Method of Manufacturing and Packing A Furniture Item's Components into A Shipping Box with Specified Geometry Requirements

Abstract

A method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements facilitates large furniture items such as sofas being packed into shipping boxes that are smaller than typical furniture dimensions by designing the furniture items accordingly. At least one shipping box is selected for a furniture item, wherein the at least one shipping box is sized to at least one specified geometric restriction. A plurality of assembly pieces are designed and sized for the furniture item in order for the assembly pieces to meet the at least one specified geometric restriction in a disassembled configuration. The assembly pieces are arranged into the disassembled configuration within the at least one shipping box, and the assembly pieces are confined within the at least one shipping box.

What is claimed is: 
     
         1 . A method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method comprises the steps of:
 (A) selecting at least one shipping box for a furniture item, wherein each of the at least one shipping box is sized to at least one specified geometric restriction;   (B) designing and sizing a plurality of assembly pieces for the furniture item in order for the plurality of assembly pieces to meet the at least one specified geometric restriction in a disassembled configuration;   (C) arranging the plurality of assembly pieces into the disassembled configuration within the at least one shipping box; and   (D) confining the plurality of assembly pieces within a set of unextended boundaries of the at least one shipping box.   
     
     
         2 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 1 , wherein the at least one specified geometric restriction comprises a maximum threshold for a box length. 
     
     
         3 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 2 , wherein the maximum threshold for the box length is 108 inches. 
     
     
         4 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 1 , wherein the at least one specified geometric restriction comprises a maximum threshold for a box length plus a box girth, and wherein the box girth is twice a box width plus twice a box height. 
     
     
         5 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 4 , wherein the maximum threshold for the box length plus box girth is less than or equal to 165 inches. 
     
     
         6 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 4 , wherein the box width is less than or equal to the box length, and wherein the box height is less than or equal to the box width. 
     
     
         7 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 4 , wherein each of the plurality of assembly pieces is dimensioned with a piece length, a piece width, and a piece height, and wherein the piece length is less than or equal to the box length, and wherein the piece width is less than or equal to the box width, and wherein the piece height is less than or equal to the box height. 
     
     
         8 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 1 , wherein the dissembled configuration arranges the plurality of assembly pieces within at least one rectangular prismatic boundary. 
     
     
         9 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 1 , wherein at least one cavity for at least one specific piece is sized to receive at least one portion of at least one other piece, and wherein the at least one specific piece and the at least one other piece are from the plurality of assembly pieces. 
     
     
         10 . The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in  claim 1  comprises the steps of:
 providing the at least one shipping box as a plurality of shipping boxes; 
 providing the disassembled configuration as a plurality of physically-separated groupings; 
 arranging the plurality of assembly pieces into the plurality of physically-separated groupings; and 
 confining each of the plurality of physically-separated groupings within the set of unextended boundaries of a corresponding box from the plurality of shipping boxes.