System and method for forming woven decorative panels within framed assemblies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing woven furniture and architectural panels face challenges in durability, UV resistance, weathering, manufacturing complexity, structural integrity, and aesthetic authenticity, particularly in outdoor environments, with prior solutions often requiring skilled labor and manual dexterity, and lacking in scalability and ergonomic considerations.
Innovation Solution
A method and system for forming decorative woven panels using engineered strip materials within a frame structure, where strips are mechanically interlaced through fixed support bars, allowing for elastic deformation and surface protection during assembly, enabling automated or semi-automated manufacturing and integration into various products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional hand-woven techniques using natural materials are used, then aesthetic appeal and tactile quality are improved, but labor intensity increases and durability decreases
Solution Approach 1:
The patent replaces manual hand-woven techniques with a mechanical weaving system that uses automated machinery to interlace strips through support bars. This substitution maintains the authentic woven aesthetic while dramatically reducing labor intensity and enabling consistent production quality.
Solution Approach 2:
The invention changes material parameters by using engineered materials with controlled elastic properties instead of traditional natural materials. These materials are designed to deform elastically during mechanical weaving and then retain their deformed state, enabling automated production while preserving aesthetic quality.
2Shape
If traditional hand-woven techniques are used, then aesthetic quality is improved, but long-term durability and UV resistance worsen
Solution Approach 1:
The patent employs composite material construction where engineered strips with enhanced properties are woven into a structured assembly. The combination of elastic material properties and the woven structural configuration creates a composite system that achieves both aesthetic quality and superior durability, including UV resistance and weathering performance.
Solution Approach 2:
The invention utilizes the elastic curvature and deformation of strips during weaving to create a resilient structure. The strips are bent into curved configurations that naturally resist degradation from environmental factors while maintaining the authentic woven appearance.
3Strength
If stiffer materials such as metal strips are used to improve structural contribution, then load-bearing capacity is improved, but ease of weaving worsens due to limited elasticity
Solution Approach 1:
The patent optimizes material parameters by selecting engineered materials with specific elastic moduli and yield strengths that allow sufficient deformation during weaving while maintaining structural integrity in the final assembly. The strips are designed to deform elastically during the weaving process and then retain their deformed state, providing both ease of manufacture and structural strength.
Solution Approach 2:
The invention introduces dynamic behavior to the material selection, choosing strips that exhibit elastic deformation characteristics during the weaving process. This dynamic flexibility during manufacturing transitions to static structural strength in the finished product, resolving the contradiction between ease of weaving and load-bearing capacity.
4Manufacturing precision
If pre-treatment of woven strips is performed before assembly, then surface finish quality is improved, but complexity of the manufacturing process increases
Solution Approach 1:
The patent applies preliminary surface treatment to the strips before they are woven into the final assembly. By pre-treating the strips with protective coatings or surface finishes, the manufacturing process achieves high surface quality while the modular nature of pre-treated components actually simplifies the overall assembly process compared to treating the finished product.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides structurally rigid, visually authentic, and surface-safe woven panels suitable for both indoor and outdoor use, with enhanced manufacturability, design flexibility, and consistent aesthetic outcomes, supporting a range of applications from furniture to architectural structures.
Implementation Method 1
Each strip is elastically deformed during insertion and held in a deformed state by contact with the support bars
Data Source
AI summary
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.