Abstract: An upholstered recliner, a frame including a pair blow molded hollow arm rest forms. Further components may be blow molded such as a back rest. The arm rest forms and backrest forms may be reinforced with metal plates and assembled into a recliner. The backrest form may have legs with kd brackets secured thereto by clamping onto the portions of the legs of the backrest forms. The connections to the backrest form and arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust that conventional wood frame recliners.

Abstract: An upholstered chair, recliner, or sofa with a frame including a pair blowmolded hollow arm rest forms, wherein frame members extend between the forms. Further components may be blowmolded such as a backrest. The arm rest forms and backrest may be reinforced with metal plates and assembled into a recliner. The connections to the arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust. Upholstery sacks are easily attached to the frame.

Abstract: An upholstered piece of furniture with a frame including a pair blow molded hollow arm rest forms, wherein spanning wood frame members extend between the forms. The wood frame members secured to the forms with interference fits, and minimal threaded fasteners. The arm rest forms have through slots which allow the seat deck and arm upholstery to be pulled through and anchored with staples providing a secure attachment. Threaded fasteners clamp onto the polymer wall of the forms for attachment of frame members. A blowmolded backrest has a metal reinforcing arms connecting to a seat platform. Holes in arm rest allow upholstery panel connections with Christmas tree connectors. The connections to the arm rest forms and providing a geometrically rigid and robust sofa frame that is weighs less, is quicker to assemble, and is more robust. The finishing of the sofa is also quicker and easier than conventional sofas.

Abstract: An upholstered chair, recliner, or sofa with a frame including a pair blowmolded hollow arm rest forms, wherein frame members extend between the forms. Further components may be blowmolded such as a backrest. The arm rest forms and backrest may be reinforced with metal plates and assembled into a recliner. The connections to the arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust. Upholstery sacks are easily attached to the frame.

Abstract: An upholstered piece of furniture with a frame including a pair blow molded hollow arm rest forms, wherein spanning wood frame members extend between the forms. The wood frame members secured to the forms with interference fits, and minimal threaded fasteners. The arm rest forms have through slots which allow the seat deck and arm upholstery to be pulled through and anchored with staples providing a secure attachment. Threaded fasteners clamp onto the polymer wall of the forms for attachment of frame members. A blowmolded backrest has a metal reinforcing arms connecting to a seat platform. Holes in arm rest allow upholstery panel connections with Christmas tree connectors. The connections to the arm rest forms and providing a geometrically rigid and robust sofa frame that is weighs less, is quicker to assemble, and is more robust. The finishing of the sofa is also quicker and easier than conventional sofas.

Abstract: An upholstered piece of furniture including a frame having a front frame member, an opposing back rest, and two arms at opposite ends of front frame member and backrest, wherein at least one of the front frame member and opposing back rest includes a wood component, and wherein the arms are made of molded plastic and at least one of the arms is coupled to the wood component. The upholstered piece of furniture includes covering material, wherein at least a portion of the at least one of the arms is covered by the covering material.

Abstract: An upholstered piece of furniture including a frame having a front frame member, an opposing back rest, and two arms at opposite ends of front frame member and backrest, wherein at least one of the front frame member and opposing back rest includes a wood component, and wherein the arms are made of molded plastic and at least one of the arms is coupled to the wood component. The upholstered piece of furniture includes covering material, wherein at least a portion of the at least one of the arms is covered by the covering material.

Abstract: A drop-in seat deck for furniture assemblies. Various embodiments reduce the complexity and bulk of the seating frame, and also reduce the labor associated with assembly. Unlike the conventional spring suspensions, which apply constant spring loaded forces on the frame rails to maintain the springs in tension, the spring load force of the disclosed drop-in seat deck is provided by solely by the structure of the drop-in seat deck. Thus, the frame can be designed to support only the weight of the seated person is transferred to the rails of the seating frame, without consideration for pre-loading the seat deck. In various embodiments, dimensional changes to the seat deck occur under load. In some embodiments, these changes are accommodated by enabling a free end of the seat deck to slide on a support surface; in other embodiments, the changes are accommodated by flexures that are integral to the seat deck.

Abstract: An assembly system permitting separate construction and transport of subcomponents for seating furniture items. The disassembled subcomponents allow for more efficient transportation by eliminating the dead space created by transporting irregularly shaped assembled furniture items. The assembly system includes a seat box having a rectangular frame defining an accessible internal cavity covered by an upper support surface. The assembly system also comprises a back rest having a seat box interface surface and at least arm rest interface surface. The back rest also defines an internal cavity accessible through closable opening for internal access to the arm rest interface surfaces. The assembly system also includes mounting an interface surface to the arm rest for securing the arm rest to the arm rest interface surface of the back rest and the rectangular frame of the seat box.

Abstract: A seat box assembly and method of fabricating utilizing a drop-in webbing assembly secured into a main box and back frame assembly. The webbing assembly has a rectangular frame with elongate members and shorter members and a central girder with a cutout extending between mid-portions of the elongate members. The central girder attachable to the seat box and a central vertical frame member of the back frame assembly. The elongate members having stub portions that fit into slots in the main seat box. A method of repair includes replacing a damaged drop-in assembly with a different drop-in assembly.

Abstract: A component interface assembly for attaching the individual subcomponents of an RTA furniture system. Each component interface assembly having an elongated alignment slot cut into one of the subcomponents of the RTA furniture kit and a retention element affixed to a second corresponding subcomponent such that the first and second subcomponents can be secured together by inserting the retention element into the alignment slot. The alignment slot is positioned on the first subcomponent such that positioning the retention element for insertion into the slot aligns the second subcomponent with the first subcomponent providing tool-less alignment and engagement of the subcomponents. The assembled components may have cutouts on confronting planar surfaces of the respective first and second subcomponents providing enhanced storage for shipping the RTA furniture components.

Abstract: A furniture jig comprises a frame member positioning portion and a spring stretcher portion with at least the positioning frame portion having a rotating feature. The positioning frame portion may surround the spring stretcher portion and comprises constraint members that define receiving regions, such as slots or channels, into which furniture components, such a box frame members, may be inserted. The receiving regions of the jig frame maintain the furniture components upright or in other useful orientations at least until they are affixed together. In embodiments, the spring stretcher has a plurality of spring receiving portions on which the ends of a spring can be releasably engaged. Support members extending from the spring receiving portions operate to move the spring receiving portions from a spring loading position in which the springs can positioned on the tips to a spring attachment position where the springs are securable to the frame members.

Abstract: A drop-in seat deck for furniture assemblies. Various embodiments reduce the complexity and bulk of the seating frame, and also reduce the labor associated with assembly. Unlike the conventional spring suspensions, which apply constant spring loaded forces on the frame rails to maintain the springs in tension, the spring load force of the disclosed drop-in seat deck is provided by solely by the structure of the drop-in seat deck. Thus, the frame can be designed to support only the weight of the seated person is transferred to the rails of the seating frame, without consideration for pre-loading the seat deck. In various embodiments, dimensional changes to the seat deck occur under load. In some embodiments, these changes are accommodated by enabling a free end of the seat deck to slide on a support surface; in other embodiments, the changes are accommodated by flexures that are integral to the seat deck.

Abstract: An assembly system permitting separate construction and transport of subcomponents for seating furniture items. The disassembled subcomponents allow for more efficient transportation by eliminating the dead space created by transporting irregularly shaped assembled furniture items. The assembly system includes a seat box having a rectangular frame defining an accessible internal cavity covered by an upper support surface. The assembly system also comprises a back rest having a seat box interface surface and at least arm rest interface surface. The back rest also defines an internal cavity accessible through closable opening for internal access to the arm rest interface surfaces. The assembly system also includes mounting an interface surface to the arm rest for securing the arm rest to the arm rest interface surface of the back rest and the rectangular frame of the seat box.

Abstract: A power mechanism for a recliner having a limiter controlling the relative angle between a transfer linkage and arm affixed to the drive axle as the transfer linkage applies tangential force to the arm to rotate the drive axle. The limiter prevents the relative angle between the transfer linkage from over collapsing to minimize strain on the linkage assembly and the motor driving the rotation of the drive axle.

Abstract: A seat box assembly and method of fabricating utilizing a drop-in webbing assembly secured into a main box and back frame assembly. The webbing assembly has a rectangular frame with elongate members and shorter members and a central girder with a cutout extending between mid-portions of the elongate members. The central girder attachable to the seat box and a central vertical frame member of the back frame assembly. The elongate members having stub portions that fit into slots in the main seat box. A method of repair includes replacing a damaged drop-in assembly with a different drop-in assembly.

Abstract: An assembly system permitting separate construction and transport of subcomponents for seating furniture items. The disassembled subcomponents allow for more efficient transportation by eliminating the dead space created by transporting irregularly shaped assembled furniture items. The assembly system includes a seat box having a rectangular frame defining an accessible internal cavity covered by an upper support surface. The assembly system also comprises a back rest having a seat box interface surface and at least arm rest interface surface. The back rest also defines an internal cavity accessible through closable opening for internal access to the arm rest interface surfaces. The assembly system also includes mounting an interface surface to the arm rest for securing the arm rest to the arm rest interface surface of the back rest and the rectangular frame of the seat box.