SYSTEM AND METHOD FOR COMPACTLY SHIPPING AND FINALLY ASSEMBLING AN UPHOLSTERED SEAT

Abstract

A method of compactly packaging an upholstered seat for shipment includes providing an upholstered seat bottom including a base with a top surface, a front edge, a rear edge, a first end, a second end, a first upwardly extending side arm attached to the first end, and a second upwardly extending side arm attached to the second end. The method further includes providing an upholstered seat back configured for secure attachment to the seat bottom after shipment, and compactly arranging the seat bottom and the seat back within a substantially rectilinear shipping carton. The upholstered seat can include at least one bracket assembly for irremovably attaching the seat back to the seat bottom after shipment.

Description

FIELD OF THE INVENTION

The invention generally relates to furniture, and more particularly relates to an upholstered seat which can be compactly packaged in a partially disassembled state, and which includes a bracket assembly for quickly and substantially irremovably connecting separate portions of the upholstered seat after shipment.

BACKGROUND

Traditional upholstered seats include a usually wooden frame having a bottom portion, a back portion, and side arm portions. As used herein, the term “seat” is used to generally refer to an upholstered chair, sofa, couch, and the like. The bottom portion, back portion, and side arm portions of such frames are permanently connected together to provide rigid support structures for the seats Spring supports can be provided on the bottom portions of the frames, and padding and fabric at least partially cover the frame. Cushions can be provided atop the spring supports and/or against the backs of the seats.

When such traditional upholstered seats are to be transported long distances on ships, for example, the seats are typically stowed in large shipping containers. Due to the irregular shapes of such seats, it can be difficult to compactly arrange the seats in a shipping container in a manner that minimizes the amount of unoccupied and wasted space within the container. Accordingly, it can advantageous to ship the seats in unassembled parts which can be more compactly arranged within a shipping container. Once such seats arrive at their final destinations, the parts must be assembled together to provide a complete article of furniture. Unfortunately, such seats can include a substantial number of unassembled parts or portions and loose connecting hardware that must be finally assembled after shipment, thus complicating final assembly of the seats.

Accordingly, there is a need for an upholstered seat which can be arranged in a partially unassembled and compact configuration, and which permits the partially unassembled and compactly arranged seat to be packaged in a single shipping carton or container in a manner that minimizes the amount of wasted space within the carton or container. In addition, there is a need for a method and device for quickly and securely assembling the unassembled portions of the upholstered seat together after shipment.

SUMMARY OF THE INVENTION

One embodiment of the invention includes a method of compactly packaging an upholstered seat for shipment. The method includes providing an upholstered seat bottom including a base with a top surface, a front edge, a rear edge, a first end, a second end, a first upwardly extending side arm attached to the first end and having a first top, and a second upwardly extending side arm attached to the second end and having a second top. The method further includes providing a separate upholstered seat back configured for secure attachment to the seat bottom after shipment, and compactly arranging the seat bottom and the separate seat back within a substantially rectilinear shipping carton.

In another embodiment, a bracket assembly for irremovably attaching a first portion of an upholstered article of furniture to a second portion of the upholstered article of furniture includes a male bracket and a female bracket. The male bracket can include an elongated end having a first side wall and an opposed second side wall, a first protrusion outwardly extending from the first side wall, and a second protrusion outwardly extending from the second side wall, and at least one mounting flange for attaching the male bracket to the first portion of article of furniture. The female bracket can include a top end and an opposed bottom end, a first side and an opposed second side defining an elongated channel therebetween, the channel extending from the top end to the bottom end and being configured to receive the elongated end of the male bracket, a first recess in the first side and a second recess in the second side, and at least one flange for attaching the female bracket to the second portion of article of furniture. When the elongated end of the male bracket is received in the channel of the female bracket, the first protrusion is received in the first recess and the second protrusion is received in the second recess such that the first and second protrusions resist extraction of the end of the male bracket from the channel of the female bracket.

In a further embodiment, an upholstered sofa, chair or couch includes a back portion having a first end, an opposed second end, and a middle portion, and a bottom portion having a first upwardly extending side arm with a first inside surface, and an opposed second upwardly extending side arm with a second inside surface. A first male bracket can be provided on the first end, and a second male bracket can be provided on the second end. The first and second male brackets can each include an elongated portion having at least outwardly extending protrusion thereon. A first female bracket can be provided on the first inside surface and a second female bracket can be provided on the second inside surface. The first and second female brackets can each include an elongated channel defined by a plurality of walls, at least one wall of each of the first and second female brackets including a recess therein. When the elongated portions of the first and second male brackets are each received in the channel of one of the first and second female brackets and the protrusions of the first and second male brackets are each received in the recess of one of the first and second female brackets, the back portion is substantially irremovably attached to the bottom portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of one embodiment of a sofa according to the invention.

FIG. 2 is a bottom perspective view of the sofa shown in FIG. 1.

FIG. 3 is another bottom perspective view of the sofa shown in FIGS. 1 and 2.

FIG. 4A shows a first packaging arrangement for a sofa like that shown in FIGS. 1-3.

FIG. 4B shows a second packaging arrangement for a sofa like that shown in FIGS. 1-3.

FIG. 5 is a perspective view of one embodiment of a female bracket for attaching a seat back to a seat bottom to produce the sofa shown in FIGS. 1-3.

FIG. 6 is a perspective view of one embodiment of a male bracket for attaching a seat back to a seat bottom to produce the sofa shown in FIGS. 1-3.

FIG. 7 is a perspective view showing the male bracket of FIG. 6 received in the female bracket shown in FIG. 4.

FIG. 8 is a cross sectional view taken along line 8-8 in FIG. 7 showing the male bracket of FIG. 6 received in the female bracket shown in FIG. 5.

FIG. 9 is a front elevation view of the female bracket shown in FIGS. 5, 7 and 8.

FIG. 10 is a bottom plan view of the female bracket shown in FIGS. 5 and 7-9.

DETAILED DESCRIPTION

FIG. 1 shows one embodiment of a sofa 10 having a separate upholstered back 20 which can be compactly packaged with the sofa's bottom 30 for shipment. As discussed in detail below, the separate back 20 and bottom 30 can be compactly packaged in a single shipping carton, and compactly stowed within a large shipping container with other similarly packaged sofas 10 such that wasted space within the shipping carton and the shipping container is minimized. Once the sofa 10 arrives at a final destination, a user can assemble the back 20 to the bottom 30 in a manner like that described below. Once the back 20 is assembled to the bottom 30, the sofa 10 has the appearance of a traditional upholstered sofa having a continuous wooden frame and a permanently attached and inseparable back and bottom.

As shown in FIG. 1, the sofa 10 can include an upholstered back 20 having a lower edge 24 and first and second opposed ends 22, 26. As also shown in FIG. 1, the bottom 30 can include an upholstered base 31 having a substantially planar upper surface 32, a first upholstered side arm 34 affixed to one end of the base 31, and a second upholstered side arm 36 affixed to an opposite end of the base 31. In the embodiment shown, the base 31 and side arms 34, 36 combine to provide the bottom 30 with an elongated U shape. The separate upholstered back 20 can be assembled to the bottom 30 as indicated by the directional arrow 12 in FIG. 1. The back 20 can be lowered between rear portions of the opposed side arms 34, 36 until the lower edge 24 of the back 20 rests upon or is proximate to a rear portion of the upper surface 32 of the base 31.

As shown in FIG. 1, the back 20 can include a first male bracket 50 on its first end 22. Though not visible in FIG. 1, the back 20 can similarly include a second male bracket 50 on its opposite end 26. As also shown in FIG. 1, a female bracket 40 can be provided on a rear portion of the inside surface 38 of the second side arm 36. Though not visible in FIG. 1, another female bracket 40 can be similarly provided on a rear portion of the inside surface 39 of the first side arm 34. As described below, each male bracket 50 can be arranged to engage an aligned female bracket 40 when the back 20 is assembled to the bottom 30 as described above. During assembly, the weight of the back 20 assists in insertion of the male brackets 50 into the female brackets 40. Once the back 20 is fully received by the bottom 30 and the male brackets 50 are fully engaged with their mating female brackets 40, the male brackets 50 and female brackets 40 can cooperate to substantially irremovably affix the ends 22, 26 of the back 20 to the side arms 34, 36. As also shown in FIG. 1, a flap 80 can downwardly extend from the back 20. In one embodiment, the flap 80 is a portion of a continuous sheet of fabric that downwardly extends from a top edge 21 of the back 20 to a lower edge 82 of the flap 80.

As shown in FIG. 2, a bolt 60 can be used to connect a mid-span portion of the back 20 to a mid-span portion of the base 31. The bolt 60 can include an elongated rod 69 including a threaded portion 62 and a head 64. As shown in FIG. 2, the head 64 can include tabs or wings 67 configured to permit the head 64 to be gripped by a person's fingers as the bolt 60 is manually rotated by the person. The bolt 60 can be inserted through an opening 33 in a rear portion of the base 31 such that the threaded portion 62 of the bolt 60 upwardly extends through the base 31. Though not shown in the drawings, the back 20 can include an aligned opening in its lower edge 24 for receiving part of the e threaded portion 62 of the bolt 60 that upwardly extends above the upper surface 32 of the base 31. The aligned opening in the back 20 can include internal threads for threadably receiving the bolt 60. Alternatively, a nut (not shown) can be provided on the threaded end of the bolt 60 for securing the back 20 to the base 31. As shown in FIG. 2, a washer 66 and a lock washer 68 can be disposed between the head 64 of the bolt 60 and a bottom surface 35 of the base 31. When the bolt 60 is threadably engaged with the aligned opening in the back 20 and the bolt 60 is tightened such that the head 64 and washers 66, 68 are seated against the bottom surface 35 of the base 31 as shown in FIG. 3, the bolt 60 substantially prevents a mid-span portion of the assembled base 20 from moving or flexing relative to the base 31 when a rearward force is applied to the mid-span portion of the back 20, such as a rearward force applied by the back of person seated on the sofa 10. In an alternative arrangement, the bolt 60 can downwardly extend from the back 20 and through the opening 33 in the base 31, and can receive a nut on its lower end for securing the back 20 to the base 31. Once the back 20 is assembled to the bottom 30, one or more cushions (not shown) can be placed on the upper surface 32 of the base 31 to form a cushioned seating surface.

As shown in FIG. 3, the flap 80 on the back 20 can downwardly extend behind a rear portion of the base 31 and between the opposed side arms 34, 36. The forward face of the lower edge 82 of the flap 80 can include a first hook-and-loop fastening material, such as Velcro® or the like. The bottom of an adjacent rear edge 37 of the base 31 can include a second hook-and-loop fastening material for engagement with the first hook-and-loop fastening material on the lower edge 82 of the flap 80. As shown in FIG. 3, the lower edge 82 of the flap 80 can be folded under the adjacent rear edge 37 of the base 31 and secured in that folded position by the first and second hook-and-loop fastening materials. The flap 80 can cover the juncture between the back 20 and the base 31, thereby providing the rear of the sofa 10 with a finished appearance. As shown in FIGS. 2 and 3, the bottom 30 can include a cavity 11 defined by the side arms 34, 36, the rear edge 37 of the base 31, a forward edge 13 of the base 31, and the bottom surface 35 of the base 31.

FIG. 4A shows one embodiment of a shipping arrangement 100 which can be used to compactly package a sofa 10 like that described above within a substantially rectilinear shipping carton 190. A shown in FIG. 4A, the unassembled back 20 can be laid substantially flat and positioned below the base 31. In one embodiment in which the back 20 is appropriately sized and shaped, at least a portion of the back 20 is received within a cavity under the bottom 30 like the bottom cavity 11 shown in FIGS. 2 and 3, for example. Loose pillows, cushions, or the like (not shown) can also be stowed within the cavity 11 as space permits. As shown in FIG. 4A, one or more seat cushions 71, 72 can be situated atop the base 31 and between the opposed side arms 34, 36. As also shown in FIG. 4A, one or more unattached pillows 75, 77 can also be positioned between the opposed side arms 34, 36. Once so arranged, the back 20, the bottom 30 and any cushions 71, 72 and/or pillows 75, 77 can be compactly packaged within the rectilinear shipping carton 190 such that there is a minimal amount of unoccupied or wasted space within the carton 190. The carton 190 can be stacked and compactly arranged with other similar cartons within a larger shipping container for long-distance transport, such as on a ship, for example. Though not shown in FIG. 4A, the shipping arrangement 100 can include additional packaging materials for securing the sofa 10 within the carton 190 and for protecting the sofa 10 against damage during shipment or handling. Once the package 100 arrives at a final destination, the sofa 10 can be unpacked from the carton 190 and the back 20 can be quickly assembled to the bottom 30 as described above.

FIG. 4B shows another embodiment of a shipping arrangement 200 which can be used to compactly package a sofa 10 like that described above within a substantially rectilinear shipping carton 90. A shown in FIG. 4B, the unassembled back 20 can be laid substantially flat and positioned above the base 31 and between the upright side arms 34, 36 of the bottom 30. In FIG. 4B, the back 20 is situated atop a pair of cushions 71, 72 which rest on the base 31 and are also positioned between the opposed side arms 34, 36. In an alternative arrangement, the back 20 can be placed directly on the base 31 without cushions 71, 72 disposed therebetween. In a further alternative arrangement, the back 20 can be placed directly on the base 31 and the cushions 71, 72 can be stacked atop the back 20, for example. Other associated items such as additional cushions, pillows, or the like can also be compactly arranged with the back 20 between the side arms 34, 36 when available space permits. As shown in FIG. 4B, the back 20 and bottom 30 can be configured such that when the unassembled back 20 is compactly stowed between the side arms 34, 36, no substantial portion of the back 20 extends above the side arms 34, 36, no substantial portion of the back 20 extends forward of the base 31, and no substantial portion of the back 20 extends rearward of the base 31. As also shown in FIG. 4B, the compactly arranged back 20, bottom 30 and any cushions 71, 72 can be packaged within the rectilinear shipping carton 90 such that there is a minimal amount of unoccupied or wasted space within the carton 90. The carton 90 can be stacked and compactly arranged with other similar cartons within a larger shipping container for long-distance transport, such as on a ship, for example. Though not shown in FIG. 4B, the shipping arrangement 200 can include additional packaging materials for securing the sofa 10 within the carton 90 and for protecting the sofa 10 against damage during shipment or handling. Once the package 200 arrives at a final destination, the sofa 10 can be unpacked from the carton 90 and the back 20 can be quickly assembled to the bottom 30 as described above.

Details of one embodiment of a female bracket 40 for use in securing the ends of the back 20 to the side arms 34, 36 of the sofa 10 is shown in FIGS. 5, 9 and 10. As shown in FIGS. 5 and 9, the bracket 40 can include a front wall 41, opposed first and second side walls 43a, 43b, opposed first and second mounting flanges 47a, 47b, an upper end 42, and a lower end 44. The front wall 41 and opposed first and second side walls 43a, 43b form an elongated channel 45 extending between the upper end 42 and the lower end 44. Each of the mounting flanges 47a, 47b can include one or more holes 49 for receiving screws or the like for securely attaching the female bracket 40 on an inside surface 38, 39 of a side arm 34, 36 as shown in FIG. 1. As best seen in FIG. 9, the female bracket 40 can further include opposed first and second upper sidewalls 46a, 46b. The upper sidewalls 46a, 46b can be spaced farther apart than the first and second side walls 43a, 43b such that the channel 45 shown in FIG. 5 is at least slightly wider at the upper end 42 than at the lower end 44. As described below, the wider upper portion of the channel 45 facilitates insertion of a portion of a mating male bracket 50 into the channel 45 as the back 20 is assembled to the bottom 30 of the sofa 10 as shown in FIG. 1 and discussed above.

As best seen in FIGS. 9 and 10, a first recess 70a is formed in an inside surface of the first side wall 43a, and a second recess 70b is formed in an inside surface of the second side wall 43b. In one embodiment, the first recess 70a and the second recess 70b are directly opposite each other on opposed sides of the channel 45. In the embodiment shown in FIGS. 9 and 10, the recesses 70a, 70b are substantially semi-spherical dimples or indentations formed in their respective side walls 43a, 43b. The recesses 70a, 70b can also have other shapes and configurations not shown in the drawings. For example, the recesses 70a, 70b can be formed by openings that extend through the respective side walls 43a, 40b, such as circular holes or the like. Other configurations are also possible. In one embodiment, the female bracket 40 is constructed of metal, such as steel, aluminum, or the like, and is constructed in a single continuous piece. In another embodiment, the female bracket 40 is constructed of a continuous, strong and durable molded plastic material, or the like. Other materials can also be used to construct the female bracket 40.

Details of one embodiment of a male bracket 50 for use in securing the ends of the back 20 to the side arms 34, 36 of the sofa 10 are shown in FIG. 6. In this embodiment, the male bracket 50 includes a back wall 51, opposed first and second side walls 53a, 53b, opposed first and second mounting flanges 57a, 57b, and upper end 52, and a lower end 54. The mounting flanges 57a, 57b are disposed proximate to the upper end 52, and have lower edges 55a, 55b that are located substantially above the lower end 54 of the male bracket 50. Each of the mounting flanges 57a, 57b can include one or more holes 59 for receiving screws or the like for securely attaching the male bracket 50 on an end 22, 26 of the back 20 as shown in FIG. 1. As shown in FIG. 6, the first side wall 53a can include a first protrusion 58a that outwardly extends from an outer surface of the first side wall 53a. Similarly, the second side wall 53b can include a second protrusion 58b that outwardly extends from an outer surface of the second side wall 53b. In the embodiment shown in the drawings, the first and second protrusions 58a, 58b are substantially semi-spherical blisters or buttons formed in the respective side walls 53a, 53b. The first and second protrusions 58a, 58b can also have other shapes and configurations not shown in the drawings. For example, the protrusions 58a, 58b can be tabs that outwardly extend from the side walls 53a, 53b, or the like. In one embodiment, the male bracket 50 is constructed of metal, such as steel, aluminum, or the like, and is formed as one continuous piece. In another embodiment, the male bracket 50 is constructed of a continuous, strong and durable molded plastic material, or the like. Other materials can also be used to construct the male bracket 50.

FIGS. 7 and 8 show the lower end 54 of the male bracket 50 received in the channel 45 of the female bracket 40. As shown in FIG. 7, when the male bracket 50 is fully inserted in the female bracket, the lower edges 55a, 55b of the mounting flanges 57a, 57b of the male bracket 50 can rest upon or be closely proximate to the upper end 42 of the female bracket 40, and the lower end 54 of the male bracket 50 can be proximate to the lower end 44 of the female bracket 40. The mounting flanges 57a, 57b on the male bracket 50 and the mounting flanges 47a, 47b on the female bracket 40 are arranged such that the male bracket 50 can be inserted into the female bracket 40 when the male bracket 50 is attached to an end 22, 26 of the back 20 and the female bracket 40 is attached to an inside surface 38, 39 of a side arm 34, 36 of the sofa 10 as shown in FIG. 1.

As shown in FIG. 8, when the male bracket 50 is inserted into the channel 45 of the male bracket, the opposed side walls 53a, 53b of the male bracket 50 are closely proximate to the respective opposed sidewalls 43a, 43b of the female bracket 40. Preferably, the lateral clearances between the opposed side walls 53a, 53b of the male bracket 50 and the respective opposed sidewalls 43a, 43b of the female bracket 40 are sufficiently small to substantially prevent relative lateral movement between the mated brackets 40, 50, but are also sufficiently large to permit the male bracket 50 to be inserted into the female bracket 40 when the brackets 40, 50 are not perfectly aligned with each other. As described above, the opposed upper side walls 46a, 46b of the female bracket 40 are spaced farther apart than the side walls 43a, 43b of the female bracket 40 and the channel 45 of the female bracket 40 is wider at the upper end 42 of the female bracket 40 than at the lower end 44. Accordingly, the lower end 54 of the male bracket 50 can enter the upper end 42 of the female bracket 40 even though there may be some lateral misalignment between the male bracket 50 and the female bracket 40.

As shown in FIG. 8, when the male bracket 50 is fully inserted into the channel 45 of the female bracket 40, each of the protrusions 58a, 58b on the side walls 53a, 53b of the male bracket 50 are received within a corresponding recess 70a, 70b in the side walls 43a, 43b of the female bracket 40. Once so engaged, the protrusions 58a, 58b substantially prevent the male bracket 50 from being extracted from the mated female bracket 4. Accordingly, the mated brackets 40, 50 combine to provide a substantially permanent attachment between the back 20 and bottom 30 of the sofa 10 shown in FIG. 1 and described above, and permit a person to assemble the back 20 to the bottom 30 without tools and with no loose hardware.

Because the opposed protrusions 58a, 58b on the male bracket 50 are wider than the channel 45 of the female bracket, the protrusions 58a, 58b can interfere with insertion of the male bracket 50 into the narrower channel 45. Preferably, the side walls 53a, 53b of the male bracket 50 are sufficiently flexible to permit the side walls 53a, 53b and protrusions 58a, 58b to resiliently deflect inwardly as the male bracket 50 is inserted into the channel 45. In addition, the opposed side walls 43a, 43b of the female bracket 40 can be sufficiently flexible to be at least slightly resiliently wedged apart by the protrusions 58a, 58b as the male bracket 50 is inserted into the female bracket 40. The semi-spherical shape of the protrusions 58a, 58b shown in the drawings can assist in resiliently wedging the side walls 43a, 53a and the side walls 43b, 53b apart as the male bracket 50 is inserted into the female bracket 40.

The above descriptions of various embodiments of the invention are provided to illustrate and highlight particular aspects and features of the invention, and not to limit the invention thereto. Persons of ordinary skill in the art will recognize that various changes and modifications can be made to the specifically described embodiments without departing from the scope of the invention. All such changes and modifications are intended to be within the scope of the appended claims.

Claims

1. A method of compactly packaging an upholstered seat for shipment, the method comprising:

a. providing an upholstered seat bottom comprising a base with a top surface, a front edge, a rear edge, a first end, a second end, a first upwardly extending side arm attached to the first end and having a first top, and a second upwardly extending side arm attached to the second end and having a second top;

b. providing a separate upholstered seat back configured for secure attachment to the seat bottom after shipment; and

c. compactly arranging the seat bottom and the separate seat back within a substantially rectilinear shipping carton.

2. A method according to claim 1 wherein the step of compactly arranging the seat bottom and the seat back within the shipping carton comprises positioning the seat back below the seat bottom.

3. A method according to claim 1 wherein the seat bottom comprises a bottom cavity and wherein the step of compactly arranging the seat bottom and the seat back within the shipping carton comprises positioning the seat back below the seat bottom such that at least a portion of the seat back is received within the bottom cavity.

4. A method according to claim 1 wherein compactly arranging the seat bottom and the seat back within the shipping carton comprises placing the seat back above the top surface of the base and between the first and second upwardly extending side arms such that no substantial portion of the seat back extends forward of the front edge, rearward of the rear edge, or above the first or second tops of the first and second side arms.

5. A method according to claim 1 wherein the upholstered seat bottom includes at least one first bracket and the upholstered seat back includes at least one second bracket, wherein the first bracket is configured to substantially irremovably engage the second bracket when the seat back is attached to the seat bottom after shipment.

6. A method according to claim 1 further comprising providing at least one seat cushion or pillow, and placing the seat cushion or pillow between the first and second upwardly extending side arms such that no substantial portion of the seat cushion or pillow extends forward of the front edge, rearward of the rear edge, or above the first or second tops of the first and second side arms, and enclosing the seat bottom, the seat back and the cushion or pillow within the substantially rectilinear shipping carton.

7. A bracket assembly for irremovably attaching a first portion of an upholstered article of furniture to a second portion of the upholstered article of furniture, the bracket assembly comprising:

a. a male bracket comprising: i. an elongated end having a first side wall and an opposed second side wall; ii. a first protrusion outwardly extending from the first side wall, and a second protrusion outwardly extending from the second side wall; and iii. at least one mounting flange for attaching the male bracket to the first portion of article of furniture;

b. a female bracket comprising: i. a top end and an opposed bottom end; ii. a first side and an opposed second side defining an elongated channel therebetween, the channel extending from the top end to the bottom end and being configured to receive the elongated end of the male bracket; and iii. a first recess in the first side and a second recess in the second side; and iv. at least one flange for attaching the female bracket to the second portion of article of furniture;

c. wherein when the elongated end of the male bracket is received in the channel of the female bracket, the first protrusion is received in the first recess and the second protrusion is received in the second recess such that the first and second protrusions resist extraction of the end of the male bracket from the channel of the female bracket.

8. A bracket assembly according to claim 7 wherein the first side wall of male bracket is parallel to the second side wall of the male bracket.

9. A bracket assembly according to claim 7 wherein the first side of the female bracket is parallel to the second side of the female bracket.

10. A bracket assembly according to claim 7 wherein the channel is wider at the top end of the female bracket than at the bottom end of the female bracket.

11. A bracket assembly according to claim 7 wherein the mounting flange of the male bracket includes a lower edge, and wherein the lower edge is proximate to the top end of the female bracket when the elongated end of the male bracket is received in the channel of the female bracket, the first protrusion is received in the first recess and the second protrusion is received in the second recess.

12. A bracket assembly according to claim 11 wherein the lower edge contacts the top end of the female bracket when the elongated end of the male bracket is received in the channel of the female bracket, the first protrusion is received in the first recess and the second protrusion is received in the second recess.

13. A bracket assembly according to claim 7 wherein the first protrusion and the second protrusion have substantially semi-spherical shapes.

14. A bracket assembly according to claim 7 wherein the first protrusion is integrally formed on the first sidewall and the second protrusion is integrally formed on the second side wall.

15. A bracket assembly according to claim 7 wherein the first recess and the second recess have substantially semi-spherical shapes.

16. A bracket assembly according to claim 7 wherein the first recess is formed by a first opening in the first side of the female bracket, and the second recess is formed by a second opening in the second side of the female bracket.

17. A bracket assembly according to claim 7 wherein the elongated end of the male bracket is non-tapered.

18. A bracket assembly according to claim 7 wherein the male bracket is constructed of a continuous piece of material.

19. A bracket assembly according to claim 7 wherein the female bracket is constructed of a continuous piece of material.

20. A sofa, chair or couch comprising the bracket assembly of claim 7.

21. An upholstered sofa, chair or couch comprising:

a. a back portion having a first end, an opposed second end, and a middle portion;

b. a bottom portion having a first upwardly extending side arm with a first inside surface, and an opposed second upwardly extending side arm with a second inside surface;

c. a first male bracket on the first end and a second male bracket on the second end, the first and second male brackets each including an elongated portion having at least outwardly extending protrusion thereon; and

d. a first female bracket on the first inside surface and a second female bracket on the second inside surface, the first and second female brackets each including an elongated channel defined by a plurality of walls, at least one wall of each of the first and second female brackets including a recess therein;

e. wherein when the elongated portions of the first and second male brackets are each received in the channel of one of the first and second female brackets and the protrusions of the first and second male brackets are each received in the recess of one of the first and second female brackets, the back portion is substantially irremovably attached to the bottom portion.

22. An upholstered sofa, chair or couch according to claim 21 further comprising at least one bolt connecting the middle portion of the back to the bottom.

23. An upholstered sofa, chair or couch according to claim 21 wherein the first male bracket, the second male bracket, the first female bracket, and the second female bracket are each constructed of a continuous piece of material.