Furniture assembly system and method

Abstract

A furniture assembly system and method is presented. The furniture assembly comprising a plurality of components having a first and a second long rails. The first and the second long rails are joined to a first and second side or end rails to form a frame. A plurality of coupling modules, each is sized smaller than the frame is then fitted to the frame to form an assembled frame. This way, the furniture components may be packaged into groups so that each group does not exceed the weight and/or size restriction of a selected carrier or a transportation vehicle.

What is claimed is:  
     
         1 . A furniture frame, comprising: 
 a first and a second long rails;    a first and a second side rails capable of being joined to said first and second long rails to form a frame; and    a plurality of coupling modules, each is sized smaller than the frame.    
     
     
         2 . The furniture frame of  claim 1  wherein the plurality of coupling modules are removably attached to the frame by a coupling mechanism to form an assembled frame.  
     
     
         3 . The furniture frame of  claim 2  wherein the coupling mechanism comprising at least one of: 1) a cleat, 2) a slot, 3) a screw, and 4) an intruding piece on the first and second long rails.  
     
     
         4 . The furniture frame of  claim 3  wherein the coupling mechanism further comprising at least one of: 1) a cleat, 2) a slot, 3) a screw, and 4) a receiving piece on the first and second side rails.  
     
     
         5 . The furniture frame of  claim 1  wherein the plurality of coupling modules comprising substantially rigid material.  
     
     
         6 . The furniture of  claim 5  wherein the plurality of coupling modules further comprising padding material.  
     
     
         7 . The furniture of  claim 1  wherein the plurality of coupling modules are substantially the same size.  
     
     
         8 . The furniture of  claim 2  wherein the furniture frame comprises more than one of the assembled frame.  
     
     
         9 . A method for shipping a furniture assembly to be assembled at a destination which when fully assembled exceeds one of weight restriction and size restriction of a shipper, comprising the steps of: 
 manufacturing the furniture assembly as separate components comprising: 
 a first and a second long rails,  
 a first and a second side rails capable of being joined to said first and second long rails to form a frame, and  
 a plurality of coupling modules, each is sized smaller than the frame; and  
   Packaging the separate components in groups such that none of the groups exceeds the one of the weight restriction and size restriction of the shipper.    
     
     
         10 . The method of  claim 10  further comprising the step of: 
 attaching the plurality of coupling modules to the frame by a coupling mechanism to form an assembled frame at the destination.  
 
     
     
         11 . The method of  claim 10  wherein the coupling mechanism comprising at least one of: 1) a cleat, 2) a slot, 3) a screw, and 4) a intruding piece on the first and second long rails.  
     
     
         12 . The method of  claim 11  wherein the coupling mechanism further comprising at least one of: 1) a cleat, 2) a slot, 3) a screw, and 4) a intruding piece on the first and second side rails.  
     
     
         13 . The method of  claim 10  wherein the plurality of coupling modules comprising substantially rigid material.  
     
     
         14 . The method of  claim 13  wherein the plurality of coupling modules further comprising padding material.  
     
     
         15 . The method of  claim 10  wherein the plurality of coupling modules are substantially the same size.  
     
     
         16 . The method of  claim 10  wherein the furniture assembly comprises more than one of the assembled frames  
     
     
         17 . A futon frame, comprising: 
 a first and a second long rails;    a first and a second side rails capable of being joined to said first and second long rails to form a frame; and    a plurality of coupling means, each is sized smaller than the frame and being removably attachable to the frame by a coupling mechanism to form an assembled frame.    
     
     
         18 . The futon frame of  claim 17  wherein the plurality of coupling means are of substantially the same size.  
     
     
         19 . The futon frame of  claim 18  wherein the futon frame comprising more than one assembled frame.  
     
     
         20 . The furniture frame of  claim 19  wherein the coupling means are substantially rigid.