Traditional furniture panels made with foam cores and plastic, or wooden exteriors are costly and complex to manufacture—especially in large or custom shapes. Integrating useful features like lighting, charging ports, or hinges usually requires extra components and labour, making furniture more expensive and less adaptable.
The
Innovation
This invention introduces a smarter, easier-to-build furniture component made of three main layers:
- A lightweight foam core (like EPS or biodegradable wood foam),
- A plastic outer shell shaped through a deep-drawing process (a cost-efficient moulding technique),
- A flat backing layer, which can also be moulded or made of stronger material like metal.
What’s special: electronic and mechanical components—like lights, sensors, USB ports, power outlets, switches, and locks—can be seamlessly integrated into the foam layer and covered neatly by the outer panels. This modular, “kit-like” approach means the same core can be adapted to various furniture needs.
The
Inventive Step
Unlike earlier designs that only included structural foam and plastic sheets, this patent introduces the ability to directly embed functional technology (like lighting and charging) within the panel—without making assembly harder. It cleverly uses deep-drawn plastic parts that include ridges, cavities, and slots to fit and protect electronics, reducing the need for extra tools or fixtures.
Key Benefits
- Lower production cost using simple forming methods
- Easy integration of lights, sensors, or power ports
- Flexible design, allowing for varied sizes and shapes
- Lightweight yet strong, thanks to stiffened moulded edges
- Environmentally friendly, with biodegradable material options
Broader Impact
This could transform furniture manufacturing—enabling smarter desks, drawers, and shelves with built-in tech features for homes, schools, and offices. It also supports sustainability by using eco-materials and reducing the need for extra fixtures, helping both industry and environment.