling the same

Description:
CROSS-REFERENCE(S) TO RELATED APPLICATION(S) AND CLAIM TO PRIORITY 
   This application claims the benefit of priority under 35 U.S.C. 119(e) from U.S. provisional patent application 60/778,974, which was filed on Mar. 6, 2006, the disclosure of which is incorporated herein in its entirety. 

   FIELD OF THE INVENTION 
   The present invention relates generally to door assemblies in general, and, more particularly, to a door having a glass insert and a method for assembling the same. 
   BACKGROUND OF THE INVENTION 
   A commonplace substitution for the traditional wooden doors in residential and commercial buildings is a door made from steel or fiberglass. One type of synthetic door is formed with resin sheets reinforced with fiber glass (in the art referred to as door skins) attached to opposite sides of rails and stiles forming a rectangular frame, with the resulting cavity between the door skins filled with a polymer foam material. Doors so constructed can include wood graining on the outer surfaces of the skins, and also raised paneling formed (molded) in the skins, which gives these doors the appearance of natural wood fabricated products. 
   Molded skins for making such doors are typically formed using mixtures having by weight 12% to 15% polyester resin, 5% to 15% polystyrene, 40% to 50% calcium carbonate and 15% to 25% chopped fiberglass. Such mixtures are deposited in a compression molding machine and subjected to pressures from 600 to 1,500 psi and elevated temperatures for a cure cycle of from 60 to 200 seconds to form rigid skins. The mixture described is one of those known as a “sheet molding compound” (SMC). 
   The door skins formed from SMC processes for doors can have thicknesses of from about 0.13 mm (0.05 inches) to about 52 mm (0.20 inches), depending on the door application in which they are used. 
   As previously noted such skins are affixed to opposite sides of a rectangular frame and the core (cavity) enclosed by the frame and skins is tilled with polymer foam to complete the door. A rigid urethane foam having a density of 0.8 pounds per cubic foot to 3.5 pounds per cubic foot is suitable for the core of such doors. 
   Previously, these doors may have had glass inserts (glazing or lights) that covered less than 30% of the door&#39;s exterior surface. Currently the marketplace demands doors with larger glass inserts, which can comprise more than 60% of the door&#39;s exterior surface. Due to building codes, these large glass inserts must be double glazed (double pane) and in some cases made of safety glass. While known doors with glass inserts have proven to be acceptable for various applications, such doors are nevertheless susceptible to improvements that may enhance their performance and lower cost. With this in mind, a need exists to develop improved doors with glass inserts that advance the art. 
   SUMMARY OF THE INVENTION 
   The present invention provides an improved door having a large central glass insert and a method for assembling the same. Alternatively, the invention is an improved building component having a lite, such as a door, a side lite, or a transom lite. 
   According to a first aspect of the present invention, a door is provided. The door features a glass insert having opposite first and second major surfaces and an outer edge extending between the first and second major surfaces, a first door skin having a first opening receiving the glass insert, a second door skin having a second opening aligned with the first opening for receiving the glass insert, a glazing rim member, and a core material disposed in a core cavity between the first and second door skins. The first door skin includes a first planar portion, a first flange portion at the first opening extending from the first planar portion substantially parallel to the outer edge of the glass insert, and a first lip portion extending the first opening to contact the first major surface of the glass insert. The second door skin includes a second planar portion that is spaced from the first planar portion to form the core cavity between the first and second planar portions, a second flange portion at the second opening extending from the second planar portion substantially parallel to the outer edge of the glass insert to contact the first flange portion, and a guide wall comprising a guide rim. The guide wall has an exterior surface generally facing away from the first door skin and angularly disposed relative to the second planar portion and the second flange portion. The glazing rim member includes a second lip portion contacting the second major surface of the glass insert, a leg portion disposed on a surface of the second flange portion, and a skirt portion. The leg portion includes a distal end and an opposite pilot edge. The distal end is interlockingly engaged between a glazing rim locking tab of the first door skin and the second flange portion and the pilot edge is engaged to the guide rim to interference fit the glazing rim member to the second door skin and the glass insert. The skirt portion is spaced from the pilot edge to define a pilot cavity that receives the guide rim, and applies contact pressure to the exterior surface of the guide wall. 
   According to a second aspect of the invention, a pre-assembled door is provided for receiving a glass insert having opposite first and second major surfaces and an outer edge extending between the first and second major surfaces. The pre-assembled door features a first door skin having a first opening for receiving the glass insert, a second door skin having a second opening that when in a door assembled state is aligned with the first opening for receiving the glass insert, and a glazing rim member. The first door skin includes a first planar portion, a first flange portion at the first opening extending from the first planar portion, and a first lip portion extending into the first opening for contacting the first major surface of the glass insert. The second door skin includes a second planar portion that when in the door assembled state is spaced from the first planar portion to form a core cavity between the first and second planar portions, a second flange portion at the second opening extending from the second planar portion for contacting the first flange portion, and a guide wall including a guide rim. The guide wall has an exterior surface generally facing away from the first door skin when in the door assembled state and angularly disposed relative to the second planar portion and the second flange portion. The glazing rim member includes a second lip portion, a leg portion having a distal end and an opposite pilot edge, and a skirt portion. When in the door assembled state, the second lip portion contacts the second major surface of the glass insert, the leg portion is disposed on a surface of the second flange portion, the distal end is interlockingly engaged between a glazing rim locking tab of the first door skin and the second flange portion, the pilot edge engages the guide rim to interference fit the glazing rim member to the second door skin and the glass insert, the skirt portion is spaced from the pilot edge to define a pilot cavity that receives the guide rim, and the skirt portion applies contact pressure to the exterior surface of the guide wall. 
   According to a third aspect of the present invention, a building component is provided. The building structure features a glass insert having opposite first and second major surfaces and an outer edge extending between the first and second major surfaces, a first building component skin having a first opening receiving the glass insert, a second building component skin having a second opening aligned with the first opening for receiving the glass insert, a glazing rim member, and a core material disposed in a core cavity between the first and second building component skins. The first building component skin includes a first planar portion, a first flange portion at the first opening extending from the first planar portion substantially parallel to the outer edge of the glass insert, and a first lip portion extending into the first opening to contact the first major surface of the glass insert. The second building component skin includes a second planar portion that is spaced from the first planar portion to form the core cavity between the first and second planar portions, a second flange portion at the second opening extending from the second planar portion substantially parallel to the outer edge of the glass insert to contact the first flange portion, and a guide wall comprising a guide rim. The guide wall has an exterior surface generally facing away from the first building component skin and angularly disposed relative to the second planar portion and the second flange portion. The glazing rim member includes a second lip portion contacting the second major surface of the glass insert, a leg portion disposed on a surface of the second flange portion, and a skirt portion. The leg portion includes a distal end and an opposite pilot edge. The distal end is interlockingly engaged between a glazing rim locking tab of the first building component skin and the second flange portion and the pilot edge is engaged to the guide rim to interference fit the glazing rim member to the second building component skin and the glass insert. The skirt portion is spaced from the pilot edge to define a pilot cavity that receives the guide rim, and applies contact pressure to the exterior surface of the guide wall. 
   According to a fourth aspect of the invention, a method for assembling a door is provided. The method involves mounting a glazing rim member on a partially constructed door. The partially constructed door includes a glass insert having opposite first and second major surfaces and an outer edge extending between the first and second major surfaces, a first door skin having a first opening receiving the glass insert, and a second door skin having a second opening aligned with the first opening for receiving the glass insert. The first door skin includes a first planar portion, a first flange portion at the first opening extending from the first planar portion substantially parallel to the outer edge of the glass insert, and a first lip portion extending into the first opening to contact the first major surface of the glass insert. The second door skin includes a second planar portion that is spaced from the first planar portion to form a core cavity between the first and second planar portions, a second flange portion at the second opening extending from the second planar portion substantially parallel to the outer edge of the glass insert to contact the first flange portion, and a guide wall including a guide rim. The guide wall has an exterior surface generally facing away from the first door skin and angularly disposed relative to the second planar portion and the second flange portion. When mounted, the glazing rim member includes a second lip portion contacting the second major surface of the glass insert, a leg portion disposed on a surface of the second flange portion, and a skirt portion. The leg portion includes a distal end and an opposite pilot edge. The distal end interlockingly engages between a glazing rim locking tab of the first door skin and the second flange portion, and the pilot edge engages the guide rim to interference fit the glazing rim member to the second door skin and the glass insert. The skirt portion is spaced from the pilot edge to define a pilot cavity that receives the guide rim, and applies contact pressure to the exterior surface of the guide wall. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in light of the accompanying drawings, wherein: 
       FIG. 1  is a plan view of a door of the present invention; 
       FIG. 2A  is a perspective view of an inner surface of a first door skin according to the preferred embodiment of the present invention; 
       FIG. 2B  is an exploded perspective view of an inner surface of a second door skin according to the preferred embodiment of the present invention; 
       FIG. 3  is a fragmentary cross-sectional view of the door in  FIG. 1  according to the preferred embodiment of the present invention; 
       FIG. 4  is a fragmentary cross-sectional view of the first door skin of  FIG. 2A  according to the preferred embodiment of the present invention; 
       FIG. 5  is a fragmentary cross-sectional view of the second door skin of  FIG. 2B  according to the preferred embodiment of the present invention; 
       FIGS. 6A through 6C  are fragmentary perspective views of positioning tabs on the first door skin depicted around arrows X, Y, and W of  FIG. 2A  according to the preferred embodiment of the present invention; and 
       FIG. 7  is a fragmentary cross-sectional view of a glazing rim member according to the preferred embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) 
   The preferred embodiment of the present invention will now be described with the reference to accompanying drawings. 
     FIG. 1  illustrates a door of the present invention indicated generally by reference numeral  2 . The door  2  being formed from fiberglass reinforced SMC door skins  10  and  20 , as best shown in  FIGS. 2A and 2B . The door  2  is provided with a preferably rectangular opening for receiving a glass insert (or panel)  6 . As best shown in  FIGS. 2A ,  2 B, and  3 , the door  2  comprises first and second door skins  10  and  20 , respectively, top and bottom rails  7 , and left and right stiles  8 . The first door skin  10  and the second door skin  20  may correspond to an exterior door skin and an interior door skin, respectively. The first and second door skins  10  and  20  are secured to each other through the top and bottom rails  7  and the left and right stiles  8 , typically secured with adhesive, such as moisture cured urethane adhesive, to the door skins  10 ,  20 , and forming a rectangular door frame. Referring now to  FIG. 3 , the first and second door skins  10  and  20  are so secured to the frame to form a cavity  34  therebetween. The cavity  34  of the door  2  is filled with an expanded foam insulating material  35  defining an insulating core  35  of the door  2 . 
   Preferably, the first and second door skins  10  and  20  are molded from an appropriate polymer material and have a thickness of about 1 to 4 mm. The material of the door skins  10  and  20  of the present invention can be sheet molding compound (SMC) reinforced with fiber glass, wood fiber, steel or wood. Preferably, the door skins  10  and  20  are molded and can be made from such materials as fiberglass reinforced plastics, pressed board, vinyl esters, polystyrenes or other moldable materials. An outer surface of the door skins  10  or  20  can be smooth without wood grain or can have a simulated wood grain. The depth of the wood grain is about 0.05 to 0.2 mm. An inner surface of the door skins may have a relatively rough surface to increase the surface area for the adhesive when the door is assembled. This results in stronger bonds between the door skins, the foam material, the rails and the stiles. 
   As best shown in  FIGS. 2A and 2B , each of the first and second door skins  10  and  20  is provided with an opening therethrough for receiving the glass insert  6 . More specifically, the first door skin  10  has an opening  11  therethrough, while the second door skin  10  has an opening  21  therethrough. While we prefer that the openings  11 ,  21  be rectangular, they can have any configuration, provided that they are complementary. As shown in  FIGS. 2A and 2B , the first and second door skins  10  and  20  include respective integral flange portions  14  and  24  that extend inward into the cavity  34  (see  FIG. 3 ) and define the respective openings  11  and  21 . 
   As best shown in  FIGS. 2A and 3 , the first door skin  10  includes a plurality of tabs  50  for positioning the flange portion  24  of the second door skin  20 , the glass insert  6 , and a glazing rim member  36 . 
   The first door skin  10 , as illustrated in  FIG. 4 , includes a substantially planar plate portion  12  formed with the opening  11  (see  FIG. 2A ) therethrough for mounting the glass insert  6 , and the flange portion  14  formed integrally with the planar plate portion  12  and extending substantially inwardly therefrom toward the second door skin  20 , as shown in  FIG. 3 . Preferably, the flange portion  14  extends substantially normal to the planar plate portion  12  of the first door skin  10 . The first door skin  10  further includes a lip portion  28  extending upwardly from the flange portion  14  and inwardly at its distal end to support the glass insert  6  positioned within the opening  11  of the first door skin  10 . According to the preferred embodiment of the present invention, the first door skin  10  is molded from an appropriate polymer material as a single-piece part. 
   Furthermore, the flange portion  14  of the first door skin  10  includes a distal end  27  with a first notch  26 . The first notch  26  has a geometry configured to mate with a distal end  16  of the flange portion  24  of the second door skin  20  (as shown in  FIG. 3 ). 
   As mentioned above, the first door skin  10  includes the plurality of positioning tabs  50  shown in  FIG. 2A . As shown in  FIGS. 3 and 4 , the tabs  50  are spread along flange portion  14  and include a plurality of skin positioning tabs  51  extending below the flange portion  14 , a plurality of glazing rim locking tabs  52 -extending above the flange portion  14 , and a plurality of glass insert positioning tabs  53  extending above the glazing rim locking tabs  52 . 
   The second door skin  20 , as illustrated in  FIG. 5 , includes a substantially planar plate portion  22  formed with the opening  21  (see  FIG. 2B ) therethrough for mounting the glass insert  6 , the flange portion  24  formed integrally with the planar plate portion  22  and extending substantially inwardly therefrom toward the first door skin  10 , as shown in  FIG. 3 . An outer peripheral preferably flat surface  18  of the flange portion  24  of the second door skin  20  defines the opening  21  (see  FIG. 2B ) therethrough, as best shown in  FIG. 5 . Preferably, the flange portion  24  extends substantially normal to the planar plate portion  22  of the second door skin  20 . 
   Furthermore, as best shown in  FIG. 5 , the first door skin  20  has a guide rim  15  extending upwardly from the outer peripheral surface  18  of the flange portion  24 . The guide rim  15  has a flat inner wall  17  spaced inwardly from and extending substantially parallel to the planar plate portion  22  and an outer wall  19  outwardly inclined relative to the plate portion  22  at an approximately 45° angle. It will be appreciated that any other appropriate angle of inclination of the outer wall  19  relative to the plate portion  22  is within the scope of the present invention. According to the preferred embodiment of the present invention, the second door skin  20  is molded from an appropriate polymer material as a single-piece part. 
   As best shown in  FIG. 3 , when the first and second door skins  10  and  20  are assembled together, the distal end  16  of the second flange portion  24  is positioned in the first notch  26  of the first flange portion  14  to form an interlocking joint. The first notch  26  extends the length of the first flange portion  14  and provides stability to the joint. The second flange portion  24  may have a length exceeding the length of the flange portion  14 . Preferably, flange portion  24  extends approximately two thirds of the thickness of the cavity  34 . 
   Although a small spacing is shown in  FIG. 3  between the second skin positioning tab  51  and the distal end  16  of the second flange portion  24 , these components may be shaped such that the distal end  16  of the flange portion  24  fits securely in the first notch  26  substantially without spacing. The first notch of the flange portion  24  cooperates to form a dam that prevents the expendable foam  35  from expanding into the area where the panel  6  is to be received. 
   Referring back to  FIG. 1 , the door  2  further comprises a rectangular glazing rim  33  provided for holding and locking the glass insert  6  in the opening of the door  2 . The glazing rim  33  comprises four elongated glazing rim members  36  (shown in  FIGS. 3 and 7 ) forming the rectangular glazing rim  33 . Each of the glazing rim members  36 , as best shown in  FIG. 7 , includes a leg portion  38  and a lip portion  40  formed integrally with the leg portion  38  and extending outwardly therefrom and having distal end  39 . 
   As shown in  FIG. 7 , the lip portion  40  of the glazing rim member  36  has a plurality of lip portion flexible sealant fins  48  extending inwardly therefrom to support the glass insert  6  positioned within the opening of the door  2  on the side opposite to the lip portion  28  of the first door skin  10 . The lip portion flexible sealant fins  48  provide a contact force against the glass insert  6  so as to prevent rattling of the glass insert  6  within the door  2 . 
   The glazing rim member  36  further includes a skirt portion  46  extending from the lip portion  40  and formed integrally therewith so as to form a pilot cavity  45  between the skirt portion  46  and a pilot edge  41  of the leg portion  38  of the glazing rim member  36 . The pilot cavity  45  is provided for receiving the guide rim  15  of the second door skin  20  therein. As best shown in  FIG. 7 , a distal end  47  of the skirt portion  46  is a skirt portion flexible sealant fin  47  that applies contact pressure to the outer wall  19  of the second door skin  20  when the glazing rim member  36  is assembled therewith. The glazing rim member  36  further includes a midsection flexible sealant fin  49  disposed between the lip portion  40  and the leg portion  38 . 
   The lip portion sealant fins  48 , the midsection sealant fin  49 , and the skirt portion sealant fin  47  allow the glazing rim member  36  to be interference fitted to the second door skin  20 , the glass insert  6 , and the glazing rim locking tabs  52 . Each of the sealant fins  48 ,  49 , and  47  is flexible so as to apply a contact force to the glass insert  6  and the second door skin  20  when assembled with the first and second door skins  10  and  20  and the glass insert  6 . Since each of these sealant fins  47 ,  48 , and  49  is pressed against a corresponding surface of the glass insert  6  or the second door skin  20 , the friction that results from the contact pressure maintains the glazing rim member  36  in engagement with the insert  6 . Accordingly, a tight seal is provided between an area on the glass insert  6  where the lip portion sealant fins  48  contact the glass insert  6  and the guide wall  19  of the second door skin  20 . 
   Additionally, the sealant fins  48 ,  49 , and  47  provide resistance to movement of the glass insert  6  within the opening in the door  2 . As a result, the door  2  assembled from the first and second door skins  10  and  20 , the glass insert  6 , and the glazing rim member  36  is maintained in a stable state without shifting or movement of the components. 
   According to the preferred embodiment of the present invention, the glazing rim member  36  is coextruded from appropriate polymer materials as a single-piece part, which may then be cut to length and mitred to provide the individual glazing rim frame members  36  with the sealant fins  47 ,  48 , and  49  formed from a flexible polyvinyl chloride and the remaining portions formed from a rigid polyvinyl chloride. 
   The lip portion  40 , the skirt portion  46 , and the leg portion  38  of the glazing rim member  36  may be made of a rigid extrusion material and the flexible sealant fins  47 ,  48 , and  49  may be made of a flexible extrusion material. 
   For example, the glazing rim member  36  may be made of polyvinyl chloride (PVC). More specifically, the glazing rim member  36  may be coextruded from PVC such that the lip portion  40 , the skirt portion  46 , and the leg portion  38  of the glazing rim member  36  are made of a rigid PVC while the sealant fins  47 ,  48 , and  49  are made of a flexible PVC (e.g., PVC 74±4 Shore A Durometer). 
   In an assembled position, illustrated in  FIG. 3 , the leg portion  38  of the glazing rim member  36  is placed in contact with the outer peripheral surface  18  of the flange portion  24  of the second door skin  10  so that a distal end  39  of the leg portion  38  is located in a second notch  23  formed by the outer peripheral surface  18  of the flange portion  24 , the distal end  27  of the flange portion  14 , and the glazing rim locking tab  52 . The glazing rim member  36  is properly oriented relative to the second door skin  20  by the guide rim  15  of the second door skin  20 . More specifically, through the application of suitable force, the guide rim  15  is received in the pilot cavity  45  so that the pilot edge  41  of the glazing rim member  36  engages the inner wall  17  of the guide rim  15 . 
   Furthermore, in the assembled position, due to the resilient nature of the material forming the flexible sealant fin  47  of the skirt portion  46 , the glazing rim member  36  tightly engages the outer wall  19  of the guide rim  15  of the second door skin  20 . Due to the intimate contact between the flexible sealant fin  47  and wall  19 , the skirt portion  46  functions as a window seal element. Also, because the material used to form the sealant fins  47 ,  48 , and  49  of the glazing rim member  36  is resilient, the glazing rim member  36  may readily be removed in the event the glass insert  6  should become broken. Thus the glass insert  6  may be replaced without the necessity of replacing the door  2 . Furthermore, because the glazing rim member  36  is formed of a resilient material, it forms a tight seal with the glass insert  6 . Preferably, door skin  20  is the interior door skin and door skin  10  is the exterior or outside door skin. 
   As further illustrated in  FIG. 3 , the glazing rim member  36  is locked in position by snap-locking the distal end  39  of the leg portion  38  thereof in the second notch  23  formed between the outer peripheral surface  18  of the flange portion  24  of the second door skin  20 , the glazing rim locking tab  52 , and the distal end  27  of the flange portion  14  of the first door skin  10 . 
   The glass insert positioning tab  53  is disposed along the flange portion  14  of the first door skin  10  above the glazing rim locking tab  52 . The glass insert positioning tab  53  maintains the glass insert in a predetermined position with respect to the opening in the door  2 . 
   As best shown in  FIGS. 6A to 6C , the flange portion  14  includes the skin positioning tabs  51 , the glass insert positioning tabs  53 , and the glazing rim locking tabs  52  spaced apart from each other in predetermined intervals (i.e., in a discontinuous manner). Furthermore, a corner glazing rim locking tab  54  may be disposed at a corner of the flange portion  14  to lock the glazing rim member  36  in the corners of the opening  11 . The corner glass insert positioning tab  54  and the glass insert positioning tab  53  prevent the glass insert  6  from shifting in the opening in the door  2 . 
   The glass insert  6  may be a preassembled two-pane unit or cassette that can be installed readily in the opening during assembly of the door  2 . Additionally, due to the strength of assembly of the door  2 , laminate glass may be used as the glass insert  6  and the possibility of glass breakage is minimized. The glass insert  6  may be impact resistant. 
   The procedure of assembling the door  2  with the glass insert  6  according to the preferred embodiment of the present invention will now be described. 
   First, the first and second door skins  10  and  20  are formed preferably by a compression molding process from any appropriate polymer material, such as fiber glass reinforced SMC. The openings  11 ,  21  are preferably molded into the door skins  10 ,  20  in order to reduce material cost and minimize manufacturing costs. 
   Then, the first and second door skins  10  and  20 , the top and bottom rails  7 , and the left and right stiles  8  are aligned and attached to each other with adhesive. In this position, the first notch  26  of the flange portion  14  of the first door skin  10  engages the distal end  16  of the flange portion  24  of the second door skin  20  to form a joint and define the cavity  34  (as shown in  FIG. 3 ) between the first and second door skins  10  and  20 , respectively. The distal end  16  of the flange portion  24  is maintained in the first notch  26  by the second skin positioning tab  51  and the distal end  27  of the flange portion  14 . 
   Next, the cavity  34  between the first and second door skins  10  and  20  is filled with the expandable foam material  35  which expands within the cavity  34  and may force together the flanges  14  and  24  of the first and second door skins  10  and  20 , respectively. The expandable foam may be a polyurethane foam or other foamable material that adds weight to the door  2  and also provides sound and thermal insulation properties. 
   Preferably, the step of filling the cavity  34  with the foam material  35  is performed while the semi-assembled door  2  is held in an appropriate press (not shown). The semi-assembled door  2  is placed into the press to hold the skins  10 ,  20  into engagement with the stiles and rails. The press platens may be heated to enhance curing of the adhesive bonding the stiles and rails to the door skins. The press platens have sufficient strength to prevent deflection of the planar plate portions  12 ,  22  of the door skins  10 ,  20  during the foaming operation. 
   The door  2  is then removed from the press. Thereafter, a sealant  100  may be applied to the lip portion  28  of the first door skin  10  in groove  102 , as best shown in  FIG. 3 . The sealant  100  may be a silicone material, caulk, or other material that seals the insert  6  to prevent water from leaking beyond flange  104  and  106  into the interior of the door  2 . The glass insert  6  is then inserted through the opening  21  in the second door skin  20  until the glass insert  6  engages the lip portion  28  of the first door skin  10 . 
   Subsequently, the glazing rim member  36  is mounted to the flange portion  24  of the second door skin  20  so that the leg portion  38  of the glazing rim member  36  is angled downward and moved in contact with the outer peripheral surface  18  of the flange portion  24  of the second door skin  20 . As noted above, the glazing rim member  36  is properly oriented relative to the first door skin  10  by the guide rim  15  of the second door skin  20  engaging the pilot edge  41  and the skirt portion flexible sealant fin  47  of the glazing rim member  36 . 
   As the glazing rim member  36  is forced into position, the flexible sealant fins  47 ,  48  and  49  apply a flexible resistance until the pilot edge  41  is moved passed the inner wall  17  of the guide rim  15 . At this time, the pilot edge  41  is pushed down along the inner wall  17  such that the guide rim  15  is disposed within the pilot cavity  45 . In this position, the glazing rim member  36  is interference fitted to the second door skin  20  and the glass insert  6 . Accordingly, the force provided by the flexible sealant fins  47 ,  48 , and  49  push the surface  41  of the glazing rim member  36  into the wall  17  to prevent the glazing rim member  33  from coming out of engagement and prevents the glazing rim member  36  from moving. Also in this position, the flexible sealant fins  47 ,  48 , and  49  may be slightly deformed due to the interference fitting. 
   Additionally, the glazing rim member  36  is snap-locked into position such that the distal end  39  of the leg portion  38  is secured in the second notch  23  formed between the outer peripheral surface  18  of the flange portion  24 , the distal end  27  of the flange portion  14 , and the glazing rim member locking tab  52 . Also in this position, the lip portion  40  of the glazing rim member  36  is placed against the glass insert  6  laid in the opening of the door  2  on the side opposite to the lip portion  28  of the first door skin  10 . This procedure is repeated for each of the glazing rim frame members  36 . Thus, the glass insert  6  is locked in place. 
   We prefer that the door  2  be removed from the press and stored in inventory, so that the appropriate glazing unit  6  may be installed as ordered by consumers. 
   While we prefer that the flange portion  14  provide a dam, it should be recognized that the expansion of foam  35  could be sufficient to force flange portion  24  upwardly into secure contact of flange portion  14  to further enhance the seal provided by the flange portions. In other words, the flange  24  may be deflected by the expansion force of foam  35 . 
   Also, while we prefer that the core be foam  35 , the core could be a wood composite, wood, wood, wood substrate, or foam cement. 
   The foregoing description of the preferred embodiment of the present invention has been presented for the purpose of illustration in accordance with the provisions of the patent statutes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment disclosed hereinabove was chosen in order to best illustrate the principles of the present invention and its practical application to thereby enable those of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated, as long as the principles described herein are followed. Thus, changes can be made in the above-described invention without departing from the intent and scope thereof. It is also intended that the scope of the present invention be defined by the claims appended thereto.