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.

Claims

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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:

[0037] FIG. 1 presents a front perspective view of a woven panel integrated into an armchair frame, in accordance with a first illustrative embodiment of the present invention;

[0038] FIG. 2 presents a rear perspective view of the armchair illustrated in FIG. 1, showing the frame construction and rear woven panel structure;

[0039] FIG. 3 presents a side elevation view of the armchair illustrated in FIG. 1, highlighting the woven strip configuration along the side support region;

[0040] FIG. 4 presents a front elevation view of the armchair illustrated in FIG. 1, showing the arrangement of woven strips relative to the armrests and support bars;

[0041] FIG. 5 presents a top plan view of the armchair illustrated in FIG. 1, illustrating the positioning of the woven seat and the upper frame members;

[0042] FIG. 6 presents a bottom plan view of the armchair illustrated in FIG. 1, showing the underside frame components and the retention of the woven panel elements;

[0043] FIG. 7 presents a rear elevation view of the armchair illustrated in FIG. 1, highlighting the attachment between the woven panel and the rear vertical frame supports;

[0044] FIG. 8 presents a perspective view of a second illustrative embodiment of an armchair featuring a woven panel configuration and a different frame geometry;

[0045] FIG. 9 presents a close-up perspective view of a corner portion of a frame subassembly, illustrating the attachment between the lateral and transverse frame members and the end caps, in accordance with an illustrative embodiment of the present invention;

[0046] FIG. 10 presents a perspective view of a pair of polymer or elastomeric grommets or spacer rings, which are used to reduce friction and surface wear during assembly when the support bars and frame are made from similar materials, thereby preventing galling or abrasion at points of contact;

[0047] FIG. 11 presents a close-up perspective view of a frame member and multiple support bars, each fitted with grommets at the interface between the bar ends and the frame to reduce friction, accommodate dimensional tolerances, and prevent material wear when similar materials are used for both components;

[0048] FIG. 12 presents a perspective view of a partially assembled frame fixture secured by external clamps, showing multiple support bars installed between opposing frame members in preparation for weaving strip materials through the assembly; and

[0049] FIG. 13 presents a perspective view of a partially assembled frame showing one support bar temporarily removed to allow weaving access, and highlighting the positional variance of support bars relative to the frame during a staged or interrupted assembly process.

[0050] Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0051] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word exemplary or illustrative means serving as an example, instance, or illustration. Any implementation described herein as exemplary or illustrative is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms upper, lower, left, rear, right, front, vertical, horizontal, and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0052] The present invention is directed to a method and system, generally designated as system 100, for forming decorative woven panels suitable for integration into furniture products, architectural panels, and structural inserts. The method may be implemented using both pre-assembled and partially assembled frame configurations, and may involve forming a frame 104, positioning a plurality of support bars 108 within the frame, and weaving a plurality of strip elements 112 through the support bars to create a woven array. The sequence of steps may vary depending on the assembly strategy, with some implementations utilizing a fully assembled frame at the start of the process and others deferring final frame completion until after weaving has occurred. In either approach, the method leverages the elastic deformation of each woven strip 112 to retain tension and increase rigidity in the final panel. FIGS. 1 through 13 illustrate various stages of this method as applied to both single-panel assemblies and multi-surface furniture products.

[0053] In one implementation, the method begins by assembling frame 104, which may comprise a plurality of metallic or polymeric frame members arranged to define a perimeter boundary. The frame 104 may be rectangular or square, and the members may be joined by welding, mechanical fasteners, or press-fit joints. Apertures 120 may be pre-formed in opposing frame members to receive support bars 108. In pre-assembled configurations, all four sides of the frame 104 may be joined before proceeding with the next step. In alternative methods, one side of the frame may remain unattached, enabling partial frame access during weaving. FIG. 9 shows a corner assembly of frame 104 with end caps and perpendicular joints, and FIG. 13 demonstrates a partially assembled configuration where one support bar 108 is removed to allow strip insertion.

[0054] Next, the method may include installing support bars 108 into the frame 104. Each support bar 108 may extend between opposing frame members, received into apertures 120 formed in the lateral edges. The support bars may be installed all at once or in a staged fashion. In some cases, one or more support bars 108 may be temporarily omitted to facilitate insertion of woven strips 112, and then reinstalled to complete the panel. FIGS. 3 and 4 depict the support bars 108 arranged in a parallel configuration along one axis of frame 104. These bars may be positioned at equal intervals to create consistent spacing for the woven array. The number of bars and spacing may be determined by aesthetic preference, desired flexibility of the finished panel, and the width of the strips 112.

[0055] Once the support bars 108 are in place, the method proceeds to weaving the strip elements 112. Each strip 112 may be inserted manually in an alternating over-under configuration relative to the support bars. The user may bend and guide each strip through the gaps between bars 108, threading it across the width or height of frame 104. In some methods, strips may be woven sequentially, with each new strip offset from the prior to create a consistent weave pattern. As shown in FIG. 1, the woven array may define a uniform field of interlaced strips 112 held under elastic deformation. The ends of each strip may abut the internal surface of frame 104 or may overlap slightly, depending on tolerance constraints.

[0056] To reduce damage to the surface of strips 112 during the weaving process, the method may further include placing a protective polymer sleeve 132 or film onto at least one face of each strip. The sleeve may be applied prior to insertion and may remain in place during the full weaving operation. Once the strip is in position, the sleeve may be withdrawn or peeled away. FIG. 12 illustrates this method, showing a frame 104 secured in clamps 128 with a strip 112 in the process of being woven through the support bars 108. The use of temporary protective layers ensures that any pre-applied surface treatment on the strips, such as powder coating or texturing, remains intact. In some implementations, the method may also include the installation of grommets or bushings 116 between the support bars 108 and frame 104. These grommets 116 may be composed of polymeric or elastomeric materials, and may serve to reduce friction during bar installation, accommodate small dimensional variations, and prevent metal-on-metal contact. FIGS. 10 and 11 show these grommets 116 in position, seated within apertures 120 to cradle the ends of support bars 108. The grommets may be press-fit, adhesive bonded, or mechanically locked into the frame members, depending on material compatibility and process preference. The use of grommets 116 is especially beneficial where the frame and bars are made from the same base material, such as aluminum, to prevent galling.

[0057] Throughout the weaving process, the frame 104 may be held in a stationary position using clamps 128 or fixture plates. As shown in FIG. 12, clamping ensures that frame 104 maintains its squareness and rigidity during the insertion of strips 112. The clamps may be applied at multiple locations to prevent twisting or spreading of the frame under load. Once the entire panel has been woven, and all strips 112 are retained in a deformed state, any temporarily removed support bars 108 may be reinstalled. The finished panel may then be removed from the clamping fixture and inspected for uniformity.

[0058] The system 100 produced by the above method may include a completed woven panel comprising frame 104, a plurality of support bars 108, and a woven array of strips 112. As depicted in FIG. 1, this structure may be directly integrated into a chair or similar product, forming both decorative and functional surfaces. The frame 104 may be composed of extruded or machined aluminum members, joined to form a rigid perimeter. The apertures 120 located along opposing frame members provide anchoring points for support bars 108, which may be cylindrical in shape. The spacing of support bars 108 may range from 10 mm to 40 mm center-to-center, depending on the application and desired visual density.

[0059] Support bars 108 are structural members that serve dual purposes-providing internal reinforcement to the frame 104 and serving as anchor points for woven strips 112. These bars may be composed of aluminum, stainless steel, or high-strength thermoplastics. Each bar may be press-fit into frame apertures or supported by grommets 116 as shown in FIG. 11. The bars may be cut to specific lengths with tolerance matching the internal width of frame 104, ensuring a tight fit without inducing residual stress. The bars may be surface finished by anodizing, brushing, or coating to match or contrast with adjacent strip elements.

[0060] The woven strips 112 serve as the defining visual and functional element of the panel. These strips may be fabricated from sheet stock using laser cutting or waterjet cutting methods to produce high-aspect-ratio slats. In one embodiment, strips 112 may have a width of approximately 25 mm and a thickness of 1.5 mm. The length of each strip may be slightly greater than the internal dimension of the frame 104, accounting for bending curvature during weaving. FIGS. 1, 5, and 6 show the woven array in different orientations. The strips may be surface treated using powder coating or film transfer methods to simulate wood grain, leather, or textile patterns. Strip materials may include aluminum alloy, polyvinyl chloride (PVC), polyethylene terephthalate (PET), or other elastically deformable materials.

[0061] As each strip 112 is woven through support bars 108, it is elastically bent over and under adjacent bars. The elastic deformation induces a restoring force within the strip, causing it to press against the bars and frame. This preload effect increases the overall stiffness of the panel and prevents unwanted movement or rattling. As illustrated in FIG. 4, the woven pattern may appear uniform and symmetrical when the strips are properly tensioned. The elasticity of the strips also allows them to return toward a flat state if removed, enabling reconfiguration or replacement if needed. In practice, each strip may be pre-tested for bend compliance to ensure performance within the elastic range of the material.

[0062] To protect the decorative surface of strips 112, the method may involve temporary sleeves 132 as shown in FIG. 12. These sleeves may be composed of flexible thermoplastic film or co-extruded tubing that envelops the strip during handling. During weaving, the sleeve may act as a low-friction barrier between the strip and support bars 108. After the strip has been positioned, the sleeve may be manually withdrawn or split and peeled away. This process helps preserve surface treatments such as painted finishes, printed graphics, or embossed textures. Where surface durability is critical, the sleeves may also include antistatic or UV-blocking additives.

[0063] Grommets 116 serve as both alignment features and friction control elements. When used with metallic bars and frames, they prevent wear caused by thermal expansion or mechanical vibration. Grommets may be molded with concentric shoulders to seat snugly within frame apertures 120, as shown in FIG. 10. In addition to isolating support bars 108 from direct contact with the frame, grommets may facilitate easier assembly and disassembly of the panel. In some designs, grommets 116 may include keyed features or stops to control bar rotation, ensuring that bars 108 remain aligned during the weaving process.

[0064] The completed panel formed by the described method may be incorporated into furniture products or architectural assemblies. As shown in FIGS. 1 and 8, the panel may serve as a load-bearing surface or a visual insert. In chairs, for instance, the panel may function as a backrest or seat. In other applications, the panel may be installed into vertical structures such as privacy screens, gates, or pergolas. The modular nature of the system allows for mass production and standardization. Panels of varying size and pattern may be produced using the same base components with adjustments in length, spacing, and material.

[0065] Variations in weaving pattern, frame geometry, and strip dimension allow the system to be customized for different visual and mechanical effects. For instance, the spacing of support bars may be varied to create denser or looser weave configurations. The strips 112 may alternate in width, thickness, or surface finish to create a more dynamic visual rhythm. Additionally, frame 104 may be curved or angled, enabling three-dimensional surfaces to be formed using the same core method. The panel may also incorporate lighting, acoustic dampening materials, or water drainage features in architectural implementations.

[0066] In summary, the method and system 100 disclosed herein provide a robust and flexible approach to forming woven panels using engineered strips, modular frame components, and scalable fabrication processes. The integration of support bars 108, woven strips 112, protective sleeves 132, and optional grommets 116 results in a structurally rigid and visually appealing product that may be customized for a wide range of applications. Each feature-whether material, structural, or proceduralmay be varied or substituted while maintaining the core inventive concept of elastic weaving through a retained bar network within a frame. As shown throughout FIGS. 1 to 13, the invention supports repeatable manufacturing, visual consistency, and functional durability in both furniture and architectural contexts.

[0067] Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Furthermore, it is understood that any of the features presented in the embodiments may be integrated into any of the other embodiments unless explicitly stated otherwise. The scope of the invention should be determined by the appended claims and their legal equivalents.