Furniture component manufacturing method

Abstract

A method of manufacturing a furniture component, such as a panel or door panel, comprising providing a furniture component 110a, 110b comprising a surface 120 to be covered, the surface comprising a l

Description

The present disclosure relates to methods of manufacturing a furniture component. Background Furniture components generally comprise range of structures and surface finishes which contribute to their decorative or aesthetic appearance. Typical manufacturing methods for providing a decorative surface finish include vacuum forming cover material over shaped components. Light sources may be incorporated to provide a modern decorative aspect. However, due to the competing requirements for incorporating light sources versus those for providing a decorative surface finish, current manufacturing methods are limited to producing decorative components having a light source that is visibly distinct from the remainder of the furniture component, even when inactive. Summary It is an aim of embodiments of the invention to provide a manufacturing method that produces a furniture component having modern decorative aspects, i.e., lighting, incorporated in a way that does not detract from the surface finish of the component. According to the present disclosure there is provided a method of manufacturing a furniture component and there is provided a furniture component as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows. In a first aspect, there is provided a method of manufacturing a furniture component. The method comprises providing a furniture component comprising a surface to be covered, the surface comprising a light source receiving portion vacuum, and forming material over the surface to form a cover for the light source receiving portion, such that a light source received by the light source receiving portion is operable to shine through said cover. Advantageously, by providing cover, the light source is obscured when the light source is off. Further advantageously, the manufacturing method provides a cover for the light source so that it is easy to clean, protects the light source from damage and eliminates the possibility of contamination accumulating between the light source and component in the area where the light source and component material meet. In some examples, the light source receiving portion comprises an opening. Advantageously, the light source can be fitted in light source receiving portion via the opening on a surface of the furniture component. In some examples, vacuum forming material over the surface forms a unitary cover for a majority of the surface to be covered, and wherein the unitary cover provides the cover for the light source receiving portion. Advantageously, the provision of the cover for the light source occurs during the same single vacuum-forming step used to cover the furniture component. Due to this simultaneous covering, a single and seamless vacuum forming material may provide a protective cover for the light source and the remainder of the surface comprising the light source receiving portion, with no cracks, seams or gaps in which dirt or contamination can accumulate. In some examples, vacuum forming material over the surface comprises: stretching the material over the light source receiving portion to thereby increase light transmissivity of the cover. Stretching thins the material to thereby increase light transmissivity of the material. Accordingly, different degrees of light transmissivity are obtainable from same vacuum formed material. Advantageously, light transmissivity of the light source cover can therefore be controlled as part of the vacuum forming process. In some examples, prior to vacuum forming, arranging a spacer in the light source receiving portion such that the spacer forms part of the surface to be covered. The extent of vacuum forming into the light source receiving portion can be controlled. Additionally, because the cover for the light source forms against the spacer, the spacer can be adjusted at the light source receiving portion to adapt the profile of the surface to be vacuum formed. Accordingly, the spacer can be used to adjust the profile of the cover for the light source. In some examples, the spacer forms a continuous surface to be covered across an edge of the light source receiving portion, such that the surface to be covered is level. In this arrangement, the spacer provides a flat (e.g., flush) surface across the light source receiving portion. As a result, after vacuum forming, there is no change in form across the light source receiving portion, meaning there is no visible indication of the presence of the light source when the light is turned off. In some examples, the spacer forms a discontinuous surface across an edge of the light source receiving portion, such that the surface to be covered is stepped. In this arrangement, the spacer provides an uneven surface across the light source receiving portion. As a result, after vacuum forming, a change in form remains visible across the light source receiving portion. This change in form may advantageously provide an aesthetic contribution that is in line with traditional design considerations. For example, although the light source itself may not be visible when the light source is switched off, the stepped cover for the light source receiving portion may still provide an aesthetic design aspect, in terms of 3D form and / or shape. In some examples, spacer is arranged at a depth of the furniture component to thereby form a step of the stepped surface to be covered. In some examples, the spacer arranged at depth provides a recess into which the material is vacuum formed. In some examples, vacuum forming material over the surface to form a cover comprises stretching, by vacuum forming into the light source receiving portion, material over the light source receiving portion to thereby increase light transmissivity of the cover. By controlling the depth of the spacer formed recess, the degree of stretching and resultant light transmissivity can be controlled. In some examples, after vacuum forming, removing the spacer from the light source receiving portion. In some examples, the spacer is removed from behind the cover, such that the spacer is removed in the direction of vacuum forming. Thus, the spacer is removed from the furniture component without damaging the vacuum formed material. In some examples, inserting a light source into the light source receiving portion, such that the light source is arranged behind the cover and is operable to shine through the cover. The inserted light source is, in this regard, not recognisable from the front of the vacuum formed decorative furniture component. The presence of the light source is made evident only when the light source is turned on. The light source is inserted into the light source receiving portion without damaging the vacuum formed material. Accordingly, the vacuum formed material provides a protective cover for the received light source. In some examples, the method comprises arranging a support behind the light source to thereby retain the light source behind the cover. In some examples, the method comprises removing material from the furniture component to form the light source receiving portion using a drill. The method is thus compatible with existing drilling and / or cutting methods used in furniture component manufacture. In some examples, the method comprises determining a thickness of the furniture component, and determining one or more dimensions of the light source receiving portion to be formed based on the determined thickness. The formation and scale of the light source receiving portion may thus be dynamically adjusted according to the specifications of the furniture component to be covered. In this way, multiple furniture components having different thicknesses and forms can be manufactured according to the method. In some examples, removing material from the furniture component to form the light source receiving portion comprises forming, in a first drilling step, a first end of the light source receiving portion such that the first end has a first profile, and forming, in a second drilling step, a second end of the light source receiving portion such that the second end has a second profile. By performing at least two drilling steps, the light source receiving portion may formed to have a more complex 3D profile (e.g., height, depth, and width) and / or may be formed to comprise different pitch angles along the thickness of the furniture component. In some examples, the second profile comprises a different shape to the first profile. Advantageously, creating a more complex shape for the light source receiving portion, (e.g. a shape comprising a plurality of cross-sectional forms) allows for improved stability of the furniture component once material is removed, provides flexibility for accommodating the spacer at the second end prior to vacuum forming, and provides flexibility for accommodating insertion of the light source and / or support materials at the first end after vacuum forming. In some examples, a direction of drilling for the first drilling step opposes a direction of drilling for the second drilling step. Advantageously, by arranging the drilling to occur in these directions, the furniture panel does not need repositioning during formation of the light source receiving portion. In some examples, a duration of the first drilling step overlaps with a duration of the second drilling step. Advantageously, a light source receiving portion having a complex shape is formed quickly and efficiently, without requiring repositioning (e.g., rotation or flipping) of the furniture component. In some examples, the light source receiving portion extends through the furniture component. Advantageously, the spacer may thus be inserted in the direction of vacuum forming prior to vacuum forming. In some examples, the furniture component comprises a wood or wood composite panel. In some examples, the material is vinyl. Vinyl materials include heat deformable materials that are suitable for stretching over the light source receiving portion to provide covers for the light sources. In some examples, the light source comprises one or more light emitting diodes, LEDs. In a second aspect, there is provided a furniture component manufactured according to a method as described herein. The furniture component comprises a wood composite body, a light source receiving portion for receiving a light source, and a cover over the light source receiving portion, the cover comprising a vinyl material. In use, a light source received by the light source receiving portion is operable to shine through said cover. Advantageously, the light source receiving portion is covered such that a light source received therein is not, in itself, recognisable from the front of the decorative furniture component. In other words, due to the vinyl cover, the light source is obscured. The presence of the light source is made evident only when the light source is turned on. Further advantageously, the vinyl provides a protective cover for the received light source. In some examples, the decorative furniture component further comprises a unitary cover over a majority of the wood composite body, wherein the unitary cover provides the cover over the light source receiving portion. Advantageously, the vacuum formed vinyl provides a single seamless cover for both the light source and the remaining surface of the wood composite body which comprises the light source receiving portion. Further advantageously, the vinyl provides a protective cover for the received light source and the wood composite body of the furniture component. Features of the above aspect may be combined, or incorporated into each other, as desired or as appropriate. Other advantageous features of the invention will be apparent from the following description. Brief Description of the Drawings Examples of the present disclosure will now be described with reference to the accompanying drawings, in which: Figure 1 depicts a method of manufacturing a furniture component; Figure 2 depicts steps of the method of manufacturing the furniture component; Figures 3 depicts steps of a method of manufacturing a furniture component using a spacer; Figure 4 depicts cross-sectional views of spacer arrangements; and Figure 5 depicts a cross-sectional view of light source receiving portions having complex profiles. Detailed Description Figure 1 depicts a method 100 of manufacturing a furniture component. A furniture component, such as a panel or door panel, may be installed in combination with other decorative components, such as beading and architraves, and / or with non-decorative components, such as supporting frame or hinge. At step 102, the method includes providing a furniture component comprising a surface to be covered, the surface comprising a light source receiving portion. The surface to be covered includes an exposed surface of the furniture component and may refer to collection of exposed surfaces of the furniture component. For example, when the furniture component is mounted in a vacuum forming apparatus, a surface of the furniture component may be, in part, unexposed due to contact with the mount the remaining surface may be exposed during the vacuum forming process so as to be covered. At step 104, the method includes vacuum forming material over the surface to form a cover for the light source receiving portion, such that a light source received by the light source receiving portion is operable to shine through said cover. The cover for the light source receiving portion is thus formed in a single vacuum forming step. Advantageously, by providing this vacuum formed cover, not only is the activated (i.e., switched on) light source operable to shine through the cover, but the light source is obscured by the cover when the light source is inactive (i.e., switched off). Accordingly, the manufacturing method produces a decorative furniture component that can incorporate light sources in a way that does not detract from the traditional decorative aspects of the furniture component. Figure 2 depicts steps corresponding to the method 100 of manufacturing the furniture component shown in Figure 1. Figure 2(a) corresponds to step 102 of Figure 1 and Figures 2(b)-(d) correspond to step 104 of Figure 1. An order of progress through the steps is indicated by the solid black arrows, with a further optional step is depicted by a dashed arrow. In Figure 2(a), the furniture component 110 comprising a surface to be covered 120, by material during vacuum forming, is provided. The surface to be covered 120 may include a surface of the furniture component 110 which is covered during a single vacuum forming step, for example a front face of the furniture component. The surface to be covered 120 may also collectively include one or more surfaces capable of being vacuum formed in a single vacuum forming step, for example a front face and / or one or more sides of the furniture component 110. The surface to be covered 120 comprises a light source receiving portion 140. In Figure 2(b), vacuum formable material 160 is arranged to overlie the surface to be covered 120. Here, the material 160 is depicted as a planar sheet. In some examples, the material 160 may have other forms. In Figure 2(c), the furniture component 110 is shown after vacuum forming has occurred. Here, the vacuum formed material 160 provides a cover 180 for the light source receiving portion 140. The cover 180 for the light source receiving portion 140 is formed such that a light source received by the light source receiving portion is operable to shine through said cover 180, as depicted in Figure 2(d). Accordingly, the method of manufacturing provides a furniture component that can incorporate light sources in a way that does not detract from the traditional decorative aspects of the furniture component. In Figures 2(c)-(d) a dashed line delineates the cover 180. This delineation may be perceivable by the viewer when the light source is active, but is not perceivable while light source is inactive, unless otherwise purposefully distinguished, as described below. In some examples, the light source receiving portion 140 comprises an opening or protrusion. In Figures 2 to 4, the light source receiving portion 140 comprises an opening in the surface to the covered 120. Where the light source receiving portion 140 comprises an opening, the light source can be fitted in light source receiving portion 140 via the hole. Examples of openings include a recess extending to a portion of the thickness (e.g. depth) of the furniture component or a hole extending through the thickness of the furniture component. Where the opening comprises a through hole, the furniture component 110 may be flipped after vacuum forming to expose an uncovered opening at the opposing end of the through hole. Accordingly, the hole thus provides means for forming the cover 180 and means for inserting the light source at the light source receiving portion 140. In some examples, the step 104 of vacuum forming forms a unitary cover for a portion of the surface to be covered 120, wherein the unitary cover provides the cover 180 for the light source receiving portion 140. As noted above, the surface to be covered 120 may include one or more surfaces of the furniture component 110 which are covered during a single vacuum forming step. In some examples, the unitary cover may provide a cover for the portion of the surface to be cover 120 that surrounds the light source receiving portion. Accordingly, the method simultaneously covers the furniture component 110 with a single, seamless vacuum formed material 160 to thereby provide a protective cover for the light source and a remainder of the covered surface. In some examples, the step 104 of vacuum forming forms a unitary cover for a majority of the surface to be covered 120, wherein the unitary cover provides the cover 180 for the light source receiving portion 140. The majority of the surface to be covered 120 refers to at least a face (e.g. side) of the furniture component. For example, where the surface to be covered 120 comprises a front face and one or more sides of furniture component, the majority may comprise at least the front face of or at least one of the sides of the furniture component 110. In some examples, the majority of the surface is covered where the material 160 forms over at least half of front face of the furniture component 110. Accordingly, the method simultaneously covers the furniture component 110 with a single, seamless vacuum formed material 160 to thereby provide a protective cover for the light source and the remainder of the covered surface. In some examples, the step 104 of vacuum forming stretches the material 160 over the light source receiving portion 140 to thereby increase light transmissivity of the cover. Stretching effectively thins the material 160. Stretching of the material 160 may be facilitated by contact with the furniture component 110. Different degrees of light transmissivity are obtainable from same material 160 by stretching. This means the transmissivity of the cover 180 can be controlled at the point of vacuum forming, in addition to, or in the place of, pre-stretching prior to vacuum forming. In some examples, the method further comprises prior to vacuum forming, arranging a spacer 200 in the light source receiving portion 140 such that the spacer forms part of the surface to be covered. Figure 3 depicts steps of a method of manufacturing a furniture component using said spacer 200. The method shown in Figure 3(a)-(e) includes the steps depicted in the method 100 of Figures 1 and 2(a)-(d). Accordingly, the description of Figures 1 and 2(a)-(d) applies to the method depicted in Figures 3(a)-(e). Figures 3(a), 3(c), and 3(d) correspond to Figures 2(a), 2(b), and 2(c) respectively. An order of progress through the steps is indicated by the solid black arrows with a further optional step is depicted by a dashed arrow. In Figure 3(a), the furniture component 110 comprising a surface to be covered 120 by material 160 is provided. Figure 3(b), depicts a step prior to vacuum forming, involving arranging a spacer 200 in the light source receiving portion 140 such that the spacer 200 forms part of the surface to be covered 120. Once arranged, the spacer 200 comprises an exposed surface to be covered by the vacuum formable material 160 during vacuum forming. Accordingly, the cover 180 is formed against the spacer 200. In Figure 3(c), the material 160 is arranged to overlie the surface to be covered 120 including the part of the surface 120 that is provided by the spacer 200. Figure 3(d) depicts the furniture component 110 after vacuum forming. The spacer 200 has been removed from the light source receiving portion 140 and the cover 180 for the light source remains. The cover 180 for the light source receiving portion 140 is formed such that a light source received by the light source receiving portion is operable to shine through said cover 180, as depicted in Figure 3(e). Figure 4 depicts cross-sectional views of arrangements for the spacer 200 depicted in Figure 3(b). Specifically, Figures 4(a) and (b) depict arrangements of the spacer 200 in the light source receiving portion 140, where the spacer 200 is arranged relative to the surface to be covered 120. For example, the spacer may be arranged at a depth of the light source receiving portion 140 such than the exposed surface of the spacer 200 is level with, or distanced by a depth from, the surface to be covered 120. In both Figures 4(a) and (b), portions of the furniture component 110a, 110b providing part of the surface to be covered 120 are shown. Although in Figures 4(a) and (b) the light source receiving portion 140 and spacer 200 are depicted as having a rectangular cross-sectional profile, the disclosed method may be used with light source receiving portions 140 having complex cross-sectional profiles, as described in relation to Figure 5. In Figure 4(a), the spacer 200 forms a continuous surface to be covered across an edge of the light source receiving portion, such that the surface to be covered 120 is level. In this arrangement, the spacer 200 provides a flat (e.g., flush) surface across the light source receiving portion. As a result, after vacuum forming, there is no change in form across the light source receiving portion, meaning there is no visible indication of the presence of the light source when the light is inactive. In Figure 4(b), the spacer 200 forms a discontinuous surface across an edge of the light source receiving portion 140, such that the surface to be covered 120 is stepped. In this arrangement, the discontinuity at the step edge formed by the arrangement of the spacer 120 facilitates stretching of the material 160. For example, the step 104 of vacuum forming may comprise stretching, by vacuum forming into the light source receiving portion, material over the light source receiving portion to thereby increase light transmissivity of the cover. That is, stretching occurs by the vacuum forming of the material 160 into the light source receiving portion comprising the spacer 200, as shown in Figure 4(b). By controlling the depth of the spacer formed recess, the degree of stretching and resultant light transmissivity of the material 160 can be controlled. Although in Figure 4(b) the exposed surface of the spacer 200 is recessed from the surface to be covered 120, in some examples the exposed surface of the spacer 200 protrudes outwardly to provide a step upwards from the surface to be covered 120. For the latter, the step 104 of vacuum forming may comprise stretching, by vacuum forming over the light source receiving portion comprising the spacer 200, material 160 over the light source receiving portion 140 to thereby increase light transmissivity of the cover. In Figure 4(b) the stepped recess formed by the spacer 200 is depicted as having a substantially flat base due to the flat exposed surface of the spacer 200. In some examples, the spacer 200 may comprise a curved exposed surface to contribute a curved portion to the surface to be formed 120. An example surface to be formed 120 comprising a curved portion, for forming a curved cover 180b, is depicted across the light source receiving portion 140b of Figure 5. In a stepped arrangement, the spacer provides an uneven surface across the light source receiving portion 140. As a result, after vacuum forming, a change in form remains visible across the light source receiving portion. This change in form may advantageously provide an aesthetic contribution that according to traditional design considerations. For example, although the light source itself may not be visible when the light source is inactive, the stepped cover 180 over the light source receiving portion 140 may still provide an aesthetic design contribution to the furniture component 110, in terms of 3D form or shaping. In some examples, the above-described methods may comprise arranging a first spacer 200 to provide continuity across a first light source receiving portion 140 and arranging a second spacer 200 to provide discontinuity across a second light source receiving portion 140. The above-described methods may further comprise a step of after vacuum forming, removing the spacer 200 from the light source receiving portion. For example, the spacer can be removed from behind the cover 180, such that the spacer 200 is removed in the direction of vacuum forming. The direction of vacuum forming, i.e., the direction in which the material 160 is applied under vacuum, is shown by the large arrows in Figures 4(a) and (b). By removing the spacer 200 in the direction of vacuum forming, the light source receiving portion 140 is vacated without causing damage to the vacuum formed cover 180. The above-described methods may further comprise inserting a light source into the light source receiving portion 140, such that the light source is arranged behind the cover and is operable to shine through the cover 180. For example, the light source may be inserted in a direction opposing the vacuum forming direction shown in Figures 4(a) and (b). By inserting the light source this way, damage to the cover 180 is avoided. The presence of the light source at the light receiving product is evident only when the light source is turned on. Accordingly, the cover 180 provides a protective cover for the received light source. After insertion of the light source, the method may further comprise arranging a support behind the light source to thereby retain the light source behind the cover. Advantageously the received light source is retained in the light source receiving portion 140, whilst the support is not visible from the front of the decorative furniture component, i.e., the vacuum formed surface of the furniture component. The above-described methods may further comprise removing material from the furniture component 110 to form the light source receiving portion 140, using a drill. The drill may be a computer numerical control (CNC) drill operated by a processor which controls the position and / or angling of the drill. Advantageously, the method is compatible with existing drilling and / or cutting methods used in furniture component manufacture. In some examples, the formation of the light source receiving portion 140 by drilling is dependent on a thickness (e.g. depth) of the furniture component 110. This thickness may be measured by a detector in communication with the processor operating the drill. The thickness of the furniture component 110 may be measured in the direction of drilling. As an example, where a drill is angled relative to the surface to be covered 120, a first thickness of the furniture component 110 may be determined. Where the same drill is repositioned to a different angle relative to the surface to be covered 120, a different thickness of the furniture component 110 may be determined. By first determining the thickness, a 3D profile (e.g., height, depth, and width) and / or pitch angle form of the light source receiving portion 140 can be controlled and scaled appropriately. In some examples, a first 3D profile and / or pitch angle is formed when determined furniture component 110 thickness is below a threshold and second, different 3D profile and / or pitch angle is formed when determined furniture component 110 thickness is above a threshold. Advantageously, the formation of the light source receiving portion 140 may be dynamically adjusted according to the specifications of the furniture component 110 to be covered. In this way, multiple furniture components 110 having different thicknesses and forms can be manufactured according to the disclosed method. In some examples, the light source receiving portion 140 extends through the furniture component 110. For example, the light source receiving portion comprises a through hole, as described above. The through hole may have a first opening providing the light source receiving portion 140 on the surface to be covered 120, and a second opening. The second opening may be on a surface opposing the surface to be cover 120, such a surface which is not covered by the vacuum forming material 160 during vacuum forming. Advantageously, this provides access for insertion and removal of the spacer 200 and / or the light source, without causing damage to the vacuum formed material 160. Further advantageously, the spacer may 200 be inserted in the direction of vacuum forming, prior to vacuum forming. Accordingly, the furniture component 110 may be prepared for vacuum forming without requiring repositioning to accommodate insertion a spacer 200. In some examples, the light source receiving portion 140 is formed according to at least two drilling steps. Advantageously, by performing at least two drilling steps, the light source receiving portion may formed to have a more complex 3D profile and / or may be formed to comprise different pitch angles along the thickness of the furniture component. Figure 5 depicts a cross-sectional view of formed light source receiving portions 140a,b. These light source receiving portions 140a,b extend through the furniture component 110. Although spacers 200 are omitted for clarity, a curved cover 180b may be formed by arrangement of a spacer 200 comprising a curved surface in the light source receiving portion 140b, and a flat cover 180a may be formed by arrangement of a spacer 200 spacer 200 comprising a flat surface in the light source receiving portion 140b. In Figure 5, the light receiving portions 140a,b each comprise a complex shape comprising a plurality of cross-sectional profiles extending along the thickness of the furniture component 110. Accordingly, each light source receiving portions 140a,b comprises a first end 142a,b having a first profile and a second end 144a,b having a second profile. Specifically, in Figure 5 the light source receiving portion 140a comprises a first end 142a arranged adjacent to a second end 144a, and light source receiving portion 140b comprises a first end 142b arranged adjacent to a second end 144b. The first and second profiles have different shapes and / or dimensions. As depicted, the second end 144a,b is proximal the surface to the covered 120 and the first end 142a,b is proximal a surface not to be covered. In some examples, an end may itself be formed of a plurality of profiles. For example, in Figure 5 the first end 142a of light source receiving portion 140a comprises multiple profiles arranged collectively form a stepped profile. These profiles have the same overall shape but differ in cross-sectional width to collectively form the stepped profile of the first end 142a. The light source receiving portions 140a,b of Figure 5 are formed where the method comprises forming the light source receiving portion 140 using first and second drilling steps. The first drilling step forms a first end of the light source receiving portion such that the first end has a first profile. The second drilling forms a second end of the light source receiving portion such that the second end has a second profile. The different shaping of the first and second profile is achieved using different shaped drill bits for the drilling steps. Advantageously, creating a more complex profile (e.g. a shape comprising a plurality of cross-sectional forms) for the light source receiving portion 140a,b allows for improved stability of the furniture component 110 once material is removed, provides flexibility for accommodating the spacer 200 at the second end 144a,b prior to vacuum forming, and provides flexibility for accommodating insertion of the light source and / or support materials at the first end 142a,b after vacuum forming. Figure 5 further depicts example drilling directions using hashed arrows. In some examples, a direction of drilling for the first drilling step opposes a direction of drilling for the second drilling step. For example, the second end 144a of light source receiving portion 140a may be drilled in a top-down direction, from above and the first end 144b may be drilled in a bottom-up direction, from below. The top-down direction may be the same direction as the vacuum forming direction for the surface to be covered 120. Advantageously, by arranging the drilling to occur in opposing directions, the furniture panel 110 does not need repositioning during formation of the light source receiving portion 140. In some examples, the first and second drilling steps alternate according to a sequence. In some examples, a duration of the first drilling step overlaps with a duration of the second drilling step. Accordingly, the first and second drilling steps may occur simultaneously for at least a period of time. As a specific example, top-down and bottom-up drilling occur alternately and / or at the same time to form a light source receiving portion 140 having a complex shape comprising multiple cross-sectional profiles. Advantageously, the light source receiving portion 140 having a complex shape is formed quickly and efficiently, without requiring flipping or rotating between drilling steps. As will be appreciated, the methods described herein are compatible with existing vacuum forming techniques used for wood and wood composite materials that use vinyl materials, such as PVC. In some examples, light source comprises one or more LED strips. The light sources may be arranged in a decorative light pattern. Accordingly, the light source form letters, numbers and / or graphics, for example, to convey a message to a viewer. LED light sources are readily available in various configurations that are suitable for light source receiving portions of various shapes and sizes, and with dedicated controllers / drivers that can be operated remotely, or programmed with various illumination patterns, colours and so on. According to the above-described method a furniture component as depicted in Figures 2(c) and 3(d) is obtained. The decorative furniture component comprises a material 160 vacuum formed over a surface 120 that comprises a light source receiving portion 140 for receiving a light source, and a cover 180 over the light source receiving portion 140, wherein the cover 180 was formed by vacuum forming the material 160 over the surface 120. Figures 2(d) and 3(e) depict a decorative furniture component. In some examples, the decorative furniture component comprises a wood composite body, a light source receiving portion for receiving a light source, and a cover over the light source receiving portion, the cover comprising a vinyl material. In use, a light source received by the light source receiving portion is operable to shine through said cover. Advantageously, the light source receiving portion is covered such that a light source received therein is not, in itself, recognisable from the front of the decorative furniture component because, due to the vinyl cover, the light source is obscured. The presence of the light source is made evident only when the light source is turned on. Further advantageously, the vinyl provides a protective cover for the received light source. In some examples, the decorative furniture component further comprises a unitary cover over a majority of the wood composite body, wherein the unitary cover provides the cover over the light source receiving portion. The wood composite body may be covered on one or more surfaces by the vinyl. The majority of the wood composite body may refer to at least a face (e.g. side) of the body being covered by the vinyl. For example, the majority may comprise at least the front face of or at least one of the sides of the wood composite body. In some examples, the majority of the surface is covered where the vinyl is formed over at least half of front face of the wood composite body. Advantageously, the vacuum formed vinyl provides a seamless unitary cover for both the light source and the remaining surface of the wood composite body. Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. 5 Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic 10 series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to 15 any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A method of manufacturing a furniture component, comprising:providing a furniture component comprising a surface to be covered, the surface comprising a light source receiving portion;vacuum forming material over the surface to form a cover for the light source receiving portion, such that a light source received by the light source receiving portion is operable to shine through said cover.

2. The method of claim 1, wherein the light source receiving portion comprises an opening.

3. The method of claim any preceding claim, wherein vacuum forming material over the surface forms a unitary cover for a majority of the surface to be covered, and wherein the unitary cover provides the cover for the light source receiving portion.

4. The method of any preceding claim, wherein vacuum forming material over the surface comprises:stretching the material over the light source receiving portion to thereby increase light transmissivity of the cover.

5. The method of any one of the preceding claims, further comprising:prior to vacuum forming, arranging a spacer in the light source receiving portion such that the spacer forms part of the surface to be covered.

6. The method of claim 5, wherein the spacer forms a continuous surface to be covered across an edge of the light source receiving portion, such that the surface to be covered is level.

7. The method according to claim 5, wherein the spacer forms a discontinuous surface across an edge of the light source receiving portion, such that the surface to be covered is stepped.

8. The method according to claim 7, wherein spacer is arranged at a depth of the furniture component to thereby form a step of the stepped surface to be covered.

9. The method according to claims 7 or 8, wherein vacuum forming material over the surface to form a cover comprises:stretching, by vacuum forming into the light source receiving portion, material over the light source receiving portion to thereby increase light transmissivity of the cover.

10. The method according to any of claims 5 to 9, further comprising:after vacuum forming, removing the spacer from the light source receiving portion.

11. The method according to claim 10, wherein the spacer is removed from behind the cover, such that the spacer is removed in the direction of vacuum forming.

12. The method according to claims 10 or 11, further comprising:inserting a light source into the light source receiving portion, such that the light source is arranged behind the cover and is operable to shine through the cover.

13. The method according to claim 12, further comprising:arranging a support behind the light source to thereby retain the light source behind the cover.

14. The method according to any preceding claim, further comprising:removing material from the furniture component to form the light source receiving portion using a drill.

15. The method according to claim 14, further comprising:determining a thickness of the furniture component; anddetermining one or more dimensions of the light source receiving portion to be formed based on the determined thickness.

16. The method according to claims 14 or 15, wherein removing material from the furniture component to form the light source receiving portion comprises:forming, in a first drilling step, a first end of the light source receiving portion such that the first end has a first profile; andforming, in a second drilling step, a second end of the light source receiving portion such that the second end has a second profile.

17. The method according to claim 16, wherein the second profile comprises a different shape to the first profile.

18. The method according to claims 16 or 17, wherein a direction of drilling for the first drilling step opposes a direction of drilling for the second drilling step.

19. The method according any of claims 16 to 18, wherein a duration of the first drilling step overlaps with a duration of the second drilling step.

20. The method according to any preceding claim wherein the light source receiving portion extends through the furniture component.

21. The method according to any preceding claim, wherein the furniture component comprises a wood or wood composite panel, and / or wherein the material is vinyl.

22. The method according to any preceding claim, wherein the light source comprises one or more light emitting diodes, LED.

23. A furniture component obtained by the method of any of claims 1 to 22.

24. A furniture component comprising:a wood composite body;a light source receiving portion for receiving a light source; anda cover over the light source receiving portion, the cover comprising a vinyl material;wherein in use, a light source received by the light source receiving portion is operable to shine through said cover.

25. The furniture component of claim 24, further comprising:a unitary cover over a majority of the wood composite body, wherein the unitary cover provides the cover over the light source receiving portion.A

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