System and Method for Forming Woven Decorative Panels Within Framed Assemblies

The present application is based on, and a claim of priority is made under 35 U.S.C. Section 119(e) to a U.S. Provisional Patent Application 63/632,978 filed on Apr. 11, 2024, which is incorporated by reference herein in its entirety.

The present invention relates generally to decorative architectural and furniture panels, and more specifically to systems and methods for forming woven panels within framed assemblies. Such woven panels may be fabricated from engineered materials to mimic the aesthetic of natural materials such as rattan, wood, or leather, and may be incorporated into furniture, partitions, facades, and other functional or ornamental structures.

Woven structures have long been favored in furniture and architectural design due to their tactile appeal, breathable surface configuration, and organic visual characteristics. Traditional woven furniture, including chairs, screens, and storage units, often relies on hand-woven techniques utilizing natural materials such as cane, wicker, bamboo, jute, or leather. These methods, while aesthetically pleasing, can be labor-intensive and are often associated with limitations in terms of long-term durability, UV resistance, and weathering performance, particularly in exterior or high-humidity environments.

In recent years, the demand for outdoor furniture and architectural installations capable of withstanding extended environmental exposure has increased. As such, manufacturers have sought alternative materials and processes that can preserve the desirable woven aesthetic while delivering superior mechanical performance, dimensional stability, and ease of manufacture. To address this, various attempts have been made to substitute traditional woven materials with synthetic counterparts, including vinyl, thermoplastics, and polymer-coated fibers. While these solutions offer certain benefits in terms of longevity and color retention, they are typically installed by hand in a weave-over-frame process, which may still require skilled labor and manual dexterity.

Additionally, prior solutions often rely on flexible cordage, rope, or extrusions which necessitate tensioning mechanisms or anchoring fixtures. These methods can complicate manufacturing processes and introduce quality control challenges. Misalignment, sagging, and inconsistent weave tightness are common concerns, particularly where volume production is involved. Further, many prior systems do not adequately accommodate the pre-treatment of woven strips for consistent finish application or allow for efficient assembly post-treatment. As a result, there remains a need for improved systems and methods for forming decorative woven panels, particularly ones that are compatible with automated or semi-automated manufacturing and do not sacrifice aesthetic quality.

Another drawback in conventional woven systems lies in the limited structural contribution of the woven elements themselves. Traditional woven panels, whether used in seat backs, privacy screens, or wall inserts, primarily serve decorative or ergonomic purposes but often lack meaningful stiffness or load-bearing capacity. This is due to the flexible and often elastic nature of the materials selected. In contrast, there is a desire for woven panels to serve as structural elements, especially where they are integrated into aluminum or polymer frames for commercial furniture or architectural applications. However, attempts to use stiffer materials such as metal strips or rigid polymers have introduced challenges in the actual weaving process, since such materials exhibit limited elasticity and may deform plastically when manipulated beyond their yield point.

Some known methods involve pre-bending metallic slats into a serpentine profile to simulate a woven appearance without actual weaving, or employing post-installed decorative fasteners to mimic crossovers, but these approaches often yield a visibly artificial result that lacks the authenticity of true over-under weaving. Other methods attempt to bond pre-cut strips to the surface of rigid backplanes using adhesives or mechanical fasteners, which again reduces the depth and three-dimensional character that true weaving provides. In addition, bonded or faux-woven systems typically do not exhibit the same surface tactility or dynamic tensioning effects as actual woven constructions, nor do they afford the same opportunities for airflow or light filtration.

There also remains an unmet need for processes that allow pre-treated or surface-coated strips to be woven into a support structure without compromising their surface quality. When weaving is performed after coating or decorative surface treatment-such as powder coating, anodizing, or applying synthetic grain patterns—the contact between the strip and support bar during deformation may introduce scratches, abrasions, or edge damage. This can lead to inconsistencies in appearance or corrosion susceptibility if protective layers are breached. In order to protect these treated surfaces during assembly, temporary buffers such as polymer sleeves or protective films may be used. However, existing techniques do not provide reliable ways to maintain alignment and tension while still permitting removal of these buffer layers post-assembly.

In response to these and other challenges, there is a need for a process that allows for a structurally sound, visually authentic, and surface-safe weaving method, preferably one that integrates with a preassembled frame containing support bars or rails. Such support bars must be dimensioned and spaced in a manner that allows alternating over-under passage of strip materials while maintaining consistent tension and compression throughout the woven grid. Furthermore, the ability to pre-assemble a frame and subsequently weave rigid or semi-rigid strips through captive support members would enhance manufacturability and quality control, particularly in commercial production lines.

Also lacking in the related art are features that optimize post-assembly surface uniformity and eliminate post-finishing inconsistencies. Ideally, the weaving process should accommodate strips with non-functional terminal features such as tabs, perforations, or hanging loops for surface treatment purposes-allowing these features to be removed post-treatment without impacting the visible portions of the assembled panel. Moreover, strip materials should be selected and dimensioned to undergo elastic deformation during weaving but avoid permanent plastic set. This ensures that the residual internal stress enhances panel rigidity without risk of fatigue or creep.

In addition to structural and aesthetic goals, ergonomic considerations also influence the desirability of a refined weaving process. For example, when such panels are used in seating products like armchairs or sofas, the weave must be tight enough to support the user's weight while conforming gently to body contours. Furthermore, integration with modular cushions, adjustable feet, or weather-resistant covers with rainwater management features may necessitate compatibility with additional hardware or secondary components.

Finally, scalability remains a concern in commercial applications. In the hospitality or outdoor furniture industries, repeatability and rapid assembly are key. Systems that enable weaving to be performed in a guided, semi-automated process-either by robotic handling or with removable jigs-would improve throughput while maintaining design integrity. Similarly, the use of standardized frames with common dimensions and support bar placements could enable interchangeability across multiple product types or sizes, reducing inventory complexity.

Accordingly, there remains a need for improved methods and systems for forming woven decorative panels within framed assemblies that address one or more of the limitations of the prior art. The desired solution would combine structural integrity, design flexibility, surface preservation, and manufacturing efficiency. Ideally, such a solution would support use in a variety of finished products, including but not limited to seating furniture, privacy screens, planters, pergolas, trash enclosures, and facade elements. The present invention fulfills these needs by offering a novel approach to forming and assembling woven panels using engineered strip materials and frame-supported configurations that allow for high-quality, repeatable results suitable for both indoor and outdoor environments.

The present invention is directed to a method and system for forming decorative woven panels within a frame structure, wherein a plurality of elongated strip elements are mechanically interlaced through a series of fixed support bars that span across at least one axis of the frame. The strips may be composed of metal alloys, such as aluminum, or polymeric materials, and are preferably dimensioned to undergo elastic deformation during the weaving process without exceeding their yield strength. The support bars may be fixed within a pre-assembled frame or may be positioned during a progressive or staged assembly process, such that the frame is completed after the weaving operation. The strips are woven in an alternating over-under configuration to simulate a traditional woven appearance. To facilitate surface preservation during assembly, temporary polymer sleeves or protective layers may be interposed between the strip surfaces and the support bars, and subsequently removed post-weave. In preferred embodiments, the strip materials are pre-treated to achieve an aesthetically desirable surface finish prior to weaving, with optional sacrificial tabs provided for handling during surface treatment and removed thereafter to preserve visual uniformity.

Compared to conventional woven systems that rely on flexible, tensioned cordage or labor-intensive manual weaving with natural materials, the present invention provides a structurally rigid, surface-safe, and repeatable solution suitable for scaled manufacturing. The system is compatible with both pre-assembled frames-which enable efficient direct weaving into fixed structural members—and non pre-assembled frames, which allow for insertion of pre-formed or partially woven panels prior to final frame construction. The ability to choose between these configurations offers significant flexibility in production workflows. The use of engineered materials enables the woven panel to serve both decorative and structural functions, enhancing rigidity and eliminating the sag or deformation common in prior art solutions. The induced elastic stress within the woven strips further contributes to the panel's structural integrity. Additionally, the modular and material-agnostic nature of the disclosed system supports integration into a broad range of architectural and furniture applications while enabling design uniformity, high throughput, and consistent aesthetic outcomes across production runs.

In a first implementation of the invention, a method is provided for forming a decorative panel. The method comprises forming a frame including a plurality of frame members, positioning a plurality of support bars extending between opposing frame members such that 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. Each strip is elastically deformed during insertion and held in a deformed state by contact with the support bars.

In a second aspect, the frame may be pre-assembled prior to the step of weaving the plurality of strips.

In another aspect, the frame may not be fully assembled prior to the step of weaving the plurality of strips, and at least one frame member may be installed after the weaving step is complete.

In another aspect, the support bars may be arranged parallel to one another and may be spaced apart along a single axis of the frame.

In another aspect, the plurality of strips may be composed of a metal material.

In another aspect, the metal material may comprise aluminum or an aluminum alloy.

In another aspect, the plurality of strips may be composed of a polymeric material.

In another aspect, at least one of the strips may be elastically deformed during insertion through the support bars and may be held in a deformed state by the frame and support bars.

In another aspect, the system may further comprise grommets or bushings disposed between the support bars and the frame.

In another aspect, the grommets or bushings may be made of a polymeric or elastomeric material.

In another aspect, the grommets or bushings may reduce friction and surface wear between the support bars and the frame.

In another aspect, a polymer sleeve or a protective layer may be placed between at least one strip and the support bars during weaving.

In another aspect, the polymer sleeve or protective layer may be removed after weaving is complete.

In another aspect, at least one of the support bars may be temporarily removed during weaving and may be reinstalled after a strip is positioned.

In another aspect, the strips may be woven manually over and under alternating support bars.

In another aspect, the frame may be held in position using external clamps during at least a portion of the weaving process.

In another aspect, the support bars may be retained in corresponding apertures formed in opposing frame members.

In another aspect, the resulting woven panel may be incorporated into a furniture product selected from the group consisting of chairs, loungers, benches, and armrests.

In another implementation of the present invention, a method for forming a decorative woven panel may include pre-assembling a frame that may include a plurality of metallic frame members joined to define a rectangular perimeter, and installing a plurality of cylindrical support bars between opposing frame members, wherein the support bars may be retained in corresponding apertures and may be spaced apart along a single axis of the frame. The method may further include installing a polymeric or elastomeric grommet or bushing between each end of at least one support bar and the corresponding frame member to reduce friction and surface wear, and clamping the frame using external fixtures to hold it in position during panel formation. The method may also include placing a protective polymer sleeve or layer onto at least one strip prior to weaving, and manually inserting a plurality of metallic strips composed of an aluminum alloy in an alternating over-under configuration relative to the support bars, such that each strip may be elastically deformed during insertion and held in a deformed state by the frame and support bars. The polymer sleeve or protective layer may then be removed to complete the woven array.

In another implementation of the present invention, a decorative panel system may include a pre-assembled frame having a plurality of metallic frame members joined to define a rectangular perimeter, and a plurality of cylindrical support bars extending between opposing frame members, wherein the support bars may be retained in corresponding apertures and may be arranged parallel to one another and spaced along a single axis of the frame. The system may further include a plurality of metallic strips composed of an aluminum alloy woven through the support bars in an alternating over-under configuration, each strip being elastically deformed and held in a deformed state by the support bars and frame. The system may also include 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. The woven array may be placed under residual elastic stress, thereby increasing the rigidity of the decorative panel.

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

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. 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.

The present invention is directed to a method and system, generally designated as system, 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, positioning a plurality of support barswithin the frame, and weaving a plurality of strip elementsthrough 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 stripto retain tension and increase rigidity in the final panel.illustrate various stages of this method as applied to both single-panel assemblies and multi-surface furniture products.

In one implementation, the method begins by assembling frame, which may comprise a plurality of metallic or polymeric frame members arranged to define a perimeter boundary. The framemay be rectangular or square, and the members may be joined by welding, mechanical fasteners, or press-fit joints. Aperturesmay be pre-formed in opposing frame members to receive support bars. In pre-assembled configurations, all four sides of the framemay 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.shows a corner assembly of framewith end caps and perpendicular joints, anddemonstrates a partially assembled configuration where one support baris removed to allow strip insertion.

Next, the method may include installing support barsinto the frame. Each support barmay extend between opposing frame members, received into aperturesformed 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 barsmay be temporarily omitted to facilitate insertion of woven strips, and then reinstalled to complete the panel.depict the support barsarranged in a parallel configuration along one axis of frame. 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.

Once the support barsare in place, the method proceeds to weaving the strip elements. Each stripmay 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, threading it across the width or height of frame. 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, the woven array may define a uniform field of interlaced stripsheld under elastic deformation. The ends of each strip may abut the internal surface of frameor may overlap slightly, depending on tolerance constraints.

To reduce damage to the surface of stripsduring the weaving process, the method may further include placing a protective polymer sleeveor 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.illustrates this method, showing a framesecured in clampswith a stripin the process of being woven through the support bars. 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 bushingsbetween the support barsand frame. These grommetsmay 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.show these grommetsin position, seated within aperturesto cradle the ends of support bars. 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 grommetsis especially beneficial where the frame and bars are made from the same base material, such as aluminum, to prevent galling.

Throughout the weaving process, the framemay be held in a stationary position using clampsor fixture plates. As shown in, clamping ensures that framemaintains its squareness and rigidity during the insertion of strips. 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 stripsare retained in a deformed state, any temporarily removed support barsmay be reinstalled. The finished panel may then be removed from the clamping fixture and inspected for uniformity.

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

Support barsare structural members that serve dual purposes-providing internal reinforcement to the frameand serving as anchor points for woven strips. 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 grommetsas shown in. The bars may be cut to specific lengths with tolerance matching the internal width of frame, 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.

The woven stripsserve 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, stripsmay 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, accounting for bending curvature during weaving.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.

As each stripis woven through support bars, 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, 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.

To protect the decorative surface of strips, the method may involve temporary sleevesas shown in. 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. 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.

Grommetsserve 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, as shown in. In addition to isolating support barsfrom direct contact with the frame, grommets may facilitate easier assembly and disassembly of the panel. In some designs, grommetsmay include keyed features or stops to control bar rotation, ensuring that barsremain aligned during the weaving process.

The completed panel formed by the described method may be incorporated into furniture products or architectural assemblies. As shown in, 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.