Patent ID: 8286352
Filing Date: 2012-10-16
Classification: A01G,A47G,E04H,Y10T

Abstract:
1. A method for constructing at least one framework to form a modular ornamental structure, the method comprising the steps of: (a) placing a first end rail, a second end rail, a first side rail, and a second side rail flatly on a flat, horizontal support surface, the first end rail and the second end rail each having an inside wall, each inside wall has a front side opposing a rear side and includes an upper edge and a lower edge, each inside wall further includes opposing longitudinally extending edges to which vertical side walls are integrally joined respectively, the vertical side walls each extend generally perpendicularly from the respective opposing longitudinally extending edges of the inside wall, the vertical side walls each include an upper end and a lower end, the upper end and the lower end of the vertical side walls are coped so as to form an upper L-shaped recess and a lower L-shaped recess, each inside wall and the respective vertical side walls collectively form a substrate receiving channel, the first side rail and the second side rail each having an inside wall segment, each inside wall segment having a front side opposing a rear side and having opposing longitudinally extending edges to which vertical side walls are integrally joined respectively, the vertical side walls of the inside wall segment each extend generally perpendicularly from the respective opposing longitudinally extending edges of the inside wall segment, each inside wall segment and the respective vertical side walls thereof collectively form a substrate receiving channel; (b) positioning the first end rail and the second end rail longitudinally and parallel in a manner such that the upper L-shaped recess of the first end rail faces the upper L-shaped recess of the second end rail, and the lower L-shaped recess of the first end rail faces the lower L-shaped recess of the second end rail; (c) positioning the first side rail and the second side rail generally horizontal and parallel between the first end rail and the second end rail; (d) positioning the first side rail above the second side rail in a manner such that the rear side of the inside wall segment of the first side rail is oriented upward; (e) positioning the second side rail below the first side rail in a manner such that the front side of the inside wall segment of the second side rail is oriented upward; (f) aligning an end of the first side rail in the upper L-shaped recess of the first end rail in a manner such that the end of the first side rail mates flush with the upper L-shaped recess of the first end rail; (g) tack welding the first end rail to the end of the first side rail at an engaged mating alignment, thereby forming a first upper interface; (h) aligning an opposite end of the first side rail in the upper L-shaped recess of the second end rail in a manner such that the opposite end of the first side rail mates flush with the upper L-shaped recess of the second end rail; (i) tack welding the second end rail to the opposite end of the first side rail at an engaged mating alignment, thereby forming a second upper interface; (j) aligning an end of the second side rail in the lower L-shaped recess of the first end rail in a manner such that the end of the second side rail mates flush with the lower L-shaped recess of the first end rail; (k) tack welding the first end rail to the end of the second side rail at an engaged mating alignment, thereby forming a first lower interface; (l) aligning an opposite end of the second side rail in the lower L-shaped recess of the second end rail in a manner such that the opposite end of the second side rail mates flush with the lower L-shaped recess of the second end rail; (m) tack welding the second end rail to the opposite end of the second side rail at an engaged mating alignment, thereby forming a second lower interface; (n) positioning an upper end of a first substrate reinforcement member at the first upper interface against a proximal inner wall of one of the vertical sidewalls of the first side rail; (o) positioning a lower end of the first substrate reinforcement member at the second lower interface against a corresponding proximal inner wall of one of the vertical sidewalls of the second side rail; (p) tack welding the upper end of the first substrate reinforcement member to the proximal inner wall of one of the vertical sidewalls of the first side rail; (q) tack welding the lower end of the first substrate reinforcement member to the corresponding proximal inner wall of one of the vertical sidewalls of the second side rail; (r) positioning an upper end of a second substrate reinforcement member at the second upper interface against a distal inner wall of one of the vertical sidewalls of the first side rail; (s) positioning a lower end of the second substrate reinforcement member at the first lower interface against a corresponding distal inner wall of one of the vertical sidewalls of the second side rail; (t) tack welding the upper end of the second substrate reinforcement member to the distal inner wall of one of the vertical sidewalls of the first side rail; (u) tack welding the lower end of the second substrate reinforcement member to the corresponding distal inner wall of one of the vertical sidewalls of the second side rail in a manner so that the second substrate reinforcement member traverses the first substrate reinforcement member; (v) grounding exterior welds of the one framework so that the exterior welds are flush with an external surface of the first end rail, the second end rail, the first side rail, and the second side rail, the one framework having a framework void; and (w) coating the one framework with an epoxy primer.