Corner joint and method of manufacturing

A method of forming a corner joint, the method comprising:

• forming a first mitered surface on a first corner end of a first frame member, wherein the first mitered surface is located between an inner squared flange and an outer squared flange at the first corner end of the first frame member, wherein the inner squared flange defines a first surface on one side of the first mitered surface and the outer squared flange defines a second surface on an opposite side of the first frame member substantially parallel to the first surface such that the first mitered surface is located between the first and second surfaces, and wherein the inner squared flange comprises a free edge aligned with a longitudinal axis of the first frame member and the outer squared flange comprises a free edge aligned with the longitudinal axis of the first frame member;
• forming a second mitered surface on a second corner end of a second frame member;
• forming an inner edge on the second frame member that is spaced longitudinally inwardly from the second mitered surface along a longitudinal axis of the second frame member, and forming an outer edge on the second frame member that is spaced longitudinally inwardly from the second mitered surface, wherein the inner edge and outer edge extend transversely to the longitudinal axis of the second frame member;
• positioning the first frame member and the second frame member such that:
• the free edge of the inner squared flange on the first frame member faces the inner edge of the second frame member to form an inner joint aligned with the longitudinal axis of the first frame member;
• the free edge of the outer squared flange on the first frame member faces the outer edge of the second frame member to form an outer joint aligned with the longitudinal axis of the first frame member;
• and
• the first mitered surface faces the second mitered surface between the first surface of the inner squared flange and the second surface of the outer squared flange of the first frame member, wherein the first mitered surface and the second mitered surface define a miter joint plane that forms an acute angle with the longitudinal axis of the first frame member and an acute angle with the longitudinal axis of the second frame member;
• and
• attaching the first frame member to the second frame member after positioning the first frame member and the second frame member such that the inner joint and the outer joint are formed.

A window or door frame comprising a first frame member and a second frame member attached to each other at a corner joint, wherein the corner joint comprises:

• a first frame member defining a longitudinal axis and comprising a first corner end, wherein the first corner end comprises a first mitered surface located between an inner squared flange and an outer squared flange, wherein the inner squared flange defines a first surface on one side of the first mitered surface and the outer squared flange defines a second surface on an opposite side of the first mitered surface substantially parallel to the first surface such that the first mitered surface is located between the first and second surfaces, wherein the inner squared flange comprises a free edge aligned with the longitudinal axis of the first frame member and wherein the outer squared flange comprises a free edge aligned with the longitudinal axis of the first frame member;
• and
• a second frame member defining a longitudinal axis and comprising a second corner end, wherein the second corner end comprises a second mitered surface, an inner edge spaced longitudinally inwardly from the second mitered surface, and an outer edge spaced longitudinally inwardly from the second mitered surface, wherein the inner edge and outer edge extend transversely to the longitudinal axis of the second frame member, wherein the free edge of the inner squared flange on the first frame member faces the inner edge of the second frame member to form an inner joint aligned with the longitudinal axis of the first frame member, and wherein the free edge of the outer squared flange on the first frame member faces the outer edge of the second frame member to form an outer joint aligned with the longitudinal axis of the first frame member;
• wherein the first mitered surface faces the second mitered surface between the first surface of the inner squared flange and the second surface of the outer squared flange of the first frame member, wherein the first mitered surface and the second mitered surface define a miter joint plane that forms an acute angle with the longitudinal axis of the first frame member and an acute angle with the longitudinal axis of the second frame member.