Door with glass insert and method for assembling the same

Abstract

A door comprising first and second door skins secured to each other to form a cavity therebetween filled with expended foam. Each of the door skins has an opening therethrough for receiving a glass insert and a flange portion. Distal ends of the flange portions of the first and second door skins engage each other in an overlapping relationship by the expansion pressure of the expanded foam. The door further comprises a glazing rim member having a leg portion snap-locked between the flange portions of the first and second door skins. The method for assembling the door comprises the steps of filling the cavity between the door skins with foam material, then inserting the glass insert through the openings in the door skins and mounting the glazing rim member to the first door skin by snap-locking between the flange portions of the first and second door skins.

Description

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.

Claims

1. A door, comprising: a first door skin having a first planar portion formed with a first opening for receiving a glass insert, said first opening being defined by a first flange extending inward from said first planar portion and a lip portion extending from where said first flange meets said first planar portion and substantially parallel to said first planar portion to contact a first major surface of said glass insert;a second door skin opposite to said first door skin to form a cavity therebetween and having a second planar portion formed with a second opening for receiving said glass insert, said second opening defined by a second flange extending into said cavity from said second planar portion to engage said first flange;a glazing rim member having a leg portion disposed on a surface of said second flange with and a lip portion extending substantially parallel to said second planar portion of said second door skin and having at least one flexible sealant fin extending from the lip portion to apply a contact pressure to a second major surface of said glass insert; anda core material disposed in the cavity between said first and second door skins.

2. The door according to claim 1, wherein said second flange extends more than half the width of the cavity.

3. The door according to claim 1, wherein said at least one flexible sealant fin of the glazing rim member is deformed by pressure exerted on the glass insert.

4. The door according to claim 1, wherein: said second flange includes a guide rim extending outward from the surface of the second flange; andsaid glazing rim member includes a pilot cavity extending into a surface of said leg portion, said pilot cavity securing said guide rim of the second flange therein.

5. The door according to claim 1, wherein: said first door skin includes a glazing rim positioning tab extending from the lip portion above said first flange; andsaid first flange has and a distal end with a first notch that engages a distal end of said second flange and a second notch formed between the second flange, the distal end of the first flange, and said glazing rim positioning tab in which said leg portion of the glazing rim member is secured.

6. The door according to claim 1, wherein said core is one of a foam material, wood composite, wood, or foam cement.

7. The door according to claim 1, wherein said at least one flexible sealant fin includes a plurality of flexible sealant fins extending from a top of the lip portion to contact a first region of the second major surface of the glass insert and at least one flexible sealant fin extending from a middle of the lip portion to contact a second region of the second major surface of the glass insert.

8. The door according to claim 1, wherein: said second door skin has an outer wall formed where said second flange meets said second planar portion, said outer wall being angled with respect to said second planar portion and said second flange; andsaid glazing rim member has a flexible sealant fin angled with respect to said leg portion and said lip portion thereof, said flexible sealant fin engaging said outer wall of the second door skin.

9. The door according to claim 1, wherein said lip portion and said leg portion of said rim glazing member are formed of a rigid extrusion material, and said at least one flexible sealant fin is formed of a flexible extrusion material.

10. The door according to claim 9, wherein said second door skin includes a guide rim extending from a region where said second flange meets said second planar portion, and said rim glazing member includes a skirt portion extending from a region where the leg portion meets the lip portion, said skirt portion defining a cavity to engage said guide rim on the second flange.

11. The door according to claim 9, wherein said rigid extrusion material comprises rigid PVC and said flexible extrusion material comprises flexible PVC.

12. The door according to claim 9, wherein said lip portion of said glazing rim member, said leg portion of said glazing rim member, and said at least one flexible sealant fin are coextruded from a predetermined polymer material.

13. The door according to claim 1, wherein said first flange extends normally from said first planar portion, and said second flange extends normally from said second planar portion.

14. A door, comprising: first and second door skins operatively secured to form a cavity therebetween filled with a foam material;each of said first and second door skins has a substantially planar plate portion formed with an opening therethrough for receiving a glass insert, each opening defined by a flange portion formed integrally with said planar plate portion and extending substantially inwardly therefrom toward the opposite door skin;said second door skin has a lip portion formed integrally with said planar plate portion of said second door skin and extending from said flange portion substantially along said planar plate portion;said flange portion of said first door skin has a thickness allowing substantially no deflection thereof due to the expansion pressure of the expanding foam material within said cavity;said flange portion of said second door skin has a thickness allowing some deflection thereof due to the expansion pressure of the expanding foam material within said cavity;distal ends of said flange portions of said first and second door skins engaging each other in an overlapping relationship to form an interlocking lap joint and define said cavity between said first and second door skins; anda glazing rim member including a lip portion disposed opposite said lip portion of said second door skin and a leg portion supported by said flange portion of said first door skin.

15. The door according to claim 14, wherein a distal end of said leg portion of said glazing rim member is snap-locked between said flange portion of said second door skin and said distal end of said flange portion of said first door skin.

16. The door according to claim 14, wherein said lip portion of said glazing rim member is formed of a resilient material.

17. The door according to claim 14, wherein said interlocking lap joint is disposed intermediate between said planar plate portions of said first and second door skins.

18. The door according to claim 14, wherein said first door skin flange portion has a thickness exceeding the thickness of said second door skin flange portion.

19. The door according to claim 14, wherein said second door skin has an upwardly extending guide rim lockingly engaged with a pilot edge of said glazing rim member.

20. The door of claim 19, wherein said second door skin includes an angularly disposed outer wall operatively engaged with a bearing surface of said glazing rim member.

21. The door of claim 20, wherein said glazing rim member has a lip portion opposite to said first door skin lip portion.

22. A building component, comprising: a first building component skin having a first planar portion formed with a first opening for receiving a glass insert, said first opening being defined by a first flange extending inward from said first planar portion and a lip portion extending from where said first flange meets said first planar portion and substantially parallel to said first planar portion to contact a first major surface of said glass insert;a second building component skin opposite to said first building component skin to form a cavity therebetween and having a second planar portion formed with a second opening for receiving said glass insert, said second opening defined by a second flange extending into said cavity from said second planar portion to engage said first flange;a glazing rim member having a leg portion disposed on a surface of said second flange with and a lip portion extending substantially parallel to said second planar portion of said second building component skin and having at least one flexible sealant fin extending from the lip portion to apply a contact pressure to a second major surface of said glass insert; anda core material disposed in the cavity between said first and second building component skins.

23. A method for assembling a door, said method comprising: providing a first door skin having a substantially planar plate portion integrally formed with a flange portion extending substantially normally therefrom so as to define an opening through the first door skin;providing a second door skin having a substantially planar plate portion integrally formed with a flange portion extending substantially normally therefrom so as to define an opening through the second door skin and a lip portion formed integrally with the planar plate portion of the second door skin and extending from the flange portion substantially along said planar plate portion;holding the first and second door skins together by engaging distal ends of the flange portions of the first and second door skins in an overlapping relationship to form a lap joint and to define a cavity between the first and second door skins;inserting a core material into the cavity;inserting a glass insert through the opening in the second door skin so that the glass insert engages the lip portion of the first door skin;providing a glazing rim member including a lip portion and a leg portion;mounting the glazing rim member to the second door skin so that the lip portion of the glazing rim member is disposed opposite the lip portion of the first door skin and a distal end of the leg portion is snap-locked between the flange portion of the second door skin and the distal end of the flange portion of the first door skin.