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.

Description:
RELATED APPLICATION 
       [0001]    The present application claims the benefit of U.S. Provisional Application No. 61/563,429 entitled READY TO ASSEMBLE FURNITURE SYSTEM, filed Nov. 23, 2011; U.S. Provisional Application No. 61/621,236 entitled RTA FURNITURE WITH COMPONENT INTERFACE FEATURES, filed Apr. 6, 2012; and U.S. Provisional Application No. 61/677,731 entitled RTA FURNITURE WITH COMPONENT INTERFACE FEATURES, filed Jul. 31, 2012, all of which are incorporated herein by reference in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is generally directed to interface components and related methods for securing together subcomponents of ready to assemble furniture systems. Specifically, the present invention is generally directed to interface components that align and secure subcomponents of ready to assembly furniture systems. 
       BACKGROUND OF THE INVENTION 
       [0003]    Furniture items used for seating commonly comprise a support structure covered by upholstery and/or cushioning. In particular, sofas typically comprise a seat base, a back rest and at least one arm rest. A common aesthetic and practical design consideration is assembling the sofa to minimize the visible gaps between the subcomponents. Similarly, if the components are not properly aligned during assembly, the misaligned subcomponents can form an uneven edge between the subcomponents creating an unpleasant aesthetic appearance. Typically, the furniture item is fully assembled at the factory by factory workers or machinery to ensure the individual subcomponents are properly assembled and aligned to minimize the appearance of visible gaps or uneven edges in the assembled furniture item. 
         [0004]    The inherent drawback of assembling the furniture item at the factory is that the L-shape of the back and seat rest assembly typical of the seating portion of sofas often prevents efficient packing of the furniture items for transport. Depending on the shape and size of subcomponents of the furniture item, inefficient packing of the furniture item can result in a significant amount of dead space within the shipping container or truck. In addition to increasing the cost of transportation, the dead space can allow the furniture items to shift during transport resulting in potential injury when the shipping containers are opened or damage to the furniture item itself. Similarly, the awkward shape of the assembled furniture items can make it difficult to navigate into or through a home or other structure without significant positioning and reorienting of the furniture item often resulting in injury to the movers and/or damage to the furniture or the structure. 
         [0005]    An approach to addressing the drawbacks of factory assembled furniture items comprises providing individually upholstered subcomponents as a ready to assemble (“RTA”) furniture kit that can be assembled by the end user. The individual subcomponents can be more efficiently packed than the fully assembled furniture item and allows the furniture item to be assembled in situ, thereby eliminating the need for navigating the assembled furniture item through the building. However, the inherent challenge of providing RTA furniture kits is that the consumers who assemble the furniture kits are typically unfamiliar with furniture assembly and may not have the experience or ready access to the tools necessary to properly assemble the subcomponents. In addition, manually aligning the often heavy and large subcomponents to install the fasteners for connecting the subcomponents can be difficult, particularly if a single individual is assembling the furniture item. Moreover, as the number of subcomponents assembled together increases, maneuvering the components becomes increasingly challenging as the weight and bulkiness of the assembly increases. A similar concern is that if the fasteners linking the subcomponents are not properly installed, the structural integrity of the furniture item could be compromised resulting in the furniture item collapsing possibly resulting in the injury of users. 
         [0006]    Another challenge of RTA furniture kits is affixing fasteners to pre-upholstered furniture subcomponents can be difficult. With most RTA furniture kits, the interface surfaces between the various subcomponents are typically not easily accessible from the exterior of the furniture item following assembly. A common approach of accessing the interfacing surfaces is through the bottom of the seat box of the furniture item. However, this approach typically requires upending the couch and fastening the subcomponents while the furniture item is balanced on its side or back. The often awkward and precarious positioning of the furniture item during assembly can make alignment of the subcomponents even or more difficult. In particular, the awkward positioning can make the determination as to whether the subcomponents are properly aligned difficult. Similarly, if the fasteners are treaded through the pre-drilled holes, the awkward positioning of the subcomponents can create substantial friction making threading the subcomponents even more difficult. 
         [0007]    Although there are numerous advantages to ready to RTA furniture systems, there is a need for an efficient means of assembling the subcomponents of the RTA furniture system by untrained or unskilled individuals while still providing an assembled furniture item that is aesthetically pleasing. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention is generally directed to a ready-to-assemble furniture (“RTA”) system in which each RTA furniture item comprises at least two subcomponents assembled by interfacing a connection bracket affixed to a first subcomponent and defining a tapered frustum surface with a corresponding slot defined by a second subcomponent. In embodiments, the frustum surface of the connection bracket engages the edges of the slot at an angle transverse to the slot surface of the second subcomponent defining the slot to prevent movement of the subcomponents transverse to the slot as well as separation of first and second subcomponents. The slot is positioned on the second subcomponent such that the engagement of the bracket to the slot properly aligns the first and second subcomponent. 
         [0009]    In one aspect, the first subcomponent comprises a first planar or interface face and the second subcomponent comprises a second planar or interface face. In this configuration, a connection bracket is affixed to the first planar face of the first subcomponent. The connection bracket can comprise at least one of a conical frustum portion and a pyramidal frustum portion. The connection bracket can also define an inwardly facing lesser surface abutting the first planar surface and a outwardly facing greater surface opposite the lesser surface with a tapered frustum surface extending there between. Similarly, a slot corresponding to the connection bracket is cut in the second planar face of the second subcomponent, wherein at least one of the conical frustum portion and a rectangular pyramidal frustum portion is sized for an interference fit with the slot. In this configuration, the first subcomponent is affixed to the second subcomponent by inserting the bracket into the slot. 
         [0010]    Each subcomponent may be box framed formed from boards or panelar members each formed of wood or wood products. “Panelar members” includes, for example, pieces of plywood or chip board or composite boards, or the like. The subcomponents may be part of chairs, including sofas, and may be arms, seat bases, and seat backs. The subcomponents may be upholstered or unupholstered. All of the subcomponents of a chair may be packaged in a box including instructions for assembly without tools and separate cushions for the seat and/or back. 
         [0011]    In one aspect, the present invention is generally directed to a component interface assembly for attaching the individual subcomponents of an RTA furniture system. Each component interface assembly, according to an embodiment of the present invention, comprises an elongated alignment slot positioned on a first subcomponent and at least one interlocking retention element positioned on a second corresponding subcomponent, wherein the retention element is insertable into the slot to secure the first and second subcomponents together. 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, thereby eliminating the need to maintain first and second subcomponent in alignment as the subcomponents are fastened together with conventional fasteners. 
         [0012]    In one aspect, at least a portion of the alignment slot is vertically oriented when the assembled furniture item is oriented upright such that the first subcomponent must be lifted relative to the second subcomponent to slide the retention element along the slot to disengage the second subcomponent from the first subcomponent. Accordingly, the weight of the first subcomponent maintains the retention element in place within slot of the first subcomponent preventing accidental separation of the first and second subcomponents. In one aspect, the edges of the slot engage a portion of the retention element to provide a friction fit further improving retention of the retention element within the slot. 
         [0013]    In one aspect, the slot can further comprise a polymer lining facilitating movement of the retention element through the slot without damaging the slot. Each slot is positioned on the second component such that the first and second components are properly aligned when the retention element is slid into the corresponding slot. In certain aspects of the present invention, the edges of the slots can be shaped to engage the retention elements as the retention element is being slid through the slot to adjust to the relative alignment of the subcomponents to correct minor misalignments between the subcomponents. 
         [0014]    A component interface assembly, according to an embodiment of the present invention, comprises a retention element affixed to a first subcomponent and an alignment slot defined in a second subcomponent, wherein the retention element comprises a lug. The lug comprises a cylindrical body affixed to the first subcomponent at one end and having an engagement feature at the opposite end. The slot is sized such that the engagement feature engages the edges of the slot to lock the first and second subcomponents together when the lug is slid into the slot. Similarly, the width of the slot corresponds to the diameter of the cylinder such that the lug can be slid along the longitudinal axis defined by the slot, but not moved perpendicularly to the slot relative to the longitudinal axis. 
         [0015]    In one aspect, the alignment slot can comprise at least two linear segments, wherein the segments are arranged in an L-shaped configuration. In this configuration, the first segment can define a generally horizontal axis when the first subcomponent is positioned in the ordinary upright orientation while the second segment can define a generally vertical axis. In operation, the second component can be moved horizontally such that the lug travels along the first segment until the lug reaches the second segment. The horizontal axis of the first segment can make positioning the retention element within the slot easier as the second subcomponent does not have to be vertically aligned with the lug, which can be challenging with heavier components such as back rests. The second component can be than be moved vertically manually or by gravity until the lug reaches the end of the second segment positioning the first and second components in the correct horizontal and vertical alignment. 
         [0016]    In one aspect, the slot can comprise a polymer lining protecting the edges of the slot and facilitating the sliding of the lug through the slot to the end of the slot. The support structure of the subcomponents is often wood or plywood, which can slow the lug as the lug moves through the slot. In this configuration, the polymer lining can comprise a narrowed portion positioned at the end of the slot to grip the cylindrical body of the lug when the lug is slid to the end of the slot. In one aspect, the polymer lining can further comprise at least one protrusion extending outward from the slot to engage the engagement feature of the lug once the lug is slid to the end of the slot. The narrowed portion prevents the lug from moving backwards along the slot and disengaging the first and second subcomponents together. 
         [0017]    A method of assembling a furniture item, according to an embodiment of the present invention, comprises cutting a slot in a first planar surface of a first furniture component and affixing a lug to a second planar surface of a second furniture component, wherein the first and second planar surfaces are positioned in parallel when the furniture item is assembled. The method further comprises cutting the slot such that at least a portion of the slot proximate to the end of the slot defines a vertical axis. Finally, the method comprises maneuvering the second subcomponent such that the lug is slid along the slot until lug reaches end of the slot, wherein the slot is retained at the end of the slot by the weight of the first subcomponent. 
         [0018]    A component interface assembly, according to an embodiment of the present invention, comprises a retention element affixed to a first component and a corresponding alignment slot defined in a second component, wherein the retention element comprises an elongated bracket. The elongated bracket comprises an elongated body having a first face affixed against the first component and defining a protruding lip around a second face opposite the first face. In one aspect, the first face comprises a smaller cross-sectional area than the second face. The slot is sized such that the lip engages the edges of the slot when the elongated bracket is inserted into the slot to engage the first component to the second component. In this configuration, the bracket can comprise a V-shape, wherein the elongated bracket defines a tapered edge between the first face and the second face. In this configuration, the tapered edge engages the edge of the slot to retain the first component to the second component. The width of the slot corresponds to the width of the elongated body such that the bracket can be slid along the longitudinal axis defined by the slot, but not moved perpendicularly to the slot. The elongated body engages an elongated length of the edge of the slot to prevent the rotation of the second component around the bracket. 
         [0019]    In one aspect, the slot can be oriented to define a linear vertical axis. In this configuration, the second component can be positioned such that the slot aligns with the elongated bracket before the second component is moved vertically to slide the bracket into the slot and engage the first and second components together. In one aspect, the elongated bracket can comprise a rounded end for simplifying alignment of the elongated bracket with the slot as the rounded end can engage the edge of the slot to shift the second component relative to the first component to correct minor misalignments between the subcomponents. 
         [0020]    A method of assembling a furniture item, according to an embodiment of the present invention, comprises cutting a slot in a first planar surface of a first furniture component and affixing an elongated bracket to a second planar surface of a second furniture component, wherein the first and second planar surfaces are positioned in parallel when the furniture item is assembled. The method further comprises cutting the slot such that the slot defines a vertical axis. Finally, the method comprises maneuvering the second subcomponent such that the bracket is slid along the slot until the elongated bracket reaches end of the slot, wherein the slot is retained at the end of the slot by the weight of the first subcomponent. 
         [0021]    A component interface assembly, according to an embodiment of the present invention, comprises a retention element affixed to a first component and a corresponding slot defined in a second component, wherein the retention element comprises a frustoconical bracket. The frustoconical bracket can comprise a frustoconical body having a first face with a cross-sectional area smaller than the opposing second face. The frustoconical body can also define a tapered edge extending between the first and second faces. The frustoconical bracket can be mounted to the first component such that first face is positioned against the corresponding surface of the first component such that the larger cross-sectional area of the second face is positioned away from the first component. In this configuration, the slot is sized such that the tapered edge of the frustoconical bracket engages the edges of the slot when the frustoconical bracket is inserted into the slot to engage the first component to the second component. In this configuration, at least two frustoconical brackets can be used affix the first component and the second component together such that the frustoconical brackets cooperate to prevent rotation of the first component relative to the second component around one of the frustoconical brackets. 
         [0022]    In one aspect, the slot can be oriented to define a substantially vertical axis. The second component can be positioned such that the slot aligns with the frustoconical bracket before the second component is moved vertically to slide the bracket into the slot and engage the first and second components together. In this configuration, the rounded tapered edge of frustoconical bracket engages the edges of the slot to shift the second component horizontally to align the first and second components as the bracket is inserted into the slot. In one aspect, the slot can comprise tapered edges that engage the tapered edge of the frustoconical bracket to guide the frustoconical bracket as the bracket is slid into the slot to correct any misalignments between the first and second components. 
         [0023]    A method of assembling a furniture item, according to an embodiment of the present invention, comprises cutting a slot in a first planar surface of a first furniture component and affixing a frustoconical bracket to a second planar surface of a second furniture component, wherein the first and second planar surfaces are positioned in parallel when the furniture item is assembled. The method further comprises cutting the slot such that the slot defines a substantially vertical axis. Finally, the method comprises maneuvering the second subcomponent such that the frustoconical bracket is slid along the slot until the elongated bracket reaches end of the slot, wherein the slot is retained at the end of the slot by the weight of the first subcomponent. In one aspect, the slot is cut to define a tapered edge to guide the frustoconical bracket into the slot and correct misalignments between the first and second subcomponents. 
         [0024]    The present invention is directed to a RTA furniture kit having component interface features for tool-less alignment and assembly of the subcomponents. Each component interface feature can comprise a retention element affixed to a first subcomponent and a corresponding slot defined in the second subcomponent. The slots are positioned such that sliding the retention element through the corresponding slot aligns and engages subcomponents together. When the retention element is slid to the end of the slot, the retention element engages the parallel sides and end of the slot to prevent movement of the first subcomponent relative to the second subcomponent. The slot can be oriented such that gravity or friction will prevent relative movement of the first and second subcomponents such that the retention element travels back along the slot once the retention element is positioned at the end of the slot. In one aspect, the slot can further comprise a polymer lining facilitating movement of the retention element through the slot allowing for easy assembly and disassembly of the furniture item without damaging the slot. 
         [0025]    A ready to assemble furniture kit, according to an embodiment, comprises a plurality of disassembled subcomponents with integrated component interfaces for tool-less assembly of the subcomponents, wherein at least one of the subcomponents comprises at least one retention element and at least subcomponent comprises at least one alignment slot corresponding to the retention element. The plurality of subcomponents can comprise a seat box with integrated arm rests and a back rest. In one aspect, each retention element comprises at least two t-shaped knobs receivable within each alignment slot to prevent torqueing of the back rest once the first subcomponent is engaged to the second subcomponent. 
         [0026]    In one aspect, the plurality of subcomponents can further comprise at least one back rest cushion. In this configuration, the seat box can define an interior cavity sized to receive the back rest cushions when the kit is packaged. The seat box and each arm rest can define corresponding cutouts to combine the interior cavity defined by the set box and the interior cavities defined by each arm rest to increase the space within the seat box-arm rest assembly for receiving, for example, the back rest cushions and furniture components. According to an embodiment, the expanded space can be used to store oversized back or arm rest cushions that would otherwise not fit within the interior space of the seat box. The seat box can comprise an open bottom for accessing the interior cavities of the seat box and the arm rests via the cutouts. 
         [0027]    In one aspect, the kit can further comprise at least one removable arm rest cushion affixable to the arm rest. An engagement mechanism, such as a zipper, is affixed to the exterior arm rest and releasably engagable to a corresponding engagement mechanism on each arm rest cushion. Alternatively, the arm rest cushion can be stored within the cavity defined by the arm rest when the kit is packaged. 
         [0028]    A method of assembling a ready to assembly furniture kit, according to an embodiment of the present invention, comprises providing a seat box with integrated arm rests and having at least one alignment bracket defining a u-shaped slot, wherein each arm rest comprises an engagement mechanism. The method also comprises providing a back rest having at least one corresponding alignment bracket having at least one t-shaped knob receivable within the u-shaped slot of the seat box alignment bracket. The method further comprises storing at least one back cushion in a cavity defined within the seat box. The method can also comprises storing the back rest cushions in an expanded storage cavity defined by combining the interior cavities of the seat box and arm rests. 
         [0029]    The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE CLAIMS 
         [0030]    The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
           [0031]      FIG. 1  is a front perspective view of an un-upholstered furniture frame for a furniture item according to an embodiment of the present invention. 
           [0032]      FIG. 2  is a partial side view of a component interface feature having a lug according to an embodiment of the present invention. 
           [0033]      FIG. 3  is a partial front perspective view of the component interface feature shown in  FIG. 2 . 
           [0034]      FIG. 4  is a partial rear view of the component interface feature shown in  FIG. 2 . 
           [0035]      FIG. 5  is a partial front perspective view of the component interface feature having a lug according to an embodiment of the present invention. 
           [0036]      FIG. 6  is a partial rear view of the component interface feature shown in  FIG. 5 . 
           [0037]      FIG. 7  is a partial exploded view of a furniture frame for a furniture item according to an embodiment of the present invention. 
           [0038]      FIG. 8  is a partial rear perspective view of a furniture frame for a furniture item according to an embodiment of the present invention. 
           [0039]      FIG. 9  is a perspective view of a polymer liner according to an embodiment of the present invention. 
           [0040]      FIG. 10  is a perspective view of a lug according to an embodiment of the present invention. 
           [0041]      FIG. 11  is a representative perspective side view of a lug sliding horizontally along a polymer liner to engage two furniture components together according to an embodiment of the present invention. 
           [0042]      FIG. 12  is a representative perspective side view of the lug depicted in  FIG. 11  sliding vertically along a polymer liner to engage two furniture components together according to an embodiment of the present invention. 
           [0043]      FIG. 13  is a front perspective view of an un-upholstered furniture frame for a furniture item according to an embodiment of the present invention. 
           [0044]      FIG. 14  is a partial front perspective view of the furniture frame depicted in  FIG. 9  illustrating the engagement of the subcomponents of the furniture frame. 
           [0045]      FIG. 15  is a partial front perspective view of the furniture frame depicted in  FIG. 9  illustrating the engagement of the subcomponents of the furniture frame. 
           [0046]      FIG. 16  is an exploded perspective view of the furniture frame depicted in  FIG. 9 . 
           [0047]      FIG. 17  is a front perspective view of an un-upholstered furniture frame for a furniture item according to an embodiment of the present invention. 
           [0048]      FIG. 18  is a partial side perspective view of the furniture frame depicted in  FIG. 17  illustrating the engagement of the subcomponents of the furniture frame. 
           [0049]      FIG. 19  is a partial rear perspective view of the furniture frame depicted in  FIG. 17 . 
           [0050]      FIG. 20  is a front perspective view of an elongated bracket according to an embodiment of the present invention. 
           [0051]      FIG. 21  is a rear perspective view of the elongated bracket depicted in  FIG. 20 . 
           [0052]      FIG. 22  is a perspective view of an elongated bracket travelling vertically along a slot to engage the subcomponents together. 
           [0053]      FIG. 23  is a perspective view of the bracket depicted in  FIG. 22  illustrating the elongated bracket correcting misalignment of the subcomponents. 
           [0054]      FIG. 24  is a front perspective view of the elongated bracket depicted in  FIG. 22  engaging the end of the slot to lock the subcomponents together. 
           [0055]      FIG. 25  is a rear perspective view of the elongated bracket depicted in  FIG. 22  engaging the end of the slot to lock the subcomponents together. 
           [0056]      FIG. 26  is a rear perspective view of an un-upholstered furniture frame for a furniture item according to an embodiment of the present invention. 
           [0057]      FIG. 27  is a rear perspective view of the furniture frame depicted in  FIG. 26  illustrating the engagement of the subcomponents of the furniture frame. 
           [0058]      FIG. 28  is a perspective view of a frustoconical bracket according to an embodiment of the present invention. 
           [0059]      FIG. 29  is partial cross-sectional side view of the frustoconical bracket depicted in  FIG. 28 . 
           [0060]      FIG. 30  is top view of the frustoconical bracket depicted in  FIG. 28 . 
           [0061]      FIG. 31  is a representative diagram depicting the packaging a ready to assemble furniture kit according to embodiment of the present invention. 
           [0062]      FIG. 32  is a top view of a seat box according to an embodiment of the present invention without an upper support surface removed. 
           [0063]      FIG. 33  is a perspective view of the seat box depicted in  FIG. 32  with the upper support surface installed. 
           [0064]      FIG. 34  is a perspective view of a plurality of back rest cushions for a ready to assemble furniture kit according to an embodiment of the present invention. 
           [0065]      FIG. 35  is a front perspective view of an upholstered seat box according to an embodiment of the present invention. 
           [0066]      FIG. 36  is a side perspective view of an upholstered arm rest according to an embodiment of the present invention. 
           [0067]      FIG. 37  is an enlarged partial perspective view of the upholstered arm rest depicted in  FIG. 36 . 
           [0068]      FIG. 38  is a side perspective view of the upholstered arm rest depicted in  FIG. 36 . 
           [0069]      FIG. 39  is a front perspective view of an arm rest-seat box assembly according to an embodiment of the present invention. 
           [0070]      FIG. 40  is a rear partial perspective view of the arm rest-seat box assembly depicted in  FIG. 39 . 
           [0071]      FIG. 41  is a bottom partial perspective view of the arm rest-seat box assembly depicted in  FIG. 39 . 
           [0072]      FIG. 42  is a rear perspective view of a back rest frame for a ready to assemble furniture kit according to an embodiment of the present invention. 
           [0073]      FIG. 43  is a rear perspective view of a back rest for a ready to assemble furniture kit according to an embodiment of the present invention. 
           [0074]      FIG. 44  is an enlarged partial rear perspective view of the back rest depicted in  FIG. 43 . 
           [0075]      FIG. 45  is a diagram view of depicting assembly of a ready to assembly furniture kit according to an embodiment of the present invention. 
           [0076]      FIG. 46  is a perspective view of a furniture item assembled from a ready to assemble furniture kit according to an embodiment of the present invention. 
           [0077]      FIG. 47  is a diagram view of a bracket alignment assembly according to an embodiment of present invention. 
           [0078]      FIG. 48  is a top cross-sectional view of the bracket alignment assembly depicted in  FIG. 47 . 
           [0079]      FIG. 49  is a bottom view of a furniture item according to an embodiment of the present invention. 
           [0080]      FIG. 50  is a cross-sectional side view of a portion of a furniture item according to an embodiment of the present invention. 
           [0081]      FIG. 51  is a cross-sectional side view of a portion of a furniture item according to an embodiment of the present invention. 
       
    
    
       [0082]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0083]    As shown in  FIGS. 1 and 13 , a RTA furniture item  10 , according to an embodiment, comprises a kit having at least a first subcomponent  12  and a second subcomponent  14 . As depicted, the RTA furniture item  10  is directed to a RTA sofa kit, wherein the first subcomponent  12  is the arm rest and the second subcomponent  14  is the seat box. The present invention is not limited to sofas and can be applicable to any type of upholstered or partially upholstered furniture items including, but not limited to, chaises, sectionals, lounge chairs and recliners. Moreover, the assignment of the first subcomponent  12  to the arm rest and second subcomponent  14  to the seat box is intended to assist in the description of the present invention and not intended to be limiting. The first subcomponent  12  further comprises at least one first planar or interface surface  16 . Similarly, the second subcomponent  14  further comprises at least one second planar or interface surface  18 . The first and second planar surfaces  16 ,  18  are generally planar such that the interface surfaces  16 ,  18  can be positioned proximate to each other and affixed together to secure the first subcomponent  12  to the second component  14 . In one aspect, the furniture item  10  can further comprise a third subcomponent  20  having a third interface surface  22  that can be positioned proximately to the first or second planar surfaces  16 ,  18 . As depicted in  FIG. 1 , the third subcomponent  20  is the back rest. 
         [0084]    As shown in  FIGS. 1-12 , the furniture item  10  can further comprise at least one component interface feature  24 , each interface feature  24  comprising a retention element  26  affixed to the first planar surface  16  and a corresponding slot  28  defined in the second planar surface  18 . Each retention element  16  comprises an axial portion extending outwardly from the first planar surface  16  and a radial portion extending transversely from the axial portion such that each retention element  16  can prevent movement of an engaged second component  14  from moving in at least two directions. 
         [0085]    In one embodiment of the present invention, depicted in  FIGS. 1-12 , the retention element  26  can comprise a lug  30  having a cylindrical body  32  and an engagement feature  34  positioned at one end of the cylindrical body  32  and having a greater diameter than the cylindrical body  32 . In one aspect, the interface feature  24  can further comprise a polymer liner  37  positioned within the slot  28 . The polymer liner  37  can comprise a durable polymer that allows the lug  30  to slide easily along the slot  28  without gouging or denting the slot  28 . 
         [0086]    The lug  30  is affixed to the first planar surface  16  at the end of the cylindrical body  32  opposite the engagement feature  34  such that the lug  30  extends perpendicularly from the first planar surface  16 . As shown in  FIGS. 9-10 , in one aspect, the lug  30  can define a bore hole  62  for receiving a fastener  64  such as a screw, bolt, rivet or other conventional fastener for affixing the lug  30  to the first planar surface  16 . The slot  28  begins at an edge of the first planar surface  16  and terminates at a predetermined point within the first planar surface  16 . In one aspect, the slot  28  can be cut in the third interface surface  22  as shown in FIGS.  1  and  7 - 8 . In operation, the second subcomponent  14  is maneuvered such that the end of the slot  28  is aligned with the lug  30  before the cylindrical body  32  of the lug  30  is slid into the slot  28  until the lug  30  reaches the end of the slot  28 . In this aspect, the second component  14  can be the lighter than the first component  12  to avoid having the maneuver and position a larger component. The slot  28  is sized and positioned such that the first and second subcomponents  16 ,  18  are positioned in the proper alignment when the lug  30  reaches the end of the slot  28 . The width of the slot  28  generally corresponds to the cylindrical body  32  such that the lug  30  cannot move perpendicular to the slot  28 . The diameter of the engagement feature  34  is greater than the width of the slot  28  such that the first and second planar surfaces  16 ,  18  cannot be separated once the lug  30  is inserted into the slot  28 . 
         [0087]    In one aspect, the slot  28  can comprise at least a first linear segment  36  and a second linear segment  38  arranged in an L-shaped configuration. In this configuration, the first linear segment  36  begins at the edge of the second planar surface  26  and defines a generally horizontal axis, while the second linear segment  38  defines a generally vertical axis intersecting the horizontal axis defined by the first linear segment  36 . In operation, the second subcomponent  14  is positioned to align the lug  30  with the first linear segment  38  and moved horizontally to slide the lug  30  into the slot  28 . Once the lug  30  reaches the end of the first linear segment  38 , second subcomponent  14  can be moved vertically to position the lug  30  at the end of the second linear segment  38 . In one aspect, the second subcomponent  14  can be moved vertically by gravity to position the lug  30  at the end of the second linear segment  38  and slot  28 . In this configuration, the vertical orientation of the second linear segment uses gravity to maintain the lug  30  at the end of the slot  28 . 
         [0088]    In one aspect, the polymer liner  37  can comprise a narrowed portion  40  proximate to the end of the slot  28 . The narrowed portion  40  is narrower than the width of the slot  28  to grip the cylindrical body  32  once the lug  30  is positioned at the end of the slot  28  to prevent the lug  30  from moving backwards along the slot  28 . In another aspect, the polymer liner  37  can comprise at least one protrusion  33  extending from the slot  28  to engage the lug  30  once the lug  30  reaches the end of the slot  28  to releasably secure the lug  30  at the end of the slot  28 . Correspondingly, the engagement feature  34  can define a detent  35  for receiving the protrusion  33  to secure the lug  30  to the liner  37 . In one aspect, the protrusion  33  can comprise a ring shape encircling the end of the slot  28  and having an opening corresponding to the slot  28 . 
         [0089]    In one aspect, as shown in  FIG. 7 , the furniture item  10  can comprise at least two component interface features  24  each having lugs  30  such that the two lugs  30  cooperate to prevent rotation of the second subcomponent  14  around the lug  30 . As shown in  FIG. 7 , the at least two component interface features  24  can be arranged in parallel along a single vertical or horizontal axis. In this configuration, the third component  20  can be slid into engagement with a second component  14  on either side of the furniture item  10  at the same time. Alternatively, the at least two component interface features  24  can positioned in an offset configuration. In either configuration, the first and second linear segments  36 ,  38  of each component interface feature  24  are positioned in parallel to each other. In another aspect, the furniture item  10  can comprise a secondary interface feature  42  that cooperates with the primary interface feature  24  in affixing the first and second subcomponents  16 ,  18  and prevents rotation of the second subcomponent  14  around the lug  30 . 
         [0090]    As shown in  FIGS. 13-25 , the retention element  26  can comprise an elongated bracket  44  having an elongated body  46  defining a first face  48  and a second face  50  opposite the first face  48 . The elongated bracket  44  can further comprise a lip  52  protruding radially outward from the elongated bracket  44  and extending at least partially around the second face  50 . In one aspect, the elongated bracket  44  can comprise a durable injection moldable polymer material that is lighter than conventional metal materials. For example, nylons, polyethelenes, polyesters, PBT, PET, and such materials with fillers. The brackets also may be formed of metals such as steel, aluminum and alloys. The first face  48  of the elongated bracket  44  is affixable to the first planar surface  16  such that the elongated bracket  44  extends from the first planar surface  16 . In one aspect, the elongated bracket  44  can comprise a tapered edge  58  such that the elongated bracket  44  comprises a trapezoidal cross-section. In this configuration, the elongated bracket  44  can comprise a plurality of ribs  60  for reinforcing the elongated bracket  44 . The ribs are configured as gussets As shown in  FIGS. 20 to 23 , the elongated bracket  44  can further comprise at least one bore hole  66  for receiving a fastener  68  for affixing the elongated bracket  44  to the first planar surface  16 . 
         [0091]    In operation, the elongated bracket  44  is aligned and inserted into the slot  28 . The slot  28  is sized to engage the edge of the elongated bracket  44  once the elongated bracket  44  is inserted into the slot  28  to prevent perpendicular movement of the elongated bracket  44  relative to the slot  28 . The slot  28  is positioned such that the first and second subcomponents  14 ,  16  are properly aligned when the elongated bracket  44  reaches the end of the slot  28 . The elongated body  46  engages the slot  28  along the length of the slot  28  to prevent rotation of the second subcomponent  14  relative to the second subcomponent  14 . The outer diameter of the lip  52  is greater than the width of the slot  28  to engage the first subcomponent  12  to the second subcomponent  14  once the elongated bracket  44  is inserted into the slot  28 . 
         [0092]    In one aspect, as shown in  FIGS. 14 and 15 , the slot  28  can be tapered such that a portion of the slot  28  has a width greater than the width of the lip  52  such that the elongated bracket  44  can be threaded through the slot  28 . In operation, a first subcomponent  12  having an elongated bracket  44  can be maneuvered such that the elongated bracket  44  is threaded through the slot  28  and slid such that the elongated bracket  44  engages the narrower portion of the slot  28  to attach the first subcomponent  12  to the second subcomponent  14  as shown in  FIG. 14 . 
         [0093]    In one aspect, the slot  28  can comprise a third linear segment  54  extending vertically from the bottom of the second planar surface  26 . In this configuration, the second subcomponent  14  is positioned to align the slot  28  with the elongated bracket  44  and lowered to slide the elongated bracket  44  into the slot  28 . The second subcomponent  14  can be lowered manually or with the assistance of gravity simplifying the interlocking process. In one aspect, the elongated bracket  44  can further comprise a rounded end  56  for aligning the elongated bracket  44  with the slot  28  as the first component  16  is lowered onto the elongated bracket  44 . 
         [0094]    In one aspect, as shown in  FIGS. 13-19 , the furniture item  10  can comprises a plurality of brackets  44  that cooperate to engage the subcomponents  14 ,  16 ,  20  together. The plurality of brackets  44  can be arranged along a single horizontal or vertical axis. In one aspect, one or more brackets  44  can be offset from the brackets  44  arranged along a horizontal or vertical axis. In either configuration, the corresponding slots  28  can be oriented in parallel such that the subcomponents  14 ,  16 ,  20  can be slid along a single axis to be engaged together as shown in  FIGS. 13-14 . 
         [0095]    As shown in  FIGS. 28-30 , the retention element  26  can comprise a frustum shaped, for example, a frustoconical shaped, bracket  70  having a frustoconical body  72  defining a first face  74  and a second face  76  opposite the first face  72 . The first face  74  has a smaller cross-sectional spanning area than the second face  76 . The frustoconical body  72  defines a frustum surface, a tapered surface  78  on the periphery of the frustoconical body  72  and extending between the first and second faces  74 ,  76  such that the frustoconical body  72  comprises a trapezoidal cross-section at planes perpendicular to the first and second surfaces. The first face  74  of the frustoconical bracket  70  is affixable to the first planar surface  16  of the subcomponent such that the frustoconical body  72  extends from the first planar surface  16 . In one aspect, the frustoconical bracket  70  can comprise a plurality of ribs  80  for reinforcing the tapered wall with the tapered surface  78  of the frustoconical bracket  70 . As shown in  FIGS. 28-30 , the frustoconical bracket  70  can further comprise at least one bore hole  82  for receiving a fastener  84  for affixing the elongated bracket  44  to the first planar surface  16 . 
         [0096]    As shown in  FIGS. 26-27 , in operation, the frustoconical bracket  70  is aligned and inserted into the slot  28 . The slot  28  is sized to engage the tapered surface  78  of the frustoconical bracket  70  as the frustoconical bracket  70  is inserted into the slot  28  to prevent movement of the frustoconical bracket  70  perpendicular to the slot  28 . The slot  28  is positioned such that the first and second subcomponents  14 ,  16  are properly aligned when the elongated bracket  44  reaches the end of the slot  28 . In one aspect, a pair of frustoconical bracket  70  is positioned on the first planar surface  16  to prevent rotation of the second component  16  around the frustoconical bracket  70 . The outer diameter of the second face  76  is greater than the width of the slot  28  to engage the first subcomponent  12  to the second subcomponent  14  once the frustoconical bracket  70  is inserted into the slot  28 . 
         [0097]    In one aspect, the slot  28  can comprise a third linear segment  54  extending vertically from the bottom of the second planar surface  26 . In this configuration, the second subcomponent  14  is positioned to align the slot  28  with the frustoconical bracket  70  and lowered to slide the frustoconical bracket  70  into the slot  28 . The second subcomponent  14  can be lowered manually or with the assistance of gravity simplifying the interlocking process. The rounded shape of the frustoconical bracket  70  can engage the edges of the slot  28  to align the frustoconical bracket  70  with the slot  28  as the first component  16  is lowered onto the frustoconical bracket  70 . In one aspect, the slot  28  can comprise a tapered edge  86  to engage the frustoconical bracket  70  to align the second component  14  with the first component  12  as the as the second component  14  is lowered onto the first component  12 . 
         [0098]    As shown in  FIGS. 31 and 45 , a ready to assembly furniture item  102 , according to an embodiment of the present invention, a seat box  104  with at least one integrated arm rest  106  and a back rest  108 . As depicted, the item  102  is for assembly of a sofa, but can be for any number of conventional furniture types including, for example, chaises, sectionals, love seats, chairs, benches, or recliners. As shown in  FIG. 31 , the entire item  102  can be packaged into a single box  103 . 
         [0099]    As shown in  FIGS. 32-33  and  35 , the seat box  104 , according to an embodiment, can comprise a rectangular frame  110  having two opposing walls  112  and two end walls  114 . Each end wall  114  can further define at least one cut out  116 . According to an embodiment, the seat box  104  can further comprise an upper support assembly  118  having a support surface  120  and at least one spring  122  tensioned between the opposing walls  112 . The upper support assembly  118  is positioned on the rectangular frame  110  to define a cavity within the seat box  104 . According to an embodiment, the seat box  104  can further comprise at least one seat cushion  124  affixed to the exterior of the upper support surface  120 . 
         [0100]    As shown in  FIGS. 36-38 , the arm rest  106 , according to an embodiment, comprise a frame  126  having an interface plate  128 . The frame  126  defines a cavity within the arm rest  6  that can be used to retain furniture components during shipment of the item  102 . The interface plate  128  can define a cutout  130  corresponding to the cut out  116  in the end walls  114 . As shown in  FIGS. 39 and 41 , the interface plate  128  can be aligned with the end walls  114  such that the arm rests  106  can be affixed to the seat box  104  by inserting at least one fastener  132  through the end wall  114  and interface plate  128 . 
         [0101]    As shown in  FIG. 40 , each arm rest  106  can further comprise an alignment bracket  134  defining an elongated u-shaped notch  136 . The arm rest  6  is mounted to the seat box  104  such that a portion of the arm rest  106  protrudes past the seat box  104 . According to an embodiment, the alignment bracket  134  is positioned within the portion of the arm rest  106  that protrudes past the seat box  104 . 
         [0102]    As shown in  FIG. 45 , each arm rest  106  can further comprise at least one arm rest cushion  150 . The arm rest  106  can further comprise at least one releasable engagement feature  152  for engaging the arm rest cushion  150  to the arm rest  106 . The engagement feature  152  can comprise a zipper, VELCRO or other conventional means of releasably affixing a cushion. 
         [0103]    As shown in  FIGS. 42-44 , the back rest  108  can further comprise a frame  138  and at least one alignment bracket  140  corresponding to each alignment bracket  134  of each arm rest  106 . Each alignment bracket  134  further comprises at least one t-shaped knob  142  receivable within the u-shaped notch  136  of the arm rest alignment bracket  134 . According to an embodiment, the alignment bracket  134  can further comprise at least two t-shaped knobs  142  receivable within each u-shaped notch  136  to prevent torqueing of the back rest  108  once the back rest  108  is fitted to the arm rest  106  and seat box  104  assembly. The back rest  108  can further comprise at least one removable back cushion  144  each having an engagement feature  148  such as a zipper, VELCRO or other conventional means for releasably affixing the back rest cushion  144  to the back rest frame  38 . 
         [0104]    As shown in  FIG. 45 , the item  102  is assembled by sliding the back rest  108  between the protruding portions of the arm rests  106  such that t-shaped knobs  142  slide into the corresponding u-shaped notches  136 . The back rest cushions  144  and arm rest cushions  150  can be removed from the seat box  104  and arm rest  106  cavities before being be affixed to the back rest  108  and arm rest  106 , respectively. 
         [0105]    According to an embodiment, as shown in  FIGS. 46-47 , the arm rest  106  can further comprise an alignment bracket  154  defining a track  156  and having at least two walls  158  extending along the track  156 . Similarly, the back rest  108  can further comprise an alignment bracket  160  similarly defining a track  162  and having at least two walls  164  extending along the track  158 . The arm rest alignment bracket  154  and the back rest alignment bracket  160  can be affixed by sliding the corresponding walls  158 ,  164  along a first axis. The walls  158 ,  164  are shaped to prevent movement of the alignment brackets  154 ,  160  relative to each other in any direction except along the sliding axis. According to an embodiment, the arm rest alignment bracket  154  can comprise at least one stop  186  positioned within the track  156  to prevent sliding of the back rest  108  past a predetermined point. 
         [0106]    According to an embodiment, the furniture item  102  can further comprise at least one manual handled threaded fastener  66 . Each manual handled threaded fastener  166  can further comprise an elongated threaded shank  168  and a handle  170  for rotating the shank  168 . In this configuration, the back rest  108  can further comprise a bushing assembly  172  having a bushing portion  174  with a threaded interior and at least one engagement feature  176 . The bushing portion  174  is inserted into a bore hole  178  that is positioned proximate to the set box  104  when the back rest  108  is fitted to the seat box  104 . The engagement feature  176  is adapted to engage the frame  138  of the back rest  108  to maintain the bushing portion  174  within the bore hole  178 . The manual handled threaded fastener  66  can be threaded through a bore hole  180  in the corresponding opposing wall  112  of the seat box  4  and into the bushing portion  174  to affix the back rest  8  to the seat box  104 . 
         [0107]    According to an embodiment, the seat box  104  can further comprise a sealing feature  182  engagable to a corresponding sealing feature  184  on the back rest  108 . The sealing features  182 ,  84  can comprise a zipper, VELCRO or other conventional means of engaging the seat box  4  and back rest  108 . The sealing features  182 ,  184  can be engaged to seal any gaps between the seat box  104  and the back rest  108  are joined. 
         [0108]    As depicted in  FIG. 51 , according to an embodiment of the present invention, the RTA furniture item  10  comprises a connection bracket  200  affixed to the first planar surface  16  of the first subcomponent  12  and a slot  202  defined in the second planar surface  18  of the second subcomponent  14 . In one aspect, the connection bracket  200  can comprise a conical frustum portion as shown in  FIGS. 28-30 . In another aspect, the connection bracket  200  can comprise a rectangular pyramidal frustum portion. As shown in  FIGS. 20-21 , in yet another aspect, the connection bracket  200  can comprise a rectangular pyramidal frustum portion combined with a conical frustum portion, such that the bracket  200  comprises the shape of an arched doorway. As depicted in  FIGS. 51 and 52 , the connection bracket  200  comprises an inwardly facing lesser spanning area  204 , an outer facing greater spanning area  206  and a tapered frustum surface  208  extending there between. In one aspect, the bracket  200  can comprise an injection molded plastic or metal. 
         [0109]    In operation, the lesser spanning area  204  is secured to the first planar surface  16  of the first subcomponent  12  such that the greater spanning area  206  is opposite the first planar surface  16 . In one aspect, the first subcomponent  12  is secured to the second subcomponent  14  by inserting the connection bracket  200  into the slot  202  such that the frustum surface  208  engages the edges of the slot  202 . The slot  202  is dimensioned to having a cooperating fit between the slot  202  and the frustum surface  208 . In one aspect, the slot  202  is dimensioned such that the cooperating fit is an interface fit. The frustum surface  208  is angled to prevent movement of the first subcomponent  12  relative to the second subcomponent  12  transverse slot  202 . Similarly, the angle of the frustum surface  208  prevents the first subcomponent  12  from being pulled apart from the second subcomponent  14 . In one aspect, the edges of the slot  202  are deformed by the bracket  200  as the bracket  200  is inserted into the slot  202 . 
         [0110]    As depicted in  FIG. 52 , in one aspect, the connection bracket  200  can comprise a shaft portion  210  having a first end  212  secured to the first planar surface  16  and a second end  214 , wherein an knob portion  216  having an engagement surface  218  affixed to the second end  214  such that the engagement surface  218  is oriented toward the first planar surface  16 . In this configuration, the slot  202  is sized having a cooperating fit with the shaft portion  210  such that the shaft portion  210  cannot move transversely to the slot  202  once the shaft portion  210  is inserted into the slot  202  to secure the first and second subcomponents  12 ,  14 . 
         [0111]    In one aspect, the second subcomponent  14  can further comprise a slot lining receiver  220  positioned within the slot  202  and having a pair of opposing walls  222  defining a receiving slot  224  and a retention portion  226  on the second planar surface  18  for engaging the engagement surface  218 . Upon insertion of the shaft  210  into the slot  224 , the engagement surface  218  of the knob portion  216  engages the retention portion  226  to fix the shaft  210  within the slot  224  and secure the first subcomponent  12  to the second subcomponent  14 . 
         [0112]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.