System and method for forming woven decorative panels within framed assemblies

Abstract

A method and system are disclosed for forming decorative woven panels using a frame, support bars, and elongated strip elements. The frame may be pre-assembled or staged during assembly, and includes a series of apertures for receiving parallel support bars. A plurality of strips, composed of metallic or polymeric materials, are woven in an alternating over-under configuration relative to the support bars. Each strip is elastically deformed during insertion and retained in a deformed state, contributing to panel rigidity. Optional grommets may be positioned between the support bars and frame to reduce friction and wear. Protective sleeves may be applied to strips during weaving to preserve surface treatments. The resulting woven panel may be integrated into furniture or architectural products such as chairs, screens, and benches. The system enables repeatable, scalable production of structurally reinforced panels with decorative appearances that emulate traditional weaving patterns using engineered materials.

What is claimed is: 
     
         1 . A method of forming a decorative panel, the method comprising:
 forming a frame comprising a plurality of frame members;   positioning a plurality of support bars extending between opposing frame members, wherein the support bars are retained in fixed positions relative to the frame or are installed during the assembly process; and   inserting a plurality of strips through the support bars in an alternating over-under weaving configuration to form a woven array, wherein each strip is elastically deformed during insertion and held in a deformed state by contact with the support bars.   
     
     
         2 . The method of  claim 1 , wherein the frame is pre-assembled prior to the step of weaving the plurality of strips. 
     
     
         3 . The method of  claim 1 , wherein the frame is not fully assembled prior to the step of weaving the plurality of strips, and at least one frame member is installed after the weaving step is complete. 
     
     
         4 . The method of  claim 1 , wherein the support bars are arranged parallel to one another and are spaced apart along a single axis of the frame. 
     
     
         5 . The method of  claim 1 , wherein the plurality of strips are composed of a metal material. 
     
     
         6 . The method of  claim 5 , wherein the metal material comprises aluminum or an aluminum alloy. 
     
     
         7 . The method of  claim 1 , wherein the plurality of strips are composed of a polymeric material. 
     
     
         8 . The method of  claim 1 , wherein at least one of the strips is elastically deformed during insertion through the support bars and held in a deformed state by the frame and support bars. 
     
     
         9 . The method of  claim 1 , further comprising the step of installing grommets or bushings between the support bars and the frame. 
     
     
         10 . The method of  claim 9 , wherein the grommets or bushings are made of polymeric or elastomeric material. 
     
     
         11 . The method of  claim 9 , wherein the grommets or bushings reduce friction and surface wear between the support bars and the frame. 
     
     
         12 . The method of  claim 1 , further comprising placing a polymer sleeve or a protective layer between at least one strip and the support bars during weaving. 
     
     
         13 . The method of  claim 12 , further comprising removing the polymer sleeve or protective layer after weaving is complete. 
     
     
         14 . The method of  claim 1 , wherein at least one of the support bars is temporarily removed during weaving and reinstalled after a strip is positioned. 
     
     
         15 . The method of  claim 1 , wherein the strips are woven manually over and under alternating support bars. 
     
     
         16 . The method of  claim 1 , wherein the frame is held in position using external clamps during at least a portion of the weaving process. 
     
     
         17 . The method of  claim 1 , wherein the support bars are retained in corresponding apertures in opposing frame members. 
     
     
         18 . The method of  claim 1 , wherein the resulting woven panel is incorporated into a furniture product selected from the group consisting of chairs, loungers, benches, and armrests. 
     
     
         19 . A method for forming a decorative panel, the method comprising:
 pre-assembling a frame comprising a plurality of frame members and a plurality of support bars retained in corresponding apertures formed in opposing frame members, wherein the support bars are arranged parallel to one another and spaced apart along a single axis of the frame;   installing a polymeric or elastomeric grommet or bushing between each end of at least one of the support bars and the corresponding frame member to reduce friction and surface wear;   clamping the frame using external fixtures to hold it in position during panel formation;   placing a protective polymer sleeve or layer onto at least one strip prior to weaving;   manually inserting a plurality of metallic strips composed of an aluminum alloy over and under the support bars in an alternating configuration, such that each strip is elastically deformed during insertion and held in a deformed state by contact with the support bars; and   removing the polymer sleeve or layer after the strip has been woven into position, thereby forming a woven decorative panel.   
     
     
         20 . A decorative panel system, comprising:
 a pre-assembled frame comprising a plurality of metallic frame members joined to define a rectangular perimeter;   a plurality of cylindrical support bars extending between opposing frame members and retained in corresponding apertures formed in the frame members, the support bars being arranged parallel to one another and spaced apart along a single axis of the frame;   a plurality of metallic strips composed of an aluminum alloy woven through the support bars in an alternating over-under configuration to form a woven array, each strip being elastically deformed and held in a deformed state by the support bars and frame; and   a plurality of polymeric or elastomeric grommets positioned between each end of at least one of the support bars and the corresponding frame member to reduce friction and surface wear; wherein   the woven array is under residual stress resulting from elastic deformation of the strips, thereby increasing the rigidity of the decorative panel.