Patent ID: 8529716

Claim:
A method for forming a frame comprising: providing a plurality of lineals each defined by a peripheral wall having interior surfaces defining a hollow interior; forming at least one corner between the lineals so as to complete the frame defined by the plurality of the lineals and at least one corner between the lineals; wherein said at least one corner is formed by the steps of: butting an end of a first lineal with a second lineal at the corner so that an edge of the peripheral wall of the first lineal contacts the second lineal with the hollow interior of the first lineal being in communication with the hollow interior of the second lineal; arranging the corner with the butting peripheral walls of the first and second lineals at a bottom with the first and second lineals diverging upwardly and outwardly from the corner; introducing into the corner a settable liquid material so as to flow to and collect at the corner and to extend from corner upwardly at least partly into the first and second lineals to a distance to a level to fill the hollow interiors of the first and second lineals at the corner; providing in the liquid a viscosity selected so that the liquid settles at a position within the first and second lineals which is substantially at the same height up the first and second lineals from the corner; causing the liquid to set into a solid material; arranging the solid material so that the solid material forms a structural member extending between the first and second lineals to hold the lineals connected at the corner; and arranging the solid material so that the solid material bonds to the interior surfaces of the lineals to hold the lineals against separation.