Abstract: A method of assembling an upholstered furniture piece comprising decorative fasteners comprising providing an underlayment material layer, a foam material layer and a covering material layer. The foam material layer is positioned between the underlayment material layer and the covering material layer. The covering material layer extends beyond the underlayment material layer and the foam material layer. Fasteners are used to fasten the underlayment material layer, the foam material layer and the covering material layer together forming a layered component. A template may be used to guide positioning of the fasteners. The fasteners are decorative fasteners. Excess covering material that extends beyond the fasteners is stretched around the edges of the layered component and is affixed to a bottom surface of the layered component, thereby forming a layered assembly. The layered assembly is affixed to an upholstered furniture piece.

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 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: Improved methods and apparatuses relating to installation of a sleeper mechanism into a frame of a sofa sleeper are disclosed. In one embodiment, initially the frame is aligned such that an open bottom portion of the frame is upright and facing outwardly. The sleeper mechanism is then advanced towards the open bottom portion and hook apertures on the brackets are engaged with upper fasteners on the frame. The sleeper mechanism is then swung inwardly towards the top portion of the frame until notches on the bracket are passed lower fasteners on the frame and then swung back towards the open bottom portion to engage the notches with the lower fasteners.

Abstract: A method of manufacturing furniture, such as sofas, that have a lower exposed front rail with corner block portions. The method including injection molding the front rail with the corner block and assembling it to side rails and a rear rail whereby there are no exposed junctures at the corner blocks on the front rail.

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 stretcher that can be positioned in the seat box of a sofa to maintain the structural integrity of the seat box against the compressive force of the seat springs. The seat stretcher mounts without fasteners and without additional hardward. In embodiments, the seat stretcher has an offset portion that can be rotated to create space within the seat box for storing cushions or legs within the cavity defined by the seat box.

Abstract: A sofa includes a furniture base assembly that is easily assembled without the need of a jig or fixture, provides for a reduced number of component parts, and provides for aesthetically pleasing base assembly joints. In one embodiment, the front rail member and the back rail member are integrally formed with the corner block members, side rails are connected thus forming an integrated rail member and thereby dispensing with a base joint exposed on the front of the furniture product. The base is affixed to the sofa frame and upholstery is attached to the frame for providing a finished sofa with a showood base.

Abstract: A sofa includes a furniture base assembly that is easily assembled without the need of a jig or fixture, provides for a reduced number of component parts, and provides for aesthetically pleasing base assembly joints. In one embodiment, the front rail member and the back rail member are integrally formed with the corner block members, side rails are connected thus forming an integrated rail member and thereby dispensing with a base joint exposed on the front of the furniture product. The base is affixed to the sofa frame and upholstery is attached to the frame for providing a finished sofa with a showood base.

Abstract: Improved methods and apparatuses relating to installation of a sleeper mechanism into a frame of a sofa sleeper are disclosed. In one embodiment, initially the frame is aligned such that an open bottom portion of the frame is upright and facing outwardly. The sleeper mechanism is then advanced towards the open bottom portion and hook apertures on the brackets are engaged with upper fasteners on the frame. The sleeper mechanism is then swung inwardly towards the top portion of the frame until notches on the bracket are passed lower fasteners on the frame and then swung back towards the open bottom portion to engage the notches with the lower fasteners.

Abstract: A method of assembling an upholstered furniture piece comprising decorative fasteners comprising providing an underlayment material layer, a foam material layer and a covering material layer. The foam material layer is positioned between the underlayment material layer and the covering material layer. The covering material layer extends beyond the underlayment material layer and the foam material layer. Fasteners are used to fasten the underlayment material layer, the foam material layer and the covering material layer together forming a layered component. A template may be used to guide positioning of the fasteners. The fasteners are decorative fasteners. Excess covering material that extends beyond the fasteners is stretched around the edges of the layered component and is affixed to a bottom surface of the layered component, thereby forming a layered assembly. The layered assembly is affixed to an upholstered furniture piece.

Abstract: A sofa includes a furniture base assembly that is easily assembled without the need of a jig or fixture, provides for a reduced number of component parts, and provides for aesthetically pleasing base assembly joints. In one embodiment, the front rail member and the back rail member are integrally formed with the corner block members, side rails are connected thus forming an integrated rail member and thereby dispensing with a base joint exposed on the front of the furniture product. The base is affixed to the sofa frame and upholstery is attached to the frame for providing a finished sofa with a showood base.