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.

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.