Upholstered recliner including molded furniture components

Abstract

An upholstered seat, a frame including a pair blow molded hollow arm rest forms. Further components may be blow molded such as a back rest. The arm rest forms and backrest forms may be reinforced with metal plates and assembled into a recliner. Form fit upholstery coverings with closures on the blow molded components. The backrest form may have legs with kd brackets secured thereto by clamping onto the portions of the legs of the backrest forms. The connections to the backrest form and arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust.

What is claimed is: 
     
         1 - 6 . (canceled) 
     
     
         7 . An upholstered recliner comprising:
 a pair of blow molded polymer arm rest forms, each of the arm rest forms being hollow and having a continuous wall extending around a top, two lateral sides, a forward side, a rearward side, and a bottom side;   a seat deck bolted inbetween the pair of molded polymer arm rest forms;   a recliner mechanism positioned below and attached to the seat deck; and   a blow molded back rest attached to the recliner mechanism.   
     
     
         8 . The upholstered recliner of  claim 7 , wherein each of the molded arm rest forms having threaded fasteners clamped to respective wall portions of each one of the pair of molded polymer arm rest forms, wherein each of the threaded fasteners is a rivet nut. 
     
     
         9 . The upholstered recliner of  claim 7 , wherein each of polymeric arm rest forms having a recess for a lower rearward spanning wood rail and each of the recesses having a plurality of threaded inserts therein and the lower rearward rail is attached to each of the polymeric arm rest forms with a threaded screw extending through the lower rearward rail into the threaded inserts. 
     
     
         10 . The upholstered recliner of  claim 7 , wherein each of polymeric arm rest forms having a vertical column defined by a pair of windows therein. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . The upholstered recliner of  claim 7 , wherein each arm rest form has an internal volume of at least 1 cubic foot. 
     
     
         14 . A method of assembling a recliner, the method comprising:
 putting a pair of conforming sock portions over a pair of blow molded armrest forms;   putting a pair of conforming sock portion over a blow molded backrest form;   putting a conforming sock over a seat deck;   attaching the arm rest forms to the seat deck;   attaching a recliner mechanism to the seat deck; and   attaching the blow molded back rest form to the recliner mechanism;   
     
     
         15 . (canceled) 
     
     
         16 . The method of  claim 14 , further comprising having the seat deck upside down when the blow molded arm rest forms are attached to the seat deck and when the recliner mechanism is attached to the seat deck. 
     
     
         17 . The method of claim  15 , further comprising attaching two kd brackets to the backrest form. 
     
     
         18 . The method of  claim 17 , wherein the arms are hollow with opposing walls and a unitary tubular portion extending between the opposing walls and wherein the method further comprises attaching each of the kd brackets to the blow molded backrest form with threaded fasteners. 
     
     
         19 . (canceled) 
     
     
         20 . The method of claim  15 , wherein the seat deck has a metal frame and the attachment of the arm rest forms to the seat deck comprises extending threaded fasteners between each of the pair of arm rest forms and the metal frame. 
     
     
         21 . An upholstered seat comprising: two blow molded arm rest forms, a blow molded backrest form, a seat deck, and a recliner mechanism, wherein each of the blow molded arm rest forms and the blow molded backrest form being hollow and having a continuous polymeric wall extending around a top, two lateral sides, a forward side, a rearward side, and a bottom side, wherein the seat deck is attached to one of the arm rest forms and the seat deck having the recliner mechanism positioned thereunder and attached to the seat deck, and wherein the backrest form is attached to the recliner mechanism. 
     
     
         22 . The upholstered seat of  claim 21 , further comprising a pair of upholstery socks conformingly sized and positioned on respective ones of the two blow molded arm rest forms. 
     
     
         23 . The upholstered seat of  claim 22 , further comprising an upholstery sock conformingly sized and positioned on the seat deck. 
     
     
         24 . The upholstered seat of  claim 21 , wherein the seat deck is attached to both blow molded arm rest forms. 
     
     
         25 . The upholstered recliner of  claim 21 , wherein each of the blow molded arm rest forms have a respective reinforcing plate on an exterior lateral side of each of the blow molded arm rest forms.