Interlocking door assembly and method of manufacturing thereof

1. A metal door comprising:

a first skin;

a first mechanical connector integrally formed with the first skin;

a second mechanical connector integrally formed with the first skin whereby the first mechanical connector is different from the second mechanical connector;

a second skin having a third mechanical connector integrally formed therewith;

an end cap having a fourth mechanical connector, wherein said end cap is fixedly secured to said first skin upon operative engagement of said first mechanical connector and said fourth mechanical connector; and

wherein said second skin is secured to said first skin upon engagement of said second mechanical connector and said third mechanical connector.

2. The door of claim 1 wherein the engagement of the first mechanical connector and the fourth mechanical connector prevents removal of the end cap.

3. The door of claim 1 wherein the first skin further comprises a stop preventing movement of the end cap beyond said stop.

4. The door of claim 1 wherein the first mechanical connector includes at least one of a locking tab and a mounting slot, the second mechanical connector includes at least one of a mounting slot and a protrusion, the third mechanical connector includes at least one of a mounting slot and a protrusion, and the fourth mechanical connector includes at least one of a locking tab and a mounting slot.

5. The door as defined in claim 1 in which the end cap is fixedly secured to said first skin upon a sliding engagement between the first mechanical connector and the fourth mechanical connector.

6. The door of claim 1 wherein the second mechanical connector comprises a mounting slot having a positioning portion and a locking portion.

7. The door of claim 6 wherein the third mechanical connector comprises a protrusion and wherein the second skin is releasably secured to the first skin upon sliding engagement of the protrusion from the positioning portion to the locking portion.

8. The door of claim 1 wherein the end cap further comprises a plurality of bosses.

9. The door of claim 1 wherein the second mechanical connector comprises a plurality of mounting slots disposed about a periphery of the first skin.

10. The door of claim 1 wherein the end cap is fixedly secured to the first skin with an adhesive and the second skin is fixedly secured to the first skin with an adhesive.

11. The door of claim 3 wherein the end cap is releasably secured within the stop.

12. The door of claim 1 wherein the first skin further comprises a first wall and a second wall generally parallel to and adapted to be spaced away from the first wall by a side wall.

13. The door of claim 12 wherein the side wall further comprises at least one axial protrusion, a plurality of sliding locks, and at least one mounting hole.

14. The door of claim 13 further comprising at least one hinge reinforcement plate having at least one mounting slot, a plurality of locking slots, and at least one securing hole.

15. The door of claim 14 wherein the at least one hinge reinforcement plate is fixedly secured to the side wall upon sliding engagement of the at least one axial protrusion and the at least one mounting slot.

16. The door of claim 14 wherein the at least one hinge reinforcement plate is fixedly secured to the side wall upon sliding engagement of the plurality of sliding locks and the plurality of locking slots.

17. A metal door comprising:

a first skin;

a first mechanical connector formed with the first skin;

a second mechanical connector formed with the first skin whereby the first mechanical connector is different from the second mechanical connector;

a second skin having a third mechanical connector formed with the second skin;

at least one hinge plate having at least one hinge plate mechanical connector formed with the hinge plate, wherein the at least one hinge plate is secured to the first skin upon engagement of the first mechanical connector and the at least one hinge plate mechanical connector;

wherein the second skin is secured to the first skin upon engagement of the second mechanical connector and the third mechanical connector; and

wherein the at least one hinge plate mechanical connector comprises at least one mounting slot and a plurality of locking slots and the first mechanical connector comprises at least one axial protrusion and a plurality of sliding locks.

18. The metal door of claim 17 , wherein the at least one hinge plate mechanical connector further comprises at least one securing hole and the first mechanical connector further comprises at least one at least one mounting hole.

19. The metal door of claim 18 wherein the at least one hinge plate is fixedly secured to the first skin upon sliding engagement of at least one of the at least one axial protrusion and the at least one mounting slot and the plurality of sliding locks and the plurality of locking slots.

20. A metal door comprising:

a first skin;

a first, second and third mechanical connector formed with the first skin, wherein the first, second and third mechanical connectors are different from one another;

a second skin having a fourth mechanical connector formed with the second skin;

an end cap having a fifth mechanical connector, wherein said end cap is fixedly secured to said first skin upon operative engagement of said first mechanical connector and said fifth mechanical connector;

at least one hinge plate having at least one hinge plate mechanical connector formed with the hinge plate, wherein the at least one hinge plate is secured to the first skin upon engagement of the third mechanical connector and the at least one hinge plate mechanical connector; and

wherein the second skin is secured to the first skin upon engagement of the second mechanical connector and the fourth mechanical connector.