Composite door with lite and method of making same
First Claim
Patent Images
1. A composite door with a lite comprising:
- (a) a pair of spaced panels providing the faces of the door and having aligned cutouts therein;
(b) a foam retaining member extending about the periphery of said cutouts with a first portion extending between said panels to effect a seal therewith and a mounting portion extending inwardly of said periphery of said cutouts;
(c) a translucent lite configured cooperatively with said cutouts and disposed therein;
(d) an external frame element extending about said periphery of said cutout in one of said panels and having a first portion overlying the outer surface of said one panel about said cutout and a second portion overlying said mounting portion and a marginal portion of the adjacent surface of said lite;
(e) engaging means securing said mounting portion of said foam retaining member and said external frame element in assembly and clamping said lite to said external frame element;
(f) an internal frame element extending about said periphery of said cutout in the other of said panels and having a first portion overlying the outer surface of said other panel about said cutout and a second portion overlying said mounting portion of said retaining member, a marginal portion of the other surface of said lite and said engaging means; and
(g) cellular synthetic resin in a cavity defined by said panels and said foam retaining member, said cellular synthetic resin abutting said form retaining member.
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Accused Products
Abstract
A composite door with a lite utilizes panels with aligned cutouts and a foam retainer member which extends about the cutouts between the panels to effect a seal. The retainer has a mounting portion extending inwardly from the cutout periphery. The lite is disposed in the cutout and it is secured by an external frame which has portions overlying the outer surface of the panel and its marginal portion. A clamp secured to the foam retainer and external frame and clamps the lite to the external frame, and an internal frame has portions overlying the outer surface of the other panel and the marginal portion of the other surface of the lite and conceals the clamp and fastener.
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Citations
15 Claims
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1. A composite door with a lite comprising:
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(a) a pair of spaced panels providing the faces of the door and having aligned cutouts therein; (b) a foam retaining member extending about the periphery of said cutouts with a first portion extending between said panels to effect a seal therewith and a mounting portion extending inwardly of said periphery of said cutouts; (c) a translucent lite configured cooperatively with said cutouts and disposed therein; (d) an external frame element extending about said periphery of said cutout in one of said panels and having a first portion overlying the outer surface of said one panel about said cutout and a second portion overlying said mounting portion and a marginal portion of the adjacent surface of said lite; (e) engaging means securing said mounting portion of said foam retaining member and said external frame element in assembly and clamping said lite to said external frame element; (f) an internal frame element extending about said periphery of said cutout in the other of said panels and having a first portion overlying the outer surface of said other panel about said cutout and a second portion overlying said mounting portion of said retaining member, a marginal portion of the other surface of said lite and said engaging means; and (g) cellular synthetic resin in a cavity defined by said panels and said foam retaining member, said cellular synthetic resin abutting said form retaining member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for forming a composite door having a lite comprising the steps of:
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(a) assembling a pair of substantially planar rectangular door panels in spaced relationship with cutouts formed therein in substantial alignment; (b) placing a foam retaining member in said cutouts with a first portion extending between said panels in sealing relationship with said panels about said cutouts and a second portion extending inwardly of the periphery of said cutouts; (c) introducing synthetic resin foam into the cavity defined by said panels and said foam retaining member; (d) inserting a translucent lite into said cutouts; and (e) securing said lite to said foam retaining member by; (i) providing an external lite frame element on the external surface of one of said panels and said lite; (ii) placing a lite clamping element against the other surface of said lite; and (iii) securing said external lite frame element and said lite clamping element to said second portion of said foam retaining member to clamp said lite between said lite clamping element and said frame element. - View Dependent Claims (11, 12, 13, 14, 15)
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Specification