Apparatus and method of fabricating a door

Abstract

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.

1 - 19 . (canceled) 
   
   
       20 . A door having a window, said door comprising a first door skin and a second door skin, said door fabricated according to a method comprising the following steps in the order named:
 a) forming a first door light opening perimeter comprising a first plurality of tabs arranged about said first door light opening perimeter, wherein said first door light opening perimeter defines a first door light portion;   b) forming a second door light opening perimeter comprising a second plurality of tabs arranged about said second door light opening perimeter, wherein said second door light opening perimeter defines a second door light portion;   c) positioning said first door skin on a first press;   d) positioning an insert in aligned registration with said first plurality of tabs;   e) positioning said second door skin over said insert, wherein said second plurality of tabs are in aligned registration with said insert, and said first door light opening perimeter is aligned with said second door light opening perimeter;   f) applying pressure with said first press to secure said first and second door skins with said insert;   g) injecting a foam into a first cavity formed between said first door skin outside said first door light portion, said second door skin outside said second door light portion and said insert; and,   h) removing said first and second door light portions.   
   
   
       21 . A door comprising:
 a first door skin comprising a first door light opening perimeter, said first door light opening perimeter comprises a first plurality of tabs arranged about said first door light opening perimeter;   a second door skin comprising a second door light opening perimeter, said second door light opening perimeter comprises a second plurality of tabs arranged about said second door light opening perimeter, wherein said first and second door skins are oppositely disposed and arranged to form a first cavity therebetween and said first and second door light opening perimeters are in registered alignment; and,   an insert comprising a pair of sealing flanges and a connection portion integral to and between said pair of sealing flanges, said sealing flanges arranged to provide seals about said first and second door light opening perimeters, each of said pair of sealing flanges comprises a substantially planar surface arranged for engagement with said first and second door skins to close said first cavity between said first and second door skins to prevent an infill of a foam into a second cavity during fabrication of said door, wherein said second cavity is defined by said first and second door light opening perimeters and said insert.   
   
   
       22 . The door of  claim 21  wherein said first door light opening perimeter further comprises a first plurality of breakaway connectors arranged to permit the removal of a first door light portion of said first door skin within said first door light opening perimeter, and said second door light opening perimeter further comprises a second plurality of breakaway connectors arranged to permit the removal of a second door light portion of said second door skin within said second door light opening perimeter.