System and method for forming woven decorative panels within framed assemblies

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.

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.